Valve terminal type 03 Pneumatics Manual MIDI/MAXI-valves

Transcription

1 Valve terminal type 03 Pneumatics Manual MIDI/MAXI-valves GB Only valid in agreement with the printed documentation accompanying the product! Compare this edition code C

2 Authors: U. Will, E. Klotz Editor: H.-J. Drung Translation: Douglas Smith Layout: Festo KG, Dept. PV-IDM Type setting: DUCOM 9703c 1997 Festo KG, Esslingen, Federal Republic of Germany All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Festo KG. 9703c I

3 Part no.: Title: Designation: MANUAL P.BE-MIDI/MAXI-03-GB II 9703c

4 Contents Chapter 1 USER INSTRUCTIONS AND SUMMARY OF SYSTEM 1.1 Important user instructions Danger categories Pictograms Instructions on this manual 1.2 Summary of system System structure Description of components Description of function Combination possibilities of valves and valve sub-bases (MIDI/MAXI) Chapter 2 FITTING THE PNEUMATIC COMPONENTS 2.1 Fitting the components Pneumatic modules Valves End plates Hat rail clamping unit 2.2 Fitting the valve terminal Wall fitting Hat rail fitting 9703c III

5 Chapter 3 CONNECTING THE PNEUMATIC COMPONENTS 3.1 General connecting methods Laying the tubing General information 3.2 Connecting the valve terminal Assigning the connections Auxiliary pilot air 3.3 Connecting additional air supply modules MIDI air supply MIDI intermediate air supply MIDI-MAXI air supply adapter MAXI additional air supply MIDI air supply, flat MIDI intermediate air supply, flat MIDI-MAXI air supply adapter, flat MAXI additional air supply, flat MAXI isolating disc MAXI isolating disc 3.4 Connecting vacuum/low pressure Chapter 4 COMMISSIONING 4.1 Commissioning tests Checking the valve functions Manual override 4.2 Error analysis Impairment of functions LED displays of the valves Appendix A Appendix B TECHNICAL APPENDIX INDEX IV 9703c

6 1. User instructions 1. USER INSTRUCTIONS AND SUMMARY OF SYSTEM 9703c 1-1

7 1. User instructions Contents 1.1 IMPORTANT USER INSTRUCTIONS 1-3 Danger categories 1-3 Pictograms 1-4 Instructions on this manual DETAILED SUMMARY OF SYSTEM 1-8 System structure 1-8 Description of components 1-10 Description of function 1-15 Combination possibilities of valve and valve sub-base (MIDI/MAXI) c

8 1. User instructions 1.1 IMPORTANT USER INSTRUCTIONS Danger categories This manual contains instructions on the possible dangers which can occur with valve terminal type 03. A distinction is made between the following: WARNING... means that personal injury or material damage can occur if the instructions are not followed. CAUTION... means that material damage can occur if the instructions are not followed. PLEASE NOTE... means that this instruction must also be observed. 9703c 1-3

9 1. User instructions Pictograms Pictograms and symbols supplement the danger instructions and draw the attention of the user to the nature and consequences of the dangers. The following pictograms are used: Uncontrolled movement of loose tubing. Undesired movements of the connected actuators. High electric voltages or undefined switching states of the electronic components can affect connected circuits. Electrostatically vulnerable components. These components will be destroyed if the contact surfaces are touched c

10 1. User instructions Instructions on this manual The following product-specific abbreviations are used in this manual: Abbreviations Terminal Node Valve sub-base I O I/O P module I/O module 4-input module 8-input module 4-output module Components Regulator Meaning Valve terminal with/without el. I/Os Multipin node or field bus node control block or ASI-BUS node Pneumatic sub-base for single solenoid valves or double solenoid/mid-position valves Input Output Input and/or output Pneumatic module in general Module with digital inputs/outputs in general (input/output modules) Module with 4 digital inputs Module with 8 digital inputs Module with 4 digital outputs Common term for valve, blanking plate Pressure regulator This manual contains a description of the following pneumatic modules: Product Design/fitting No. of valve locations Valve terminal type 03 MIDI/MAXI valves with separate auxiliary pilot air (18 mm; size 4.0 / 25 mm; size 7.0) Single solenoid valves Double solenoid valves Mid-position valves blocked, pressurized, exhausted Additional air supply Air supply adapter Air supply Intermediate air supply End plate with regulator Fig. 1/1: Pneumatic module type c 1-5

11 1. User instructions Festo field bus node FB1 FB2 Field bus protocol ET100 SUCONET Kl.1 Festo field bus D-Bus Modnet 1 SFB Printa The manual includes a technical appendix with the technical specifications of the pneumatic components of your valve terminal. All information on power supply and on the electronic modules of valve terminal type 03 are to be found in the appropriate manual (see below). Valve terminal type 03 can be connected with a multipin plug or with the following field bus nodes: PLC/I-PC manufacturer SIEMENS Klöckner-Moeller Festo ABB AEG Honeywell FB3 PROFIBUS Open bus as per DIN19245 Appropriate Festo manual (electronics, field bus) P.BE-VIFB1-03/05-GB P.BE-VIFB2-03/05-GB P.BE-VIFB3-03/05-GB FB4 MELSEC MININET Mitsubishi P.BE-VIFB4-03/05-GB FB5 CS-31 ABB P.BE-VIFB5-03/05-GB FB6 INTERBUS-S Phoenix, open field bus P.BE-VIFB6-03/05-GB FB7 II/O-bus EDP-L Beckhoff Eberle P.BE-VIFB7-03/05-GB FB Remote-I/O Allen-Bradley P.BE-VIFB8-03/05-GB FB9 SINEC L2-DP SIEMENS, P.BE-VIFB9-03/05-GB open field bus Fig. 1/2: Automation systems/field bus protocols c

