Valve terminal type 03

Transcription

1 Valve terminal type 03 Pneumatics manual Valve terminal with MIDI/MAXI pneumatics Type IFB..-03 Manual en 0209f

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3 Contents and general instructions Authors... M. Simons, U. Will Editor... M.Holder Original... German text Layout... Festo AG & Co., Dept. KG-GD Type setting... DUCOM Edition... en 0209f Designation... P.BE-MIDI/MAXI-03-EN Order no E (Festo AG & Co., D Esslingen, Federal Republic of Germany, 2002) 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 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 registration. I

4 Contents and general instructions II

5 Contents and general instructions Contents Designated use... Target group... Service... Notesontheuseofthismanual... Important user instructions... Abbreviations... VI VI VI VII X XII 1. Summary of components Overview of multifunctional Festo valve terminals Component description of the pneumatic modules Midi pneumatic modules Maxi pneumatic modules Commissioning Valve terminal type 03 with modular electrical periphery type 03/04B Hat rail fitting Fitting onto a wall Diagnosis Preparing the compressed air Operation with non-lubricated compressed air Operation with lubricated compressed air General connecting methods Connecting the valve terminal Assignment of connections Auxiliary pilot air Pressure supply modules Operation with pressure zones Connnecting vacuum/underpressure Address assignment of the valves III

6 Contents and general instructions 4. Commissioning Settings Commissioning tests Checking the valve functions Checking the valve-cylinder combination Eliminating faults Impairment of function LED display of the valves Diagnosis and error treatment Combination possibilities valve/ sub-base General precautionary measures Dismantling valve terminal type Loosening the electrical connections Loosening the pneumatic connections Dismantling valve terminal type 03 (wall fitting) Dismantling valve terminal type 03 (hat rail fitting) Fitting the modules and components Large surface-mounted silencer Valves and additional plates Sub-bases and pressure supply modules End plates A. Technical appendix... A-1 A.1 Technical specifications - pneumatics... A-3 A.2 Index... A-9 IV

7 Contents and general instructions Designated use The pneumatic midi/maxi modules described in this manual are intended exclusively for use in conjunction with the modular electrical periphery type 03/04B, the CPX terminal or the multipin connection type 03 from Festo. They are intended exclusively for controlling pneumatic actuators and may only be used in conjunction with external devices and components recommended or approved of by Festo. Please observe the safety regulations specified in this manual as well as the instructions concerning the designated use of the valve terminal. The valve terminals may only be used as follows: in accordance with designated use without any modifications by the user in faultless technical condition. The maximum values specified for pressures, temperatures, electrical data, torques etc. must be observed. Observe also national and local regulations. Target group This manual is directed exclusively at technicians trained in control and automation technology. Service Please consult your local Festo repair service if you have any technical problems. V

8 Contents and general instructions Notesontheuseofthismanual This manual deals with the following pneumatic modules: Product Design/fitting Number of valve locations Pneumatic type 03 MIDI/MAXI valves with separate auxiliary pilot air (18 mm; NW 4,0/25 mm; NW 7,0) Single-solenoid valves Double-solenoid valve Mid-position valves blocked, pressurized, exhausted (Additional) pressure supply Pressure zone supply Pressure supply adapter Pressure regulator and throttle plate End plate with regulator Table. 0/1: Pneumatic modules type 03 This manual includes a technical appendix with the technical specifications of the pneumatic components on the valve terminal. All information on power supply and on the electric modules can be found in the relevant electronics manuals for the CPX terminal or valve terminal 03/04B (see following tables). VI

9 Contents and general instructions The following Festo manuals are necessary for the complete documentation of the modular valve terminal, depending on what you have ordered and on further equipment for your complete system: Valveterminaltype03withCPXterminal Type Title Manual Electronics manual Pneumatics manual System manual type P.BE-CPX-SYS-... CPX I/O modules Type P.BE-CPX-EA-... CPX field bus node Type P.BE-CPX-FB... Valve terminals with midi/maxi pneumatics type P.BE-Midi/ Maxi (this manual) Overview of structure, components and method of operation of CPX terminals; Installation and commissioning instructions as well as basic principles of parametrizing Connection types and instructions on fitting, installing and commissioning input and output modules of type CPX-... as well as type CPA and midi/maxi pneumatic interfaces Instructions on fitting, installing, commissioning and diagnosing the relevant field bus node Instructions on fitting, installing, commissioning and diagnosing midi/maxi pneumatics (type 03) Table. 0/2: Manuals for valve terminal type 03 with CPX terminal VII

