Valve terminal CDVI. Description of CDVI pneumatics. Valve terminal type 15 Clean Design Type: CDVI Description en 1202e [762312]

Transcription

1 Valve terminal CDVI Description of CDVI pneumatics Valve terminal type 15 Clean Design Type: CDVI Description en 1202e [762312]

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3 Contents and general safety instructions Original... de Edition... en 1202e Designation... P.BE-CDVI-EN Order-no (Festo AG & Co. KG, D Esslingen, Federal Republic of Germany, 2012) Internet: The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders shall be held liable for payment of damages. All rights are reserved, in particular the right to carry out patent, registered design or ornamental design registration. I

4 Contents and general safety instructions II

5 Contents and general safety instructions Contents Intended use... Target group... Service... Notesontheuseofthismanual... Important user instructions... Abbreviations... V VI VI VII IX XI 1. Overview of components The Clean Design valve terminal (CDVI) from Festo Description of variants Description of components In-line valve manifolds End plates Valves Connection, display and control elements Assembly Mounting the valve terminal Wall mounting Installation Compressed air preparation Operation with unlubricated compressed air Operation with lubricated compressed air General instructions on installation Laying the tubing Notes on installing the CDVI Pilot control of the solenoid coils (pilot air supply) CDVI with pressure zone separation Operating the CDVI with vacuum/low pressure Connecting the CDVI Connecting the pneumatic lines III

6 Contents and general safety instructions Connecting the electric cables Address assignment of the valves Commissioning Instructions on commissioning Before commissioning Pressure increase in the overall supply Checking the valves and the valve-actuator combination Manual override Checking LED displays of the valves Troubleshooting Impairment of function Operating status of the pneumatic system Cleaning, maintenance and conversion Cleaning the CDVI General preventive action Dismantling/fitting the CDVI Replacing valve terminal components Valves and blanking plates Extension and conversion of the valve terminal Expansion block Pilot air supply Pressure zones End plates A. Technical appendix... A-1 A.1 Technical data... A-3 A.2 Accessories... A-9 A.3 Overview of the valves for the CDVI... A-10 B. Index... B-1 IV

7 Contents and general safety instructions Intended use The valve terminals described in this manual are intended for fitting into a machine or automated system. Please observe the safety regulations specified in this manual as well as the instructions concerning the intended use of the specific valve terminal. The valve terminals may only be used as follows: As specified in industrial applications. In original condition without unauthorised alterations. Only the conversions or modifications described in the documentation supplied with the product are permitted. In perfect technical condition. When used together with commercially available components, 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. If implementing an emergency stop function, note the measures listed in Chapter Range of application and certifications The product fulfils the requirements of EU directives and is marked with the CE marking. Standards and test values, which the product must comply with and fulfil, can be found in the section Technical data. The product-relevant EU directives can be found in the declaration of conformity. V

8 Contents and general safety instructions Target group This manual is directed exclusively at technicians trained in control and automation technology. Service Please consult your local Festo Service if you have any technical problems. VI

9 Contents and general safety instructions Notes on the use of this manual This manual contains specific information on fitting, installing, commissioning, servicing, converting and cleaning the CDVI. The manual describes only the following pneumatic components: 2/2-way valves (monostable) Two 3/2-way valves (monostable) per valve housing 3/2-way valves (monostable), with external compressed air supply 5/2-way valve (monostable and bistable) 5/3-way mid-position valves Manifold block Expansion block (with 1 or 2 valve positions) without additional supply Expansion block (with 1 or 2 valve positions) without additional pneumatic supply Expansion block (with 1 or 2 valve positions) with additional electrical supply (only on fieldbus version) Expansion block (with 1 or 2 valve positions) with additional pneumatic and electrical supply (only on fieldbus version) Separator plates without duct separation or separator plates with duct separation for forming up to 9 pressure zones Right-hand end plates for internal or external pilot air supply Left-hand end plate, on the CDVI-MP with internal multi-pin plug connection VII

10 Contents and general safety instructions Technical specifications for the above-named components can be found in the appendix. Notes on the electrical installation of the CDVI with multi-pin plug connection can be found in the brief description of this valve terminal. Instructions on the electrical installation of the CDVI with fieldbus direct connection DeviceNet can be found in the electronics description CDVI-DN (P.BE-CDVI-DN-...). VIII

11 Contents and general safety instructions Important user instructions Danger categories This manual contains instructions on the possible dangers which can 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... means that failure to observe this instruction may result in serious personal injury or damage to property. Caution... means that failure to observe this instruction may result in personal injury or damage to property. Note... means that failure to observe this instruction may result in damage to property. The following pictogram marks passages in the text which describe activities using electrostatically sensitive devices. Electrostatically sensitive devices: inappropriate handling can result in damage to components. IX

12 Contents and general safety instructions Identification of specific information The following pictograms mark passages in the text which contain special information. Pictograms Information: Recommendations, tips and references to other sources of information. Accessories: Information on necessary or useful accessories for the Festo product. Environment: Information on the environmentally friendly use of Festo products. Text designations The bullet indicates activities which may be carried out in any order. 1. Digits indicate activities which must be carried out in the specified sequence. Arrowheads indicate general lists. X

