Compact performance - Smart cubic

Transcription

1 Compact performance - Smart cubic Pneumatics manual CPV-SC valve terminal Type CPVSC1-VI Manual en 0112NH [659699]

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3 Contents and general instructions Author... M. Simons Editors... H.-J. Drung, M. Holder Original... de Translation... transline Deutschland Layout... Festo AG & Co., Dept. KG-GD Type setting... KI-DT Edition... en 0112NH Designation... P.BE-CPVSC-EN Order no E (Festo AG & Co., D Esslingen, Federal Republic of Germany, 2001) Internet: service_international@festo.com The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders willbe 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 Contents and general instructions II

5 Contents and general instructions Contents Designated use... Target group... Service... Notesonthismanual... Important user instructions... List of abbreviations... V V V VI VII IX 1. Summary of components Description of variants Description of components Fitting Fitting variants Fitting onto a wall Fitting the manual override cover (optional) Installation Preparing the compressed air Operation with non-lubricated compressed air Operation with lubricated compressed air General connection technology Connecting the CPV-SC valve terminal Auxiliary pilot air Pressure zones Connecting the supply and work lines Connecting the electric cables Commissioning General instructions Testing the valves Eliminating faults III

6 Contents and general instructions 5. Maintenance and conversion Cleaning/replacing the large-area silencer Fitting/removing components in valve locations A. Technical appendix... A-1 A.1 Accessories... A-3 A.2 Technical specifications... A-4 A.3 Overview of end plates... A-9 B. Index... B-1 B.1 Index... B-3 IV

7 Contents and general instructions Designated use The CPV-SC valve terminals described in this documentation have been designed exclusively for controlling pneumatic actuators. They may only be used in conjunction with devices and components recommended or approved of by Festo as follows: in accordance with designated use in their original state without any modifications by the user in faultless technical condition. The maximum values specified for pressures, temperatures, electrical data, torques etc. must be observed. Please comply with national and local safety laws and regulations. Target group This manual is intended exclusively for technicians trained in control and automation technology, who have experience in fitting, installing, commissioning, servicing and converting pneumatic components. Service Please consult your local Festo service centre if you have any technical problems. V

8 Contents and general instructions Notesonthismanual This manual contains specific information on fitting, installing, commissioning, servicing and converting the CPV-SC valve terminal. This manual describes only the pneumatic components and refers to the CPV-SC valve terminal with electric multipin connection. For information on the electrics/electronics see leaflet supplied with the product. VI

9 Contents and general instructions Important user instructions Danger categories This manual contains instructions on the possible dangers which may occur if the product is not used correctly. These instructions are marked (Warning, Caution, etc.), printed on a shaded background and marked additionally with a pictogram. A distinction is made between the following danger warnings: Warning This means that failure to observe this instruction may result in serious personal injury or damage to property. Caution This means that failure to observe this instruction may result in personal injury or damage to property. Please note This means that failure to observe this instruction may result in damage to property. The following pictogram marks passages in the text which describe activities with electrostatically sensitive components. Electrostatically sensitive components may be damaged if they are not handled correctly. VII

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

11 Contents and general instructions List of abbreviations The following product-specific terms and abbreviations are used in this manual: Term Additional pressure supply plate Blanking plate Components Connecting tubing CP CPVSC1 Meaning Plate for additional pressurization and exhausting of the valve terminal Plate without valve function in order to fill an unused location Common term for sub-bases, end plates, blanking plates, separator plates and valve sub-bases Connecting the supplylines (tubing) to the CPV-SCvalve terminal Compact Performance Size designations of the CPV-SC valve terminals and micro valve sub-bases CPV-SC valve terminal Compact Performance valve terminal - Smart Cubic (type 80) Electrical sub-base End plate Manual override MP connection (multipin connection) Separator plates Valve block Valve plate Sub-base with electric multipin connection Terminationplate at the left andright-handends of the CPV valve terminal with channels or connections for supplying the valves with compressed air and for conducting the exhaust air. Manual override Variant of valve terminal with 15-pin Sub-D plug or flat cable connection. All valve solenoid coils are connected centrally via this connection. Plate for dividingthe valve terminalinto pressure zones Basic unit withvalvesub-base, blankingandendplates Plate with single-solenoidordouble-solenoid valve IX

12 Contents and general instructions X

13 Summary of components Chapter 1 1-1

14 1. Summary of components Contents 1. Summary of components Description of variants Description of components

15 1. Summary of components 1.1 Description of variants Festo assists you in solving your automation tasks at machine level with valve terminals. Due to its compact structure the CPV-SC valve terminal can be mounted close to the actuators to be controlled. Short compressed air tubing can therefore be used. With short compressed air tubing, system losses can be minimized and the times required for pressurizing and exhausting the tubing can be minimized. This enables very compact valves with high flow rate to be used, therefore helping to reduce costs. CPV-SC valve terminal with MP connection This CPV-SC valve terminal is available with 4, 8 or 12 CP valve sub-bases. The valve solenoid coils are connected centrally via the multipin connection. This is available in the following designs: 15-pin Sub-D plug 20-pin flat cable. 1.2 Description of components Sizes of the CPV-SC valve terminals The CPV-SC valve terminal is available in the following sizes: CPVSC1 10 mm Micro valves 1-3

