Valve terminal type 03/05 Electronics Manual Field bus connection FB17

Transcription

1 Valve terminal type 03/05 Electronics Manual Field bus connection FB17 Field bus protocol: Jetter JETway-R GB Only valid in agreement with the printed documentation accompanying the product! Compare this edition code. 9610NH

2 Authors: Editors Translation: Layout: Type setting: Eberhard Klotz, D. Ruckwied, H. Wilhelm H.J. Drung, M.Holder Douglas Smith Festo KG, Dept. PV-IDM DUCOM 1st. edition October 1996 Printed on 100% recycled paper 1996 Festo KG, D Esslingen Federal Republic of Germany All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical photocopying or otherwise, without the prior written permission of Festo KG NH I

3 Part no.: Title: Designation: MANUAL P.BE-VIFB17-03/05-GB II 9610 NH

4 Contents GENERAL SAFETY INSTRUCTIONS Designated use Target group IMPORTANT USER INSTRUCTIONS Danger categories Pictograms Instructions on this manual Service VII VII VIII IX IX X XI XII Chapter 1 SYSTEM SUMMARY SYSTEM SUMMARY 1-3 System structure 1-3 Type 03: Description of components 1-5 Type 05: Description of components 1-9 Method of operation 1-11 Chapter 2 FITTING FITTING THE COMPONENTS 2-3 Input/output modules 2-4 End plates 2-6 Hat rail clamping unit (type 03) TYPE 03: FITTING THE VALVE TERMINAL 2-9 Wall fitting (type 03) 2-9 Fitting the hat rail (type 03) TYPE 05: FITTING THE VALVE TERMINAL 2-12 Wall fitting (type 05) NH III

5 Chapter 3 INSTALLATION GENERAL CONNECTING METHODS 3-3 Selecting the field bus cable 3-4 Selecting the operating voltage cable 3-5 Connecting the cables to the plugs/sockets FIELD BUS NODE 3-8 Opening and closing the node 3-8 Configuring the valve terminal 3-10 Setting the field bus address (network address) 3-11 Setting the baud rate 3-14 Setting the protocol Type 03: Connecting the operating voltages Type 05: Connecting the operating voltages Connecting the JETway-R 3-30 General instructions on the controllers CONNECTING THE INPUT MODULES 3-39 Pin assignment CONNECTING THE OUTPUT MODULES 3-42 Pin assignment 3-44 IV 9610 NH

6 Chapter 4 COMMISSIONING BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING 4-3 General 4-3 Switching on the operating voltages 4-4 Calculating the configuration data 4-5 Calculating the number of inputs and outputs (type 03) 4-6 Calculating the number of inputs and outputs (type 05) 4-7 Address assignment of the valve terminal 4-8 General for type 03 and Basic rule Basic rule Basic rule Address assignment after extension/conversion 4-13 Example of addressing type 03 MIDI/MAXI valves 4-15 Example of addressing type 05 ISO valves JETTER 4-17 Register for the configuration 4-17 Instructions on the registers 4-17 Register 2: Number of input bytes 4-17 Register 3: Number of output bytes 4-18 Register 6: Register offset 4-18 Register 7: Input offset 4-18 Register 8: Output offset 4-18 Register 9: Version number NH V

7 Chapter 5 DIAGNOSIS AND ERROR TREATMENT SUMMARY OF DIAGNOSTIC POSSIBILITIES ON-THE-SPOT DIAGNOSIS 5-4 LED displays 5-4 Field bus node 5-4 Valves 5-6 Input/output modules 5-8 Testing the valves DIAGNOSIS VIA JETway REGISTER 5-11 Register for the diagnosis 5-11 Register 0: Status register 5-11 Registers 10, 11, 14 and 15: status of the inputs and outputs ERROR TREATMENT 5-13 Reaction to faults in the control system 5-13 Short circuit/overload at an output module 5-14 Faults in initialization 5-15 Appendix A TECHNICAL APPENDIX A-1 TECHNICAL SPECIFICATIONS A-3 CABLE LENGTH AND CROSS SECTION A-7 CIRCUITRY EXAMPLES A-12 Appendix B INDEX B-1 VI 9610 NH

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

9 General safety instructions Target group This manual is directed exclusively at technicians who are trained in control and automation technology and who have experience in installing, commissioning, programming and diagnosing programmable logic controllers (PLC) and field bus systems. VIII 9610 NH

10 General safety instructions IMPORTANT USER INSTRUCTIONS Danger categories This manual contains instructions on the hazards which may arise from improper or negligent use of the valve terminal. A distinction is made between the following instructions: WARNING This means that injury to human beings as well as material damage can occur if these instructions are not observed. CAUTION This means that material damage can occur if these instructions are not observed. PLEASE NOTE This means that this instruction must also be observed NH IX

11 General safety instructions Pictograms Pictograms and symbols supplement the danger instructions and draw attention to the consequences of dangers. The following pictograms are used: Uncontrolled movements of loose tubing. Uncontrolled movement of the connected actuators. High electric voltage or undefined switching states of the electronic components which affect the connected circuits. Electrostatically vulnerable components which will be destroyed if their contact surfaces are touched. The ISO valve terminal type 05 is very heavy. Please ensure that it is fastened correctly and see that all operating personnel wear safety shoes. X 9610 NH