10 Contents and general instructions Valve terminal type 03 with modular electrical periphery type 03/04B. Type Title Manual Electronics manual Supplementary manual I/O modules Type P.BE-VIEA Manual for analogue input/output modules type P.BE-VIAX Connection types and instructions on fitting, installing and commissioning input and output modules of type 03/04B (digital I/O modules 4I,8I,4O,high-currentoutputmodules,multi I/O modules) Connection types and instructions on fitting, installing and commissioning analogue input and output modules of type 03/04B Pneumatics manual Manual for AS-i master type P.BE-VIASI Electronics manual for your field bus connection type P.BE-VIFB or Control unit type P.BE-VIS Valve terminals with midi/maxi pneumatics type P.BE-Midi/ Maxi (this manual) Connection types and instructions on fitting, installing and commissioning the AS-i interface master of type 03/04B Instructions on fitting, installing, commissioning and diagnosing the relevant field bus node or control unit Available field bus nodes: FB5, FB6, FB8, FB11, FB13, FB16 and FB21 Available control units: SB60, SF3, SF60 Information on fitting, installing, commissioning and diagnosing midi/maxi pneumatics Table. 0/3: Manuals for valve terminal type 03 with electrical periphery type 03/04B. VIII

11 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. IX

12 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. X

13 Contents and general instructions Abbreviations The following product-specific abbreviations are used in this manual: Abbreviation Sub-base Single-solenoid sub-base Double-solenoid sub-base Meaning Pneumatic sub-base for two valves Sub-base for single-solenoid valves Sub-base for double-solenoid or mid-position valves CPX terminal Modular electric terminaltype 50 CPX modules Throttle I O I/O I/O module Commonterm for the variousmoduleswhich canbe incorporatedin acpxterminal Throttle plate input output input and/or output module with general digital inputs or outputs Terminal or valve terminal Valve terminal type 03 with or without electric I/Os of type 03/04B or type 50 (CPX terminal) Node Components Pneumatic modules Regulator field bus node or control unit SB202, SF202 SB50, SF50 Common term for valves, cover plates, large surface-mounted silencers, throttles and regulators Commontermforsub-bases, pressure supply, pressure zone supply and end plates Pressure regulating valve Table. 0/4: Product-specific terms and abbreviations XI

14 Contents and general instructions XII

15 Summary of components Chapter 1 1-1

16 1. Summary of components Contents 1. Summary of components Overview of multifunctional Festo valve terminals Component description of the pneumatic modules Midi pneumatic modules Maxi pneumatic modules

17 1. Summary of components Contents of this chapter Further information This chapter provides an overview of the structure and components of the midi/maxi pneumatics of valve terminal type 03. More detailed information on the electric modules can be found in the following manuals: Modules Manuals on the modular electrical periphery type 03/04B on the CPX terminal Field bus Electronics manual CPX field bus node I/O modules Supplementary manual for the I/O modules CPX I/O modules Pneumatic interface --- CPX I/O modules Table 1/1: Overview of supplementary manuals 1-3

18 1. Summary of components Festo assists you in solving your automation tasks at machine level with valve terminals. Valve terminals type 03 are built up on a modular basis and permit combinations of pneumatic modules type 03 and modular electrical periphery type 03/04B or CPX terminal. Valve terminal type 03 with field bus connection or CPX terminal offer the following advantages: variable fitting with electrical inputs and outputs and pneumatic valve locations subsequent extension/conversion possible application-specific valve designs Midi valve series, 18 mm wide Maxi valve series, 25 mm wide various control systems can be connected minimum cabling required clear system structure due to physical separation of control system and machine valves already fitted valve solenoid coils already wired central compressed air supply central exhaust unit already tested 1-4

19 1. Summary of components 1.1 Overview of multifunctional Festo valve terminals The multifunctional valve terminal type 03 consists of individual modules and components. Valve terminal Type 03 Electric modules CPX terminal (type 50) Electric modules Type03 Pneumatic modules X1 X2 X3 X4 X1 X2 X3 X4 X1 X2 X3 X4 Description of the modules Electric modules suitable for modular electric periphery type 03/04B (PNP or NPN), fitted with: field bus node or control unit digital inputs (modules with 4, 8 or 16 inputs) digital outputs (modules with 4 outputs) 0.5A high-currentoutputs2a Multi I/Os (module with 12 inputs/8 outputs) 0.5 A analogue I/Os, AS-i master (not possible with all nodes) Electric modules suitable for CPX terminal (type 50) fitted with: fieldbusnode digital inputs/outputs (8 inputs and 8 outputs) digital inputs (modules with 4 or 8 inputs) digital outputs (modules with 4 outputs) analogue inputs (modules with 2 inputs) analogue outputs (modules with 2 outputs) Pneumatic modules type 03 fitted with: sub-bases (midi and maxi fitted with 5/2-way single-solenoid valves, 5/2-way double-solenoid valves, 5/3-way mid-position valves (with auxiliary pilot air) or cover plates Special modules for (additional) pressure supply, pressure zone forming, pressure regulation and throttling. End plate right, with/without integrated regulator or with/without pneumatic common line connections Table 1/2: Overview of the modules on the multifunctional Festo valve terminals 1-5

