Valve terminal Type 04-B User manual Pneumatics Valve terminal with ISO-valves Type IFB..-04B User manual 163 941 en 0005c
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... KI-TD Edition... en 0005c Title... MANUAL-EN Designation... P.BE-VIISO-04B-EN Order-no.... 163 941 (Festo AG & Co., D-73726 Esslingen, Federal Republic of Germany, 2000) 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 registrations. I
Contents and general instructions II
Contents and general instructions Contents Designated use... Target group... Service... Important user instructions... Abbreviations... Manuals for this valve terminal... V VI VI VII IX XI 1. Summary of components... 1-1 1.1 Overview of multi-functional Festo valve terminals... 1-3 1.2 Component description... 1-4 1.2.1 Type 03/04-B: Electric modules... 1-4 1.2.2 ISO pneumatic module type 04-B... 1-5 1.3 Combination options per valve location... 1-7 1.4 Method of operation... 1-9 1.5 System structure... 1-11 2. Fitting... 2-1 2.1 Mounting the valve terminal... 2-3 2.1.1 Installing a valve in a vacant valve location... 2-5 2.1.2 Installation of additional components... 2-7 2.1.3 Earthing the end plates... 2-8 2.2 Wall mounting the valve terminal... 2-9 2.2.1 Rear side mounting... 2-11 III
Contents and general instructions 3. Installation... 3-1 3.1 General connection methods... 3-3 3.1.1 Laying thetubing... 3-3 3.1.2 Basic information... 3-4 3.2 Connecting the valve terminal... 3-5 3.2.1 Preparing the sub-base... 3-5 3.2.2 Connecting the supply lines... 3-7 3.2.3 Connecting the working lines... 3-9 3.2.4 Auxiliary pilot air... 3-10 3.2.5 Conversion from internal to external auxiliary pilot air... 3-11 3.2.6 Changing the position of the stopping pin... 3-12 3.2.7 Rotating the code seal... 3-13 3.2.8 Terminal with external pilot air and two different pressure zones... 3-14 4. Commissioning... 4-1 4.1 Commissioning tests... 4-3 4.1.1 Checking the valve functions... 4-4 4.1.2 Checking the valve-cylinder combination... 4-6 4.2 Error diagnosis... 4-8 4.2.1 Impairment of function... 4-8 4.2.2 LED displays of the valves... 4-10 4.3 Troubleshooting... 4-11 4.3.1 Replacing the valve solenoid coil fuse... 4-11 A. Technical appendix... A-1 A.1 Technical specifications... A-3 A.2 Manual valve terminal configuration type 04-B... A-9 A.2.1 Differences between automatic/manual valve terminal configuration... A-10 A.2.2 Manual configuration procedure... A-11 A.2.3 Notes regarding configuration... A-15 A.3 Index... A-17 IV
Contents and general instructions Designated use The valve terminal described in this manual is intended exclusively for use as follows: for controlling pneumatic and electric actuators (valves and output modules) for interrogating electric sensor signals by means of the input modules. Use the valve terminal only as follows: in accordance with designated use in faultless technical condition without any modifications by the user. If additional commercially-available components such as sensors and actuators are connected, the specified limits for pressures, temperatures, electrical data, torques, etc. must not be exceeded. Please observe the standards specified in the relevant chapters and comply with technical regulations, as well as with national and local regulations. V
Contents and general instructions Additional modules for this valve terminal The multifunctional valve terminal can be extended with the following modules: I/O modules Type designation VIGE-03-FB-... VIGE-03-FB-16-SUBD-S VIGA-03-FB-... VIGV-03-FB-... VIEA-03-FB-... VIA-03-FB VIAP-03-FB VIASI-03-M Title Input module with 4 or 8 inputs, PNP or NPN, 4-pin or 5-pin, with/without electronic fuse Input module with 16 inputs, PNP, 15-pin sub-d connection socket, with electronic fuse Output module with 4 outputs, PNP or NPN, 4-pin or 5-pin Additional supply module 24 V/25 A for high-current outputs Multi I/O module with 12 inputs and 8 outputs, PNP Analog I/O module with 3 inputs and 3 outputs Analog I/O module with 1 input and 1 output AS-Interface Master Target group This manual is intended exclusively for technicians trained in control and automation technology, who have experience in installing, commissioning, programming and diagnosing programmable logic controllers and field bus systems. Service Please consult your local Festo service centre if you have any technical problems. VI
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. VII
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 information sources. Accessories Information on necessary or suitable accessories for the Festo product. Environment: Information on environment-friendly use of Festo products. Text markings The bullet point indicates activities that can be carried out in any order. 1. Figures denote activities which must be carried out in the numerical order specified. Hyphens indicate general activities. VIII
Contents and general instructions Abbreviations The following product-specific abbreviations are used in this manual: Abbreviation Components Flow control I O I/O I/O module Nodes P-module PLC Regulator Solenoid intermediate plate Sub-base Single-solenoid sub-base Double-solenoid sub-base Terminal or valve terminal Meaning General term for valves, flow control plates, pressure regulator intermediate plates, cover plates Flow control plate Input Output Input/output General module with digital inputs or outputs Fieldbus nodes or control unit SB202, SF202 SB50, SF50 General pneumatic module Programmable logic controller; abbreviation: controller Pressure regulator intermediate plate Plate with pilot solenoids, air ducts and electric plug connection as per ISO 5599/2 Manifold sub-base with MUH solenoid intermediate plate and pneumatic valve with hole pattern as per ISO 5599/2, size 1, 2 or 3 Sub-base for single-solenoid valves Sub-base for double-solenoid or mid-position valves Valve terminal, type 04-B as per ISO 5599/2 with/without electric inputs/outputs Fig. 0/1: List of abbreviations IX