12 General safety instructions Instructions on this manual This manual contains specific information on the installation, commissioning, programming and disgnosis of the valve terminals types 03/05 and the input/output modules. The following product-specific abbreviations are used in this manual: Abbreviation Terminal or Valve terminal Node Valve-sub base S sub-base D sub-base ISO sub-base I O I/O P module I/O module PLC Meaning Valve terminal type 03 (MIDI/MAXI) or type 05 (ISO) with/without electric I/Os Field bus node Pneumatic sub-base for valves For two single valves type 03 (MIDI/MAXI) For two double solenoid valves or mid-position valves type 03 (MIDI/MAXI) Sub-base for 4, 8 or 12 ISO valves type 05 (as per ISO 5599/I, size 1 or 2) Input Output Input and/or output Pneumatic module in general Module with digital inputs/outputs in general (input/output modules Programmable logic controller; or simply controller Fig. 0/1: Abbreviations 9610 NH XI

13 General safety instructions PLEASE NOTE All information on the pneumatic modules is to be found in the Pneumatics Manual P.BE-MIDI/MAXI-03-GB or P.BE-ISO-05-GB. A valve terminal with four pneumatic valve sub-bases and four input/output modules is used for the diagrams in this manual. Fig. 0/2: Standard fitting for the drawings The valve terminals can be connected to all processing PLCs from Jetter via the JETway-R. Service If you have any technical problems, please consult your local Festo Service XII 9610 NH

14 1. System summary 1. SYSTEM SUMMARY 9610 NH 1-1

15 1. System summary Contents 1.1 SYSTEM SUMMARY 1-3 System structure 1-3 Type 03: Description of components 1-5 Type 05: Description of components 1-9 Method of operation NH

16 1. System summary 1.1 SYSTEM SUMMARY System structure Festo solves your automation tasks at the machine level by means of valve terminals. Valve terminals types 03 and 05 are constructed on a modular basis and permit combinations of pneumatic and electronic modules. The following groupings are possible. Processing PLC - JETTER AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAAAAAAA AAAA AAAA AAAA AAAA A AAAA AAAA AAAA AAAA A AAAA AAAA AAAA AAAA A AAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAA AAAA AAAA AAAA AAAA AAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA AAA AAAAAAAAA AA AAA AAAA AAA AAAA AAA AAA AAAAAAAAA AA AAA AAAA AAA AAAA AAA AAA AAAAAAAAA AA AAA AAAA AAA AAAA AAA AAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA Valve terminal type 03: MIDI/MAXI valves and electronic modules Field bus JETway-R Valve terminal type 03: MAXI valves only Valve terminal type 05: ISO valves and electronic modules Further field bus slaves Fig. 1/1: Summary of system and possible variants of valve terminals 9610 NH 1-3

17 1. System summary The valve terminal with field bus connection offers the following advantages: can be equipped in various ways with digital I/Os and pneumatic valve locations subsequent extension/conversion possible different valve designs can be fitted can be connected to various control systems fewer cabling required due to two-core cables easy-to-understand system structure due to physical separation of controller and machine. valves already fitted wired pilot valve solenoid coils central air supply central exhaust valve terminal is tested before leaving the factory. A field bus system also offers the following advantages: fewer output assemblies in the controller economic data transfer over long distances high baud rate a large number of slaves can be connected error diagnosis is made easier NH

18 1. System summary Type 03: Description of components Valve terminal type 03 consists of individual modules. Each module is assigned with different functions and different elements for connection, display and operation. The diagram below summarizes the modules No. Modules 1 Node 2 Electronic modules (input/output modules), fitted with digital inputs (modules with 4 or 8 inputs) digital outputs (modules with 4 outputs) 3 End plate left with hole for additional earth cable connection 4 Pneumatic MIDI, MAXI modules (valve sub-bases) fitted with S valves: 5/2 single solenoid valves 5/2 double solenoid valves 5/3 mid-position valves (exhausted, pressurized, blocked) blanking plates S = Auxiliary pilot air 5 Pneumatic MIDI or MAXI modules: pressure supply with integrated exhaust (MIDI) intermediate air supply with integrated exhaust (MIDI) pressure supply adapter with/without regulator (MIDI/MAXI) additional air supply module (MAXI) Fig. 1/2: Modules of the valve terminal type NH 1-5

19 1. System summary The following connection and display elements are to be found on the electronic modules: Further modules A4 A4 E4 E No Meaning Output socket for electronic output Yellow LED (status display per output) Red LED (error display per output) Input socket for one electrical input Green LED (per input) Input socket for two electrical inputs Two green LEDs (one LED per input) Node with LEDs and field bus connection, detailed description in Chapter "Installation" Right-hand end plate Fuse for internal inputs/sensors Operating voltage connection Further modules (e.g. additional supply, high current outputs PNP/NPN) Fig. 1/3: Display and connection elements of the electronic modules NH

20 1. System summary The following connection, display and operating elements are to be found on the pneumatic MIDI modules type 03: 1 2a 3a b 2b No. 1 2a 2b 3a 3b Meaning Node with LEDs an field bus connection, further details in the chapter "Installation" Yellow LED upper valve solenoid coil Yellow LED lower valve solenoid coil Manual override upper valve solenoid coil (14, A) Manual override lower valve solenoid coil (12, B) Valve location inscription field Unused valve location with cover plate Common pneumatic tubing connections Work connections (per valve) Fuse for inputs/sensors Power supply connection Fig. 1/4: Operation, display and connection elements of the pneumatic MIDI modules type NH 1-7

21 1. System summary The following connection, display and operating elements are to be found on the pneumatic MAXI modules type 03: No Fig. 1/5: Meaning Node with LEDs an field bus connection, further details in the chapter "Installation" Yellow LED (per valve solenoid coil) Manual override (per valve solenoid coil) Valve location inscription field (labels) Unused valve location with cover plate Common pneumatic tubing connections Work connections (2 per valve, placed one obove the other) Regulator for limitted pressure of auxiliary pilot air Common pneumatic tubing connection Exhausts Operation, display and connection elements of the pneumatic MAXI modules type NH

