Compact performance. US patent no. 6,077,094. Manual. CPA pneumatics. Valve terminal with. Type CPA... VI. Manual en 0903e [ ] ÔÔ Ô Ô ÔÔ

Transcription

1 US patent no. 6,077,094 Compact performance Manual CPA pneumatic Valve terminal with CPA pneumatics Type CPA... VI ÔÔ Ô ÔÔ ÔÔ ÔÔ ÔÔ Ô ÔÔ ÔÔ ÔÔ Ô Ô Ô ÔÔ ÔÔ Ô ÔÔ Ô Ô ÓÓ Ó ÓÓ ÓÓ Ó Ó ÓÓ ÓÓ ÓÓ Manual en 0903e [ ]

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3 Contents and general instructions Original de Edition en 0903e Designation P.BE CPA EN Order no (Festo AG & Co. KG, D Esslingen, Germany, 2009) Internet: E Mail: service_international@festo.com The reproduction, distribution and utilization of this docu ment as well as the comunication of its contents to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights re served in the event of the grant of a patent, utility module or design. I

4 Contents and general instructions AS Interface is a registered trademark of the AS Interface Association II

5 Contents and general instructions Contents Intended use Target group Service Notes on the use of this manual Important user instructions VII VII VII VIII XIII 1. System summary Overview of variants Description of components Fitting Mounting variants Wall mounting Hat rail mounting Installation Compressed air preparation Operation with unlubricated compressed air Operation with lubricated compressed air General instructions on installation Laying the tubing Connecting the CPA valve terminal Pilot air supply CPA valve terminal with pressure zone separation Vacuum/low pressure operation Connecting the pneumatic lines Connecting the electric cables Address assignment of the valves III

6 Contents and general instructions 4. Commissioning General Information Before commissioning Pressure increase in the overall supply Manual override (MO) Checking the valves and the valve actuator combination LED display of the valves Troubleshooting Impairment of function Operating states of the pneumatic system Maintenance and conversion General preventive action Dismantling the CPA valve terminal Maintenance of the CPA valve terminal Cleaning the flat plate silencer Replacing CPA valve terminal components Replacing valve sub bases, blanking plates or additional supply plates Replacing the large surface mounted silencer Replacing the end plate, sub base or interlinking block Conversion work on the CPA valve terminal Conversion from non detenting to detenting/non detenting manual over ride Conversion to internal or external pilot air supply Converting the CPA valve terminal to different pressure zones Conversion of valve position for actuating one or two solenoid coils Adding/removing valve positions A. Technical appendix A 1 A.1 Technical specifications A 3 A.2 Festo accessories A 10 IV

7 Contents and general instructions B. Supplementary summary of components and fitting instructions B 1 B.1 Overview of valve sub bases B 3 B.2 Disconnecting electronic components from the CPA valve terminal B 6 C. Index C 1 V

8 Contents and general instructions VI

9 Contents and general instructions Intended use The CPA valve terminals described in this manual are in tended for fitting into a machine or automated system. Please observe the safety regulations specified in this manual as well as the instructions concerning the designated use of the relevant CPA valve terminal. CPA valve terminals may only be used as follows: as intended in industrial applications without any modifications by the user. Only the conversions or modifications described in the documentation accompanying the product are permitted. In perfect technical condition. When used together with commercially available compo nents, such as actuators, the specified limits for pressures, temperatures, electrical data, torques etc. must be observed. National and local safety regulations must also be observed. 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. VII

10 Contents and general instructions Notes on the use of this manual This manual contains specific information on fitting, installing, commissioning, servicing and converting the CPA valve ter minal. This manual describes only the pneumatic components and refers to the valve terminal variants listed in the tables below. CPA valve terminal with CPX terminal, type CPA... Information on the electric/electronic components: see manual CPX system, installation and commissioning" ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓÓ Tab. 0/1: CPA valve terminal with CPX terminal Connection variants of the CPA valve terminal CPA valve terminal with IC connection Information on the electric/electronic components: in this manual ÓÓÓ ÓÓÓ ÓÓÓÓ ÓÓÓ ÓÓÓ ÓÓ ÓÓ ÓÓÓ VIII

11 Contents and general instructions Connection variants of the CPA valve terminal CPA valve terminal with MP connection type CPA... IMP Information on the electric/electronic components: see leaflet with product Ó ÓÓÓÓÓ ÓÓÓ Ó ÓÓ ÓÓ CPA valve terminal with CP connection types CPA... IFB CP and CPA... IFB DN Information on the electric/electronic components: see manual CP system, installation and commissioning" ÓÓÓ ÓÓÓ ÓÓÓ Ó ÔÓÓÓ Ó ÓÓ ÔÓÓÓ CPA valve terminal with AS Interface connection type CPA... IFB ASI or CPA... IFB ASI Z Information on the electric/electronic components: see leaflet with product ÓÓÓ ÓÓÓ Ó ÓÓÓÓ Ó Ó Ó Ó CPA valve terminal with AS Interface connection: and 4 inputs type CPA... GE ASI 4E4A Z and 8 inputs type CPA... GE ASI 8E8A Z Information on the electric/electronic components: see leaflet with product ÓÓÓ ÓÓÓÓÓ Ó ÓÓÓ ÓÓÓ Ó Ó Tab. 0/2: Connection variants of the CPA valve terminal IX