16 1. Summary of components Identification code With the identification code (I.C.) you can ascertain the equipment fitted on your CPV-SC valve terminal. The code is printed on the front below the manual overrides. I.C. Pneumatic components Valve sub-bases M J N K D 5/2-way valve, single-solenoid 5/2-way valve, double-solenoid. This valve consists of two valve plates and therefore occupies two valve locations. The control valve is marked with j 12, the work valve with Ident. code J. 3/2-way valves, single-solenoid, neutral position open 3/2-way valves, single-solenoid, neutral position closed 2/2-way valves, single-solenoid, neutral position closed Separator plate with additional pressure supply T S Compressed air channel (1) blocked Compressed air channel (1) and exhaust air channel (3/5) blocked Additional pressure supply U Additional supply of compressed air (1) and additional exhaust removal (3/5) Blanking plate L Plate without valve function for reserving a valve location Further information on the valve plates can be found in Appendix A. 1-4

17 1. Summary of components Overview of components The CPV-SC valve terminal can consist of the following components, depending on what has been ordered: Right-hand end plate depending on variant with connection 3/5, 82/84 or large-scale silencer 2 Blanking plate (without valve function) for reserving a valve location 3 Valve sub-bases with single-solenoid or double-solenoid valves (doublesolenoid valve occupies 2 valve locations) Fig. 1/1: Components of the CPV-SC valve terminal 4 Separator plate with additional pressure supply 5 Electrical sub-base with MP connection 6 Left-hand end plate depending on variant with connection 1 or 1 and 12/

18 1. Summary of components Connecting, display and operating elements On the CPV-SC valve terminal you will find the following connecting, display and operating elements: Manual override (per pilot solenoid, locking and non-locking) 2 Exhaust connections (3/5, 82/84) 3 Work connections (2, 4) per valve 4 Supply connections (1, 12/14) Fig. 1/2: Pneumatic connecting and operating elements of the CPV-SC valve terminal 1-6

19 1. Summary of components On the CPV-SC valve terminal with multipin connection you will find the following electrical connecting and display elements: Multipin connection with 20-pin flat cable or 15-pin Sub-D multipin connection 2 Valve location identification label 3 Yellow LED, signal status displays per pilot solenoid Fig. 1/3: Electrical connecting and display elements of the CPV-SC valve terminal with MP connection 1-7

20 1. Summary of components 1-8

21 Fitting Chapter 2 2-1

22 2. Fitting Contents 2. Fitting Fitting variants Fitting onto a wall Fitting the manual override cover (optional)

23 2. Fitting Warning Switch off the following power supplies before undertaking installation and/or maintenance work: the compressed air supply the power supply for the valve solenoid coils. You can thereby avoid: uncontrolled movements of loose tubing unexpected movements of the connected actuators non-defined switching states of the electronic components. 2.1 Fitting variants The CPV-SC valve terminal with individual tubing has already been prepared for integration in a system or machine for the following fitting variants: Fitting onto a wall 2-3

24 2. Fitting Fitting onto a wall Proceed as follows: 1. Make sure that the fastening surface can support the weight of the CPV-SC valve terminal. 2. Make sure there is sufficient space for connecting the compressed air supply tubing. 3. Bore 4 fastening holes with 3.2 mm diameter or threaded holes for M3 screws in the fastening surface (distance between holes see table): L2 L1 Valve locations L1 L mm 114 mm 156 mm 198 mm Then fasten the CPV-SC valve terminal with four M3 screws of sufficient length to the wall (tightening torque Nm). 2-4

25 2. Fitting 2.2 Fitting the manual override cover (optional) Covers can be fitted onto the manual override to protect it against unauthorized use. Proceed as follows: Clipthecoversintothegroovesinthemanualoverride (see diagram) Manual override 2 Cover Fig. 2/1: Fitting the manual override cover 2-5

26 2. Fitting 2-6

27 Installation Chapter 3 3-1

28 3. Installation Contents 3. Installation Preparing the compressed air Operation with non-lubricated compressed air Operation with lubricated compressed air General connection technology Connecting the CPV-SC valve terminal Auxiliary pilot air Pressure zones Connecting the supply and work lines Connecting the electric cables

