Valve Terminal Type 03/05 Electronics Manual Field Bus Connection FB14

Valve terminal type 03/05 Electronics Manual Field bus connection FB14

Field bus protocols: CANopen SDS Smart Distributed System

9801A 163959 GB VIFB14 - 03/05

Author: S. Breuer, H. Hohner, H.-J.Drung Editor: H.-J. Drung, M. Holder Translation: Douglas Smith Layout: Festo, Dept. PV-IDM Type setting: DUCOM

Edition: January 1998

 (Festo AG & Co., D-73726 Esslingen, 1998)

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authoriza- cycled paper cycled tion 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

printed on 100% re registrations.

9801 A I VIFB14 - 03/05

Part no.: 163 959

Titel: MANUAL

Designation: P.BE-VIFB14-03/05-GB

II 9801 A VIFB14 - 03/05

Contents GENERAL SAFETY INSTRUCTIONS IX Designated use IX Target group X IMPORTANT USER INSTRUCTIONS XI Danger categories XI Pictograms XII Instructions on this manual XIII Service XV

Chapter 1 SYSTEM SUMMARY 1.1 SYSTEM SUMMARY 1-3 System structure 1-3 Type 03: Description of components 1-5 Type 05: Description of components 1-9

Chapter 2 FITTING 2.1 FITTING THE COMPONENTS 2-3 Input/output modules 2-4 End plates 2-6 Hat rail clamping unit (type 03) 2-8 2.2 TYPE 03: FITTING THE VALVE TERMINAL 2-9 Fitting onto a wall (type 03) 2-9 Fitting onto a hat rail (type 03) 2-10 2.3 TYPE 05: FITTING THE VALVE TERMINAL 2-13 Fitting onto a wall (type 05) 2-13

9801 A III VIFB14 - 03/05

Chapter 3 INSTALLATION 3.1 GENERAL CONNECTION TECHNIQUES 3-3 Selecting the field bus cable 3-4 Selecting the operating voltage cable 3-5 Connecting the cables to the plugs/sockets 3-6 3.2 FIELD BUS NODE 3-8 Opening and closing the node 3-8 Configuring the valve terminal 3-11 Setting the station number with CANopen 3-12 Permitted station numbers 3-13 Setting the field bus baud rate 3-19 Setting the field bus protocol 3-20 3.2.1 TYPE 03: CONNECTING THE OPERATING VOLTAGES 3-21 Calculating the current consumption for type 03 3-25 Connection example (type 03) 3-27 3.2.2 TYPE 05: CONNECTING THE OPERATING VOLTAGES 3-29 Calculating the current consumption for type 05 3-33 Connection example (type 05) 3-36 3.2.3 CONNECTING THE FIELD BUS 3-38 Connection instructions for CANopen 3-42 Connecting instructions for the Smart Distributed System 3-43 Terminating resistor 3-44 3.3 CONNECTING THE INPUT MODULES 3-45 Pin assignment 3-47 3.4 CONNECTING THE OUTPUT MODULES 3-48 Pin assignment 3-50

IV 9801 A VIFB14 - 03/05

Chapter 4 COMMISSIONING 4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING 4-5 General 4-5 Switching on the operating voltage 4-6 Calculating the configuration data 4-7 Calculating the number of inputs/outputs type 03 4-9 Calculating the number of inputs/outputs type 05 4-10 Address assignment of the valve terminal 4-11 General type 03 and type 05 4-11 Basic rule 1 4-12 Basic rule 2 4-15 Address assignment after extension/conversion 4-16 Addressing example type 03 MIDI/MAXI valves 4-19 Addressing example type 05 ISO valves 4-20 4.2 BASIC PRINCIPLES OF COMMISSIONING AND DIAGNOSIS 4-21 General 4-21 Selecting the inputs/outputs 4-21 General information on CANopen 4-22 Brief summary of scope of function 4-23 Summary of object directory 4-24 Default identifier distribution 4-27 Summary of object directory 4-28 PDO communication parameter record 4-29 PDO communication mapping parameter field 4-31 Digital inputs 4-32 Digital outputs 4-32 Reaction of the digital outputs in the event of a fault 4-33 Definition of emergency object 4-35

9801 A V VIFB14 - 03/05

Addressing inputs and outputs 4-36 Examples: communication process 4-38 Diagnosis of status bits 4-41 Position of the status bits 4-42 4.3 BASIC PRINCIPLES OF THE SMART DISTRIBUTED SYSTEM (HONEYWELL) 4-43 General information 4-43 Commissioning 4-43 Number of inputs and outputs 4-44 Summary of implemented object models 4-45 Summary of actions 4-48 Summary of events 4-49 Assignment of SDS IDs 4-49 Diagnosis 4-50 Diagnosis via status bits 4-51 Setting the transmission mode 4-53 Bus configuration 4-54 4.3.1 CONFIGURING/ADDRESSING THE HONEYWELL SDS PC CONTROL 4-55 General information 4-55 Settings in the Device Editor 4-55 Settings in the Tag Editor 4-58 Setting the transmission types for inputs by means of the programming software 4-60 Setting the Cyclical Timer 4-61 Diagnosis 4-63 Diagnosis via the network manager 4-63 Diagnosis via the SDS user program 4-63 Structure of the SDS diagnostic register 4-65 Diagnosis via the status bits 4-66

VI 9801 A VIFB14 - 03/05

4.3.2 CONFIGURING/ADDRESSING WITH THE GE FANUC SERIES 90/30 4-67 General information 4-67 Bus configuration 4-68 Assigning the I/O addresses 4-68 Diagnosis 4-73 Diagnosis via the SDS interface 4-73 Diagnosis via status bits 4-75

Chapter 5 DIAGNOSIS AND ERROR TREATMENT 5.1 SUMMARY OF DIAGNOSTIC POSSIBILITIES 5-3 5.2 ON-THE-SPOT DIAGNOSIS 5-4 LED display (node) 5-4 Valves 5-8 Input/output modules 5-10 5.3 TESTING THE VALVES 5-11 5.4 STATUS BITS 5-13 5.5 ERROR TREATMENT 5-15 Reaction to faults in the CANopen 5-16 Reaction to faults in the Smart Distributed System 5-17 Short circuit/overload at an output module 5-18

9801 A VII VIFB14 - 03/05

APPENDIX A TECHNICAL APPENDIX TECHNICAL SPECIFICATIONS A-3 CABLE LENGTH AND CROSS SECTION A-7 Calculating with a graph A-8 Calculating with a formula A-10 EXAMPLES OF CIRCUITRY A-12 Operating voltage connection type 03 A-12 Operating voltage connection type 05 A-13 4-input module (PNP) A-14 8-input module (PNP) A-15 4-input module (NPN) A-16 8-input module (NPN) A-17 4-output module (NPN) A-18 ACCESSORIES A-19 Bus connection A-19

APPENDIX B INDEX

VIII 9801 A VIFB14 - 03/05 General safety instructions

GENERAL SAFETY INSTRUCTIONS

Designated use The valve terminal type 03/05 described in this manual is designated exclusively for use as follows: • for controlling pneumatic and electrical actuators (valves and output modules) • for interrogating electrical sensor signals by means of the input modules. Use the valve terminal only as follows: • as designated in the instructions • in technically faultless condition • without any modifications. The specified limit values for pressures, tempe- ratures, electrical data, moments, etc. must be observed when additional commercially- available components such as sensors and actuators are connected.

Please comply also with national and local safety laws and regulations.

9801 A IX VIFB14 - 03/05 General safety instructions

Target group This manual is directed exclusively at technicians who are trained in control and automation technology and who have experien- ce in installing, commissioning, programming and diagnosing programmable logic controllers (PLC) and field bus systems.

X 9801 A VIFB14 - 03/05 General safety instructions

IMPORTANT USER INSTRUCTIONS

Danger categories This manual contains instructions on the possible dangers which can occur when the valve terminals types 03/05 are used.

A distinction is made between the following instructions:

WARNING This means that injury to human beings as well as material damage can occur if these instructions are not observed.

CAUTION This means that material damage can occur if these instructions are not observed.

PLEASE NOTE This means that this instruction must also be observed.

9801 A XI VIFB14 - 03/05 General safety instructions

Pictograms Pictograms and symbols supplement the danger instructions and draw attention to the consequences of dangers. The following pictograms are used:

Uncontrolled movements of loose tubing.

Uncontrolled movement of the connected actuators.

High electric voltage or undefined switching states of the electronic components which affect the connected circuits.

Electrostatically vulnerable components which will be destroyed if their contact surfaces are touched.

The ISO valve terminal type 05 is very heavy. Please ensure that it is fastened correctly and see that all operating personnel wear safety shoes.

XII 9801 A VIFB14 - 03/05 General safety instructions

Instructions on this manual The following product-specific abbreviations are used in this manual:

Abbreviation Meaning

Terminal Valve terminal type 03 (MIDI/MAXI) or type 05 (ISO) with/without electrical I/Os

Node Field bus node

Sub-base Pneumatic sub-base for valves

Single sub-base for single solenoid valves type 03 (MIDI/MAXI)

Double sub-base for double solenoid valves or mid-position valves type 03 (MIDI/MAXI)

ISO sub-base Manifold base for 4, 8 or 12 valves type 05 (ISO 5599/I, size 1 or 2)

I Input O Output I/O Input/output

P module Pneumatic module in general

I/O module Module with digital inputs/outputs

Fig. 1: Abbreviations

Valve terminal type 03/05 consists basically of the following components: • the node • pneumatic modules (valve sub-bases with valve and valve bridge or intermediate air supply modules). • electronic modules (4 or 8-input modules, 4-output modules).

9801 A XIII VIFB14 - 03/05 General safety instructions

This electronics manual describes node FB14 and the input/output modules.

PLEASE NOTE All information on the pneumatic modules is to be found in the Pneumatics Manual P.BE-MIDI/MAXI-03-GB or P.BE-ISO-05-GB.

Valve terminals types 03/05 consist of different components:

PLEASE NOTE A valve terminal with four pneumatic valve sub-bases and four input/output modules is used for the diagrams in this manual.

Fig. 2: Standard fitting for the drawings

XIV 9801 A VIFB14 - 03/05 General safety instructions

The valve terminals can be connected to the control systems of various manufacturers. This manual describes the protocols CANopen and SDS and the addressing.

Interface manufacturer Controller Interface Field bus

ESD GmbH VME-System VME-CAN2 Vahrenwalder Str. 205 VME-System VME-CAN2B D-30165 Hannover S5-115U ... 155U CAN-CS515 S5-95U, S5-100U CAN-CS595

Janz Computer AG VME-System VMOD-ICAN2 Im Dörener Feld 8 VME-System VMOD-ICAN3 D-33100 Paderborn CANopen Eberle Controls GmbH PLS vario CAN 21 Postfach 130 153 PLS 514 CAN 41 D-90113 Nürnberg

Selectron System GmbH Selecontrol MAS CBI 751 Schupferstr. 1 IPC/PC PCI 517 D-90482 Nürnberg

Fig. 3: Summary of possible controllers/field bus protocols (extract)

Service If you have any technical problems, please consult your local Festo Service.

