Valve Terminal/Valve Sensor Terminal with Field Bus Connection VIFB8-/IIFB Manual

Transcription

1 Valve Terminal/Valve Sensor Terminal with Field Bus Connection VIFB8-/IIFB Manual Fieldbus protocol: Allen-Bradley Remote I/O link GB 0503a

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3 Authors: Editors: Translation: Layout: Type setting: H.-J. Drung, E. Klotz, M. Prinzen Michael Holder, H.-J. Drung Douglas Smith Festo, Dept. PV-IDM DUCOM Edition 0503a gedruckt auf 100 % Recyclingpapier 0503a (Festo AG & Co., Esslingen, Federal Republic of germany, 1997) The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registrations. I

4 Order no.: Title: Designation: MANUAL P.BE-VIFB8-02-GB PLC-2 PLC-3 PLC-5 SLC-500 is a registered trademark of Allen-Bradley Company Inc. is a registered trademark of Allen-Bradley Company Inc. is a trademark of Allen-Bradley Company Inc. is a trademark of Allen-Bradley Company Inc. II 0503a

5 Contents Contents Chapter 1 IMPORTANT USER INSTRUCTIONS Chapter 2 SYSTEM STRUCTURE Chapter 3 TECHNICAL DESCRIPTION Chapter 4 INSTALLATION 4.1 Fitting the valve terminal/ valve sensor terminal Installing the pneumatic components Installing the electronic components Chapter 5 COMMISSIONING Chapter 6 DIAGNOSIS AND ERROR TREATMENT Appendix A INDEX 0503a III

6 IV 0503a

7 1. Important user instructions 1. IMPORTANT USER INSTRUCTIONS

8 1. Important user instructions Contents IMPORTANT USER INSTRUCTIONS

9 1. Important user instructions IMPORTANT USER INSTRUCTIONS This description contains instructions on the possible dangers which can occur with the valve terminal/valve sensor terminal. A distinction is made between the following instructions: WARNING Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided may result in minor or moderate injury. PLEASE NOTE This means that this instruction must also be observed

10 1. Important user instructions This documentation describes the following products: Product Design Remote I/O (RIO) link for programmable controller from Valve size No. of valve locations Valve terminal type 02 VIFB Valve sensor terrminal type 02 IIFB Allen-Bradley 1 8" or 1 4" 4 or 6 or 8 or 10 or 12 or 14 or 16 Fig. 1/1: Designs of valve terminal/valve sensor terminal Included with this manual is a service card. This is to be used for diagnostic and error treatment during on-the-spot service. The Allen-Bradley remote I/O link is referred to in the description as the Allen-Bradley RIO link. PLEASE NOTE This product incorporates technology which is licensed by Allen-Bradley Company Inc.. Allen-Bradley does not technically approve, nor does it warrant or support this product. All warranty and support for this product is provided by Festo

11 2. System structure 2. SYSTEM STRUCTURE

12 2. System structure Contents SYSTEM STRUCTURE Valve terminal Valve sensor terminal Valve terminal/valve sensor terminal in the control system

13 2. System structure SYSTEM STRUCTURE Valve terminal Festo offers a solution to automation problems at the machine level in the form of the valve terminal. Solenoid valves, solenoid pulse valves etc. are ready fitted onto a connection block and have already been tested. Valve terminals with from valve locations are available for the automation process. Valve terminal Circuitry RIO connection via shielded twisted-pair cable Type 02 Fig. 2/1: Valve terminal type 02 The valve terminal with 1771 RIO offers the following advantages: decentralized preprocessing relieves the programmable controller less wiring due to 2-wire twisted pair cables clarity in system structure due to separation of controller and machine valves already fitted wired valve solenoid coils central air supply central exhaust device already tested

14 2. System structure A remote I/O link also offers the following advantages: a reduction in the number of output modules in the controller economic data transfer over long distances high baud rate a large number of slaves can be linked into the network error diagnosis is made easier Valve sensor terminal Complex automation tasks require the use of sensors for which Festo offers the valve sensor terminal. Solenoid valves, solenoid pulse valves etc. are fitted onto a connection block and have already been tested; two sensors per valve can be connected on site. Valve sensor terminals with from valves are available for the automation process. Valve sensor terminal Circuitry RIO connection via shielded twisted-pair cable Type 02 Fig 2/2: Valve sensor terminal type 02 The valve sensor terminal includes all the advantages of the valve terminal. It also offers: two inputs per valve location, e.g. for position sensors two additional inputs two additional outputs, e.g. for electric actuators, displays etc

15 2. System structure Valve terminal/valve sensor terminal in the control system The valve terminal/valve sensor terminals are participants in the Allen-Bradley RIO link. They can be connected to RIO scanner ports of the following automation systems: Programmable controller family RIO scanner A-B PLC-2 RIO scanner 1772-SD, SD2 PLC S4A, -S4B, -S5, -SR or SR5 module PLC-5 TM N.B.: PLC-5/250 requires a 5150-RS built-in scanner SLC-5/02 TM 1747-SN Fig. 2/3: Allen-Bradley automation systems Fig. 2/4 shows a valve terminal/valve sensor terminal with RIO links connection as part of a A-B control system. PLEASE NOTE The valve terminals and valve sensor terminals are not compatible with the Data Highway, Data Highway Plus TM, DIO bus system or DH

16 2. System structure A-B PLC-3 Allen-Bradley 1771 I/O chassis RIO RIO Power unit VIFB AC 24 V = Actuator IIFB Sensor Actuator Sensor Fig. 2/4: System structure of Allen-Bradley RIO link with valve terminal valve sensor terminal