22 1. System summary Type 05: Description of components Valve terminal type 05 consists of individual modules. Each module is assigned with different functions and different elements for connection, display and operation. The diagram below summarizes the modules No. Modules 1 Node 2 Electronic modules (input/output modules), fitted with digital inputs (modules with 4 or 8 inputs) digital outputs (modules with 4 outputs) 3 End plate left with opening for additional earth connection 4 Adapter plate for ISO sub-base (manifold) as per ISO 5599/I sizes 1 or 2 5 ISO sub-base (manifolds for 4, 8 or 12 locations) fitted with: Pneumatic valves with hole pattern as per ISO 5599/I - single pneumatic valves - double pneumatic valves - pneumatic mid-position valves components for vertical stacking (regulator plates, flow control plates etc.) blanking plates Fig. 1/6: Modules of the valve terminal type NH 1-9

23 1. System summary The following connection, display and operating elements are to be found on the pneumatic ISO modules type 05: No Meaning Node with LEDs and field bus connection, detailed description see chapter "Installation" Fuse for inputs/sensors (pin 1) Adapter plate Operating voltage connection of valve terminal type 05 Fuse for valves (pin 2) Valve location inscription field Yellow LEDs (per pilot solenoid) Manual override (per pilot solenoid, pressing or locking) External air control connection Common connections Work connections (per valve) Adapter cable for operating voltage of node and I/O modules Fig. 1/7: Operating, display and connection elements of ISO modules type 05 The electronic modules are described in the section "Description of components type 03" NH

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

25 1. System summary The input modules process the input signals (e.g. from sensors) and transmit these signals via the field bus to the controller. The output modules are universal electrical outputs and control small current-consuming devices with positive logic, e.g. further valves, lights etc.. The pneumatic modules are used for the following: common channels for supply and exhaust air electrical signals from all solenoid valve coils. Work connections 2 and 4 are supplied for each valve location on the individual pneumatic modules. By means of the common channels on the pneumatic end plate, the valves are supplied with compressed air and both the exhaust air and the pilot air from the valves are vented. Further modules for air supply are also available, in order that different work pressures can be used or in order that either MIDI/MAXI valves or ISO valves can be fitted on a terminal. Further information on their use is to be found in the Pneumatics Manual for the valve terminal. Only the electronic modules and the node are described here NH

26 2. Fitting 2. FITTING 9610 NH 2-1

27 2. Fitting Contents 2. FITTING 2.1 FITTING THE COMPONENTS 2-3 Input/output modules 2-4 End plates 2-6 Hat rail clamping unit (type 03) TYPE 03: FITTING THE VALVE TERMINAL 2-9 Wall fitting (type 03) 2-9 Fitting the hat rail (type 03) TYPE 05: FITTING THE VALVE TERMINAL 2-12 Wall fitting (type 05) NH

28 2. Fitting 2.1 FITTING THE COMPONENTS WARNING Before fitting the components switch off the following: the compressed air supply the power supply for the outputs (pin 2) the power supply for the electronic components (pin 1) You thereby avoid: uncontrolled movement of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components. CAUTION The valve terminal components contain parts which can be damaged by electrostatic charges. Do not therefore touch the contact surfaces of the plug connectors at the side of the modules. Observe the instructions for dealing with components liable to damage by electrostatic charges. You thereby avoid destroying the valve terminal components NH 2-3

29 2. Fitting PLEASE NOTE Treat all the modules and the components of the valve terminal with the utmost care. Pay special attention to the following: Screw connectors must not be twisted or subjected to mechanical stress. The screws must fit accurately (otherwise the threads will be damaged). The specified torques must be observed. The modules must be aligned correctly (IP 65). The contact surfaces must be clean (avoid leakage and faulty contacts). The contacts of the type 03 MIDI valve solenoid coils must not be bent (they are not resistant to alternate bending and will break off if bent backwards). In the case of modules and components ordered at a later stage, observe also the fitting instructions included with the product. Input/output modules Before the valve terminal can be extended or converted, it must first be dismantled. Dismantling (see also following diagram) Remove completely the screws of the relevant modules. The modules are now held together only by the electrical plug connectors. Pull the modules carefully and without tipping away from the electrical plug connectors. Replace broken or damaged seals NH

30 2. Fitting Fitting (see also following diagram) PLEASE NOTE Always place the subsequently ordered modules after the last module before the end plate. Do not fit more than 12 electronic modules. Please note also the addressing limits of your field bus protocol. Fit the modules as follows: Fit a new seal on the right-hand contact surface facing the node. Fit the module as shown below. Seal Fastening screws max. 1 Nm Fig. 2/1: Fitting electronic I/O modules 9610 NH 2-5

31 2. Fitting End plates A left-hand and a right-hand plate are required as mechanical termination of the modular terminal. These end plates fulfil the following functions: They comply with protection class IP 65. They contain connections/contacts for the protective earth cable. They contain holes for fitting onto walls and onto the hat rail clamping unit. By means of screw connectors and the ready fitted spring contacts, the right-hand end plate of the ISO terminal is connected conductively to the manifold sub-bases. It is therefore sufficiently earthed. There are various designs of right-hand end plate for the terminls of type 03 (MIDI/MAXI). Each design is already fitted with a protective earth cable. CAUTION Earth the right-hand end plate with the protective earth cable before fitting the terminal type 03. You thereby avoid high voltages on the metal surfaces in the case of a fault NH

