Valve terminal type 03/04 B

Transcription

1 Valve terminal type 03/04 B Electronics manual Field bus node Type IFB13 03 Field bus protocol PROFIBUS DP 12 MBaud Manual en 0503f

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3 Contents and general instructions Author U. Reimann Editor M. Holder Original de Translation transline Deutschland Layout Festo AG & Co. KG, Dept. KG GD Type setting DUCOM Edition en 0503f Designation P.BE VIFB13 03 EN Orderno E (Festo AG&Co. KG, D73726 Esslingen, Federal Republic of Germany, 2003) Internet: E Mail:service_international@festo.com 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 are reserved, in particular the right to carry out patent, utility model or orna mental design registration. I

4 Contents and general instructions II

5 Contents and general instructions Contents Designated use Additional modules for this valve terminal Target group Service Important user instructions Abbreviations Manuals on this valve terminal Further notes VI VII VIII VIII IX XI XIII XIII 1. Summary of components Overview of multifunctional Festo valve terminals Description of components Type 03/04 B: Electric modules Type 03: MIDI pneumatic modules Type 03: MAXI pneumatic modules Type 04 B ISO pneumatic modules Method of operation Fitting Fitting the modules and components Earthing the end plates Fitting onto a hat rail (type 03) Fitting the valve terminal onto a wall Installation General notes on connecting the tubing Cable selection Connecting the cables to the plugs/sockets Setting the field bus node Opening and closing the node Configuring the valve terminal Connecting the field bus III

6 Contents and general instructions Field bus cable Field bus baud rate and field bus length Field bus interface Connection possibilities Bus connection with terminating resistors Connecting the power supply Calculating the current consumption Connecting the power supply Commissioning Configuring and addressing the valve terminal Ascertaining the configuration data Address assignment of the valve terminal Address assignment after extension/conversion Preparing the valve terminal for commissioning Switching on the power supply Information on commissioning Device master file (GSD) and symbol files Configuration with a Siemens master STEP 7 HW Config (up to V 5.2) Diagnosis and error treatment Overview of diagnostic possibilities On the spot diagnosis LEDs on the field bus node LEDs of the valves LEDs of the input/output modules Test routines Status bits Short circuit/overload Diagnosis via PROFIBUS DP Diagnostic words Diagnostic steps Overview of diagnostic bytes IV

7 Contents and general instructions Details on standard diagnostic information Position of the status bits Fault treatment Reaction to faults in the control system Siemens SIMATIC S5/S Online diagnosis with STEP Read diagnostic buffer with STEP 7 (up to V5.2) Device related diagnosis with STEP 7 (up to V5.2) Short circuit/overload at an output module Type 04 B: Fuses for the pilot solenoids A. Technical appendix A 1 A.1 Technical specifications A 3 A.2 Cable length and cross sectional area A 6 A.3 Examples of circuitry A 12 A.3.1 Power supply for type 03 internal layout A 13 A.3.2 Power supply for type 04 B internal layout A 14 A.4 Commissioning with the general DP master A 15 A.4.1 Bus start A 16 A.4.2 Send parametrizing data A 17 A.4.3 Check the configuration data A 18 A.4.4 Transferring input and output data A 20 A.4.5 Read diagnostic information A 22 A.4.6 Example of addressing A 22 A.4.7 Implemented functions and service access points (SAP) A 24 A.4.8 Bus parameters/reaction times A 24 A.4.9 Device master file (GSD) A 25 A.4.10 Configuration examples A 26 B. Index B 1 V

8 Contents and general instructions Designated use The valve terminal described in this manual is intended exclusively for use as follows: for controlling pneumatic and electric actuators (valves and output modules) for interrogating electric sensor signals by means of the input modules. Use the valve terminal only as follows: as specified in industrial applications without any modifications by the user. Only the conver sions or modifications described in the documentation supplied with the product are permitted. in faultless technical condition. The maximum values specified for pressures, temperatures, electrical data, torques etc. must be observed. If additional commercially available components such as sen sors and actuators are connected, the specifiedlimits for pres sures, temperatures, electrical data, torques, etc. must not be exceeded. Please comply with national and local safety laws and regula tions. VI

9 Contents and general instructions This manual decribes operation of the Festo valve terminal type 03/04 B in conjunction with the PROFIBUS DP field bus protocol as per EN (DIN 19245). The valve terminal can be connected to controllers of various manufacturers. Please note The valve terminal does not contain the PROFIBUS FMS protocol (no combi slave functionality). Additional modules for this valve terminal The multifunctional valve terminal can be extended with the following modules: I/O modules Type designation VIGE 03 FB... VIGA 03 FB... VIGV 03 FB... VIEA 03 FB... VIAP 03 FB VIAU 03 FB... VIASI 03 M Title Input module with 4, 8 or 16 inputs, PNP or NPN, 4 pin or 5 pin, with/without electronic fuse Output module with 4 outputs, PNP or NPN, 4 pin or 5 pin Additional supply module 24 V/25 A for high current outputs Multi I/O module with 12 inputs and 8 outputs, PNP Analogue I/O module with 1 input and 1 output Analogue I/O module with 3 inputs and 1 output type voltage ( U) or current ( I) AS Interface master Tab.0/1: Modules for extending the valve terminal VII

10 Contents and general instructions Target group This manual is intended exclusively for technicians trained in control and automation technology, who have experience in installing, commissioning, programming and diagnosing pro grammablelogic controllers (PLC) and field bus systems. Service Please consult your local Festo repair service if you have any technical problems. VIII

11 Contents and general 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 a shaded background and marked additionally with a picto gram. A distinction is made between the following danger warnings: Warning This means that failure to observe this instruction may result in serious personal injury or damage to property. Caution This means that failure to observe this instruction may result in personal injury or damage to property. Please note This means that failure to observe this instruction may result in damage to property. The following pictogram marks passages in the text which describe activities with electrostatically sensitive compo nents. Electrostatically sensitive components These may be dam aged if they are not handled correctly. IX

12 Contents and general instructions Marking special information The following pictograms mark passages in the text contain ing special information. Pictograms Information Recommendations, tips and references to other sources of information. Accessories: Information on necessary or useful accessories for the Festo product. Environment: Information on environment friendly use of Festo products. Text markings The bullet indicates activities which may be carried out in any order. 1. Figures denote activities which must be carried out in the numerical order specified. Hyphens indicate general activities. X

13 Contents and general instructions Abbreviations The following product specific abbreviations are used in this manual: Abbreviation Terminal or valve terminal Node Sub base Single solenoid sub base Double solenoid sub base I O I/O Pneumatic module I/O module PLC Fibre optic cable Meaning Valve terminal type 03 or type 04 B with or without electric I/Os Field bus node/control unit Type 03: Pneumatic sub base for two valves Type 04 B Manifold sub base incl. solenoid intermediate sub base MUH for 1, 4, 8 or 12 valves Sub base for single solenoid valves Sub base for double solenoid or mid position valves Input Output Input and/or output General pneumatic module Module with digital inputs or outputs Programmable logic controller; in brief: controller Fibre optic cable Tab.0/2: List of abbreviations XI

14 Contents and general instructions Please note A simplified representation of a type 03 valve terminal with four pneumatic sub bases and four input/output modules (standard fitting) has been used for most drawings in this manual. 1 Input/output modules Field bus node 3 Valves Fig.0/1: Standard fitting for the drawings XII

15 Contents and general instructions Manuals on this valve terminal Depending on what you have ordered and on the further ex tension of your complete system, the following Festo manuals are necessary for the complete documentation of the modular valve terminal: Festo designation P.BE MIDI/MAXI P.BE VIISO 04 B... P.BE VIEA P.BE VIAX P.BE VIASI P.BE VIFB Title/product Pneumatics manual Valve terminal type 03, MIDI/MAXI Pneumatics manual Valve terminal type 04 B, ISO Supplementary description of the I/O modules (digital I/O modules 4I, 8O, 4O, high current output modules, multi I/O modules) Analogue I/Os manual AS Interface master manual Electronics manual Field bus connection FB13 (this manual) Tab.0/3: Manuals on this valve terminal Further notes Please note All information on the pneumatic modules can be found in the Pneumatics manual P.BE MIDI/MAXI or P.BE VIISO 04 B.... XIII

16 Contents and general instructions XIV

17 Summary of components Chapter 1 1 1

18 1. Summary of components Contents 1. Summary of components Overview of multifunctional Festo valve terminals Description of components Type 03/04 B: Electric modules Type 03: MIDI pneumatic modules Type 03: MAXI pneumatic modules Type 04 B ISO pneumatic modules Method of operation

19 1. Summary of components 1.1 Overview of multifunctional Festo valve terminals The multifunctional valve terminal consists of individual mod ules and components. Valve terminal Type 03 Electric modules Type 03 Pneumatic modules Description of the modules Electric modules suitable for type 03/04B (PNP or NPN), fitted with: Digital inputs (modules with 4, 8 or 16 inputs) Digital outputs (modules with 4 outputs) 0.5A High current outputs 2 A Multi I/Os (module with 12 inputs/8 outputs) 0.5 A Analogue I/Os, AS Interface master (not possible with all nodes) Pneumatic modules type 03, fitted with: Sub bases (MIDI and MAXI) fitted with 5/2 way single solenoid valves, 5/2 way double solenoid valves, 5/3 way mid position valves (with auxiliary pilot air) or cover plates Special modules for pressure supply, pressure zone formation Type 04 B ISO pneumatic modules Pneumatic modules type 04 B, fitted with: Adapter plate for ISO manifold sub bases as per ISO sizes 1, 2 and 3 Manifold sub bases for solenoid intermediate plates with hole pattern as per ISO , fitted with pneumatic single sole noid valves, double solenoid valves, mid position valves or cover plates Components for vertical linking (pressure regulator intermedi ate plates, restrictor plates etc.) Tab.1/1: Overview of the modules on the multifunctional Festo valve terminals 1 3

20 1. Summary of components 1.2 Description of components Type 03/04 B: Electric modules You will find the following connecting and display elements on the electric modules: Input socket for two electric inputs (PNP or NPN) 2 Red LED (fault display per input module with electronic fuse) 3 Two green LEDs (one LED per input) 4 Input socket for one electric input (PNP or NPN) 8 6 Output socket for electric output (PNP) 7 Yellow LEDs (status display per output) 8 Red LED (fault display per output) 9 Further modules (e.g. additional supply, high current outputs PNP/NPN) 5 Green LED (per input) Fig.1/1: Connecting and display elements on the electric modules 1 4