13 Contents and general safety instructions Abbreviations The following product-specific terms and abbreviations are used in this manual: Term / abbreviation Bi-expansion block Blanking plate CDVI-DN CDVI-FB CDVI-MP CDVI/terminal or valve terminal Component DI connection End plate Ident. code/i.d. Connection block Manifold block MO Mo expansion block MP connection Regulators Meaning Expansion block that supports triggering 2 solenoid coils per valve position. Plate with hood for covering an unused valve position (vacant position) CDVI with fieldbus direct link DeviceNet General for CDVI with fieldbus direct link CDVI with electrical multi-pin plug connection (MP connection) Clean Design Valve terminal (type 15) Common term for manifold blocks, expansion blocks, end plates, valves and blanking plates Fieldbus direct. This variant of the CDVI can be connected directly to the appropriate fieldbus, e.g. DeviceNet. Blanking plate at the left and right-hand ends of the CDVI with connections for supplying the valves with compressed air and for removing the exhaust air. Identification code General for manifold block and expansion block Connection block with 4 or 8 valve positions that always supports triggering 2 solenoid coils per valve position Manual override Expansion block that supports triggering 1 solenoid coil per valve position Valve terminal variant with multi-pin plug connection and cable. All solenoid coils are connected centrally via the multi-pin cable. Pressure regulator XI

14 Contents and general safety instructions Term / abbreviation Separator plate Tubing connection Meaning Sealing variant with open or closed supply ducts. The variants with closed supply ducts serve to form pressure zones. Connecting the supply lines (tubing) to the CDVI. Tab. 0/1: Index of terms and abbreviations XII

15 Overview of components Chapter 1 Overview of components 1-1

16 1. Overview of components Contents 1. Overview of components The Clean Design valve terminal (CDVI) from Festo Description of variants Description of components In-line valve manifolds End plates Valves Connection, display and control elements

17 1. Overview of components Contents of this chapter This chapter provides an overview of the following aspects of the CDVI: Variants of the valve terminal The components of the valve terminal Identification code of the pneumatic components Connection, display and control elements Further information Information on the electrical components of the CDVI with MP connection can be found in the brief description of the Clean Design valve terminal (CDVI, type 15) with multi-pin connection. Information on the electrical components of the CDVI with DI connection DeviceNet can be found in the Electronics Manual CDVI-DN. 1-3

18 1. Overview of components 1.1 The Clean Design valve terminal (CDVI) from Festo The CDVI from Festo is a valve terminal especially for the splash range in the food and packing industry. It offers the following advantages: Easy to clean (larger spaces between the valves, no sharp edges, no narrow radii, no dirty corners) Increased resistance to corrosion Resistance to acid and alkaline cleaning agents Complies with relevant protection classes (see Appendix A Technical data ). Low maintenance Pre-assembled valves Wired solenoid coils Central air supply Centrally ducted exhaust air Inspected unit Extension/conversion possible at a later stage 1-4

19 1. Overview of components 1.2 Description of variants The CDVI is available with the following alternative electrical connections: CDVI variant Remarks CDVI with MP connection With this CDVI, the multi-pin cable has already been fitted onto the valve terminal at the factory. CDVI with DI connection DeviceNet Tab. 1/1: Variants of the CDVI 1-5

20 1. Overview of components 1.3 Description of components The CDVI consists of individual components Left-hand end plate with pneumatic connections (1), (12/14), (3/5), (82/84) and on the CDVI-MP with MP connection 2 Manifold block 4 or 8 valve positions 3 Optionally up to 8 expansion blocks possible with 1 valve position each 4 Right-hand end plate with pneumatic connections (1), (3/5) for internal or external pilot air supply 5 Blanking plate on vacant position 6 Valves Fig. 1/1: Overview of components of the CDVI 1-6

21 1. Overview of components In-line valve manifolds There are two types of in-line manifold blocks on the CDVI: The manifold block has 4 or 8 valve positions. Each CDVI consists of at the most one manifold block, i.e. no further manifold blocks can be used for additional valve positions. The expansion blocks (2-valve or 1-valve expansion block) are available in four different versions: Standard version without power supply Version with pneumatic supply connection In addition, on the CDVI with fieldbus connection: Version with electrical power supply Version with pneumatic supply connection and electrical power supply Both versions provide 1 or 2 valve positions. A maximum of 8Mo-expansionblocksor4Bi-expansionblockscanbe mounted to one manifold block. Mixed components are permissible. Valves and blanking plates are fitted on the in-line valve manifolds. The working lines (2) and (4) are provided for each valve position on the in-line valve manifolds. Each valve position supports triggering 2 solenoid valves (only applies to manifold blocks, otherwise depends on expansion). The end plates form the termination. The in-line valve manifolds provide the following connections: Common channels for supply and exhaust air for: Compressed air supply to the valves Removal of the exhaust and pilot exhaust air at the valves. Electric signals from all solenoid coils. 1-7