32 2. Fitting Earth the end plates as follows: Right-hand end plate (type 03): To earth the right-hand end plate connect the cable fitted on the inside to the appropriate contacts on the pneumatic modules or on the node (see following diagram). Left-hand end plate (type 03 and type 05): The left-hand end plate is connected conductively to the other components via spring contacts which are already fitted. Please note: Instructions on earthing the complete valve terminal are to be found in the chapter "Installation". The diagram below shows how both end plates are fitted. Seal Contact for earth cable Seal Ready-fitted earth cable Fastening screws max. 1 Nm Fig. 2/2: Fitting the end plates (example with terminal type 03) 9610 NH 2-7

33 2. Fitting Hat rail clamping unit (type 03) If the terminal is to be fitted onto a hat rail (support rail as per EN 50022), you will require the hat rail clamping unit. This unit must be fastened to the rear of the end plates as shown in the following diagram. Before fitting ensure that: the glueing surfaces are clean (clean with spirit) the flat-head screws are tightened (6) After fitting ensure that: the levers are secured with the locking screw (7). 1 Rubber foot, self-adhesive 2 Clamping elements 3 Left-hand lever *) 4 Right-hand lever *) 5 O ring 6 Flat head screw 7 Retaining screw *) Levers differ in length for MIDI or MAXI Fig. 2/3: Fitting the hat rail clamping unit NH

34 2. Fitting 2.2 TYPE 03: FITTING THE VALVE TERMINAL Wall fitting (type 03) WARNING With long terminals use additional support brackets approximately every 200 mm. You thereby avoid: overloading the fastening eyes on the end plates the terminal sagging natural resonances 7.6 mm Proceed as follows: Calculate the weight of your terminal (weigh or estimate). General rule: MIDI MAXI per pneumatic module 800 g 1200 g per node 1000 g 1000 g per electronic module 400 g 400 g Make sure that the fastening surface can carry this weight. Fasten the terminal with four M6 screws as shown below (fitting position as desired). Use spacers if necessary. M6 Fig. 2/4: Fitting the valve terminal typ 03 on the wall 9610 NH 2-9

35 2. Fitting Fitting the hat rail (type 03) The terminal is suitable for fitting onto a hat rail (support rail as per EN 50022). For this purpose there is a guide groove on the rear of all modules for hanging the terminal on the hat rail. CAUTION Hat rail fitting without the hat rail clamping unit is not permitted. If the terminal is fitted in a sloping position or at a point subjected to vibration, protect the hat rail clamping unit against slipping and, by means of the screws (7), against unintentional loosening/opening. PLEASE NOTE If the terminal is fitted in a horizontal position without vibration, the screws (7) are not required for fastening the hat rail clamping unit. If your terminal does not have a hat rail clamping unit, this can be ordered and fitted later. The use of MIDI or MAXI clamping units depends on the end plates fitted (MIDI/MAXI). Proceed as follows: Calculate the weight of your terminal (weigh or estimate). General rule: MIDI MAXI per pneumatic module 800 g 1200 g per node 1000 g 1000 g per electronic module 400 g 400 g NH

36 2. Fitting Make sure that the fastening surface can carry this weight. Fit a hat rail (support rail as per EN x15; width 35 mm, height 15 mm). Fasten the hat rail approximately every 100 mm on the fastening surface. Hang the terminal onto the hat rail. Use the hat rail clamping unit to secure the terminal on both sides against tilting or slipping (see diagram below). If the terminal is fitted in a sloping position or at a point subjected to vibration, protect the hat rail clamping unit with two screws (7) against unintentional loosening/opening. Valve terminal type 03 Hat rail clamping unit unlocked Hat rail clamping unit (locked) Retaining screw (7) Fig. 2/5: Fitting the valve terminal typ 03 onto a hat rail 9610 NH 2-11

37 2. Fitting 2.3 TYPE 05: FITTING THE VALVE TERMINAL Wall fitting (type 05) WARNING With long terminals use additional support brackets approximately every 200 mm. You thereby avoid: overloading the fastening eyes on the end plates the terminal sagging (I/O side) natural resonances Proceed as follows: Calculate the weight of your terminal (weigh or estimate). General rule: Sub-base *) - 4 valve locations incl. valves - 8 valve locations incl. valves - 12 valve locations incl. valves ISO size 1 ISO size 2 8 kg 14 kg 20 kg 12 kg 20 kg 28 kg per node 1 kg per electronic module 0.4 kg *) Components for vertical stacking: Please see pneumatics manual P.BE-ISO-05-GB for weights. Make sure that the fastening surface can carry this weight NH

38 2. Fitting Fasten the terminal as follows: with three M10 screws on the adapter plate and on the right-hand end plate (2) with two M6 screws on the left-hand end plate (1) If required, use the following additional fastening methods: the hole on the bottom of the right-hand end plate with an M10 thread "blind hole" (3) the supporting angles for the I/O modules (see fitting instructions supplied with the angles) The terminal can be fitted in any desired position. If necessary, use spacers as well as the mounting and transport threads M8 (e.g. lifting eye bolts for crane hooks). 1 2 Thread M8 for lifting eye bolts 3 M6 M10 Fig. 2/6: Fitting the ISO valve terminal type 05 on the wall 9610 NH 2-13