12 Contents and general instructions Information on further CP modules or CPX modules can be found in the manual for the relevant module. The table below gives an overview. Manuals on the CPA valve terminal with CPX terminal Manual System manual" type P.BE CPX SYS... Contents Overview of structure, components and method of operation of CPX terminals; instructions on installation and commissioning as well as basic information on parametrizing. Manual CPX fieldbus node" type P.BE CPX FB... CPX I/O modules" type P.BE CPX EA... Valve terminal with CPA pneumatics" type P.BE CPA... or Valve terminal with Midi/Maxi pneumatics" type P.BE MIDI/MAXI Contents Instructions for the assembly, installation, commissioning and diagnosis of the relevant fieldbus nodes Notes on connections and instructions on fitting, in stalling and commissioning input and output modules of type CPX... as well as type CPA... and the Midi/ Maxi pneumatic interface Information on fitting, installing and commissioning the relevant pneumatic modules Ó ÓÓ ÓÓ ÓÓ Ó Tab. 0/3: Manuals on the CPA valve terminal with CPX terminal X

13 Contents and general instructions Manuals on the CP system Peripherals Manual CP system, installation and commissioning" type P.BE CPSYS... Contents General basic information on the method of operation, fitting, installation and commissioning of CP systems. Manual CP fieldbus node, programming and diagnosis" type P.BE CP FB... or P.BE VIFB CPV valve terminal, pneumatics" or CPA valve terminal, pneumatics" type: P.BE CPV... or P.BE CPA... CP modules, Electronics" type P.BE CPEA... Contents Special information on commissioning, programming and diagnosing related to the node used Information on fitting, installing and commis sioning CPA or CPV valve terminals Information on fitting, installing and commissioning CP I/O modules. ÖÖ ÔÔÔÔÔ ÔÔ Ô Ô Tab. 0/4: Manuals on the CP system XI

14 Contents and general instructions The CPA valve terminal consists of the following pneumatic and electrical components: The most important pneumatic components are the valve sub bases, connection sub bases and end plates (see diagram). 1 Valve sub bases 2 Manifold sub bases 3 End plates 1 ÓÓÓÓ ÓÓÓÓ Ó ÓÓÓÓ ÓÓ ÓÓ ÓÓÓÓ ÓÓÓÓ Ó ÓÓÓÓ ÓÓ Fig. 0/1: Main components of the CPA valve terminal This manual contains the documentation for the valve sub bases with Ident. codes B, E, G, H, J, K, M and N (see chapter System overview, description of components"). XII

15 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 picto gram. 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. 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 compo nents. Electrostatically sensitive components may be damaged if they are not handled correctly. XIII

16 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. XIV

17 Contents and general instructions The following product specific terms and abbreviations are used in this manual: Term Additional pressure supply plate AS Interface Blanking plate Cartridge Components Connecting plate CP CP cable CP modules CP system CPA10 CPA14 CPA valve terminal CPA valve terminal with AS Interface connection CPA valve terminal with CP connection Meaning Plate for supplying pressure zones which are in the centre of the CPA valve terminal. In this plate the compressed air is diverted from work connection (2), so that the relevant valve sub bases can be supplied with compressed air. The exhaust air can also be expelled through connection (4). Actuator sensor interface Plate without valve function, for reserving valve positions Plug connection (with/without inner thread) for connecting the supply cables to the CPA valve terminal Common term for pneumatic sub bases, valve sub bases, additional pressure supply plates, blanking plates, end plates, CPX adapters, electrical connection blocks (with IC, MP, CP or AS Interface connection), electrical manifold blocks, cover blocks, end plate covers, silencers Pneumatic manifold sub base with open or closed compressed air channel for one or two single solenoid valves or one double solenoid valve with work connections (2) and (4) Compact Performance Special cable for connecting the different CP modules Collective term for the various modules that can be integrated in a CP system Complete system consisting of CP fieldbus node and CP modules Designation of the CPA valve terminal sizes: CPA valve terminal with micro valve sub bases CPA valve terminal with mini valve sub bases CPA valve terminal (type 12) for CPX terminal, field bus systems, IC, MP, or AS Interface connections CPA valve terminal variant which enables the CPA valve terminal to be connected to the AS Interface bus CPA valve terminal variant with plug and socket which enables the CPA valve terminal to be connected to further CP modules XV

18 Contents and general instructions Term CPA valve terminal with individual connection (IC connection) CPA valve terminal with multi pin connection (MP connection) CPX modules Meaning CPA valve terminal variant on which every solenoid coil can be connected individually with a special cable CPA valve terminal variant with sub D plug via which all solenoid coils are centrally connected Common term for the various modules which can be incorporated in a CPX terminal CPX terminal Modular, electric terminal type 50 Current bridge Electrical connection block End plate I/O Interlinking block MO Pneumatic interface Pneumatic sub base Tubing connection Valve sub base Conducts the power supply from the manifold block to the solenoid coils on CPA valve terminals with MP, CP or AS Interface connection Block with multi pin, CP or AS Interface connection Outer left and right hand end plates of the CPA valve terminal for supplying the valves with compressed air and for conducting the exhaust air, as well as for connecting silencers Input/output modules Block for the electrical linking of the solenoid coils with the electrical connection block or the CPX pneumatic interface Manual override facility The pneumatic interface is the interface between the modular electrical periphery of the CPX terminal and the CPA pneumatics Pneumatic manifold sub base for the valve sub bases, with work connections 2 and 4 and open or closed compressed air channel 1 Connecting the supply lines (tubing) to the CPA valve terminal Plate with one or two single solenoid valves or one double solenoid valve Tab. 0/5: Product specific terms and abbreviations XVI