22 1. Overview of components In-line valve manifolds Manifold block Description Manifold block with 4 valve positions Identification features 4 valve positions, working lines Manifold block with 8 valve positions 8 valve positions, working lines 2-valve expansion block 1-valvle expansion block Standard expansion block with 2 valve positions Expansion block with additional supply with 2 valve positions and connections 1, 3 and 5. This expansion block can be used e.g. for creating further pressure zones. Standard expansion block with 1 valve position Expansion block with additional supply with 1 valve position and ports 1, 3 and 5. This expansion block can be used e.g. for creating further pressure zones. 2 valve positions, working lines, no supply ports 2 valve positions, working lines, pneum. supply ports 2 valve positions, working lines, power supply 1) 2 valve positions, working lines, pneum. ports and power supply 1) 1 valve position, working lines, no supply ports 1 valve position, working lines, pneum. supply ports 1 valve position, working lines, power supply 1) 1 valve position, working lines, pneum. ports and power supply 1) 1) only on the CDVI with fieldbus connection Tab. 1/2: Overview of in-line valve manifolds for the CDVI 1-8

23 1. Overview of components Note With more than 2 pressure zones: Ensure that there is a corresponding pneumatic supply port for each pressure zone. Separator plates with sealing function are located between the manifold block and the expansion block. There are designs with or without channel separation (see following table). The in-line valve manifolds of the CDVI can be fitted with the following components: Component Valves and blanking plate Separator plates *) End plates, right End plates, left Design/type see Tab. 1/4 All supply ducts open: CDVI5.0-EB-DZ Separating the compressed air channel (1): CDVI5.0-EB-DZP Separating the exhaust duct (3/5): CDVI5.0-EB-DZR Separating the compressed air channel and the exhaust duct: CDVI5.0-EB- DZPR For operating the CDVI with internal pilot air supply: CDVI5.0-EPR For operating the CDVI with external pilot air supply: CDVI5.0-EPR-S With CDVI-MP: CDVI5.0-EPL-MP-... (with electric multi-pin and cable) With CDVI-FB: CDVI5.0-EPL-FB *) Pressure zones are only possible for CDVIs with at least one expansion block. Tab. 1/3: Pneumatic components of the CDVI End plates The CDVI possesses as mechanical termination of the terminal both a left and a right-hand end plate. These end plates fulfil the following functions: 1-9

24 1. Overview of components Ensure the protection class (see Appendix A Technical data ). Via the left-hand end plate, the CDVI is supplied with compressed air (connections (1), (12/14)), the exhaust air is removed (connections (3/5), (82/84)) and with the CDVI- MP the terminal is supplied with voltage. Via the right-hand end plate the CDVI can also be supplied with compressed air (connection (1)) and the exhaust air can be removed (connection (3/5)). The righthand end plate variant determines whether the CDVI is to be operated with internal or external pilot air supply: Right-hand end plate type CDVI5.0-EPR for supplying the valves with internal pilot air, branched from the overall supply (compressed air channel (1)). Right-hand end plate type CDVI5.0-EPR-S for supplying the valves with external pilot air, pressure regulated separately ( bar). The external pilot air is supplied via connection (12/14) on the lefthand end plate Valves Note The valve positions are intended for Festo valves and may be fitted only with the valves approved of by Festo. The valve positions must not be used for any other purpose. The components on the valve positions are marked with identification codes. With these codes you can ascertain the equipment fitted on your CDVI. The codes are printed on the covers of the valves or on the blanking plate. An overview of the valves can be found in Appendix A. 1-10

25 1. Overview of components Ident. code A B E G H J K M N R S W X Component Blanking plate for vacant position 5/3-way valve, open in mid-position 5/3-way valve, mid-position exhausted 5/3-way valve, mid-position closed Two 3/2-way valves, monostable, control side 14 closed in normal position, control side 12 open in normal position 5/2-way valve, bistable Two 3/2-way valves, monostable, normal position closed 5/2-way valve, monostable Two 3/2-way valves, monostable, open in normal position 2/2-way valves, monostable, control side 14 closed in normal position, external compressed air supply 2/2-way valve, monostable, open in normal position, external compressed air supply One 3/2-way valve, monostable, open in normal position, external compressed air supply One 3/2-way valve, monostable, closed in normal position, external compressed air supply Tab. 1/4: Identification code of the valve position components 1-11

26 1. Overview of components Connection, display and control elements The following display and control elements can be found on the valve side of the CDVI with MP connection: Yellow LEDs, status display of the solenoid coils 2 Manual overrides (per solenoid coil) Fig. 1/2: Display and control elements of the CDVI with MP connection 1-12

27 1. Overview of components The following display and control elements can be found on the valve side of the CDVI with DI connection DeviceNet: Green LED PS Power System, electronics operating voltage 2 Yellow LEDs, status display of the solenoid coils 3 Manual overrides (per solenoid coil) 4 Green/red LED CP Compact Performance, CP extension modules 5 Green/red LED MNS Module/ Network Status 6 Green LED PL Power Load, valve load voltage Fig. 1/3: Display and control elements of the CDVI with DI connection DeviceNet 1-13