21 1. Summary of components Type 03: MIDI pneumatic modules The following display and operating elements can be found on the components of the pneumatic MIDI modules type03: Yellow LEDs (per valve solenoid coil) 2 Manual override (per valve solenoid coil), either locking or non locking 3 Valve location identification field (labels) 4 Unused valve location with cover plate Fig.1/2: Display and operating elements of the MIDI modules type

22 1. Summary of components Type 03: MAXI pneumatic modules The following display and operating elements can be found on the components of the pneumatic MAXI modules type 03: Yellow LEDs (per valve solenoid coil) 2 Manual override (per valve solenoid coil), either locking or non locking 3 Unused valve location with cover plate 4 Valve location identification field (labels) 5 Regulator for limiting the pressure for auxiliary pilot air Fig.1/3: Display and operating elements of the MAXI modules type

23 1. Summary of components Type 04 B ISO pneumatic modules The following connecting, display and operating elements can be found on the components of the pneumatic ISO modules type04 B: Adapter plate type 04 B 2 Fuse for valves 3 Connecting the power supply 4 1 Yellow LEDs (per pilot solenoid 14) 2 Yellow LEDs (per pilot solenoid 12) 5 1 Manual override (per pilot solenoid 14, non locking) 2 Manual override (per pilot solenoid 12, non locking) 6 Valve location identification field 7 Fuse 0.135A (perpilot solenoid) 8 Adapter cable for power supply to node and I/O modules Fig.1/4: Operating, display and connecting elements on the ISO modules type 04 B 1 7

24 1. Summary of components 1.3 Method of operation The node takes over the following tasks: The connection of the terminal to the relevant field bus and to the power supply. The system settings of the valve terminal. An automatic valve test and further node dependent functions can be set. The control of data transfer to/from the field bus module of your control system. Internal control of the valve terminal. 1 Field bus (incoming) Field bus (continuing) 3 Node 4 4 Compressed air 5 Work air (2/4) 3 ÏÏ 5 Fig.1/5: Function overview of a valve terminal 1 8

25 1. Summary of components The input modules process input signals (e.g. from sensors) and transmit these signals via the field bus to the controller. The output modules are universal electric outputs and control low current consuming devices with positive logic, e.g. further valves, bulbs, etc. Additional I/O modules for special applications are also available. Further information on the use of all the I/O modules can be found in the Supplementary description of the I/O modules" for your valve terminal. The pneumatic modules provide the following: the common channels for supply and exhaust air the electric signals from all solenoid valve coils. Work connections 2 and 4 are provided for each valve loca tion on the individual pneumatic modules. The valves are supplied with compressed air via the common channels in the pneumatic end plate or via special supply modules. Both the air and auxiliary pilot air from the valves are also exhausted via these common channels. Further mod ules for pressure supply are also available, e.g. in order to permit work to be carried out with different work pressures, or in order to fit MIDI/MAXI valves or ISO valves on a node. Further information on their use can be found in the Pneu matics manual" for your valve terminal. 1 9

26 1. Summary of components 1 10

27 Fitting Chapter 2 2 1

28 2. Fitting Contents 2. Fitting Fitting the modules and components Earthing the end plates Fitting onto a hat rail (type 03) Fitting the valve terminal onto a wall

29 2. Fitting 2.1 Fitting the modules and components The valve terminal is supplied ready fitted from the factory. If you wish to add or replace individual modules or compo nents, please consult the following manuals: Supplementary description of the I/O modules" for fitting the electric I/O modules Pneumatics manual" for fitting the pneumatic modules The fitting instructions supplied with the product in the case of modules and components ordered at a later stage Please note Handle all modules and components of the valve terminal with great care. Please note especially the following: Screw connections must be fitted free of offset 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 (IP65). Contact surfaces must be clean (avoid leakage and con tact faults). The contacts of the type 03 valve solenoid coils must not be bent (not resistant to bending, i.e. they will break off if they are bent back). Electrostatically sensitive components Do not touch the contact surfaces of the plug connectors on the sides of the modules and components. 2 3

30 2. Fitting Earthing the end plates The valve terminal possesses a left hand and a right hand end plate as the mechanical termination of the valve terminal. These end plates fulfil the following functions: They comply with protection class IP65. They contain connections/contacts for earthing. They contain holes for fitting the valve terminal onto a wall and, in the case of type03, also for the hat rail clamp ing unit. Please note The end plates are earthed internally when the valve ter minal is supplied from the factory. If you undertake exten sions/conversions to valve terminal type 03, earth the end plates of the terminal as described below. In this way, you will avoid interference caused by electro magnetic influences. Earth the end plates after extension/conversion as follows: 1. Right hand end plate (type 03): 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 node (see following dia gram). 2. Left hand end plate: The left hand end plate is connected conductively with the other components by means of ready fitted spring contacts. Please note: Instructions on earthing the complete valve terminal can be found in the chapter Installation." 2 4

31 2. Fitting The following diagram shows how both end plates are fitted, using as an example valve terminal type Seal 2 Contact for earth cable 3 Pre fitted earthing cable 4 Fastening screws max.1nm Fig.2/1: Fitting the end plates (example valve terminal type 03) 2 5

32 2. Fitting 2.2 Fitting onto a hat rail (type 03) The valve terminal is suitable for fitting onto a hat rail (sup port rail as per EN 50022). There is a guide groove on the back of all modules for hanging them on a hat rail (see Fig.2/3). Caution A hat rail fitting without a hat rail clamping unit is not permitted. If the terminal is fitted in a sloping position or if it is sub jected to vibration, secure the hat rail clamping unit additionally against sliding down and against unintentional opening or closing with the retaining screws (item 3). Please note If the terminal is fitted in a horizontal position and if the load is at rest, it is not necessary to use the screws (item3) to secure the hat rail clamping unit. If your terminal does not have a hat rail clamping unit, you can order this and fit it at a later stage. Whether MIDI or MAXI clamping elements are to be used depends on the end plates fitted. Hat rail clamping unit (type 03) For fitting the valve terminal on to the hat rail you will require a hat rail clamping unit. This must be fastened to the rear of the end plates as shown in the following diagram. Pay par ticular attention to the following: 2 6

33 2. Fitting Before fitting The adhesive surfaces for the rubber feet must be clean (cleaned with spirit). The flat head screws must be tightened (item 3). After fitting The levers must be locked with retaining screws (item 6) Lever *) 2 O ring 3 Flat head screw 4 Self adhesive rubber foot 5 Clamping elements 6 Retaining screw *) Different lever lengths with MIDI and MAXI Fig.2/2: Fitting the hat rail clamping unit 2 7

34 2. Fitting Proceed as follows: 1. Ascertain the weight of your valve terminal as described in section Make sure that the mounting surface can support this weight. 3. Fit a hat rail (support rail as per EN x15; width35mm, height 15 mm). 4. Fasten the hat rail to the fastening surface at intervals of at least every 100 mm. 5. Hang the terminal onto the hat rail. Secure the valve ter minal on both sides with the hat rail clamping unit against tilting or sliding down (see Fig.2/3). 6. If the load vibrates or if the valve terminal is fitted in a sloping position, secure the hat rail clamping unit against unintentional loosening or opening with two screws (item3). 1 Hat rail clamping unit unlocked 2 Hat rail clamping unit locked 3 Retaining screw Fig.2/3: Fitting valve terminal type 03 onto a hat rail 2 8

35 2. Fitting 2.3 Fitting the valve terminal onto a wall Caution In the case of long valve terminals with several I/O modules, use additional support brackets for the modules (approx. every 200 mm). You can thereby avoid: overloading the fastening eyes on the left hand end plate the terminal hanging down (I/O side) internal oscillations. Proceed as follows: 1. Ascertain the weight of your valve terminal (weigh or calculate). Guidelines: Valve terminal module Typ 03 *) Per pneumatic module (incl. valves) MIDI 0.8 kg MAXI 1.2 kg Type 04 B manifold sub bases *) Adapter plate and right hand end plate Per pneumatic module (incl. manifold sub base, solenoid intermediate plate and valve) ISO size kg 1.2 kg ISO size kg 1.6 kg ISO size kg 2.4 kg Node 1 kg 1 kg 1 kg I/O module 0.4 kg 0.4 kg 0.4 kg *) Components for vertical stacking: Weight see Pneumatics manual Tab.2/1: Ascertaining the weight of the valve terminal 2. Make sure that the mounting surface can support this weight. Check to see if you require support brackets for the I/O modules. 3. If necessary, use washers. 2 9

36 2. Fitting 4. Fasten the valve terminal, depending on the type, as shown in the table below. The valve terminal can be fitted in any position. Type of valve terminal Type 03 Fastening possibilities With four M6 screws on both the left and right hand end plates. In the case of valve terminals with several I/O modules, use additional support brackets for the modules (approx. every 200 mm). Type 04 B With two M6 screws on the left hand end plate With three M6 screws (ISO sizes 1 and 2) or M8 (ISO size 3) on the adapter plate and on the right hand end plate. If required, use the following additional fastening methods: The fastening screw per manifold sub base The hole on the bottom of the manifold sub base (Blind hole," see Pneumatics manual) In the case of valve terminals with several I/O modules, use additional support brackets for the modules (approx. every 200 mm). Tab.2/2: Fastening possibilities for fitting onto a wall 2 10

37 Installation Chapter 3 3 1

38 3. Installation Contents 3. Installation General notes on connecting the tubing Cable selection Connecting the cables to the plugs/sockets Setting the field bus node Opening and closing the node Configuring the valve terminal Connecting the field bus Field bus cable Field bus baud rate and field bus length Field bus interface Connection possibilities Bus connection with terminating resistors Connecting the power supply Calculating the current consumption Connecting the power supply

39 3. Installation 3.1 General notes on connecting the tubing Warning Before carrying out installation and maintenance work, switch off the following: the compressed air supply the operating voltage for the electronics (pin 1) the load voltage supply for the outputs/valves (pin2). You can thereby avoid: uncontrolled movements of loose tubing unexpected movements of the connected actuators non defined switching states of the electronic compo nents Cable selection Field bus cable Use a twisted, screened two wire cable for the field bus. Refer to section in the manual for your controller for the types of cables to be used. Power supply Several parameters must be taken into consideration when the two operating voltages are to be connected. Further in formation can be found in the following sections: Calculating the current consumption, selecting the power unit: Section Calculating the current consumption" Cable length and cross sectional area: Section 3.5 Connecting the power supply" Ascertaining the cable length and cross section with tables or formulae: Appendix A.2 3 3