9801 A XV VIFB14 - 03/05 General safety instructions

XVI 9801 A VIFB14 - 03/05 1. System summary

1. SYSTEM SUMMARY

9801 A 1-1 VIFB14 - 03/05 1. System summary

Contents

1.1 SYSTEM SUMMARY 1-3 System structure 1-3 Type 03: Description of components 1-5 Type 05: Description of components 1-9

1-2 9801 A VIFB14 - 03/05 1. System summary

1.1 SYSTEM SUMMARY

System structure Festo offers a solution to automation problems at machine level with valve terminals. Valve terminals of types 03 and 05 are constructed on a modular basis and permit combinations of pneumatic and electronic modules such as the

following:

AA AAAAAAAA AAAA AAAA AAAA AAAA AAAA AAAA

AAAA AA AAAA AAAA AAAA AAAA AAAA AAAA AAAA

AAAA AA AAAAAAAA AAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AA AA AA AA AAAA AAAA AAAA AAAA

AAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA AA AA AA AA

A A A A AA AAAAA AAAAA A AAAAAAAAA AA AA AAAAAAA AAAA AAAA AA AA AAAAAAAAAA AA AA AA AA

AAAA AA AA AAAAAAA AAAA AAAA AAAAAAAAAA AAA A A AAAAA AAAAAAAAAAAAAA AA AA AA AA AA

Industrial PC/ AAAA

AAAAAAAAAA AAAA AA AAAAAAAAAAAAAAAAAAAAA AAAAAA AA AA AA AA A A A AA A A A A A

AAAAAAAAAAAAAAAA AAAA AA AAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAA AAAAAA A A A AA A A A A A AA AA AA

controller AA

AAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA AA AA AA AA

AAAAAAAAAAAAAAAAAAA AA AA AAAAAAA AAAA AAAA A A A A A AA A A A A A AA AA AA AA

AAAAAAAAAAAAAA AAAA AAAA AAAAAAAAAAAAAAAAAAAAAAAA AA AA AA AA

AA AA AAAAAAA AAAA AAAA A AAA AAA AA A AAA A AAA A

AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA

AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA

Field bus

Valve terminal type 03: MIDI/MAXI valves and electronic modules

Valve terminal type 03: only MAXI valves

Valve terminal type 05: ISO valves and electronic modules

Further field bus slaves

Fig. 1/1: System summary and possible variants of the valve terminals

9801 A 1-3 VIFB14 - 03/05 1. System summary

The valve terminal with field bus connection offers the following advantages: • can be fitted with digital I/Os and pneumatic valves • subsequent extension/conversion possible • small-scale valves • can be connected to various control systems • less wiring due to two-core cables • clarity in system structure due to physical se- paration of controller and machine • valves already fitted • pre-wired (pilot) valve solenoid coils • central compressed air supply • central exhust • device already tested

A field bus system also offers the following advantages: • fewer output modules in the controller • economic data transfer over long distances • high baud rate • a large number of slaves can be connected • error diagnosis is made easier

1-4 9801 A VIFB14 - 03/05 1. System summary

Type 03: Description of components Valve terminal type 03 consists of individual modules. Each module is assigned with different functions as well as different connecting, display and operating elements. These are summarized in the diagram below.

3 2 1 4 5 4 5 4 5 4 6

Figure Module 1 Node FB14 2 Electronic modules (input/output modules), fitted with • digital inputs (modules with 4 or 8 inputs) • digital outputs (modules with 4 outputs) 3 End plate left with opening for additional earth/ground connection 4 Pneumatic MIDI, MAXI modules (sub-bases) fitted with S-valves: • 5/2-way solenoid valves • 5/2-way double solenoid valves • 5/3-way mid-position valves (exhausted, pressurized, blocked) • blanking plates S = auxiliary pilot air 5 Pneumatic MIDI, MAXI modules: • pressure supply with integrated exhaust (MIDI) • intermediate pressure supply with integrated exhaust (MIDI) • pressure supply adapter with/without regulator (MIDI – MAXI) • additional pressure supply (MAXI) 6 End plate right, depending on size of last sub-base with either: • common pneumatic tubing and integrated regulator for 5 bar auxiliary pilot air (non-regulated auxiliary pilot air is not permitted) • common pneumatic tubing connections, but without regulator • without common tubing connections (only MAXI) Fig. 1/2: Modules of the valve terminal type 03

9801 A 1-5 VIFB14 - 03/05 1. System summary

The following connecting, display and operating elements are to be found on the electronic modules:

1 2 3 4 5 6 7 8

O4 O4 I4 I8

11 10 9

Figure Meaning 1 Output socket for electrical output 2 Yellow LED (status display per output) 3 Red LED (error display per output) 4 Input socket for one electrical input 5 Green LED (per input) 6 Input socket for two electrical inputs 7 Two green LEDs (one LED per input) 8 Node with LEDs and field bus connection detailed description in chapter "Installation" 9 End plate right 10 Fuse for inputs/sensors 11 Operating voltage connection Fig. 1/3: Display and operating elements on the electronic modules

1-6 9801 A VIFB14 - 03/05 1. System summary

The connecting, display and operating elements shown below are to be found on the pneumatic MIDI modules type 03.

1 234 5

9 8 7

Figure Meaning 1 Node with LEDs and field bus connection, detailed description in chapter "Installation" 2 Yellow LEDs 3 Manual override for valve solenoid coils 4 Valve location inscription field 5 Unused valve location with blanking plate 6 Common tubing connections 7 Work connections (per valve) 8 Fuse for inputs/sensors 9 Operating voltage connection Fig. 1/4: Operating, display and connecting elements

9801 A 1-7 VIFB14 - 03/05 1. System summary

The following connecting, display and operating elements are to be found on the pneumatic MAXI modules type 03.

1 2 3 4 5

10 9 8 7

Figure Meaning 1 Node with LEDs and field bus connection, detailed description in the chapter "Installation" 2 Yellow LEDs (per valve solenoid coil) 3 Manual override (per valve solenoid coil) 4 Valve location inscription field (designation labels) 5 Unused valve location with blanking plate 6 Common tubing connections 7 Work connections (2 per valve, one above the other) 8 Regulator for limiting the pressure of the auxiliary pilot air 9 Common tubing connection 10 Exhaust connections

Fig. 1/5: Operating, display and connecting elements of the MAXI modules type 03

1-8 9801 A VIFB14 - 03/05 1. System summary

Type 05: Description of components Valve terminal type 05 consists of individual modules. Each module is assigned with different functions as well as different connecting, display and operating elements. These are summarized in the diagram below.

3 2 1 4 5 6

Figure Module 1 Node FB14 2 Electronic modules (input/output modules), fitted with • digital inputs (modules with 4 or 8 inputs) • digital outputs (modules with 4 outputs) 3 End plate left with opening for additional earthing connection 4 Pneumatic modules (manifold sub-bases) fitted with: • Pneumatic valves with hole pattern as per ISO 5599/I - Pneumatic single solenoid valves - Pneumatic double solenoid valves - Pneumatic mid-position valves • Components for vertical linking (pressure regulator intermediate plate, throttle plate, etc.) • Blanking plates 5 Adapter plate for ISO sub-base (manifold sub-bases) as per ISO 5599/I sizes 1 and 2 6 End plate right with fitting holes and thread for M8 ring screws (for transport) Fig. 1/6: Modules of valve terminal type 05

9801 A 1-9 VIFB14 - 03/05 1. System summary

The connecting, display and operating elements shown below are to be found on the pneumatic ISO modules type 05.

1 2 3 4 5 6 7 8

12 10 10

9 11

Figure Module 1 Node with LEDs and field bus connection, detailed description in the chapter "Installation" 2 Fuse for inputs/sensors 3 Adapter plate 4 Operating voltage connection for terminal type 05 5 Fuses for valves 6 Valve location inscription field 7 Yellow LEDs (per pilot solenoid coil) 8 Manual override (per pilot solenoid coil, either pushing or locking) 9 External control connection 10 Common pneumatic tubing connections 11 Work connections (per valve) 12 Adapter cable for operating voltage supply to node and I/O modules

Fig. 1/7: Operating, display and connecting elements of ISO modules type 05

The electronic modules have already been described in the section "Description of components type 03."

1-10 9801 A VIFB14 - 03/05 1. System summary

Incoming field bus Continuing field bus

Node

2 AA

AA 1 = Compressed air

AA AA

AA AA 2 , 4 = Work air

Electrical signal flow

Fig. 1/8: Function summery of valve terminal type 03/05

The node controls the following functions: • connection of the terminal to the field bus module of your control system and to further field bus slaves via the field bus interface • adaption of the field bus baud rate and protocol to the control system • control of data transfer to/from the field bus module of your control system • internal control of the terminal

9801 A 1-11 VIFB14 - 03/05 1. System summary

The input modules process the input signals (e.g. from sensors) and transmit these signals via the field bus to the controller. The output modules are universal electrical outputs and control low current consuming devices, e.g. further valves, lights etc..

The pneumatic modules provide the following: • common channels for supply air and exhaust • electrical signals from all solenoid valve coils Work connections 2 and 4 have been provided for each valve location on the individual pneumatic modules.

The common channels in the pneumatic end plate or special intermediate supply modules are used to supply the valves with compressed air and to vent the exhaust and pilot exhaust air. Futher modules for intermediate air supply are also available, e.g. in order that different working pressures can be used or that MIDI/MAXI valves or ISO valves can be fitted on a node.

Further information on their use can be found in the pneumatics manual for your valve terminal. Only the electronic modules and the node are described here.

1-12 9801 A VIFB14 - 03/05 2. Fitting

2. FITTING

9801 A 2-1 VIFB14 - 03/05 2. Fitting

Contents

2.1 FITTING THE COMPONENTS 2-3 Input/output modules 2-4 End plates 2-6 Hat rail clamping unit (type 03) 2-8

2.2 TYPE 03: FITTING THE VALVE TERMINAL 2-9 Fitting onto a wall (type 03) 2-9 Fitting onto a hat rail (type 03) 2-10

2.3 TYPE 05: FITTING THE VALVE TERMINAL 2-13 Fitting onto a wall (type 05) 2-13

2-2 9801 A VIFB14 - 03/05 2. Fitting

2.1 FITTING THE COMPONENTS

WARNING Before fitting the components, switch off the following: • the compressed air supply • the power supply for the outputs (pin 2) • the power supply for the electronic components (pin 1)

You can thereby avoid: • uncontrolled movements of loose tubing • undesired movements of the connected actuators • undefined switching states of the electronic components

CAUTION The valve terminal components contain electrostatically vulnerable elements. • Do not therefore touch any contact surfaces on the side plug connectors of the components. • Please observe the instructions for handling elements liable to damage by electrostatic charges.

You thereby avoid destroying the valve terminal components.

9801 A 2-3 VIFB14 - 03/05 2. Fitting

PLEASE NOTE Treat all the modules and valve terminal components with great care. Pay special attention to the following: • Screw connections must not be distorted or subjected to mechanical stress. • The screws must fit exactly (otherwise the threads will be damaged). • The specified torques must be observed. • The modules must be aligned correctly (IP 65). • The contact surfaces must be clean (avoid leaks and faulty connections). • The contacts of type 03-MIDI valve solenoid coils must not be bent (they are not resistant to bending in alternate directions, i.e. they will break off if bent backwards). Please observe also the fitting instructions en- closed with modules and components ordered at a later date.

Input/output modules Before the valve terminal can be extended or converted, it must first be dismantled.

Dismantling (see also following diagram) • Remove completely the screws of the relevant modules. The modules are now held together only by the plug connectors. • Pull the modules carefully and without tilting away from the plug connectors. • Replace any seals which are damaged.

2-4 9801 A VIFB14 - 03/05 2. Fitting

Fitting (see also following diagram)

PLEASE NOTE • Modules ordered at a later date should be placed, where possible, after the last module before the end plate. • Do not fit more than 12 electronic modules.

Fit the modules as follows: • Fit a (new) seal on the right-hand contact surface facing the node. • Then fit the module as shown in the diagram below.

Seal

Fastening screws max. 1 Nm

Fig. 2/1: Fitting the electronic I/O modules

9801 A 2-5 VIFB14 - 03/05 2. Fitting

End plates A left-hand and a right-hand end plate are required as a mechanical termination of the valve terminal. These end plates fulfil the following functions: • They comply with protection class IP 65. • They contain connections/contacts for the protective earth cable. • They contain openings for fitting onto walls and onto the hat rail clamping unit.

