Festo Compact Performance System Installation And Commissioning Manual
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Festo Compact Performance System Installation And Commissioning Manual

Festo Compact Performance System Installation And Commissioning Manual

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Compact Performance
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  • Page 1 Compact Performance CP system Installation and commissioning...
  • Page 2 Festo, Dept. PV-IDM Type setting: PV-IDM Edition: 9806A © Festo AG & Co. 73726 Esslingen 1998 Federal Republic of Germany The copying, distribution and utilization of this docu- ment as well as the communication of its contents to others without expressed authorization is prohibited. Of- fenders will be held liable for the payment of damages.
  • Page 3 Part no.: 165 226 Title: Manual Designation: P.BE-CPSYS-GB CP... 9806A...

  • Page 4: Table Of Contents

    Contents Designated use..........V Target group .
  • Page 5 4. Commissioning The commissioning procedure ......4-3 Preparing the CP system for commissioning ....4-4 4.2.1 Saving the string assignment .

  • Page 6: Designated Use

    Designated use The CP system, consisting of a CP node, CP valve ter- minals and CP input/output modules, referred to in the following as CP modules, is designed to be fitted into a machine or automation system. Depending on the CP node used, the system can be connected to a special fieldbus system and can be used for scanning sensor signals and for controlling pneumatic and electric actua-...

  • Page 7: Target Group

    Target group This manual is directed exclusively at technicians who are trained in control and automation technology. Important user instructions Danger This manual contains instructions on the possible categories dangers which may occur if the CP modules are not used correctly. These instructions are always printed in italics, are framed and signalled by pictograms.
  • Page 8 Pictograms Pictograms and symbols complement the danger warn- ings and draw attention to the nature and conse- quences of dangers. The following pictograms are used: Uncontrolled movements of loose tubing. Unintentional movements of the connected actuators. High voltages or undefined switching states of the elec- tronic components which may influence connected cir- cuits.

  • Page 9: Information On This Manual

    Information on this manual This manual contains specific information on the method of operation, fitting, installation and com- missioning of the CP system. Special information on commissioning, programming and diagnosis of a CP system with the fieldbus node which you are using can be found in the relevant ma- nual for the fieldbus node.
  • Page 10 Manuals for the CP system Peripherals Manual "CP system, installation and commissioning" Contents General, basic information on operating, fitting, installing and commissioning CP systems. Manual "CP fieldbus node, "CPV valve "CP modules, programming and terminal, electronics" diagnosis" CPA valve terminal pneumatics"...

  • Page 11: Product-Specific Terms And Abbreviations

    Product-specific terms and abbreviations The following product-specific terms and abbreviations are used in this manual. Term/ Meaning abbreviation Digital output O-module CP output module Compact Performance CP valve terminal CPV valve terminal type 10 or CPA valve terminal type 12 CP system Complete system consisting of CP fieldbus node and CP modules CP modules...

  • Page 12: System Overview

    1. System overview Chapter 1 System overview CP... 9806A...
  • Page 13 1. System overview Contents 1. System overview Structure of CP systems....... 1-3 1.1.1 CP system module functions .

  • Page 14: Structure Of Cp Systems

    1. System overview 1.1 Structure of CP systems Festo can assist you in solving your automation tasks at the machine level by means of valve terminals. Due to their modular structure, valve terminals and I/O modules from Festo can be incorporated to the best advantage in your machines and systems.
  • Page 15 1. System overview The CP system consists of individual modules which are connected by means of the CP cable. This permits a decentralized arrangement of the CP system. The compact CP valve terminals can be mounted very close to the cylinders which are to be actuated, thereby enab- ling short compressed air tubing to be used.