19 System summary Chapter 1 1 1

20 1. System summary Contents 1. System summary Overview of variants Description of components

21 1. System summary Contents of this chapter This chapter provides an overview of the following for the CPA valve terminal: The connection variants and components of the valve terminal The maximum number of valve positions Identification code of the pneumatic components Connection, display and operating elements Further information Information on the electric multi pin can be found in the brief description of the CPA valve terminal with multi pin connection. 1 3

22 1. System summary 1.1 Overview of variants Festo assists you in solving your automation tasks at machine level with CPA valve terminals. The modular structure of the CPA valve terminal for the CP system enables you to use the CPA valve terminals optimally in your machine or system. Due to its compact structure the CPA valve terminal can be mounted close to the actuators to be actuated. This means that short air supply lines can be used. System losses will therefore be minimized and the times required for pressurizing and exhausting the compressed air tubing will be reduced. This is made possible by the use of very compact valves with sufficient flow, thereby helping to reduce costs. CPA valve terminal with CPX terminal This CPA valve terminal is available with 2 to max. 22 single coil valve positions or up to max. 11 double coil valve positions. A maximum of 22 solenoid coils can be actuated. ÎÎ ÎÎÎÎÎ ÎÎÎ Î Î ÎÎ ÎÎ ÎÎ Fig. 1/1: CPA valve terminal with CPX terminal 1 4

23 1. System summary Electrical connection variants of the CPA valve terminal The CPA valve terminals are available with the following types of electrical connections: 1 MP connection 2 IC connection 3 AS Interface connection 4 CP connection 5 AS Interface connection with inputs 1 2 ÎÎÎ ÎÎÎ Î ÎÎÎ ÎÎÎ Î ÎÎÎÎÎ ÎÎÎÎÎÎ Î ÎÎÎÎ Î ÎÎ ÎÎ ÎÎÎ Î Î 5 ÎÎÎ ÎÎÎÎ ÎÎ ÎÎÎ ÎÎ ÎÎ ÎÎ 4 ÎÎÎ ÎÎÎ ÎÎÎ Î ÎÑÑ ÎÎÎÎ ÎÎÎÎ ÎÑÑÎ ÎÎÎ 3 Î ÎÎ ÎÎ ÎÎÎ ÎÎ Î Fig. 1/2: Variants of the CPA valve terminal 1 5

24 1. System summary CPA valve terminal with IC connection CPA valve terminal with MP connection CPA valve terminal with CP connection CPA valve terminal with AS Interface connection This CPA valve terminal is available with 2 to max. 22 valve positions. The electrical connection of the solenoid coils is made via individual connector plugs. A maximum of 44 solenoid coils can be actuated. This CPA valve terminal is available with 2 to max. 22 single coil valve positions or up to max. 11 double coil valve posi tions. A maximum of 22 solenoid coils can be actuated. The electrical connection of the solenoid coils is made centrally via the multi pin plug. This CPA valve terminal is available with 2 to max. 16 single coil valve positions or up to max. 8 double coil valve posi tions. A maximum of 16 solenoid coils can be actuated. The connection to the higher order fieldbus node is made via special ready to use CP cables. This CPA valve terminal is connected to the AS Interface bus via special AS Interface cables. It is available with the following types of electrical connections: without additional supply connection, type CPA... IFB ASI with additional power supply connection (load voltage can be switched off separately), type CPA... IFB ASI Z with 4 inputs and additional supply connection (load voltage, can be disconnected separately), type CPA... GE ASI 4E4A Z with 8 inputs and additional supply connection (load voltage, can be disconnected separately), type CPA... GE ASI 8E8A Z The first three variants listed above (CPA... IFB ASI, CPA... IFB ASI Z and CPA... GE ASI 4E4A Z) are available with 2 to max. 4 single coil valve positions or up to max. 2 double coil valve positions. A maximum of 4 solenoid coils can be actuated. The variant with 8 inputs (CPA... GE ASI 8E8A Z) is available with 2 to max. 8 single coil valve positions or up to max. 4 double coil valve positions. A maximum of 8 solenoid coils can be actuated. 1 6

25 1. System summary 1.2 Description of components The CPA valve terminal consists of the following electrical components: ÑÑÑ ÑÑÑ ÑÑ ÑÑ Ñ Ñ 6 ÑÑÑ ÑÑÑ ÑÑ CPA valve terminals with AS Interface and inputs: AS Interface module 2 CPA valve terminal: MP, CP or AS Interface sub base 3 Adapter for elect. interlinking with CPX terminal or AS Interface with I/Os 4 The electrical manifold block (manifold block EV1 occupies 1 address, EV2 occupies 2 addresses) 5 Electrical bridge with manual override and LEDs 6 Cover block 7 CPA valve terminals with CPX terminal: CPX pneumatic interface 8 CPA valve terminals with CPX terminal or AS Interface and inputs: Adapter for mounting of the CPX pneumatic interface or the AS Interface module Fig. 1/3: Electrical components of the CPA valve terminal 1 7

26 1. System summary 1 2 The CPA valve terminal consists of the following pneumatic components: ÑÑ ÑÑÑÑ Ñ Ñ 2 3 ÑÑÑ ÑÑÑ Ñ ÑÑ ÑÑ End plate cover or large surface mounted silencer 2 Valve sub bases with single solenoid or double solenoid valves 3 Right hand end plate with supply and exhaust connections 4 Additional supply plate or blanking plate 5 Sub base: with work connections with/without pressure zone separation in combination with supply plate for the compressed air supply 6 Left hand end plate with supply and exhaust connections Fig. 1/4: Pneumatic components of the CPA valve terminal 1 8

