Compact Performance
CP Valve terminal
Pneumatics
Only valid in a greem ent wi th the printe d docum enta tion
accompanyin g the prod uct! Com pare this ed ition cod e.
Author: M. Simons
Editors: H.-J. Drung, M. Holder
Translation: Douglas Smith
Layout: Festo, Dept. PV-IDM
Type setting: DUCOM
Edition: 9802C
Festo AG & Co., 73726 Esslingen, 1998
Federal Republic of Germany
The copying, distribution and utilization of this document as well as the communication of its contents to
others without expressed authorization is prohibited. Offenders will be held lia ble for the payment of damages.
All rights reserved, in particular the right to carry out
Printed on 100 % rec ycled p aper
CPV... 9802 I
patent, utility model or ornamental design registration.
Part no.: 165 200
Title: MANUAL
Designation: P.BE-CPV-GB
II CPV.. 9802
Contents
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Important user instructio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Information on this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI
1. System overview
1.1 Summary of vari a nts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Description of components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2. Fitting
2.1 CP valve terminal with individual tubing . . . . . . . . . . . . . . . . . . . 2-3
2.1.1 Fitting onto a wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.1.2 Fitting onto a hat rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.1.3 Fitting with feet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.2 CP valve terminal with pneumatic multiple connector plate . . . 2-10
2.2.1 Fitting the pneumatic multiple connector plate . . . . . . . . . . . . . 2-11
2.2.2 Fitting the CP valve terminal onto the pneumatic
multiple connector plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.3 Fitting the designation support. . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
3. Installation
3.1 General connecting principles . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Connecting the CP valve terminal . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.1 Auxiliary pilot air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.2 Connecting the supply and work tubing. . . . . . . . . . . . . . . . . . . 3-8
3.2.3 Connecting the electrical cables . . . . . . . . . . . . . . . . . . . . . . . . 3-11
4. Commissioning
4.1 Commissi oning – Testing the valves. . . . . . . . . . . . . . . . . . . . . . 4-3
4.2 Locating faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
CPV... 9802 III
5. Maintenance and conversion
5.1 Fitting/removing CP terminal components . . . . . . . . . . . . . . . . . 5-3
5.1.1 Removing components from valve locations . . . . . . . . . . . . . . . 5-4
5.1.2 Fitting components into the valve locations . . . . . . . . . . . . . . . . 5-7
5.2 Conversion from pushing to locking manual override . . . . . . 5-12
5.3 Conversion from internal to external pilot air . . . . . . . . . . . . . 5-13
5.4 Conversion from individual to central tubing . . . . . . . . . . . . . . 5-18
5.5 Converting the CP valve terminal to two pressure zones . . . . 5-19
5.6 Converting the CP valve terminal to
different electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . 5-20
A. Technical appendix
A.1 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
A.2 Technic al specificatio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.3 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
IV CPV.. 9802
Designated use
Target group
The CP valve terminals documented in this manual are
designated exclusively for controlling pneumatic actuators and may only be used in conjunction with devices
and components from other manufacturers providing
these are recommended by Festo:
– as intended for use
– in original condition
– without unauthorized modifications
– in faultless technical condition.
The specified limit values for pressures, temperatures,
electrical data, torques etc. must be observed.
Please comply also with national and local safety laws
and regulations.
This manual is directed exclusively at technicians who
are trained in control and automation technology and
who have experience in the installation, commissioning
and maintenance of pneumatic components.
CPV... 9802 V
Important user instructions
Danger
categories
This manual contains instructions on the dangers which
may occur if the CP valve terminal is not used correctly.
These instructions are always printed in italics, are framed and also signalled by pictograms.
A distinction is made between the following:
WARNING
This means that personal injury or damage to property may occur if these instructions are not
observed.
CAUTION
This means that damage to property may occur if
these instructions are not observed.
PLEASE NOTE
This means that this instruction must also be observed.
VI CPV.. 9802
Pictograms
Pictograms and symbols complement the danger warnings and draw attention to the nature and consequences of dangers.
The following pictograms are used:
Uncontrolled movements of loose tubing.
Unintentional movements of the connected actuators.
High vo ltages or undefined switching states of the electronic components which may influence connected circuits .
Electrostatically vulnerable components.
These will be damaged if you touch the contact surfaces.
Text
markings
•• This mark indicates activities which can be carried
out in any order.
1. Figures indicate activites which must be carried out
in the numerical order of the figures.
– Hyphens indicate general, non-compulsory activites.
CPV... 9802 VII
Information on this manual
This manual contains specific information on the fitting,
installation, commissioning, maintenance and conversion of the CP valve terminal. It includes only the des cription of the pneumatic components and refers to the
variations of the valve terminal listed in the table below.