17 2. System structure The Allen-Bradley RIO link creates data communication between the controller and the slaves (e.g. valve terminal/valve sensor terminal or remote I/O) distributed throughout the system. Baud rates up to 57.6K, 115.2K or K Baud can be set. The valve terminal as a decentralized output device proceses the RIO signals transmitted and controls the actuators which are connected. The valve terminal is supplied with current via an external power unit (AC 115V/230 V/DC 24V). The valve sensor terminal as a decentralized input/output device functions like a valve terminal. It also processes up to 30 inputs for valve position sensors. The actuators produce motion via air controlled by the valve terminal/valve sensor terminal. The sensors provide digital valve position information and pass this on to programmable controller through the terminal

18 2. System structure

19 3. Technical description 3. TECHNICAL DESCRIPTION 0503a 3-1

20 3. Technical description Contents TECHNICAL DESCRIPTION Structure Valve terminal Valve sensor terminal Function Explanation on function summary Technical specifications General Electronic components RIO link Pneumatic components Connection block Valves a

21 3. Technical description TECHNICAL DESCRIPTION Structure Valve terminal The valve terminal consists of the following components: Figure Components 1 RIO node 2 Valve terminal base unit consisting of: Valve coupling unit (upper part) Connection block (lower part) 3 Valve locations for Solenoid pulse valves or Solenoid mid-position valves Solenoid valves or Relay boards or Cover plates 4 Earth connection (M4 thread) Fig. 3/1: Components of the valve terminal 0503a 3-3

22 3. Technical description The following operation and display elements are to be found on the components of the valve terminal: Valve terminal inscription field 2 Red LED (Power) 3 Green LED (Bus) 4 Operating voltage connection 5 RIO interface 6 Type plate 7 Valve location inscription field (per valve solenoid coil) 8 Yellow LED (per valve solenoid coil) 9 Common cable connections 10 Work line connections 11 Earth connection (M4 thread) 8 Fig. 3/2: Operation and display elements of the valve terminal The composition of the type plate is shown in Fig. 3/5 using the valve sensor terminal as an example: a

23 3. Technical description Valve sensor terminal The valve sensor terminal consists of the following components: Figure Components 1 RIO node 2 Valve sensor terminal base unit consisting of: Valve sensor coupling unit (upper part) Connection block (lower part) 3 Valve locations for Solenoid pulse valves or Solenoid mid-position valves or Solenoid valves or Relay boards Cover plates 4 Earth connection (M4 thread) Fig. 3/3: Components of the valve sensor terminal 0503a 3-5

24 3. Technical description The following operation and display elements are to be found on the components of the valve sensor terminal: Connections for additional outputs 12 2 Common fuse for inputs 13 3 Valve sensor terminal inscription field 4 Red LED (Power) 5 Green LED (Bus) 6 Operating voltage connection 7 RIO interface 8 Type plate 9 Connections for inputs (e.g. sensors) 10 Inscription field inputs/additional outputs (per connection) 11 Yellow or green LED (per additional input/output) 12 Yellow LED (per valve solenoid coil) 13 Valve location inscription field (per valve solenoid coil) 14 Common cable connections 15 Work line connections (per valve) 16 Earth connection (M4 thread) Fig. 3/4: Operation and display elements of the valve sensor terminal a

25 3. Technical description The composition of the type plate is shown in Fig. 3/5 using the valve sensor terminal as an example. The type plate is situated below the RIO node and contains the following specifications: IIFG Max. bar 10 max. PSI V DC Type designation of base unit (here valve sensor terminal) Part number Max. operating pressure in bar and psi Permitted operating voltage Fig. 3/5: Example type plate of valve sensor terminal 0503a 3-7

26 3. Technical description Function The valve terminal or valve sensor terminal should be placed in the immediate vicinity of the processing unit. Connection to the control level is made via the RIO link which operates on the master-slave principle. The RIO scanner of the A-B PLC functions here as master, and the valve terminal/valve sensor terminal as slave. The scanner transmits a message to the valve terminal/valve sensor terminal. The valve terminal sends a reply message to the RIO scanner. Programmable controller RIO scanner RIO Valve coupling unit or Valve-sensor coupling unit Operating voltage connection RIO node RIO interface Valve Pneumatic interface (see also opposite) Actuator Connection block RIO slave Fig. 3/6: Function summary of valve terminal/valve sensor terminal a

27 3. Technical description Explanation of the function summary The RIO node controls the following functions: The connection of the valve terminal/valve sensor terminal to the A-B RIO scanner of the programmable controller and to further RIO slaves via the RIO interface. The control of data transfer to/from the RIO scanner. The internal control of the valve terminal/valve sensor terminal. The valve coupling unit of the valve terminal contains the operating voltage connection and a decoder. This decodes the signals from the RIO node and transmits the pulses to the valves. The valve-sensor coupling unit of the valve sensor terminal contains the operating voltage connection and a decoder. This decodes the signals from the RIO node and transmits the pulses to the valves. The electrical inputs for valve position sensors, as well as two additional outputs are also situated here. The valves control the flow of air to the actuators. The valves are supplied with compressed air via the common channels of the connection block. The exhaust and pilot exhaust from the valves are also ventilated via these channels. The connection block is connected to the common cables of the pneumatic system via the pneumatic interfaces. 0503a 3-9