28 1. Overview of components The following pneumatic connecting elements can be found on the connection side of the CDVI: aa aj 9 aa aj Supply port (1) 2 Exhaust port (3/5) 3 Expansion block with additional supply ports 4 Exhaust port (5) on the expansion block 7 Exhaust port (82/84) 8 Pilot air supply port (12/14) 9 Working line (2) per valve aj Supply port (1) on expansion block aa Exhaust port (3) on expansion block 5 Working line (4) per valve 6 Pressure compensation connection (L) Fig. 1/4: Connection elements of the pneumatic components 1-14

29 1. Overview of components The following electrical connection can be found on the connection side of the CDVI with MP connection: 1 1 Electric multi-pin plug connection Fig. 1/5: Electrical connection element of the CDVI with MP connection 1-15

30 1. Overview of components The following electrical connection elements can be found on the connection side of the CDVI with DI connection DeviceNet: Fieldbus output (socket, M12) 2 Fieldbus input (plug, M12) 3 CP expansion (M9) 4 Power supply (plug, M12) 5 Additional electrical supply on expansion block Fig. 1/6: Electrical connections of the CDVI with DI connection DeviceNet 1-16

31 Assembly Chapter 2 Assembly 2-1

32 2. Assembly Contents 2. Assembly Mounting the valve terminal Wall mounting

33 2. Assembly Contents of this chapter Further information This chapter describes how to assemble the CDVI on a mounting surface. The CDVI is pre-mounted when supplied by the plant. If you wish to supplement or replace pneumatic components, note the instructions in chapter 5 Cleaning, maintenance and conversion. 2-3

34 2. Assembly 2.1 Mounting the valve terminal Warning Uncontrolled movements of the connected actuators and uncontrolled movements of loose tubing can cause injury to persons and/or damage to property. Make sure that the higher-order controller has not sent control signals to the solenoid coils. Before carrying out conversion work on the CDVI, switch off the following: The compressed air supply The power supply Note Handle all the components of the CDVI with great care. Note especially the following: Avoid an offset between the components, otherwise the protection class requirements may no longer be fulfilled (see Appendix A, Technical data ). Components must be screwed without offset and mechanical stress. Screws must be fitted accurately (otherwise threads may be damaged) Observe the specified tightening torques. Make sure that the connecting surfaces are clean (avoid leakage and contact faults). Avoid operating the CDVI in the resonant range. 2-4

35 2. Assembly Wall mounting It may be sensible to connect the tubing prior to mounting the CDVI, depending on the space available for mounting. The tubing of the terminal is described in chapter 3. Caution The CDVI can bend and therefore become damaged and may leak if it is mounted on an uneven and pliable surface. Mount the CDVI only on an even rigid surface. Procedure: 1. Ascertain the weight of your terminal (weigh or calculate). Guidelines: Components of the CDVI Basic weight: 1) CDVI with 4 valve positions CDVI with 8 valve positions Weight CDVI-MP approx g approx g CDVI-FB approx g approx g Expansion block with 1 valve position 2) With/without additional supply approx. 255 g Expansion block with 2 valve positions: 2) With/without additional supply approx. 510 g Valve Blanking plate approx. 210 g/item approx. 85 g/item Multi-pin connecting cable per metre approx. 168 g/m --- Spacer bolt approx. 80 g/item 1) Manifold block, without: separator plates, left-hand and right-hand end plates, pneum. threaded connectors, cable, valve 2) Expansion block without: separator plate and pneum. threaded connectors, valves Tab. 2/1: Weight specifications for the CDVI 2-5

36 2. Assembly 2. Make sure that your mounting surface can support this weight and that it is sufficiently earthed. Note Attaching the CDVI manifold block: The 8-valve manifold block must always be fastened to all 4 M6 drill holes. Attaching the CDVI with expansion blocks: 1 valve position may protrude unfastened. If the expansion provides more than one valve position, fasten the last expansion block. However, please note that a maximum of 4 valve positions may lie unsupported between the manifold block and last expansion block, i.e. you need to fit an intermediate retainer after 4 valve positions at the latest. 3. Drill corresponding mounting holes 6 mm intothe mounting surface Mounting holes Fig. 2/1: Position of the mounting holes 2-6

37 2. Assembly 4. Fasten the terminal conductively with the earthed mounting surface (see Fig. 2/2). If necessary use washers. The terminal can be mounted in any desired position, but the CDVI should be mounted so that dirt will be washed out during cleaning and the cleaning agent can drip off Earthed mounting surface 2 Spacer bolt, tightening torque 10 Nm (±2 Nm) 3 Manifold block with threaded holes forspacerbolts Fig. 2/2: Example of vertical attachment 2-7

38 2. Assembly Note If you do not use the spacer bolts from Festo, note the following: Make sure that there is a gap of at least 90 mm around the CDVI, e.g. by means of mounting profiles or a section cut out of the mounting surface, so that the tubing is not bent. Make sure that there is a good conductive connection between the mounting profile and the earthed mounting surface. Use the M6 mounting holes in the manifold block if you wish to mount the CDVI on a wall (thread depth 9.5 mm). 2-8

39 Installation Chapter 3 Installation 3-1

40 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 Notes on installing the CDVI Pilot control of the solenoid coils (pilot air supply) CDVI with pressure zone separation Operating the CDVI with vacuum/low pressure Connecting the CDVI Connecting the pneumatic lines Connecting the electric cables Address assignment of the valves