29 3. Installation 3.1 Preparing the compressed air Caution Dirty or incorrectly lubricated compressed air will reduce the service life of the valve terminal Operation with non-lubricated compressed air Caution Excessive residual oil in the compressed air will reduce the service life of the valve terminal. If bio oil is used (oils based on synthetic ester or true ester, e.g. rape oil methyl ester), the residual oil content must not exceed 0.1 mg/m² (see ISO class 2). If mineral oils are used (e.g. HLP oils as per DIN parts 1 to 3) or corresponding oils on the basis of polyalphaolefin (PAO), the residual oil content must not exceed 5 mg/m² (see ISO class 4). In this way you will avoid functional damage to the valves. A higher amount of residual oil cannot be permitted irrespective of the compressor oil, as otherwise the basic lubricating oil will be washed out in the course of time. 3-3

30 3. Installation Operation with lubricated compressed air Please note If possible, operate your system with non-lubricated compressed air in order to protect the environment. Festo pneumatic valves and cylinders have been designed so that they do not require any additional lubrication if used as designated, yet still achieve a long service life. Vorsicht Operation with lubricated compressed air leads to the service life lubrication, which is required for non-lubricated operation, being washed out. Please observe the following instructions if lubricated compressed air has to be used. The compressed air prepared with the compressor must be of the same quality as the non-lubricated compressed air. If possible, do not operate the complete system with lubricated compressed air. If possible, fit the lubricators only directly in front of the cylinder to be lubricated. Caution Incorrect additional oil and an excessive oil content in the compressed air will reduce the service life of the valve terminal. Use the Festo special oil OFSW-32 or the alternative listed in the Festo Catalogue (as per DIN51524-HLP32, basic viscosity 32cST at 40 C). the amount of additional oil must not exceed 25 mg/m² (ISO class 5). Make sure that the lubricator is set correctly (see following section). In this way you will avoid functional damage to the valves. 3-4

31 3. Installation Setting the lubricator With the machine running (typical operating status) 0.2 to max. 1 drop/min. or 0.5 to 5 drops/1000 l air. Checking the lubricator setting Proceed as follows: Check the service units with respect to condensate and lubricator setting twice a week. 1. Ascertain the cylinder which is furthest from the lubricator. 2. Ascertain the valve terminal which controls this cylinder. 3. If applicable, remove the silencer at connection 3/5. 4. Hold a piece of white cardboard 10 cm in front of the exhaust bore. 5. Let the system operate for some time. There must be only a slight yellowish discolouring on the cardboard. If oil drops out, then there is excessive lubrication. A further indication of excessive lubrication is the colouring or the status of the exhaust silencers. A clear yellowish discolouring of the filter element or drops of oil on the silencers indicate that the lubricator is set too high. 3-5

32 3. Installation 3.2 General connection technology Warning Switch off the following power supplies before undertaking installation and/or maintenance work: the compressed air supply the power supply for the valve solenoid coils. You can thereby avoid: sudden uncontrolled movements of loose tubing unexpected movements of the connected actuators non-defined switching states of the electronic components. Pay particular attention to the following: The components of the valve terminal contain electrostatically sensitive elements. The components will be damaged if you touch the contact surfaces of the plug connectors and if you do not observe the regulations for handling electrostatically sensitive components. Laying the tubing Please note If necessary, place a suitable seal under each M5/M7 screw connector or silencer in order to avoid leakage. If elbow screw connectors or multiple distributors are used, the airflow will be reduced slightly. 3-6

33 3. Installation Basic information Connecting 1. Push the tubing as far as possible over or into the tube connection of the screw connector. 2. Pull locking ring 1 over the tube connection or tighten locking screw For reasons of clarity, group the tubing together with tubestrapsor multiplehoseholders. Removing 1. Loosen the locking screw or locking ring of the screw connector. 2. Pull out the tubing. 3. Replace non-required screw connectors with blanking plugs 3. Connecting 2 1 Removing 3 Fig. 3/1: Tubing variants 3-7

34 3. Installation 3.3 Connecting the CPV-SC valve terminal Auxiliary pilot air Caution Operate the CPV-SC valve terminal only with the medium described below: If possible, use non-lubricated auxiliary pilot air (connections 12/14). Otherwise observe the instructions in the section Preparing the compressed air. With CPV-SC valve terminals with internally branched auxiliary pilot air, the above mentioned remark also applies to the supply air (connection 1). The CPV-SC valve terminal is intended for internal or external pilot air, depending on the end plates fitted. Terminals for operation with external pilot air are available in two designs: for ducted exhaust air with connections 12/14 and 82/84, for non-ducted exhaust air with connection 12/14 and a large-scale silencer. Internal pilot air If the supply pressure of your CPV-SC valve terminal lies between 3 and 8 bar, you can operate it with internally branched auxiliary pilot air. In this case the auxiliary pilot air will be taken from connection 1 in the left-hand end plate. 3-8