28 3. Technical description Technical specifications General Protection class (as per DIN 40050) Temperature at operation storage/transport IP 65-5 o C o C -20 o C o C Dimensions (LxWxH) when base unit is fully fitted Valve terminal VIFB-02-1/4(1/8)-4 VIFB-02-1/4(1/8)-6 VIFB-02-1/4(1/8)-8 VIFB-02-1/4(1/8)-10 VIFB-02-1/4(1/8)-12 VIFB-02-1/4(1/8)-14 VIFB-02-1/4(1/8)-16 Valve sensor terminal IIFB-02-1/4(1/8)-4 IIFB-02-1/4(1/8)-6 IIFB-02-1/4(1/8)-8 IIFB-02-1/4(1/8)-10 IIFB-02-1/4(1/8)-12 IIFB-02-1/4(1/8)-14 Specifications of the 1 8" design are given in round brackets 259.5x 288 x 141 mm (235.5x x mm) 325.5x 288 x 141 mm (289.5x x 139,5 mm) 391.5x 288 x 141 mm (343.5x 275,4 x mm) 457.5x 288 x 141 mm (397.5x x mm) 523.5x 288 x 141 mm (415.5x 275,4 x mm) 589.5x 288 x 141 mm (505.5x x mm) 655.5x 288 x 141 mm (559.5x x mm) 259.5x x 141 mm (235.5x x mm) 325.5x x 141 mm (289.5x x mm) 391.5x x 141 mm (343.5x x mm) 457.5x x 141 mm (397.5x x mm) 523.5x x 141 mm (415.5x x mm) 589.5x x 141 mm (505.5x x mm) a

29 3. Technical description Electronic components Operating voltage Electronic components and inputs (Pin 1 Operating voltage connection) Rated value (protection against incorrect polarity) Tolerance Residual ripple Current capacity (at 24 V) Valve terminal/ Valve sensor terminal Power consumption (P) Calculation Power failure holdup time Operating voltage outputs (Pin 2 Operating voltage connection) Rated value (protected against incorrect polarity) Tolerance Residual ripple Current capacity (at 24 V) Power consumption (P) Calculation DC 24 V ± 25 % (DC18 V V) ± 4Vss 200 ma 200 ma + sum of current capacity of inputs P[W] = (0.2 A + I Inputs) 24 V min. 20 ms DC 24 V ± 10 % (DC 21.6 V V) ± 4 Vss 10 ma +Sum current capacity additional outputs +Sum current capacity of switched valve solenoid coils (per valve solenoid coil 120 ma) P[W] = (0.01 A + IAdditional outputs + ISolenoid coil) 24 V 0503a 3-11

30 3. Technical description Elektromagnetic compatibility Interference emitted Immunity against interference Protection against electric shock (protection against direct and indirect contact as per IEC/DIN EN ) Additional outputs/ installation terminal Loading per additional output Electronic fusing (short circuit, overload) Trigger current Response time (short circuit) Inputs/valve sensor terminal Logic level ON OFF Tested as per DIN EN (industry) 1) Tested as per DIN EN (industry) by means of PELV circuits (Protective Extra-Low Voltage) max. 0.5 A (Bulbs max. 10 W because of PTC resistor characteristics max. 1 A max. 1 s 12 V 7.5 V Voltage range Current capacity (at 24V) (Current from sensor to input) Response delay of valve sensor terminal inputs (at 24 V) 0 V V typ. 9 ma typ. 5 ms Common fuse for operating voltage supply to sensors 4A, slow-blowing 1) The component is intended for industrial use a

31 3. Technical description RIO link Transmission type master/slave Protocol Allen-Bradley RIO Baud rate 57.6 kbaud kbaud kbaud Cable type Belden 9463 shielded twisted-pair Cable length 3.3 km at 57.6 kbaud 1.6 km at kbaud 0.8 km at kbaud Terminators refer to A-B publications Cable installation Plug connector see Chapter 4.3 Connection instructions 0503a 3-13

32 3. Technical description Pneumatic components Air quality Filter fineness (standard) Poppet valve Spool valve Pressure Operating pressure range Rated pressure Highest pressure at 1 filtered or filtered and dried compressed air lubricated or unlubricated compressed air 40 μm 40 μm 2 bar bar; 29 psi psi 6 bar, 87 psi 10 bar, 145 psi Connection block Fastening Type Mounting Size of connection with 1 (compressed air) 3 and 5 (exhaust) 82 and 84 (pilot exhaust) 4 through holes From the front with 4 hexagon head bolts (M6x60) G 1 2 (G 3 8) G 1 8 (G 1 8) a

33 3. Technical description Please unfold for page 3-16 Please unfold for page

34 3. Technical description Technical specifications of valves Designation Size Switching symbol Construction Pilot air Manual override Lubrication Fastening with 2 slotted head screws Type Form Basic setting (as at factory) Option (conversion necessary) MVH-5-1/4 B-VI 1/4" M4x55 without MVH-5-1/8 B-VI 1/8" Poppet valve unilaterallyoperated Single spindle with cyl. compression M4x50 MVH-5-1/4-S B-VI 1/4" spring for basic 5/2 way position. with M4x55 MVH-5-1/8-S B-VI 1/8" Service life M4x50 lubrication MVH-5-1/4-L B-VI 1/4" (free of M4x55 Spool valve without PWIS) MVH-5-1/8-L B-VI 1/8" bilaterallyoperated M4x50 MVH-5-1/4-L-S B-VI 1/4" 5/2 way M4x55 with MVH-5-1/8-L-S B-VI 1/8" M4x50 IMVH-5-1/4 B-VI 1/4" M4x65 Spool valve without IMVH-5-1/8 B-VI 1/8" bilaterallyoperated with pressure relief automatic safety lock Soft piston in sleeve With With lock or M4x60 5/2 way IMVH-5-1/4-S B-VI 1/4" slots. Outlet slots return M4x65 are overrun. with IMVH-5-1/8-S B-VI 1/8" M4x60 MVH-5/3G-1/4 B-VI MVH-5/3G-1/8 B-VI 1/4" 1/8" Service life lubrication (can contain PWIS) M4x65 M4x60 MVH-5/3E-1/4 B-VI 1/4" Spool valve bilaterallyoperated M4x65 MVH-5/3E-1/8 B-VI 1/8" without 5/3 way M4x60 MVH-5/3B-1/4 B-VI 1/4" M4x65 MVH-5/3B-1/8 B-VI 1/8" M4x