Contents and general instructions Please note A simplified representation of a type 03 valve terminal with four pneumatic sub-bases and four input/output modules (standard fitting) has been used for most drawings in this manual. 1 Input/output modules 1 2 3 2 Fieldbus node 3 Valves Fig. 0/2: Standard fitting for the drawings X
Contents and general instructions Manuals for this valve terminal This handbook contains manuals for the following pneumatic components: Product ValveTerminaltype04-B Design/accessory ISO valves, sizes 1, 2 or 3 with separate auxiliary pilot air Single-solenoid valves (up to 26 valves) Double-solenoid valves (up to 13 valves) Mid-position valves, blocked, pressurized, exhausted (upto13valves) Flow control plate Pressure regulator intermediate plate Pressure switch Differential pressure switch Fig. 0/3: Pneumatic module type 04-B The manual includes a technical annex with the technical data for the pneumatic components of the valve terminal. For information regarding power supply and the electric modules of the valve terminal type 04-B, look at the appropriate electronics manual for the valve terminal. XI
Contents and general instructions Depending on what you have ordered and on the further extension of your complete system, the following Festo manuals are necessary for the complete documentation of the modular valve terminal: Festo designation P.BE-VIISO-04-B-... P.BE-VIEA-03... P.BE-VIAX-03... P.BE-VIASI-03... P.BE-VIFB-03... Title/product Pneumatics manual Valve terminal type 04-B, ISO 5599-2(this manual) Supplementary manual for I/O modules (digital I/O modules 4I, 8I, 4O, high-current output modules, multi I/O modules) Analog I/O manual AS-i Master manual Electronics manual (for the fieldbus connection) Fig. 0/4: Manuals for this valve terminal XII
Summary of components Chapter 1 1-1
1. Summary of components Contents 1. Summary of components... 1-1 1.1 Overview of multi-functional Festo valve terminals... 1-3 1.2 Component description... 1-4 1.2.1 Type 03/04-B: Electric modules... 1-4 1.2.2 ISO pneumatic module type 04-B... 1-5 1.3 Combination options per valve location... 1-7 1.4 Method of operation... 1-9 1.5 System structure... 1-11 1-2
1. Summary of components 1.1 Overview of multi-functional Festo valve terminals The multi-functional valve terminal is composed of individual modules and components. Valve terminal Type 03 Electric modules Type 04-B ISO pneumatic modules Description of the modules Electric modules suitable for Type 03/04B (PNP or NPN), fitted with: digital inputs (modules with 4, 8 or 16 inputs) digital outputs (modules with 4 outputs), 0.5 A high-current outputs 2 A multi-i/os (modules with 12I/8O), 0.5 A analog I/Os, AS-i-Master (not possible with all nodes) Pneumatic modules, Type 04-B, fitted with: adapter plate for sub-bases as per ISO 5599/2, in sizes 1, 2 and 3 sub-bases for solenoid intermediate plates with hole pattern as per ISO 5599/2, fitted with single-solenoid pneumatic valves, double-pilot valves, mid-position valves or cover plates components for vertical linking (pressure regulator intermediate plates, flow control plates, etc.) Fig. 1/1: Overview of modules in the multi-functional Festo valve terminals 1-3
1. Summary of components 1.2 Component description 1.2.1 Type 03/04-B: Electric modules You will find the following connecting and display elements on the electric modules: 2 3 4 5 6 7 1 9 1 Inputsocketfortwoelectricinputs (PNP or NPN) 2 RedLED(errordisplayforinput module with electronic fuse) 3 Two green LEDs (one LED for each input) 4 Input socket for one electric input (PNP or NPN) 8 6 Output socket for electric output (PNP) 7 Yellow LED (status display for output) 8 Red LED (error display per output) 9 Further modules (e.g. auxiliary power supply, high-current outputs PNP/ NPN) 5 Green LED (per input) Fig. 1/2: Connecting and display elements of the electric modules 1-4
1. Summary of components 1.2.2 ISO pneumatic module type 04-B The following connecting, display and operating elements are located on the components of the pneumatic ISO modules: 1 2 3 4 5 6 7 1 1 aj 2 2 8 5 6 9 8 1 Adapter plate 2 Valve fuses 3 Connection of power supply 4 Valve location inscription field 5 1 Yellow LEDs (for each pilot solenoid 14) 2 Yellow LEDs (for each pilot solenoid 12) 6 1 Manual override (for each pilot solenoid 14, non-locking) 2 Manual override (for each pilot solenoid 12, non-locking) 7 Fuse 0.315 A protected with cover (per pilot solenoid) 8 Central air supply 9 Working connections (per valve) aj Adapter cable for power supply to nodes and IO modules Fig. 1/3: Operating, display and connecting elements of the ISO module type 04-B 1-5
1. Summary of components The following connecting and operating elements are located on the components for vertical linking of pneumatic modules: Flow control plate 1 Pressure regulator 2 3 Pressure switch *) 4 Differential pressure switch *) 5 *) General schematic representation of these components: more detailed information can be found in the product leaflets 1 Adjusting screw for flow control rate 2 Connection for manometer 3 Regulator knob with snap-in locking (to adjust: pull knob out of the lock-in position and rotate) 4 Adjusting screw for pressure switch 5 Adjusting screw for differential pressure switch Fig. 1/4: Operating and connecting elements of the components for vertical linking 1-6
1. Summary of components 1.3 Combination options per valve location It is possible, on each valve location, to mount additional pneumatic components between the sub-base and the valve. This vertical linking permits the user to implement specific additionally desired operations. The following diagram shows theavailablecomponents: Valve Flow control plate, actuator speed adjustable Pressure regulator *) actuator strength adjustable Pressure switch *) rectified pressure interrogation (with signal output) Differential pressure switch *) rectified pressure interrogation (with signal output) Sub-base with solenoid intermediate plate **) **) *) Please note the instructions regarding the combination options on the following page. **) General schematic representation of these components. Fig. 1/5: Components for linking up higher levels 1-7