27 1. System summary The max. number of valve positions on the CPA valve terminal variants is shown in the following table. Max. number of valve positions CPA valve terminal with If only the manifold block EV1 is used (for valve sub base with one solenoid coil) If only the manifold block EV2 is used (for valve sub base with two solenoid coils) Maximum number of solenoid coils which can be actuated CPX terminal IC connection MP connection CP connection 22 2) (8) 11 2) (4) (8) AS Interface connection 1) 1) Values in brackets for variants with 8 inputs type CPA... GE ASI 8E8A Z 2) In the case of CPA valve terminals with IC connection, the maximum number of valve positions is limited to 22 due to the tie rod. Tab. 1/1: Maximum number of valve positions depending on the CPA valve terminal variants Sizes of the CPA valve terminal All CPA valve terminal variants are available with micro valves (valve width 10 mm, CPA10) or with mini valves (valve width 14 mm, CPA14). Mixed operation with valves of both sizes in not possible on a CPA valve terminal. 1 9

28 1. System summary By means of the identification code, you can ascertain which valve sub bass are fitted on your CPA valve terminal. This code is printed on the front of the valve sub base. Ident. code B D E G H J K M N T Y Tab. 1/2: Pneumatic components Valve sub base, 5/3 way, mid position pressurized Additional supply plate, for compressed air supply of three and more pressure zones Valve sub base, 5/3 way, mid position exhausted Valve sub base, 5/3 way, mid position closed Valve sub base, two 3/2 way, control side 12 normally open, control side 14 normally closed Valve sub base, 5/2 way, double solenoid Valve sub base, two 3/2 way, single solenoid, normally closed Valve sub base, 5/2 way, single solenoid Valve sub base, two 3/2 way, single solenoid, normally open Sub base for pressure zone separation, compressed air channel (1) blocked Valve sub base, 5/2 way, single solenoid on two coil valve position Ident. code of the pneumatic components Further information on the valve sub bases can be found in appendix A. 1 10

29 1. System summary CPA valve terminal with IC connection You will find the following connecting, display and operating elements on the CPA valve terminal: CPA valve terminal with MP, CP or AS Interface connection or with CPX terminal Î ÎÎ ÎÎ ÎÎÎÎÎ ÎÎÎÎ ÎÎÎ ÎÎÎÎ Î ÎÎÎÎ Î ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎÎÎ ÎÎÎÎ ÎÎÎÎÎÎÎÎ Î ÎÎÎÎÎ ÎÎÎ ÎÎÎÎÎ Î Î ÎÎÎ ÎÎ ÎÎÎ ÎÎ ÎÎ Manual override (per pilot solenoid coil, non detenting or detenting) 2 Clip (only with detenting manual override) 3 Supply connections (1), (12/14) and exhaust connections (3/5) on the right hand end plate 4 Work connections(2), (4) per valve sub base 5 Supply connection (1) and exhaust connections (3/5), (82/84) on the left hand end plate Fig. 1/5: Pneumatic connecting and operating elements of the CPA valve terminal 1 11

30 1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal: ÎÎ Î ÎÎ ÎÎ ÎÎ ÎÎ ÎÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ ÎÎ ÎÎ ÎÎÎÎÎÎ Î ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ Pre assembled cable with socket for connecting a solenoid coil 2 Clip with inscription field (per cable socket) 3 Yellow LED per cable socket, shows signal status of the pilot solenoid coils 4 Terminal lugs of pilot solenoid coils 12 5 Terminal lugs of pilot solenoid coils 14 Fig. 1/6: Electrical connecting and display elements of the CPA valve terminal with IC connection 1 12

31 1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal with MP connection: 1 2 ÎÎ ÎÎ ÎÎÎÎÎ ÎÎ ÎÎ ÎÎÎÎÎ ÎÎ ÎÎ ÎÎÎÎÎ Î Î ÎÎÎÎÎ Î Î ÎÎ ÎÎ ÎÎ ÎÎ 3 1 Inscription clips 2 Yellow LEDs, signal status displays of the pilot solenoid coils 3 SUB D multi pin plug (25 pin) Fig. 1/7: Electrical connecting and display elements of the CPA valve terminal with MP connection 1 13

32 1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal with CP connection: ÎÎ ÎÎ 6 5 ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÑÑ Î ÎÎÎÎÎ ÑÑ Î ÎÎ ÎÎÑÑ ÎÎÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ Î 4 1 Green LED, status display of the CP connection 2 Incoming CP cable 3 Yellow LEDs, signal status displays of the pilot solenoid coils 4 Continuing CP cable 5 Earth terminal 6 Inscription clips Fig. 1/8: Electrical connecting and display elements of the CPA valve terminal with CP connection 1 14

33 1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal with AS Interface connection: ÎÎ Î ÎÎÎ ÎÎÎÎ ÎÎÎ ÎÎÎ ÎÎ ÎÎ ÎÎ Î ÎÎÎ ÎÎÎÎÎÎ ÎÎ ÎÎ AS Interface cable cap 2 Inscription clips of the valve sub bases 3 Yellow LEDs, signal status displays of the pilot solenoid coils 4 Inscription clips of the AS Interface connection 5 AS Interface bus socket with yellow bus cable 6 Earth terminal 7 Green LED, status display of the CP connection 8 Cable socket for additional supply with black additional supply cable (optional) Fig. 1/9: Electrical connecting and display elements of the CPA valve terminal with AS Interface connection 1 15