35 3. Technical description Size Pressure Flow Times 1/4" Operating pressure Auxiliary pilot air Pilot pressure (Pneumatic spring) bar 2 and 4 (work air) G 1/4 Size of connection with 12 and 14 (Auxiliary pilot air) Nominal size 1 2 or 1 4 [l/min] 7 mm Q = 1300 CV = 1.32 Rated flow Switch position 1/8" G 1/8 5 mm Q = 750 CV = /4" bar bar G1/4 7 mm Q = 1300 CV = /8" bar G1/8 G 1/8 5 mm Q = 750 CV = /4" G1/4 10 mm Q = bar CV = /8" G1/8 8 mm Q = 1000 CV = /4" G1/4 10 mm Q = bar bar bar CV = /8" G1/8 8 mm Q = 1000 CV = /4" bar G1/4 10 mm Q = 1600 CV = 1.63 Notes: 1 ) Mid-position Q=1000, C V= ) Mid-position Q= 400, C V= or 4 5 [l/min] Q = 1100 CV = 1.12 Q = 1100 CV = /8" G1/8 8 mm Q = 1000 G1/8 CV = /4" G1/4 10 mm Q = bar bar CV = /8" G1/8 8 mm Q = 1000 CV = /4" G1/4 10 mm Q = bar CV = /8" G1/8 8 mm Q = 1000 CV = /4" G1/4 10 mm Q = ) G1/ bar CV = /8" G1/8 8 mm Q = ) CV = /4" G1/4 10 mm Q = ) bar CV = /8" G1/8 8 mm Q = ) CV = 1.02 Valve switching times ON at 6 bar OFF at 6 bar 19 ms 41 ms 17 ms 36 ms 19 ms 41 ms 17 ms 36 ms 33 ms 40 ms 30 ms 100 ms 33 ms 40 ms 30 ms 100 ms 18 ms 22 ms 18 ms 22 ms Switchover time 27 ms 36 ms 30 ms 30 ms 33 ms 45 ms 40 ms 50 ms 32 ms 38 ms 40 ms 50 ms Reaction time calculation Field bus transmission time (see PLC manual) + valve switching times

36 3. Technical description Please unfold for page 3-17 Please unfold for page

37 4. Installation 4.1 FITTING THE VALVE TERMINAL/ VALVE SENSOR TERMINAL

38 4. Installation Contents FITTING THE VALVE TERMINAL/ VALVE SENSOR TERMINAL

39 4. Installation FITTING THE VALVE TERMINAL/VALVE SENSOR TERMINAL Before fitting the valve terminal/valve sensor terminal please see that there is sufficient space to the left and/or right of the connection block for fitting the hoses and, if necessary, the silencers. There are 4 through holes on the right and lefthand edges of the connection block for fastening the valve terminal/valve sensor terminal (see following diagram) Mounting holes for M6 hexagon head bolts Fig. 4/1: Through holes for mounting

40 4. Installation The following procedure should be adopted: 1. Bore four holes in the mounting surface. The distance between the holes depends on the type of valve terminal/valve sensor terminal used (specifications of the 1 8" design are given in round brackets). 6.8 mm L1 L2 Valve terminal/ valve sensor terminal VIFB-/IIFB-02-1/4(1/8)-4 VIFB-/IIFB-02-1/4(1/8)-6 VIFB-/IIFB-02-1/4(1/8)-8 VIFB-/IIFB-02-1/4(1/8)-10 VIFB-/IIFB-02-1/4(1/8)-12 VIFB-/IIFB-02-1/4(1/8)-14 VIFB-02-1/4(1/8)-16 Distance between holes [mm] L1 L2 32 (27.5) 222 (198) 32 (27.5) 288 (252) 32 (27.5) 354 (306) 32 (27.5) 420 (360) 32 (27.5) 486 (414) 32 (27.5) 552 (468) 32 (27.5) 618 (522) Fig. 4/2: Fitting the valve terminal/valve sensor terminal 2. Fasten the valve terminal onto the mounting surface with 4 hexagon head bolts (M6x60). The bolts should be tightened in diagonally opposite sequence

41 4. Installation 4.2 INSTALLING THE PNEUMATIC COMPONENTS

42 4. Installation Contents INSTALLING THE PNEUMATIC COMPONENTS Laying the hoses General Preparing the connection block Connecting the connection block Connecting the valves Solenoid valve (5/2-way) Solenoid pulse valve (5/2-way) and Solenoid mid-position valve (5/3-way) Checking the valve functions Manual overrride Designs of manual override Testing Locking the manual override

43 4. Installation INSTALLING THE PNEUMATIC COMPONENTS WARNING Before installation or maintenance work is carried out the following must be switched off: the operating voltage for electronic components and/or inputs. the operating voltage supply. the compressed air. You thereby avoid: uncontrolled movement of loosened hoses. undesired movement of the actuators connected. undefined switching states of the electronic components

44 4. Installation Laying the hoses PLEASE NOTE A suitable seal should be placed under each screw connection or each silencer. If elbow connectors or multiple distributors are used the air flow will usually be reduced. General Connecting 1. Push the hose as far as it will go into or over the screw connection. 2. Pull the locking ring over the hose connection or tighten the locking screw. 3. For reasons of clarity the hoses should be grouped together with: hose straps or multiple hose holders. Disconnecting 1. Loosen the locking screw or locking ring on the connection. 2. Remove the hose. 3. If necessary, replace the screw connection by blind plugs