12 1. User instructions Festo field bus node Field bus protocol PLC/I-PC manufacturer Appropriate Festo manual (electronics, field bus) FB10 Genius bus GE Fanuc P.BE-VIFB10-03/05-GB FB 11 CAN-bus, Device Net DIOS SELECAN Allen-Bradley Philips Selection P.BE-VIFB11-03/05-GB FB 12 Sysmac-b+us Omron P.BE-VIFB12-03/05-GB FB 13 PROFIBUS-DP open field bus P.BE-VIFB13-03/05-GB (12 Mbaud) FB 15 EAE field bus 2 EAE P.BE-VIFB15-03/05-GB FB 16 FIP-IO Télémécanique P.BE-VIFB16-03/05-GB FB 17 JETway-R Jetter P.BE-VIFB17-03/05-GB SB50 SINEC L2 DP SIEMENS, open field bus P.BE-SF50-03/05-GB (!) SB202 No field bus Festo-PLC internal P.BE-SB202-03/05-GB SF3 SF50 SINEC L2 DP SIEMENS, open field bus P.BE-SF50-03/05-GB SF202 Festo field bus Festo-PLC internal P.BE-SF202-03/05-GB Fig. 1/2: Automation systems/field bus protocols 9703c 1-7

13 1. User instructions 1.2 DETAILED SUMMARY OF SYSTEM System structure Festo valve terminals can be used for solving automation tasks at the machine level. The valve terminals of type 03 are constructed on a modular basis and permit combinations of pneumatic and electronic modules. The following groups are therefore possible on the field bus: Industrial PC or PLC (I-PC) Valve terminal type 03: pneumatic and electronic modules Field bus Valve terminal type 03: only pneumatic modules Valve terminals type 03: only electronic modules Valve terminal/valve sensor terminal type 02: Further field bus slaves Fig. 1/3: System summary and possible variants of valve terminals c

14 1. User instructions Valve terminal type 03 with field bus connection offers the following advantages: variable fitting of locations with electrical inputs and outputs as well as pneumatic valves subsequent extension/conversion possible valve designs for specific purposes MIDI valve series, 18 mm wide MAXI valve series, 25 mm wide can be connected to various control systems simpler circuitry easy-to-understand system structure with physical separation of controller and machine valves already fitted wired valve solenoid coils central compressed air supply central exhaust device already tested A field bus system offers the following advantages: fewer output modules required in the controller economic data transmission over long distances high baud rates a large number of slaves can be connected easier error diagnosis 9703c 1-9

15 1. User instructions Description of components Valve terminal type 03 is composed of individual modules of two different sizes MIDI, MAXI. Each module is assigned with different functions and elements for connection, display and operation. The diagram below summarizes the modules in the valve terminal Figure Module 1 Node 2 Electronic modules (input/output modules), fitted with digital inputs (modules with 4 or 8 inputs) digital outputs (modules with 4 outputs; only for field bus node) 3 End plate left 4 Pneumatic MIDI, MAXI modules (sub-bases) fitted with auxiliary pilot air valves: 5/2-way solenoid valves 5/2-way double solenoid valves 5/3-way mid-position valves (exhausted, pressurized, blocked) blanking plates 5 Pneumatic MIDI, MAXI modules: air supply with integrated exhaust (MIDI) intermediate air supply with integrated exhaust (MIDI) air supply adapter with/without regulator (MIDI MAXI) additional air supply (MAXI) 6 End plate right, according to size of last sub-base with either: pneumatic common tubing connections and integrated regulator for 5 bar auxiliary pilot air (uncontrolled auxiliary pilot air is not permitted) pneumatic common tubing connections, but without integrated regulator without pneumatic common tubing connections Fig. 1/4: Modules of valve terminal type c

16 1. User instructions The following connection, display and operating elements are to be found on the pneumatic MIDI modules: a 5b Node or integrated end plate 2 Yellow LEDs (status) 3 Manual override for valve solenoid coils 4 Valve location inscription field 5a Unused valve location with blanking plate 5b Common tubing connections 6 Work connections (2 per valve, one above the other) 7 Regulator Fig. 1/5: Operation, display and connecting elements of the MIDI modules 9703c 1-11

17 1. User instructions The following connection, display and operating elements are to be found on the pneumatic MAXI modules: a 5b Node or integrated end plate 2 Yellow LEDs (status) 3 Manual override for valve solenoid coils 4 Valve location inscription field (designation signs) 5a Unused valve location with blanking plate 5b Common tubing connections 6 Work connections (2 per valve, one above the other) 7 Regulator for limiting the auxiliary pilot air pressure 8 Common tubing connection 9 Exhaust connections Fig. 1/6: Operation, display and connection elements of the MAXI modules c