40 3. Installation Connecting the cables to the plugs/sockets Caution The position of the pins on the plug is different from that on the socket. The connections on the input and output modules are in the form of sockets. The connections for the power supply are in the form of plugs. The pin assignment can be found in the following sections. 1 Cable 2 Strain relief 3 Housing 4 Connecting part Fig.3/1: Individual parts of the plug/socket and cable exit When you have selected suitable cables, connect them to the plugs/sockets as follows: 3 4

41 3. Installation 1. Open plugs/sockets from Festo as follows (see Fig.3/1): Power supply socket: Insert the the power supply socket into the power supply connection of the valve terminal. Unscrew the housing of the socket. Remove the connection part of the socket which is still inserted in the power supply connection. Sensor plug (for input/output modules): Loosen the knurled nut. 2. Open the strain relief on the rear of the housing. Pull the cable through as follows (see diagram). Cable outer diameter: PG7: 4, mm PG9: 6, mm PG13.5: 10, mm Plug/socket (straight or angled): Mains power socket PG7, 9 or 13.5 Sensor plug PG7 Bus cable socket PG7, 9 or Remove the insulation from the end of the conductors and fit core end sleeves. 4. Connect the conductors. 5. Replace the connecting part on the housing of the plug/ socket and screw it tight. Pull the cable back so that there are no loops inside the housing. 6. Tighten the strain relief. 3 5

42 3. Installation 3.2 Setting the field bus node You will find the following connecting and display elements on the cover of the node: 1 Green LED 2 Red LED 3 Operating voltage connection Fuse for the operating voltage of the inputs 5 5 Plug for field bus cable 4 3 Fig.3/2: Cover of the node Opening and closing the node Warning Before carrying out installation and maintenance work, switch off the following: the compressed air supply the operating voltage for the electronics (pin 1) the load voltage supply for the outputs/valves (pin2). You can thereby avoid: uncontrolled movements of loose tubing unexpected movements of the connected actuators 3 6

43 3. Installation non defined switching states of the electronic compo nents. Caution The node contains electrostatically sensitive components. Do not therefore touch any contacts. Observe the regulations for handling electrostatically sensitive components. You will then prevent the electronics in the node from being damaged. Opening Please note The cover is connected to the internal printed circuit boards by the cables for the operating voltage connection. It cannot therefore be removed completely. 1. Unscrew and remove the six screws in the cover. 2. Loosen the screws on the sub D plug. 3. Carefully lift up the cover. Do not damage the cable. Closing 1. Replace the cover. Place the cables for the operating volt age in the housing so that they are not squashed. 2. Tighten the screws in the cover in diagonally opposite sequence. 3. Tighten the screws on the sub D plug. 3 7

44 3. Installation Configuring the valve terminal There are three printed circuit boards in the node. On board 2 there is an LED and a plug for the field bus cables; on board 3 there are two LEDs and switches for setting the configuration. 1 Board 1 2 Board 2 3 Board Address selector switch (station no.) 5 Voltage monitoring on/off aa aj Reserved 7 Flat plug for power supply 8 Screening plate Socket for field bus cable aj Red LED 7 aa Green LEDs Fig.3/3: Connecting, display and operating elements on the node Please note Boards 2 and 3 are connected together. They can only be removed or inserted together. 3 8

45 3. Installation Setting the station number You can set the station number with the rotary switches and element 1 of the DIL switch. 1 Rotary switch for the UNITS figure 2 Rotary switch for the TENS figure 3 DIL switch for the HUNDREDS figure 1 2 UNITS TENS 3 HUNDREDS ON{ ON{ Example of set station numbers: Fig.3/4: Setting the station number and examples Proceed as follows: 1. Switch off the operating voltage. 2. Assign an unused PROFIBUS address to the valve terminal. 3. Use a screwdriver to set the arrow of the relevant rotary switch or element 1 of the DIL switch to the units, tens or hundreds figure of the desired station number. 3 9

46 3. Installation The following station numbers are permitted: Protocol Address designation Permitted station numbers PROFIBUS DP Station number 1;...; 125 Tab.3/1: Permitted station numbers Please note The station number (DP slave address) of the valve ter minal cannot be modified by the DP master. The valve ter minal can only be addressed by the station number set on the rotary/dil switches. Station numbers may only be assigned once per field bus module/profibus DPinterface. Observe any possible limitations as regards the assign ment of field bus addresses by your DP master. Recommendation: Assign the station numbers in ascending order. If necessary, assign the station numbers to suit the machine structure of your system. 3 10

47 3. Installation Setting the voltage monitoring With switch element 2 of the DIL switch, you can specify whether or not the load voltage of the valves and the output modules is to be monitored (see chapter 5 Diagnosis and fault treatment"). DIL switch Voltage monitoring active Voltage monitoring inactive DIL 2: ON DIL 2: OFF Tab.3/2: Setting the voltage monitoring Reserved DIL switch elements 3 and 4 Leave the switch elements 3 and 4 of the DIL switch set as follows: DIL switch Setting reserved DIL 3: ON, DIL 4: OFF Tab.3/3: Reserved DIL switch elements 3 and 4 Please note If necessary, display the configuration data before the cover of the node is closed. It is then still possible to make any modifications. 3 11

48 3. Installation 3.3 Connecting the field bus Field bus cable Please note With incorrect installation and high baud rates, data trans mission errors may occur as a result of signal reflexions and attenuations. Causes of the transmission errors may be: missing or incorrect terminating resistor incorrect screening/shield connection branches transmission over long distances unsuitable cables. Observe the cable specifications. Refer to the manual for your controller for information on the type of cable to be used. Please note If the valve terminal is fitted onto the moving part of a ma chine, the field bus cable on the moving part must be pro vided with strain relief. Please observe also the relevant regulations in IEC/DIN EN

49 3. Installation Use a twisted, screened 2 wire cable for the field bus. Cable specification as per EN (cable type A): Surge impedance: Ohm ( MHz) Capacitance per unit length: < 30 nf/km Loop resistance: < 110 Ohm/km Core diameter: > 0.64 mm Core cross sectional area: > 0.34 mm 2 Bus length Exact specifications on the bus length can be found in the next section and in the manuals for your control system. 3 13

50 3. Installation Field bus baud rate and field bus length Please note The maximum permitted field bus length and branch line length depend on the baud rate used. Please observe the maximum permitted length of the field bus cable, if you connect the bus node viaa branch line. Take into account also the sum of the branch line lengths when calculating the maximum permitted length of the field bus cable. Field bus node FB13 sets itself automatically to one of the following baud rates: Baud rate (inkbaud) Field bus length (max.) Max. permitted branch line length m 500 m m 500 m m 100 m m 33.3 m m 20 m m 6.6 m m Tab.3/4: Max. field bus length and branch line length for PROFIBUS DP depending on the baud rate 3 14

51 3. Installation Field bus interface There is a 9 pin sub D socket on the node for connecting the valve terminal to the field bus. This connection is used for the incoming cable, as well as for the continuing field bus cable. You can connect the valve terminal with the field bus plug from Festo type FBS SUB 9 GS DP B. Please note Only the Festo field bus plug complies with IP65. Before connecting the field bus plugs from other manufacturers: Replace the two flat screws by bolts (part no ). Socket on node Pin Field bus plug IP65 from Festo 1) PROFIBUS DP Designation Housing B A Clamp strap Screening/shield n.c. RxD/TxD P CNTR P 2) DGND VP n.c. RxD/TxD N n.c. Screening/shield Connection to functional earth Not connected Receive/send data P Repeater control signal 2) Data reference potential (M5V) Power supply positive (P5V) Not connected Receive/send data N Not connected Connection to functional earth 1) Type FBS SUB 9 GS DP B (part no ) 2) Repeater control signal CNTR P is in the form of a TTL signal. Tab.3/5: Pin assignment of the field bus interface 3 15

52 3. Installation Connection possibilities Please note Use a protective cap or blanking plug to seal unused con nections. You will then comply with protection class IP65. Connection with field bus plugs from Festo Observe the fitting instructions for the field bus plug. You can connect the valve terminal to the field bus easily with the field bus plug from Festo (type FBS SUB 9 GS DP B, part no ). You can disconnect the plug from the valve ter minal without interrupting the bus cable (T TAP function). 1 Hinged cover with display window 2 Blanking plug if connection is not used 3 Clamp strap for screening/shield connection Bus out Bus in 4 Field bus incoming (IN) AB ON AB 5 Switch for bus termination and continuing field bus 6 Field bus continuing (OUT) 7 Only connected capacitively Fig.3/5: Field bus plug from Festo, type FBS SUB 9 GS DP B 3 16

53 3. Installation Please note The clamp strap in the field bus plug from Festo is con nected internally only capacitively with the metallic hous ing of the sub D plug. This is to prevent equalizing currents flowing through the screening of the field bus cable. DIL switches With the switch in the field bus plug you can switch the following: Switch position OFF: The bus termination is switched off and the continuing field bus cable is switched in. Switch position ON: The bus termination is switched on and the continuing field bus cable is switched off (seefig.3/6). Please note Note the type designation of your field bus plug. The new plug type FBS SUB 9 GS DP B switches the continuing field bus cable off when the bus termination is switched on. 3 17

54 3. Installation Connection with M12 adapter (reverse key coded) With adapter (type: FBA 2 M12 5POL RK, part no ), you can connect the valve terminal to the field bus via an M12 plug connector. The plug connectors have an inverted mech anical coding (reverse key or B coded), to avoid confusion between incoming and continuing connections. You can disconnect the M12 adapter from the valve terminal without interrupting the bus cable (T TAP function). Connection to the bus is made with a 5 pin M12 plug with PG9 screw connector. Use the second connection socket for the continuation of the field bus. M12 adapter (reverse key coded) Pin no VP: Power supply positive (P5V) 2. RxD/TxD N: Receive/Send data N DGND: Data reference potential (M5V) 4. RxD/TxD P: Receive/Send data P 5. FE: Functional earth Housing/thread: Screening/shield Bus in Bus out Protective cap or plug with bus termination resistor if connection is not used. Tab.3/6: Pin assignment of the field bus interface with adapter for M12 connection, 5 pin 3 18