  • Page 16: Cp System Module Functions

    1. System overview 1.1.1 CP system module functions CP systems consists of the following modules: CP module Function CP node There are special CP fieldbus nodes for the various fieldbuses. – They provide the connection to certain fieldbuses – They offer connections for up to 4 strings to which I/O modules and valve terminals can be connected –...
  • Page 17 1. System overview Depending on type, the CP nodes control the transfer of data to a wide variety of control systems via the various fieldbuses. Some nodes have an integrated PLC. This enables the CP system to be operated au- tonomously without being coupled to a fieldbus.

  • Page 18: Cp Fieldbus Node

    1. System overview 1.2 CP fieldbus node Designs of Special CP fieldbus nodes are available for connecting CP node a CP system to the various fieldbus systems. These are in one of the following designs: Design *) Explanation Standard design Node in standard housing with adapter...
  • Page 19 1. System overview Layout of the The following diagrams show the general operating, dis- CP nodes play and connecting elements of the CP nodes. PLEASE NOTE Special information on the layout of the node you are using can be found in the appropriate node manual. SAVE button Label fields String error LEDs...
  • Page 20 1. System overview Operating voltage connection Fieldbus connection (design depending on type used, see node manual) Further LEDs depending on design of node CP connections for up to 4 strings (0...3) String error LEDs Label fields SAVE button Fig. 1/4: General operating, display and connecting elements (fieldbus node in compact design) CP...
  • Page 21 1. System overview The CP fieldbus nodes offer connections for up to four strings. Further modules with inputs and outputs can be connected to each string. CP fieldbus node CP output module Modules with outputs CP cable Modules with inputs CP connection CPV valve terminal String...

  • Page 22: Address Range Of The Cp System

    1. System overview 1.3 Address range of the CP system Size of The size of the address range occupied by the CP sy- occupied stem depends on the number of the string last used. address There is a complete word (16 bits) available as address range range for inputs and outputs for each string in the CP system.
  • Page 23 1. System overview The table below shows the address range depending on the last string used. Last string used Occupied address range Explanation String 0 16 I/Os No CP modules are connected to strings 3, 2 and 1. String 1 32 I/Os No CP modules are connected to strings 3 and 2.

  • Page 24: Basic Rules Of Addressing

    1. System overview 1.3.1 Basic rules of addressing CP node – A CP node provides four strings with a total of 64 input addresses and 64 output addresses. – A string occupies 16 input addresses and 16 output addresses. – The addresses are assigned fixed to the individual strings and in ascending order.
  • Page 25 1. System overview CP valve – A CP valve terminal with CP connection always oc- terminal cupies 16 output addresses, irrespective of how many valve solenoid coils are fitted on it. Therefore only one valve terminal can be connected to each string.
  • Page 26 1. System overview CPV valve – The address assignment of the CPV valve terminal is terminal made from left to right and on the individual valve locations from the front to the rear. LED row for pilot solenoid 14 LED row for pilot solenoid 12 Fig.
  • Page 27 1. System overview CPA valve A valve location occupies 1 or 2 addresses on the CPA terminal valve terminal, depending on the manifold block. Electrical bridge for single soelnoid or double solenoid valves with manual override and LEDs Electrical manifold block (EV1 or EV2) Fig.
  • Page 28 1. System overview – Addresses are assigned on the CPA valve terminal from left to right and on the individual valve locations from the rear to the front. – On manifold block type CPA..-EV2 the following ap- plies: - pilot solenoid 14 occupies the lower-value address - pilot solenoid 12 occupies the higher-value address Manifold block Addresses of coil 12...
  • Page 29 1. System overview – Input and output modules usually occupy a complete I/O modules input or output word (16 outputs or 16 inputs). – Addresses are assigned from left to right and from the front to the rear. Fig. 1/10: Example: address assignment with input module (type CP-E16-M8) String lengths –...
  • Page 30 1. System overview The diagram below shows the address assignment of a CP system. A0...A7 (A8...A15) (E0...E15) A0...A63 E0...E63 A16...A23 E16...E31 (A24...A31) (A32...A47) (E32...E47) A48...A55 E48...E63 (A56...A63) Address range occupied by the CP system A = Output Address range occupied by the module E = Input ( ) = Reserved address range Fig.