18 1. User instructions The connection, display and operating elements shown below are to be found on the electronic modules. Further information on their use is to be found in the manual for the field bus node. Only the pneumatic modules are described here A4 A4 E4 E8 only in connection with field bus node 1 Output socket for electronic output 2 Yellow LED (per output) 3 Red LED (per output) 4 Input socket for electrical input 5 Green LED (per input) 6 Input socket for two electronic inputs 7 Two green LEDs (one LED per input) 8 Node with LEDs and field bus connection, detailed description included with packing or in chapter "Connecting the pneumatic components" in the node manual Fig. 1/7: Operation, display and connection elements of the electronic modules 9703c 1-13

19 1. User instructions Fig. 1/8: Alternative for electrically switching integrated (left-hand) end plate c

20 1. User instructions Description of function Digital I/O modules Field bus Pneumatic modules Node 1 Input module (4 inputs) 2 4 Work connections Cylinder Sensors Signal directions 2, 1 4 Compressed air Work air Fig. 1/9: Function summary of valve terminal type 03 (see example with I/O-switching) The node/control block controls the following functions: connection of the terminal to the field bus module of the control system and to further slaves via the field bus interface adaption of field bus baud rate and field bus protocol to the control system control of data transfer to/from the field bus module of the control system internal control of the terminal 9703c 1-15

21 1. User instructions The pneumatic modules permit the following connections: pneumatic (common channels for supply and exhaust air) electrical (electrical signals of all solenoid coils) Work connections 2 and 4 are provided for each valve location on the individual pneumatic modules. The valves are supplied with compressed air and the exhaust air and pilot air from the valves are vented via the common channels of the pneumatic end plate. There are two possibilities of supplying the S-valves with auxiliary pilot air: Auxiliary pilot air taken from the main supply. An end plate with regulator is required here. separately regulated auxiliary pilot air (3-5 bar) There are also modules available e.g. for creating different working pressures. The digital input/output modules process input signals (e.g. from sensors) and transmit these signals via the field bus to the controller. All electrical outputs control low-current consuming devices with positive logic c

22 1. User instructions Combination possibilities valve/sub-base MIDI PLEASE NOTE The valve locations are intended for Festo valves of the appropriate size and may only be fitted with valves released by Festo. The valve locations must not be used for any other purpose. Sub-base used Valve Alternative VIGM MT2H-5/2 IAP-4.0 VIGI JMT2H MT2H-5/2 IAP-4.0 MT2H-5/3 MT2H-5/2 IAP-4.0 Fig. 1/10: Combination possibilities of valve/valve sub-base MIDI 9703c 1-17

23 1. User instructions Combination possibilities valve/sub-base MAXI Sub-base used Valve Alternative VIGM MTH-5/2 IAP-7.0 VIGI JMTH-5/2 MTH-5/2 IAP-7.0 MTH-5/3 G,E,B MTH-5/2 IAP-7.0 Fig. 1/11: Combination possibilities of valve/valve sub-base - MAXI c

24 2. Fitting pneumatic components 2. FITTING THE PNEUMATIC COMPONENTS 9507 B 2-1

25 2. Fitting pneumatic components Contents 2.1 FITTING THE PNEUMATIC COMPONENTS 2-3 Pneumatic modules 2-4 Valves 2-6 End plates 2-9 Hat-rail clamping unit FITTING THE VALVE TERMINAL 2-14 Wall fitting 2-14 Hat rail fitting B

26 2. Fitting pneumatic components 2.1 FITTING THE PNEUMATIC COMPONENTS WARNING Before fitting the components switch off the following: compressed air supply operating voltage supply You can thereby avoid: uncontrolled movement of loose tubing undesired movement of the connected actuators undefined switching states of the electronic components WARNING The modules of the valve terminal contain electrostatically vulnerable components. Do not therefore touch any contact surfaces on the side plug connectors of the modules. Please observe the regulations for dealing with electrostatically vulnerable components. You can thereby avoid damage to the valve terminal modules B 2-3

27 2. Fitting pneumatic components PLEASE NOTE Treat all modules and components of the valve terminal with the utmost care. Pay special attention to the following: Screw connectors must not be distorted or subjected to mechanical stress. Screws must fit correctly (otherwise the threads will be damaged). The specified torques must be observed. The modules must not be offset (IP 65). Connecting surfaces must be clean (avoid leakage and contact errors). With modules ordered at a later stage, please observe the fitting instructions included in the package. Pneumatic modules Before the valve terminal can be extended or converted, it must first be dismantled. Dismantling (see also following diagram) Switch off the power and compressed air supply to the terminal. Remove the terminal from the fastening surface and place it on an even surface. Remove completely the screws of the relevant modules. The modules are now held together only by the electric plug connector. Pull the modules carefully and without tipping away from the electric plug connectors B