The right-hand end plate of the ISO terminal is connected conductively via screw connectors and ready fitted spring contacts to the manifold sub-base. It is therefore sufficently earthed.

There are different designs of right-hand end plate for terminal type 03 (MIDI/MAXI). Each design has a ready fitted protective earth cable.

CAUTION Before operating terminal type 03, you must earth the right-hand end plate by means of the protective earth cable. This is to avoid high voltages on the metal surface if there is a technical fault.

2-6 9801 A VIFB14 - 03/05 2. Fitting

Earth the end plates as follows: • Right-hand end plate (type 03) In order to earth the right-hand end plate, connect the cable fitted inside to the appropriate contacts on the pneumatic modules or node (see following diagram). • Left-hand end plate (types 03 and 05) Connect the left-hand end plate conductively to the other components by means of the ready fitted spring contacts. Please note: Instructions on earthing the complete valve terminal are to be found in the chapter "Installation".

The following diagram shows how both end plates are fitted.

Seal Contact for protective earth cable

Seal

Pre-fitted protective Fastening screws earth cable max. 1 Nm

Fig. 2/2: Fitting the end plates (example terminal type 03)

9801 A 2-7 VIFB14 - 03/05 2. Fitting

Hat rail clamping unit (type 03) If the valve terminal is to be fitted onto a hat rail (support rail as per EN 50022), you will require a hat rail clamping unit. The hat rail clamping unit is fastened to the back of the end plates as shown in the diagram below.

Before fitting ensure that: • the fastening surfaces are clean (clean with spirit); • the flat head screws are tightened (6).

After fitting ensure that: • the levers are secured with a locking screw (7).

1 Self adhesive rubber foot 2 Clamping elements 3 Left-hand lever *) 4 Right-hand lever *) 5O-ring 6 Flat head screw 7 Retaining screw

*) Different lever lengths with MIDI and MAXI Fig. 2/3: Fitting the hat rail clamping unit

2-8 9801 A VIFB14 - 03/05 2. Fitting

2.2 TYPE 03: FITTING THE VALVE TERMINAL

Fitting onto a wall (type 03)

WARNING In the case of long terminals, use additional support brackets approx. every 200 mm. You thereby avoid: • overloading the fastening eyes on the end plates • the terminal sagging • natural resonances

Proceed as follows: • Calculate the weight of the terminal (weigh or estimate). General rule:

MIDI MAXI Per pneumatic module 800 g 1200 g per node 1000 g 1000 g Per electronic module 400 g 400 g

• Make sure that the fastening surface can support this weight.

9801 A 2-9 VIFB14 - 03/05 2. Fitting

• Fasten the terminal with four M6 screws as shown below (fitting position as desired). Use spacers if necessary.

7.6 mm

Fig. 2/4: Fitting terminal type 03 on a wall

Fitting onto a hat rail (type 03) The terminal is suitable for fitting onto a hat rail (support rail as per EN 50022). For this purpose there is a guide groove on the rear of all modules for hanging the terminal on the hat rail.

CAUTION • Fitting onto the hat rail without the hat rail clamping unit is not permitted. • If the terminal is fitted in a sloping position or is subjected to vibration, protect it against slipping and use the screws supplied (7) to protect it against unintentional loosening/ opening.

2-10 9801 A VIFB14 - 03/05 2. Fitting

PLEASE NOTE • If the terminal is fitted in a horizontal position and is not subjected to vibration, the fastening of the hat rail clamping unit will be sufficient without the screws (7). • If your terminal does not have a hat rail clamping unit, this can be ordered and fitted at a later date. • Whether MIDI or MAXI clamping units are to be used depends on the end plates (MIDI/MAXI).

Proceed as follows: • Calculate the weight of the terminal (weigh or estimate). General rule:

MIDI MAXI

Per pneumatic module 800 g 1200 g

Per node 1000 g 1000 g Per electronic module 400 g 400 g

• Make sure that the fastening surface can support this weight.

9801 A 2-11 VIFB14 - 03/05 2. Fitting

• Fit a hat rail (support rail as per EN 50022 - 35x15; width 35 mm, height 15 mm). • Fasten the hat rail to the fastening surface at least every 100 mm. • Hang the terminal onto the hat rail. Secure the terminal on both sides against tilting or slipping with the hat rail clamping unit (see diagram below). • If the terminal is fitted in a sloping position or is subjected to vibration, use two screws (7) to protect the hat rail clamping unit against unintentional loosening/opening.

Valve terminal type 03

Hat rail clamping unit Locking screw (7)

Fig. 2/5: Fitting terminal type 03 onto a hat rail

2-12 9801 A VIFB14 - 03/05 2. Fitting

2.3 TYPE 05: FITTING THE VALVE TERMINAL

Fitting onto a wall (type 05)

WARNING In the case of long terminals with several I/O modules, use additional support brackets ap- proximately every 200 mm. You thereby avoid: • overloading the fastening eyes on the left-hand end plate • the terminal sagging (I/O side) • natural resonances

• Proceed as follows: • Calculate the weight of the terminal (weigh or estimate). General rule:

ISO ISO Size 1 Size 2

Sub-base *) - 4 valve locations with valves 8 kg 12 kg - 8 valve locations with valves 14 kg 20 kg - 12 valve locations with valves 20 kg 28 kg Per node 1 kg 1 kg

Per electronic module 0.4 kg 0.4 kg

*) Components for vertical linking: For weight see Pneumatics Manual P.BE-ISO-05-GB.

• Make sure that the fastening surface can support this weight.

9801 A 2-13 VIFB14 - 03/05 2. Fitting

Fasten the terminal as follows: • with three M10 screws on the adapter plate and on the right-hand end plate (2); • with two M6 screws on the left-hand end plate (1). If necessary, use the following additional fastening methods: • the opening on the bottom of the right-hand end plate with an M10 thread ("blind hole" 3); • the support bracket for the I/O modules (see fitting instructions with support bracket). The terminal can be fitted in any position. If necessary, use spacers and the thread for an M8 ring screw (transport aid).

Thread for M8 ring screw (for transport) 1 2

M10

Fig. 2/6: Fitting an ISO terminal type 05 on wall

2-14 9801 A VIFB14 - 03/05 3. Installation

3. INSTALLATION

9801 A 3-1 VIFB14 - 03/05 3. Installation

Contents

3.1 GENERAL CONNECTION TECHNIQUES 3-3 Selecting the field bus cable 3-4 Selecting the operating voltage cable 3-5 Connecting the cables to the plugs/sockets 3-6

3.2 FIELD BUS NODE 3-8 Opening and closing the node 3-8 Configuring the valve terminal 3-11 Setting the station number with CANopen 3-12 Permitted station numbers: 1; ...; 98 3-13 Setting the field bus baud rate 3-19 Setting the field bus protocol 3-20 3.2.1 Type 03: Connecting the operating voltages 3-21 Calculating the current consumption for type 03 3-25 Connection example (type 03) 3-27 3.2.2 Type 05: Connecting the operating voltages 3-29 Calculating the current consumption for type 05 3-33 Protective earthing 3-35 Connection example (type 05) 3-36 3.2.3 Connecting the field bus 3-38 Connection instructions for CANopen 3-42 Connecting instructions for the Smart Distributed System 3-43 Terminating resistor 3-44

3.3 CONNECTING THE INPUT MODULES 3-45 Pin assignment 3-47

3.4 CONNECTING THE OUTPUT MODULES 3-48 Pin assignment 3-50

3-2 9801 A VIFB14 - 03/05 3. Installation

3.1 GENERAL CONNECTION TECHNIQUES

WARNING Before installation or maintenance work is carried out, the following must be switched off: • the compressed air supply • the power supply to the electronic components (pin 1) • the power supply to the outputs/valves (pin 2).

You thereby avoid: • uncontrolled movements of loose tubing • undesired movements of the connected actuators • undefined switching states of the electronic components

9801 A 3-3 VIFB14 - 03/05 3. Installation

Selecting the field bus cable A twisted, screened 4-core cable should be used as the field bus cable.

PLEASE NOTE You must refer to the PLC manual for your controller to see which type of cable you should use. Also take into account the distance and the field bus baud rate selected.

The table below shows the approximate values for the maximum distances depending on the baud rate selected. Precise specifications are to be found in the manuals for your control system.

Baud rate Maximum Max. branch distance length

1000 kBaud 10-40 m 0.3 m

500 kBaud 50-100 m 0.75 m - 3 m

125 kBaud 500 m 3 m

20 kBaud 1000 m 7.5 m

Not all the baud rates named can be used with all PLCs, controllers or PCs/IPCs.

Please note also any restrictions of the maximum branch length.

3-4 9801 A VIFB14 - 03/05 3. Installation

Selecting the operating voltage cable Several parameters must be taken into consideration when the operating voltages are connected. Further information can be found in subsequent chapters. • Chapter 3: Installation Section: "Connecting the operating voltages" - Calculating the current consumption - Type of power unit - Cable length and cross section • Chapter 3: Installation Section: "Connecting the field bus" - Calculating the current consumption bus interfaces - Cable length and cross section • Appendix A: Cable length and cross section - Calculating the length and cross section with a table - Calculating with a graph

9801 A 3-5 VIFB14 - 03/05 3. Installation

Connecting the cables to the plugs/sockets

CAUTION The position of the pins is different depending on whether they are in the form of plugs or sockets. • The connections of the input and output modules are in the form of sockets. • The connections of the field bus interface and tf the operating voltage are in the form of plugs. The pin assignment can be found in the chapters which follow.

When you have selected suitable cables, connect them according to steps 1...7. 1. Open the plugs/sockets as follows (see diagram): • Power supply socket Insert the power supply socket into the operating voltage connection on the valve terminal. Unscrew the housing of the socket and remove it. The socket remains inserted in the operating voltage connection. • Sensor plug and field bus socket Unscrew the centre knurled nut. 2. Open the strain relief on the rear part of the housing. Pass the cable through as shown in the diagram below.

3-6 9801 A VIFB14 - 03/05 3. Installation

Cable outer diameter PG7: 4.0 ... 6.0 mm PG9: 6.0 ... 8.0 mm PG13.5: 10.0 ... 12.0 mm Plugs/sockets (straight or angled) power supply socket: PG7, 9 or 13.5 sensor plug: PG7 bus cable socket: PG9

AAAA Cable

AAA A AAAA Strain relief

Housing

AAA

AA A

A AA

AAAA AAA AAAA AAA

AAA Connecting

AAAAAA AAAAAA A A

AAA AAA AAAAAAA AAAAAAA

AAAA part AAAAAA AAAAAA A A

AAAAAAA AAAAAAA

Socket Plug

Fig. 3/1: Individual plug/socket parts and cable routing

3. Remove 5 mm of insulation from the end of the cable. 4. Fit the strands with cable end sleeves. 5. Connect the ends of the cables. 6. Close the strain relief again and screw the housing back onto the socket. Pull the cable back so that it is not looped inside the housing. 7. Tighten the strain relief.

9801 A 3-7 VIFB14 - 03/05 3. Installation

3.2 FIELD BUS NODE

Opening and closing the node

WARNING Before installation or maintenance work is carried out, the following must be switched off: • the compressed air supply • the operating voltage supply to the electronic components (pin 1). • the operating voltage supply to the outputs/valves (pin 2).

You thereby avoid: • uncontrolled movements of loose tubing • undesired movements of the connected actuators • undefined switching states of the electronic components.

3-8 9801 A VIFB14 - 03/05 3. Installation

CAUTION The valve terminal node contains electrostatically vulnerable components. • Do not therefore touch any components. • Observe the regulations for dealing with electrostatically vulnerable components.

In this way the electronic components of the node will not be destroyed.

