Compact performance CPA pneumatics manual Valve terminal with CPA pneumatics Type CPA..-VI Manual 173 515 en 0207c
Contents and general instructions Author... M. Simons Editors... H.-J. Drung, M. Holder Original... de Translation... transline Deutschland Layout... Festo AG & Co., Dept. KG-GD Type setting... DUCOM Edition... en 0207c Designation... P.BE-CPA-EN Order no.... 173 515 AS-Interface is a registered trademark of AS-Interface Association E (Festo AG & Co., D-73726 Esslingen, Federal Republic of Germany, 2002) Internet: http://www.festo.com e-mail: service_international@festo.com The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration. I
Contents and general instructions II
Contents and general instructions Contents Designated use... Target group... Service... Notes on this manual... Important user instructions... V V V VI XI 1. System summary... 1-1 1.1 Overview of variants... 1-4 1.2 Description of components... 1-7 2. Fitting... 2-1 2.1 Fitting variants... 2-4 2.1.1 Fitting onto a wall... 2-5 2.1.2 Hat rail fitting... 2-6 3. Installation... 3-1 3.1 Preparing the compressed air... 3-4 3.1.1 Operation with non-lubricated compressed air... 3-4 3.1.2 Operation with lubricated compressed air... 3-5 3.2 General connecting methods... 3-7 3.2.1 Laying the tubing... 3-7 3.2.2 Basic information... 3-8 3.3 Connecting the CPA valve terminal... 3-9 3.3.1 Auxiliary pilot air... 3-9 3.3.2 CPA valve terminal with pressure zone separation... 3-12 3.3.3 Connecting the supply, exhaust and work lines... 3-14 3.3.4 Connecting the electric cables... 3-20 3.4 Address assignment of the valves... 3-24 III
Contents and general instructions 4. Commissioning... 4-1 4.1 Testing the valves... 4-4 4.1.1 Checking the valve functions... 4-5 4.1.2 Checking the valve-cylinder combination... 4-9 4.2 Eliminating faults... 4-15 4.2.1 Impairment of function... 4-15 4.2.2 LED display of the valves... 4-17 5. Maintenance and conversion... 5-1 5.1 General precautionary measures... 5-4 5.2 Dismantling the CPA valve terminal... 5-5 5.3 Replacing CPA valve terminal components... 5-9 5.3.1 Replacing valve sub-bases, blanking plates or additional supply plates... 5-9 5.3.2 Replacing the large surface-mounted silencer... 5-11 5.3.3 Replacing the end plate, sub-base or manifold block... 5-12 5.4 Conversion work on the CPA valve terminal... 5-19 5.4.1 Conversion from non-locking to locking/non-locking manual override... 5-19 5.4.2 Conversion to internal or external pilot air... 5-21 5.4.3 Converting the CPA valve terminal to different pressure zones... 5-22 5.4.4 Conversion of valve location for actuating one or two solenoid coils... 5-24 5.5 Adding/removing valve locations... 5-25 A. Technical appendix... A-1 A.1 Festo accessories... A-3 A.2 Technical specifications... A-4 B. Supplementary component summary and installation instructions... B-1 B.1 Overview of end plates... B-3 B.2 Separating the CPA valve terminal from the CPX terminal... B-6 C. Index... C-1 IV
Contents and general instructions Designated use The CPA 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 designated use of the relevant CPA valve terminal. CPA valve terminals may only be used as follows: in accordance with designated use in their original state without any modifications by the user in faultless technical condition. When used together with commercially available components, such as sensors and 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 service centre if you have any technical problems. V
Contents and general instructions Notesonthismanual This manual contains specific information on fitting, installing, commissioning, servicing and converting the CPA valve terminal. This manual describes only the pneumatic components and refers to the valve terminal variants listed in the table below. CPA valve terminal with CPX terminal, type CPA.. Informationontheelectric/electroniccomponents: see manual CPX system, installation and commissioning Tab. 0/1: CPA valve terminal with CPX terminal VI
Contents and general instructions Variants of the CPA valve terminal for incorporation in the CP system, type CPA..-VI With IC connection: Information on the electric/electronic components: in this manual With MP connection: type CPA..-IMP Information on the electric/electronic components: see leaflet with product With CP connection: types CPA..-IFB-CP and CPA..-IFB-DN Information on the electric/electronic components: see manual CP system, installation and commissioning With AS-Interface connection; type CPA..-IFB-ASI or CPA..-IFB-ASI-Z Information on the electric/electronic components: see leaflet with product Tab. 0/2: Connection variants of the CPA valve terminal VII
Contents and general instructions Information on further CP modules or CPX modules can be found in the manual for the relevant module. The tables below give 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 field bus 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-03-... Contents Instructions on fitting, installing, commissioning and diagnosing the appropriate field bus node Connection techniques and instructions on fitting, installing and commissioning input and output modules of type CPX-... as well as type CPA and Midi/ Maxi pneumatic interfaces Informationonfitting, installing and commissioning the relevant pneumatic modules Tab. 0/3: Manuals on the CPA valve terminal with CPX terminal VIII