28 2. Fitting pneumatic components Replace damaged seals. PLEASE NOTE Place subsequently ordered modules, where possible, after the last module of the same size. An extension to include a further valve size requires adaption of the size. Fit the modules as follows: Fit a (new) seal to the contact surface on the left facing the node. Fit only the intended pneumatic modules in the appropriate sizes. Seal Fastening screws max. 1 Nm Fig. 2/1: Fitting the pneumatic modules (example of MIDI) 9507 B 2-5

29 2. Fitting pneumatic components Valves/valve bridges Proceed as follows: Check the individual air channels on the module for dirt. Clean the surfaces and, if necessary, the individual air channels of the modules by blowing them out before assembly. Insert missing seals. Fit according to the following diagrams B

30 2. Fitting pneumatic components Manual override Through bolt max. 0.6 Nm Blanking plate Fig. 2/2: Fitting MIDI valves 9507 B 2-7

31 2. Fitting pneumatic components Designation signs Grooved screw M4 max. 1.5 Nm Manual override Imprinted sign frame for removal Blanking plate Fig. 2/3: Fitting MAXI valves B

32 2. Fitting pneumatic components End plates CAUTION Earth the right-hand end plate before assembly. You thereby avoid high voltages on the metal surfaces if there are faults. PLEASE NOTE If the valve terminal is switched on with a safety start-up valve (slow pressurization), use the end plate, if necessary, for separate supply of the auxiliary pilot air (see commissioning). Supply only compressed air to modules with regulator (end plate). The regulator function has no effect with vacuum operation. Both a left-hand and a right-hand end plate are required as mechanical conclusions of the terminal. These end plates fulfil the following functions: They comply with protection class IP65. They contain connections/holes for the protective earth cable. They contain holes for the wall fitting and the hat rail clamping unit B 2-9

33 2. Fitting pneumatic components The right-hand end plate is available in various sizes and designs: MIDI with common tubing connections for the compressed air supply to the pneumatic modules and integrated regulator for the adapted auxiliary pilot air required (5 bar). Fig. 2/4: MIDI end plate with regulator B

34 2. Fitting pneumatic components MIDI and MAXI with common tubing connections for the compressed air supply to the pneumatic modules but without integrated regulator. Fig. 2/5: End plate right without common tubing connections for valve terminals without valves. Fig. 2/6: Example - MAXI end plate without connections 9507 B 2-11

35 2. Fitting pneumatic components Earth the end plates as follows: Right-hand end plate In order to earth the right-hand end plate, connect the fitted cable to the appropriate contact of the pneumatic module or of the field bus node (see following diagram). Left-hand end plate This is connected conductively to the other components by means of spring contacts already fitted. Multipin valve terminal: see "Earthing the right-hand end plate". Multiplan node with integrated left-hand end plate. Earthing is via the looped contact rail. Remark: For information on earthing the complete valve terminal, please consult the chapter "Installation" in the relevant node manual. The diagram below shows how the end plates are fitted. Left-hand end plate Seal All fastening screws max. 1 Nm Contact for PE cable Ready fitted PE cable Fig. 2/7: Fitting the end plates Right-hand end plate B

36 2. Fitting pneumatic components Hat rail clamping unit The hat rail clamping unit is required if the terminal is to be fitted onto a hat rail (support rail as per EN 50022). The hat rail clamping unit is fastened to the rear of the end plates as shown in the diagram below. This applies to MIDI and MAXI clamping units which only have different lever lengths (3), (4). Before fitting ensure that: the surfaces to be glued are clean (cleaned with spirit). the flat-head screws are tightened (6). the levers are secured with a locking screw (7) when hung in position. 1 Self-adhesive rubber foot 2 Clamping elements 3 Left-hand lever*) 4 Right-hand lever*) 5 O-ring 6 Flat head screw 7 Locking screw *) Different lever lengths with MIDI and MAXI Fig. 2/8: Fitting the hat rail clamping unit (numbers indicate fitting sequence 9507 B 2-13

37 2. Fitting pneumatic components 2.2 FITTING THE VALVE TERMINAL Wall fitting WARNING With long terminals use additional supports approximately every 200 mm. You thereby avoid: overloading the fastening eyes on the end plates the terminal sagging natural resonance Proceed as follows: Calculate the weight of the terminal (weigh or estimate). General rule: MIDI MAXI Per pneumatic module 700 g 1200 g Per node 1000 g 1000 g Per electronic module 400 g 400 g Make sure that the fastening surface can support this weight. Fasten the terminal with four M6 screws as shown in Fig. 2/9 (fitting position as desired). Use spacers and support brackets if necessary. 7,6 mm M6 Fig. 2/9: Example of fitting the terminal on a wall B

38 2. Fitting pneumatic components Hat rail fitting The terminal is suitable for fitting onto a hat rail (support rail as per EN 50022). For this purpose there is a guide groove on the rear of all modules for hanging the terminal on the hat rail. CAUTION A hat rail fitting without the clamping unit is not permitted. If fitted in a sloping position or at a point subjected to vibration, the hat rail clamping unit must be additionally protected against slipping and protected against unintentional loosening or opening with the screws (7) supplied (see Fig. 2/8). PLEASE NOTE In a horizontal fitting position and with a non-vibrating load, the fastening of the hat rail clamping unit is sufficient without screws (7) (see Fig. 2/8). If there is no hat rail clamping unit on the terminal, it can be ordered and fitted at a later stage. The use of MIDI or MAXI end plates is governed by the available end plates (MIDI/MAXI). Proceed as follows: Calculate the weight of the terminal (weigh or estimate). General rule: MIDI MAXI Per pneumatic module 700 g 1200 g Per node 1000 g 1000 g Per electronic module 400 g 400 g 9507 B 2-15