The following connecting and display elements

are to be found on the cover of the node. AAA

Green LED AAA MOD/NET AAA AAAPOWER

STATUS Red LED

AAA AAA AAA

Green LED BUS AAAERROR AAA POWER AAA Green LED

Plug for BUS field bus cable

Fuse for Operating operating voltage voltage of connection inputs

Fig. 3/2: Cover of node

9801 A 3-9 VIFB14 - 03/05 3. Installation

PLEASE NOTE The cover is connected to the internal printed circuit boards by means of the operating voltage cable. It cannot, therefore, be removed completely.

• Opening Unscrew and remove the 6 Philips screws in the cover. Carefully lift up the cover. Do not damage the cable through mechanical stress. • Closing Replace the cover. Place the operating voltage cables back into the housing so that they are not clamped. Tighten the Philips screws in the cover in diagonally opposite sequence.

3-10 9801 A VIFB14 - 03/05 3. Installation

Configuring the valve terminal There are four printed circuit boards in the node. Board 2 contains two LEDs and a plug for the field bus cable; board 3 contains two LEDs and switches for setting the configurati-

on.

AA AAA AA

Green LED AAA Green LED

AA AA

AAA AA

Green LED AA Red LED

AAA AA AA AA 8 AA

7 AA

6 9

5 0 1

2 4

3 A Address A

Plug for A

A A

AAA selector

A AA A A A

A AAA A field bus 7 8 A

6 9 A A

A switch

5 0

A A 4 2

cables 3

A A

A (station number)

A A

A A A 1

2 AA Baud rate 3 AA 4 AA

AA Protocol

AA AA

Board 1 AA AA AA Board 4

Screening AAA AAA Board 2 Board 3

Flat plug for operating voltage connection

Fig. 3/3: Connecting, display and operating elements of the node

9801 A 3-11 VIFB14 - 03/05 3. Installation

Setting the station number with CANopen You can set the station number of the valve terminal with the two address selector switches on board 3. The switches are numbered from 0 ... 9. The arrow on the address selector switches indicates the tens or units figures of the station number set.

7 8 6 9 Address selector switch 5 0 UNITS figure 4 1 3 2 7 8 6 9 Address selector switch 5 0 TENS figure 4 1 3 2

Fig. 3/4: Address selector switch

PLEASE NOTE • Station numbers may only be assigned once per CANopen interface.

Recommendation Assign the station numbers in ascending order and, if necessary, select them to suit the machine structure of your system.

3-12 9801 A VIFB14 - 03/05 3. Installation

Permitted station numbers: 1; ...; 98

PLEASE NOTE Observe any limitations concerning the station numbers as stipulated by the CAN master and your controller.

Proceed as follows: 1. Switch off the operating voltage. 2. Assign an unused station number to the valve terminal. 3. Use a screwdriver to set the arrow of the relevant address selector switch to the units or tens figure of the desired station number.

Example

7 8 6 9 UNITS 5 0 4 1 3 2 Setting with 7 8 6 9 field bus address: 05 TENS 5 0 4 1 3 2

7 8 6 9 UNITS 5 0 4 1 Setting with 3 2 7 8 field bus address: 38 6 9 TENS 5 0 4 1 3 2

Fig. 3/5: Examples of address settings

9801 A 3-13 VIFB14 - 03/05 3. Installation

Setting/saving the station number with the Smart Distributed System, Honeywell

PLEASE NOTE • With the Smart Distributed System protocol the station number set must always be an odd number. If the valve terminal detects an even station number when the station number is saved, this will automatically be corrected to the next lower odd number. • Valve terminals which only have inputs cannot be addressed.

The station number can be set with the following devices: • Handheld Activator for Honeywell Smart Distributed System or • a suitable Smart Distributed System Master. With this protocol, it is not necesary to set the station number by means of the address selector switches.

3-14 9801 A VIFB14 - 03/05 3. Installation

The station number (= SDS-ID) is stored in a non-volatile memory in the field bus node of the valve terminal. The station number can be modified at any time. The station number last entered remains stored in the node.

Assigning station numbers with the valve terminal

Valve terminal Assigned station numbers

max. 32 outputs One n = odd (valves/electrical outputs)

max. 28 inputs and Two n = odd max. 32 outputs n + 1 is assigned automatically by valve terminal

Example: Setting and saving the station number with the Honeywell Handheld Activator 1. Supply the valve terminal with 24 V. Connect the bus connection of the valve terminal with the Handheld Activator. 2. Switch on the Activator. Wait until the following menu appears:

F1 - Select Device F2 - Data / Function F3 - Test F4 - Bus Status

9801 A 3-15 VIFB14 - 03/05 3. Installation

3. Press key F1 - Select Device. The following menu will appear:

Address: NONE F1 - Select Device F2 - Change Address F3 - Options

Press key F1- Address: NONE. The following menu will appear:

-- Select Device -- Address: NONE Enter: STAT Å ì ESC ENT

Press the STAT key. The Activator will now search for the station number of the valve terminal. When you commission the valve terminal for the first time, station number 125 will appear, otherwise the last station number saved. You can transfer the station number found with ENTER. You can continue the search with ↓ ↑.

3-16 9801 A VIFB14 - 03/05 3. Installation

Now enter the new station number.

PLEASE NOTE Always label the field bus node with the last saved station number. You can then be sure that, in the event of the fieldbus node being replaced, the station number is known and can be loaded into the new node.

Protocol Baud rate Max. number of Permitted statíon valve terminals numbers

Honeywell Smart Up to 500 kBaud 64 0; ...; 126 Distributed System Over 500 kBaud 32

Fig. 3/6: Summary of possible station numbers

9801 A 3-17 VIFB14 - 03/05 3. Installation

Besides the address selector switch there is also a DIL switch in the node. The following functions can be set on this DIL switch: • the field bus baud rate • the field bus protocol. The DIL switch consists of four switch elements. These are numbered from 1 to 4.

The position ON is marked.

AA AA

AA AA AA AA

AA AA AA AA 7 8 AA 6 9

5 1 0

4 2

AA AA

AAA AA AA

7 8

AA 6 9 AA

5 1 0

2 AA AA

AA AA AA

AA AA 1

2 AA

3 AA 4

ON AA

AAA AAA

1 Field bus baud rate 2 3 Field bus protocol 4 ON

Fig. 3/7: Position of the DIL switch

3-18 9801 A VIFB14 - 03/05 3. Installation

Setting the field bus baud rate

PLEASE NOTE Set the field bus baud rate of the valve terminal so that it corresponds to that set on the master interface.

Protocol Field bus baud rate [kBaud]

Smart Distributed automatic setting of baud rate System

CANopen 20 kBaud 125 kBaud 500 kBaud 1000 kBaud

1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 ON

Fig. 3/8: Setting the field bus baud rate

9801 A 3-19 VIFB14 - 03/05 3. Installation

Setting the field bus protocol Set switch elements 3 and 4 to the desired protocol:

Protocol CANopen Smart Reserved Reserved Distributed System

DIL switch settings

1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 ON ON ON ON ON

Fig. 3/9: Setting the field bus protocol

3-20 9801 A VIFB14 - 03/05 3. Installation

3.2.1 TYPE 03: CONNECTING THE OPERATING VOLTAGES

WARNING Use only power units which guarantee reliable electrical isolation of the operating voltages in accordance with IEC 742/EN 60742 with at least 4 kV isolation resistance. Switch power packs are permitted, providing they guarantee reliable electrical isolation as per EN 60950.

CAUTION The operating voltage supply to the outputs/valves (pin 2) must be fused externally with max. 10 A. The external fuse prevents the valve terminal from being damaged in the event of a short circuit.

9801 A 3-21 VIFB14 - 03/05 3. Installation

The 24V operating voltages are connected at

the lower left-hand edge of the node. AAA AAA MOD/NET

POWER AAA

AAA STATUS

AAA AAA AAA

BUS AAA ERROR AAA POWERAAA

BUS

Operating voltage connection

Fig. 3/10: Position of the operating voltage connection

3-22 9801 A VIFB14 - 03/05 3. Installation

The following elements of the valve terminal are supplied with + 24 V DC operating voltage via this connection: • the internal electronic components and the inputs of the input modules (pin 1: + 24 V DC, tolerance ± 25%). • the outputs of the valves and the outputs of the output modules (pin 2: + 24 V DC, tolerance ± 10%, external fuse max. 10 A required). Recommendation: Connect the operating voltage for the outputs/valves via the EMERGENCY STOP circuit.

PLEASE NOTE If there is a common voltage supply for pin 1 (electronic components and inputs) and pin 2 (outputs/valves) the lower tolerance of ±10% for both circuits must be observed.

9801 A 3-23 VIFB14 - 03/05 3. Installation

Check the 24 V operating voltage for the outputs whilst your system is operating. Please ensure that this voltage lies within the permitted tolerances even during full operation.

Recommendation • Use a closed loop power unit. • Calculate the complete current consumption in accordance with the following table and then select a suitable power unit and cable cross section. • Avoid long distances between the power unit and the terminal. Calculate the permitted distance in accordance with Appendix A. The following general rule applies to type 03:

Supply voltage Cable cross Distance section

Pin 1 = 2.2 A 1.5 mm2 ≤ 8 m Pin 2 = 10 A

2.5 mm2 ≤ 14 m VO = 24 V

3-24 9801 A VIFB14 - 03/05 3. Installation

Calculating the current consumption for type 03 The table below shows how to calculate the total current consumption for terminal type 03. The values quoted have been rounded up. If other valves or modules are used, you should consult the appropriate technical specifications for their current consumption.

Current consumption of electronic components on node type 03 and inputs (pin 1, 24 V ± 25 %) Node 0.200 A Number of simultaneously occupied sensor inputs: ____x0.010 A + ∑ A

Sensor supplies: ____x_____ A + ∑ A (see manufacturer specifications)

Current consumption of electronic components on the node = ∑ A A and inputs (pin 1) max. 2.2 A Current consumption of outputs type 03 (pin 2, 24 V ± 10 %) Number of MIDI valve coils (simultaneously under power): ____ x 0.055 A + ∑ A

Number of MAXI valve coils (simultaneously under power): ____ x 0.100 A + ∑ A

Number of simultaneously activated ∑ electrical outputs: _____x 0.010 A + A

Load current of simultaneously activated electrical outputs: _____x_____ A + ∑ A

∑ ∑ Current consumption outputs (pin 2) max. 10 A = A + A Total current consumption of valve terminal type 03 = ∑ A

Fig. 3/11: Calculating the total current consumption type 03

9801 A 3-25 VIFB14 - 03/05 3. Installation

The following diagram shows the pin assignment of the operating voltage connection.

24 V supply to 24 V electronic supply to components valves and and inputs outputs

PE (protective 0 V earth connection, incoming contact) Fig. 3/12: Pin assignment of the operating voltage connection (type 03)

Protective earthing The valve terminal has two protective earth connections as follows: • on the operating voltage connection (pin 4 incoming contact) • on the left-hand end plate (M4 thread)

3-26 9801 A VIFB14 - 03/05 3. Installation

PLEASE NOTE Always connect the earth/ground cable to pin 4 of the operating voltage connection. Ensure that the valve terminal housing and the protective earth conductor at pin 4 have the same voltage and that no equalizing currents flow. Connect a protective earth conductor with sufficient cross section to the left-hand end plate if the valve terminal is not fitted on an earthed machine stand.

You can thereby avoid: • interference from electromagnetic sources.

Connection example (type 03) The following diagram shows the connection of a common 24 V supply for pins 1 and 2. Please note that: • the supply to the outputs/valves must be protected against short circuit/overload with an external fuse max. 10 A; • the supply to the electronic components and inputs must be protected against short circuit/overload with an external 3.15 A fuse (recommendation);

9801 A 3-27 VIFB14 - 03/05 3. Installation

• the common tolerance of 24 V DC ± 10 % must be observed; • equalizing currents must be avoided when both earth cables are connected, e.g. by the use of cables with suitable cross section as voltage compensation.