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 field bus node, programming and diagnosis type P.BE-CP-FB... or P.BE-VIFB...-10... 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 Informationonfitting, installing and commissioning CPA or CPV valve terminals Informationonfitting, installing and commissioning CP I/O modules Tab. 0/4: Manuals on the CP system IX
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 Connection sub-bases 1 3 End plates 3 2 3 Fig. 0/1: Main components of the CPA valve terminal This manual contains the documentation for the valve subbases with Ident. codes B, E, G, H, J, K, M and N (see chapter System overview, description of components ). X
Contents and general instructions Important user instructions Danger categories This manual contains instructions on the possible dangers which may occur if the product is not used correctly. These instructions are marked (Warning, Caution, etc.), printed on a shaded background and marked additionally with a pictogram. A distinction is made between the following danger warnings: Warning This means that failure to observe this instruction may result in serious personal injury or damage to property. Caution This means that failure to observe this instruction may result in personal injury or damage to property. Please note This means that failure to observe this instruction may result in damage to property. The following pictogram marks passages in the text which describe activities with electrostatically sensitive components. Electrostatically sensitive components may be damaged if they are not handled correctly. XI
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. XII
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 Components Connecting the tubing 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 CPA valve terminal with individual connection (IC 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 Platewithoutvalvefunctionfor filling anunusedlocation. Common term for pneumatic Sub-bases, valve sub-bases, additional pressure supply plates, blanking plates, end plates, CPX adapters, electrical sub-bases (with IC, MP, CP or AS-Interface connection), electrical manifold blocks, cover blocks, end plate covers, silencers. Connecting the supply lines (tubing) to the CPA valve terminal. Compact Performance Specialcablefor coupling thevarious CP modules Commonterm for various modules which canbeincorporatedina CP system Complete system consisting of CP field bus 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 with serial connections which enables the CPA valveterminaltobeconnectedtotheas-interfacebus. CPA valve terminal variant with plug and socket which enables the CPA valve terminal to be connected to further CP modules. CPA valve terminal variant on which every valve solenoid coil can be connected individually with a special cable. XIII
Contents and general instructions Term CPA valve terminal with multipin connection (MP connection) CPX modules Meaning CPA valve terminal variant with sub-d plug via which all valve solenoid coils are centrally connected. Commonterm for thevariousmoduleswhich canbeincorporatedina CPX terminal CPX terminal Modular electric terminal type 50 Electrical bridge Electrical sub-base End plate I/O Manifold block Manual override Pin-type Pneumatic interface Pneumatic sub-base Sub-base 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 multipin, 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 valve solenoid coils with the electrical sub-base or the CPX pneumatic interface. Manual override Plug connection (with/without inner thread) for connecting the supply cables to the CPA valve terminal 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. Pneumatic manifold sub-base with open or closed compressed air channel for single-solenoid, double-solenoid or mid-position valves with work connections 2 and 4. Plate with single-solenoid, double-solenoid or mid-positionvalve. Tab. 0/5: Product-specific terms and abbreviations XIV
System summary Chapter 1 1-1
1. System summary Contents 1. System summary... 1-1 1.1 Overview of variants... 1-4 1.2 Description of components... 1-7 1-2
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 locations the identification code of the pneumatic components the connecting, display and operating elements. Further information Information on the electric multipin can be found in the brief description of the CPA valve terminal with multipin connection. 1-3
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. Short compressed air tubing can therefore be used. System losses can therefore be minimized and the times required for pressurizing and exhausting the tubing can be minimized. This enables very compact valves with high flow rate to be used, therefore helping to reduce costs. CPA valve terminal with CPX terminal This CPA valve terminal is available with 2 to max. 22 singlecoil valve locations or up to max. 11 double-coil valve locations. Maximum 22 valve coils can be actuated. Fig. 1/1: CPA valve terminal with CPX terminal 1-4
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 1 2 3 CP connection 4 AS-Interface connection 3 4 Fig. 1/2: Variants of the CPA valve terminal CPA valve terminal with IC connection This CPA valve terminal is available with 2 to max. 22 valve locations. The electrical connection of the valve solenoid coils is made via individual connector plugs. Maximum 44 valve coils can be actuated. 1-5