20 1. Summary of components 1.2 Component description of the pneumatic modules Midi pneumatic modules The following connecting, display and operating elements can be found on the components of the pneumatic midi modules: : Yellow LEDs (per valve solenoid coil) ) 2 Manual override(per valve solenoid coil) 3 Valve location identification field 4 Unused valve location with cover plate 5 Common line connections 6 Regulator 7 Pessure regulating screw 8 Work connections (2) per valve, one above the other) Fig. 1/1: Display, connecting and operating elements of the midi modules type

21 1. Summary of components Maxi pneumatic modules The following connecting, display and operating elements can be found on the components of the pneumatic maxi modules: Yellow LEDs (per valve solenoid coil) 2 Manual override (per valve solenoid coil), either locking or non-locking 3 Unused valve location with cover plate 4 Common line connections 5 Valve location identification field (labels) 6 Work connections 2, 4 (two per valve, one above the other) 7 Regulator for limiting the pressure for auxiliary pilot air Fig. 1/2: Display, connecting and operating elements of the maxi modules type

22 1. Summary of components The pneumatic modules provide the following: the common channels for supply and exhaust air the electric signals from all solenoid valve coils Work connections 2 and 4 are provided for each valve location on the individual pneumatic modules. The valves are supplied with compressed air via the common channels and the exhaust air and pilot exhaust air are vented via these common channels. There are two variants for supplying the valves with auxiliary pilot air: internal auxiliary pilot air branched from the complete supply; an end plate with regulator is required for this. external auxiliary pilot air, separately pressure-regulated (4-6 bar) Further modules for pressure supply are also available, e.g. in order to permit work to be carried out with different work pressures. 1-8

23 1. Summary of components As an alternative for electrical switching, a multipin node with integrated left-hand end plate can be used. 1 Multipin node with integrated (left-hand) end plate 1 Fig. 1/3: Valve terminal type 03 with multipin node 1-9

24 1. Summary of components 1-10

25 Fitting Chapter 2 2-1

26 2. Fitting Contents 2. Commissioning Valve terminal type 03 with modular electrical periphery type 03/04B Hat rail fitting Fitting onto a wall

27 2. Fitting Contents of this chapter Further information This chapter describes the hat rail fitting and wall fitting of valve terminal type 03. The valve terminal is supplied ready fitted from the factory. If you wish to supplement or replace individual modules or components, please consult the following manuals: Pneumatics manual for fitting and removing the pneumatic modules and components (chapter 5 in this manual) The fitting instructions supplied with the product in the case of modules and components ordered at a later stage. Supplementary description of the I/O modules for fitting electrical I/O modules of the modular electrical periphery type 03/04B CPX I/O modules for fitting the electronic components of the modules and sub-bases of valve terminal type 03 with CPX terminal. 2-3

28 2. Fitting 2.1 Valve terminal type 03 with modular electrical periphery type 03/04B Please note Fitting valve terminal with type 03 with CPX terminal onto a hat rail or wall is described in the CPX system manual Hat rail fitting The valve terminal is suitable for fitting onto a hat rail (support rail as per EN 50022). There is a guide groove on the back of all modules for hanging them on a hat rail. Caution A hat-rail fitting without a hat-rail clamping unit is not permitted. If the terminal is fitted in a sloping position or if it is subjected to vibration, secure the hat-rail clamping unit additionally with the retaining screws intended for this purpose (see diagram, item 6): against sliding down against unintentional loosening/opening. Please note If the terminal is fitted in a horizontal position and the load is at rest, it is not necessary to use the retaining screws to secure the hat-rail clamping unit (see diagram item 6). If your terminal does not have a hat-rail clamping unit, youcanorderthisandfititatalaterstage. The existing end plates (MIDI/MAXI) determine whether MIDI or MAXI clamping elements are to be used. 2-4

29 2. Fitting Hat rail clamping unit For fitting the valve terminal on to the hat rail you will require a hat rail clamping unit. This must be fastened to the rear of the end plates as shown in the following diagram. Pay particular attention to the following: Before fitting Thesurfacestobegluedmustbeclean(cleanedwith spirit). The flat head screws must be tightened (item 3). After fitting Theleversmustbelockedwithretainingscrews(item6) Lever *) 2 Flat-head screw 3 O-ring 4 Rubber foot (self-adhesive) 5 Clamping elements 6 Retaining screw *) Different lever lengths with midi and maxi Fig. 2/1: Fitting the hat rail clamping unit 2-5

30 2. Fitting Proceed as follows: 1. Ascertain the weight of your valve terminal as described in section Make sure that the mounting surface can support the weight of the node. 3. Fit a hat rail (support rail as per EN x15; width 35 mm, height 15 mm). 4. Fasten the hat rail to the fastening surface at intervals of approx. every 100 mm. 5. Hang the terminal onto the hat rail. Secure the terminal on both sides with the hat rail clamping unit against slipping or sliding down (see diagram below). 6. With a vibrating load or if the terminal is fitted in a sloping position, secure the hat rail clamping unit against unintentional loosening or opening with two screws (diagram item 3). 1 Hat-rail clamping unit unlocked 2 Hat rail clamping unit locked 3 Retaining screw Fig. 2/2: Example of fitting the valve terminal onto a hat rail 2-6