39 2. Fitting pneumatic components Make sure that the fastening surface can support this weight. Fit a hat rail (support rail EN x15; width 35 mm, height 15 mm). Fasten the hat rail to the mounting surface approximately every 100 mm. Hang the terminal onto the hat rail. Use the hat rail clamping unit to secure the terminal on both sides against tilting or slipping (see diagram below). With a vibrating load or in a sloping position, secure the hat rail clamping unit with two screws (7) against unintentional loosening/opening. Valve terminal type 03 Hat rail clamping unit Locking screw 7 Fig. 2/10: Example of fitting the terminal onto a hat rail B

40 3. Connecting components 3. CONNECTING THE PNEUMATIC COMPONENTS 9703c 3-1

41 3. Connecting components Contents 3.1 GENERAL CONNECTION METHODS 3-3 Laying the tubing 3-3 General information CONNECTING THE VALVE TERMINAL 3-5 Assigning the connections 3-6 Auxiliary pilot air CONNECTING ADDITIONAL AIR SUPPLY MODULES 3-10 MIDI air supply 3-12 MIDI intermediate air supply 3-12 MIDI-MAXI air supply adapter 3-13 MAXI additional air supply 3-13 MIDI air supply, flat 3-14 MIDI intermediate air supply, flat 3-14 MIDI-MAXI air supply adapter, flat 3-15 MAXI additional air supply, flat 3-15 MAXI isolating disc CONNECTING VACUUM/ LOW PRESSURE c

42 3. Connecting components 3.1 GENERAL CONNECTION METHODS WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the operating voltage supply You thereby avoid: uncontrolled movement of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components Laying the tubing PLEASE NOTE Place a suitable seal under each screw connector or silencer in order to prevent leakage. By lightly greasing the seals, you can increase the sealing effect. If elbow connectors or multiple distributors are used, the air flow will usually be reduced. 9703c 3-3

43 3. Connecting components General information Connecting 1. Push the tubing as far as it will go into or over the screw connector. 2. If necessary, pull the locking ring (A) over the tube coupling or tighten the locking screw (B). 3. For reasons of clarity, group the tubing together with: - tube straps or - multiple tube holders. Disconnecting 1. Where applicable, loosen the locking screw or locking ring on the screw connector. 2. Pull the tubing out. 3. If necessary, replace the screw connector with blind plugs (C). (B) (A) Connecting Disconnecting (C) Fig. 3/1: Tubing variants c

44 3. Connecting components 3.2 CONNECTING THE VALVE TERMINAL PLEASE NOTE Some connections are covered with adhesive foil to protect them against dirt. Remove all adhesive foils from the connections. If unused, cover as follows: free valve locations with blanking plates work connections (2, 4) with blind plugs Observe the following sequence when connecting the air supply, depending on the tool used: Any sequence is possible if a hexagon socket wrench is used. If an external hexagon socket wrench is used, the connections must be made from left to right (space required for wrench). 9703c 3-5

45 3. Connecting components Assigning the connections 3/5 3/5 82/84 12/14 82/ Valve Valve 2 1 3/5 3/5 Tubing Compressed air/vacuum Connection code (ISO 5599) Size of connection (ISO 228) Connection 1 G 3/8 Screw connector Work air/vacuum 2/4 G 1/8 Screw connector Auxiliary pilot air 12/14 G 1/8 (G 1/4) Screw connector in end plate without regulator (no screw connector if end plate with regulator) Exhaust 3/5 82/84 Fig. 3/2: Assigning the sub-bases G 1/2 G 1/8 (G 1/4) Screw connector (with nonreturn valve or silencer) PLEASE NOTE Supply only compressed air (> 3 bar) to modules with regulator (end plate). With vacuum operation the regulator function has no effect c

46 3. Connecting components PLEASE NOTE If there are several systems with centrally ducted exhaust air, use non-return valves in the common exhaust connections so that the function is not impaired as a result of back pressures. System 1 Central 82/84 System 2 Common 3/5 Common 82/84 Common 3/5 Common 82/84 Valve terminal Common 3/5 Central 3/5 Valve terminal Fig. 3/3: Common tubing with non-return valves 9703c 3-7

47 3. Connecting components Auxiliary pilot air The auximiliary pilot air connections 12/14 are required if the auxiliary pilot air is to be supplied externally. Auxiliary pilot air connections on modules for air supply are series-fitted with blind plugs. PLEASE NOTE Use only either: internally controlled auxiliary pilot air or externally controlled auxiliary pilot air (3-5 bar) This will guarantee reliable, interference-free operation of the terminal. Internally controlled auxiliary pilot air is taken from the complete supply and limited to 5 bar by means of an integrated regulator. Please note that the controlled auxiliary pilot air for all pneumatic modules via common tubing is fed in or taken at only one position. This also applies when the valve terminal is operated with different pressures c