55 3. Installation Connection with optical fibre waveguide The PROFIBUS DP interface of the node complies with specifi cation EN and supports the control of network com ponents for optical fibre waveguides. Use optical fibre waveguides when transmission is affected by heavy interference, as well as for extending the trans mission range when high baud rates are used. Example of optical fibre waveguide network components: Siemens Optical Link Module (OLM) for PROFIBUS plus Siemens Optical Link Plug (OLP) for PROFIBUS (IP20) Harting Han InduNet Media converter IP65 in combina tion with adapter cable for Festo products (optical data transmission in DESINA installation concept). 3 19

56 3. Installation 3.4 Bus connection with terminating resistors Please note If the valve terminal is at the beginning or the end of the field bus system, a bus termination will be required. Fit a bus termination to both ends of the bus segment. Recommendation: Use the ready to use field bus plugs from Festo for the bus termination. A suitable resistor network is incorporated in the housing of this plug (see Fig.3/6). Pin 6: Power supply 390 Receive/send data P (data cable B) Pin nh 220 Receive/send data N (data cable A) Pin nh 390 Pin 5: Data reference potential Fig.3/6: Circuit diagram for bus connection network for cable type A as per EN (switch in Festo field bus plug set to ON) 3 20

57 3. Installation 3.5 Connecting the power supply Warning Use only PELV circuits as per IEC/DIN EN (Pro tective Extra Low Voltage, PELV) for the electrical supply. Consider also the general requirements for PELV circuits in accordance with IEC/DIN EN Use power supplies which guarantee reliable electrical isolation of the operating voltage as per IEC/DIN EN By the use of PELV circuits, protection against electric shock (protection against direct and indirect contact) is guaranteed in accordance with IEC/EN (Electrical equipment for machines, General requirements). Caution The load voltage supplyfor the outputs/valves must be protected with an external fuse with maximum 10 A (slow blowing). With the external fuse you can avoid functional damage to the valve terminal in the event of a short circuit. 3 21

58 3. Installation Before you start to connect the power supply, please observe the following: Avoid long distances between the power unit and the valve terminal. If necessary, calculate the permitted dis tance in accordance with Appendix A. The following apply as orientation values for your valve terminal: Cable cross sectional area 1.5 mm mm 2 Distance 8 m 14 m Current consumption (at V B = 24 V): Operating voltage (pin 1) = 2.2 A Operating voltage (pin 2) = 10 A Tab.3/7: Orienation values for the cable cross sectional area Ascertain the total current consumption in accordance with the following table and then select a suitable power unit as well as suitable cable cross sectional areas Calculating the current consumption The following table shows you how to calculate the total cur rent consumption of the valve terminal. The values specified have been rounded up. If you use other valves or modules, please refer to the relevant technical specifications for their current consumption. 3 22

59 3. Installation Current consumption of electronics and inputs (pin 1 on node, 24 V ± 25 %) Node 0.200A Number of simultaneously assigned sensor inputs x A + Σ A Sensor supply (see manufacturer s specifications) x A + Σ A Current consumption of electronics and inputs (pin 1 on the node) max.2.2 A = Σ A A Current consumption of valves and outputs (pin2on the node, 24 V ± 10 %) Number of valve coils (simultaneously energized): Type 03 MIDI: x A MAXI: x A Type 04 B ISO: Sizes x A Σ A Number of simultaneously activated electric outputs: Load current of simultaneously activated electric outputs: x A x A + Σ A + Σ A Current consumption of outputs (pin 2 on the node) max.10a = Σ A + A Current consumption on the node = Σ A Current consumption of high current outputs *) (pin 1 of additional supply *) 24 V/25 A) Number of fitted high current output modules Load current of simultaneously activated high current output modules x A x A Σ A + Σ A Current consumption of high current outputs *) *) Per additional supply max. 25 A = Σ A Σ A Tab.3/8: Calculating the total current consumption 3 23

60 3. Installation Connecting the power supply The following components on the valve terminal are supplied separately with + 24V DC via the power supply connection: The operating voltage for the internal electronics and the inputs of the input modules (pin 1: + 24 V DC, tolerance ±25%, external fuse M3.15A recommended). The load voltage for the valves and outputs of the output modules (pin 2: + 24V DC, tolerance ± 10%, external fuse 10 A (slow blowing) required). 1 Power supply type 03 2 Power supply type 04 B 1 2 Fig.3/7: Type specific power supply connection Please note Check within the framework of your EMERGENCY STOP circuit, to ascertain the measures necessary for putting your machine/system into a safe state in the event of an EMERGENCY STOP (e.g. switching off the operating voltage for the valves and output modules, switching off the com pressed air). 3 24

61 3. Installation The pin assignment of the power supply connection on the node (type 03) or adapter block (type 04 B) is identical V Operating voltage for electronics and inputs 2 24 V Load voltage forvalves and outputs 3 0V 4 Earthing connection Fig.3/8: Pin assignment of power supply connection type 03/04 B Please note If there is a common power supply for operating and load voltages at pin 1 (electronics and inputs) and pin 2 (out puts/valves): Observe the lower tolerance of ± 10% for both current circuits. Check the 24V load voltage of the outputs while your system is operating. Make sure that the load voltage of the outputs lies within the permitted tolerance even during full load oper ation. Recommendation: Use a closed loop power unit. 3 25

62 3. Installation Potential equalization The valve terminal has two earthing connections for potential equalization: on the power supply connection (pin 4, incoming, Fig.3/8) on the left hand end plate (M4 thread). Please note Always connect the earth potential to pin 4 of the power supply connection. Connect the earth connection of the left hand end plate to the earth potential with low impedance (short cable with large cross sectional area). With low impedance connections you can ensure that the housing of the valve terminal and the earth connec tion at pin 4 have the same potential and that there are no equalizing currents. In this way you can avoid faults due to electromagnetic influences and ensure electromagnetic compatibility in accordance with EMC guidelines. 3 26

63 3. Installation Connection example The diagram below shows as an example the connection of a common 24V power supply for pins 1 and 2. Please note here that: the load voltage of the outputs/valves must be fused ex ternally with maximum 10A (slow blowing) against short circuit/overload. the power supply for the electronics and inputs must be protected against short circuit/overload with an external fuse with 3.15 A. the power supply for the sensors must be protected addi tionally with the built in fuse (2 A). the common tolerance of 24 V DC ± 10 % must be ob served. both connections for potential equalization are connected and that equalizing currents must be prevented. the load voltage at pin 2 (valves/electric outputs) can be switched off separately. 3 27

64 3. Installation V 24V 10% 0V 24 V 3.15A 10A Fuse for sensor inputs (2A) 2 Earth connection pin 4 is designed for12a 4 Load voltage can be switched off separately 5 External fuses 3 Potential equalization Fig.3/9: Example connecting a common 24V power supply and the potential equalization (example type 03) 3 28

65 Commissioning Chapter 4 4 1

66 4. Commissioning Contents 4. Commissioning Configuring and addressing the valve terminal Ascertaining the configuration data Address assignment of the valve terminal Address assignment after extension/conversion Preparing the valve terminal for commissioning Switching on the power supply Information on commissioning Device master file (GSD) and symbol files Configuration with a Siemens master STEP 7 HW Config (up to V 5.2)

67 4. Commissioning 4.1 Configuring and addressing the valve terminal Ascertaining the configuration data Before configuring, ascertain the exact number of available inputs/outputs. A multifunctional valve terminal consists of I/Os, the number of which may vary depending on what you have ordered. Please note The status bits must be treated like inputs and occupy four additional input addresses. The maximum amount of equipment which can be fitted on the valve terminal is limited by the addressing limits of the relevant field bus protocol and the mechanical limits of the terminal. Type 04 B: With this valve terminal, the assignment of the valve addresses can be set fixed by means of a DIL switch in the adapter block. This manual valve terminal configur ation (Address reserving") is described in the Appendix of the manual Pneumatics type 04 B." 4 3

68 4. Commissioning The following table specifies the I/Os required per module for configuration: Type of module MIDI/MAXI sub base (type 03) Single solenoid sub base Double solenoid sub base ISO sub base (type 04 B) Single solenoid sub base Double solenoid sub base 4 output module (4 digital outputs) 4 input module (4 digital inputs) 8 input module (8 digital inputs) 16 input module (16 digital inputs) Multi I/O module Status bits **) Number of assigned I/Os *) 2 O 4 O 1 O 2 O 4 O 4 I 8 I 16 I 12 I + 8 O 4 I *) The I/Os are assigned automatically within the valve terminal, irrespective of whether an input/output is actually used. **) The status bits are assigned automatically within the valve terminal as soon as there are input modules. Tab.4/1: Number of assigned I/Os per module Copy the following table for further calculations. 4 4

69 4. Commissioning Calculating the number of inputs/outputs Inputs 1. Number of 4 input modules x 4 Σ I 2. Number of 8 input modules x 8 + Σ I 3. Number of 16 input modules x 16 + Σ EI 4. Number of other inputs, e.b. multi I/O module 5. The 4 status bits are assigned automatically internally by the valve terminal. + Σ I + 4 I Total number of inputs to be configured = Σ I Outputs 6. Number of single solenoid MIDI/MAXI sub bases x 2 7. Number of double solenoid MIDI/MAXI sub bases x 4 8. Number of type 04 B single solenoid sub bases *) x 1 9. Number of type 04 B double solenoid sub bases *) x 2 Σ O + Σ O + Σ O + Σ O *) Note any possible address reservations with type 04 B Intermediate sum Check whether sum of is divisible by 4 without remainder. This check must be carried out because of the 4 bit orientated internal addressing of the valve terminal. Case distinction: a) If divisible by 4 without remainder: continue with 11. b) If not: round up to next half byte ( ). 11.Number of electric 4 output modules x 4 12.Number of other outputs, e.g. multi I/O module = Σ O + 2 O + Σ O + Σ O Total number of outputs to be configured = Σ O Tab.4/2: Calculating the number of inputs/outputs 4 5

70 4. Commissioning Address assignment of the valve terminal The address assignment of the outputs of a multifunctional valve terminal depends on the equipment fitted on the valve terminal. A distinction must be made between the following fitting variants: valves and digital I/O modules valves only digital I/O modules only. The basic rules described below apply to the addressing of these fitting variants. A detailed example is given after these basic rules. Please note If two addresses are assigned for a valve location, the following sequence applies: lower value address: pilot solenoid 14 higher value address: pilot solenoid 12 Information on address reservation of the valves on the valve terminal type 04 B can be found in the manual Pneumatics type 04 B." 4 6