31 2. Fitting Fitting onto a wall Caution In the case of long valve terminals with several I/O modules, use additional support brackets for the modules(approx. every 200 mm). You can thereby avoid: overloading the fastening eyes on the left-hand end plate the terminal hanging down (I/O side) internal oscillations Proceed as follows: 1. Ascertain the weight of your valve terminal (weigh or calculate). Guidelines: midi maxi per pneumatic module 0.8 k g 1.2 kg per node 1 kg 1 kg per electronic module 0.4kg 0.4kg Table 2/1: Component weights 2. Make sure that the mounting surface can support this weight. Check to see if you require support brackets for the I/O modules. 3. If necessary, use washers. 4. Fasten the valve terminal as shown in the table below. The valve terminal can be fitted in any position. 2-7

32 2. Fitting ,6 mm 2 M6 screw Fig. 2/3: Fastening possibilities for fitting onto a wall 2-8

33 Installation Chapter 3 3-1

34 3. Installation Contents 3. Diagnosis Preparing the compressed air Operation with non-lubricated compressed air Operation with lubricated compressed air General connecting methods Connecting the valve terminal Assignment of connections Auxiliary pilot air Pressure supply modules Operation with pressure zones Connnecting vacuum/underpressure Address assignment of the valves

35 3. Installation Contents of this chapter This chapter describes the electrical and pneumatic connections of the midi/maxi valve terminal. The following in particular belong here: General instructions on preparing the compressed air and on connecting the tubing Instructions on operating the valve terminal with internal or external auxiliary pilot air and under vacuum/low pressure Connecting the pneumatic equipment Connecting additional pressure supply modules, pressure regulators and throttle plates Operating the valve terminal with several pressure zones The address assignment of the valves Further information Information on the power supply to valve terminal type 03 with CPX terminal can be found in the CPX system manual. Instructions on connecting the electrical components of valve terminal type 03 with modular electrical periphery type 03/04B can be found in the manual for the relevant field bus node. Instructions on connecting the electrical components of valve terminals type 03 with multipin connection can be found in the relevant information supplied with the product. Further information on addressing the inputs and outputs of valve terminal type 03 can be found in the manual for your field bus. 3-3

36 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 Too much residual oil in the compressed air will reduce the service life of the valve terminal. If bio-oils are used (oils with synthetic ester or true ester basis, e.g. rape oil methylester) the residual oil content must not exceed 0.1 mg/m 3 (see ISO class 2). If mineral oils are used (e.g. HLP oils as per DIN parts 1 to 3) or corresponding oils on a polyalphaolefine basis (PAO), the residual oil content must not exceed 5 mg/m 3 (see ISO class 4). You will thereby avoid functional damage to the valves. Excessive residual oil cannot be permitted irrespective of the compressor oil, as otherwise the basic lubrication will be washed out during the course of time. 3-4

37 3. Installation Operation with lubricated compressed air Please note Please use non-lubricated air in your system if possible in order to protect the environment. Festo pneumatic valves and cylinders have been designed so that, if used as intended, they will not require additional lubrication and will still achieve a long service life. Please note the following instructions if lubricated compressed air must be used. The compressed air prepared with the compressor must correspond in quality to non-lubricated compressed air. If possible, do not operate the complete system with lubricated compressed air. If possible, always install the lubricators directly in front of the consuming cylinder. Caution Incorrect additional oil and too much residual oil content in the compressed air will reduce the service life of the valve terminal. Use Festo special oil OFSW-32 or the other oils listed in the Festo catalogue (as per DIN51524-HLP32, basic viscosity 32cST at 40 C). The additional lubrication must not exceed 25 mg/m 3 (ISO class 5). Make sure that the lubricator setting is correct (see following section) You will thereby avoid functional damage to the valves. 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. 3-5

38 3. Installation Checking the lubricator setting Check the service units in respect of condensate and lubricator setting twice a week. Proceed as follows: 1. Ascertain the cylinder which is furthest from the lubricator. 2. Ascertain the valve terminal which controls this cylinder. 3. Remove the silencer, if fitted, from connection 3/5. 4. Hold a piece of white cardboard 10 cm in front of the exhaustportandletthesystemrunforsometime. There must only be a slight yellow colouring on the cardboard. If oil drops out, this is an indication that too much oil has been used. A further indication of excessive lubrication is the colouring or status of the exhaust silencer. A distinctly yellow colouring of the filter element or drops of oil on the silencer indicate that the lubricator setting is too high. 3-6

39 3. Installation 3.2 General connecting methods Warning Before carrying out installation and maintenance work, switch off the following: the compressed air supply the load voltage supply (pin 2) You can thereby avoid: uncontrolled movements of loose tubing. unexpected movements of the connected actuators non-defined switching states of the electronic components. Laying the tubing Please note Ifnecessary,placeasuitablesealundereachscrewconnector or silencer in order to avoid leakage. By slightly greasing the seal rings, you can increase the sealing effect. If elbow screw connectors or multiple distributors are used, the airflow will be reduced slightly. 3-7