48 3. Connecting components R Fig. 3/4: Example of a terminal with controlled auxiliary pilot air and different pressure zones WARNING When individual pressure zones are exhausted (e.g. during EMERGENCY OFF, the regulator must never be without pressure. Otherwise, there is no auxiliary pilot air available for the other pressure zones. 9703c 3-9

49 3. Connecting components 3.3 CONNECTING ADDITIONAL AIR SUPPLY MODULES In order that the terminal can operate with optimum efficiency, additional air supply is required in the following cases: on valve terminals with more than 10 valves (rated supply pressure 6 bar) with large-volume actuators Modules required in the relevant size Desired operating status Pressure zones Linking of sizes MIDI MAXI Intermediate air supply Sub-base with isolating disc Air supply adapter and additional air supply or air supply adapter Additional performance Air supply Additional air supply Fig. 3/5: Summary of air supply modules c

50 3. Connecting components A MIDI intermediate air supply is required in the following case: for supplying a further different work pressure CAUTION If additional supply modules or intermediate supply modules are used, the terminal must also be exhausted via connections 3 and 5. PLEASE NOTE The diagrams overleaf show the following modules: the MIDI air supply modules the MAXI air supply modules without regulator PLEASE NOTE If the system is operated with different pressures, the higher pressure should be fed in at the air supply adapter with regulator or at the end plate with regulator. The degree of control accuracy is thereby increased. 9703c 3-11

51 3. Connecting components MIDI air supply module Air supply 3/5 82/84 3/5 Air supply, two-directional flow 1 Fig. 3/6: Connections for air supply MIDI intermediate air supply Intermediate air supply 3/5 82/84 3/5 1 Air supply only in the left-hand zone (single-directional flow) Fig. 3/7: Connections for intermediate air supply c

52 3. Connecting components MIDI-MAXI air supply adapter 3/5 3/5 82/84 MIDI side 12/14 MAXI side 1 Fig. 3/8: Connections for air supply adapter MAXI additional air supply 3/5 82/84 3/5 12/14 1 Fig. 3/9: Connections for additional air supply 9703c 3-13

53 3. Connecting components MIDI air supply module, flat 12/14 1 Air supply, two-directional flow Fig. 3/10: Connections for air supply MIDI intermediate air supply, flat 12/14 1 Air supply only in the left-hand zone (single-directional flow) Fig. 3/11: Connections for intermediate air supply c

54 3. Connecting components MIDI-MAXI air supply adapter, flat MIDI side 12/14 1 MAXI side Fig. 3/12: Connections for air supply adapter MAXI additional air supply, flat 12/14 1 Fig. 3/13: Connections for additional air supply 9703c 3-15

55 3. Connecting components MAXI isolating disc PLEASE NOTE If the system is operated with different pressures, the higher pressure should be fed in at the air supply adapter with regulator or at the end plate with regulator. The degree of control accuracy is thereby increased. Isolating discs enable MAXI valve terminals to be operated at different pressures. When the isolating disc is inserted, the pressure zone is separated (see diagram). Isolating discs can only be laid in the sub-bases. The intermediate air is supplied by the following modules: additional air module air supply adapter right-hand end plate (An isolating disc cannot be fitted) Fix a sign to indicate that the isolating disc has been fitted. Insert the sign in the space intended before you screw the sub-bases together. Fig. 3/14: Locating the isolating disc for MAXI pressure zones c

56 3. Connecting components 3.4 CONNECTING VACUUM/LOW PRESSURE The valve terminal can be operated with vacuum or low pressure (< 3 bar) under the following conditions: When there is a separate supply of externally controlled auxiliary pilot air. When the internally controlled auxiliary pilot air is taken from the main supply and limited with an internal regulator. This regulator operates only at > 3 bar pressure. 9703c 3-17

57 3. Connecting components c

58 4. Commissioning 4. COMMISSIONING 9507 B 4-1

59 4. Commissioning Contents 4.1 COMMISSIONING TESTS 4-3 Checking the valve functions 4-4 Manual override 4-4 Designs of manual override 4-6 Checking the valve-cylinder combination 4-6 Locking the manual override ERROR DIAGNOSIS 4-8 Impairment of function 4-8 LED displays of the valves B

60 4. Commissioning 4.1. COMMISSIONING TESTS The following procedure should be adopted for commissioning the valve terminal: Commissioning variants Preliminary test of pneumatic tubing Complete commissioning of whole system Activity Fig. 4/1: Commissioning variants Move valve- cylinder combination by means of manual override Fit and connect the whole system (all field bus slaves). Program control by PLC/industrial PC. Commissioning with the manual override is described overleaf. Commissioning by program is described in the relevant manual for the node B 4-3

61 4. Commissioning Checking the valve functions Manual override WARNING The manual override must be operated only when the electrical power supply to the valves is switched off. Before the valves are operated again with electrical signals, make sure that the manual override is in the basic position. The manual override is used principally during commissioning of the pneumatic system, in order that the user can check the function and effectiveness of the valve or of the valve-cylinder combination. By operating the manual override, the user can switch the valve without the electrical signal. Only the compressed air supply needs to be switched on. 1) 2) 3) 1) Single solenoid valve 2) Double solenoid valve Manual override 3) Mid-position valve Fig. 4/2: Position of the MIDI manual override B