1. System summary CPA valve terminal with MP connection This CPA valve terminal is available with 2 to max. 22 singlecoil valve locations or up to max. 11 double-coil valve locations. Maximum 22 valve coils can be actuated. The electrical connection of the valve solenoid coils is made centrally via the multipin plug. CPA valve terminal with CP connection This CPA valve terminal is available with 2 to max. 16 singlecoil valve locations or up to max. 8 double-coil valve locations. Maximum 16 valve coils can be actuated. The connection to the higher-order field bus node is made via special ready-to-use CP cables. CPA valve terminal with AS-Interface connection This CPA valve terminal is connected to the AS-Interface bus via special AS-Interface cables. It is available with two types of electrical connections: with additional power supply connection (load voltage can be switched off separately). without additional power supply connection. Both variants are available with 2 to max. 4 single-coil valve locations or up to max. 2 double-coil valve locations. Maximum 4 valve coils can be actuated. 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. 1-6
1. System summary 1.2 Description of components The CPA valve terminal consists of the following electrical components: 1 2 3 5 4 1 CPA valve terminal for the CP system: MP, CP or AS-Interface sub-base 2 The electrical manifold block (manifold block EV1 occupies 1 address, EV2 occupies 2 addresses) 3 Electrical bridge with manual override and LEDs 4 CPX adapter for fitting the CPX pneumatic interface 5 CPA valve terminals for the CPX terminal: CPX pneumatic interface Fig. 1/3: Electrical components of the CPA valve terminal 1-7
1. System summary The CPA valve terminal consists of the following pneumatic components: 1 2 9 3 3 4 5 6 8 7 1 Electrical bridge with manual override and LEDs 2 Cover block 3 End plate cover or large surfacemounted silencer 4 Right-hand end plate with supply and exhaust connections 5 Additional supply plate or blanking plate 6 Sub-base: with work connections with/without pressure zone separation in combination with supply plate for the compressed air supply 7 Left-hand end plate with supply and exhaust connections 8 CPX adapter for fitting the CPX pneumatic interface 9 Valve sub-base with single-solenoid or double-solenoid valves Fig. 1/4: Pneumatic components of the CPA valve terminal 1-8
1. System summary The max. number of valve locations on the CPA valve terminal variants is shown in the following table. Max. number of valve locations CPA valve terminal with CPX terminal IC connection MP connection CP connection AS-Interface connection 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 valve coils which can be actuated 22 *) 22 16 4 11 *) 11 8 2 22 44 22 16 4 *)InthecaseofCPAvalveterminalswithICconnection,themaximumnumberofvalvelocationsis limited to 22 due to the tie rod. Tab. 1/1: Maximum number of valve locations depending on the CPA valve terminal variants 1-9
1. System summary By means of the identification code, you can ascertain which valve sub-bases are fitted on your CPA valve terminal. This code is printed on the front of the valve sub-base. Ident. code B D I 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 blocked Valve sub-base, two 3/2-way, control side 12 in basic position open, control side 14 in basic position closed Valve sub-base, 5/2-way, double-solenoid Valve sub-base, two 3/2-way, single-solenoid, in basic position blocked Valve sub-base, 5/2-way, single-solenoid Valve sub-base, two 3/2-way, single-solenoid, in basic position open Sub-base for pressure zone separation, compressed air channel (1) blocked Valve sub-base, 5/2-way, single-solenoid on two-coil valve location Ident. code of the pneumatic components Further information on the valve sub-bases can be found in Appendix A. 1-10
1. System summary You will find the following connecting, display and operating elements on the CPA valve terminal: CPA valve terminal with IC connection CPA valve terminal with MP, CP or AS-Interface connection or with CPX terminal 1 1 2 5 4 3 5 4 3 1 Manual override (per pilot solenoid, locking or non-locking) 2 Clip (only with non-locking 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
1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal: 1 2 3 5 4 1 Ready-to-use cable with socket for connectong a valve solenoid coil 2 Clip with identification field (per cable socket) 3 Yellow LED per cable socket, shows signal status of the pilot solenoids 4 Terminal lugs of pilot solenoid coil 12 5 Terminal lugs of pilot solenoid coil 14 Fig. 1/6: Electrical connecting and display elements of the CPA valve terminal with IC connection 1-12
1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal with MP connection: 1 2 3 1 Identification clips 2 Yellow LED, signal status displays of the pilot solenoids 3 Sub-D multipin plug (25-pin) Fig. 1/7: Electrical connecting and display elements of the CPA valve terminal with MP connection 1-13
1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal with CP connection: 1 2 3 6 5 4 1 Green LED, status display of the CP connection 2 Incoming CP cable 3 Yellow LED, signal status display of the pilot solenoids 4 Continuing CP cable 5 Earth/ground connection 6 Identification clips Fig. 1/8: Electrical connecting and display elements of the CPA valve terminal with CP connection 1-14