71 4. Commissioning Basic rules for addressing With mixed fitting, the address assignment of the valves, digi tal I/O modules and status bits is taken into account. Outputs 1. The address assignment of the outputs does not depend on the inputs. 2. Address assignment of the valves Assign the addresses in ascending order without gaps. Counting begins on the node from left to right. Maximum 26 valve solenoid coils can be addressed. Type 03: Single solenoid sub bases always occupy 2 addresses Double solenoid sub bases always occupy 4 addresses Type 04 B: Single solenoid sub bases always occupy 1 address Double solenoid sub bases always occupy 2 addresses 3. Round up to 14 bits: Case distinction: a) If the number of valve addresses is divisible by 4 with out remainder: continue with point 4. a) If the number of valve addresses is not divisible by 4 without remainder: you must round up to 4 bits because of the 4 bit orientated addressing. The thus rounded bit in the address range cannot be used. 4 7

72 4. Commissioning 4. Address assignment of the output modules When the valves have been addressed (rounded up to 4 bits), the digital outputs must be addressed. Assign the addresses in ascending order without gaps. Counting begins on the node from right to left. Counting on the individual modules is from the top to the bottom. Digital output modules occupy 4 or 8 addresses. Inputs 1. The address assignment of the inputs does not depend on the outputs. 2. Address assignment of the input modules Assign the addresses in ascending order without gaps. Counting begins on the node from right to left. Counting on the individual modules is from the top to the bottom. Input modules occupy 4, 8, 12 or 16 addresses. 3. Status bits: The address assignment of the status bits depends on the equipment fitted on the inputs and on the configuration. The following always applies: The status bits are only available if: input modules are connected to the valve terminal and have been configured. Addressing: The status bits are transmitted to the four highest value positions of the configured address range. 4 8

73 4. Commissioning When the power supply is switched on, the valve terminal recognizes all available pneumatic modules and digital input/ output modules automatically and assigns the appropriate addresses. If a valve location is not used (cover plate) or if an input/output is not connected, the relevant address will still be occupied. The following diagram shows an example of the address assignment: input module 2 8 input module 3 4 output module 4 Single solenoid sub base 5 Double solenoid sub base 6 Round up Fig.4/1: Address assignment of a valve terminal with digital I/Os (example type 03) Remarks on Fig.: If single solenoid valves are fitted onto double solenoid sub bases of valve terminal type 03 (MIDI/MAXI), four addresses will be assigned for valve solenoid coils; the higher address in each case then remains unused (see address 3 or Tab.4/1). If unused valve locations are fitted with cover plates, the addresses are still reserved (see addresses 12, 13). 4 9

74 4. Commissioning Due to the 4 bit orientated addressing of the modular valve terminal, the last valve location is always rounded up to 4 full bits (providing the equipment fitted does not already use the full 4 bits). Under circumstances two ad dresses cannot be used (see addresses 14, 15). Additional instructions for valve terminals without I/O modules If only valves are used, the address assignment is always as described in Basic rules of addressing." Please note Maximum 26 valve solenoid coils can be addressed. Rounding up the last two positions on the valve side is not necessary. Valve terminals without input modules do not require a configuration for inputs. The status bits are not there fore available. Additional instructions for valve terminals without valves If only electric I/Os are used, the address assignment is always as described in Basic rules of addressing." Please note Method of counting Counting begins immediately to the left of the node. Rounding up the last two positions on the valve side is not necessary. The maximum amount of equipment which can be fitted on the valve terminal is limited by the addressing limits of the relevant field bus protocol and the mechanical limits of the terminal (max. 96 I or max. 48 O). 4 10

75 4. Commissioning Address assignment after extension/conversion A special feature of the multifunctional valve terminal is its flexibility. If the demands placed on the machine change, the equipment fitted on the valve terminal can also be modified. Caution If the valve terminal is extended or modified at a later stage, the input/output addresses may be shifted. This applies in the following cases: If one or more pneumatic sub bases are fitted or re moved at a later stage (type 03/04 B). Type 03: if a pneumatic sub base for two single solenoid valves is replaced by a sub base for two double solenoid valves or vice versa. Type 04 B: if a pneumatic sub base for one single sole noid valve is replaced by a sub base for one double solenoid valve or vice versa. If additional input/output modules are inserted between the node and existing input/output modules. If existing I/O modules are removed or replaced by I/O modules which occupy fewer or more input/output ad dresses. If the configuration of the inputs is modified, the addresses of the status bits may be shifted. 4 11

76 4. Commissioning The following diagram shows as an example the modifications to the address assignment when the standard fitting in the previous diagram is extended. Two single solenoid sub bases and two double solenoid sub bases have been added on the valve side. An 8 input module and a 4 output module have been removed from the electric I/O side input module 2 4 output module 3 Single solenoid sub base 4 Double solenoid sub base 5 Supply 6 No rounding up Fig.4/2: Address assignment of a valve terminal with digital I/Os after extension/ conversion (example type 03) Remarks on Fig.: Pressure supply modules and pressure zone supply modules do not occupy any addresses. 4 12

77 4. Commissioning 4.2 Preparing the valve terminal for commissioning Switching on the power supply Please note Please observe also the instructions in the manual for your controller. When the controller is switched on, it automatically carries out a comparison between the NOMINAL and the ACTUAL configurations. For this configuration procedure it is import ant that: the configuration specifications are complete and correct. the field bus slaves are supplied with power in order that they are recognized when the ACTUAL configuration is ascertained Information on commissioning Please note Consider the following points: You can then be sure that your system functions reliably with the Festo valve ter minal. Module IM 308 C, CP xx,... in the correct location on the automation device. The location number does not refer to the physical ar rangement of the input/output modules. Note possible limitations to the number of digital inputs/ outputs with process image, e.g. S7 300/CPU315DP

78 4. Commissioning The set station number does not correspond to the confi gured periphery address. Peripheral addresses of automation modules must not coincide with the configured periphery addresses. The number and type of the pneumatic sub bases is de cisive for the configuration of the outputs (e.g. 8DO), and not the number of valves fitted. Number of input bits: The number of bits is always in creased by 4 (= status bits). Reserve locations are not permitted. If necessary, switch in a terminating resistor on both sides. Selecting the profile Use the profile DP standard (PROFIBUS DP), in order to use the extended functions of the valve terminal. The selection of the profile is different in the individual con figuration programs. Details can be found in the relevant manuals. Status bits If the valve terminal is fitted with at least one input module (4or 8 inputs), it will always provide 4 status bits ( = inputs) for diagnostic purposes. Please note The 4 status bits always increase the number of inputs to be configured by 4. Valve terminals without inputs do not provide any status bits. 4 14

79 4. Commissioning Function and position of the status bits see chapter 5 Diagnosis and fault treatment." FREEZE and SYNC The operating modes FREEZE and SYNC are supported by the CP system in accordance with EN The method of accessing the commands FREEZE and SYNC depends on the controller used. Please refer here to the documentation for your field bus module. Caution The operating modes FREEZE or SYNC will be reset auto matically if: the valve terminal is switched on or off the field bus module is stopped. Only the operating modes FREEZE will be reset automati cally if: the bus connection to the valve terminal is interrupted (response monitoring active). FREEZE command All inputs of the valve terminal will be frozen." The valve terminal now sends a constant image of all the inputs to the master. With each further FREEZE command, the input image is updated and sent again constantly to the master. Return to normal operation: UNFREEZE command SYNC command All outputs of the valve terminal will be frozen." The valve terminal now no longer reacts to modifications to the output image in the master. With each further SYNC command, the updated output image will be transmitted. Return to normal operation: UNFREEZE command 4 15

80 4. Commissioning Module consistency The valve terminal supports the following variants of module consistency: over the complete length of the valve terminal over the selected format (byte/word). Configuration with DP identifiers The type and the number of inputs and outputs are described under PROFIBUS DP with identifiers. The DP identifiers can be entered via a dialogue or directly in the configuration tables of the configuration programs. The method of handling depends on the configuration program. The following tables give an overview of the possible entries for the valve terminal. 4 16

81 4. Commissioning Number of inputs Number of bytes Sum identifier (decimal) Individual identifier up to d 8DI 8DI up to d 16DI 8DI, 8DI up to d 24DI 8DI, 8DI, 8DI up to d 32DI 8DI, 8DI, 8DI, 8DI up to d 8DI, 8DI, 8DI, 8DI, 8DI up to d 8DI, 8DI, 8DI, 8DI, 8DI, 8DI up to d up to d up to d up to d up to d up to d Number of outputs Number of bytes Sum identifier (decimal) Individual identifier up to d 8DO 8DO up to d 16DO 8DO, 8DO up to d 24DO 8DO, 8DO, 8DO up to d 32DO 8DO, 8DO, 8DO, 8DO up to d 8DO, 8DO, 8DO, 8DO, 8DO up to d 8DO, 8DO, 8DO, 8DO, 8DO, 8DO up to d up to d up to d up to d Tab.4/3: Possible configuration of the inputs and outputs 4 17

82 4. Commissioning Individual identifier Sum identifier An identifier for 8 inputs or 8 outputs. An identifier for the sum of the input bytes or output bytes. Bit Bit Long data 00 = 1 byte/word = 16 bytes/words Input/output 00 = Specific identifier formats *) 01 = Entry 10 = Output 11 = Input/output *) Length 0 = Byte 1 = Word Consistency 0 = Byte or word 1 = Complete length *) Not supported Fig.4/3: Structure of the identifier bytes The following example shows the structure of a DP identifier. 8 digital inputs: b = 016 d (010 h ): 8DI 4 18

83 4. Commissioning Please observe the following rules when configuring the valve terminal: Caution Always configure inputs before outputs". The number of inputs/outputs (rounded up to full bytes) must correspond to the equipment fitted on the valve ter minal. The configuring of additional inputs and outputs as a later reserve is not permitted. The number of inputs/outputs (rounded up to full bytes) must correspond to the equipment fitted on the valve ter minal. If your valve terminal does not have inputs, then start with the outputs at identifier 0." The configuring of additional inputs and outputs or empty spaces as a later reserve is not permitted. Configuration is possible with an individual identifier or with a sum identifier. Max. 7 identifiers for digital inputs and digital outputs are possible for configuration with individual identifiers. If your valve terminal has more than 56 I/Os, please use the sum identifier. The following sequence applies if you are using the sum identifier: 1. Identifier 0": Digital inputs 2. Identifier 1": Digital outputs 4 19