3124 Connecting cable for voltage compensation of earth connections Fuse for inputs to sensors (2 A) 0 V AC 24 V 3,15 A External fuses DC 24V ± 10 A 10% EMERGENCY STOP

Earth cable connection pin 4 designed for 12 A

Fig. 3/13: Example – connecting a common 24V supply and both earth cables (type 03)

3-28 9801 A VIFB14 - 03/05 3. Installation

3.2.2 TYPE 05: CONNECTING THE OPERATING VOLTAGES

CAUTION The operating voltage supply to the outputs (pin 2) must be fused externally with max. 10 A. The external fuse prevents the terminal from being damaged in the event of a short circuit.

9801 A 3-29 VIFB14 - 03/05 3. Installation

The 24 V operating voltages are connected on the adapter plate between the node and the valves. The node and the I/O modules are supplied with current via the adapter cable.

Operating voltage connection type 05

Fuses for valves (4 A slow blowing)

Adapter cable

Fig. 3/14: Position of the operating voltage connection type 05

3-30 9801 A VIFB14 - 03/05 3. Installation

The following elements of valve terminal type 05 are supplied with +24 V DC operating voltage via this connection: • the internal electronic components and the inputs of the inputs modules (pin 1: + 24 V DC , tolerance 25 %, external fuse max. 3.15 A recommended). • the outputs of the valves and the outputs of the output modules (pin 2: + 24 V DC , tolerance 10 %, external fuse max. 10 A slow blowing required).

Recommendation Connect the operating voltage for the outputs/valves via the EMERGENCY STOP circuit or EMERGENCY STOP contacts.

PLEASE NOTE If there is a common voltage supply for pin 1 (electronic components and inputs) and pin 2 (outputs/valves), the lower tolerance of 10% for both circuits must be observed.

9801 A 3-31 VIFB14 - 03/05 3. Installation

Check the 24 V operating voltage of the outputs whilst your system is operating. Please ensure that this voltage lies within the permitted tolerances even during full operation.

Recommendation • Use a closed loop power unit. • Calculate the complete current consumption in accordance with the following table and then select a suitable power unit and suitable cable cross section. • Avoid long distances between the power unit and the terminal. Calculate the permitted distance in accordance with Appendix A. The following general rule applies to type 05:

Supply Cable Distance max.*) cross section

Pin 1 = 2.2 A 1.5 mm2 ≤ 8 m 2 Pin 2 = 10 A 2.5 mm ≤ 14 m

VO = 24 V

*) Please observe the maximum total current consumption (pins 1 and 2) of max. 12.2 A.

3-32 9801 A VIFB14 - 03/05 3. Installation

Calculating the current consumption for type 05 The table below shows how to calculate the total current consumption for ISO terminal type 05. The values quoted have been rounded up. If other valves or modules are used, you should consult the appropriate technical specifications for their current consumption.

Current consumption of electronic components node type 05 and inputs (pin 1, 24 V ± 25 %) Node 0.200 A Number of simultaneously occupied digital sensor inputs: ____ x 0.010 A + ∑ A

Sensor supplies: ____ x _____ A + ∑ A (see manufacturer specifications)

Current consumption of electronic components node and inputs (pin 1) max. 2.2 A∑ A = A

Current consumption of outputs type 05 (pin 2, 24 V ± 10 %) Number of pilot valve solenoids (max. 12 solenoids simultaneously under power): ___ x 0.300 A + ∑ A

Number of simultaneously activated electrical outputs: ___ x 0.010 A + ∑ A Load current of simultaneously activated ∑ electrical outputs: ___ x _____A + A

Current consumption of outputs (pin 2) max. =+∑ A ∑ A 10.0 A Total current consumption of valve terminal type 05 = ∑ A

Fig. 3/15: Calculating the total current consumption type 05

9801 A 3-33 VIFB14 - 03/05 3. Installation

The following diagram shows the pin assignment of the operating voltage connection on the adapter plate.

24 V supply to 24 V electronic supply to components valves and and inputs outputs

PE (protective 0 V earth connection, incoming contact) Fig. 3/16: Pin assignment of operating voltage connection (type 05)

3-34 9801 A VIFB14 - 03/05 3. Installation

Protective earthing The valve terminal has two protective earth connections as follows: • on the operating voltage connection (pin 4 incoming contact) • on the left-hand end plate (M4 thread).

You can thereby avoid: • interference from electromagnetic sources.

9801 A 3-35 VIFB14 - 03/05 3. Installation

Connection example (type 05) The following diagram shows the connection of a common 24 V supply for pins 1 and 2. Please note that: • the outputs must be protected against short circuit/overload with an external slow-blowing fuse of max. 10 A; • the electronic components and inputs must be protected against short circuit/overload with an external 3.15 A fuse (recommendation); • the sensors must be additionally protected with the (2 A) fuse fitted; • the valves must be additionally protected with the 4 A slow-blowing fuse fitted; • the common tolerance of 24 V DC ± 10% must be observed; • the node must be supplied with power via the adapter cable; • equalizing currents must be avoided when both earth cables are connected, e.g. by means of cables with suitable cross section as a voltage compensation.

3-36 9801 A VIFB14 - 03/05 3. Installation

Operating voltage connection Fuse for valves (4 A)

Connected adapter cable

Connecting cable for

voltage compensation 312 4 of earth connections

0 V AC 24 V 3.15 A external fuses

DC 24V 10 A ± 10% EMERGENCY STOP

Earth connection pin 4 designed for 12 A

Fig. 3/17: Example – connecting a common 24V supply and both earth cables (type 05)

9801 A 3-37 VIFB14 - 03/05 3. Installation

3.2.3 CONNECTING THE FIELD BUS There is a field bus plug on the node for connecting the valve terminal to the field bus.

The two bus cables, the voltage supply cables (+24V and 0V) for the bus interface and the cable screening are all connected to this plug. The hardware basis of the bus interface is formed by the CAN bus. A typical feature of this bus interface is that it is supplied with voltage via the field bus plug.

The bus should be connected via a branch line by means of a 5-pin M12 socket with PG9 screw connector. These can be ordered from Festo (type FBSD-GD-9-5POL, part no. 18324). Alternatively, you can use the bus cables of other manufacturers (see Appendix A, Acces- sories).

PLEASE NOTE Consult the manual for your PLC to ascertain the T-adapter and the maximum branch line length which are permitted for your controller. Appendix A contains a summary of suitable installation accessories.

The diagram overleaf shows the main bus connection.

3-38 9801 A VIFB14 - 03/05 3. Installation

Voltage supply for Field bus bus interface

Screening

Branch line

AA AAA

AA AAA AA AAA

AA AAA

T-adapter

+24 V

AA AAA

AA AAA AA

0 V AAA

AA AAA

Bus

Fig. 3/18: Structure of bus interface

9801 A 3-39 VIFB14 - 03/05 3. Installation

Current consumption of all bus interfaces

Number of Festo valve terminals ∑ A connected______* 50 mA

Current consumption of the remaining field bus interfaces ∑ A

Current consumption of sensor ∑ A inputs/sensor supply via the bus

Total current consumption of ∑ all bus interfaces A

Avoid long distances between the bus voltage supply and the bus slaves.

If necessary, calculate the permitted distance (see also Appendix A).

PLEASE NOTE Bus slaves of different manufacturers have different tolerances in respect of the interface supply. Take this into consideration when planning the bus length. The following applies to FESTO valve terminals: Vmax = 25V Vmin = 11.5V

3-40 9801 A VIFB14 - 03/05 3. Installation

CAUTION • Please observe the correct polarity when connecting the field bus interface. • Connect the screening.

The diagram below shows the pin assignment of the field bus interface. Connect the field bus cables to the terminals of the bus cable socket. Please observe also the connection instructions in the other diagrams as well as the instructions in the PLC manual for your controller.

GND bus +24V bus Data - Data + (CAN_L) (CAN_H) Screening

220 nF 1MΩ internal RC network

Node housing

Fig. 3/19: Pin assignment of the field bus interface

9801 A 3-41 VIFB14 - 03/05 3. Installation

Connection instructions for CANopen

PLEASE NOTE You must check the connection assignment of the CANopen interface in the manual for your controller.

Connect the field bus cable of your control system to the field bus interface of the valve terminal as follows:

PLC/PC/IPC plug assignment Valve terminal pin assignment of the field bus interface

View Pin Signal destination

1 * 2 CAN_L Data-/CAN_L Pin 5 3 CAN_GND GND bus Pin 3 4 * 5 CAN_SHLD Screening Pin 1 6 GND 7 CAN_H Data+/CAN_H Pin 4 8 * 9 CAN_V+ + 24 V bus Pin 2

* nc = Not connected

Fig. 3/20: Pin assignment as per DS102

3-42 9801 A VIFB14 - 03/05 3. Installation

Connecting instructions for the Smart Distributed System

PLEASE NOTE Always check the pin assignment of the Smart Distributed System interface in the manual for your controller.

Connect the field bus cable of your control system to the field bus interface of the valve terminal as follows:

Plug assignment SDS interface Valve terminal pin assignment of the field bus interface

View Pin Signal destination

1 * 2 CAN_L Data-/CAN_L Pin 5 3 GND GND bus Pin 3 4 * 5 * Screening Pin 1 6 * 7 CAN_H Data+/CAN_H Pin 4 8 * 9 V+ + 24 V bus Pin 2

* nc = Not connected

Fig. 3/21: Pin assignment (Honeywell IPC)

9801 A 3-43 VIFB14 - 03/05 3. Installation

Terminating resistor If the valve terminal to be connected is at the end of the field bus line, a terminating resistor (120 Ohm, 0.25 Watt) must be fitted in the socket of the field bus cable. Adaption is necessary.

Fitting the terminating resistor 1. Connect the wires of the resistor together with those of the field bus cable between the wires Data + (pin 4) and Data - (pin 5) of the bus cable socket.

PLEASE NOTE To guarantee reliable contact, we recommend that the wires of the resistor and those of the bus cable be crimped together in common end sleeves.

Ω 4 120

5 2 1

Fig. 3/22: Pin assignment of the field bus interface

2. Fit the bus cable socket to the field bus plug.

3-44 9801 A VIFB14 - 03/05 3. Installation

3.3 CONNECTING THE INPUT MODULES

You thereby avoid: • uncontrolled movements of loose tubing • undesired movements of the connected actuators • undefined switching states of the electronic components Four or eight inputs are available for the user on the input modules of the valve terminal. The input modules have the following switching logic depending on their type:

Input module type Switching logic INPUT PNP (positive) INPUT-N NPN (negative)

9801 A 3-45 VIFB14 - 03/05 3. Installation

Input module 4 inputs Input module 8 inputs

Socket with one Socket One digital Green with two green input LED digital LED each inputs each each per digital input

Fig. 3/23: Digital input modules (4/8 inputs)

Recommendation for the 8-input modules: Use the Festo DUO cable in order to connect two sensors with one plug.

3-46 9801 A VIFB14 - 03/05 3. Installation

Pin assignment The following diagram shows the pin assignment of all inputs.

Pin assignment 4 inputs LED Pin assignment 8 inputs LED

free 0 V Input 0 V 2 3 00Ix+1 2 3

1 4 1 4 Input Input 1 + 24 V Ix + 24 V Ix

free 0 V Input 0 V 12Ix+3 2 3 2 3

1 4 1 4 3 Input Input + 24 V Ix+1 + 24 V Ix+2

free 0 V Input 0 V Ix+5 2 3 24 2 3

1 4 1 4 5 Input Input + 24 V Ix+2 + 24 V Ix+4

free 0 V Input 0 V Ix+7 2 3 36 2 3

1 4 1 4 7 Input Input + 24 V Ix+3 + 24 V Ix+6 Fig. 3/24: Input modules: pin assignment (4/8 inputs)

9801 A 3-47 VIFB14 - 03/05 3. Installation

3.4 CONNECTING THE OUTPUT MODULES

WARNING Before installation or maintenance work is carried out, the following must be switched off: • the compressed air supply • the operating voltage for the electronic components (pin 1) • the operating voltage for the outputs/valves (pin 2)

You thereby avoid: • uncontrolled movements of loose tubing • undesired movements of the connected actuators • undefined switching states of the electronic components

3-48 9801 A VIFB14 - 03/05 3. Installation

Four transistor outputs are available for the user on the output modules of the valve terminal. The outputs have positive logic (PNP outputs).