1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal with AS-Interface connection: 1 2 3 8 7 6 5 1 AS-Interface cable cap 4 2 Identification clips of the valve sub-bases 3 Yellow LED, signal status display of the pilot solenoids 4 Identification clips of the AS-Interface connection 5 AS-Interface bus socket with yellow bus cable 6 Earth/ground connection 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
1. System summary You will find the following electrical connecting and display elements on the CPA valve terminal with CPX terminal: 1 2 3 4 1 Red LED, fault display of the pneumatic interface 2 DIL switch for setting the number of valve addresses 3 Identification clips 4 Yellow LED, signal status displays of the pilot solenoids Fig. 1/10: 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-..). 1-16
Fitting Chapter 2 2-1
2. Fitting Contents 2. Fitting... 2-1 2.1 Fitting variants... 2-4 2.1.1 Fitting onto a wall... 2-5 2.1.2 Hat rail fitting... 2-6 2-2
2. Fitting Contents of this chapter Further information This chapter explains how you should fit and dismantle the complete CPA valve terminal. Special information on replacing or adding pneumatic components can be found in chapter 5. CPA valve terminal with CPX terminal: Information on fitting the CPA valve terminal with CPX terminal can be found in the CP system manual. Information on fitting and dismantling the module electronics and sub-bases can be found in the manual 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
2. Fitting 2.1 Fitting variants Warning Switch off the following power supplies before undertaking installation and/or maintenance work: the compressed air supply the power supply for the valve solenoid coils. You can thereby avoid: uncontrolled movements of loose tubing, unexpected movements of the connected actuators, non-defined switching states of the electronic components. The CPA valve terminal has already been prepared for incorporation in a system or machine using one of the following fitting variants: fitting onto a wall fitting onto a hat rail. Please note Hat rails fitted with CPA14 valve terminals can break if they are subjected to vibration which exceeds the following values: 0.15 mm path at 10...58 Hz 2 g acceleration at 58...150 Hz. This can cause damage to the CPA valve terminal or to your machine or system. Use the wall fitting for CPA14 valve terminals. 2-4
2. Fitting 2.1.1 Fitting onto a wall Fitting the CPA valve terminal with CPX terminal onto a wall is described in the system manual P.BE-CPX-SYS-.... Proceed as follows: 1. Make sure that the fastening 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 cables and compressed air tubing. 3. Drill four mounting holes in the fastening surface (distance between holes see table). 4 1 4 2 3 2 4 CPA10 terminal 1 66.3 mm 2 23 mm 3 10.6 mm x number of sub-bases 4 4 holes for fitting onto a wall CPA14 terminal 1 76.1 mm 2 26 mm 3 14.6 mm x number of sub-bases 4 4 holes for fitting onto a wall Fig. 2/1: Position of the fastening holes 2-5
2. Fitting 4. Fasten the CPA valve terminal with four M4 screws of sufficient length to the fastening surface (tightening torque 0.8 Nm). 2.1.2 Hat rail fitting Fitting the CPA valve terminal with CPX terminal onto a hat rail is described in the system manual P.BE-CPX-SYS-.... For fitting the CPA valve terminal onto a hat rail you will require fitting kit type CPA-BG-NRH. This kit consists of 2 M4x10 screws and 2 clamping elements. Proceed as follows: 1. Make sure that the fastening surface can support the weight of the CPA valve terminal (weights see Appendix A). 2. Fit the hat rail (support rail as per EN 50022 35x7.5; width 35 mm, height 7.5 mm). Make sure there is sufficient space for connecting the power cables and compressed air tubing. 3. Fasten the hat rail to the fastening surface at intervals of approx. every 100 mm. 4. Mount the hat rail clamping units on the end plates of the CPA valve terminal (see diagram). 5. HangtheCPAvalveterminalontothehatrail(seearrowA). 6. Swing the CPA valve terminal onto the hat rail (see arrow B). Make sure that the clamping element lies horizontally to the hat rail. 7. Fasten the CPA valve terminal against tilting or sliding by tightening the locking screws on both sides with 1.3 Nm. 2-6
2. Fitting 1 Hat rail 2 Self-cutting M4x10 screw of the hat rail clamping unit 3 Clamping element of the hat rail clamping unit (A) 1 (B) 2 3 Fig. 2/2: Fitting the CPA valve terminal onto a hat rail 2-7
2. Fitting 2-8
Installation Chapter 3 3-1
3. Installation Contents 3. Installation... 3-1 3.1 Preparing the compressed air... 3-4 3.1.1 Operation with non-lubricated compressed air... 3-4 3.1.2 Operation with lubricated compressed air... 3-5 3.2 General connecting methods... 3-7 3.2.1 Laying the tubing... 3-7 3.2.2 Basic information... 3-8 3.3 Connecting the CPA valve terminal... 3-9 3.3.1 Auxiliary pilot air... 3-9 3.3.2 CPAvalveterminalwithpressurezoneseparation... 3-12 3.3.3 Connecting the supply, exhaust and work lines... 3-14 3.3.4 Connecting the electric cables... 3-20 3.4 Address assignment of the valves... 3-24 3-2