45 4. Installation Preparing the connection block Connections for common lines are provided on both sides of the connection block. The common lines can therefore be fitted either on the right or the left, depending on individual requirements. To increase the air flow we recommend that the lines for compressed air supply and ventilation be connected on both sides in the following cases: When the valve terminal/valve sensor terminal has more than 10 valves (rated supply pressure 6 bar) With large-volume actuators The connections should be made in accordance with the table below: Connections for common lines (adhesive foil) 5/3 1 3/5 Connections for common lines (blind plugs) Connection of common lines Unilateral Bilateral Fig. 4/3: Connections on the connection block Procedure Remove all adhesive fiols; remove all blind plugs and fit on one side Remove all foils and blind plugs

46 4. Installation Connecting the connection block The screw connectors or silencers should be fitted with the appropriate seals as indicated in the table below. The hoses should then be fitted into place. Pilot exhaust Pilot exhaust Exhaust 5 or 3 3 or 5 Exhaust Compressed air 1 Common lines Connection code (ISO 5599) Size of connection (ISO 228) Connection Compressed air 1 G 1 2 (G 3 8) Screw connector Exhaust 5/3 3/5 G 1 2 (G 3 8) Pilot exhaust 82 G 1 8 (G 1 8) 84 Fig. 4/4: Pin assignment of connection block Screw connector (with common exhaust) or scilencer

47 4. Installation Connecting the valves PLEASE NOTE The non-reserved or free valve locations should be protected with a cover plate. If one of the fitted valves is not used, connections 2 and 4 as well as 14 and, if necessary, 12 must be covered with blind plugs. The seals used on connections 2 and 4 should be of aluminium. Proceed as follows: Remove the lupolen plugs and fit the screw connectors with the appropriate seals as indicated in the following tables: Fig. 4/5: Pin assignment of solenoid valve Fig. 4/6: Pin assignment of solenoid pulse valve and solenoid mid-position valve The hoses should then be fitted into place. PLEASE NOTE The work connections 2 and 4 are situated in different positions on the various types of valves (see also next page)

48 4. Installation Solenoid valve (5/2-way) MVH-5-1/4-B-VI MVH-5-1/8-B-VI MVH-5-1/4-S-B-VI MVH-5-1/8-S-B-VI MVH-5-1/4-L-B-VI MVH-5-1/8-L-B-VI MVH-5-1/4-L-S-B-VI MVH-5-1/8-L-S-B-VI Line Connection code (ISO 5599) Work air 2 4 Auxiliary pilot air Pneumatic spring Fig. 4/5: Pin assignment of solenoid valve Size (ISO 228) G 1 4 (G 1 8) Connection Screw connector or multiple distributor 14 G 1 8 (G 1 8) Only with "S valves" 12 G 1 8 (G 1 8) Only with "L valves"

49 4. Installation Solenoid pulse valve (5/2-way) and Solenoid mid-position valve (5/3-way) 14 Auxiliary pilot air only "S valve" Work air 2, 4 12 Auxiliary pilot air only "S valve" 12 Line Connection code (ISO 5599) Work air 2 4 Auxiliary pilot air Fig. 4/6: Size of connection (ISO 228) G 1 4 (G 1 8 ) G 1 8 (G 1 8) Connection Screw connector or multiple distributor only "S valve" Assignment of solenoid pulse valve and solenoid mid-position valve

50 4. Installation Checking the valve functions Manual override WARNING The manual override suppresses the effect of the electric signal. Possible consequences: uncontrolled, unintended movement of the actuators. the installed EMERGENCY STOP circuit has no effect. The manual override is mainly used when commissioning the pneumatic components to test the function of the valve or valve/cylinder combination. By activating the manual override the valve can be switched without an electric signal. Only the compressed air must be switched on

51 4. Installation Pilot valve Manual override Base valve 12 Manual override Pilot valve Fig. 4/7: Position of the manual override Designs of manual override The manual override has been designed so that it can be used as follows: Manual override design Manual operation with automatic reset. Basic setting as at factory Manual override with stop. Conversion of manual override necessary (see Appendix A, Manual override). Manual override with safety lock. Conversion of manual override necessary (see Appendix A, Manual override). Fig. 4/8: Manual override designs Method of operation After operation the manual override is reset by spring force Two versions: a) see above. b) manual override can be switched to a fixed state when operated. Operation of manual override not possible

52 4. Installation Testing 1. Switch on the compressed air supply. 2. Check the function and effect of each individual valve as follows. If the valve does not function correctly see Fig. 4/11. Manual override with automatic reset: Operating the manual override Reaction of valve or of processor The valve or the processor Press the plunger of manual override as far as it will go. switches Hold plunger of manual override pressed down. remains switched Remove the screwdriver. A spring returns the plunger of manual override to start position. returns to basic setting Fig. 4/9: Manual override with automatic reset

53 4. Installation Manual override with stop: Operating the manual override Reaction of valve or of processor The valve or processor Insert screwdriver in groove of plunger. Press plunger as far as it will go and turn it to the right. switches Remove screwdriver remains switched Insert screwdriver in the groove of the plunger. Press and turn plunger to the left and remove the screwdriver. returns to basic setting Fig. 4/10: Manual override with stop 3. Switch off the compressed air supply when the valves have been tested

54 4. Installation Incorrect functioning: When the compressed air supply is switched on or during the subsequent test of the valves, the following is known about the operating status of the pneumatic system: Operating status of pneumatic system Air comes out... of common line connections of work line connections Valve or pneumatic system... does not react as expected Valve position Basic setting Switch position Switch position Error treatment after switching off compressed air supply Checking the seal or hose fitting Check the hose lines or check auxiliary pilot air does not react Switch position Fig. 4/11: Operating status of the pneumatic system Locking the manual override Check operating pressure or check auxiliary pilot air Service case WARNING The manual override must be protected against unauthorised use in systems where security is of great importance. The manual override must be converted and the protection device fitted before it can be locked. The relevant conversion instructions are to be found in Appendix A, Manual override