41 3. Installation Contents of this chapter This chapter deals with the tubing and cabling of the CDVI. These include in particular the following: General instructions on preparing the compressed air and on connecting the tubing Instructions on operating the pilot control with internal or external pilot air supply Instructions on operating the valve terminal with pressure-zone separation Fitting the QS threaded connectors Connecting the power supply EarthingtheCDVI Address assignment of the valves Further information Instructions on connecting the electric components of the CDVI with MP connection can be found in the brief description CDVI with multi-pin plug connection. Instructions on connecting the electric components and on addressing the CDVI with DI connection DeviceNet can be found in the electronics manual P.BE-CDVI-DN

42 3. Installation 3.1 Compressed air preparation Note Unfiltered or incorrectly lubricated compressed air will reduce the service life of the valve terminal Operation with unlubricated compressed air Note Too much residual oil content in the compressed air will reduce the service life of the valve terminal. If bio oils are used (oils based on synthetic esters or native esters, e.g. rapeseed oil methylic ester), the residual oil content must not exceed max. 0.1 mg/m 3 (see ISO class 2). If mineral oils are used (e.g. HLP oils to DIN Part 1 to 3) or corresponding oils based on polyalphaolefin (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 is not permissible irrespective of the compressor oil, as otherwise the basic lubrication will be washed out with time. 3-4

43 3. Installation Operation with lubricated compressed air Operate your system 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 the complete system with lubricated compressed air. If possible, always install the lubricators directly in front of the consuming actuator. 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 (conforming to DIN HLP32, basic viscosity 32 CST at 40 C). The additional lubrication must not exceed 25 mg/m 3 (ISO class 5). Check that the lubricator setting is correct (see subsequent section) This avoids operative malfunction of the valves. 3-5

44 3. Installation Setting the lubricator: Checking the setting: with the machine running (typical operating status) 0.2 to max. 1 drop/min. or 0.5 to 5 drops/1000 l air. the procedure described below can be used for checking the setting of the lubricator. Procedure: Check the service units for condensate and lubricator setting twice per 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 drips out, 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

45 3. Installation 3.2 General instructions on installation Warning Sudden unexpected movements of the connected actuators and uncontrolled movements of loose tubing lines can cause injury to human beings or damage to property. Before carrying out mounting, 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 electrostatically sensitive components. 3-7

46 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 or over the tube coupling of the threaded connector. 2. Tighten the clamping screw 1 or, if applicable, pull the locking ring 2 over the tube coupling. 3. Seal connections that are not required with blanking plugs For better system clarity, bundle together the installed tubes with: tubing straps or multi-tube holder Fig. 3/1: Fitting the tubing 3-8

47 3. Installation Disconnecting Proceed as follows: Warning Pneumatic tubing that is under pressure can execute uncontrolled movements when being dismantled, causing injury to persons. Carry out the following steps before disconnecting the pneumatic tubing on the CDVI 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. 1. Mark all pneumatic tubing. 2. Loosen the clamping screw 1 of the fitting or, if applicable, press down the locking ring of the fitting 2 e.g. with a Festo QSO releasing tool. 3. Remove the tubing from the threaded connector. 1 2 Fig. 3/2: Disconnecting the tubing 3-9

48 3. Installation 3.4 Notes on installing the CDVI Pilot control of the solenoid coils (pilot air supply) Note Operate the CDVI whenever possible with unlubricated pilot air (port (12/14)). Otherwise observe the instructions in the section Compressed air preparation. In the case of CDVI with internally branched pilot air, the above-mentioned instruction applies also to the supply air (port (1)). The pilot air is supplied centrally to all valves of the CDVI. Therefore, operate the valve terminal either with internally branched or externally supplied pilot air. This will ensure reliable operation of the valve terminal. Internal pilot air supply If the operating pressure of the CDVI is between bar, you can operate the pilot control of the solenoid coils with an internally branched pilot air supply. Note Internal pilot air supply is branched centrally from supply port (1) in the right end plate for all solenoid coils. This also applies when the CDVI is operated with several pressure zones (see Fig. 3/3 and Fig. 3/4). 3-10

49 3. Installation If the CDVI is intended for internal pilot air supply, port (12/14) on the left-hand end plate must be sealed with a blanking plug. External pilot air supply If the operating pressure of the CDVI lies below 3 bar or above 6 bar, pilot control of the solenoid coils must be operated with an external pilot air supply. Note Use regulated external pilot air (3...8 bar). Then reliable, trouble-free operation of the CDVI is possible, e.g. even with fluctuating operating pressure. The external pilot air supply is supplied centrally for all solenoid coils via the pilot port (12/14) on the left end plate. This also applies when the CDVI is operated with different pressure zones (see Fig. 3/3 and Fig. 3/4). Set the pilot pressure of the external pilot air supply to correspond to the operating pressure with which these valves are operated (see Appendix A, Fig. A/1) CDVI with pressure zone separation The CDVI can be equipped with 2 to 9 pressure zones. There is not intended to be a pressure zone separation within the manifold block. The CDVI must be fitted with at least one expansion block in order that two pressure zones can be created. 3-11