35 3. Installation External auxiliary pilot air If the supply pressure of your CPV-SC valve terminal lies in the range to 3 bar, you must operate it with external auxiliary pilot air. In this case the auxiliary pilot air is supplied externally via connection 12/14. Please note Use regulated auxiliary pilot air (3 to 8 bar). Reliable faultless operation of the CPV-SC valve terminal is then possible. Please note that the regulated pilot air for all the valve sub-bases is supplied via the left-hand end plate. This also applies if the CPV-SC valve terminal is operated with different pressure zones (see diagram). If your CPV-SC valve terminal is fitted with valve plates with Ident code J (5/2-way valve), the auxiliary pilot air must be set to correspond to the supply pressure with which the valve is operated (see diagrams). 1 Control pressure (connection 12/14), [bar] 2 Supply pressure (connection 1), [bar] 1 4 3,5 3 2,5 2 1,5 1 0, Fig. 3/2: Auxiliary pilot air diagram for valve plate with Ident code J 3-9

36 3. Installation Pressure zones The CPV-SC valve terminal can be operated with several pressure zones. A separator plate is required for each pressure zone if there are more than two pressure zones. A separator plate always occupies one valve location. The following types of separator plate are available: Ident. Code T S Function Compressed air channel (1) separated Compressed air channel (1) and exhaust channel (3/5) separated The first pressure zone is supplied with compressed air via connection 1 on the left-hand end plate; further pressure zones are supplied via connection 4 on the relevant separator plate. With separator plate with Ident. Code S, the exhaust air is removed via connection 2 on the separator plate (see diagram). 3-10

37 3. Installation / /14 82/ End plates 2 Valve sub-bases 3 Separator plates with additional supply 4 Pressure zone 1 5 Pressure zone 2 6 Pressure zone 3 Fig. 3/3: External pilot air and separation of pressure zones Please note Makesurethatpressurezones,whicharesuppliedvia separator plates, are sufficiently pressurized or exhausted. If there are more than two valve functions per pressure zone, additional compressed air supply/exhausting may be required (additional pressure supply plate Ident. Code: U). This occupies one valve location. 3-11

38 3. Installation Connecting the supply and work lines Please note Seal all connections not required for the functioning of the CPV-SC valve terminal with blanking plugs. Inthecaseofvalveswhicharenotused,sealconnections 2 and 4 with blanking plugs. Connect the work lines as follows, depending on the tool you are using: Screw connector with hexagon socket head: any sequence is possible. Screw connector with external hexagon socket head: connection must be made from left to right (space for wrench). The double-solenoid valve (Ident. Code J ) consists of two components, the control valve and the work valve. Each valve has its own housing. The control valve is situated to the left of the work valve and does not have any work connections. Fit the screw connector or the silencers according to the table below. Then connect the pneumatic tubing. 3-12

39 3. Installation 4 12/14 82/84 12/14 3/5 2 1 Connection code ISO 5599 Tubing Connection size Position and type of connection 1 Compressed air/ vacuum M7/QS6 Screw connector in the left-hand end plate 12/14 Auxiliary pilot air M5/QS4 Screw connector in the left-hand end plate 3/5 Exhausted M7/QS6 Connections in the righthand end plate for ducted exhaust air forsilencers 82/84 Exhausting the auxiliary pilot air M5/QS4 Connections in the righthand end plate for ducted exhaust air forsilencers 2 or 4 Workair/vacuum M5/QS4/QS3 Screw connector Fig. 3/4: Assignment of connections 3-13

40 3. Installation Please note With several systems with central ducted exhaust air: usenon-returnvalvesinthecommonexhaustlinesin order to prevent functional impairment due to back pressures. 1 Valve terminal 1 2 Common 3/ Common 82/84 4 Valve terminal 2 5 Central 3/5 6 Central 82/ Fig. 3/5: Common lines with non-return valves Please note The exhaust is passed through channels 3/5 and 82/84. These connections must not be sealed with blanking plugs. Exhaust channels 3 and 5 are grouped together in the CPV- SC valve terminal. Separate exhaust restriction of channels 3 or 5 is not therefore possible. 3-14

41 3. Installation Vacuum/low pressure operation The CPV-SC valve terminal can be operated with vacuum or low pressure (<3 bar), if regulated auxiliary pilot air is applied separately. An overview of the end plates required can be found in Appendix A Connecting the electric cables Warning Use only power units which guarantee reliable isolation of the operating voltages as per IEC 742/EN 60742/VDE 0551 with at least 4 kv isolation resistance (Protected Extra Low Voltage PELV). Switch power packs are permitted, providing they guarantee reliable isolation in accordance with EN 60950/VDE Please note: By the use of PELV power units, protection against electric shock (protection against direct and indirect contact) is guaranteed with the Festo valve terminals in accordance with EN /IEC 204. Safety transformers with the adjacent symbol must be used for supplying PELV networks. The valve terminals must be earthed to ensure that they function correctly (e.g. EMC). Please note Check within the framework of your EMERGENCY STOP circuit, to ascertain the measures necessary for putting your machine/system into a safe state in the event of an EMERGENCY STOP (e.g. switching off the operating voltage for the valves and output modules, switching off the compressed air). 3-15