  • Page 31: Address Assignment After Extension Or Conversion

    1. System overview 1.3.2 Address assignment after extension or conversion WARNING Please take care when modifying the string assign- ment of your CP system. The input and output addresses for the modules will change if you connect the modules to a different string.
  • Page 32 1. System overview In contrast to fig. 1/11, string 0 and string 2 have been extended by the addition of extra modules. On string 0, a CPV valve terminal with 4 valve locations has been replaced by a CPV valve terminal with 8 valve location- s.
  • Page 33 1. System overview 1-22 CP... 9806A...

  • Page 34: Fitting

    2. Fitting Chapter 2 Fitting CP... 9806A...
  • Page 35 2. Fitting Contents 2. Fitting Fitting the CP modules ....... . 2-3 Fitting the CP fieldbus node onto a wall .

  • Page 36: Fitting The Cp Modules

    2. Fitting 2.1 Fitting the CP modules WARNING Before starting with the fitting, switch off the following: • the compressed air supply to all CP valve terminals • the power supply to all output modules • the power supply to the node. You thereby avoid: –...
  • Page 37 2. Fitting Dimensions The dimensions of the threaded holes in the CP for wall fitting fieldbus node can be found in the following chapter; the dimensions of the various modules can be found in the manual for the relevant module. Fitting onto a Information on fitting the fieldbus node can be found in hat rail...

  • Page 38: Fitting The Cp Fieldbus Node Onto A Wall

    2. Fitting 2.2 Fitting the CP fieldbus node onto a wall The CP nodes can be fastened to a flat surface by means of the four holes on the left and right-hand edges of the node housing. Proceed as follows: 1.

  • Page 39: Fitting The Cp Fieldbus Node Onto A Hat Rail

    2. Fitting 2.3 Fitting the CP fieldbus node onto a hat rail CP nodes in the standard housing and in compact de- sign are suitable for fitting onto a hat rail (mounting rail as per EN 50022). 2.3.1 Mounting the node in standard housing On the rear of the standard housing there is a guide groove for hanging the node onto a hat rail.
  • Page 40 2. Fitting Fitting the hat rail clamping unit The hat rail clamping unit must be fastened to the rear of the end plate. Proceed as follows: • Fasten the hat rail clamping unit in the sequence shown in the diagram below. Fit as follows: Rubber foot (self-adhesive) Clamping elements...
  • Page 41 2. Fitting • Before fitting the rubber feet (1), make sure that the contact surfaces are clean (use spirit). • After fitting make sure that: - the flat head screws are tightened (Fig. 2/2, item 5). - the lever is secured with the retaining screw (item 6).
  • Page 42 2. Fitting Proceed as follows: 1. Make sure the fastening surface can support the weight of the node. 2. Fit a hat rail (mounting rail as per EN 50022 - 35x15; width 35 mm, height 15 mm). 3. Fasten the hat rail to the supporting surface at least every 100 mm.
  • Page 43 2. Fitting 5. If the hat rail clamping unit is subjected to vibration or if it is fitted on a slope, protect it against uninten- tional loosing/opening with two screws as shown in Fig. 2/2, item 6. 2-10 CP... 9806A...

  • Page 44: Node In Compact Design

    2. Fitting 2.3.2 Node in compact design PLEASE NOTE In order to fit the node onto a hat rail you will require fastening kit CP-TS-HS35. This kit contains 2 fasten- ings, 2 M4x12 screws and 2 washers. Proceed with the fitting as follows: 1.
  • Page 45 2. Fitting Fixture Hat rail Node housing M4x12 screw Washer Fig. 2/4: Fitting onto a hat rail Proceed as follows when dismantling: 1. Loosen the screws. 2. Remove the housing. 3. Prize the fixture out of the hat rail with a screwdriver. Fixture Screwdriver Fig.