40 3. Installation Basic information Actuators 1. Push the tubing as far as possible over or into the screw connector. 2. If necesary, pull locking ring (A) over the tube connection or tighten the locking screw (B). 3. 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. If necessary, replace the screw connector with a blanking plug (C). 1 Connecting 2 Removing 1 A B 2 Fig. 3/1: Tubing variants C 3-8

41 3. Installation 3.3 Connecting the valve terminal Please note Some connections are covered with adhesive foil to prevent dirt from entering. Remove all adhesive foil from the connections. If not used, seal: valve locations with cover plates. work connections (2, 4) with blanking plugs. Observe the following sequence when connecting the work air, depending on the tool you are using. Any sequence is possible in the case of screw connectors with socket head screw. In the case of screw connectors with external hexagonconnectionmustbemadefromlefttoright (space for the wrench). 3-9

42 3. Installation Assignment of connections 3/5 82/84 3/5 12/14 1 Valve / Valve 2 1 3/5 3/5 Tubing Connection identifier (ISO 5599) Connection size (ISO 228) Connection Compressed air/ vacuum 1 G 3/8 Screw connector Work air/vacuum 2/4 G 1/8 Screw connector Auxiliary pilot air 12/14 G1/8(G1/4) Screw connector in end plate without regulator (not necessary for end plate with regulator) Exhaust 3/5 82/84 G1/2 G1/8(G1/4) Screw connector (with non-return valve or silencer) Table 3/1: Pneumatic connections on the sub-bases 3-10

43 3. Installation Please note Supply only compressed air (> 3 bar) to modules with regulator (end plate). The regulator function has no effect with vacuum operation. Please note In the case of several systems with central ducted exhaust air, use non-return valves in the common exhaust lines in order to prevent functional impairment due to back pressures. System 1 central 82/84 System 2 common 3/5 common 82/84 common 3/5 common 82/84 common 3/5 Valve terminal central 3/5 Valve termi Fig. 3/2: Common lines with non-return valve 3-11

44 3. Installation Auxiliary pilot air The auxiliary pilot air connections 12/14 will be required if you wish to provide separate auxiliary pilot air. Auxiliary pilot air connections on modules for pressure supply are fitted as standard with blanking plugs. Please note Use either: only internally regulated auxiliary pilot air or only externally regulated auxiliary pilot air ( bar). Reliable faultless operation of the valve terminal is then possible. Internal auxiliary pilot air If the supply pressure of your valve terminal type 03 lies between bar, you can operate the terminal with internally branched auxiliary pilot air. Internally regulated auxiliary pilot air is branched from the complete supply and limited to 5 bar by means of an integrated regulator. Please note that the regulated auxiliary pilot air for all pneumatic modules is supplied or branched via common lines at only one point. This also applies when the valve terminal is operated with different pressure zones. 3-12

45 3. Installation External auxiliary pilot air If the supply pressure of your valve terminal type 03 lies below 4 bar, you can operate the valve terminal with external auxiliary pilot air. For this purpose, the auxiliary pilot air is supplied externally via connections 12/14 on the pressure supply module or on the right-hand end plate. Caution If possible, operate valve terminal type 03 with non-lubricated auxiliary pilot air (connections 12/14). Otherwise observe the instructions in the section Preparing the compressed air. In the case of valve terminals with internally branched auxiliary pilot air, the above mentioned instruction also applies to the supply air (connection 1). In the case of valve terminals with several pressure zones and internally branched auxiliary pilot air: In the pressure zone via which the valve terminal is also supplied with internal auxiliary pilot air, the supply pressure must be at least 4 bar. 3-13

46 3. Installation Fig. 3/3: Example for a valve terminal with regulated auxiliary pilot air and with different pressure zones Pressure supply modules For the optimum efficiency of your valve terminal, an additional pressure supply is required in the following cases: on valve terminals with more than 10 valves (rated supply pressure 6 bar) with large-volume actuators Caution If additional pressure supplies are used, the valve terminal must be exhausted via connections 3 and 5 of this module. 3-14

47 3. Installation Necessary mod- Desired operating status ules of theappropriate size Pressure zones Size linking Outputincrease midi Pressure zone supply Pressure supply adapter maxi Sub-base with isolating disc and additional pressure supply or pressure supply adapter or supply via end plate Pressure supply Additional pressure supply Table 3/2: Overview of the pressure supply modules Operation with pressure zones Valve terminal type 03 can be operated with several pressure zones. Warning When individual pressure zones are exhausted (e.g. in the case of an EMERGENCY STOP), the regulator must never be pressureless, otherwise there will be no auxiliary pilot air for the other pressure zones. Caution If pressure zone supplies are used, the valve terminal must be exhausted via connections 3 and 5 of this module. 3-15