34 1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal with AS Interface connection and inputs: ÎÎ ÎÎÎÎÎ ÎÎ ÎÎÎÎÎ ÎÎ ÎÎÎÎÎ ÎÎ Î ÎÎÎÎÎ Î ÎÎÎ ÎÎ Sub base for inputs with viewing window for LEDs 2 Inscription fields for addresses 3 Status LEDs: Inputs (green) Valves (yellow) 4 Cover 5 DIL switch (under cover) 6 Flat cable connections for AS Interface: Bus: Bus connection (yellow cable) 24V DC: Auxiliary power supply (black cable) 7 M12 connector for AS Interface bus and additional power supply 8 Addressing socket 9 AS Interface LEDs: ASI LED (green) Fault LED (red) AUX/PWR LED (green) Fig. 1/10: Electrical connecting, display and control elements of the CPA valve terminal with AS Interface connection and inputs 1 16

35 1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal with CPX terminal: ÎÎ ÎÎÎ ÎÎÎÎÎ Î Î ÎÎÎÎÎ ÎÎ ÎÎ ÎÎÎÎÎ Î ÎÎ Î ÎÎ ÎÎÎ ÎÎ ÎÎ ÎÎÎÎ 1 Red LED, fault display of the pneumatic interface 2 DIL switch for setting the number of valve addresses 3 Inscription clips 4 Yellow LED, signal status displays of the pilot solenoids Fig. 1/11: Electrical connecting and display elements of the CPA valve terminal with CPX terminal Detailed instructions on the CPX pneumatic interface can be found in the supplementary manual for the CPX I/O modules (P.BE CPX EA...). 1 17

36 1. System summary 1 18

37 Fitting Chapter 2 2 1

38 2. Fitting Contents 2. Fitting Mounting variants Wall mounting Hat rail mounting

39 2. Fitting Contents of this chapter This chapter explains how you should fit and dismantle the complete CPA valve terminal. Additional information Special information on replacing or adding pneumatic components can be found in chapter 5. CPA terminal with CPX terminal: Information on fitting the CPA valve terminal with CPX terminal can be found in the CPX system manual. Information on fitting and dismantling the module electronics and sub bases can be found in the Manual for CPX I/O modules" and in the leaflet supplied with the product in the case of modules and components ordered at a later stage. 2 3

40 2. Fitting 2.1 Mounting variants Warning Uncontrolled movements of the connected actuators and uncontrolled movements of loose tubing can cause injury to persons and/or damage to property. Before carrying out fitting, installation and maintenance work, switch off the following: compressed air supply operating and load voltage supplies. Note Handle all modules and components of the CPA valve terminal with great care. Note especially the following: The specified torques must be observed. Electrostatic sensitive devices. Do not touch any contact surfaces. The CPA valve terminal has already been prepared for incorporation in a system or machine using one of the following fitting variants: Wall mounting H rail mounting Note Mount the CPA valve terminal so that there is sufficient space for heat dissipation and so that the maximum limits for temperatures can be observed (see Technical Specifications). 2 4

41 2. Fitting Wall mounting Fitting the CPA valve terminal with CPX terminal onto a wall is described in the system manual P.BE CPX SYS... Fitting Proceed as follows: 1. Make sure that the mounting surface can support the weight of the CPA valve terminal (weights see appendix A). 2. Make sure there is sufficient space for connecting the power supply cables and tubing. 3. Drill four mounting holes in the mounting surface (distance between holes see illustrations) and fasten the CPA valve terminal with M4 screws (tightening torque 0.8 Nm). 4 ÓÓÓ ÓÓÓ ÓÓÓ ÓÓÓ ÓÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ CPA10 terminal mm 2 23 mm mm x number of sub bases 4 4 holes for fitting onto a wall CPA14 terminal mm 2 26 mm mm x number of sub bases 4 4 holes for fitting onto a wall Fig. 2/1: Mounting holes, CPA valve terminal 2 5

42 2. Fitting 1 1 Ó Ó Ó ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ All dimensions in millimetres CPA10 GE ASI... Z 1 Wall mounting holes mm mm mm + (10.6 mm x number of sub bases) 4 CPA14 GE ASI... Z 1 Wall mounting holes mm mm 4 52 mm + (14.6 mm x number of sub bases) Fig. 2/2: Wall mounting holes, CPA valve terminal with AS Interface and inputs 2 6

43 2. Fitting Dismantling Proceed as follows: 1. Prevent the hanging CPA valve terminal from falling down before you loosen it from the mounting surface. 2. Loosen the fastening screws as shown in the following diagram and remove the CPA valve terminal from the mounting surface. CPA variants Fastening ÓÓÓ ÓÓÓ CPA valve terminal: Two screws on both the left and right hand end plates Ó Ó Ó Ó CPA valve terminal with AS Interface and inputs: One screw on the left hand end plate and 2 screws on the right hand end plate of the CPA pneumatics Two screws on both the left and right hand side of the AS Interface module ÓÓÓ ÓÓÓ CPA terminal with CPX terminal: One screw on the left hand end plate and 2 screws on the right hand end plate of the CPA valve terminal 2 screws on the CPX pneumatic interface 2 screws on the left hand end plate of the CPX terminal Tab. 2/1: Removing the CPA valve terminal fitted onto a wall 2 7