39 2. Fitting NH

40 3. Installation 3. INSTALLATION 9610 NH 3-1

41 3. Installation Contents 3. INSTALLATION 3.1 GENERAL CONNECTING METHODS 3-3 Selecting the field bus cable 3-4 Selecting the operating voltage cable 3-5 Connecting the cables to the plugs/sockets FIELD BUS NODE 3-8 Opening and closing the node 3-8 Configuring the valve terminal 3-10 Setting the field bus address (network address) 3-11 Setting the baud rate 3-14 Setting the protocol Type 03: Connecting the operating voltages Type 05: Connecting the operating voltages Connecting the JETway-R 3-30 General instructions on the controllers CONNECTING THE INPUT MODULES 3-39 Pin assignment CONNECTING THE OUTPUT MODULES 3-42 Pin assignment NH

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

43 3. Installation Selecting the field bus cable PLEASE NOTE The cable specifications must be observed. Signal reflections and attenuation occur in data transmission particularly with high baud rates. These can lead to faults in transmission. The causes of reflection can be: missing or incorrect terminating resistor branches Causes of signal attenuation can be: transmission over long distances unsuitable cables A twisted, screened two-core cable must be used for the field bus cable. The cable types to be used are specified in the PLC manual for your controller. Take into account the distance and the field bus baud rate set NH

44 3. Installation Selecting the operating voltage cable Several parameters must be considered when the two operating voltages are connected. Further information can be found in the following chapters: Chapter 3: Installation Section: "Connecting the operating voltage" - Calculating the current consumption - Design of power unit - Cable cross section and length (worst case) Appendix A: Cable length and cross section - Determining the cross section and length by means of tables - Calculating with a formula NH 3-5

45 3. Installation Connecting the cables to the plugs/sockets CAUTION The position of the pins is different depending on whether plugs or sockets are used. The connections of the input and output modules have been designed as sockets. The connections of the field bus interface and the operating voltage connections have been designed as plugs. The pin assignment is to be found in the following chapters. When you have selected suitable cables, connect them to the plugs/sockets according to the sequence of steps Open the plugs/sockets as follows (see diagram): Power supply socket: Insert the power supply socket into the operating voltage connection on the valve terminal. Unscrew the housing of the socket, then remove the connection part of the socket which is plugged into the operating voltage connection. Sensor plug and field bus socket: Unscrew the centre knurled nut NH

46 3. Installation 2. Open the strain relief on the rear part of the housing. Pass the cable through as shown below (see diagram). Cable outer diameter: PG 7: mm PG 9: mm PG 13.5: mm Plugs/sockets (straight/angled): Power supply socket: PG 7, 9 or 13.5 Sensor plug: PG 7 Bus cable socket: PG 7, 9 or 13.5 AAA AAA A Cable Strain relief Housing AAAAAAA AAAA AAA AAAAAAA AAAAAAA AAAAAAA AAAA AAAA AAAA AAAA AAAA AAAAAAA AAA AAAA AAAAAAA AAAAAAA AAAAAAA Connection part Socket Plug Fig. 3/1: Individual plug/socket parts and cable routing 3. Remove 5 mm of insulation from the end of the cable. 4. Fit the strands with cable end sleeves. 5. Connect the ends of the conductors. 6. Place the connection part onto the housing of the plug/socket again and fasten both parts with screws. Pull the cable back so that it is not looped inside the housing. 7. Tighten the strain relief NH 3-7

47 3. Installation 3.2 FIELD BUS NODE Opening and closing the node WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the power supply to the electronic components (pin 1). the power supply to the outputs/valves (pin 2). You thereby avoid: uncontrolled movement of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components. CAUTION The node contains electrostatically vulnerable components. Do not therefore touch any components. Observe the regulations for handling electrostatically vulnerable components. You thereby avoid destroying the electronic components in the node NH

48 3. Installation The following connection and display elements are to be found on the cover of the node. Gren LED Red LED Plug for field bus cables BUS Fuse for operating voltage of inputs Power supply connection Fig. 3/2: Cover of the node PLEASE NOTE The cover is connected to the internal printed circuit boards by means of the operating voltage cable and cannot therefore be removed completely. Opening Unscrew and remove the 6 Philips screws in the cover and lift the cover up carefully. Do not damage the cable through mechanical stress. Closing Replace the cover. Place the operating voltage cables back into the housing so that they are not clamped. Tighten the Philips screws in the cover in diagonally opposite sequence NH 3-9

49 3. Installation Configuring the valve terminal There are four printed circuit boards in the node. Board 2 contains an LED and two plugs for the field bus cables; board 3 contains an LED and a switch for setting the configuration. Gren LED AA Red LED Plug for field bus cables AAA 1 2 AAA AAA 3 AAA 4 A Address selector switch DIL switch Screening plate Board 1 Board 2 Flat plug for operating voltage connection Board 4 Board 3 Fir. 3/3: Connection, display and operation elements of the node NH

50 3. Installation Setting the field bus address (network address) Use the two address selector switches on board 3 for setting the field bus address of the valve terminal. The switches are numbered from The arrow on the switches indicates the units figure or tens figure of the field bus address set. UNITS TENS Address selector switch UNITS figure Address selector switch TENS figure Fig. 3/4: Address selector switch PLEASE NOTE The valve terminal can only be used as a slave. Set only addresses from 2 to 99. Factory setting: address 2. Field bus (network) addresses must only be assigned once per field bus module. Recommendation Assign the field bus addresses in ascending order. Select field bus addresses to suit the machine structure of your system NH 3-11