3. Installation Contents of this chapter This chapter describes the tubing and cabling of the CPA valve terminal. The following belong here: General instructions on preparing the compressed air and on connecting the tubing Instructions on operation with external/internal auxiliary pilot air Instructions on operating CPA valve terminals with pressure zone separation Fitting the pin-type inserts and QS screw connectors Connecting the power supply Earthing the CPA valve terminal with CP or AS-Interface connection 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 multipin 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 CP system manual. Information on connecting the CPA valve terminal with CPX terminal can be found in the CP system manual. 3-3
3. Installation 3.1 Preparing the compressed air Caution Dirty or incorrectly lubricated compressed air will reduce the service life of the valve terminal. 3.1.1 Operation with non-lubricated 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 8573-1 class 2). If mineral oils are used (e.g. HLP oils as per DIN 51524 parts 1 to 3) or corresponding oils on a polyalphaolefine basis (PAO), the residual oil content must not exceed 5mg/m 3 (see ISO 8573-1 class 4). You will thereby avoid functional damage 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
3. Installation 3.1.2 Operation with lubricated compressed air Please note Please use non-lubricated air in your system if possible in order to protect the environment. Festo pneumatic valves and cylinders have been designed so that, if used as intended, they will not require additional lubrication and will still achieve a long service life. Please note the following instructions if lubricated compressed air must be used. The compressed air prepared with the compressor must correspond in quality to non-lubricated compressed air. If possible, do not operate the complete system with lubricated compressed air. If possible, always install the lubricators directly in front of the consuming cylinder. Caution Incorrect additional oil and too much residual oil content in the compressed air will reduce the service life of the valve terminal. Use Festo special oil OFSW-32 or the other oils listed in the Festo catalogue (as per DIN51524-HLP32, basic viscosity 32cST at 40 C). The additional lubrication must not exceed 25 mg/m 3 (ISO 8573-1 class 5). Make sure that the lubricator setting is correct (see following section). You will thereby avoid functional damage of the valves. Setting the lubricator With the machine running (typical operating status) 0.2 to max. 1 drop/min. or 0.5 to 5 drops/1000 l air. 3-5
3. Installation Checking the lubricator setting Proceed as follows: Check the service unit in respect of condensate and lubricator setting twice a week. 1. Ascertain the cylinder which is furthest from the lubricator. 2. Ascertain the valve terminal which controls this cylinder. 3. Remove the silencer, if fitted, from connection 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 only be a slight yellow colouring on the cardboard. If oil drops out, this is an indication that too much oil has been used. A further indication of excessive lubrication is the colouring or status of the exhaust silencer. A distinctly yellow colouring of the filter element or drops of oil on the silencer indicate that the lubricator setting is too high. 3-6
3. Installation 3.2 General connecting methods Warning Switch off the following power supplies before undertaking installation and/or maintenance work: the compressed air supply the power supply for the valve solenoid coils. You can thereby avoid: sudden uncontrolled movements of loose tubing, unexpected movements of the connected actuators, non-defined switching states of the electronic components. 3.2.1 Laying the tubing If elbow screw connectors or multiple distributors are used, the airflow will be reduced slightly. 3-7
3. Installation 3.2.2 Basic information Connecting 1. Push tubing (B) as far as possible into the tubing connection of the pin types or screw connector. If necessary, press down locking ring (A). 2. For reasons of clarity, group the tubing together with: tubingstrapsor multiple hose holders. Removing 1. Press down the blue locking ring (A) of the screw connector. 2. Pull out tubing (B). 3. Seal unused connections with blind plugs or threaded blind plugs (C). 1 Pin-type insert 2 Pin-type adapter (with threaded connection) 3 QS screw connector Connecting 1 2 3 Removing Fig. 3/1: Tubing variants 3-8
3. Installation 3.3 Connecting the CPA valve terminal Seal the work connections (2 or 4) with blind plugs or threaded blind plugs on sub-bases fitted with blanking plates. 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. 3.3.1 Auxiliary pilot air Caution If possible, operate the CPA valve terminal with nonlubricated auxiliary pilot air (connections 12/14). Otherwise observe the instructions in the section Preparing the compressed air. With CPA valve terminals with internally branched auxiliary pilot air, the above mentioned instruction also applies to the supply air (connection 1). With CPV valve terminals with two pressure zones and internally branched auxiliary pilot air: Due to the internally branched auxiliary pilot air in the right-hand end plate, the pressure in the right-hand pressure zone must be 3...8 bar. The CPA valve terminal can be operated with internal or external pilot air, depending on the right-hand end plate. You can ascertain the auxiliary pilot air variant for which your CPA valve terminal is equipped by the type designation on the right-hand end plate (see table). 3-9