1. Summary of components Combination options Pressure regulator Pressure switch Differential pressure switch For permissible combination options, see the pneumatics main catalogue Fig. 1/6: Combination options 1-8
1. Summary of components 1.4 Method of operation The nodes carry out the following functions: Connection of the terminal to the respective fieldbus and power supply. System settings of the terminal: settings can be made for an automatic valve test and other node-dependent functions. Control of data transfer to/from the fieldbus interface components of the control system. Internal control of the terminal. 1 To fieldbus 2 From fieldbus 1 2 3 Nodes 4 Compressed air 4 5 Work air (2, 4) 3 5 Fig. 1/7: Function overview of a valve terminal Further information regarding nodes can be found in the respective valve terminal manual Electronics manual. 1-9
1. Summary of components The input modules carry out the processing of input signals (e.g. from sensors) and forward these signals via the fieldbus to the control system. The output modules are universal electric outputs and control small consumers with positive logic, e.g. other valves, lamps, etc. Additional I/O modules for special applications are also available. Further information about the use of all I/O modules can be found in the Supplementary manual for I/O modules in the valve terminal manual. The pneumatic modules provide the following connections: common ducts for supply and exhaust air electric signals for all solenoid valve coils. Each individual pneumatic module is fitted with the working connections 2 and 4 for all valve locations. The valves are supplied with compressed air and their exhaust and pilot exhaust air is ducted away via the common ducts of the pneumatic endplates or by using special supply modules. Additional modules are also available for pressurized supplies to, e.g. work at various working pressures or to mount ISO valves on a node. 1-10
1. Summary of components 1.5 System structure Festo can support you in solving your automation requirements at machine level with their valve terminals. The type 04-B valve terminals are modular in construction and permit combinations of pneumatic and electronic modules so that the following groupings are possible in a fieldbus: 1 2 7 3 4 5 6 1 PC or PLC with interface 2 Fieldbus 3 Valve terminal type 04-B: pneumatic modules only 5 Valve terminal type 03: pneumatic and electric modules 6 Other fieldbus slaves 7 Power unit for fieldbus slave 4 Valve terminal type 04-B: pneumatic and electric modules Fig. 1/1: System structure 1-11
1. Summary of components 1-12
Fitting Chapter 2 2-1
2. Fitting Contents 2. Fitting... 2-1 2.1 Mounting the valve terminal... 2-3 2.1.1 Installing a valve in a vacant valve location... 2-5 2.1.2 Installation of additional components... 2-7 2.1.3 Earthing the end plates... 2-8 2.2 Wall mounting the valve terminal... 2-9 2.2.1 Rear side mounting... 2-11 2-2
2. Fitting 2.1 Mounting the valve terminal Please note Valve terminal with two pressure zones: The terminal can be ordered from the factory with a two pressure zone design. To see if your terminal has two pressure zones, check the order documentation for the terminal. Subsequent conversion to two pressure zones can only be implemented by Festo Service. Warning Switch off the following before undertaking mounting work: the compressed air supply the operating voltage supply for the electronics (pin 1) the load voltage supply for the outputs/valves (pin 2). You can thereby avoid: uncontrolled movements of loose tubing unexpected movements of the connected actuators non-defined switching states of the electronic components. Caution Electrostatically sensitive components. Do not touch any contact surfaces on the lateral plug connectors of the modules and components. Observe the regulations for handling electrostatically sensitive components. You will then prevent the valve terminal module from being damaged. 2-3
2. Fitting The valve terminal is delivered fully assembled from the factory. If you wish to add or replace individual modules and components, please note the following manuals: For installing electric IO modules - Supplementary manual for IO modules. For installing the nodes - Electronics manual. For modules and components ordered at a later date, see the installation instructions in the accompanying product leaflet. Please note Handle the modules and components of the valve terminal carefully. Pay particular attention to the following: tighten screws without warping or mechanical stress correct positioning of the screws (otherwise danger of damaging the threads) maintain the specified torque avoid offset between modules (IP65) clean contact surfaces (avoidance of leakages and contact faults) close vacant valve locations with the appropriate cover plate (to be ordered separately). The screwed on terminal must be removed to extend or modify the valve terminal. Proceed as follows: switch off the power and compressed air supply for the terminal remove the terminal from the connection surfaces and place it on a flat surface clean the valve terminal before removing the components to prevent dirt from entering the air ducts of the components. 2-4
2. Fitting 2.1.1 Installing a valve in a vacant valve location Please note You will require the appropriate solenoid intermediate plate when installing a single-solenoid valve with spring resetting, a single-solenoid valve with pneumatic spring or adoublepilotvalve. Vacant valve locations are sealed with cover plates. This ensures the following: the empty spaces of the sub-base are protected against dirt pressure sealed closure of the valve and coil connection levels. Removing the cover plate Undo the screws on the cover plate of the relevant valve location and remove the cover plate from the sub-base. Installing the valve 1. Fit new seals. 2. Screw the 4 stud bolts provided into the fixing bores of the sub-base. 3. Place the solenoid intermediate plate on the sub-base. 2-5