51 3. Installation Possible (network) addresses PLC Addresses JETTER Factory setting: 2 Fig. 3/5: Possible (network) addresses Proceed as follows: 1. Switch off the operating voltage. 2. Assign a non-reserved field bus address to the valve terminal. 3. Use a screwdriver to set the arrow of the appropriate address selector switch to the units or tens figure of the desired field bus address. Example: UNITS TENS UNITS TENS Field bus address set: 05 Field bus address set: 38 Fig. 3/6: Example of (network) addresses set NH

52 3. Installation In addition to the address selector switch, the node also contains a DIL switch on which the following functions can be set: the baud rate. the protocol The DIL switch consists of four switch elements. These are numbered from The position "ON" is marked. 1 AAA AAA baud rate O N AAA AAA AAA AAA AAA AAA AAA baud rate protocol protocol Fig. 3/7: Position and function of the DIL switch 9610 NH 3-13

53 3. Installation Setting the baud rate The baud rate must be set with switches 1 and 2. PLEASE NOTE Set the baud rate of the valve terminal so that it corresponds to the setting of the field bus module (master) in the control system. The system only permits the baud rates 19.2 and kbaud. Factory setting: kbaud. Baud rate [kbaud] DIL switch ON Factory setting: kbaud. Fig. 3/8: Setting the baud rate NH

54 3. Installation Setting the protocol The protocol must be set with switches 3 and 4. If both switches are in the ON position, the valve terminal will operate as slave on the JETway-R. If both switches are in the OFF position, a test routine can be activated, see chapter 5, "Testing the valves". DIL switch JETway-R Test routine Factory setting: JETway-R ON Fig. 3/9: Setting the protocol 9610 NH 3-15

55 3. Installation Type 03: Connecting the operating voltages WARNING In order that the operating voltage can be isolated reliably, you must use an isolating transformer with at least 4 kv isolation resistance complying with standard EN CAUTION The power supply to the outputs/valves (pin 2) must be separately fused externally with max. 10 A. The external fuse prevents the valve terminal from being destroyed in the event of a short circuit NH

56 3. Installation The 24 V operating voltages are connected at the lower left-hand edge of the node. Operating voltage connection type 03 Fig. 3/10: Position of the operating voltage connection The following components of valve terminal type 03 are supplied separately with + 24 V DC via this connection: The operating voltage for the internal electronic components and the inputs of the input modules (pin 1: DC + 24 V, tolerance ± 25 %). The operating voltage for the valve outputs and the ouputs of the output modules (pin 2: DC + 24 V, tolerance ± 10 %, external fuse maximum 10 A required). Recommendation The operating voltage for the outputs should be connected to the EMERGENCY STOP circuit or EMERGENCY STOP contacts NH 3-17

57 3. Installation PLEASE NOTE With common voltage supply for pin 1 (electronic components and inputs) and pin 2 (outputs/valves) the lower tolerance of ± 10 % for both circuits must be observed. Check the 24V operating voltage of the outputs whilst your system is operating. Make sure that the operating voltage of the outputs lies within the permitted tolerances even during full operation. Recommendation Use a closed loop power unit. Calculate the complete current consumption according to the following table and select both a suitable power unit and cable cross section. Avoid long distances between the power unit and the terminal. Calculate also the permitted distance according to Appendix A. The following rule applies for type 03: Operating voltage Valve terminal Pin 1 = 2.2 A Pin 2 = 10 A Vo = 24 V Cable cross section Distance 1.5 mm 2 8 m 2.5 mm 2 14 m NH

58 3. Installation Calculating the current consumption (type 03) The following table shows the calculation of the total current consumption for terminal type 03. The values given are rounded up. If you use other valves or modules, you should consult the appropriate technical specifications for their current consumption. Current consumption of electronic components node and inputs type 03 (pin 1, 24 V ± 25 %) Node A Number of simultaneously occupied sensor inputs: x A + A Sensor supplies: x A (see manufacturer specifications) + A Current consumption of electronic components, node and inputs (pin 1) max. 2.2 A = A A Current consumption of outputs type 03 (pin 2, 24 V ± 10 %) Number of MIDI valve coils (simultaneously under power): x A + A Number of MAXI valve coils (simultaneously under power): x A + A Number of simultaneously activated electrical outputs: x A + A Load current of simultaneously activated electrical outputs x A + A Current consumption of outputs = A (pin 2) max. 10 A + A Total current consumption of valve terminal type 03 = A Fig. 3/11: Calculating the total current consumption of terminal type NH 3-19

59 3. Installation The diagram below shows the pin assignment of the operating voltage connection. 24 V supply for electronic components and inputs 1 24 V supply valves, outputs 4 PE 3 (protective earth connection, leading socket) 0 V Fig. 3/12: Pin assignment of the operating voltage connection (type 03) Protective earthing The valve terminal has two protective earthing connections: at the operating voltage connection (pin 4 incoming socket). at the left-hand end plate (M4 thread). 2 PLEASE NOTE Always connect the earth cable to pin 4 of the operating voltage connection. Make sure that the housing of the valve terminal and the earth cable at pin 4 have the same potential and that no equalizing currents flow. Connect an earth cable of sufficient crosssection to the left-hand end plate if the valve terminal is not mounted on an earthed machine stand. In this way you can avoid interference due to electromagnetic sources NH

60 3. Installation Example of connection (type 03) The following diagram shows the connection of a common 24 V supply for pin 1 and pin 2. Please note that: the supply to the outputs/slaves must be protected against short circuit/overload with an external fuse 10 A max. the electronic components and inputs must be protected against short circuit/overload with an external 3.15 A fuse (recommendation). the supply to the sensors is also protected by the internal fuse (2 A). the common tolerance of DC 24 V ± 10 % must be observed. equalizing currents must be avoided when both earth cables are connected, e.g. by means of cables with appropriate cross section as potential compensation NH 3-21