44 2. Fitting Hat rail mounting Note H rails fitted with CPA14 valve terminals can break if they are subjected to vibration which exceeds the following values: 0.15 mm travel at Hz, 2 g acceleration at Hz, This can cause damage to the CPA valve terminal or to your machine or system. Use the wall fitting for CPA14 valve terminals. Fitting the CPA valve terminal with CPX terminal onto a H rail is described in the system manual P.BE CPX SYS... For H rail mounting of the CPA valve terminal, you will need the corresponding mounting kit (see table). CPA valve terminal... Mounting kit Scope of delivery with CPX terminal with AS Interface and inputs with IC connection with MP connection with CP connection with AS Interface connection CPX10/14 BG NRH CPA BG NRH 3 M4 x 10 screws 3 clamping components 2 M4 x 10 screws 2 clamping components Tab. 2/2: H rail mounting kits 2 8

45 2. Fitting Fitting Proceed as follows: 1. Make sure that the mounting surface can support the weight of the CPA valve terminal (weights see appendix A). 2. Fit the H rail (DIN mounting rail EN x7.5; width 35 mm, height 7.5 mm). Make sure that there is suffi cient space for connecting the supply cables and tubing. 3. Fasten the H rail to the mounting surface at intervals of approx. every 100 mm. 4. Mount the H rail clamping units on the end plates of the CPA valve terminal (see diagram). 5. Hang the CPA valve terminal onto the H rail (see arrow A). 6. Swing the CPA valve terminal onto the H rail (see arrow B). Make sure that the clamping component lies horizontally to the H rail. 7. Fasten the CPA valve terminal against tilting or sliding by tightening the retaining screws on both sides with 1.3 Nm. 1 H rail 2 Clamping component of the H rail clamping unit 3 Self tapping M4x10 screw of the H rail clamping unit ÓÓ ÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÔÔ ÔÔ ÔÔ ÔÔ ÔÔ ÔÔ ÔÔ ÖÖ ÔÔ ÔÔ ÔÔ ÔÔ ÔÔ (A) 1 (B) 2 3 Fig. 2/3: Fitting the CPA valve terminal onto an H rail 2 9

46 2. Fitting Dismantling Proceed as follows: 1. Loosen the retaining screw of the H rail clamping unit on the left and right hand end plates (see diagram). Make sure that the clamping component lies horizontally to the H rail. 2. Swing the CPA valve terminal forwards from the H rail (see diagram, arrow B). 3. Lift the CPA valve terminal off the H rail (see diagram, arrow A). 1 H rail 2 Clamping component of the H rail clamping unit 3 Retaining screw of the H rail clamping unit ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓ ÓÓ ÔÔ ÔÔÔ ÔÔ ÔÔ ÔÔ ÖÖÔÔ ÔÔ ÔÔ ÔÔÔ ÔÔ ÔÔ (A) 1 (B) 2 3 Fig. 2/4: Dismantling the CPA valve terminal 2 10

47 Installation Chapter 3 3 1

48 3. Installation Contents 3. Installation Compressed air preparation Operation with unlubricated compressed air Operation with lubricated compressed air General instructions on installation Laying the tubing Connecting the CPA valve terminal Pilot air supply CPA valve terminal with pressure zone separation Vacuum/low pressure operation Connecting the pneumatic lines Connecting the electric cables Address assignment of the valves

49 3. Installation Contents of this chapter This chapter describes the tubing and cabling of the CPA valve terminal. This includes in particular the following: General instructions on preparing the compressed air and on connecting the tubing Instructions on operation with an internal or external pilot air supply Instructions on operating CPA valve terminals with pressure zone separation Fitting the QS threaded connectors/cartridges Connecting the power supply Earthing the CPA valve terminal with CP or AS Interface connection (not with CPA valve terminal with AS Interface and inputs) Address assignment of the valves Further information Information on power supply to the CPA valve terminal with CPX terminals can be found in the CPX system manual Instructions on the electrical connections of the CPA valve terminal with multi pin or AS Interface connection can be found in the leaflet supplied with the product. Information on connecting the CPA valve terminal with CP connection can be found in the CPsystem manual. Information on connecting the CPA valve terminal with CPX terminal can be found in the CP system manual. 3 3

50 3. Installation 3.1 Compressed air preparation Caution Dirty or incorrectly lubricated compressed air will reduce the service life of the valve terminal Operation with unlubricated compressed air Caution Too much residual oil content 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). This avoids operative malfunction of 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

51 3. Installation Operation with lubricated compressed air Operate system equipment with unlubricated compressed air if possible. This will prevent pollution of the environment. Festo pneumatic valves and actuators have been designed so that, if used as intended, they will not require additional lubrication and will still achieve a long service life. Caution Operation with lubricated compressed air will cause the life time lubrication, which is necessary for unlubricated operation, to be washed out". Note the following instructions if lubricated compressed air must be used. The compressed air prepared with the compressor must correspond in quality to unlubricated compressed air. If possible, do not operate all of your equipment with lubricated compressed air. The lubricators should, where possible, always be installed directly upstream of the actuator used. Caution Incorrect additional oil and too much residual oil content in the compressed air will reduce the service life of the valve terminal. Use the special oil OFSW 32 from Festo or the alternative oils listed in the Festo catalogue (corresponding to DIN 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). This avoids operative malfunction of the valves. 3 5

52 3. Installation Setting the lubricator: Checking the setting: With the machine running (typical operating status) 0.2 to max. 1 drops/min. or 0.5 to 5 drops/1000 l air. The procedure described below can be used for checking the setting of the lubricator. Proceed as follows: Check the service units in respect of condensate and lubricator setting twice a week. 1. Ascertain the actuator which is furthest from the lubricator. 2. Ascertain the valve terminal which controls this cylinder. 3. Remove the silencer, if fitted, from port (3/5). 4. Hold a piece of white cardboard 10 cm in front of the exhaust port. 5. Let the system run for a short period. There must be only a slight yellow colouring on the cardboard. If oil droplets appear, this is an indication that too much oil has been used. Another indicator of over lubrication is the coloration or the condition of the exhaust air 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