2. Fitting 4. Position any additional components on the solenoid intermediate plate and screw the components on firmly. 5. Fasten the valve. 1 2 3 4 1 ISO valve 2 If required, insert vertical linking components here 3 Solenoid intermediate plate 4 Sub-base Fig. 2/1: Installing the valve 2-6
2. Fitting 2.1.2 Installation of additional components Decide where the additional component is to be inserted. Fig. 2/2: Installation of additional components Removing components 1. Undo the screws of all components above the relevant location. 2. Remove the components. Installing new components 1. Fit new seals. 2. Position the new component on the solenoid intermediate plate or if necessary on a previously fitted component. 3. Fasten the new component. 4. Install the previously removed components in the same manner as before. 2-7
2. Fitting 2.1.3 Earthing the end plates The valve terminal is fitted with left and right end plates to mechanically close the terminal. These end plates carry out the following functions: they ensure protection class IP65 they include connections/bores for the protective earthing (left end plate only) they include bores for wall mounting (ISO size 1 only) Warning The right end plate must be earthed before assembly! This will prevent high voltages on the metal surfaces in cases of faults. Right end plate This is conductively connected by metal screws to the linking plate. Left end plate This is conductively connected by pre-assembled spring contacts with the other components. Please note Notes regarding earthing of the entire valve terminal can befound in the Electronics manual, Installation chapter, of the valve terminal. 2-8
2. Fitting 2.2 Wall mounting the valve terminal Caution Use additional angle brackets for the modules (ca. every 200 mm) for longer terminals with several IO modules. You can thereby avoid: overloading the fixing eyes on the left end plate sagging of the terminal (IO side) self-resonances. Proceed as follows: 1. determine the weight of the terminal (weigh or calculate). Reference values: Determining the weight of the valve terminal Size 1 Size 2 Size 3 Per node 1.0 kg 1.0 kg 1.0 kg Per electric module 0.4 kg 0.4 kg 0.4 kg Adapter plate, right and left end plates Per sub-base including solenoid intermediate plate and valve 3.0 kg 3.2 kg 4.1 kg 1.2 kg 1.6 kg 2.4 kg Fig. 2/3: Weights of the valve terminal components 2. Ensure that your mounting surface can support this weight. Check whether angle brackets are required for the IO modules. 3. Mount the terminal in compliance with the following table. If necessary, use washers. The terminal can be installed in any position. 2-9
2. Fitting Type of terminal Type 04-B Mounting options withtwom6 screwsonthe left endplate with M6 screws (ISO size 1 and 2) or M8 screws (ISO size 3) for the adapter plate, the sub-bases and the right end plate. Where necessary, use the following additional mounting options: bores ( blind holes ) on the bottom of the sub-bases. additional angle brackets for the modules in terminals with several IO modules (ca. every 200 mm, see mounting instructions in the product leaflet of the angle brackets). Fig. 2/4: Mounting options for wall mounting 2-10
2. Fitting 2.2.1 Rear side mounting Bores (blind holes) are located on the rear side of the subbases to mount the terminal on machines or metal racks (rear side mounting). Threaded bolts must be cut for this purpose (ISO size 1: M5; ISO size 2: M6; ISO size 3: M8). All the above steps also apply in this case (see also the following diagram). 1 1 Blind hole Fig. 2/5: Blind hole for rear side mounting (diagram of sub-base ISO size 2) 2-11
2. Fitting 2-12
Installation Chapter 3 3-1
3. Installation Contents 3. Installation... 3-1 3.1 General connection methods... 3-3 3.1.1 Laying thetubing... 3-3 3.1.2 Basic information... 3-4 3.2 Connecting the valve terminal... 3-5 3.2.1 Preparing the sub-base... 3-5 3.2.2 Connecting the supply lines... 3-7 3.2.3 Connecting the working lines... 3-9 3.2.4 Auxiliary pilot air... 3-10 3.2.5 Conversion from internal to external auxiliary pilot air... 3-11 3.2.6 Changing the position of the stopping pin... 3-12 3.2.7 Rotating the code seal... 3-13 3.2.8 Terminal with external pilot air and two different pressure zones... 3-14 3-2
3. Installation 3.1 General connection methods Warning Before carrying out installation or maintenance work, switch off the following: the compressed air supply the operating voltage supply for the electronics (pin 1) the load voltage supply for the outputs (pin 2). You can thereby avoid: uncontrolled movements of loose tubing unexpected movements of the connected actuators non-defined switching states of the electronic components. 3.1.1 Laying thetubing Caution Place a suitable seal under each screw connector or silencer in order to avoid leakage. If elbow screw connectors or multiple distributors are used, the airflow will be reduced slightly. 3-3
3. Installation 3.1.2 Basic information Connecting 1. Push the tubing as far as possible over or into the tube connection of the screw connector. 2. If necessary, pull the locking ring over the tube connection or tighten the screw connector. 3. For reasons of clarity, group the tubing together with tube straps or multiple tube connector blocks. Removing 1. If necessary, loosen the locking screw or locking ring of the screw connector. 2. Pull out the tubing. 3. If necessary, replace the screw connectors with blind plugs. 3-4
3. Installation 3.2 Connecting the valve terminal 3.2.1 Preparing the sub-base Connections are available on the right end plate as well as on the top of the adapter plate. The common lines can therefore be connected as required on the left, right or both sides. In operations with two pressure zones, each side must be separately supplied with pressure. In order to guarantee the optimum efficiency of your valve terminal, we recommend in the following cases that you connect the compressed air tubing and, if necessary, also the exhaust air tubing: when large volume cylinders are operated at high speeds with basic operation cylinders when using terminals with more than 8 valves. 3-5