Output module (4-outputs)

Yellow LED per output Red LED per output

Socket with one digital output each

Fig. 3/25: Digital output module (4-outputs)

9801 A 3-49 VIFB14 - 03/05 3. Installation

Pin assignment The diagram below shows the pin assignment of all outputs.

Pin assignment 4 outputs LED

free 0 V 2 3 0

1 4

free Output Ox

free 0 V 1 2 3

1 4

free Output Ox+1

free 0 V 2 2 3

1 4

free Output Ox+2

free 0 V 3 2 3

1 4

free Output Ox+3 Fig. 3/26: Output modules: pin assignment (4 outputs)

3-50 9801 A VIFB14 - 03/05 4. Commissioning

4. COMMISSIONING

9801 A 4-1 VIFB14 - 03/05 4. Commissioning

Contents

4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING 4-5 General 4-5 Switching on the operating voltage 4-6 Calculating the configuration data 4-7 Calculating the number of inputs/outputs type 03 4-9 Calculating the number of inputs/outputs type 05 4-10 Address assignment of the valve terminal 4-11 General type 03 and type 05 4-11 Basic rule 1 4-12 Basic rule 2 4-15 Address assignment after extension/conversion 4-16 Addressing example type 03 MIDI/MAXI valves 4-19 Addressing example type 05 ISO valves 4-20

4-2 9801 A VIFB14 - 03/05 4. Commissioning

4.2 BASIC PRINCIPLES OF COMMISSIONING AND DIAGNOSIS 4-21 General 4-21 Selecting the inputs/outputs 4-21 General information on CANopen 4-22 Brief summary of scope of function 4-23 Summary of object directory 4-24 Default identifier distribution 4-27 Summary of object directory 4-28 PDO communication parameter record 4-29 PDO communication mapping parameter field 4-31 Digital inputs 4-32 Digital outputs 4-32 Reaction of the digital outputs in the event of a fault 4-33 Definition of emergency object 4-35 Addressing inputs and outputs 4-36 Examples: communication process 4-38 Diagnosis of status bits 4-41 Position of the status bits 4-42

9801 A 4-3 VIFB14 - 03/05 4. Commissioning

4.3 BASIC PRINCIPLES OF THE SMART DISTRIBUTED SYSTEM (HONEYWELL) 4-43 General information 4-43 Commissioning 4-43 Number of inputs and outputs 4-44 Summary of implemented object models 4-45 Summary of actions 4-48 Summary of events 4-49 Assignment of SDS IDs 4-49 Diagnosis 4-50 Diagnosis via status bits 4-51 Setting the transmission mode 4-53 Bus configuration 4-54 4.3.1 CONFIGURING/ADDRESSING THE HONEYWELL SDS PC CONTROL 4-55 General information 4-55 Settings in the Device Editor 4-55 Settings in the Tag Editor 4-58 Setting the transmission types for inputs by means of the programming software 4-60 Setting the Cyclical Timer 4-61 Diagnosis 4-63 Diagnosis via the network manager 4-63 Diagnosis via the SDS user program 4-63 Structure of the SDS diagnostic register 4-65 Diagnosis via the status bits 4-66 4.3.2 CONFIGURING/ADDRESSING WITH THE GE FANUC SERIES 90/30 4-67 General information 4-67 Bus configuration 4-68 Assigning the I/O addresses 4-68 Diagnosis 4-73 Diagnosis via the SDS interface 4-73 Diagnosis via status bits 4-75

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4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING

General Before commissioning or programming, you should first compile a configuration list of all the connected field bus slaves. On the basis of this list you can: • make a comparison between the ACTUAL and NOMINAL configurations in order to ascertain if there are any incorrect connections. • access these specifications during the syn- tax check of a program, in order to avoid addressing errors. The valve terminal must be configured very accurately, since different configuration specifications may be required for each terminal due to the modular structure. Please observe here also the specifications in the following sections.

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Switching on the operating voltage

PLEASE NOTE Observe also the switching-on instructions in the PLC manual for your controller.

When the controller is switched on, it automatically carries out a comparison between the NOMINAL and ACTUAL configurations. The following points are important for the configuration: • The specifications on configuration must be complete and correct. • The power supplies to the PLC and to the field bus slaves must be switched on either simultaneously or in the sequence specified below.

Please observe also the following points when switching on the power supplies: • Common supply. If the control system and all the field bus slaves have a common power supply, they should be switched on with a common central power unit or switch. • Separate supply. If the control system and the field bus slaves have separate power supplies, they should be switched on in the following sequence: 1. first the field bus slaves 2. then the control system.

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Calculating the configuration data Before configuring, calculate the exact number of inputs/outputs available. A modular valve terminal consists of a number of I/Os which differs depending on the type of valve terminal.

PLEASE NOTE • The terminal makes available four status bits for diagnosis via the field bus. These are always assigned automatically within the terminal when there are input modules. • The status bits occupy four additional input addresses.

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The following table shows the number of I/Os required for each module for configuration.

Module type Number of assigned I/Os *) Single sub-base (type 03) 2O

Double sub-base (type 03) 4O

ISO manifold sub-base (type 05) - 4 valve locations 8O - 8 valve locations 16O - 12 valve locations 24O

Output module (4 digital outputs) 4O

Input module (4 digital inputs) 4I

Input module (8 digital inputs) 8I

Status bits**) 4I *) The I/Os are assigned automatically in the terminal irrespective of whether an input/output is actually used. **) The status bits are assigned automatically in the terminal as soon as there are input modules. Fig. 4/1: Number of assigned I/Os per module

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Calculating the number of inputs/outputs type 03 Copy this table for further calculations and ascertain the number of inputs/outputs.

Table for calculating the inputs/outputs type 03 INPUTS

1. Number of 4-input modules ______⋅ 4 Σ E

+ 2. Number of 8-input modules ______⋅ 8 Σ E

3. The 4 status bits are assigned internally + automatically by the terminal. They must be treated 4E like inputs and added to the intermediate sum.

Total sum of inputs to be configured = Σ E

OUTPUTS

4. Number of single sub-bases type 03 ______⋅ 2 Σ A

5. Number of double sub-bases type 03 ______⋅ 4 + Σ A

Intermediate sum of 4.+ 5. = Σ A

6. Check whether sum of 4 + 5 can be divided without remainder. This check is necessary because of the 4-bit orientated internal addressing of the terminal. Different cases: a) If divisible by 4 without remainder continue with point 7. b) If not round up (+ 2 outputs) + 2A

7. Number of electrical 4-output modules ______⋅ 4 + Σ A

Total sum of outputs to be configured = Σ A

Fig. 4/2: Calculating the number of inputs/outputs type 03

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Calculating the number of inputs/outputs type 05 Copy this table for further calculations.

Table for calculating the number of inputs/outputs type 05 INPUTS

1. Number of 4-input modules ______⋅ 4 Σ E + Σ E 2. Number of 8-input modules ______⋅ 8

3. The 4 status bits are assigned internally + automatically by the terminal. They must be treated 4E like inputs and added to the intermediate sum.

Total sum of inputs to be configured = Σ E

OUTPUTS

4. ISO manifold sub-base for: • 4 valve locations 8O

• 8 valve locations 16O

• 12 valve locations 24O Σ A

Σ 5. Number of electrical 4-output modules ______⋅ 4 + A

Total sum of outputs to be configured = Σ A

Fig. 4/3: Calculating the number of inputs/outputs type 05

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Address assignment of the valve terminal

General type 03 and type 05 The address assignment of a modular valve terminal depends on the equipment fitted on the terminal. A distinction must be made between the following equipment fitted: • valves and digital I/O modules • valves only • digital I/O modules only The basic rules described overleaf apply to the address assignment of these fitting variants.

PLEASE NOTE If two addresses are assigned for one valve location, the following applies: • Lower-value address ⇒ pilot solenoid 14 • Higher-value address ⇒ pilot solenoid 12

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Basic rule 1 With mixed fitting, consideration is given to the address assignment of the valves, the digital I/O modules and the status bits. 1. Outputs: The address assignment of the outputs does not depend on the inputs. 1.1 Address assignment of the valves: • Addresses should be assigned in ascending order without gaps. • Counting begins on the node from left to right. • Single sub-bases always occupy two addr. • Double sub-bases always occupy four addr. • ISO valve locations always occupy two addr. • Maximum 26 valve solenoid coils can be addressed. 1.2 Rounding up to 4 bits, different cases: a) If the number of valve addresses can be divided by 4 without remainder, continue with point 1.3. b) If the number of valve addresses cannot be divided by 4 without remainder, the number must be rounded up to 4 bits because of the 4-bit orientated addressing. The 2 bits thus rounded up cannot be used. 1.3 Address assignment of the output modules: The digital outputs are addressed after the (rounded up 4-bit) addresses of the valves. • Addresses should be assigned in ascending order without gaps. • Counting begins on the node from right to left. • Counting on the individual modules is from top to bottom. • Digital output modules always occupy 4 addresses.

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2. Inputs The address assignment of the inputs does not depend on the outputs. 2.1 Address assignment of the input modules: • Addresses should be assigned in ascending order without gaps. • Counting begins on the node from right to left. • Counting on the individual modules is from top to bottom. • 4-input modules occupy 4 addresses. • 8-input modules occupy 8 addresses. 2.2 Status bits The address assignment of the status bits depends on the equipment fitted on the inputs and on the configuration.

The following rule applies: • The status bits are only available when input modules are connected to the terminal and when at least 8 inputs are configured in the PLC. • Addressing. The status bits are transferred to the four highest-value positions of the configured address range.

When the operating voltage is switched on, the valve terminal automatically recognizes all the available pneumatic modules (type 03: max. 13 modules; type 05: 4, 8, 12 valve locations) and digital input/output modules and assigns the appropriate addresses. If a valve location is not used (blanking plate) or if a digital input/output is not connected, the relevant address will still be occupied.

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The diagram below shows the address assignment with mixed fitting. 4-input module 8-input module 4-output module 8-output module Single sub-base Double sub-base Double sub-base Double sub-base Round up

012 4 6 810 12 14 802016 3 5 7 9 11 13 15 1 9221 17 3

10 4 22 18 5 11 6 23 19 7

Fig. 4/4: Address assignment of a valve terminal with digital I/Os (example type 03)

Remarks on the diagram • If single solenoid valves are fitted onto double sub-bases, four addresses will be reserved for valve solenoid coils; the higher address in each case then remains unused (see address 3). • If unused valve locations are fitted with blanking plates, the addresses will still be occupied (see addresses 12, 13). • Due to the 4-bit orientated addressing of the modular valve terminal, the address of the last valve location is always rounded up to four full bits (unless the equipment fitted already uses the four full bits). This means that two addresses cannot be used (see addresses 14, 15).

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Basic rule 2 If only valves are used, the address assignment will always be as described in basic rule 1.

PLEASE NOTE • Maximum 26 valve solenoid coils can be addressed. • There is no rounding up of the last two positions on the valve side. • Valve terminals without input modules do not require a configuration for inputs. The status bits are not therefore available.

Basic rule 3 If only electrical I/Os are used, the address assignment will always be as described in basic rule 1.

PLEASE NOTE • Counting begins immediately to the left of the node. • There is no rounding up of the last two positions on the valve side.

Please unfold for page 4-14

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Address assignment after extension/ conversion A special feature of the modular valve terminal is its flexibility. If the demands placed on the machine change, then the equipment fitted on the terminal can also be modified.