3. Installation CPA valve terminal With external pilot air With internal pilot air Right-hand end plate type CPA..-EPR-S CPA..-EPR Tab. 3/1: End plates for internal or external pilot air Internal pilot air If the supply pressure of your CPV valve terminal lies between 3...8 bar, you can operate the terminal with internally branched auxiliary pilot air. In this case the auxiliary pilot air will be taken from connection 1 in the right-hand end plate. If the CPA valve terminal with internal pilot air is used, the centre connection must be fitted with a blind plug (see diagram). 1 1 Seal connection with a blind plug Fig. 3/2: Internal pilot air 3-10
3. Installation External pilot air If the supply pressure of your CPA valve terminal does not lie between 3...8 bar, you must operate the terminal with external pilot air. In this case, the auxiliary pilot air is supplied externally via connection 12/14. Please note Used regulated pilot air (3...8 bar). Reliable and faultless operation of the CPA valve terminal is then possible. 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 must be set to correspond with the supply pressure at which these valve are operated (see diagrams). 1 Control pressure 12/14 (bar) 2 Work pressure P1 (bar) 3 Start-up pressure 1 3 2 Fig. 3/3: External pilot air diagram for valve sub-bases CPA10 with Ident. codes N, K, H 3-11
3. Installation 1 Control pressure 12/14 (bar) 3 2 Work pressure P1 (bar) 3 Start-up pressure 1 2 Fig. 3/4: External pilot air diagram for valve sub-bases CPA14 with Ident. codes N, K, H Note that the regulated external pilot air for all valve subbases on the CPV valve terminal is supplied or branched via common tubing on the right-hand end plate. This also applies if the CPA valve terminal is operated with different pressure zones (see Fig. 3/5). 3.3.2 CPAvalveterminalwithpressurezoneseparation The CPA valve terminal can be fitted with the following number of pressure zones depending on the connection variant: Electrical connection variants IC, MP or CPX CP AS-Interface Pressure zones 1...12 1...9 1...3 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). 3-12
3. Installation Valve sub-bases, which are fitted onto sub-bases with pressure zone separation, are supplied with compressed air which is provided to the left of this sub-base (see Fig. 3/5). 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 connection 1 on the left-hand end plate; the right-hand pressure zone is supplied via connection 1 on the right-hand end plate. CPA valve terminal with more than two pressure zones A sub-base with pressure zone separation is required for each pressure zone. The outer pressure zones are supplied with compressed air via connection 1 on the end plates, the remaining pressure zones are supplied with compressed air via connection 2 on the sub-bases which are fitted with additional supply plates (see diagram). As an additional aid to remove the exhaust air, a silencer can be fitted at connection 4 on these sub-bases. If connection 4 is not used, it must be sealed with a blind plug. 3-13
3. Installation 1 2 3 4 5 1 Additional pressure supply plate 2 Designation of the sub-bases with pressure zone separation (grey dot) 3 Pressure zone 1 (compressed air supply via connection 1 on the left-hand end plate) 4 Pressure zone 2 (compressed air supply via connection 2 on the sub-base with additional pressure supply plate) 5 Pressure zone 3 (compressed air supply via connection 1 on the right-hand end plate) Fig. 3/5: Example: Pressure zone separation and external pilot air 3.3.3 Connecting the supply, exhaust and work lines Fit the tubing as described below. Then lay the pneumatic tubing. 3-14
3. Installation Proceed as follows: 1. Use the following table for selecting the correct pin-type inserts: Connection code ISO 5599 Tubing CPA10 terminal Pin-type size CPA14 terminal Pin-type size 1 3/5 With threaded connection also connections 12/14 and 82/84 Compressed air/vacuum, exhaust Tubing connections: QSP14-6 QSP14-8 QSP14-1/4-U QSP14-5/16-U Blind plug: QSP14-PTB Threaded connection: CPA10-PTE-1/8-M5 CPA10-PTE-1/8NPT-10-32-UNF Blind screw: B-1/8 B-1/8NPT Tubing connections: QSP18-8 QSP18-10 QSP18-5/16-U QSP18-3/8-U Blind plug: QSP18-PTB Threaded connection: CPA14-PTE-1/4-M5 CPA14-PTE-1/4NPT-10-32-UNF Blind screw: B-1/4 B-1/4NPT 2or4 12/14 82/84 CPA14 terminal: Values in brackets for 12/14 or 82/84 With threaded connection not 12/14 or 82/84 Work air/ vacuum, additional pressure supply, pilot air exhaust Tubing connections: QSP10-4 QSP10-6 QSP10-5/32-U QSP10-3/16-U Blind plug: QSP10-PTB Threaded connection: CPA10-PTA-M5 CPA10-PTA-M7 CPA10-PTA-10-32-UNF Blind screw: B-M5-B B-M7 (only connection 2/4) Silencer: UC-QS-6H UC-QS-..H Tubing connections: QSP14-6 (QSP10-4) QSP14-8 (QSP10-6) QSP14-1/4-U (QSP10-5/32-U) QSP14-5/16-U (QSP10-3/16-U) Blind plug: QSP14-PTB (QSP10-PTB) Threaded connection: CPA14-PTA-1/8 CPA14-PTA-1/8NPT Blind screw: B-1/8 (B-M5-B) B-1/8N Tab. 3/3: Pin-type inserts 3-15