Variants of the CP valve terminal type CPV..-VI..
With IC co nne cti on
Informat ion on th e
electric/electronic
compon ents
In this manual
With CP con nect ion
Informat ion on th e
electric/electronic
compon ents
See man u al
"CP system ,
Installa tio n and
commis sion ing"
With MP co nnectio n
Inf ormation on t he
electric/electro nic
components
See product packing
With AS-i connection
Inf ormation on t he
electric/electro nic
components
See product packing
Information on further CP modules can be found in the
manual for the relevant module. The following table
gives a summary.
VIII CPV.. 9802
Manuals on the CP sys tem Peripherals
Manua l "C P syste m, i nsta llat ion and co mm is sioni ng"
Content General basic information on the method of operation,
Manual "CP field bus node,
Content Special information
fittin g, insta l lation and co mm is sioni ng of CP syst ems.
pro gra m mi ng an d
diagnosis"
on com mission ing,
pro gra m mi ng an d
diagnosis related to
the nodes used.
"CP valve
ter minal,
pneumatics"
Inf ormation on
fitting,
install ing an d
commissioning
CP valve
ter minals .
"CP modules,
ele ctroni cs "
Inform ati on on
fitting,
instal lin g and
commissioning
CP input/output
modules.
Fig. 0/1: Manuals for the CP system
CPV... 9802 IX
The CP valve terminal consists of different plates. The
main components of the CP valve terminal are the
valve plates (see drawing).
1
Valve p late s
1
Fig. 0/2: Valve plates
This manual contains documentation on the following
valve plates:
Product Equipment o n termina l Number of val ve locatio ns depe nding
CP
terminal
CP valve bo ard s with a uxili ary pil ot a ir
and the following micro or mini valves:
– a 5/2-way single solenoid valve
or
– a 5/2-way double solenoid valve
or
– two 3/2-way valv es
(used a s mid -po sit ion va lv es)
or
– a 5/3-w ay va lve b locke d in
midposition (only for CPV18)
on electrical c onnection
IC
connection
2....8
2....8
2....8
2....8
MP, CP
con nection
4, 6 or 8
4, 6 or 8
4, 6 or 8
4, 6 or 8
AS-i
conne cti on
2, 4
2
2
2
X CPV.. 9802
Abbreviations
The following product-specific terms and abbreviations
are used in this manual.
Term Meaning
AS-i Actuato r-S e nso r interface
Blanking pl ate Plate wi tho ut va lve function, fo r fi llin g em pty loca tio ns
Compon ent s Common term fo r con necto r plate s, end plat es, bl ankin g pla tes,
isolating plates, valve plates and pneuma tic multiple connector plate s
CP Compact Performan ce
CP cab le Specia l ca b le for co u pl ing th e v arious C P mo du les
CP modules Com mon term fo r the vari ous mod ules which can be integ rated in a
CP syste m
CP system Complete system con sisting of th e CP field bu s node and the
CP modules
CP valve terminal CP valve te rminal (type 10) for fieldbus systems or with IC, MP or
CP valve terminal
with AS-i connection
CP valve terminal
with CP con ne ction
CP valve terminal
with IC co nne cti on
CP valve terminal
with MP co nne cti on
(multipi n co nne ction )
CPV10
CPV14
CPV18
Electri cal ca nn ecto r
plate
CPV... 9802 XI
AS-i-connecti on
CP valve term in al va rian t wit h se ria l con necti on s ena bli ng the th e
CP valve terminal to be connect ed to the AS-i bus
CP valve terminal variant with plug and socket enabling the the
CP valve terminal to be connected to t he field bus and furth er
CP modules
CP valve terminal variant on which each valv e solenoid coil is
connected in di vid ually with a speci al CP ca bl e
CP valve terminal variant with sub-D plug by means of which all
valve solenoid coils can b e centrally connect ed
Designa tio n o f CP term in al siz es
CP termin al wi th micro v alve plate s
CP termin al with m ini v alve p lates
CP termin al with m idi v alve p lates
Plate wit h conn ectio ns for M P, AS-i- or CP conections
End plate Plate at th e left and right-h an d end s of th e CP te rmina l with
channe ls or co nnections for co mpre sse d air su pply to the valv es
and for the exhaust.