62 4. Commissioning Single solenoid valve Double solenoid valve Mid-position valve Manual override Slot for screwdriver locking pressing locking Fig. 4/3: Position of the MAXI manual override Position of manual override Resulting position of valve slide End position; connection 2 under pressure Mid-position connections 2, 4 without pressure End position; connection 4 under pressure Fig. 4/4: Function of the MAXI manual override 9507 B 4-5

63 4. Commissioning Designs of manual override The manual override has been designed for use as follows: MIDI/ MAXI Manual override design Manual override with automatic reset Manual override locking Method of operation After operation the manual override is reset by spring force. Manual override remains active until it is switched back by hand Fig. 4/5: Designs of manual override Checking the valve-cylinder combination WARNING When pressurizing or repressurizing the valve terminal under the following conditions: by means of the safety start-up valve (slow pressurization) and when electrical signals are present (e.g. after EMERGENCY OFF); Feed the auxiliary pilot air separately via an end plate without regulator (3-5 bar) B

64 4. Commissioning End plate used With regulators Without regulators Pressure increase of complete supply (1) The auxiliary pilot air must be available at full pressure as soon as it is switched on, otherwise the slow pressurization of the complete supply will have no effect with the following cylinders: control by mid-position valve with basic position exhausted control by mid-position valve with basic position blocked control by single solenoid valves control by double solenoid valves which are reversed during the pressureless phase. Pressure increase of auxiliary pilot air 12,14 Time of reversal of a valve slowly slowly after pressure increase in 1 slowly quickly before pressure increase in 1 Fig. 4/6: Effects of slow pressurization with electric signals Movement of the cylinder quickly slowly 1. Switch on the compressed air supply. 2. Check the function and effectiveness of each individual valve-cylinder combination by operating the manual override. 3. Switch the compressed air supply off again when the valves have been tested. Locking the manual override The manual override can be protected against use in systems which are accessible to unauthorised personnel. The manual override can be locked as follows: MIDI/ MAXI By removing the adjusting handle (do not lose) Fig. 4/7: Locking the manual override 9507 B 4-7

65 4. Commissioning 4.2 ERROR DIAGNOSIS Impairment of function When the compressed air supply is switched on or during the subsequent test of the individual valves, the following can be ascertained about the operating status of the pneumatic system: Operating status of pneumatic system Air comes out... of common tubing connections of work tubing connections between the modules Valve or pneumatic system... does not react as expected Valve position Basic position Switch position Basic position Switch position Error treatment when compressed air is switched off Check the seal or tubing (if necessary lightly grease) after switching on again, limit auxiliary pilot air to 3-5 bar Check the tubing does not react Switch position After switching on again check operating pressure (e.g. pressure zones) Service case does not react Basic position Check control connection (apply > 3 bar pressure to regulator) Fig. 4/8: Operating status of the pneumatic system B

66 4. Commissioning If the operating status of the pneumatic system differs from the desired pneumatic status, the following conditions are probably not fulfilled: Desired pneumatic operating status Condition Remarks No leaks Immediate reaction No faults Several pressure zones Vacuum operation/ low pressure operation EMERGENCY OFF in pressure zones Slow switch-on pressurization after EMERGENCY OFF correctly laid tubing controlled auxiliary pilot air (3-5 bar) Sufficient air supply via air supply module Non-return valves in common exhaust tubing Limitation of pressure zones on both sides by either intermediate air supply isolating disc end plate node Seperate supply of controlled auxiliary pilot air (3-5 bar) Regulator for the auxiliary pilot air must function even when main supply is switched off End plates with separate connections for auxiliary pilot air must be used Exhaust valve terminal also at additional air supply modules Applies when several systems with centrallyducted exhaust are used _ High pressure zones near the regulator, lower pressure zones away from the regulator Regulator can only be operated with > 3 bar pressure Regulator controls the auxiliary pilot air for all pneumatic modules With control signals applied, the auxiliary pilot air must be available at full pressure as soon as it is switched on Fig. 4/9: Causes of possible deviations from the nominal status 9507 B 4-9

67 4. Commissioning LED displays of the valves There is a yellow LED for each valve solenoid coil. This LED shows the switching status of the valve solenoid coil LED Switch position valve solenoid coil Meaning yellow LEDs Yellow out Basic position Logic 0 (no signal) Yellow alight switch position or basic position Logic 1 (signal present) Logic 1 but: operating voltage of outputs outside permitted tolerance range (DC 21.6V V) or compressed air supply not correct or pilot line blocked or auxiliary pilot air is outside the range 3-5 bar or service case Fig. 4/10: Example of a LED display of switching status of valve solenoid coil B