61 3. Installation Connection cable for potential equalization of earthing connections AC 230 V 0 V 24 V 3.15 A Fuse for inputs/sensors (2A) External fuses DC 24V ± 10% 10 A EMERGERCY STOP Protective earth connection pin 4 designed for 12 A Fig. 3/13: Example connecting a common 24 V supply and both protective earth cables (type 03) NH

62 3. Installation Type 05: Connecting the operating voltages WARNING In order that the operating voltage can be isolated reliably, you must use an isolating transformer with at least 4 kv isolation resistance complying with standard EN CAUTION The power supply to the outputs/valves (pin 2) must be separately fused externally with max. 10 A. The external fuse prevents the valve terminal from being destroyed in the event of a short circuit NH 3-23

63 3. Installation The 24 V operating voltages are connected on the adapter plate between the node and the valves. The node and the I/O-modules are supplied with operating voltage via the adapter cable. Operating voltage connection type 05 Fuse for valves (4 A slow blowing) Adapter cable Fig 3/14: Position of the operating voltage connection type 05 The following components of valve terminal type 05 are supplied separately with + 24 V DC via this connection: The operating voltage for the internal electronic components and the inputs of the input modules (pin 1: DC + 24 V, tolerance ± 25 %, external fuse max A recommended). The operating voltage for the valve outputs and the ouputs of the output modules (pin 2: DC + 24 V, tolerance ± 10 %, external fuse max. 10 A slow-blowing required). Recommendation: The operating voltage for the outputs/valves should be connected to the EMERGENCY STOP circuit or EMERGENCY STOP contacts NH

64 3. Installation PLEASE NOTE With common voltage supply for pin 1 (electronic components and inputs) and pin 2 (outputs/valves) the lower tolerance of ± 10 % for both circuits must be observed. Check the 24V operating voltage of the outputs whilst your system is operating. Make sure that the operating voltage of the outputs lies within the permitted tolerances even during full operation. Recommendation Use a closed-loop power unit. Calculate the complete current consumption according to the following table and select both a suitable power unit and cable cross section. Avoid long distances between the power unit and the terminal. Calculate also the permitted distance according to Appendix A. The following rule applies for type 05: Operating voltage*) Cable cross section Distance Valve terminal 1.5 mm 2 8 m Pin 1 = 2.2 A Pin 2 = 10 A Vo = 24 V 2.5 mm 2 14 m *) Please note that the max. total current consumption (pins 1 and 2) is 12.2 A 9610 NH 3-25

65 3. Installation Calculating the current consumption (type 05) The following table shows the calculation of the total current consumption for ISO terminal type 05. The values given are rounded up. If you use other valves or modules, you shuld consult the appropriate technical specifications for their current consumption. Current consumption of electronic components node and inputs type 05 (pin 1, 24 V ± 25 %) Node A Number of simultaneously occupied sensor inputs: x A + A Sensor supplies: x A (see manufacturer specifications) + A Current consumption of electronic components, node and inputs (pin 1) max. 2.2 A = A A Current consumption of outputs type 05 (pin 2, 24 V ± 10 %) Number of valve coils (simultaneously under power): x A + A Number of simultaneously activated electrical outputs: x A + A Load current of simultaneously activated electrical outputs x A + A Current consumption of outputs (pin 2) max. 10 A = A + A A Fig. 3/15: Calculating the total current consumption type NH

66 3. Installation The diagram below shows the pin assignment of the operating voltage connection on the adapter plate. 24 V supply for electronic components and inputs 1 24 V supply valves, outputs 4 PE 3 (protective earth connection, leading socket) 0 V Fig. 3/16: Pin assignment of the operating voltage connection (type 05) Protective earthing The valve terminal has two protective earthing connections as follows: at the operating voltage connection (pin 4 incoming socket) at the left-hand end plate (M4 thread) 2 PLEASE NOTE Always connect the earth cable to pin 4 of the operating voltage connection. Make sure that the housing of the valve terminal and the earth cable at pin 4 have the same potential and that no equalizing currents flow. Connect an earth cable of sufficient crosssection to the left-hand end plate if the valve terminal is not mounted on an earthed machine stand. In this way you can avoid interference due to electromagnetic sources NH 3-27

67 3. Installation Example of connection (type 05) The diagram overleaf shows the connection of a common 24 V supply for pin 1 and pin 2. Please note that: the outputs/valves must be protected against short circuit/overload with external 10 A fuse (slow blowing) the electronic components and inputs must be protected against short circuit/overload with an external 3.15 A fuse (recommendation) the supply of the sensors is protected additionally by the internal 2 A fuse the valves are protected additionally by the internal 4 A fuse (slow blowing) the common tolerance of DC 24 V ± 10 % must be observed the node must be supplied via the adapter cable equalizing currents must be avoided when both earth cables are connected, e.g. by means of cables with appropriate cross section as a potential compensation NH

68 3. Installation Fuse for inputs/sensors (2A) Operating voltage connection Fuse for valves (4 A, slow blowing) Connected adapter cable Connecting cable for potential compensation of earth connections AC 0 V 230V 24 V DC 24V ± 10% 3.15 A External fuses 10 A EMERGENCY STOP Earth cable connection pin 4 designed for 12 A Fig. 3/17: Example connecting a common 24 V supply and both earth cables (type 05) 9610 NH 3-29