3. Installation Prepare the connections as follows: 1 Right end plate 2 Connections for common tubing 1 2 2 Connectionofcommontubing Only on adapter plate or only on right end plate Onthe adapterplate and right end plate Procedure Remove all adhesive film; insert blind plugs in adapter plate or right end plate (to be ordered separately) Remove all adhesive film Fig. 3/1: Supply connections on the adapter plate and right end plate 3-6
3. Installation 3.2.2 Connecting the supply lines Mount the screw connectors and silencers with the appropriate seals in compliance with the following table. Then lay the tubing. 1 2 5 1 3 14 5 1 Adapter plate with air supply connections 12 3 1 2 Right end plate with air connection for external pilot air Common tubing Connection Connection size ISO 228 designation ISO 5599 Size 1 Size 2 Size 3 Connection Compressed air 1 G 1/2 G 3/4 G 1 Screw connectors Exhaust air 3 5 G1/2 G1/2 G3/4 G3/4 G1 G1 Screw connectors with: - non-return valve - silencer External auxiliary pilot air 12, 14 G1/8 G1/8 G1/8 Screw connectors - in right-hand end plate Fig. 3/2: Connecting the supply hose lines 3-7
3. Installation Please note With several systems ducted exhaust air: use non-return valves in the common exhaust lines in order to prevent functional impairment due to back pressures. System 1 System 2 Common 3/5 Common 3/5 Common 3/5 Valve terminal Central 3/5 Valve termi Fig. 3/3: Common lines with non-return valves 3-8
3. Installation 3.2.3 Connecting the working lines Please note Remove the adhesive film and mount the seals as in Fig. 3/4. Then connect the tubing. When a mounted valve is not used: close connections 2 and 4 with suitable blind plugs (to be ordered separately). Size 1: Working connections 1 1 Sub-bases 2 4 Size 2, 3: Working connections 1 1 Sub-bases 4 2 Tubing Connection code Connection size ISO 228 Connection ISO 5599 Size 1 Size 2 Size 3 Work air 2or4 G1/4 G3/8 G1/2 Screw connectors or multiple distributors Fig. 3/4: Assignment of linking plates 3-9
3. Installation 3.2.4 Auxiliary pilot air The valve terminal type 04-B is, dependent on your order, set to internal or external auxiliary pilot air. Internal pilot air When the supply pressure of the valve terminal is within the range of 3 to 10 bar, it can be operated with internal pilot air. The auxiliary pilot air is branched off from connection P1. If the valve is set up for internal pilot air, a stopping plug is located in each of the air ducts 12 and 14 on the underside of the solenoid intermediate plate (see Fig. 3/5). the arrow of the code seal on the pneumatic spring side points to P (see Fig. 3/6) External pilot air When the supply pressure of the valve terminal is not within therangeof3to10bar,itmustbeoperatedwithexternal pilot air. The external auxiliary pilot air is fed in through connections 12 and 14 on the right end plate. If the valve is set up for external pilot air, a stopping plug is located in air duct P1 on the underside of the solenoid intermediate plate (see Fig. 3/5). The flow from P1 to the auxiliary pilot air ducts is thereby blocked. the arrow of the code seal on the pneumatic spring side points to S (see Fig. 3/6). 3-10
3. Installation Please note Only use pressure-controlled auxiliary pilot air. This permits reliable, problem-free operation of the valve terminal. It must be ensured that pressure-controlled auxiliary pilot air is fed or branched off from only one point to the common lines for all pneumatic components. This also applies if the valve terminal is operated with two pressure zones. 3.2.5 Conversion from internal to external auxiliary pilot air Warning Switch off the compressed air supply before beginning the conversion. Conversion from internal to external pilot air can be implemented regardless of the valve terminal design. Proceed as follows: change the position of the stopping pin on the underside of the solenoid intermediate plate (see Fig. 3/5) for valves with pneumatic spring: rotate the code seal on thespringsideofthevalve(seefig.3/6) for external pilot air: connect the auxiliary pilot air supply to connections 12 and 14 on the right end plate. For internal pilot air: the connections 12 and 14 on the right end plate must be closed with blind plugs (to be ordered separately). 3-11
3. Installation 3.2.6 Changing the position of the stopping pin undo valve if necessary, undo all components for vertical linking above the solenoid intermediate plate remove and rotate solenoid intermediate plate remove the seal for external auxiliary pilot air: remove the stopping pins from the air ducts 12 and 14 and insert a stopping pin in air duct P1 for internal auxiliary pilot air: remove the stopping pin from air duct P1 and insert stopping pins in air ducts 12 and 14 insert seal Mount components in reverse sequence 1 Stopping pin connection 14 2 Stopping pin connection P1 3 Stopping pin connection 12 1 2 3 Fig. 3/5: Solenoid intermediate plate with the positions of the stopping pins in the air ducts 12, 14 and P1 3-12
3. Installation 3.2.7 Rotating the code seal Please note The code seal must only be rotated in valves with pneumatic springs. It is located under the cover plate on the ISO-C valve. undo and remove cover plate from the pneumatic spring side of the valve rotate code seal.the arrow must point to S for external pilot air and to P for internal pilot air. Ensure that the code seal is seated correctly position the cover plate on the code seal so that the shaped side points towards the arrow fasten the cover plate with both countersunk screws (torque 1.4 Nm) 1 Code seal 2 Cover plate External pilot air Internal pilot air 1 2 Fig. 3/6: Code seal 3-13
3. Installation 3.2.8 Terminal with external pilot air and two different pressure zones Warning When exhausting a pressure zone (e.g. during EMER- GENCY STOP), the external regulator must never become depressurised otherwise there will not be any auxiliary pilot air for the other pressure zones. 1 Externally controlled auxiliary pilot air 2 Pressure zone 2 1 3 Pressure zone 1 3 2 Fig. 3/7: Terminal with external pilot air and two different pressure ranges 3-14
Commissioning Chapter 4 4-1