50 3. Installation Note With more than 2 pressure zones: Ensure that there is a corresponding pneumatic supply port for each pressure zone. Conversion of the CDVI to 2 to 9 pressure zones is described in chapter 5 Cleaning, maintenance and conversion. Note All the valves of the CDVI are supplied with pilot air from a central source. The pilot air is either branched internally from channel (1) or supplied externally via port (12/14). This also applies if the CDVI has several pressure zones. With internal pilot air supply and pressure zone separation of channel (1), observe the following: The internal pilot air supply is branched in the right end plate from channel (1). The operating pressure in the right zone must therefore lie between bar. In the left and centre pressure zones the operating pressure may lie between bar and bar, depending on the valves that are used (see Appendix A Technical data ). Separator plates For the CDVI the following separator plates are available for creating pressure zones: Function Channel (1) blocked Channel (3/5) blocked Channels (1) and (3/5) blocked Separator plate type CDVI5.0-EB-DZP CDVI5.0-EB-DZR CDVI5.0-EB-DZPR Tab. 3/1: Separator plates with channel separation 3-12

51 3. Installation CDVI with 2 pressure zones Prerequisite for creating 2 pressure zones: Depending on the electrical connection variant, the CDVI must be fitted with at least one of the following standard expansion blocks: Expansion block CDVI-MP CDVI-FB Standard expansion block Type CDVI5.0-EB Type CDVI5.0-EB-FB The position of the separator plate for pressure zone separation is between the manifold block and the expansion block. 1 Separator plate without channel separation /5 1 2 Separator plate with channel separation 1 82/84 Pressure zone 1 Pressure zone 2 3/5 12/14 Fig. 3/3: Example: CDVI with two pressure zones (channel (1) and (3/5) blocked) and pilot control with external pilot air supply 3-13

52 3. Installation Note the following if the following separator plates are used: Separator plates Ventilation via Exhaust via CDVI5.0-EB-DZP EP-L and EP-R optional +EB-ZV EP-L or EP-R Other possibilities: EP-L and EP-R optional +EB-ZV CDVI5.0-EB-DZR EP-L or EP-R Other possibilities: EP-L and EP-R optional +EB-ZV EP-L and EP-R optional +EB-ZV CDVI5.0-EB-DZPR or separator plate pair CDVI5.0-EB-DZP /...-DZR EP-L and EP-R optional +EB-ZV EP-L and EP-R optional +EB-ZV EP-L = End plate left EP-R = End plate right EB-ZV = Expansion block with additional supply Unused ports must be sealed. Tab. 3/2: Separator plates for creating 2 pressure zones CDVI with 3 pressure zones Prerequisite for creating 3 pressure zones: Depending on the electrical connection variant, the CDVI must be fitted with at least one of the following expansion blocks: Expansion blocks CDVI-MP CDVI-FB Standard expansion block Expansion block with additional supply CDVI5.0-EB1-MP or CDVI5.0-EB2-MP CDVI5.0-EB...X-MP CDVI5.0-EB1-FB or CDVI5.0-EB2-FB CDVI5.0-EB...X-FB or CDVI5.0-EB...Z-FB or CDVI5.0-EB...XZ-FB Tab. 3/3: Expansion blocks 3-14

53 3. Installation The separator plates with channel separation sit between the manifold block and the expansion block as well as between the expansion blocks. 1 Separator plate without channel separation 2 Separator plate with channel separation / /84 12/14 Pressure zone Pressure zone 2 Pressure zone 3 3/5 Fig. 3/4: Example: CDVI with 3 pressure zones (channel (1) and (3/5) blocked), external supply of the second pressure zone, pilot control with external pilot air supply 3-15

54 3. Installation Note the following if the following separator plate combinations are used: Separator plate pair Ventilation via Exhaust via CDVI5.0-EB-DZP /...-DZP EP-L and EP-R and EB-ZV EP-L or EP-R Other possibilities: EP-L and EP-R Optional +EB-ZV CDVI5.0-EB-DZP /...-DZPR EP-L and EP-R and EB-ZV EP-L and EP-R Optional +EB-ZV CDVI5.0-EB-DZPR /...-DZPR EP-L and EP-R and EB-ZV EP-L and EP-R and EB-ZV EP-L = End plate left EP-R = End plate right EB-ZV = Expansion block with additional supply Unused ports must be sealed. Tab. 3/4: Separator plate combinations for creating pressure zones Operating the CDVI with vacuum/low pressure Note The valves with ident. code H, K and N (2x3/2-way valves) are not permitted for operation with vacuum/low pressure. A pneumatic spring takes over resetting these valves to the normal position. This spring is operated with the operating pressure (channel (1)). An operating pressure of at least 3 bar is required for resetting the valve. Operate these valves in a separate pressure zone. The operating pressure for this pressure zone must be set in accordance with the diagram in appendix A, Fig. A/1. Thefollowing requirements must be fulfilled so that you can operate the CDVI at the supply port (1) with vacuum or low pressure between bar: 3-16