48 3. Installation Pressure zone separation with midi valves A midi pressure zone supply is required in the following cases: If a further different work pressure is supplied With midi valves, pressure zones are formed by Pressure zone supply. With these modules compressed air channel 1 is closed. With all valves which are placed to the left of the pressure zone supply, the supply of compressed air and exhausting takes place via the pressure zone supply. Pressure zone separation with maxi valves Isolating discs permit operation of the maxi valve terminal with several pressure zones. The pressure zone will be limited if the isolating disc is placed in compressed air channel 1 (see diagram). Isolating discs can only be placed in the sub-bases. The pressure for the zones is supplied with the following modules: Additional pressure supply *) Pressure supply adapter *) Right-hand end plate *) *) An isolating disc cannot be inserted 3-16

49 3. Installation Fig. 3/4: Position of the isolating disc for maxi pressure zones 3-17

50 3. Installation Please note If valve terminal type 03 is operated with internal auxiliary pilot air, the pressure zone, via which the valve terminal is supplied with auxiliary pilot air, must be operated with a supply pressure of at least 4 bar. If the valve terminal is operated with different pressure zones, supply the higher pressure at the pressure supply adapter with regulator or at the end plate with regulator. The regulating accuracy will thereby be increased Pressure zone 1 with vacuum operation 3 Pressure zone 3 with 6 bar operating pressure 2 Pressure zone 2 with 8 bar operating pressure Fig. 3/5: Example: Valve terminal type 03 with three pressure zones 3-18

51 3. Installation 3.4 Connnecting vacuum/underpressure Internally regulated auxiliary pilot air is branched from the complete supply and limited by means of an internal regulator. This regulator only works in pressure operation (> 3bar). The valve terminal can, therefore, only be operated with externally regulated auxiliary pilot air with vacuum or low pressure (<3bar). 3-19

52 3. Installation 3.5 Address assignment of the valves The addressing of the valves is described below. The addressing of the input/output I/O module is described in the appropriate manual for your field bus. Outputs (valves) 1. The address assignment of the outputs does not depend on the inputs. 2. Address assignment of the valves (see following diagram): Assign the addresses in ascending order without gaps. Counting begins on the node from left to right. Addressable valve solenoid coils: with modular electrical periphery type 03/04B maximum 26 valve solenoid coils with CPX terminal maximum 32 valve solenoid coils 3. Sub-bases type VIGM always occupy 2 addresses (1 address per valve location) Sub-bases type VIGI always occupy 4 addresses (2 addresses per valve location). You can ascertain the sub-bases which are fitted on your valve terminal type 03 by means of the type plates on the sub-bases. 4. Pressure supply modules and pressure zone supply modules do not occupy any addresses. Please note If two addresses are assigned for a valve location, the following assignment applies: lower value address: pilot solenoid 14 higher-value address: pilot solenoid

53 3. Installation Further instructions on the address assignment of the outputs can be found in the manual for your field bus. When the power supply is switched on, the valve terminal recognizes all available pneumatic modules automatically and assigns the appropriate addresses. If a valve location remains unused (cover plate), the relevant address will still be occupied. The following diagram shows an example of the address assignment Valves each with one solenoid coil on sub-base VIGM Reserve location on sub-base VIGM Valves each with two solenoid coils on sub-base VIGI Reserve location on sub-base VIGI Addresses of coil 14 7 Addresses of coil 12 8 Valve location numbers 4 Valves each with one solenoid coil on sub-base VIGI Fig. 3/6: Example: Address assignment of valve terminal type 03 with 8 valve locations (top view) 3-21

54 3. Installation Remarks on Fig. 3/6: If valves with a solenoid coil on sub-bases type VIGIare fitted onto valve terminal type 03, four addresses will be assigned for valve solenoid coils; the higher address in each case then remains unused (see address 9 in Fig. 3/6). If unused valve locations are fitted with cover plates, the addresses are still reserved (see addresses 3, 10 and 11. Address assignment after extension/conversion A special feature of the multifunctional valve terminal is its flexibility. If the demands placed on the machine change, the equipment fitted on the valve terminal can also be modified. Caution If the valve terminal pneumatics are extended or modified at a later stage, the output addresses of the valves and output modules may be shifted. This applies in the following cases: If pneumatic sub-bases are inserted or removed at a later stage. If a pneumatic sub-base VIGM Valves is replaced by a sub-base VIGI or vice versa. 3-22

55 3. Installation The following diagram shows as an example the modifications to the address assignment if the valve equipment fitted in the previous diagram is extended. On the pneumatic side, a subbase type VIGM has been replaced by a sub-base type VIGI (valve locations 2 and 3) Shifting of the addresses due to replacement of the sub-base (valve locations 2 and 3) 2 Replaced sub-base type VIGI with valves each with two solenoid coils Fig. 3/7: Example: Address assignment of valve terminal type 03 with 8 valve locations (top view) Remarks on Fig. Pressure supply modules and pressure zone supply modules do not occupy any addresses. 3-23

56 3. Installation 3-24

57 Commissioning Chapter 4 4-1

58 4. Commissioning Contents 4. Inbetriebnahme Settings Commissioning tests Checking the valve functions Checking the valve-cylinder combination Eliminating faults Impairment of function LED display of the valves