55 4. Installation 4.3 INSTALLING THE ELECTRONIC COMPONENTS 0503a 4-19

56 4. Installation Contents INSTALLING THE ELECTRONIC COMPONENTS Opening and closing the RIO node Configuring the valve terminal/ valve sensor terminal Address selector switch Setting the RIO address Setting the RIO baud rate Connecting the valve terminal/ valve sensor terminal Connetcting the cables to the plugs/sockets V operating voltage connection Applying the 24V operating voltage RIO interface RIO cable Connecting the RIO interface Fitting the terminating resistor Outputs of valve locations Additional outputs Pin assignment od additional outputs Inputs Pin assignment of sockets Circuitry examples a

57 4. Installation INSTALLING THE ELECTRONIC COMPONENTS WARNING Before installation or maintenance work is carried out the following must be switched off: the operating voltage for electronic components and/or inputs. the operating voltage for outputs. the compressed air supply. You thereby avoid: uncontrolled movement of loosened hoses. undesired movement of the actuators connected. undefined switching states of the electronic components. 0503a 4-21

58 4. Installation PLEASE NOTE The following A-B specific functions are not implemented: Last Chassis (cf. p. 5-14) Hold Last State Processor Restart Lockout CAUTION For security applications: With Festo valve terminals/valve sensor terminals, the functions "Hold Last State" or "Processor Restart Lockout" must be realized by using double solenoid valves. The necessary pre-settings and the connections to the electronic components are described in this chapter. The following table summarizes the procedure (1...4): 1. Switching off Operating voltage. Compressed air supply. 2. Configuring the valve terminal/valve sensor terminal Opening the RIO node Address selector switch (Setting the rack no. and starting I/O group). DIL-switch (Setting the RIO baud rate). Closing the RIO node 3. Connecting the valve terminal/valve sensor terminal General (Connecting sockets). 24V operating voltage connection. RIO interface (Connecting the interfaces.) Outputs (Pin assignment). Inputs (Pin assignment and circuitry). 4. Switching on Operating voltage. Compressed air supply a

59 4. Installation Opening and closing the RIO node CAUTION Before the RIO node is opened, the operating voltage of the following must be switched off: electronic components and or inputs outputs The following connection and display elements are situated on the cover of the RIO node: Red LED POWER BUS Green LED Plug for RIO cable BUS Philips screw Fig. 4/12: Cover of the RIO node Opening Unscrew the 4 Philips screws in the cover and remove the cover. Closing Replace the cover on the RIO node and tighten the Philips screws in diagonally opposite sequence. 0503a 4-23

60 4. Installation Configuring the valve terminal/valve sensor terminal There are two PC boards in the RIO node. Board 1 contains the red LED; board 2 contains a green LED and a switch for setting the address and baud rate. Red LED 1 2 DIL-switch (baud rate) Green LED Address selector switch Board 1 Screening RIO connection Board 2 Fig. 4/13: Connections, operation and display elements of RIO node a

61 4. Installation Address selector switch The RIO address of the valve terminal/valve sensor terminal can be set with the two address selector switches on board 2. The switches are numbered from The arrow on the address selector switches indicates the tens and units figure of the RIO address which has been set. UNITS TENS Address selector switch UNITS figure Address selector switch TENS figure Fig. 4/14: Function of the address selector switch Setting the RIO address (location address) CAUTION RIO addresses may only be assigned once per RIO device. Only a clear specification of the RIO addresses guarantees the faultless NOMINAL/ACTUAL comparison in the configuration. Recommendation: We recommend that the RIO addresses be assigned in ascending order. RIO addresses should be assigned in accordance with the machine structure of the system. The RIO addresses set should be noted in the grey inscription field above the RIO node. 0503a 4-25

62 4. Installation Possible RIO addresses: PLEASE NOTE Do not use the following chart to set the address switches. Please go to chapter 5. Commissioning and refer to the tables, "Addressing facilites" for setting the switches. A-B programmable I/O rack no. controller family PLC-2 2;...; 7 PLC-3 1;...; 30 PLC-5/250 1;...; 17 PLC-5/15 01;...; 03 PLC-5/25 01;...; 07 PLC-5/30 01; 02;...; 07 PLC-5/40 01;...; 17 PLC-5/60 01;...; 27 SLC-5/02 with 1747 SN 0;...; 3 Fig. 4/15: RIO addresses The following procedure should be adopted: 1. Switch off the operating voltage. 2. Assign a non reserved RIO address to the valve terminal/valve sensor terminal. 3. With a screwdriver set the arrow of the appropriate address selector switch to the tens and/or units figure of the desired RIO address a

63 4. Installation Example: Example 1 Example 2 UNITS TENS UNITS TENS RIO address set: 05 RIO address set: 38 Fig. 4/16: Example of RIO addresses set 0503a 4-27

64 4. Installation Setting the RIO baud rate PLEASE NOTE The RIO baud rate should be set on the valve terminal/valve sensor terminal so that it agrees with the setting on the programmable controller (master). The following A-B specific functions are not implemented: Last Chassis (cf. p. 5-14) Hold Last State Processor Restart Lockout DIL switch Baud rate 57.6 kbd kbd kbd kbd ON ON ON ON ON Fig. 4/17: Setting the RIO baud rate a

65 4. Installation Connecting the valve terminal/valve sensor terminal Connecting the cables to the plug/sockets PLEASE NOTE If one of the plugs is not used, it should be sealed with a protective cap (protection class IP65). 1. Open the plugs/sockets as follows (see following diagram) Power supply socket: Insert the power supply socket into the operating voltage plug on the valve terminal/valve sensor terminal. Unscrew the connection part of the socket. Now remove the connection part of the socket from the plug. Sensor plug (for electrical inputs/outputs): Unscrew the centre knurled nut. RIO cable socket (for RIO connection): Unscrew the centre knurled nut. 0503a 4-29