69 3. Installation Connecting the JETway-R There are two field bus plugs on the node for connecting the valve terminal to the JETway-R. One of these connections is for the incoming cable and the other is for the continuing field bus cable. The signal cables of both plugs are connected with each other internally. Two methods of connection are therefore possible. Looping the field bus cable from terminal to terminal. Both field bus plugs are required here. Connecting the field bus cable by means of a T-adapter. Only one field bus plug is required here. CAUTION Branches (e.g. T-adapters) cause signal reflections under certain circumstances with high baud rates. This can lead to "telegram faults" with brief "failure" of valves. Recommendation Observe the maximum permitted distance of 15 cm between the T-adapter and the field bus plug in order to avoid signal reflections. Use the ready-made Festo T-adapter FB-TA for this purpose NH 3-30

70 3. Installation Incoming JETway-R Continuing JETway-R BUS Fig. 3/18 A: Connection variant for JETway-R Incoming JETway-R Continuing JETway-R T-adapter (e.g. Festo FB-adapter) Branch line max. 15 cm BUS Cover with protective cap (IP 65) Fig 3/18 B: Connection variant for JETway-R NH

71 3. Installation CAUTION Observe the polarity when connecting the field bus interface. Connect the screening. The diagram below shows the pin assignment of the field bus interface. Connect the field bus cables to the contacts of the bus cable socket accordingly. Note also the connection instructions in following diagrams, as well as the instructions in the PLC manual of your controller. S- 3 2 free Screening 4 1 S + BUS S free S + 1 MΩ 220 nf Internal resistor-capacity network Housing of node Fig 3/19: Pin assignment of field bus interface 9610 NH 3-32

72 3. Installation General instructions on the controllers Connection drawings The following drawings show the different possibilities of connecting a valve terminal to a controller from the JETTER processing PLC family. The framework of broken lines represents the screening connection on the controller side. Screening/shielding With PASE-E and Delta, connection to the field bus is made via the SUB-D plug. The cable screening must be connected here over a large area under the conductive strain relief. With Micro, the signal connections are on plug-in terminals. The screening connection is made via specially provided strain relief, under which the screening braiding of the cable must be fastened over a large area. Further instructions on screening can be found in the appropriate controller manuals NH

73 3. Installation Connection to PASE-E/CPU PLEASE NOTE The connnection instructions in the PASE-E manual must also be observed. With the PASE-E controller, the field bus is connected via the 9-pin or 15-pin SUB-D plug connector on the front panel of the CPU. With both plugs, the field bus signals are transmitted through pins 8 and 9. SUB-D plug 9-/15-pin 8 D D 3 PASE Screening 4 Valve terminal Fig. 3/20: Connecting cable for PASE-E/CPU 9610 NH 3-34

74 3. Installation Connection to PASE-E via INT5 card PLEASE NOTE The connnection instructions for the INT5 card in the PASE-E manual must also be observed. With the INT5 card, the field bus is connected for the operating mode "remote scan" via the 9-pin SUB-D plug connector of the second interface. The field bus signals are transmitted through pins 1 and 6. SUB-D plug 9-pin 8 DATA+ Bus cable socket 9-pin 1 9 DATA 3 PASE-E INT5 Screening 4 Valve terminal Fig. 3/21: Connecting cable for controller/int5 card NH

75 3. Installation Connection to Delta PLEASE NOTE The connnection instructions in the Delta manual must also be observed. With the Delta controller, the field bus is connected for network 1 via the 9-pin or SUB-D plug connector designated NET 1 and for network 2 via the 9-pin SUB-D plug connector designated NET 2. With both plugs, the field bus signals are transmitted through pins 8 and 9. SUB-D plug 9-pin Bus cable socket 4-pin 8 DATA DATA 3 Delta Screening Valve terminal 4 Fig. 3/22: Connecting cable for Delta 9610 NH 3-36

76 3. Installation Connection to Micro PLEASE NOTE The connnection instructions in the Micro manual must also be observed. With the Micro controller, the field bus is connected for network 1 via the terminal NET and for network 2 via the terminal SERIAL. Terminal NET D D DATA + DATA 1 3 Micro (network 1) 4 Valve terminal D2 D2 Terminal SERIAL DATA + DATA 1 3 Micro (network 2) 4 Valve terminal Fig. 3/23: Connecting cable for Micro NH

77 3. Installation Terminating resistor If the terminal to be connected is at the end of a field bus line, a terminating resistor must be fitted into the socket of the incoming field bus cable (120 Ohm, 0.25 Watt). The socket must be adapted for this purpose. The free field bus plug must be fitted with a protective cap (protection class IP 65). Proceed as follows (see diagram below): 1. Crimp the wires of the resistor together with those of the incoming field bus cable between the cores D+ (D, pin 1) and D- (D, pin 3) of the bus cable socket. In order to guarantee reliable contact, we recommend that the wires of the resistor and those of the incoming field bus cable be crimped together in common end sleeves. AAAA AAAA AAAA AAAAAA AAAA AAAA AAAA AAAAAA AAAA AAAA AAAA AAAA AAAAAAAAAAAAA AAAA AAAA AAAA AAAA AAAA AAAAAAAAAAAAAA AAAA AAAA AAAA AAAA AAAA AAAAAAAAAAAAAA AAAA AAAA AAAA AAAA AAAAAAAAAAAAAA AAAA AAAA AAAA AAAAAA AAAA AAAA AAAA AAAAAA 3 A 120 Ω 4 1 Fig 3/24: Fitting the terminating resistor 2. Fit the bus cable socket onto one of the field bus plugs. 3. Cover the unused field bus plug with a protective cap NH 3-38