68 Appendix A TECHNICAL APPENDIX 9703c A-1

69 Appendix A Inhalt TECHNICAL DATA A-3 Pneumatics A-3 A c

70 Appendix A Medium Fitting position Design Module dimensions/width valves sub-base Multipin-Quader-Sub D ASI bus node input/output modules end plate right air supply module Pressure range with integrated regulator with external auxiliary pilot air Temperature range storage operation medium Technical Data Pneumatics Compressed air, filtered (40 µm), lubricated (oil: VG 32) or non-lubricated/limited vacuum As desired Modular system for central control of valves and for receiving sensor message signals MIDI 18 mm (size 4.0) 36 mm (size 4.0) 45 mm 45 mm 36 mm 27 mm 36 mm bar (NW 4.0) P 12, P14: bar P1: bar C C C Voltages operation DC 24 V ±10 % Valve switching times MIDI (5/2 single) ON: 15 ms, (5/2 double) OFF: 25 ms (5/3 mid-position) SWITCH OVER: 10 ms ON: 15 ms, OFF: 30 ms Protection class IP 65 (completely fitted) as per DIN Materials Valves Sub-base Multipin ASI bus node End plate right Cover plate Seals MAXI 25 mm 50 mm 45 mm 45 mm 36 mm 36 mm 36 mm MAXI ON: 25 ms, OFF: 30 ms SWITCH OVER: 18 ms ON: 25 ms, OFF: 55 ms AL, PEI, POM, PA, PPS, NBR, Ms, St, PC AL AL, St, NBR AL, St, PC, NBR AL AL NBR 9703c A-3

71 Appendix A Starting current consumption per solenoid coil at approx. 24 V (with LED) total with max. no. of valve coils (with LEDs) Power consumption per solenoid coil Manual override of valves single double mid-position Weights end plate without connections input modules multipin node blanking plate field bus node output modules sub-base valves: single double mid-position MIDI 62 ma 1.6 A MIDI 1.5 W MIDI locking non-locking locking MIDI 120 g 360 g 580 g 60 g 1000 g approx. 400 g 300 g 140 g 150 g 160 g MAXI 100 ma 2.6 A MAXI 2.2 W MAXI locking non locking locking MAXI 435 g 360 g 580 g 63 g 1000 g approx. 400 g 552 g 313 g approx. A c

72 Appendix A Rated flows of the MIDI valves [l/min] 5/2 (single), operated/not operated 5/2 (double) op./not op. 5/3 (mid-position), closed, op./not op. 5/3 (mid-position), exhausted, op./not op. 5/3 (mid-position), pressurized, op./not op. Rated flows of the MAXI valves [l/min] *) / /- 500/- 300/- 300/- 300/ /2 (single), operated/not operated 5/2 (double) op./not op. 5/3 (mid-position), closed, op./not op. 5/3 (mid-position), exhausted, op./not op. 5/3 (mid-position), pressurized, op./not op. Standard flow rate [l/min] Flow rates (dependent on standard flow) Torques fastening screws trough bolt screws grooved screw Connections compressed air exhaust auxiliary pilot air pilot exhaust work air -/ /- MIDI -/ /- 500/- 300/- 300/- 300/- 1300/- 1300/- 1300/- 1300/ Nm modules 0.6 Nm valves 1.5 Nm valves MIDI G 3/8 G 1/2 G 1/8 G 1/8 (G 1/4) G 1/8 *) Specifications without screw connectors MAXI MAXI G 1/2 G 1/2 (2x) G 1/4 (G 1/8) G 1/4 size 6 -/ /- 1600/- 1600/- 1600/ / c A-5

73 Appendix A A c

74 Appendix B INDEX 9703c B-1

75 Appendix B B c

76 Appendix B PLEASE NOTE The index is based on key words. It therefore supplements the contents which are based on a function/action-orientated grouping. In the index you will not therefore find "Connecting tubing" but the separate entries "Connections" and "tubing". A Abbreviations Adaption Additional air supply , 3-13, 3-15 Air quality (medium) A-3 Air supply Air supply adapter , 3-13, 3-15 Auxiliary pilot air , 2-9, 3-8 B Blanking plates , 3-5 Blowing out c B-3

77 Appendix B C Calculating the weight Cleaning Combination possibilities Common exhaust connections Components definition Compressed air A-3 Connection element Connections air supply , 3-14 code size tubing Conversion of terminal D Description of function Designation signs , 3-16 Display element E Earthing components , 2-12 valve terminal Electronics manual EMERGENCY OFF , 4-6, 4-9 End plate integrated separate Error diagnosis Exhaust central Extension of terminal B c

78 Appendix B F Fastening eyes Function description G Grooved screw H Hat rail clamping unit , 2-13, 2-15 fitting I Individual air channels Intermediate air supply Isolating disc L LED LED display electronics valves , 4-10 Locations Low pressure Low pressure operation M Manual electronics Manual override locking summary Modules definition summary c B-5

79 Appendix B N Node field bus Non-return valves O Operating element Operating status , P Pressure increase Pressure regulator Pressure zones , 3-11, 3-16, 4-9 Pressurization slow , 4-7, 4-9 R Regulator , 1-11 control pressure Repressurization Reversal S Screw connectors Slow pressurization , 4-6, 4-9 Sub-base Support bracket Switch-on pressurization System structure B c

80 Appendix B T Testing the valves Torques flat head screw , 2-13 locking screw , 2-13 Tubing V Vacuum Vacuum operation , 4-9 Valves combinations locations W Wall fitting , c B-7

81 Appendix B B c