42 3. Installation CPV-SC valve terminal with multipin connection Connecting the multipin cable Caution Long signal cables reduce the immunity to interference. Do not exceed the maximum permitted signal cable length of 10 m. Detailed information on fitting the electrical connections can be found in the leaflet supplied with the product. 3-16

43 Commissioning Chapter 4 4-1

44 4. Commissioning Contents 4. Commissioning General instructions Testing the valves Eliminating faults

45 4. Commissioning 4.1 General instructions Before commissioning Switch off the power supply before connecting or disconnecting plugs (otherwise this could lead to functional damage). Commission only a valve terminal which has been fitted and wired completely. Make sure that there is a sufficient supply of fresh air (cooling) for the following operating conditions: when the maximum number of valves are fitted, when the maximum operating voltage is applied, when the solenoid coil is constantly under stress. Warning When pressurizing or re-pressurizing the valve terminal under the following conditions: with the safety start-up valve (slow build up of pressure) and when there are electric signals (e.g. after EMERGENCY STOP). Apply the auxiliary pilot air externally (3 to 7 bar). You will then prevent the cylinder from extending or retracting suddenly. The auxiliary pilot air must be applied with a pressure of 3 to 7 bar immediately after being switched on, otherwise there is no guarantee that the valve will switch directly (see diagram). If the pressure is less than 3 bar, there may be a delay before the valve is switched, in spite of an electric signal being present. The slow increase in pressure of the complete supply does not then affect the cylinder. Depending on the valve function, the cylinder would extend or retract suddenly. 4-3

46 4. Commissioning Externally supplied auxiliary pilot air (3 to 7 bar) 2 Safety start-up valve (slow build up of pressure of complete supply) Fig. 4/1: Example of valve-cylinder combination with slow increase in pressure of the complete supply The table below shows the effects of slow start-up pressurization when there are electric signals. External auxiliary pilot air Pressure increase in complete supply Pressure increase in the auxiliary pilot air (12/14) Time of switching point of a valve Movement of the cylinder Branched after the safety start-up valve Branched in front of the safety start-up valve slow slow after pressure increase with (1) slow fast before pressure increase with (1) fast slow 4-4

47 4. Commissioning 4.2 Testing the valves Please note Before commissioning the CPV-SC valve terminal, note the specifications concerning the medium, see section Auxiliary pilot air in the chapter Installation. The CPV-SC valve terminal should be commissioned as follows: Commissioning variants Preliminary test of the pneumatic tubing Complete commissioning of the complete system Activity Testing the valve-cylinder-combination by means of the manual override Installing and connecting the complete system. Program control via PLC/industrial PC Commissioning the pneumatic components by means of the manual override is described below. 4-5

48 4. Commissioning Checking the valve functions Manual override Warning Before actuating the manual override: Disconnect the power supply for the valve solenoid coils from the multipin connection. You will thereby avoid undesired actuation of the valve solenoid coils. Before switching on the power supply, make sure that all manual override locking actuations are in their basic positions. You will thereby avoid undefined switching states of the valves. You should use the manual override especially when commissioning the pneumatic system, in order to check the functioning and operation of the valve or the valve-cylinder-combination. By actuating the manual override, you can switch the valve without an electric signal. You only need to switch on the compressed air supply. Types of manual override The manual override has been designed to be used in locking or non-locking form. Method of actuation Non-locking Locking Method of operation After actuation the manual override is reset by a spring. Themanualoverrideremains actuated until it is reset by hand. 4-6

49 4. Commissioning The assignment of the manual override actuations to the valves is as follows: Single-solenoid valves (Ident. Code: D, N, K, M) Double-solenoid valves (Ident. Code: J) 1 Manual override to pilot solenoid 14 2 Manual override to pilot solenoid 12 3 Manual override to pilot solenoid

50 4. Commissioning Checking the valve-cylinder combination Warning Before checking the valve-cylinder combination: Make sure that nobody is in the danger zone. Testing Proceed as follows: 1. Switch on the compressed air supply. 2. Check the functioning and operation of each individual valve-cylinder combination by actuating the manual overrideasshowninthefollowingdiagrams. 3. Make sure that all the valves are in their basic positions before commissioning the valve terminal. 4. Switch off the compressed air supply after checking the valves. 4-8

51 4. Commissioning Actuating the manual override with automatic reset (non-locking) Reaction of the valve Use a screwdriver to carefully press down the plunger of the manual override as far as possible. The valve: Moves to the switching position Hold the plunger of the manual override pressed down. Release the plunger. The spring resets the plunger of themanualoverridetothe starting position. Remains in the switch position Moves back to the basic position (not with 5/2-way double-solenoid valve, Ident. Code J) Caution Before commissioning your machine/system: Make sure that double-solenoid valves (Ident. Code J) are in their basic positions again. To do this actuate manual override 12 of the relevant valve or apply current to pilot solenoid 12. Bring the locking manual override actuations into the basic position again. In this way you will avoid undefined switching states when commissioning the machine/system. 4-9