4. Commissioning Contents 4. Commissioning... 4-1 4.1 Commissioning tests... 4-3 4.1.1 Checking the valve functions... 4-4 4.1.2 Checking the valve-cylinder combination... 4-6 4.2 Error diagnosis... 4-8 4.2.1 Impairment of function... 4-8 4.2.2 LED displays of the valves... 4-10 4.3 Troubleshooting... 4-11 4.3.1 Replacing the valve solenoid coil fuse... 4-11 4-2
4. Commissioning 4.1 Commissioning tests The following procedures are recommended when commissioning the valve terminal: Commissioning variants Pre-testing the pneumatic hose lines Full commissioning of the complete system Measures Moving the valve-cylinder-combination by means of the manual override (MO) Installing and connecting the complete system (all fieldbus slaves). Program control using PLC/industrial PC Fig. 4/1: Commissioning variants Commissioning with MO is described below. Program controlled commissioning is described in the manual for the relevant node. 4-3
4. Commissioning 4.1.1 Checking the valve functions Manual override (MO) Warning Only use the MO when the valves are in a voltage-free state. Before actuating the electronic signals: Ensure that all MO are reset to the start position. The MO is mainly used during commissioning of the pneumatic system to check the function and operation of the valve or the valve-cylinder combination. The MO is used to switch the valve without an electric signal. You only need to switch on the compressed air supply. 4-4
4. Commissioning Types of manual override The MO is designed for the following uses: MO type MO with automatic return (non-locking) Method of operation After actuation, the MO is reset by spring force. Fig. 4/2: MO type 1 1 Non-locking manual override Fig. 4/3: Position of the MO 4-5
4. Commissioning 4.1.2 Checking the valve-cylinder combination Warning When pressurizing or re-pressurizing the valve terminal under the following conditions: using a safety switch-on valve (slow pressurizing) and with existing electric signals (e.g.followinganemergencystop). The auxiliary pilot air must reach full pressure immediately after being switched on, otherwise the slow build-up in pressure of the complete supply will have no effect on the cylinders: activated by the mid-position valve exhausted in the normal position activated by the mid-position valve blocked in the normal position activated by single-solenoid valves activated by double-solenoid valves which are switched to flow position during the pressureless phase. Separately supplied auxiliary pilot air Pressure increase of complete supply Pressure increase in the auxiliary pilot air (12,14) Switching time of a valve Movement of the cylinder With regulator Slowly Slowly After pressure increase with (1) Fast Without regulator Slowly Fast Before pressure increase with (1) Slowly Fig. 4/4: Effects of slow switch-on pressurization with existing electric signals 4-6
4. Commissioning Execution of test 1. Switch on the compressed air supply. 2. Check the function and operation of each individual valvecylinder combination by actuating the manual override as shown in the following diagrams. 3. Switch off the compressed air supply. Actuation of MO with automatic return (non-locking) Push the MO piston in as far as possible Reaction of the valve The valve: switches Hold the piston down Release the piston. The spring resets the piston of the MO to the normal position. remains switched returns to the normal position Fig. 4/5: MO with automatic return 4-7
4. Commissioning 4.2 Error diagnosis 4.2.1 Impairment of function After switching on the compressed air supply or when subsequently testing the individual valves, you can learn the following about the operating status of the pneumatic system: Operating status of the pneumatic system Valve position Measures after the compressed air supply is switched off Air escaping... from connections of common hose lines from connections of working lines between the modules Valve or pneumatic system... does not react as expected does not react does not react Normal position Switching position Normal position Switching position Switching position Normal position Check seals and hose lines After restarting, restrict the auxiliary pilot air to 3...10 bar Check hose lines After switching on again check the operating pressure (e.g. pressure zones) Send in for repair Check the controller connection (apply pressure >3 bar at regulator) Fig. 4/6: Operating status of the pneumatic system 4-8
4. Commissioning If the operating status of the pneumatic system differs from the desired operating status, the following conditions are probably not met: Desired pneumatic operating status Prerequisites Comments No leaks Immediate reaction No malfunctions Two pressure zones Vacuum/low pressure operation EMERGENCY STOP in pressure zones Slow switch-on pressurization following an EMERGENCY STOP Correctly positioned hose lines Regulated auxiliary pilot air Sufficient compressed air supply from compressed air supply module Non-return valves in common exhaust line Limiting the pressure zones using an insulation plate Separate supply with controlled auxiliary pilot air (3...10 bar) The regulator for the auxiliary pilot air must function even when the main compressed air supply is switched off When the control signal is present, the auxiliary pilot air must be available at full pressure immediately after being switched on Exhausting of valve terminal at right end plate and adapter plate Applies when using several systems with centrally ducted exhaust Subsequent restructuring only permitted by Festo service Regulator can only be operated at a pressure of >3bar The regulator controls the auxiliary pilot air for all pneumatic modules Fig. 4/7: Causes of possible deviations from the nominal status 4-9
4. Commissioning 4.2.2 LED displays of the valves A yellow LED is located on the solenoid intermediate plate for each valve solenoid coil. These LED s show the switching state of the solenoid coil. 1 Yellow LED 1 1 LED Switching state of the valve solenoid coil Meaning Yellow OFF Normal position Logic 1 (no signal) Yellow ON Switching position or Normal position Logic 1 (signal present) Logic 1, but: operating voltage of outputs below permissible tolerance range (21.6 V DC...26.4 V DC) or compressed air supply not correct or blocked control line or send in for repair Fig. 4/8: LED display for switching status of ISO valve solenoid coil 4-10