66 4. Installation 2. Unscrew the strain relief part at the rear of the housing. Insert the cable as follows (see diagram): Cable diameter: for power supply socket: 6.5 mm mm for sensor plug: 4.0 mm mm for RIO cable socket PG 9: 8.0 mm mm PG13.5: 12.0 mm mm Cable Strain relief Housing Connecting part Socket Plug Fig. 4/18: Plug/socket parts and cable routing 3. Remove the insulation from 5 mm of the end of the cables. 4. If necessary, fit the strands with cable end sleeves a

67 4. Installation 5. Connect the ends of the conductors. 6. Replace the connection part onto the housing of the plug/socket. Pull the cable back so that it is not looped around inside the bushing. 7. Close the plug as follows: Power supply socket: Press with the thumb from the front onto the socket and tighten the housing. Sensor plug, RIO cable socket: Tighten the knurled nut. 8. Tighten the strain relief of the plug/socket to prevent the cable connection from becoming loose. 24 V operating voltage connection The connection for the operating voltage is on the left-hand edge of the base unit of the valve terminal/valve sensor terminal. Warning Use only PELV circuits as per IEC/DIN EN (Protective 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 a 4-31

68 4. Installation 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). Operating voltage connection Fig. 4/19: Position of operating voltage connection The following components of the valve terminal/valve sensor terminal are supplied separately with +24V DC via this connection: The operating voltage for the electronic components and/or inputs (tolerance: ± 25%) The operating voltage for the outputs (tolerance: ± 10%) a

69 4. Installation PLEASE NOTE The electronic components and the inputs show a greater tolerance range of the 24V DC operating voltage than the outputs. Under certain circumstances this can cause the electronic components to indicate the switching status of the outputs, although the latter are not in the switched position (operating voltage of the outputs outside tolerance range). The 24 V DC operating voltage of the outputs should be tested whilst the system is operating. Please see that the operating voltage of the outputs is within the permitted tolerances even during full operation. PLEASE NOTE Always connect the earth potential to pin 4 of the operating voltage connection. Connect the earth cable of the left-hand end plate to the earth potential with low impedance (short cable with large diameter). By means of low impedance connections, make sure that the housing of the valve terminal and the earth connection at pin 4 have the same potential and that there are no equalizing currents. You can thereby avoid interference due to electromagnetic influences. 0503a 4-33

70 4. Installation Applying the 24V operating voltage CAUTION Please observe the polarity when the operating voltage is applied. Connect the earthing to pin 4, PE. The following diagram shows the pin assignment of the operating voltage connection. A suitable 24V DC supply should be connected via the mains connection socket (see Chapter 3, Technical specifications). Please see also the example of connection in Fig. 4/ V supply (electronic components and/or inputs) V supply (outputs) 0 V PE (Protective Earth) Fig. 4/20: Pin assignment of operation voltage connection The operating voltage supply to the electronic components and for inputs is fused at the valve terminal/valve sensor terminal (4A, slow blowing). PLEASE NOTE The operating voltage supply to the outputs is not fused a

71 4. Installation Recommendation Protect the 24 V DC supply to the outputs with a fuse. The 24 V DC output supply should be connected to the EMERGENCY STOP circuit (see figure below). The valves can then be switched off in an emergency. The electronic components continue to run and can display the error status and react accordingly. AC DC 24 V ± 10% Fuse EMERGENCY STOP Pin 1 Pin 2 Pin 3 Pin 4 Operating voltage supply (Inputs, electronic comp.) (Outputs, valves) 0 V Earth connection Fig. 4/21: Suggested circuit for fusing and emergency off PLEASE NOTE Check your EMERGENCY STOP circuritry, to see which measures are required in order to place your machine/system in a safe state in the event of an EMERGENCY STOP (e.g. switching off the power supply to the valves and output modules, switching off the compressed air supply). 0503a 4-35

72 4. Installation Current consumption of electronic components (field bus node) and inputs (pin 1, 24 V ± 25 %) VIFB-/IIFB-02-1/x-4 VIFB-/IIFB-02-1/x-6 VIFB-/IIFB-02-1/x-8 VIFB-/IIFB-02-1/x-10 VIFB-/IIFB-02-1/x A VIFB-/IIFB-02-1/x-14 Number of sensor inputs assigned simultaneously: x0.010 A + A Sensor supply: x A (see manufacturer specifications) + A Current consumption of electronic components (field bus node) and inputs (sensors) max. 4 A = A A Current consumption of outputs (pin 2, 24 V ± 10 %) Number of valve coils (simultaneously supplied with current): x0.120 A + A Number of relay boards (simultaneously supplied with current): x0.020 A + A Additional output 0 (max. 0.5 A ): + A Additional output 1 (max. 0.5 A ): + A Current consumption of outputs = A + A Total current consumtion of valve terminal/ valve sensor terminal = A Fig. 4/22: Calculating the current consumption a

73 4. Installation RIO interface There are two plugs on the RIO node for connecting the valve terminal/valve sensor terminal to the RIO. One of these plugs is intended for the incoming RIO cable, the other is for the continuing RIO cable. The signal cables of the two plugs are connected together. This enables the RIO to be connected to further RIO participants. Recommendation: On all valve terminal/valve sensor terminals the connection should be used for the incoming RIO cable. POWER BUS BUS Incoming RIO cable Continuing RIO cable Fig. 4/23: Connection of the RIO interface 0503a 4-37

74 4. Installation RIO cable A shielded twisted-pair cable (Belden 9463) should be used as the RIO cable. The distance and the RIO baud rate set should be taken into account as shown in the diagram below. Connecting the RIO interface CAUTION Please observe the polarity when the RIO cables are connected. The following diagram shows the pin assignment of the RIO interface. The RIO cables should be connected to the sensor cable socket or to the RIO cable socket. S (clear) shield free S+ (blue) BUS S (clear) shield free S+ (blue) Fig. 4/24: Pin asignment of RIO interface