53 3. Installation 3.2 General instructions on installation Warning Uncontrolled movements of the connected actuators and uncontrolled movements of loose tubing can cause injury to persons and/or damage to property. Before carrying out fitting, installation and maintenance work, switch off the following: compressed air supply operating and load voltage supplies. Pay attention to the following: The components of the valve terminal contain electrostatically sensitive elements. The components will be damaged if you touch the contact surfaces of the plug connectors or if you do not observe the handling specifications for electrostatically sensitive components. 3 7

54 3. Installation 3.3 Laying the tubing If elbow connectors or multiple distributors are used, the airflow will be reduced slightly. Connecting Proceed as follows: 1. Push the tubing as far as possible into the tube coupling of the cartridge 1 (see Fig. 3/1). 2. If necessary, pull the locking ring 2 over the tube coupling. 3. For reasons of clarity, group the tubing together with: tubing straps or multiple hose holders. 1 Cartridge insert 2 Locking ring 1 2 Fig. 3/1: Fitting the tubing Disconnecting Proceed as follows: Warning If the pneumatic tubing is under pressure when disas sembled, it may perform sudden unexpected movements, causing injury to persons. Carry out the following steps before disconnecting the pneumatic tubing on the valve terminal: Switch off the compressed air supply. Make sure that all pneumatic tubing is pressureless. Exhaust all actuators controlled by valves which are closed in normal or mid positions. 3 8

55 3. Installation Note To disconnect the hoses in the cartridges, use releasing tool type QSO from Festo, or a screwdriver. When using a screwdriver: Press down the locking ring only with the broad side of the blade. 1. Press down the locking ring 2 of the cartridge Pull out the tubing. 3. Seal unused connections with blanking plugs 3. 1 Cartridge insert 2 Locking ring 1 3 Blanking plug 2 3 Fig. 3/2: Disconnecting the tubing 3 9

56 3. Installation 3.4 Connecting the CPA valve terminal In the case of sub bases fitted with blanking plates, seal the working lines (2) and (4) with blanking plugs or blanking plugs to prevent dirt from entering. In order to guarantee the optimum efficiency of your CPA valve terminal, we recommend in the following cases that you connect the compressed air tubing and, if necessary, also the exhaust air tubing on both sides: when large volume cylinders are operated at high speeds when several valves are switched simultaneously to the flow position Pilot air supply Caution If possible, operate the CPA valve terminal with non lubricated pilot air (connections 12/14). Otherwise observe the instructions in the section With CPA valve terminals with internally branched pilot air supply, the above mentioned instruction also applies to the supply air (port (1)). With CPA valve terminals with two pressure zones and internally branched pilot air: Due to the internally branched pilot air supply in the right end plate, the pressure in the right hand pressure zone must be bar. Pilot control of the valve solenoid coils can be undertaken with internal or external pilot air, depending on the right end plate. You can ascertain the pilot control variant for which your CPA valve terminal is equipped by the type designation on the right end plate (see table). 3 10

57 3. Installation CPA valve terminal with external pilot air supply with internal pilot air supply Right end plate type CPA... EPR S CPA... EPR Tab. 3/1: End plates for internal or external pilot air supply Internal pilot air supply If the supply pressure of your CPA valve terminal lies between bar, you can operate the pilot control with internally branched pilot air. The pilot air supply in the right end plate is branched here from supply channel 1. Note Internal pilot air supply is branched centrally from supply port (1) to the right end plate for all pilot controls. This also applies if the MPA valve terminal is operated with several pressure zones (see Fig. 3/6). If the CPA valve terminal with internal pilot air supply is used, the port (12/14) must be fitted with a blanking plug (Fig. 3/3). ÓÓ ÓÓÓ ÓÓÓ ÓÓÓÓÓ ÓÓ ÓÓÓÓÓ Ó ÓÓ ÓÓÓÓÓ Ó ÓÓ ÓÓ ÓÓ Ó ÓÓ 1 1 Port (12/14) Fig. 3/3: Internal pilot air supply 3 11

58 3. Installation External pilot air supply If the supply pressure lies below 3 bar or above 8 bar, pilot control of the valve solenoid coils must be carried out with external pilot air. In this case, the pilot air is supplied externally via the pilot port (12/14). Note Use closed loop regulated external pilot air ( bar), reliable faultless operation of the CPA valve terminal is then possible, e.g. even with fluctuating supply pressure. The external pilot air is supplied centrally via pilot port 12/14 on the right end plate. This also applies when the CPA valve terminal is operated with different pressure zones (see Fig. 3/6). If your CPA valve terminal is fitted with valve sub bases with Ident. code H, K or N (3/2 way valves), the external pilot air supply must be set to correspond with the supply pressure at which these valve are operated (see diagrams). 1 Pilot pressure of the external pilot air supply at port (12/14) [bar] 3 2 Supply pressure at port (1) [bar] 1 3 Switch on pilot pressure of the pilot control 2 Fig. 3/4: Diagram for CPA10: External pilot air supply as a factor of the supply pressure for valve sub bases with Ident. code N, K and H 3 12