59 4. Commissioning Contents of this chapter Further information This chapter provides an overview of the structure and components of the valve terminal with midi/maxi pneumatics. More detailed information on the field bus node can be found in the following manuals: for type 03/04B: Electronics manual for CPX terminal: CPX field bus node Further information on the use of all the I/O modules on the valve terminal with electrical periphery 03/05B can be found in the Supplementary description of the I/O modules. Further information on the possible connection methods of thei/omodulesaswellasinformationonthepneumaticinterface can be found in the manual CPX I/O modules. 4-3

60 4. Commissioning 4.1 Settings Prerequisites The valve terminal must be fitted with pressure regulators and one-way flow control valves. Pressure regulator plate 1. Tighten the regulating screw on the pressure regulator plates at first completey in an anti-clockwise direction. The lowest possible pressure is then set. 2. Replace the blanking plugs with sealing disc during the setting procedure by a connecting tube with a manometer. 3. Pressurize the valve terminal with the operating pressure. 4. Turn the regulating screw in a clockwise direction until the manometer shows the desired pressure (see following diagrams). 1 Regulating screws Lock nut 3 Connection for pressure display 3 Fig. 4/1: Position of the regulating screws on the pressure regulator 4-4

61 4. Commissioning 1 Output pressure P2 [bar] 2 Flow qn[l/min] 3 Fig. 4/2: Characteristic flow curves of the midi pressure regulator type ILR ,0 4 1 Output pressure P2 [bar] 2 Flow qn[l/min] 1 Fig. 4/3: Characteristic flow curves of the maxi pressure regulator type ILR , Exhaust the valve terminal again. 6. Replace the connecting tube with manometer again by the blanking plug with sealing disc. 7. If required, repeat this setting on all the other pressure regulator plates. 4-5

62 4. Commissioning Throttle plate 1. Close the flow control screws in the throttle plates at first completely, then open them again one turn. You can then avoid undesired or dangerous movements of the connected actuators. 2. Pressurize the valve terminal with the operating pressure. 3. Start a test run of the connected components. 4. Open up the flow control screws in stages until the component reaches the desired speed (see following diagrams). 5. Conclude the test run. 6. Exhaust the valve terminal again. 1 Regulating screws for work connection 2 2 Regulating screw for work connection Fig. 4/4: Position of the regulating screws on the one-way flow control valve 4-6

63 4. Commissioning 1 Characteristic flow curve for maxi flow control valve type IGR ,0 2 Characteristic flow curve for midi flow control valve type IGR Standard rated flow qnn [l/min] 4 Number of turns of the regulating screws 4 Fig. 4/5: Characteristic curves of the flow control valves 4.2 Commissioning tests The valve terminal should be commissioned as follows: Commissioning variants Preliminary test of the pneumatic tubing Complete commissioning of thecompletesystem Actiivity Moving out the valve-cylinder combination by means of the manual override Installing and connecting the complete system (all field bus slaves) Program control via PLC/industrial PC Table 4/1: Commissioning variants Commissioning by manual override is described below. Commissioning by program is described in the relevant manual for the node. 4-7

64 4. Commissioning Checking the valve functions Manual override Warning Actuate the manual override only when the valves are switched off or disconnected from the power supply. Before controlling by means of electric signals: Make sure that all manual override actuations are in their basic positions. You should use the manual override especially when commissioning the pneumatic system, in order to check the function 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. 1 Solenoid valve, single-solenoid 2 Double-solenoid valve 3 Mid-position valve 4 Manual override 5 Slot for screwdriver Fig. 4/6: Position of the midi manual override 4-8

65 4. Commissioning 1 Solenoid valve, single-solenoid, locking Double-solenoid valve, non-locking 3 Mid-position valve, locking 4 Manual override 5 Slot for screwdriver 5 4 Fig. 4/7: Position of the maxi manual override 4-9

66 4. Commissioning Setting of the manual override Resulting position of the valve slide End position Connection 2 under pressure Mid-position; Connections 2, 4 pressureless End position; Connection 4 under pressure Table 4/2: Function of the midi/maxi manual override Manual override design The manual override has been designed to be used as follows: Midi/maxi Manual override design manual override with automatic return (nonlock) Locking manual override Method of operation After operation the manual override is reset by aspring. The manual override remains actuated until it is reset by hand. Table 4/3: Types of manual override 4-10

67 4. Commissioning Checking the valve-cylinder combination Warning If the build-up in pressure of the auxiliary pilot air is too slow or delayed, this may cause the actuators to perform sudden unexpected movements under the following conditions: If the compressed air is switched on with a safety start-up valve (slow build up of pressure) and when there are electric signals (e.g. after EMERGENCY STOP). In this way you can avoid damage to the machine or system or injury to human beings. Supply the auxiliary pilot air separately via the righthand end plate ( bar). The auxiliary pilot air must reach a pressure of bar as soon as it is switched on, otherwise the valve cannot be guaranteed to switch (see diagram). Ifthepressureislessthan4bar,theremaybeadelaybefore the valve is switched, in spite of an electric signal being present. The cylinder would suddenly move in or out, depending on the valve function, as the slow build-up in pressure of the complete supply cannot have an effect on the cylinder. 4-11