HHB Manual ov erride
I/O Input /output modules
Isolatin g p late Plate fo r di vidin g th e val ve term in al int o tw o pre ssure zo nes
Pneumat ic mu ltiple
connecto r p late
Relay plate Plate with relay coils for contro lli ng two ele ctri ca lly i sola ted ou tputs
Tubing co nnectio n s Co nne cti on of su ppl y tu bing (ho ses) to th e CP term inal
Valve plate Plate with single or double so lenoid val ves
Valve block Basic unit with valv e, isolating, blanking, relay and end plates
Board for ce ntral w iring of the valve te rm inal
(connectio n s for sup pl y air, exhau st and work air)
XII CPV.. 9802
1. System overview
Chapter 1
Sy stem overview
CPV... 9802 1-1
1. System overview
Contents
1. System overview
1.1 Summary of variants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Description of components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-2 CPV... 9802
1. System overview
1.1 Summary of variants
Festo can assist you with your automation problems at
the machine level by means of valve terminals. The
modular structure of the CP system enables you to incorporate the CP valve terminals and I/O modules to
best advantage in your machine or system.
Due to its compact structure, the CP valve terminal can
be mounted near to the actuators which it is to control.
This means that shorter compressed air tubing can be
used. Loss of air is therefore minimized and the time
required for pressurizing and exhausting the pressure
tubing is reduced. This is made possib le by the use of
very compact valves with high flow which help to reduce costs.
CPV... 9802 1-3
1. System overview
Valve terminal
variants
CP terminal
with
IC connection
The CP valve terminals are available with the following
electrical connections:
IC co nne c ti on CP con ne ct ion
MP connection AS-i connection
Fig. 1/1: Variants of the CP valve terminal
The CP terminal with single connection is available with
2 to 8 valve plates (also in uneven spacing). The
electrical connection on this type of terminal is made
separately by means o f a socket on each solenoid coil.
CP terminal
with
MP connection
CP terminal
with
CP connection
1-4 CPV... 9802
This CP terminal is available with 4, 6 or 8 valve locations. The electrical connection of the solenoid coils is
made centrally via the multiple connector plate.
The CP terminal with CP connector is available with 4,
6 and 8 valve plates. Connection to the higher-order
fieldbus node is made by means of a special CP cable.
1. System overview
CP terminal
with AS-i
connection
This CP terminal is connected to the AS-i bus by means of a special AS-i cable. It is available with three
types of electrical connections:
– with additional supply connection for implementing an
emergency stop function
– with additional supply connection and 4 inputs (not
CPV18)
– without additional supply connection.
The CP valve terminals with AS-i connection can be fit-
ted with the following valve plates:
– two or four valve plates with 5/2-way single solenoid
valves
– two valve plates with 5/2-way doubkle solenoid
valves
– 2 valve plates each with 3/2-way single solenoid
valves
– Only CPV18: two valve plates with 5/3-way valves
blocked in mid-position.
PLEASE NOTE
The CP valve terminal with AS-i connection and 4 inputs is always with fitted 4 valve locations. Depending on the equipment fitted, these CP valve terminals are filled, where necessary, with 1 or 2 reserve
plates.
CPV... 9802 1-5
1. System overview
The CP terminals are available in the following sizes:Grid size s of
the CP terminals
Mixed operation with both grid sizes on one CP terminal is not permitted.
Designa tion Va lve pla te Valve
CPV10 10 mm Micro valves
CPV14 14 mm Mini valves
CPV18 18 mm Midi valves
Isolating plate
Relay plate
You can divide the CP valve terminal into two pressure
zones with the aid of the isolating plate. The isolating
plate is available in two variants:
– Isolating plate with blocked compressed air channels
(1 and 11)
– Only CPV14: isolating plate with blocked exhaust
channels (3/5) and blocked compressed air channels
(1 and 11)
The CP valve terminal with CP connection can be fitted
with relay plates. Each relay plate contains two relays
for controlling two electrically-isolated outputs.
1-6 CPV... 9802
2
1. System overview
Pneumatic
multi p le
connector plate
The supply and work tubing can be connected centrally
to CP terminals with the pneumatic multiple connector
plate. The CP terminals can be separated quickly from
the supply and work tubing. By means of appropriate
end plates, conversion from individual tubing to tubing
with the pneumatic multiple connector plate can be
made at any time. The pneumatic multiple connector
plate is available in two variants :
– Standard design of pneumatic multiple connector pla-
te which fits flush with the end plates of the CP valve
terminal. The holes for fastening to the wall or for
foot mounting are on the connection side of the
pneumatic multiple connector plate.
– Extended pneumatic multiple connector plate with ex-
ternal fastening holes.