75 4. Installation PLEASE NOTE Some products within each programmable controller family are limited to less terminals or are not capable of all three baud rates. Consult A-B product literature for specifications. Programmab Scanner le used controller family used Max. no. of terminals Terminating resistor in Ohm Selected baud rate in kbaud Max. net length in km PLC-2 all PLC S4A S PLC-5 built-in or RS for PLC 5/ SLC-5/ SN Fig. 4/25: Allen-Bradley system parameters The following scanner devices are only compatible with 150 Ω terminating resistors: 1771-SN, 1772-SD, 1772-SD2, 1775-SR, 1775-S4A, 1775-S4B, 6008-SQ, 1771-AS, 1771-ASB, 1771-DCM, 1771-AF

76 4. Installation Fitting the terminating resistor PLEASE NOTE If a terminating resistor is used, one of the RIO plugs on the last valve/installation terminal of a RIO line is not assigned. Protection in accordance with protection class IP65 as per DIN is therefore no longer guaranteed. For this reason a protective cap must be fitted to the non-used bus plug. A terminating resistor is required at both ends of the RIO cable. If the valve terminal/valve sensor terminal to be connected is at the end of a RIO cable, a suitable terminating resistor must be fitted into the socket of the incoming RIO cable. The non-assigned plug must then be covered with a protective cap

77 4. Installation Proceed as follows: 1. Connect the wires of the resistor together with those of the incoming RIO cable between the wires S+ (pin 1) and S- (pin 3) of the sensor/rio cable socket (see following figure). To guarantee more reliable contact, we recommend that the wires of the resistor and those of the incoming RIO cable be crimped together in common cable end sleeves. 3(S ) clear Terminating resistor 4(shield) 1(S+) = blue Fig. 4/26: Installing the terminating resistor, when valve terminal/valve sensor terminal is at end of line 2. Fit the sensor/rio cable socket onto one of the plugs on the RIO node. 3. Cover the non-used plug with a protective cap

78 4. Installation Outputs of valve locations The outputs for the valves correspond to the valve solenoid coils. They can only be used in the intended form. In general the following applies: Outputs are not short-circuit protected Two outputs per valve location With unilaterally-operated valves the output with the even bit number is used. The other output cannot be used for other purposes. Additional outputs There are two additional outputs (O0.00 and O0.01) on the valve-sensor coupling unit of the valve sensor terminal. These additional outputs are transistor outputs with positive logic (PNP outputs). PNP outputs (0,5A/24V) Fig. 4/27: Additional outputs on valve sensor terminal

79 4. Installation Pin assignment of additional outputs Socket free free O V O0.00 O0.01 free free O V Fig. 4/28: Pin assignment of sockets with additional outputs

80 4. Installation Inputs There are two inputs for each valve location on the valve sensor coupling unit of the valve sensor terminal. There are two additional inputs above the RIO node. The inputs have positive logic (PNP inputs). PNP inputs Common fuse, (4 A, slow blowing) for operating voltage supply to sensors (PNP inputs) Fig. 4/29: Inputs on the valve sensor terminal

81 4. Installation Pin assignment of sockets The following diagram shows the pin assignment of all the inputs in socket form using inputs I0.00 and I0.01 as examples. Input socket Pin assignment of sockets Internal connection of pins Explanation Bridge between pins 2 and 4 24V (fused) I 0.00 Upper row I V 4 3 I 0.00 I V (fused) I 0.00 Bridge between pins 4,2 (socket upper row) and Pin 2 (socket lower row) Lower row I V Advantage: Two inputs on lower socket (here I0.00 and I0.01), thereby fewer cables, connection to changeover switch or converter possible. Please note: If the lower socket is used for two input cables, the upper socket must remain unused. (see example 2, p. 4-46). Fig. 4/30: Pin assignment of input sockets

82 4. Installation Circuitry examples Recommendation: If sensors are required, e.g. for a valve-cylinder combination, for interrogating limit switches, the inputs above the relevant valve should be used (clearer overview of the system). Examples Valve-cylinder combination with interrogation of limit switches via sensors. Example 1 Connecting two sensors with two plugs. Sensor 1 (I0.08) Sensor 2 (I0.09) S S 2 1 Fig. 4/31: Example 1 Connection of sensors, two plugs/sockets

83 4. Installation Example 2 Connecting e.g. two sensors with one plug (sockets on lower row). Sensor 1 Pin 1 24 V Pin 3 0 V Pin 4 I0.08 Sensor 2 Pin 1 24 V Pin 3 0 V Pin 4 I0.09 Input plug Pin 1 24 V Pin 2 I0.08 Pin 3 0 V Pin 4 I0.09 Pin Sensor 1 I0.08 Pin Pin Sensor 2 I0.09 must remain free Sensor 1 and 2 2-fold distributor * Sensor 2 S S Sensor * Reference source: e.g. Karl Lumberg GmbH & Co, Postfach 1360, 5885 Schalksmühle, Germany Fig. 4/32: Example 2 Connection of sensors with one socket

84 4. Installation

85 5. Commissioning 5. COMMISSIONING

86 5. Commissioning Contents COMMISSIONING Configuring the programmable controller Allen-Bradley Switching on the operating voltage Addressing the inputs and outputs Valve terminal Valve locations Valve sensor terminal Valve locations, inputs and additional outputs Status bits Manufacturer-specific features Allen-Bradley

87 5. Commissioning COMMISSIONING Configuring the programmable controller Before commissioning or programming, the user should compile a configuration list of the connected RIO slaves. On the basis of this list he can: make a comparison between the ACTUAL and NOMINAL configurations in order to eliminate connection faults. access specifications during a syntax check of a program in order to avoid addressing errors