84 4. Commissioning Valve terminal configuration The valve terminal with FB13 ascertains automatically the valve terminal configuration of the connected peripherals and makes it available for the user. You can display the data of the valve terminal configuration (see section 5.2.4): number of input bytes of local inputs number of output bytes of local outputs number of AS Interface input bytes number of AS Interface output bytes number of analogue input words number of analogue output words. Station selection The station selection is different in the individual configur ation programs. Device master files (GSD) are available for selection (see section 4.3). Please note Information on using the GSD files can be found: in the manual for your configuration program in your reference source for the GSD files (see section 4.3). The following sections show an example of station selection and configuration with software STEP

85 4. Commissioning 4.3 Device master file (GSD) and symbol files In order to configure the valve terminal with a PC/pro grammer, you will require the appropriate GSD file. In addi tion to slave typical entries (Ident. number, Revision, etc.), the device master file (GSD) also contains a selection of ident ifiers. Reference sources Current GSD files can be found on the Festo Internet pages under: You can then also obtain the GSD files and further configur ation aids with the CD ROM Utilities" from Festo: type P.CD VI UTILITIES 2, TN The most up to date GSD files are always available via the Internet. GSD files You will require one of the following files for the valve ter minal with field bus node 13: VI03FB13.GSD (German version) or VI03FB13.GSE (international version) Symbol files In order to represent the valve terminal in your configuration software, you will find symbol files under the above men tioned Internet address. Normal operating status Diagnostic case Special operating status File: Pbfb13en.dib File: Pbfb13ed.dib File: Pbfb13es.dib Tab.4/4: Symbol files for configuration software 4 21

86 4. Commissioning 4.4 Configuration with a Siemens master Please note Various configuration programs are available for use in conjunction with a Siemens master. Please observe the relevant procedure for your configuration program. The following sections describe as an example the main con figuration steps with the STEP7 software. It is assumed that the reader is already familiar with the contents of the manual for the STEP7 software. Information on operation with general DP masters can be found in A.4. Before commissioning or programming, compile a configur ation list of all connected field bus slaves. On the basis of this list you can: carry out a comparison between the NOMINAL and the ACTUAL configurations to ascertain if there are any con nection faults. accesss these specifications during the syntax check of a program, in order to avoid addressing faults. Configuration of the CP system requires a very accurate pro cedure, as the modular structure sometimes demands differ ent configuration specifications for each valve terminal. Please observe here the specifications in the following sec tions. 4 22

87 4. Commissioning STEP 7 HW Config (up to V 5.2) Preparations GSD 1. Copy the GSD of the valve terminals into the directory...\step7\s7data\gsd on your PC/programmer. File: VI03FB13.GS* (Reference sources for the GSD see section 4.3) The GSDs can either be: copied manually into the above mentioned directory (e.g. with Windows Explorer) or loaded via the menu [Options] [Install new GSD]. Please note Update the hardware catalogue, if you copy the GSD during work with STEP 7. Menu HW Config [Options] [Update Catalog] Please note As from STEP 7 V4.02, GSDs are stored within the STEP 7 project (station GSD). This can cause the updating/reading of new GSD files to appear as if incorrect. Please inform yourself about handling the station GSD files in the STEP 7 help. 2. Process the dialogue window Properties PROFIBUS interface" Baud rate Profile 4 23

88 4. Commissioning Symbols 3. Copy the symbol files (see section 4.3) for the CPX ter minal into directory...\step7\s7data\nsbmp on your PC or programmer. The symbol files can either be copied manually into the above named directory or be loaded via the menu [Options] [Install new GSD] file type Bitmap files" in HW Config. 4. Add a DP master system: right hand mouse click on DP" under CPU" in the rack click on [Add Master System] in the context menu. The line of the DP master system will be displayed. Station selection with STEP 7 1. If the hardware catalogue is not open: click on the cata logue icon (see Fig.4/4 1). The hardware catalogue will be displayed. 2. Open the following folder in the hardware catalogue: \PROFIBUS DP\Additional Field Devices\Valves." The folder VALVES is displayed when you copy the GSD (see step 1 of the preparations). Pull the station type FESTO type 03 FB13" onto the line of the DP master system 2. The dialogue window Properties PROFIBUS interface" will be displayed Select the PROFIBUS address identical to the selected setting on the DIL/rotary switch in the node (see section 3.2.2) and confirm this with OK. The dialogue window Properties DP slave" will be displayed Process the dialogue window, if necessary, and close it. The symbol of the valve terminal will be displayed on the line of the DP master system. 4 24

89 4. Commissioning Fig.4/4: Station selection with STEP 7 HW Config (the windows displayed are not all visible at the same time, see text) 4 25

90 4. Commissioning Configuration with STEP 7 In STEP7 the sum identifier is used for the configuration of the valve terminal (see also Tab.4/3). Assign the DP ident ifiers in ascending order without gaps. No field may remain unused. Enter: inputs before outputs. Assign the configuration table of your valve terminal as fol lows: 1. Mark the symbol of the valve terminal to be configured in HW Config (see Fig.4/5 1). The configuration table will be displayed under the rack Open the module FESTO type 03 FB13" (folder\ PROFIBUS DP\Additional Field Devices\Valves\...) in the hardware catalogue Pull the required number of input bytes onto slot 0 in the configuration table. Assign the starting address in the window Properties DP slave"4. 4. Pull the required number of output bytes onto slot 1 in the configuration table. Assign the starting address in the window Properties DP slave"4. Modifying the address Double click the appropriate line in the configuration table and modify the starting address of the inputs or outputs in the window Properties DP slave." Please note With S7 400 controllers, up to 4 bytes of addresses are reserved for each DP identifier depending on the version status. 4 26

91 4. Commissioning Fig.4/5: Configuration with STEP 7 HW Config (explanations see text, see also example 3) This concludes the station selection and configuration. 4 27

92 4. Commissioning Examples of configuration and addressing Example 1: DP identifier Order number 0 Local : DI 4 bytes 1 Local : DO 2 bytes Tab.4/5: Configuration example 1: Valve terminal with 3 x 8 input modules and 12 single solenoid valves 4 28

93 4. Commissioning Example 2: DP identifier Order number Input address Output address 0 Local : DO 2 bytes Tab.4/6: Configuration example 2: Valve terminal with 3single solenoid valves and 5 double solenoid valves A = O (Output) *Unused A34.0 A34.1 A34.2 A34.3* A34.4 A34.5 A34.6 A34.7 A35.0 A35.1 A35.2 A35.3 A35.4 A35.5 A35.6 A * Fig.4/6: Addressing, example 2 Program : := O34.4 //O0.04 (4th. valve, right hand coil) := O35.3 //O0.011 (7th. valve, left hand coil) := 4 29

94 4. Commissioning Example 3: DP identifier Order number Input address Output address 0 Local : DI 6 bytes Local : DO 4 bytes Tab.4/7: Configuration example 3: Valve terminal with 44inputs (+ 4 status bits) and 3 single solenoid/ 5double solenoid valves and 16 digital outputs E E57.0 E E56.0 E E55.0 E E54.0 E E53.0 E E52.0 A A55.4 A A55.0 A A54.4 A A54.0 A52.0 A52.1 A52.2A52.3* A52.4A52.5 A52.6A52.7 A53.0A53.1 A53.2A53.3 A53.4A53.5 A53.6A53.7 E = I (Input); A = O (Output) *Unused Fig.4/7: Addressing, example 3 Program : :U I53.0 //I0.08 (2nd. input module, 1st. input) := O52.5 //O0.05 (4th. valve, left hand coil) : :U I55.4 //I1.12 (4th. input module, 5th. input) := O53.0 //O0.08 (6th. valve, right hand coil) := O54.6 //O1.06 (2nd. output module, 3rd. output) 4 30

95 Diagnosis and error treatment Chapter 5 5 1

96 5. Diagnosis and error treatment Contents 5. Diagnosis and error treatment Overview of diagnostic possibilities On the spot diagnosis LEDs on the field bus node LEDs of the valves LEDs of the input/output modules Test routines Status bits Short circuit/overload Diagnosis via PROFIBUS DP Diagnostic words Diagnostic steps Overview of diagnostic bytes Details on standard diagnostic information Position of the status bits Fault treatment Reaction to faults in the control system Siemens SIMATIC S5/S Online diagnosis with STEP Read diagnostic buffer with STEP 7 (up to V5.2) Device related diagnosis with STEP 7 (up to V5.2) Short circuit/overload at an output module Type 04 B: Fuses for the pilot solenoids

97 5. Diagnosis and error treatment 5.1 Overview of diagnostic possibilities The modular valve terminal offers extensive and user friendly possibilities of diagnosis and fault treatment. The following possibilities are available depending on the equipment fitted on the valve terminal: Fitting equipment on the valve terminal Input modules Field bus node FB13 Diagnostic possibilities Status bits Bit 2 7 Bit 2 6 Bit 2 5 Bit 2 4 LEDs Diagnostic word X X X 1 X X X X X 0 X X X X 1 X = Not relevant Brief description The four status bits are transmitted to the module as inputs" cyclically with the normal inputs. The LEDs show directly configuration faults, hardware faults, bus faults, etc. The diagnostic word must be read out and evaluated user program controlled (acyclic). Advantages Fast access to fault messages Fast on the spot" fault recognition Detailed fault recognition Detailed description Section 5.3 Section 5.2 Section 5.4 Tab.5/1: Possibilities of diagnosis and error treatment 5 3

98 5. Diagnosis and error treatment 5.2 On the spot diagnosis LEDs on the field bus node The LEDs on the cover of the node indicate the operating status of the valve terminal. 1 Green LED: operating voltage Green LED: load voltage 3 Red LED: fault display POWER POWER V BUS ERROR 3 Fig.5/1: LEDs on the node 5 4

99 5. Diagnosis and error treatment LEDs Sequence Operating status Fault treatment Power ON OFF Operating voltage applied None ON OFF Operating voltage not applied Check the operating voltage connection for the electronics (pin1). POWER V ON OFF ON OFF Load voltage for outputs (valves, electric outputs) applied Load voltage for outputs (valves, electric outputs) <21.6V Check the operating voltage connection for the outputs (pin2). ON OFF Load voltage for outputs (valves, electric outputs) <10V off flashes green flashes red lights up green lights up red Tab.5/2: LED display for operating and load voltage (POWER LEDs) 5 5