4. Commissioning 4.3 Troubleshooting 4.3.1 Replacing the valve solenoid coil fuse Each valve solenoid coil is protected with a (quick-acting) 0.315 A fuse. These fuses are located behind the covers of the sub-bases on the circuit board. Each single-solenoid subbase has one fuse, each double-solenoid sub-base is fitted with two fuses (see diagram below). Proceed as follows to replace the fuse (follow the diagram below): 1. switch off the compressed air supply and the power supply (connections 1 and 2). 2. open the cover of the relevant sub-base. 3. carefully remove the built-in fuse from its holder. (diagram, right: Fuse for solenoid coil No. 14; left: Fuse for solenoid coil No. 12). 4. insert the new (quick-acting) 0.315 A fuse. 5. close the cover. 6. to replace other valve solenoid coil fuses, repeat steps 1to5. 4-11
4. Commissioning 1 2 1 Undo the fixing screws of the cover 2 Carefully remove the fuse from the holder. Right fuse for valve solenoid 14 Left fuse for valve solenoid 12 Fig. 4/9: Replacing a valve solenoid coil fuse 4-12
Technical appendix Appendix A A-1
A. Technical appendix Contents A. Technical appendix... A-1 A.1 Technical specifications... A-3 A.2 Manual valve terminal configuration type 04-B... A-9 A.2.1 Differences between automatic/manual valve terminal configuration... A-10 A.2.2 Manual configuration procedure... A-11 A.2.3 Notes regarding configuration... A-15 A.3 Index... A-17 A-2
A. Technical appendix A.1 Technical specifications General Mounting position Design As desired Modular system for centralized control of valves and acquiring sensor signals Module dimensions, valve terminal: Adapter plate (in mm) Base plate including solenoid intermediate plate and valve (mm) Nodes Input/output modules End plate left End plate right Size 1 L W H 152 x 100 x 86 198 x 43 x 138 72 mm 36 mm 27 mm 22 mm Size 2 L W H 191 x 100 x 86 214 x 59 x 153 72 mm 36 mm 27 mm 23 mm Size 3 L W H 232 x 100 x 86 241 x 72 x 173 72 mm 36 mm 27 mm 28 mm Height of individual components: Valves (single, double, mid-position) Pressure regulator Flow control plate 46 mm 45 mm 26 mm 58 mm 58 mm 26 mm 63 mm 63 mm 40 mm Length of individual components: Silencer 106 mm 126 mm 165 mm Weights End plate left Input modules Output modules Fieldbus nodes Adapter plate Baseplate End plate right Solenoid intermediate plate Valves single, double, mid-position Cover plate Flow control plate Pressure regulator (P, B, A or A/B) Size 1 120 g 360 g 400 g approx. 1000 g 2280 g 540 g 540 g 370 g 290 g 320 g 100 g 265 g 520 g or 840 g Size 2 120 g 360 g 400 g approx. 1000 g 2440 g 640 g 640 g 430 g 550 g 620 g 140 g 870 g 960 g or 1490 g Size 3 120 g 360 g 400 g approx. 1000 g 2860 g 1120 g 1110 g 500 g 760 g 840 g 180 g 870 g 1220 g or 1770 g A-3
A. Technical appendix General Connections Compressed air Exhaust air Auxiliary pilot air Workair Size 1 G1/2 G1/2 G1/8 G1/4 Size 2 G3/4 G3/4 G1/8 G3/8 Size 3 G1 G1 G1/8 G1/2 Materials End plates Housing and cover (nodes) Cover plate (valve location) Valves Pressure regulator Flow control plate Seals Baseplate Al Al (anodised), PA 6 Al Al,Ms,St,POM Al, Si 12, St Al, Ms NBR Al Vibration resistance (as per DIN/IEC 68, part 2-6 and as per IEC 721/part 2-3) Transport: Operation: Shock resistance (as per DIN/IEC 68, part 2-6 and IEC 721/part 2-3) Temperature range Storage Operation Medium 3.5 m amplitude at 2...8 Hz 1 g acceleration at 8...25 Hz 0.35 mm amplitude at 25...57 Hz 5 g acceleration at 57...150 Hz 1 g acceleration at 150...200 Hz 30 g at 11 ms duration - 15... + 50 C + 5... + 50 C - 10... + 60 C A-4
A. Technical appendix Pneumatics Medium Pressure range With auxiliary pilot air branched from P1 (internal pilot air) Compressed air, filtered, lubricated or not lubricated, suitable for vacuum operation Up to 10 bar With externally supplied auxiliary pilot air (external pilot air) P 12, 14: P 1: 3...10 bar (-0.9) +2... +16 bar (depending on the valve) Manual override of the valve Non-locking (automatic return) Caution The valve switching times refer only to the valves. The valve switching times will be increased by sub-bases, solenoid intermediate plates and in combination with components for vertical linking on the valve terminal. Pneumatics Valve switching times in [ms] at 10 % as per VDI 3290, 6 bar Size 1 Size 2 Size 3 Measuring method 10 % as per FN 942032 5/2, single-solenoid, pneumatic spring 5/2, single-solenoid, return spring 5/2, double-pilot, double-solenoid 5/2, double-pilot, double-solenoid, dominating 5/3, mid-position blocked 5/3, mid-position exhausted 5/3, mid-position pressurized ON 9ms 6ms 6ms _ms 7ms 7ms 7ms OFF 18 ms 23 ms 44 ms 45 ms 44 ms ON 23 ms 11 ms 8ms _ms 15 ms 16 ms 15 ms OFF 39 ms 39 ms 56 ms 59 ms 57 ms ON 29 ms 13 ms 8ms _ms 17 ms 18 ms 16 ms OFF 36 ms 43 ms 61 ms 63 ms 60 ms Caution The nominal flow rates refer only to the respective valves. The flow rates will decrease when using the sub-base, the screw connectors of the supply and work lines and in combinations with other valves. A-5
A. Technical appendix Pneumatics Rated flow in [l/min] of ISO valve size 1 1 2 1 4 2 3 4 5 5/2, single-solenoid actuated/not actuated 5/2, double-solenoid actuated/not actuated 5/3, mid-position blocked actuated/not actuated 5/3, mid-position exhausted actuated/not actuated 5/3, mid-position pressurized actuated/not actuated -/1200 -/1200 1200/- 1200/- 1200/700 1200/- 1200/- 1200/- 1200/- 1200/700 1200/- -/1200 1200/- 1200/700 1200/- -/1200 1200/- 1200/- 1200/700 1200/- Rated flow in [l/min] of ISO valve size 2 1 2 1 4 2 3 4 5 5/2, single-solenoid actuated/not actuated 5/2, double-solenoid actuated/not actuated 5/3, mid-position blocked actuated/not actuated 5/3, mid-position exhausted actuated/not actuated 5/3, mid-position pressurized actuated/not actuated -/2300 -/2300 2300/- 2300/- 2300/2000 2300/- 2300/- 2300/- 2300/- 2300/2000 2300/- -/2300 2300/- 2000/2000 2000/- -/2300 2300/- 2300/- 2000/2000 2000/- Rated flow in [l/min] of ISO valve size 3 1 2 1 4 2 3 4 5 5/2, single-solenoid actuated/not actuated 5/2, double-solenoid actuated/not actuated 5/3, mid-position blocked actuated/not actuated 5/3, mid-position exhausted actuated/not actuated 5/3, mid-position pressurized actuated/not actuated -/4500 -/4500 4100/- 4600/- 4100/4000 4500/- 4500/- 4100/- 4600/- 4100/4000 4500/- -/4500 3600/- 4000/3300 3800/- -/4500 4500/- 3600/- 4000/3300 3800/- A-6