CAUTION If extensions or conversions are made to the terminal at a later stage, this may result in a shifting of the input/output addresses. This applies in the following cases: • if one or more pneumatic modules is/are fitted/removed at a later stage (type 03). • if a pneumatic module with single valves is replaced by a new module with double valves or vice versa (type 03). • if additional input/output modules are inserted between the node and existing input/output modules. • if existing 4-input modules are replaced by 8-input modules or vice versa.

If the configuration of the inputs is changed, the addresses of the status bits will always be shifted.

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The diagram below shows the modifications to the address assignment if the standard fitting in the previous diagram is extended. 4-input module 4-input 4-output module 4-output module Single sub-base Double sub-base 8-input module Double sub-base Single sub-base notDo round up Double sub-base SUPPLY Double sub-base

012 4 6 8 10 12 14 16 18 19 8 0 24 20 3 5 7 9 11 13 15 17 1 9225 21 3

10 4 26 22 5 11 6 27 23 7

Fig. 4/5: Address assignment of a valve terminal after extension/conversion

Please note: Air supply modules and intermediate air supply modules do not occupy any addresses.

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Addressing example type 03 MIDI/MAXI valves 4-input module 4-input module 8-input module 4-output 4-output module 4-output sub-base Double sub-base Double Double sub-base Double Double sub-base Double up Round Single sub-base Single Double sub-base Double

Please note: If a valve location occupies two addresses, the following applies: • Lower-value address ⇒ pilot solenoid 14 • Higher-value address ⇒ pilot solenoid 12

Fig. 4/6: Address assignment of a valve terminal type 03 (MIDI/MAXI valves)

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Addressing example type 05 ISO valves Double valve Double valve Double Double valve Double Double valve Double valve Double valve Double Single valve up round not Do 4-input module 8-input module module 4-output module 4-output Single valve

12 14 12 14 12 1414 12 14 12 14 12 14 14 8 0 20 16 1 9 2 21 17 3 10 4 22 18 1 0 3572 469 8101113 12 15 14 5 11 6 23 19 7

Please note: If a valve location occupies two addresses, the following applies: • Lower-value address ⇒ pilot solenoid 14 • Higher-value address ⇒ pilot solenoid 12

Fig. 4/7: Address assignment of a valve terminal type 05 (ISO valves)

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4.2 BASIC PRINCIPLES OF COMMISSIONING AND DIAGNOSIS

General This chapter describes the configuration and addressing of a valve terminal on a CANopen Interface or CANopen master.

The following standards have been taken into account:

DS 301 Draft Standard 301 concerns the communications profile based on CAL DSP 401 Draft Standard Proposal 401 defines the device profiles for input/output DS 201.. CAN Application Layer CAL DS 207

In order to understand this chapter, the user should be familiar with CANopen and the specifications DS 301 and DSP 401.

Selecting the inputs/outputs

PLEASE NOTE The sum of the input bytes must not exceed 8 bytes (60 inputs + 4 status bits) and 8 output bytes (64 outputs).

The number of inputs and outputs is different due to the modular structure of the valve terminal. The number of input bytes and/or output bytes which actually exist on the valve terminal can be read via the appropriate index.

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General information on CANopen CANopen devices have an object directory which provides access in a standardized man- ner to all important node parameters. You can configure a CANopen system mainly by acces- sing the object directory of the individual nodes. The access mechanism is made available by Service Data Objects (SDOs).

There are two different communication mecha- nisms in a CANopen system.

"Process Data Objects” (PDOs) serves for the fast transfer of processing data and is transmitted by simple CAN messages without protocol overhead and in the broadcast procedure. Process Data Objects can be transmitted event-controlled, synchronous to a system time interval or on demand.

Die ”Service Data Objects” (SDO) forms a point-to-point conection and permits access to every entry in the object directory of a node.

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Brief summary of scope of function • Module states and boot up after communication profile DS 301 • All the entries in the communication part of the object directory are included • A service data object for read/write access to the object directory • A process data object for access to digital input/outputs • PDO-COB identifier for read/write access can be selected individually • PDO transmission types for read/write access can be set separately as asynchro- nous (255), synchronous cyclic (1-240), synchronous acyclic (0) as per DS 301 • PDO emergency telegram for error message to the master • Synchronous mode • Node guarding • All COB-IDs of the implemented functions (except for SDO) can be selected separately in the object directory via SDO transfer, both for sending and for receiving • Default setting of all identifiers as per DS 301 and the node address

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Summary of object directory The following table shows the implemented objects of the Festo valve terminal. The table is based on DS 301 (Draft Standard Proposal):

Index (hex) Objects 1000-100E Communication part of the object directories 1400 Communication parameter for receive PDO 1600 Mapping parameter for receive PDO (variable mapping not implemented) 1800 Communication parameter for send PDO 1803 Communication parameter for emergency PDO 1A00 Mapping parameter for send PDO (variable mapping not implemented) 1A03 Mapping parameter for emergency PDO (variable mapping not implemented) 6000 Input array 6200 Output array 6206 Fault mode array for the output lines 6207 Fault state array for the output lines

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COB identifier The Festo valve terminal with CANopen repre- sents a "minimum capability device" (minimum device). The PDO-COB identifier can be selected individually for read and write access.

Bit 10 Bit 7 Bit 6 Bit 0

Function code Module-ID

Fig. 4/9: Structure of COB identifier

Max. 127 slaves can be controlled with the module-ID. Addresses from 1 ... 98 can be set with the address selector switches of the valve terminal. Address 99 is reserved for the self test. Address 00 is not valid. The address is also referred to as station number, MAC-ID or "MESSAGE-ID."

Example: COB-ID for valve terminal. Set address (rotary switch): 10D.

Bit 10 Bit 7 Bit 6 Bit 0 0 0 0 1 0 1 0

Function code Module-ID

Fig. 4/10: Structure of COB identifier for valve terminal no. 10

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Switch-on reaction of the valve terminal Status diagram of the Festo valve terminal

Switch on

Hardware initialization 1

Communication initialization 1 4 5 Pre-Operational [cs=82H] [cs=81H]

[cs=80H] 3 2 [cs=01H] 4 5 Operational [cs=82H] [cs=81H]

Fig. 4/11: Status diagram of the valve terminal

Description of the status transfers

Status Designation Command Function transfer specifier (CS) 1 Automatic initialization after switching on

2 Start_remote_Node_Indication 01H – Start valve terminal – Release outputs – Start PDO transmission

3 Enter_Pre_Operation_ State 80H Stops PDO transmission; SDO remains active

4 Reset_Communication_ 82H Reset communication Indication functions

5 Reset_Node_Indication 81H Reset module including application

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Default identifier distribution The following table shows the identifier distribution.

Peer-to-Peer Objects Object Object Function CMS Value range of Name designation code priority COB identifier (binary) group with Festo valve terminals

SYNC 0001 0 128D 80H

EMER- For high-priority 0001 0, 1 129D to 226D GENCY processes 081H 0E2H e.g. voltage failure

Send 0011 1, 2 385D to 482D PDO 181H 1E2H

Receive 0100 2 513D to 610D PDO 201H 262H

Send 1011 6 1409D to 1506D SDO 581H 5E2H

Receive 1100 6, 7 1537D to 1634D SDO 601H 662H

Node 1110 7 1793D to 1890D guarding 701H 762H

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Summary of object directory The communication part of the objects contains the following objects. Values and examples refer to module-ID = 1.

Communication profile Index Object name Object Object Object Values/ Explanation of values (hex) symbolic designation type attributes subindex 1000 VAR Device type U32 ro 91 01 03 00 0191 = Device profile for I/O module x: 0300 = Digital inputs and digital outputs exist 1001 VAR Manufacturer U8 ro xx 00 = No error error field 81 = Generic manufacturer error 1002 VAR Predef_status U32 ro 00 00 00 00 Not defined 1003 ARRAY Predef_error U16 ro "0"= 0x xx Number of errors field [2] "1"= xx xx Standard error field 2023 = Short circuit/ overload 2033 = Valve voltage < 21.6 V 3033 = Valve voltage > 10 V 2031 = Sensor voltage < 10 V 1004 ARRAY No. of PDOs [3] U32 ro "0"= 02 01 No. of transmit PDOs supported 01 00 No. of receive PDOs "1"= 01 00 No. of syn. transmit PDOs 01 00 No. of syn. receive PDOs "2"= 02 00 No. of asyn transmit PDOs 01 00 No. of asyn. receive PDOs 1005 VAR COB Id U32 rw 80 00 00 80 8000 = Device supports SYNC SYNC message. message Does not generate SYNC message. 0080 = Default COB-ID 80 1006 VAR Communication U32 rw 80 96 98 00 = 10 sec cycle period U = unsigned, ro = read only, rw = read write Table continued on next page

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Table continued Communication profile Index Object name Object Object Object Values/ Explanation of values (hex) symbolic designation type attributes subindex 1007 VAR Synchronous U32 rw 00 00 00 00 Without function window length 1008 ARRAY Manufacturer String 46 42 31 34 FB14 device name 1009 ARRAY Manufacturer String 30 38 39 36 min. 0896 hardware version 100A ARRAY Manufacturer String 56 31 2E 31 V1.1 software version 100B VAR Node-ID U32 ro 01 00 00 00 Node address 100C VAR Guard time U16 rw E8 03 e.g. 1000 ms 100D VAR Lifetime factor U8 rw 03 Life time for the node guarding protocol 100E VAR Nodeguard_id U32 rw 01 07 00 80 Nodeguard identifier U = unsigned, ro = read only, rw = read write

PDO communication parameter record The following object directory is defined in the "Receive" PDO communication parameter. Va- lues and examples refer to module-ID = 1.

Communication profile Index Object name Object Object Object Values/ Explanation of (hex) symbolic designation type attributes subindex values 1400 RECORD Communication PDOComm rw "0"=02 = No. of entries parameter for parameter "1"=01 02 00 00 = COB-ID 200 + receive PDO module-ID "2"=xx = transmission type Default = FF 01 = async. FF= acyc. async.

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The following object directory is defined in the "Transmit" PDO communication parameter. Va- lues and examples refer to module-ID = 1.

PLEASE NOTE With transmission type "synchronous", the parameter (01...F0) specifies the number of SYNC messages which must be received until the send PDO is transmitted.

Communication profile Index Object name Object Object Object Values/ Explanation of (hex) symbolic designation type attributes subindex values 1800 1. Communication PDOComm rw "0"=02 = No. of entries parameter for parameter "1"=01 81 00 00 = COB-ID 180 + send PDO module-ID "2"=xx transm. type Default = FF 00 = acyclic synch. 01-F0 = synch. FF = acyclic asynch. 1803 RECORD 4. Communication PDOComm rw "0"=02 = No. of entries parameter for parameter "1"=81 00 00 00 = COB-ID 80 + send PDO module-ID "2"=FE = transmission type asynch. (not changeable)

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PDO communication mapping parameter field

PLEASE NOTE Variables mapping is not supported.