100 5. Diagnosis and error treatment LEDs Sequence Operating status Fault treatment BUS ERROR ON OFF ON OFF ON OFF Operating status normal Bus connection not OK. Possible causes: Station number does not correspond to the configured number Field bus module/master is switched off or is defective Interrupted, short circuited bus connection Incorrect number of I/O bytes Station number not permitted (>125) None Check the... setting of the address selector switch field bus module field bus connection configuration Correct station number ON OFF ON OFF Modules not fitted correctly More than 12 I/O modules fitted Number of analogue channels >12 Module type not permitted Hardware fault Reduce the... number of I/O modules use only permitted module types Servicing required off flashes green flashes red lights up green lights up red Tab.5/3: LED for fault display (BUS ERROR) 5 6

101 5. Diagnosis and error treatment LEDs of the valves There is a yellow LED for each valve solenoid coil on the valve terminal. These LEDs indicate the switching status of the valve solenoid coils. Valve terminal type LEDs of the valve solenoid coils Type 03 Type 04 B Tab.5/4: Positions of the valve solenoid coil LEDs 5 7

102 5. Diagnosis and error treatment LED Switching position of the valve solenoid coil Meaning Yellow out Basic position Logical 0 (no signal) Yellow alight Switch position or Basic position Logical 1 (signal present) Logical 1 but: operating voltage of outputs lies below the permitted tolerance range ( V DC) or compressed air supply not OK or pilot exhaust blocked or servicing required Tab.5/5: LEDs for status display of the valve solenoid coils Short circuit/overload (only type 04 B) The valve solenoid coils of valve terminal type 04 B are fitted with special fuses to protect them against short circuit or overload. The method of replacing these fuses is explained in section

103 5. Diagnosis and error treatment LEDs of the input/output modules Specific explanations of further I/O modules can be found in the Supplementary description of the I/O modules." Next to the relevant connections on the input/output mod ules there are one or two LEDs (status displays) in the co lours: green (status display of the digital inputs) yellow (status display of the digital outputs) red (fault display of the digital outputs). The current signal at the relevant input or output is shown by means of the yellow and green LEDs. The red LEDs of the out puts register a short circuit/overload at the relevant output. 5 9

104 5. Diagnosis and error treatment Description LED Status 1 Short circuit/overload display of the sensor power supply (only input modules with electronic fuse) 2 Switching status display of inputs 3 Switching status display of outputs 4 Short circuit/overload display of the outputs Red out Red lights up Green out Green lights up Yellow out Yellow alight Red out Red lights up Input without short circuit/overload Short circuit/overload at the relevant input *) Logical 0 (no signal) Logical 1 (signal present) Output without short circuit/overload Short circuit/overload at relevant input or output (only input modules with electronic fuse *) ) Logical 0 (no signal) Logical 1 (signal present) *) Treatment of short circuit/overload see Supplementary manual for the I/O modules" Tab.5/6: LED displays of the input/output modules 5 10

105 5. Diagnosis and error treatment Test routines Warning Before starting the test, switch off the compressed air supply to the valves. You can then avoid undesired or dangerous movements of the actuators. Caution This test function runs automatically in the valve ter minal. All the valves are switched on/off cyclically. None of the programmed lockings or further switching conditions will be taken into account. The valve terminal provides the following test routines: Test routine Meaning Test outputs Parallel All outputs are switched on/off cyclically and simultaneously. Byte serial Display configuration data All outputs are switched on/off cyclically and simultaneously. Number of individual input and output bytes via flashing of the LEDs POWER V and BUS ERROR Tab.5/7: Test routines which can be set 5 11

106 5. Diagnosis and error treatment Starting the test routine 1. Switch off the operating voltage and the load voltage supplies (pins 1 and 2). 2. Open the node in accordance with section 3.2, Opening and closing the node." 3. Setting the DIL switch elements. 4. Set DIL switch element 3 to OFF. 5. Set station number Switch on the power supplies (pins 1 and 2). 7. Set the desired test routine on the address selector switches as follows: Test routine Address to be set Parallel 100, 101 or 102 Serial 103 Displaying the configuration data 104 Tab.5/8: Setting the test routine 8. Start: Set DIL switch element 1 to OFF. If faults occur when the test routine is started, the red LED on the node will flash quickly. The procedure must then be re peated. 5 12

107 5. Diagnosis and error treatment Concluding the test routine 1. Switch off the power supplies (pins 1 and 2) on the valve terminal. 2. Set the address selector switch and the DIL switch el ements to their original positions again. Please note: If the yellow LED of the valves does not light up, this may be due to the following: The LED or the solenoid coil is defective. Only type 04 B: The internal 0.315A fuse of the sub base has burnt through (see section 5.8). Displaying the valve terminal configuration With the setting Display the configuration data," the LEDs POWER V or BUS ERROR show the number of input or output bytes. Concluding the test routine: Operating voltage OFF The Display the configuration data" is shown continu ously. The sequence of the flashing signals can be seen in the following diagram. 5 13

108 5. Diagnosis and error treatment Sequence LED POWER V LED BUS ERROR Meaning Start Starting the test routine 1 Number of input bytes of local valve terminal inputs 2 Number of output bytes of local valve terminal outputs 3 Number of AS Interface input bytes 4 Number of AS Interface output bytes 5 Number of input words Analogue 6 Number of analogue output words New cycle New run of the test routine Operating voltage OFF: End of the test routine Tab.5/9: Test routine: Sequence of the flashing signals 5 14

109 5. Diagnosis and error treatment 5.3 Status bits Irrespective of the protocol set, the valve terminal provides four status bits for diagnostic purposes. Please note The four status bits of the valve terminal are only available if the valve terminal is fitted with at least one input mod ule. The status bits are configured like inputs and always occupy the four highest value addresses of theavailable address range. If the inputs of the addresses thereunder are not used, the valve terminal will set them to logical zero." The position of the four status bits within the address range of the valve terminal can be found in the following sections on diagnosis via the appropriate field bus protocol. 5 15

110 5. Diagnosis and error treatment The four status bits supply coded diagnostic information with the following meaning: Status bits *) Diagnostic information No fault X 0 1 X Short circuit/overload at the output X 1 0 X V valves < 21.6V **) X 1 1 X V outputs < 10V **) 1 X X X V sensor < 10V or short circuit/overload in sensor supply X X X 1 Output fault bit (AS Interface analogue I/O) X = Not relevant *) The status bits can always be addressed with the four highest value addresses of theconfigured address range. **) Only if the voltage monitoring has been activated (see section 3.2.2, DIL switch) Tab.5/10: Coded diagnostic information of the four status bits 5 16

111 5. Diagnosis and error treatment Diagnostic information Description Function Short circuit/overload at the output V valves < 21.6V V outputs < 10V V sensor < 10V Output bit Output short circuited or overloaded Load voltage at pin 2 (valves and outputs) of the operating voltage connection < 21.6V Load voltage at pin 2 (valves and outputs) of the operating voltage connection < 10V Operating voltage at pin1 (electronics and inputs) of operating voltage connection <10V Fault at AS Interface or hardware fault on the analogue module Monitoring the electric outputs of the output modules Monitoring the tolerance of the load voltage for valves and electric outputs Monitoring the load voltage for valves and electric outputs (no voltage, e.g. EMERGENCY STOP) Monitoring the operating voltage for inputs (sensors) Shows whether an internal fuse has been triggered (fuse on node or at least one electronic fuseon the input module *) VIGE 03 FB 8 S) Common diagnostic information on the AS Interface/analogue I/O modules *) Electronic fuse for input modules available since February Tab.5/11: Diagnostic information 5 17

112 5. Diagnosis and error treatment Short circuit/overload In the event of a short circuit or overload, the fault code Short circuit/overload" will be entered in the four status bits in the node. Depending on the field bus protocol used, the valve terminal provides one or more diagnostic status regis ters (bytes, words). With most field bus protocols, a short circuit can thereby be recognized and evaluated (see sec tion5.4). Short circuit/overload at an I/O module Valve terminals types 03 or 04 B can be fitted with the follow ing I/O modules: output modules high current output modules multi I/O modules input modules input modules with fuse. The reaction of these modules to a short circuit/overload is described in the Supplementary description of the I/O modules." 5 18

113 5. Diagnosis and error treatment 5.4 Diagnosis via PROFIBUS DP Valve terminal type 03/04 B provides the diagnostic informa tion in accordance with standard EN as follows: Diagnostic words The diagnostic information of a valve terminal is grouped together in diagnostic words. By means of these diagnostic words, the following fault states are sent to the programmer: Operating voltage of the valves/outputs < 21.6 V (V val ) Operating voltage of the valves/outputs < 10 V (V out ) Operating voltage of the sensors < 10 V (V sen ) Output overloaded or short circuited AS Interface fault (bus, power and slave faults) Fault in analogue processing Please note Evaluation of the Device related diagnostic information (octets ) is only sensible in conjunction with an AS Interface master integrated in the valve terminal. The identifier related or channel related diagnosis listed in EN is not supported. 5 19

114 5. Diagnosis and error treatment Diagnostic steps The valve terminal offers extensive diagnostic possibilities via the PROFIBUS DP. The diagram below shows you the steps required for diagnosing the valve terminal. Only the diagnos tic bits, which require a further diagnostic step, are repre sented. 1 It is sensible to read out Device related diagnosis Bit 1 Station status 1 2 It is sensible to read out Device related diagnoses Bit Device related diagnosis 1 3 It is sensible to read out Device related diagnoses 2 and Fig.5/2: Diagnostic steps 5 20

115 5. Diagnosis and error treatment Overview of diagnostic bytes Byte * Octet ** Contents Explanation 0 1 Station status 1 See Tab.5/ Station status 2 See Tab.5/ Station status 2 See Tab.5/ Diag.Master_Add Master address 4 5 Ident_number high byte 5 6 Ident_number low byte Manufacturer identifier (FB13 h ) 6 7 Ext_Diag_Data Header Device related diagnosis 7 8 Device related diagnosis 1 Overview of faults 8 9 Device related diagnosis 2 Bit no. = faulty output 9 10 Device related diagnosis 3 Byte no. = faulty output Device related diagnosis 4 Fault bits AS Interface bus slaves Device related diagnosis 5 Fault bits AS Interface bus slaves Device related diagnosis 6 Fault bits AS Interface bus slaves Device related diagnosis 7 Fault bits AS Interface bus slaves bold = Contents are modified by the valve terminal * = Siemens ** = EN Tab.5/12: Overview of diagnostic bytes: Standard diagnostic information 5 21