59 3. Installation 1 Pilot pressure of the external pilot air supply at port (12/14) [bar] 3 2 Supply pressure at port (1) [bar] 1 3 Switch on pilot pressure of the pilot control 2 Fig. 3/5: Diagram for CPA14: External pilot air supply as a factor of the supply pressure for valve sub bases with Ident. code N, K and H CPA valve terminal with pressure zone separation The CPA valve terminal can be fitted with the following number of pressure zones depending on the connection variant: Electrical connection variant IC, MP or CPX CP AS Interface Pressure zones Tab. 3/2: Maximum number of pressure zones The pressure zones are implemented by means of special sub bases which block the compressed air channel (1). 3 13

60 3. Installation Note Note the following in the case of CPA valve terminals which are operated with internal pilot air supply and which have two or more pressure zones: The pilot air supply for all pilot controls is branched centrally from supply port (1) in the right end plate (see Fig. 3/6). The pressure zone on the outside right (supplied via supply port (1) of the right end plate), must be operated with a pressure of between bar. Note Valve sub bases on sub bases with pressure zone separation are supplied with compressed air which is provided to the left of the sub bases (see Fig. 3/6). You can ascertain the number of pressure zones with which your CPA valve terminal is equipped,by the designation on the special sub base (grey dot above work connection (2)). CPA valve terminal with two pressure zones These CPA valve terminals have a sub base with pressure zone separation. The left hand pressure zone is supplied with compressed air via port (1) on the left end plate, while the right pressure zone is supplied with compressed air via port (1) on the right end plate. 3 14

61 3. Installation CPA valve terminal with more than two pressure zones A sub base with pressure zone separation is required for each pressure zone. The external pressure zones are supplied with compressed air via port (1) on the end plates, while the other pressure zones are supplied with compressed air via port (2) of the sub bases, which are equipped with additional compressed air supply plates (see fig.). To remove the exhaust air, a silencer can be installed in port (4) of these sub bases. If port (4) is not used, it must be sealed with a blanking plug. ÓÓÓ ÓÓÓ ÓÓÓ Ö Ó ÓÓÓ ÓÓÓ ÓÓÓ Additional pressure supply plate 2 Designation of the sub bases with pressure zone separation (grey dot) 3 Pressure zone 1 (compressed air supply via port (1) of the left end plate) 4 Pressure zone 2 (compressed air supply via port (2) of the sub base with additional compressed air supply plate) 5 Pressure zone 3 (compressed air supply via port (1) of the right end plate) Fig. 3/6: Example: Pressure zone separation and external pilot air supply 3 15

62 3. Installation Vacuum/low pressure operation The CPA valve terminal can be operated with vacuum or low pressure, bar under the following conditions: Note Valve sub bases with 3/2 way valves (Ident. code N, K or H) are not suitable for operation with vacuum or low pressure. Operate these valves in a separate pressure zone. The supply pressure for this pressure zone must be set in accordance with the diagram in Fig. 3/4 (CPA10) or Fig. 3/5 (CPA14) The following conditions must be fulfilled, in order that you can operate your CPA valve terminal at supply port 1 with vacuum or low pressure between bar: The pilot control is operated with regulated external pilot air supply. The valve terminal is fitted with the following valve sub bases: 5/2 way valve, single solenoid (Ident. code M) 5/2 way valve, double solenoid (Ident. code J) 5/3 way valves pressurized in mid position (Ident. code B), blocked (Ident. code G) or exhausted (Ident. code E). 3 16

63 3. Installation Connecting the pneumatic lines Note Seal unused connections on the CPA valve terminal with blanking plugs. Fit the tubing as described below. Then lay the tubing. Note On CPA valve terminals with large surface mounted silencers, exhaust connections (3/5) and (82/84) are routed via the silencer. Port (82/84) on the left end plate is then sealed with a blanking plug. ÓÓÓ ÓÓ Ó ÓÓÓÓÓÓ ÓÓ ÓÓ ÓÓÓÓÓÓ ÓÓ ÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ ÓÓ 3/5 12/14 3/5 82/ Fig. 3/7: Pneumatic connections on the CPA valve terminal 3 17

64 3. Installation Proceed as follows: 1. Use the following table for selecting the correct cartridge: Connection identifier ISO 5599 Line CPA10 terminal Cartridge size CPA14 terminal Cartridge size (1) (3/5) Compressed air/vacuum, exhaust air Tube coupling: QSP14 6 QSP14 8 QSP14 1/4 U QSP14 5/16 U Blanking plugs: QSP14 PTB Tube coupling: QSP18 8 QSP18 10 QSP18 5/16 U QSP18 3/8 U Blanking plugs: QSP18 PTB (2) or (4) (12/14) (82/84) CPA14 terminal: Values in brackets for (12/14) or (82/84) Work air/vacuum, additional pressure supply, exhaust of pilot air supply Tube coupling: QSP10 4 QSP10 6 QSP10 5/32 U QSP10 3/16 U Blanking plugs: QSP10 PTB Silencer: UC QS 6H UC QS...H Tube coupling: QSP14 6 (QSP10 4) QSP14 8 (QSP10 6) QSP14 1/4 U (QSP10 5/32 U) QSP14 5/16 U (QSP10 3/16 U) Blanking plugs: QSP14 PTB (QSP10 PTB) Tab. 3/3: Cartridge 2. Check that the seal of the cartridge is greased. If necessary, grease the seal with Festo F2 grease. 3. Press the cartridges into the ports. 4. Make sure that the cartridge is seated as far as possible in the hole. Measure here the distance between the connection surface and the locking ring (see diagram). 3 18