"Receive" PDO mapping parameter:

Communication profile Index Object name Object Object Object Values/ Explanation of (hex) symbolic designation type attributes subindex values 1600 ARRAY Mapping PDOComm ro "0"= 0x = No. of available parameter for parameter output bytes receive PDO "1"= 08 01 00 62 = O 0.0 - O 0.7 "2"= 08 02 00 62 = O 1.0 - O 1.7 "3"= 08 03 00 62 = O 2.0 - O 2.7 "4"= 08 04 00 62 = O 3.0 - O 3.7 "5"= 08 05 00 62 = O 4.0 - O 4.7 "6"= 08 06 00 62 = O 5.0 - O 5.7 "7"= 08 07 00 62 = O 6.0 - O 6.7 "8"= 08 08 00 62 = O 7.0 - O 7.7

"Transmit" PDO mapping parameter:

Communication profile Index Object name Object Object Object Values/ Explanation of (hex) symbolic designation type attributes subindex values 1A00 ARRAY Mapping PDOComm ro "0"= 0x = No. of available parameter for parameter input bytes send PDO "1"= 08 01 00 60 = I 0.0 - I 0.7 "2"= 08 02 00 60 = I 1.0 - I 1.7 "3"= 08 03 00 60 = I 2.0 - I 2.7 "4"= 08 04 00 60 = I 3.0 - I 3.7 "5"= 08 05 00 60 = I 4.0 - I 4.7 "6"= 08 06 00 60 = I 5.0 - I 5.7 "7"= 08 07 00 60 = I 6.0 - I 6.7 "8"= 08 08 00 60 = I 7.0 - I 7.7 1A03 ARRAY Mapping PDOComm ro ”0”=07 = No. of bytes parameter for Parameter ”1”=10 01 03 10 = Manufacturer emergency error field PDO Emergency error code ”2”...”7” = Reserved

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Digital inputs Festo supports the "INPUT ARRAY" and "OUTPUT ARRAY" for the 8-bit commands. The following tables apply:

Communication profile Index Object name Object Object Object Values/ Explanation of (hex) symbolic designation type attributes subindex values 6000 ARRAY Read state 8 Unsigned 8 ro ”0”= 0x = No. of available input lines[9] input bytes "1" =xx = I 0.0 - I 0.7 "2" =xx = I 1.0 - I 1.7 "3" =xx = I 2.0 - I 2.7 "4" =xx = I 3.0 - I 3.7 "5" =xx = I 4.0 - I 4.7 "6" =xx = I 5.0 - I 5.7 "7" =xx = I 6.0 - I 6.7 "8" =xx I 7.0 - I 7.7

Digital outputs

Communication profile Index Object name Object Object Object Values/ Explanation of (hex) symbolic designation type attributes subindex values 6200 ARRAY Write state 8 Unsigned 8 rw ”0”= 0x = No. of available output lines[9] output bytes "1" = xx = O 0.0 - O 0.7 "2" = xx = O 1.0 - O 1.7 "3" = xx = O 2.0 - O 2.7 "4" = xx = O 3.0 - O 3.7 "5" = xx = O 4.0 - O 4.7 "6" = xx = O 5.0 - O 5.7 "7" = xx = O 6.0 - O 6.7 "8" = xx = O 7.0 - O 7.7

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Reaction of the digital outputs in the event of a fault Festo supports the "FAULT MODE ARRAY" for the 8-bit commands. The following tables apply:

Communication profile Index Object name Object Object Object Values/ Explanation of values (hex) symbolic designation type attributes subindex 6206 ARRAY Fault mode Unsigned 8 rw "0"= 0x = No. of available 8 output output bytes lines[9]. "1" = xx = Masking Define masking O 0.0 - O 0.7 "2" = xx = Masking O 1.0 - O 1.7 "3" = xx = Masking O 2.0 - O 2.7 "4" = xx = Masking O 3.0 - O 3.7 "5" = xx = Masking O 4.0 - O 4.7 "6" = xx = Masking O 5.0 - O 5.7 "7" = xx = Masking O 6.0 - O 6.7 "8" = xx = Masking O 7.0 - O 7.7 Default value: FF

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Festo supports the "FAULT STATE ARRAY" for the 8-bit commands. The following tables apply:

Communication profile Index Object name Object Object Object Values/ Explanation of (hex) symbolic designation type attributes subindex values

6207 ARRAY Fault state Unsigned 8 rw "0"= 0x = No. of available 8 output output bytes lines[9] "1" = xx = Fault state Set masking O 0.0 - O 0.7 "2" = xx = Fault state O 1.0 - O 1.7 "3" = xx = Fault state O 2.0 - O 2.7 "4" = xx = Fault state O 3.0 - O 3.7 "5" = xx = Fault state O 4.0 - O 4.7 "6" = xx = Fault state O 5.0 - O 5.7 "7" = xx = Fault state O 6.0 - O 6.7 "8" = xx = Fault state O 7.0 - O 7.7 Default value: 00

PLEASE NOTE With index 6206, you can determine the outputs which are to assume a default status in the event of an error. With index 6207, you can determine the status which the outputs are to assume in the event of an error.

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Definition of emergency object Festo supports a "PDO Emergency Object" as per DS 401 (see diagram). The PDO object is sent by the valve terminal in the following cases: • undervoltage at valves and outputs < 21.6 V • undervoltage at valves and outputs < 10 V • short circuit/overload at an output

• undervoltage at sensor supply < 10 V The emergency PDO is sent when a fault occurs and when the fault has been eliminated.

Byte Byte 0 1234567

Emergency Error code 2320 = SC/O 3320 = Vval < 21,6 V 3330 = Voff < 10 V 3120 = Vsen > 10 V

Error register 00 = no error 81 = Generic and Manufacturer error

Manufacturer specific error field (reserved)

Fig. 4/12: Definition of Emergency Object

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Addressing inputs and outputs

PLAESE NOTE Observe also the basic addressing rules at the beginning of the chapter. rounding) I 3.4 ... I 3.7 ... I 3.4 I 3.3 ... I 3.0 I 2.7 ... I 2.0 I 1.7 ... I 1.0 I 0.7 ... I 0.0 O 1.4; 1.7 O O 0.0 O 0.1 O 0.3; 0.2 O O 0.5; 0.4 O O 0.7; 0.6 O O 1.1; 1.0 O (free due to due (free

Fig. 4/13: Assignment of inputs/outputs

The following table shows the assignment of all the inputs and outputs:

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Valve terminal inputs

ByteBit 7Bit 6Bit 5Bit 4Bit 3Bit 2Bit 1Bit 0 Byte 0 I0.7 I0.6 I0.5 I0.4 I0.3 I0.2 I0.1 I0.0 Byte 1 I1.7 I1.6 I1.5 I1.4 I1.3 I1.2 I1.1 I1.0 Byte 2 I2.7 I2.6 I2.5 I2.4 I2.3 I2.2 I2.1 I2.0 Byte 3 I3.7 I3.6 I3.5 I3.4 I3.3 I3.2 I3.1 I3.0 Byte 4 I4.7 I4.6 I4.5 I4.4 I4.3 I4.2 I4.1 I4.0 Byte 5 I5.7 I5.6 I5.5 I5.4 I5.3 I5.2 I5.1 I5.0 Byte 6 I6.7 I6.6 I6.5 I6.4 I6.3 I6.2 I6.1 I6.0 Byte 7 I7.7 I7.6 I7.5 I7.4 I7.3 I7.2 I7.1 I7.0

Valve terminal outputs

ByteBit 7Bit 6Bit 5Bit 4Bit 3Bit 2Bit 1Bit 0 Byte 0O0.7O0.6O0.5O0.4O0.3O0.2O0.1O0.0 Byte 1O1.7O1.6O1.5O1.4O1.3O1.2O1.1O1.0 Byte 2O2.7O2.6O2.5O2.4O2.3O2.2O2.1O2.0 Byte 3O3.7O3.6O3.5O3.4O3.3O3.2O3.1O3.0 Byte 4O4.7O4.6O4.5O4.4O4.3O4.2O4.1O4.0 Byte 5O5.7O5.6O5.5O5.4O5.3O5.2O5.1O5.0 Byte 6O6.7O6.6O6.5O6.4O6.3O6.2O6.1O6.0 Byte 7O7.7O7.6O7.5O7.4O7.3O7.2O7.1O7.0

Fig. 4/14: Assignment of inputs/outputs

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Examples: communication process All the examples refer to module-ID = 1, i.e. the set valve terminal address 1.

Example 1: Signal change 0 → 1 input 0

COB-ID Data PLC PC 181 01 00 00 00 00 00 00 00 IPC

values in hex

Fig. 4/15: Signal change at input 0

When there is a signal change, the valve terminal automatically sends the status of the inputs (send PDO). In the example only input 0 is at "log. 1."

Example 2: Set output 0 of the valve terminal

COB-ID Data PLC PC 201 IPC 01 00 00 00 00 00 00 00

values in hex

Fig. 4/16: Output 0 (set 1st. valve)

In order to set valves and outputs on the valve terminal, the receive PDO must be sent by the master. In the example only output 0 is set. Any outputs already set will be reset.

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Example 3: Read object 1000H, subindex 0 (device type: device profile, device equipping).

COB-ID Index Sub-Index *) Data Initiate DomainInitiate Upload Request

601 40 00 10 00 00 00 00 00 PLC PC IPC 581 43 00 10 00 91 01 03 00

Values in hex *) with 4 data bytes Initiate Domain Initiate Upload Response Index Sub-Index Data*)

Fig. 4/17: Read object 1000H

In order to read objects of a valve terminal, the send SDO must be loaded with the Upload command, the index and the subindex. The valve terminal then sends the number of data bytes, the index, the subindex and the data bytes.

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Example 4: Write object 100CH, subindex 0 (Guard time).

COB-ID Index Sub-Index *) Data Initiate DomainInitiate Download Request 601 PLC 2B 0C 10 00 04 7F 00 00 PC IPC 581 60 0C 10 00 xx xx xx xx

Values in hex *) with 2 data bytes xx = Value not defined Initiate Domain Initiate Upload Response Index Sub-Index Data*)

Fig. 4/18: Write object 100CH

In order to write objects of a valve terminal, the receive SDO must be loaded with the Download command, the index, the subindex and the value. The valve terminal then sends as acknowlegement the index, the subindex and a data byte.

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Diagnosis of status bits The status bits signalize internal errors in the valve terminal. The following errors are reco- gnized: • Undervoltage at valves/outputs < 21.6V • Undervoltage at valves/outputs < 10V • Short circuit/overload of an electrical output • Undervoltage in sensor supply < 10V Further information can be found in chapter 5 "Diagnosis and error treatment" (chapter 5.3 Status bits).

The status bits are treated and transferred like inputs. They always occupy the four highest- value addresses/bits of the available address range. If the inputs of the input addresses/bits thereunder are not used, the valve terminal will set them to "logic zero."

PLEASE NOTE The status bits always increase the number of inputs by 4 and, therefore, also the sum of any input bytes.

Example: Valve terminal fitted with 32 inputs. The number of available input bytes is then: 5 input bytes (28 inputs + 4 status bits).

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Position of the status bits The addresses of the status bits in the address range of a valve terminal (depending on the extent to which the valve terminal is equipped) are shown in the following table:

Valve terminal Available address Addresses of equipment range the status bits None No address No status bits range for inputs available up to 4 inputs I 0.0 - I 0.3 I 0.4 - I 0.7 up to 12 inputs I 0.0 - I 1.3 I 1.4 - I 1.7 up to 20 inputs I 0.0 - I 2.3 I 2.4 - I 2.7 up to 28 inputs I 0.0 - I 3.3 I 3.4 - I 3.7 up to 36 inputs I 0.0 - I 4.3 I 4.4 - I 4.7 up to 44 inputs I 0.0 - I 5.3 I 5.4 - I 5.7 up to 52 inputs I 0.0 - I 6.3 I 6.4 - I 6.7 up to 60 inputs I 0.0 - I 7.3 I 7.4 - I 7.7

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4.3 BASIC PRINCIPLES OF THE SMART DISTRIBUTED SYSTEM (HONEYWELL)

General information

PLEASE NOTE When using the valve terminal on the Ho- neywell Smart Distributed System (SDS), observe the instructions on setting the station number (see chapter 3).

Commissioning Carry out the following steps in order to commission the system:

Step Activity 1 Setting the protocol • Remove the cover of the node • Set the protocol (Smart Distributed System) • Replace the node cover and screw it tight 2 Setting the station number • Connect the Handheld Activator to the valve terminal • Apply 24 V DC to the valve terminal • Switch on the Handheld Activator • Select the menu