  • Page 46: Installation

    3. Installation Chapter 3 Installation CP... 9806A...
  • Page 47 3. Installation Contents 3. Installation General instructions on installation ..... . 3-3 3.1.1 Connecting cable ........3-4 3.1.2 Selecting the power unit .

  • Page 48: General Instructions On Installation

    3. Installation 3.1 General instructions on installation WARNING Before undertaking installation or maintenance work, switch off: • the compressed air supply • the power supply to the CP fieldbus node (pins 1 and 2) • the power supply to the CP output modules. You thereby avoid: –...

  • Page 49: Connecting Cable

    3. Installation 3.1.1 Connecting cable CP cable The CP cable (type KVI-CP-1-...) from Festo is used for connecting the CP modules to a string. For all other connections, you can use self-assembled cables. Please observe the instructions in the sections which follow.
  • Page 50 "CP fieldbus node." – The pin assignment of the operating voltage connection can be found in the chapters which follow. Use Festo plugs and sockets which correspond to the outer diameter of the cables you are using. Cable diameter Type of plug/socket 4.0...6.0 mm...
  • Page 51 3. Installation Preparing When you have selected a suitable cable, connect it as the cable follows: 1. Open the plug/socket as follows: • Mains power socket. Insert the mains power socket into the operating volt- age connection on the valve terminal. Unscrew the housing of the socket.
  • Page 52 3. Installation 2. Open the strain relief on the rear of the housing and pass the cable through as follows. 3. Strip 5 mm from the end of the cables and fit fer- rules into the strands. 4. Connect the ends. 5.

  • Page 53: Selecting The Power Unit

    3. Installation 3.1.2 Selecting the power unit WARNING Use only power packs which guarantee reliable electrical isolation of the operating voltages as per IEC 742/EN 60742/VDE 0551 with at least 4 kV isolation resistance. Switch power packs are per- mitted, providing they guarantee reliable isolation as per EN 60950/VDE 0805.
  • Page 54 3. Installation Current consumption at pin 1 of CP fieldbus node Current consumption of CP fieldbus node 250 mA Maximum current consumption of electronic + 560 mA components (internal electronic components of all CP modules) Current consumption of all connected sensors (see manufacturer specifications) + _____ A Sum of current consumption at pin 1...

  • Page 55: Configuring The Cp System

    3. Installation 3.1.3 Configuring the CP system CP systems can be coupled to various fieldbuses. The coupling is made via the CP node which has been adapted to suit the appropriate fieldbus. CP nodes usually support various fieldbus protocols and baud rates for the appropriate fieldbus.

  • Page 56: Connections On The Cp Fieldbus Node

    3. Installation 3.2 Connections on the CP fieldbus node CP fieldbus nodes have the following connections: – fieldbus connection (design depends on type) – operating voltage connection – earth/ground connection – CP connections Earth/ground connection Fieldbus connection (design depends on type used, see node manual) Operating voltage connection CP connections for up to 4 strings (0...3) Fig.

  • Page 57: Connecting The Cp Modules

    3.2.1 Connecting the CP modules WARNING • Use the special CP cable (type KVI-CP-1-...) from Festo for connecting the CP modules to a string. • Please note that the total length of the cable must not exceed 10 m. You thereby avoid: –...
  • Page 58 3. Installation Valve terminal and input module on string 0 Output module and input module on string 1 Input module on string 2 CP connection (plug) CP cable CP connections (sockets) CP node Fig. 3/3: Connecting possibilities of the CP modules (example) 3-13 CP...