55 3. Installation The pilot control of the solenoid coils is operated with a regulated external pilot air supply. The valve terminal is fitted with the following valve subbases and, in some cases has two pressure zones. Valve sub-bases Pressure zone with vacuum or low pressure supply Pressure zone with excess pressure supply 1) via port (1) The pressure zone must be equipped only with the following valve sub-bases: 5/2-way valve, monostable (ident. code M) 5/2-way valve, double solenoid (Ident. code J) 5/3-way valve (ident. code B, E and G) 3/2-way valve (Ident. code W and X) (see also subsequent note). 2/2-way valve (ident. code R and S) The valve sub-bases with Ident. code N, K and H, if supplied via port (1), are not suitable for vacuum/low pressure! The pressure zone can additionally be equipped with the following valve sub-bases: 2x3/2-way valves (Ident. code H, K and N) 1) In accordance with diagrams in Appendix A, Fig. A/1 Tab. 3/5: Valve sub-bases Note 3/2-way valves with ident. code W and X: 2/2-way valves with ident. code R and S: These valves can be supplied individually and therefore operated in the pressure range of bar. They are independent of supply port 1 of the valve terminal. The ports via which these valves are supplied with compressed air or vacuum and via which exhaust air is removed are shown in Appendix A, Tab. A/6, or Tab. A/7. The above mentioned valves are supplied with pilot air via port 12/14 of the valve terminal. 3-17

56 3. Installation Directional control valve Compressed air or vacuum via port Exhaust via port Ident. code R and X (4) (3) Ident. code S and W (2) (5) Tab. 3/6: Ports at the valves with ident. code R, S, X and W 3.5 Connecting the CDVI Connecting the pneumatic lines In the case of connecting plates fitted with blanking plates, seal the working lines (2) and (4) with blanking plugs or threaded blanking plugs to prevent dirt from entering. For optimum efficiency of your terminal, the compressed air supply and the exhausting should take place in the following cases via the left and right-hand end plates: Onvalveterminalswithmorethan10valves(nominal supply pressure 6 bar) On large capacity actuators: 3-18

57 3. Installation Caution Larger actuators or actuators operated simultaneously (e.g. cylinders) can create a back pressure in the exhaust duct of the valve terminal. The size of this back pressure depends on the capacity of the ducted exhaust tubing. This may lead to malfunctioning of the CDVI. In this case, exhaust the CDVI via ports (3/5) on both end plates and, if necessary, on the expansion block. In order to avoid interactions with adjacent valves, valves on expansion blocks can be separated by means of a separate exhaust duct (3/5). Note Under certain circumstances, excess pressure can build up under the valve covers of the CDVI. This pressure is reduced via the pressure compensation hole in the manifold block. Do not on any account plug the hole for the pressure compensation. Remove the excess pressure with ducted tubing. Do not use any non-return valve in the line. Note Some ports have been covered with adhesive transparency as protection against contamination. Remove all adhesive transparencies from the ports. Seal the following if not used: unused valve positions with blanking plates working ports (2), (4) with blanking plugs or plugs for QSF plug connectors. 3-19

58 3. Installation Expansion block with ports for additional supply (optional) Port (L) for pressure compensation 82/84 12/14 1 3/ /5 Line Port code (ISO 5599) Port size (ISO 228) Port threaded connector 1) Compressed air/vacuum (1) G 3/8 G 1/8 in the left/right end plate in the expansion block with auxiliary power supply Air/vacuum (2), (4) G 1/8 G 1/8 in the manifold block in the expansion block with auxiliary power supply Pilot air supply (12/14) G 1/8 in the left end plate Exhaust air (3/5) (3), (5) G 3/8 G 1/8 in the left/right end plate in the expansion block with auxiliary power supply Exhaust air of the pilot air supply (82/84) G 1/8 in the left end plate Pressure compensation G1/8 in the manifold block 2) 1) Depending on what you have ordered, the CDVI may already be fitted with QSF threaded connectors. 2) Note the instructions on pages 3-17 on connecting the pressure compensation. Tab. 3/7: Pneumatic ports of the CDVI 3-20

59 3. Installation Caution In the case of several systems with centrally ducted exhaust air, back pressures in the common exhaust tubing (3/5) or (82/84) can lead to functional impairments of the CDVI. Use non-return valves in the common exhaust lines (3/5) and (82/84). System 1 Central (82/84) Common (3/5) Central pressure compensation Pressure compensation Common (82/84) Common (3/5) System 2 Pressure compensation Common (82/84) Common (3/5) Valve terminal Central (3/5) Valve terminal Fig. 3/5: Common lines with non-return valves 3-21

60 3. Installation Connecting the electric cables Warning Use for the electrical power supply only PELVcircuits in accordance with IEC/DIN EN (Protective Extra- Low Voltage, PELV). Also comply with the general requirements for PELV circuits in accordance with IEC/DIN EN Use only powersources that guarantee reliable electrical isolation of the operating voltage according to IEC/DIN EN By the use of PELV circuits, protection against electric shock (protection against direct and indirect contact) is guaranteed in accordance with IEC/DIN EN (electrical equipment of machines, general requirements). Note Check within the framework of your EMERGENCY STOP circuit, to ascertain the measures necessary for putting your machine/system into a safe state in the event of an EMERGENCY STOP (e.g. switching offthe operating voltage for the valves and output modules, switching off the compressed air). Note Due to energy stored in the input circuitry of valve terminals, there may be a delayed reaction of the valves when the load voltage is switched off. Take this into consideration, e.g. as follows: Detect that the load voltage has been switched off by means of an input signal in the controller. Block the control signal for the valves by locking the output signal with the input signal Load voltage. 3-22