52 4. Commissioning Actuating the manual override with stop (locking) Reaction of the valve Use a screwdriver to carefully press down the plunger of the manual override as far as possible. Then turn it 90 in a clockwise direction. The valve: Moves to the switching position Leave the plunger in the lower position. Then turn it 90 in an anticlockwise direction. Then release the plunger. Remains in the switch position Moves back to the basic position (not with 5/2-way double-solenoid valve, Ident. Code J) Please note Use a blunt pencil for actuating the non-locking manual override. Actuate the manual override at 8 bar only with max 25 N. You will then avoid malfunctioning or damage to the manual override. 4-10

53 4. Commissioning 4.3 Eliminating faults Impairment of function After switching on the compressed air supply or when subsequently testing the individual valves, you can learn the following about the operating status of the pneumatic system: Operating status of the pneumatic system Valve position Error treatment when the compressed air supply has been switched off Air escapes... from the common line connections from the work line connections between the modules The valve or the pneumatic system does not react as expected does not react does not react Basicposition Switchposition Basicposition Switchposition Switchposition Basicposition Checkthesealringorthetubefittings After switching on again, regulate the separate auxiliary pilot air to 3 to 7 bar. Check the tubing After switching on again check the operating pressure (e.g. pressure zones) Servicing required Check the controller connection (apply pressure> 3 bar at controller) 4-11

54 4. Commissioning If the operating status of the pneumatic system differs from the desired pneumatic operating status, the following conditions are probably not fulfilled: Desired pneumatic operating status Prerequisites Remarks Free of leakage Fast reaction Faultless Vacuum operation/low-pressure operation EMERGENCY STOP of pressure zones Slow start-up after EMERGENCY STOP Tubing connected with care Regulated auxiliary pilot air Sufficient pressuresupplyvia pressure supply points Non-return valves in common exhaust line Separately supplied closedloop regulated auxiliary pilot air (3...7 bar) Guaranteed the regulator function for the auxiliary pilot air despite the complete supply being switched off. If there are control signals, the auxiliary pilot air must be at full pressure immediately after being switched on. Exhaust the valve terminal additionally with a large-area silencer in the right-hand end plate (3/5, 82/84) Applies in the case of several systems with centrally ducted exhaust Regulator can only be operated with pressure (between 3and7bar) The controller regulates the auxiliary pilot air of all the valves plates on a valve terminal. 4-12

55 4. Commissioning LED display of the valves There is a yellow LED for every valve solenoid coil. This LED indicates the switching status of the valve solenoid coil when the CPV-SC valve terminal is ready for operation. The LEDs are assigned to the valve locations in numerically ascending order. Therefore LED 0 is assigned to valve location 0, etc. The valve locations are numbered in ascending order from left to right (see diagram) LED for valve location 0 2 Valve location 0 3 Valve location 3 4 LED for valve location 3 Fig. 4/2: Assignment of LED to valve location 4-13

56 4. Commissioning With valve plates the LEDs indicate the switching status of the valve solenoid coils. The following table explains the meanings. LED Switching position of the valve Meaning Yellow out Basic position Logical 0 (no signal) Yellow alight *) Switch position Logical1(signalpresent) Basic position Logical 1 but: Operating voltage of outputs below permitted tolerance range (21.6 V to 26.4 V DC) or Compressed air supply not OK. or Pilot exhaust blocked or Servicing required *) With double-solenoid valves the LED lights up only when the signal is present. 4-14

57 Maintenance and conversion Chapter 5 5-1

58 5. Maintenance and conversion Contents 5. Maintenance and conversion Cleaning/replacing the large-area silencer Fitting/removing components in valve locations

59 5. Maintenance and conversion 5.1 Cleaning/replacing the large-area silencer Caution Dirt in the large-area silencer can cause an increase in pressure in the exhaust channel. Clean the silencer insert if it is yellow/black or a dark colour or replace it by a new one. Do not use TRI for cleaning, but benzine or paraffin. In this way you can ensure that the large-area silencer functions correctly and that the valves operate correctly. Proceed as follows: 1. Loosen and remove the screws in the fastening frame. 2. Remove the silencer insert from the end plate. 3. Replace the silencer insert or clean it. 4. Place the cleaned or the new silencer insert and the fastening frame on the end plate. 5. Fasten the silencer insert only with the original screws (see table). Fastening screws of the silencer insert Torx T6, strength class 10.9 Valve terminal Screw Tightening torque CPVSC1 M2x Nm 5-3

60 5. Maintenance and conversion 5.2 Fitting/removing components in valve locations Please note The double-solenoid valve (Ident.code J) consists of two components: the control valve and the work valve. Each sits in its own valve plate. The control valve is marked on the front with j 12, has no work connections and sits to the left of the work valve. The work valve is marked with Ident. code J. Warning Switch off the following power supplies before undertaking installation and/or maintenance work: the compressed air supply, the power supply for the valve solenoid coils. You can thereby avoid: uncontrolled movements of loose tubing unexpected movements of the connected actuators non-defined switching states of the electronic components. Components in valve locations can be exchanged easily without much trouble. Proceed as follows: Preparing the CPV-SC valve terminal 1. Loosen the multipin plug and disconnect it carefully. 2. Loosen the tubing at work connections 2 and 4 of the valvesub-basetobereplaced(seesection3.2 General connection methods ). 3. Loosen the wall fastening on the right-hand end plate. 5-4