3. Installation 2. Check that the seal of the pin-type is greased. If necessary, grease the seal with Festo F2 grease. 3. Press the pin type inserts into the holes in the sub-base. 4. Make sure that the pin-type inserts are seated as far as possible in the holes. Measure here the distance between the connecting level and the locking ring of the pin-type inserts (see diagram). 1 1 5.5 mm (CPA10) or 6.5 mm (CPA14) Fig. 3/6: Checking the pin-type fitting 3-16
3. Installation 5. Secure the pin type inserts with the clamping springs (see diagram). 1 Clamping springs 2 Pin-type inserts 1 2 Fig. 3/7: Fitting and removing the pin-type inserts 6. In the case of pin type inserts with threaded connection, screw in the connectors. 7. Fit the tubing as shown in Fig. 3/1. 3-17
3. Installation Observe the following instructions on installing the pneumatic components. Only then can you guarantee faultless operation. If you have several systems with central ducted exhaust air, use non-return valves in the common exhaust lines in order to prevent functional impairment due to back pressures. 1 CPA valve terminal 1 2 Common 3/5 3 Central 82/84 1 2 3 4 5 4 Central 3/5 5 CPA valve terminal 2 6 Common 82/84 6 2 6 2 Fig. 3/8: Common lines with non-return valves In the case of CPA valve terminals with two or more pressure zones and auxiliary pilot air branched internally on the right-hand side, the pressure for the pressure zone on the outside right must be 3...8 bar. 3-18
3. Installation Vacuum/low pressure operation The CPA valve terminal can be operated with vacuum or low pressure > 0.9... < 3 bar under the following conditions: regulated auxiliary pilot air must be supplied separately. the CPA valve terminal must be 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 in mid-position pressurized (Ident. code B), blocked (Ident. code G) or exhausted (Ident. code E). Please note Valve sub-bases with 3/2-way valves (Ident. code N, K or H) cannot be used for vacuum or low-pressure operation. If your CPA valve terminal is fitted with these valve subbases, a separate pressure zone must be provided for these valves (supply pressure see Fig. 3/3 for CPA10 or Fig. 3/4 for CPA14). 3-19
3. Installation 3.3.4 Connecting the electric cables Information on the connection procedure as well as on cables and current requirements can be found in the manual CP System, installation and commissioning. Warning Use only power units which guarantee reliable isolation of the operating voltages as per IEC 742/EN 60742/VDE 0551 with at least 4 kv isolation resistance (Protected Extra Low Voltage PELV). Switch power packs are permitted, providing they guarantee reliable isolation in accordance with EN 60950/VDE 0805. Please note: By the use of PELV power units, protection against electric shock (protection against direct and indirect contact) is guaranteed with the Festo valve terminals in accordance with EN 60204-1/IEC 204. Safety transformers with the adjacent symbol must be used for supplying PELV networks. The valve terminals must be earthed to ensure that they function correctly (e.g. EMC). Please note Check within the framework of your EMERGENCY STOP circuit, to ascertain the measures necessary for putting your machine/system into a safe state in the event of an EMERGENCY STOP (e.g. switching off the operating voltage for the valves and output modules, switching off the compressed air). Earthing the CPA valve terminal with CPX terminal Instructions on earthing the CPA valve terminal with CPX terminal can be found in the CPX system manual. 3-20
3. Installation EarthingtheCPAvalveterminalwithCPorAS-Interface connection Please note Earth your CPA valve terminal. Connect the earth connection on the electrical sub-base (see diagram) with low impedance (short cable with large cross-sectional area) to the earth potential. In this way, you will avoid interference caused by electromagnetic influences. 1 1 Earth/ground connection Fig. 3/9: of the CPA valve terminal with CP connection CPA valve terminal with IC connection With this variant of the CPA valve terminal each valve solenoid coil is connected separately. 3-21
3. Installation Use the ready-to-use connector socket KMYZ-7-24-...-LED from Festo for connecting the valve solenoid coils. The holding current reduction for the valve solenoid coil and an LED are incorporated in the transparent plug of this connector socket. The LED indicates the switching status of the valve solenoid coils. Please note If the CPA valve terminal with IC connection is used at maximum operating temperature and 100 % switch-on duration, it must be operated wth current reduction. Use here the connector socket KMYZ-7-24-...-LED. Connect the valve solenoid coils as follows: 1. Insert the socket onto the terminal lugs of the appropriate pilot solenoid or intermediate plug. The socket can be fittedturned180.makesurethatthecentringboltbetween the terminal lugs grips into the hole in the socket (see diagram). 2. Screw the socket together with the locking screw with 0.2 Nm. 3-22
3. Installation 1 Connector socket 2 Terminal lug of valve solenoid 1 2 Fig. 3/10: Fitting the individual connector sockets 3-23
3. Installation 3.4 Address assignment of the valves CPA valve terminal with MP, CP, AS-Interface connection or CPX terminal The addresses must be assigned in ascending order without gaps. Depending on the manifold block, a valve location occupies one address (CPA..-EV1) or two addresses (CPA..-EV2). You can ascertain which manifold blocks are fitted on your CPA valve terminal by means of the identification marking on the manifold block (see diagram). 1 Fig. 3/11: Marking the manifold blocks Counting begins from left to right, on the individual valve plates from the rear to the front (see diagram). 3-24