  • Page 59: Connecting The Operating Voltage

    3. Installation Connecting CP modules 1. Check which address range is intended for the CP module (see chapter 1). 2. Connect the CP module with the CP cable to the string which provides this address range. 3. Fasten the plug and socket of the CP cable with the union nut.
  • Page 60 3. Installation Recommendation • Connect the operating voltage for the valve coils (pin 2) via EMERGENCY STOP. PLEASE NOTE: Check whether a pressure switch-off is also necessary for EMERGENCY STOP on your machine/system. The output modules have an additional operating volt- age connection for supplying the connected actuators.
  • Page 61 3. Installation Protective The node has two protective earth connections: earth – on the operating voltage connection (pin 4 leading contact). – on the node housing (earthing connection see Fig. 3/2). PLEASE NOTE • Always connect a protective earth conductor to pin 4 of the operating voltage connection.
  • Page 62 3. Installation Connection Please observe the following if there is a common 24 V example supply for pins 1 and 2: • Maintain the common tolerance of 24 V DC + 10/ - 15 %. • When connecting the two protective earth conduc- tors, avoid equalizing currents, e.g.

  • Page 63: Connecting The Fieldbus

    3. Installation 3.2.3 Connecting the fieldbus Before you connect the fieldbus cable, you should first prepare the CP system for commissioning on the fieldbus (see chapter 4). PLEASE NOTE A description of the fieldbus of your node can be found in the appropriate manual for the CP fieldbus node.

  • Page 64: Commissioning

    4. Commissioning Chapter 4 Commissioning CP... 9806A...
  • Page 65 4. Commissioning Contents 4. Commissioning The commissioning procedure ......4-3 Preparing the CP system for commissioning ....4-4 4.2.1 Saving the string assignment .

  • Page 66: The Commissioning Procedure

    4. Commissioning 4.1 The commissioning procedure In order to avoid connecting and addressing errors, you should proceed with commissioning in steps. The diagram below shows the individual steps: Step 1 – Check the valve/cylinder combinations see CP valve terminal, pneumatic components Step 2 –...

  • Page 67: Preparing The Cp System For Commissioning

    4. Commissioning 4.2 Preparing the CP system for commissioning WARNING Leave the fieldbus unconnected while you are com- missioning the CP system. You thereby avoid: – addressing errors which arise due to modification of the address ranges with various fieldbus systems while they are operating.

  • Page 68: Saving The String Assignment

    4. Commissioning 4.2.1 Saving the string assignment WARNING If you later modify the string assignment of your CP system: • Check the address assignment of your CP system after saving the string assignment and before starting any user programs. You thereby avoid: –...
  • Page 69 4. Commissioning Save the string assignment as follows: 1. Check that the CP modules are connected to the string which provides the intended address range (see also chapter 1). 2. Check also that the modules are correctly marked and that the CP cables are correctly fastened with the union nut.
  • Page 70 4. Commissioning Test phases With the aid of the saved string assignment, the CP node helps to avoid connecting errors and therefore ad- dressing errors. It checks automatically whether the current string assignment corresponds to the saved string assignment. A distinction is made here between the following test phases: –...

  • Page 71: Reaction Of The Cp System When Switched On

    4. Commissioning 4.3 Reaction of the CP system when switched on When the voltage supply is switched on, the node as- certains the current string assignment automatically. It ascertains, one after the other, which CP modules are connected to which strings. If the current assignment corresponds to the saved as- signment, the fieldbus node will switch immediately to ready status.
  • Page 72 4. Commissioning The ready status can be restored in one of the following ways: – by eliminating assignment errors manually – by saving the current assignment as the nominal as- signment (see section 4.2.1). Eliminating assignment errors manually • Restore the saved assignment by connecting the node with the appropriate modules again.
  • Page 73 4. Commissioning Power-up Registering of current string assignment Current string assignment Saved string assignment? CP system ready LED on relevant string flashes Manual error elimination possible SAVE button pressed? Current string assignment is saved Due to saving the string assignment, the scope of data for fieldbus communication may also be changed.