61 5. Maintenance and conversion Remove the components 1. Unclamp the valve block. Loosen the tie rods one turn. Unscrew the tie rods so that the screw heads project up to 9 mm out of the end plate (do not remove the tie rods). 2. Pull the valve terminal apart so that there is a gap of at least 2 mm to the left and the right of the component to be replaced Components to be replaced 2 Tie rod 3 2 mm gap to the left and right of the component to be replaced Fig. 5/1: Loosening the tie rods 3. When the double-solenoid valve Ident. code J is removed, both valve plates and the control and work valves must also be removed. 5-5

62 5. Maintenance and conversion 4. Pull the component forwards so that it can be disconnected from the plug of the electric circuit. Then lift it up slightly and pull it forwards away from the tie rod. Fig. 5/2: Removing a component in a valve location Fitting a component Please note The valve with the work connection sub-base is a unit tested for leakage by Festo. Donot disconnect the screw connectors in the work connection sub-base. They guarantee that the unit does not leak. Proceed as follows: 1. Make sure that the seals are correctly seated between the components on the valve terminal. They must lie correctly in the appropriate seal grooves. 5-6

63 5. Maintenance and conversion Please note When fitting the double-solenoid valve (Ident. code J), note the correct position of the control and work valves. -Thecontrolvalvemustbeontheleftoftheworkvalve. You will then guarantee correct operation of the doublesolenoid valve. 2. If you wish to add a double-solenoid valve, you must remove two other components for each double-solenoid valve. 3. Place the component on the tie rod. Press against the componentsothatitsnapsintopositionintheelectric circuit link. Fig. 5/3: Fitting a component in a valve location 4. Align the CPV-SC valve terminal components on a flat surface so that they are not offset. 5. Tighten the tie rods with Nm. 5-7

64 5. Maintenance and conversion Fitting the CPV-SC valve terminal Fasten the right-hand wall fastening with two M3 screws of sufficient length to the wall. Complete the pneumatic and electric connections (see chapter 3). 5-8

65 Technical appendix Appendix A A-1

66 A. Technical appendix Contents A. Technical appendix... A-1 A.1 Accessories... A-3 A.2 Technical specifications... A-4 A.3 Overview of end plates... A-9 A-2

67 A. Technical appendix A.1 Accessories General Components Identification labels Blanking plug for screw connector: M5 M7 forquickstar: QS 3 QS 4 QS 6 CPV-SC valve terminal with MP connection Ready-to-use multipin cable (suitable for drag chain) Flat band cable Plug connector for flat band cable Type MH-BZ-80x BM5 BM7 QSMC-3H QSC-4H QSC-6H KMP6-15-P Flat cable with round conductors in grid 1.27 mm, Cable cross-sectional area 0.13 mm 2 (AWG26) Unused plug connector form C with strain relief, with 20 sockets with insulation-piercing connection, contact surface gold ICE C020FD-7C1E-2 A-3

68 A. Technical appendix A.2 Technical specifications General Permitted temperature range Storage Operation Medium Protection class as per EN C C C IP40 Relative humidity 90 % at 40 C Corrosion protection (as per FN ) KBK 1 Mounting position Torques Fastening screw for wall support Tierod Large-area silencer element on the end plate As desired Nm Nm Nm Large fastening screws Forfasteningontoawall M3 (length of screw depends on the features of the fastening surface) Materials End plates, electrical sub-base Seal Valvehousing Power connection plates PAXMD6-GF50 NBR AL PA66-GF30 A-4

69 A. Technical appendix General Vibration (as per DIN/IEC 68 part 2-6) Transport: Operation: Shock: (as per DIN/IEC 68 part 2-27) 3.5 mm path at Hz 1 g acceleration at Hz 0.35 mm path at Hz 5 g acceleration at Hz 30 g acceleration at 11 ms duration General Weight Electrical sub-base with MP connection EndplatesetwithQS4connection Per valve location Approx. weight 44 g 71 g 35 g Caution OperatetheCPV-SCvalveterminalonlywiththemedia described below: If possible, use non-lubricated auxiliary pilot air (connections 12/14). Otherwise observe the instructions in the section Preparing the compressed air. With CPV-SC valve terminals with internally branched auxiliary pilot air, the above mentioned remark also applies to the supply air (connection 1). A-5