A. Technical appendix Electricity Voltages Operating voltage 24 V DC ± 10 % Switch-on peak consumption Per solenoid coil at ca. 24 V (with LEDs) Total with maximum number of valve solenoid coils (with LEDs) Power consumption Per solenoid coil 140 Am 4A 3.1 W A-7
A. Technical appendix A.2 Manual valve terminal configuration type 04-B The valve terminal type 04-B is set up at the factory for automatic address assignment. This is described in detail in the Electronics manual (type 03/04-B). The settings can be altered at a later date using the DIL switches. The manual valve terminal configuration is described below. Caution Manual modification of the valve terminal configuration may affect the control of the connected actuators. This intervention causes the following changes: the calculation for the number of outputs is changed the configuration of the terminal on the bus is correspondingly changed (dependent on the protocol) the addressing of the output modules starts at a precisely defined address limited address space is available for additionally mounted valves in expansion/conversion work unpermitted settings on the DIL switch may trigger error messages These possible effects are not taken into account in the Electronics manual type 03/04-B of the node. Pay careful attention, therefore, to the instructions and notes in the following sections. A-8
A. Technical appendix A.2.1 Differences between automatic/manual valve terminal configuration Automatic Configuration The valve is set to automatic address assignment at the factory (0...26 valves). During initialisation, the valve terminal detects all valves during automatic configuration and assigns the addresses according to the basic rules (see the Electronics manual of the valve terminal). Additional output stages are addressed with reference to the (rounded 4 bit) valve addresses. If valve locations are added at a later date, the output addresses are shifted accordingly. Manual In manual configuration, the size of the valve address area does not change during expansion/conversion of the valves as long as sufficient address space was initially reserved for the expansion. In this case, the addresses of the electric outputs are not shifted. Manual pre-setting of the valve address area is implemented with the DIL switch module located under the cover of the adapter plate. Warning Changes to the DIL switch settings will cause changes to the digital output addressing when the valve terminal is started up! A-9
A. Technical appendix A.2.2 Manual configuration procedure Caution Before starting any configuration procedures, switch off the following: the compressed air supply the operating voltage supply for the electronics (pin 1 of the power supply plug) the load voltage supply for the outputs/valves (pin 2 of the power supply plug). You can thereby avoid: uncontrolled movements of loose tubing unexpected movements of the connected actuators non-defined switching states of the electronic components. Please note The cover on the adapter plate is connected via the power supply cable to the circuit boards within and should therefore not be completely removed. Proceed as follows: 1. undo and remove the four Phillips screws on the cover. Carefully raise the cover and ensure that the cable is not damaged by pulling, bending or twisting. A-10
A. Technical appendix M4 x 12 Fig. A/1: Removing the cover of the adapter plate 2. Use a suitable tool to set the DIL switch, e.g. a pen. Set the DIL switch elements in accordance with the following table. Four valve outputs correspond to each DIL switch element. Fig. A/2: Setting the DIL switch A-11
A. Technical appendix DIL switch positions *) Valve configuration 1 2 3 4 5 6 7 8 Automatic configuration (default setting) in compliance with basic rules (see the Electronics manual of the valve terminal). OPEN 1 2 3 4 5 6 7 8 4 outputs for valves OPEN 1 2 3 4 5 6 7 8 8 outputs for valves OPEN 1 2 3 4 5 6 7 8 12 outputs for valves OPEN 1 2 3 4 5 6 7 8 26 outputs for valves OPEN 1 2 3 4 5 6 7 8 This setting is not permitted as it does not increase sequentially. It will trigger the error message Module mounting incorrect. OPEN *) Switch S8 has no effect on the valve configuration. Fig. A/3: DIL switch settings and valve configurations A-12
A. Technical appendix 3. Replace the cover on the adapter plate and insert the power supply cable back into the housing. Ensure that it cannot be damaged when fastening down the cover. Screw in the four Phillips screws and tighten them in diagonally opposite sequence. Please note The modifications to the manual configuration will only become effective after the operating voltage is switched on again. A-13
A. Technical appendix A.2.3 Notes regarding configuration Valve terminal expansion and DIL switch settings The number of connected valves is greater that the number of addresses assigned with the DIL switches. 1 2 3 4 5 6 7 8 Effect The settings of the DIL switch are not applicable. The addresses of the valves and electric outputs will be assigned automatically. OPEN The number of addresses assigned with the DIL switches is greater that the number of valves actually connected. 1 2 3 4 5 6 7 8 OPEN The assigned address area is greater than the number of the valve solenoid coils actually present in the valve terminal. These addresses can be used during a modification or expan- sion of the valve terminal. In this case, the addresses of the electric outputs are not shifted. Fig. A/4: Valve terminal expansion and DIL switch settings A-14