3. Installation If a manifold block occupies 2 addresses, the following applies: solenoid coil 14 occupies the lower-value address; solenoid coil 12 occupies the higher-value address. 1 Valve sub-base with two solenoid coils 1 1 1 2 2 Blanking plate with manifold block EV2 3 Blanking plate with manifold block EV1 6 0 2 4 5 7 8 10 12 4 Valve sub-base with one solenoid coil 5 Addresses of coil 12 5 14 14 12 12 1 3 14 14 14 12 12 6 9 11 6 Addresses of coil 14 4 4 3 Fig. 3/12: Example: Address assignment of CPA valve terminal with MP connection and 8 valve locations (top view) CPA valve terminal with MP or AS-Interface connection Connecting the MP or AS-Interface cable Instructions on the electrical connections can be found in the leaflet supplied with the product. 3-25
3. Installation CPA valve terminal with IC connection The addresses must be assigned in ascending order without gaps Counting begins from left to right, on the individual valve plates from the rear to the front (see diagram). 1 Valve sub-base with two solenoid coils 0 2 4 5 7 8 2 Valve sub-base with one solenoid coil 3 Blanking plate 1 3 6 9 1 2 3 Fig. 3/13: Address assignment of a CPA valve terminal with IC connection and 8 valve locations (top view) CPA valve terminal with CP connection Connecting the CP cable Instructions on the electrical connections can be found in the manual CP system, general installation and commissioning, chapter 3. CPA valve terminal with CPX terminal Instructions on the electrical connections can be found in chapter 3 of the system manual. 3-26
Commissioning Chapter 4 4-1
4. Commissioning Contents 4. Commissioning... 4-1 4.1 Testing the valves... 4-4 4.1.1 Checking the valve functions... 4-5 4.1.2 Checking the valve-cylinder combination... 4-9 4.2 Eliminating faults... 4-15 4.2.1 Impairment of function... 4-15 4.2.2 LED display of the valves... 4-17 4-2
4. Commissioning Contents of this chapter This chapter describes the commissioning of the CPA valve terminal. The following belong here: Checking the valve functions Operating the manual override Checking the valve-cylinder combination Eliminating faults TheassignmentoftheLEDs Further information Commissioning of the CP system is described in the appropriatemanualforthecpnode. Commissioning of the CPX terminal is described in the appropriatemanualforthecpxfieldbusnode. 4-3
4. Commissioning 4.1 Testing the valves The CPA valve terminal should be commissioned as follows: Commissioning variants Preliminary test of the pneumatic tubing Complete commissioning of the complete system Actiivity Testing the valve-cylindercombination by means of the manual override Installing and connecting thecompletesystem. Program control via PLC/ industrial PC. Tab. 4/1: Commissioning variants Commissioning the pneumatic components by means of the manual override is described below. 4-4
4. Commissioning 4.1.1 Checking the valve functions Manual override Warning Before actuating the manual override: Uncontrolled actuation of the valve solenoid coils can cause the actuators to perform sudden unexpected movements which may cause injury to human beings and damage to property. Disconnect the power supply for the valve solenoid coils from the relevant connections on the CPA valve terminal. You will thereby avoid undesired actuation of the valve solenoid coils. Before switching on the power supply: During commissioning, manual override actuations which are in the switched state can cause actuators to perform sudden unexpected movements. These movements can cause injury to human beings and damage to property. Make sure that all manual override actuations are in their basic positions. You will thereby avoid undefined switching states of the valves. You should use the manual override especially when commissioning the pneumatic system, in order to check the function and operation of the valve or the valve-cylinder-combination. By actuating the manual override, you can switch the valve without an electric signal. You only need to switch on the compressed air supply. 4-5
4. Commissioning Types of manual override The manual override has been designed to be used as follows: Types of manual override Manual override with automatic reset (non-locking) Locking manual override Manual override covered Method of operation After actuation the manual override is reset by a pneumatic spring. The manual override remains actuated until it is reset by hand. No manual override function Tab. 4/2: Variants of the manual override The following manual override variants are available for CPA valve terminals with MP, CP, AS-Interface connection or CPX terminal: 4-6
4. Commissioning Locking manual override 1 Non-locking manual override 3 2 4 1 Slide of locking manual override to pilot solenoid 14 2 Slide of locking manual override to pilot solenoid 12 3 Push button of non-locking manual override to pilot solenoid 14 4 Push button of non-locking manual override to pilot solenoid 12 Fig. 4/1: Manual override variants of the CPA valve terminal with MP, CP, AS-Interface connection or CPX terminal Both the locking and the non-locking types of manual override can be used with CPA valve terminals with IC connection. 4-7