70 A. Technical appendix Pneumatics Medium Compressed air, filtered (40 ìm), lubricated (oil: VG 32) or non-lubricated/vacuum Design Pressure range Optimum operating pressure Rated supply pressure With auxiliary pilot air internally branched from 1 With externally supplied auxiliary pilot air 1 (compressed air) 12/14 (auxiliary pilot air) Manual override Valve plates with spool valves bar 6bar bar bar bar Locking or non-locking 1 Control pressure (connection 12/14), [bar] 2 Supply pressure (connection 1), [bar] 1 4 3,5 3 2,5 2 1,5 1 0, Fig. A/4: Auxiliary pilot air diagram for valve plate with Ident code J 2 Please note The fitted pneumatic screw connectors cause a reduction in the flow rate of the valves. A-6

71 A. Technical appendix Pneumatics Flow rates (with QS4 screw connector) in [l/min] From1 2or1 4 From2 3/5 or 4 3/5 Valve switching times in ms 2/2-way valves (I.C. D) /2 and 5/2-way valves(i.c.m,j,n,k) Measuring method 10 % as per FN On, changeover Off 2/2-way valve (Ident. Code D and I) 3/2-way valve, open or closed (Ident. Code K, N) 5/2-way, single-solenoid (Ident. Code M) 5/2-way double-solenoid (Ident. Code J) (at 0 %) Connections Compressed air (1) Exhaust(3/5) Auxiliary pilot air (12; 14; 82/84) Workair(2;4) Switching frequency M7, QS6 or QS1/4 M7, QS6 or QS1/4 M5, QS4 or QS5/32 M5, QS4, QS3, QS5/32 or QS1/8 10 Hz Electric components Electromagnetic compatibility of the CPV-SC valve terminal with CP connection Interference emitted Tested as per EN 55011, limit class A Immunity to interference 1) Tested as per EN Protection against electric shock (Protectionagainstdirectandindirectcontactas per EN /IEC 204) Operating voltage Tolerance By connection to a PELV power unit (Protected Extra- Low Voltage) 24 V DC ± 10 % (21.6 V V DC) Power consumption (at 24 V, on the multipin plug) Per valve solenoid coil 1W 1) The maximum permitted signal cable length is 10 m. A-7

72 A. Technical appendix Please note Data on the electrics of the CPV-SC valve terminal with multipin connection are enclosed with the product. A-8

73 A. Technical appendix A.3 Overview of end plates Please note The numbers in the following circuit diagrams are the designations for the connections, coils and manual overrides. For example, designation 14 stands for manual override 14 or for coil 14. These are not logic designations. The following valve sub-bases are available for the CPV-SC valve terminal: Valve sub-bases 14 82/84 2 Ident. Code D Method of operation Two single-solenoid 2/2-way valves blocked in basic position, pneumatic spring reset 12/ / Ident. Code N Method of operation Two single-solenoid 3/2-way valves open in basic position, pneumatic spring reset 12/ /5 A-9

74 A. Technical appendix Valve sub-bases (continued) 14 82/84 2 Ident. Code K Method of operation Two single-solenoid 3/2-way valves blocked in basic position, pneumatic spring reset 12/ / / Ident. Code M Method of operation Single-solenoid 5/2-way valve, pneumatic spring reset 12/ /5 82/ Ident. Code J Method of operation - Double-solenoid 5/2-way valve 14 12/ /5 12 Please note The double-solenoid valve consists of two valve plates: the control valve and the work valve. The control valve is marked on the front with j 12; the workvalveismarkedwithident.codej. A-10

75 Index Appendix B B-1

76 B. Index Contents B. Index... B-1 B-2

77 B. Index B.1 Index A Abbreviations... IX Auxiliary pilot air Branched internally Supplied externally B Blanking plates C Common pneumatic lines Components Identification code Valve sub-bases... A-9 Compressed air, Requirements... A-5 Connections Electrical (CPV-SC valve terminal with MP connection). 1-7 Pneumatic , A-7 CPV-SC valve terminal Components Pressure zones Size Valve sub-bases... A-9 D Designated use... Display elements, CPV-SC valve terminal with MP connection V B-3

78 B. Index E EMERGENCY STOP F Fitting variants Flow rates... A-7 I Identification code Impairment of function Important user instructions... VII L Large-area silencer, Cleaning/replacing LED display, Valves Low-pressure operation , 4-12 M Manual override Cover Types Materials... A-4 Medium, Compressed air requirement... A-5 Micro valves MP connection B-4

79 B. Index N Notes on this manual... VI O Operating elements, Pneumatic Operating status Operating voltage... A-7 Overview of components P Pictograms... VIII Pneumatic operating status Power consumption... A-7 Pressure range... A-6 Pressure zones , 3-10 S Service... V Size of connection of pneumatic screw connectors Start-up pressurization Supply pressure External auxiliary pilot air Internal auxiliary pilot air Switching status display B-5

80 B. Index T Target group... V Text markings... VIII Tightening torques... A-4 Tubing variants V Vacuum operation , 4-12 Valve sub-bases , A-9 Valve switching times... A-7 Valve test Vibration... A-5 W Weights... A-5 B-6