116 5. Diagnosis and error treatment Details on standard diagnostic information The diagnostic information can be requested by the valve terminal via the function Slave_Diag. The valve terminal replies with an octet string of length 15. Octet 1: Station status_1 Bit Meaning Explanation 0 Diag.Station_Non_Existent Valve terminal is no longer/not yet addressable Possible causes: operating voltage not applied data cable interrupted fault in data cable 1 Diag.Station_Not_Ready Valve terminal is not yet ready for data exchange 2 Diag.Cfg_Fault The configuration data received from the master do not agree with those ascertained by the valve terminal. 3 Diag.Ext_Diag There is a Device related diagnosis Possible causes: short circuit/overload at electric outputs or sensor supply for inputs V Valves < 21.6 V V Outputs < 10 V V Sensor < 10 V AS Interface faults faults in analogue data processing 4 Diag.Not_Supported 1 = Valve terminal does not support the function requested 5 Diag.Invalid_Slave_Response Always 0 (set by valve terminal) 6 Diag.Prm_Fault Last parametrizing telegram faulty 7 Diag.Master_Lock Always 0 (set by valve terminal) bold = Contents are modified by the valve terminal Tab.5/13: Diagnostic bits station status

117 5. Diagnosis and error treatment Octet 2: Station status_2 Bit Meaning Explanation 0 Diag.Prm_Req 1 = Master must configure the valve terminal again 1 Diag.Stat_Diag 1 = Master must request diagnostic data until this bit is set to 0 2 Always 1 (set by valve terminal) 3 Diag.WD_On 1 = Watchdog (response monitoring) activated 4 Diag.Freeze_Mode Not supported 5 Diag.Sync_Mode Not supported 6 Reserved 7 Diag.Deactivated Always 0 (set by valve terminal) bold = Valve terminal related bits Tab.5/14: Diagnostic bits of station status 2 Octet 3: Station status_3 Bit Meaning Explanation Reserved 7 Diag.Ext_Diag_Overflow Always 0 (set by valve terminal) Tab.5/15: Diagnostic bits of station status

118 5. Diagnosis and error treatment Further octets Octets : Overview Octet Designation Explanation 4 Diag.Master_Add Master address: The address of the master, which parametrized the valve terminal, is entered in this octet Ident_number Manufacturer identification: These octets contain the manufacturer identification: FB13 H for the Festo valve terminal type 03/04 B. 7 Ext_Diag_Data (Device related diagnosis) Header Device related diagnosis: This octet represents the header for the device diagnosis. The valve terminal enters the fixed value 8 in this octet, i.e. 8 octets Device related diagnosis", incl. the header octet, are made available/trans ferred, irrespective of the equipment fitted on the valve terminal, e.g. with/without analogue processing, with/without AS Interface master. Tab.5/16: Overview of the octets

119 5. Diagnosis and error treatment Structure of Device related diagnosis Octet 8: Device related diagnosis 1 Bit Meaning Explanation 0 AS Interface fault (bus fault) 1 = AS Interface bus faulty 1 AS Interface fault (nominal <> actual configuration) 2 Short circuit/overload at electric outputs 3 AS Interface fault (power failure) 1 = AS Interface nominal configuration is not the same as the AS Interface actual configuration 1 = At least one electric output short circuited or overloaded. The faulty output can be localized more accurately with Device related diagnoses" 2 and 3. 1 = AS Interface power supply voltage outside of tolerances 4 V sen Supply voltage for sensors < 10 V or short circuit/overload of sensor supply of an input module 5 V val *) Supply voltage for valve coils <21.6 V *) 6 V out *) Supply voltage for valve coils and electric outputs <10V *) 7 Analogue faults 1 = Short circuit of an analogue voltage input or hardware fault on the analogue module *) Only with activated voltage monitoring (see section 3.2.2, DIL switch) Tab.5/17: Diagnostic bits Device related diagnosis

120 5. Diagnosis and error treatment Octet 9: Device related diagnosis 2 Bit Meaning Explanation Bit no. of channel with fault message In this octet the valve terminal enters the bit no. of the first short circuited or overloaded channel of an output module. The entry remains saved until all faults have been rectified. Octet 10: Device related diagnosis 3 Bit Meaning Explanation Bit no. of channel with fault message In this octet the valve terminal enters the bit no. of the first short circuited or overloaded channel of an output module. The entry remains saved until all faults have been rectified. Tab.5/18: Diagnostic Device related diagnoses 2 and 3 Octets : Device related diagnoses Octet Meaning Explanation Each set bit (log. 1") of this octet represents a faulty AS Interface slave (see manual for AS Interface master). 11 Device related diagnosis 4 Fault bits AS Interface bus slaves Device related diagnosis 5 Fault bits AS Interface bus slaves Device related diagnosis 6 Fault bits AS Interface bus slaves Device related diagnosis 7 Fault bits AS Interface bus slaves Tab.5/19: Structure of Device related diagnoses

121 5. Diagnosis and error treatment Position of the status bits Mounted inputs Byte/octet no. Addresses of the status bits None None available ,..., *) 13 *) Inputs cannot be used Tab.5/20: Position of the status bits 5 27

122 5. Diagnosis and error treatment Example: Valve terminal with 40 inputs (+ 4 status bits) and 20 outputs. Peripheral addresses Inputs: 68 Outputs: 68 Configuration Inputs Outputs Inputs Outputs Status bits 8DI 8DI 8DI 8DI 8DI 8DI 8DO 8DO 8DO or Byte/octet 6, bits 4,..., (I I73.7) 7) Tab.5/21: Example of configuration 5 28

123 5. Diagnosis and error treatment 5.5 Fault treatment Reaction to faults in the control system With the following faults, the behaviour of the Festo valve terminal type 03/04 B depends on the configured behaviour of the master module: telegram failure master stopped interruption in the bus cable. Depending on the setting or configuration, all the outputs (valves and electric outputs) will be switched off or retain their status. Warning Make sure that valves and outputs are put into a safe state when the faults named occur. An incorrect status of the valves and outputs may lead to dangerous situations. Please note Please observe the following if the outputs are reset in the event of a PLC stop, field bus interruption or field bus fault: Single solenoid valves move to the basic position Double solenoid valves remain in the current position Mid position valves move to the mid position (depend ing on valve type: pressurized, exhausted or blocked). 5 29

124 5. Diagnosis and error treatment Siemens SIMATIC S5/S7 With these controllers, you have the possibility of determin ing the reaction of the valve terminal to the faults named (details see controller manual). Almost all configuration programs contain the function Re sponse monitoring." For the operating modes named, the time specified corresponds to the drop off time of the valves and electric outputs. There are two ways in which you can set the control system to react to faults: hard fault reaction: When a fault occurs, the controller switches to the operating mode STOP." soft fault reaction: When a fault occurs, the controller remains in the operating mode RUN." Control system Module Meaning STOP RUN SIMATIC S5 with IM308C OB23 Reaction to QVZ with direct periphery access default OB is programmed OB24 Reaction to QVZ with periphery access via process image default OB is programmed OB35 Reaction to PEU (periphery not clear) default OB is programmed SIMATIC S7/M7 OB82 Reaction to a device specific diagnosis default OB is programmed OB86 Reaction to failure of a DP slave default OB is programmed QVZ: Quitting delay; OB: Organisation module; PEU: Periphery not clear Tab.5/22: Fault reaction STOP and RUN with S5/S7 Further details on response monitoring can be found in the relevant controller manuals. 5 30

125 5. Diagnosis and error treatment Possibilities for reading out the diagnosis for S5/S7 The diagnosis for PROFIBUS DP is supported in the various control systems by function modules. These read out the slave diagnosis and write it into a data range of the user program. Control system Function module See... Manufacturer SIMATIC S5 with IM 308C FB 192 IM 308C" Manual ET 200 decentral periphery system" Siemens SIMATIC S5 with S5 95U/DP master FB 230 S_DIAG" Manual ET 200 decentral periphery system" Siemens SIMATIC S5 with SF 50/ DP master FB 230 S_DIAG" Manual Programmable valve terminal with SB/SF 50" Festo SIMATIC S7/M7 SFC 13 DP NRM_DG" Reference manual System functions and standard functions" Siemens Tab.5/23: Information on diagnosis with S5/S7 Example for a STEP 7 user program STL CALL SFC 13 REQ:=TRUE LADDR:=W#16#03FE RET_VAL:=MW100 RECORD:=P#M110.0 WORD 7 BUSY:=M10.0 Explanation Reading request Pointer at diagnostic address, e.g d = 03FE h (see mask Properties DP slave" in HW Config.) If fault occurs, output fault code Pointer at start of data range for diagnosis and length of diagnostic data Reading concluded Fig.5/3: Example 5 31

126 5. Diagnosis and error treatment 5.6 Online diagnosis with STEP 7 Direct diagnostic events in conjunction with the valve terminal can be: Decentral periphery: station failure Communication between slave and master interrupted. Faulty component (see device specific diagnosis) Transition of the operating status from START to RUN (nominal/actual difference exists) The configuration data of the valve terminal do not agree with the periphery. Valve terminal has incorrect DIL/rotary switch setting Read diagnostic buffer with STEP 7 (up to V5.2) The diagnostic buffer of STEP7 offers the possibility of dis playing diagnostic events of the S7 systemin the sequence in which they occur. Prerequisites: HW Config has been accessed. Proceed as follows (Fig.5/4): 1. Switch from offline to online Click with the right hand mouse button on the CPU in the rack Click on [Module Information] in the context menu which now appears. The window Module Information" will be shown Select the register Diagnostic Buffer" Click on the event and read the details. These supply more detailed information on the further procedure and depend on the S7 controller 5sed. 5 32

127 5. Diagnosis and error treatment Fig.5/4: Online diagnosis via Diagnostic Buffer" (explanation see text) 5 33

128 5. Diagnosis and error treatment Device related diagnosis with STEP 7 (up to V5.2) You can display fault messages of the device related diag nosis via the window Module Information" (see Fig.5/5): 1. Click with the right hand mouse key on the icon of the valve terminal Click on [Module Information] in the context menu which now appears. The window Module Information" will be shown. 3. Read the diagnostic information Fig.5/5: Device related diagnosis with STEP 7 (explanation see text) 5 34