61 3. Installation Detailed instructions on installing the electrical connections ofthecdvi-mpcanbefoundintheleaflettypep.be-k-cdvi supplied with the product. Detailed instructions on wiring the electrical connections of the CDVI with DI connection DeviceNet can be found in the electronics manual P.BE-CDVI-DN-... Earthing the CDVI Note Interference from electromagnetic sources. Earth your CDVI. Make sure that there is a conductive connection (low impedance, short cable with large cross section) between the CDVI and the earth potential. 3.6 Address assignment of the valves Detailed instructions on addressing CDVI with DI connection DeviceNet can be found in the electronics manual P.BE-CDVI-DN-... The CDVI occupies 16 or 24 addresses, depending on the number of valve positions, irrespective of the types of valves fitted. This enables the CDVI valve terminal to be extended at a later date without the need to shift the addresses. Addresses should be allocated in ascending consecutive order. Counting begins on the CDVI from left to right, but on the individual valve positions from right to left. A valve position on the CDVI valve terminal always occupies 2 addresses, even if it is only fitted with a blanking plate. 3-23

62 3. Installation In the case of valves with two solenoids coils, solenoid coil 14 occupies the less significant address and solenoid coil 12 occupies the higher-value address. In the case of valves with only one solenoid coil, the higher-value address remains unused. The following diagram shows the addressing sequence using the example of the CDVI with 9 valve positions valve manifold block 2 2-valve Bi-expansion block 3 2-valve Mo-expansion block 4 1-valve Bi-expansion block 6 5 Addresses of the solenoid coils 6 Vacant position on Mo-expansion block (occupies 1 address) 7 Vacant position on 4-valve manifold block (occupies 2 addresses) Fig. 3/6: Example: Address assignment of the CDVI with MP connection 3-24

63 Commissioning Chapter 4 Commissioning 4-1

64 4. Commissioning Contents 4. Commissioning Instructions on commissioning Before commissioning Pressure increase in the overall supply Checking the valves and the valve-actuator combination Manual override Checking LED displays of the valves Troubleshooting Impairment of function Operating status of the pneumatic system

65 4. Commissioning Contents of this chapter This chapter deals with the commissioning of the CDVI. This includes in particular the following: Instructions on building up pressure in the overall supply Checking the valves and the valve-actuator combination The function of the manual overrides Troubleshooting Assignment of the LEDs Further information Instructions on diagnosing and troubleshooting on the CDVI with DI connection DeviceNet can be found in the Electronics Manual P.BE-CDVI-DN

66 4. Commissioning 4.1 Instructions on commissioning Before commissioning Switch off the power supply before connecting or disconnecting plugs (otherwise this could lead to functional damage). Commission only a valve terminal which has been fitted and wired completely. Make sure that there is a sufficient supply of fresh air (cooling) for the following operating conditions: When the maximum number of valves are fitted When the maximum operating voltage is applied When the solenoid coil is constantly under stress Please observe the following instructions on building up pressure in the overall supply Pressure increase in the overall supply Warning If the pressure build-up of the pilot air supply is too slow or delayed, this may cause the actuators to perform sudden unexpected movements under the following conditions: When the compressed air is connected via a soft-start valve (gradual pressure build-up) and When there are electric signals (e.g. after EMERGENCY STOP). This can cause damage to the machine or system and even injury to persons. Operate the valve terminal with an external pilot air supply ( bar). Branch the pilot air supply before the soft-start valve (see Fig. 4/1). 4-4

67 4. Commissioning The pilot air must be applied with a pressure of bar immediately after being switched on, otherwise there is no guarantee that the valve will reverse directly (see diagram). If the pressure is less than 3 bar, there may be a delay before the valve reverses, in spite of an electric signal. The gradual pressure build-up of the overall supply does not affect the actuator in that case. The actuator would react suddenly (e.g. a cylinder would extend or retract suddenly, depending on the valve function). 82/ / / Externally supplied pilot air ( bar), branched before the soft-start valve 2 Soft-start valve (gradual pressure build-up of the overall supply) Fig. 4/1: Example of valve-cylinder combination with gradual pressure build-up of the overall supply 4-5

68 4. Commissioning The table below shows the effects of slow start-up pressurisation when there are electric signals: External pilot air supply Pressure rise in overall supply Pressure rise in the pilot air supply (12/14) Time when a valve reverses Movement of the actuator branched after the soft-start valve branched in front of the soft-start valve slow slow after pressure rise at (1) slow fast before pressure rise at (1) fast slow Tab. 4/1: Effects of slow start-up pressurisation 4.2 Checking the valves and the valve-actuator combination Manual override 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-actuator 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. The manual override has been designed to be used as follows: Manual override design Manual override with automatic return (pushing) Mode of operation The manual override is reset automatically by spring force. Tab. 4/2: Actuation types of the manual override 4-6