  • Page 74: Reaction Of The Cp System To Operating Faults

    4. Commissioning 4.4 Reaction of the CP system to operating faults If there is a fault on a CP module during operation, e.g. due to cable fracture etc., the LED on the appropriate string of the fieldbus node will light up. The status LED on the relevant module will go out.
  • Page 75 4. Commissioning Fault, CP connection interrupted String error LED lights up; non-affected modules are still active. error been eliminated manually? Have not more than 1 I-module and 1 O-module/valve terminal been replaced? (max. 2 modules) String error LED is Failed CP modules switched off.
  • Page 76 4. Commissioning Replacing modules during operation WARNING • Check whether the organisational concept of your machine/system permits the replacement of modules during operation. • Make sure that modules are not separated from a string and then connected to another string during operation.
  • Page 77 4. Commissioning Please observe the following rules: Basic rules Only modules of the same type can be replaced during operation. • Replace I-module by I-module of same type (replacement of CP-E16-M8 by CP-E16-M12x2 is not permitted during operation) • Replace O-module by O-module •...
  • Page 78 4. Commissioning If more than the above-mentioned modules are separ- ated from and then connected again to the CP system simultaneously, there is a danger of a connection error (reversal of module connections). Operation of these modules is not, therefore, resumed while the system is operating.

  • Page 79: Correcting String Assignment Errors

    4. Commissioning 4.5 Correcting string assignment errors With the four string LEDs on the node and the status LEDs on the CP modules, you can check the string assignment of the CP system. The LEDs have the fol- lowing meanings: String LEDs Meaning Error treatment...
  • Page 80 4. Commissioning Correct the string assignment as follows: • Use the string LEDs to ascertain on which strings there is an assignment error. • Check whether the correct modules or module types are connected to these strings. • Replace defective modules or defective CP cables. If the node ascertains an incorrect string assignment during the power-up phase, the status LEDs of all the connected modules will flash.
  • Page 81 4. Commissioning If you wish to correct a string assignment error by sav- ing the string assignment: PLEASE NOTE When you have saved the string assignment, check the address assignment of your CP system before you start user programs. You thereby avoid: –...

  • Page 82: Technical Appendix

    A. Technical appendix Appendix A Technical appendix CP... 9806A...
  • Page 83 A. Technical appendix Contents A. Technical appendix Cable length and cross section ......A-3 Index ..........A-7 CP...

  • Page 84: Cable Length And Cross Section

    A. Technical appendix A.1 Cable length and cross section PLEASE NOTE The following information is for the exclusive use of personnel trained in electrical engineering who are al- ready familiar with the contents of the chapter "Instal- lation" in this manual. A load-dependent drop in voltage occurs on all three cables for operating voltage supply to a node.
  • Page 85 A. Technical appendix Calculating with a formula Proceed as follows: 1. Calculate the maximum current consumption of the inputs and electronic components (I ) as well as of the valves (I 2. Calculate the lowest voltage (V ) to be expected =Omin on the power unit during operation.
  • Page 86 A. Technical appendix Operating voltage supply Equivalent circuit diagram Pin 1 Pin 2 Pin 3 NODE Cable resistor (incoming) Cable resistor (outgoing) Node The 24 V supply for the valves can be switched off separately. Distance (cable length) Fig. A/1: Cable length (L) and cable resistance (R CP...
  • Page 87 A. Technical appendix Formula for the maximum length κ ) ⋅ A ⋅ − V Omin NODE min L ≤ 2 ⋅ I Key: • V = 24 V + 10/- 15 % NODE ≥ 20.4 V minimum: V NODEmin •...

  • Page 88: Index

    A. Technical appendix A.2 Index Address assignment,example ....1-19 Address range basic principles of addressing ....1-13 CP I/O module .
  • Page 89 A. Technical appendix Earthing valve terminal......3-16 EMERGENCY STOP ....3-8, 3-15, A-5 Fitting fitting onto a hat rail .
  • Page 90 A. Technical appendix Pictograms ....... . . VII Power unit selecting the power unit.
  • Page 91 A. Technical appendix Voltage connecting ......3-14 selecting the cable ..... . . 3-16 A-10 CP...

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