68 4. Commissioning 82/ / / Externally supplied auxiliary pilot air (4 to 6 bar) branched from the safety start-up valve 2 Safety start-up valve (slow build up of pressure of complete supply) Fig. 4/8: Example of valve-cylinder combination with slow increase in pressure of the complete supply 4-12

69 4. Commissioning 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 point when a valve switches Movement of the cylinder branched after the safety start-up valve or supplied via an end plate with integrated pressure regulator branched in front of the safety startup valve or supplied via an end plate without integrated pressure regulator slow slow after pressure increase with (1) slow fast before pressure increase with (1) fast slow Table 4/4: Effects of slow start-up pressurization when there are electric signals Carry out the test Proceed as follows: 1. Switch on the compressed air supply. 2. Check the functioning and effect of each individual valvecylinder combination by actuating the manual override. 3. With locking manual override: After testing the valves, check that all manual override actuations are in their basic positions again. 4. Switch off the compressed air supply after checking the valves. 4-13

70 4. Commissioning Caution During commissioning, manual override actuations which areintheswitchedstatecancauseactuatorstoperform sudden unexpected movements. These movements can cause injury to human beings and damage to property. Make sure that double-solenoid valves 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. Protecting the manual override Onopenaccessiblesystemsthemanualoverridecanbeprotected against unauthorized use. The manual override can be protected if the adjusting toggle is removed (keep in a safe place). 4-14

71 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: The operating status of the pneumatic system The valve position Fault treatment when the compressed air supply has been switched off Air escapes from... the common line connections 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 Checkthesealringorthetubefitting (if necessary, grease lightly) Checkthesealringorthetubefitting (if necessary, grease lightly) After switching on again, regulate external pilot air to bar). Check the tubing After switching on again check the operating pressure (e.g. pressure zones) Bring the locking manual override into the basic position Servicing required Check the basic setting, controller connection (apply pressure > 3 bar at controller) Table 4/5: Operating status of the pneumatic system 4-15

72 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 Several pressure zones Vacuum operation/ lowpressure operation EMERGENCY STOP of pressure zones Slow start-up pressurization after EMERGENCY STOP tubing connected with care regulated auxiliary pilot air ( bar) sufficient pressure supply via pressure supply points Non-return valves in common exhaust line Limiting the pressure zones on both sides with one of the following: pressure zone supply isolating disc endplate node Externally supplied auxiliary pilot air ( bar) Guaranteeing the regulator controller function for the auxiliary pilot air despite the complete supply being switched off Using end plates with separate connections for the auxiliary pilot air Exhaust the valve terminal also at the additional pressure supply points This applies when several systems with centrally ducted exhaust are used Higher pressure zones regulatornear, lower pressure zones regulator-remote Regulator can only be operated with pressure (3 >bar) Regulator regulates the auxiliary pilot air of all the pneumatic modules When there are control signals: The auxiliary pilot air must be at full pressure immediately after being switched on. Table 4/6: Causes of possible deviations from the nominal status 4-16

73 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. The diagram below shows the position of the LEDs for the manual override actuations. 1 LED for pilot solenoid coil LED for pilot solenoid coil 14 3 Plunger for pilot valve 14 (manual override 14) 4 Plunger for pilot valve 12 (manual override 12) 4 3 Fig. 4/9: Position of the LEDs and manual overrides 4-17

74 4. Commissioning Manual override actuation type LED for solenoid coil 12 Position: to the left on the valve LED for solenoid coil 14 Position: to the right on the valve Locking, switch position to the left (anti-clockwise) to the right (clockwise) Non-locking, position of plunger: to the left on the valve to the right on the valve Table4/7: AssignmentoftheLEDstotheappropriatemanualoverrides: LED Switching position of the valve solenoid coil Meaning yellow out Basic position logical 0 (no signal) yellow alight Switchposition or basicposition logical1(signalpresent) logical 1 but: operating voltage of outputs lies outside permitted tolerance range (21.6 V V DC) or compressed air supply not OK or pilot exhaust blocked or auxiliary pilot air outside the range bar or servicingrequired Table 4/8: Example of LED display of switching status of the valve solenoid coil 4-18

75 Diagnosis and error treatment Chapter 5 5-1

76 5. Diagnosis and error treatment Contents 5. Wartung und Umbau Combination possibilities valve/ sub-base General precautionary measures Dismantling valve terminal type Loosening the electrical connections Loosening the pneumatic connections Dismantling valve terminal type 03 (wall fitting) Dismantling valve terminal type 03 (hat rail fitting) Fitting the modules and components Large surface-mounted silencer Valves and additional plates Sub-bases and pressure supply modules End plates