CP valve te rmin al with pneu mati c CP valv e term ina l wit h exte nd ed
multiple connector plate (stan dard) pneumatic mu ltiple connecto r plate
1
Fasteni ng holes for fitting on to a w all o n th e sta nd ard de sig n of p neum at ic mu ltiple
1
connecto r plate
Fasteni ng holes for fitting on to a w all o n th e ext en ded p neum ati c multip le conn ecto r
2
plate
Fig. 1/2: Versions of the pneumatic multiple connector plate
CPV... 9802 1-7
1
4
6
1. System overview
1.2 Description of components
The CP terminal consists of the following components:
0
2
9
8
7
Electrical conne ctor plate with MP, AS-i or CP connection
1
Right-han d end plate (with /with out s upply conn ectio ns or fo r pne um. m.c. plate)
2
Relay plate (only for CPV10 /14 te rminals with CP connection)
3
Blanking or iso lati ng plate (with blo cked air chan nel s 1 and 11 an d
4
exhaust channel (3 /5) or only block ed air channe ls 1 and 11
Valve plates fi tted with sing le or d ouble sole noid valves
5
Ident ifying pl ate and co ver of man ual o ve rride fo r inscription clips (optional) not in
6
connectio n w ith re lay plate
Pneumat ic mu ltip le co nnecto r p la te (opt ion al)
7
Left-h and e nd pla te (w ith/w ithou t sup ply co nnectio n s or fo r pne um. m.c. plate)
8
Support for ha t-ra il mou nti ng (op tiona l) fo r CPV10/14 or CPV18
9
Support for wall faste ning (optional ) for CPV10/14 or CPV1 8
0
Fig. 1/3: Components of the valve terminal
3
5
1-8 CPV... 9802
1. System overview
Identification
code
Valve plates
Valve plate
82/84
By means of the identification code, you can ascertain
which plates are fitted on your CP terminal. This code
is printed on the front between the manual overrides 12
and 14. The identification codes are as fo llows:
Ident. co des Pneumati c comp onent
C
G
H
J
L
M
N
R
S
T
Valve plate, tw o 3/2-way, basic position closed
Valve p late , 5/3 -way, mid-po sitio n blo cke
Valve p la te, tw o 3/2 -way, one op en in basi c
position , one clo se d in ba sic position
Valve p la te, 5/2 -way, doubl e sole no id
Blan king p la te
Valve p la te, 5/2 -way, single so leno id
Valve plate, tw o 3/2-way, basic position open
Re la y p la t e
Isolating plate , exh aust cha nnel (3/5) an d air
chann el s (1 ,11) blocked
Isolating plate, a ir channe ls (1, 11) blocked
The CP terminals are available with the following valve
plates:
Ident. co de M
4
2
Function: 5/ 2-way sing le solenoi d valve
14 112
1
11
12/14
82/8 4
14
12/1 4
CPV... 9802 1-9
3/5
Ident. co de J
4
2
112
1
11
Function: 5/2-way double solenoid valve
14
1. System overview
14
12/1 4
82/84 4
10
12/1 4
82/84
12/14
82/84
2
4
11
1
3/5
2
3/5
1
4
3/5
1
11
2
11
Ident.co d e G
Only for CPV18 te rmina l
Functio n:
112
5/3-wa y val ve blo cked in mid-p ositio n
Ident. cod e N
Functio n:
– Two single 3/2-way valv es open in basic
positio n
110
– 5/3-way v alve pressuriz ed in mid-p ositio n.
This function is implemen ted with two
3/2-wa y val ve s ope n in ba si c position.
Ident.co d e C
Funk tion :
– Two 3/2 -way valves , blo cked in basi c positio n
112
– 5/3-wa y val ve ex hauste d in mi d-position.
This function is implemen ted with two
3/2-wa y val ve s blocke d in b asi c position .
– In prepa rat ion: 5 /3-w ay v alve block ed in mi d-
positio n. This f unctio n is im plem ente d o n th e
CPV10/14 terminals with two 3/2-way valves
blocked in basic position in comb ination with
externa lly fitted swi tchab le non-return valv es.
PLEASE N OTE
• I f yo u are u sing t he 3/2 -way valv es as a
5/3-wa y mid -po sitio n v alve, ma ke su re t hat
your co ntro l p rog ram does not a ctu ate both
valve solenoid coils of the 3/2-way valves at
the sam e tim e t hereb y a ctvat ing a dou bleacting cy linde r.
82/84
14
12/14
1-10 CPV... 9802
4
3/5
1
2
11
Ident. cod e H
Functio n:
two 3/ 2-wa y valv es on co ntro l sid e 110 basi c
110
positio n ope n and on co nt rol sid e 14 b asic
positio n clo se d.
8
1. System overview
On the CP valve terminal you will find the following
pneumatic connections and operating elements:
1
3
2
4
5
6
0
8
9
9
8
Valve location inscrip tion clip (per va lve)
1
Support for inscript ion clip and cove r of manual override
2
Type plate
3
Manual overri de (pe r pilot sol enoid, p ushing o r locking )
4
Clip of pu shing m anua l overri de
5
Re ces s for labe l s upport
6
Earth/g round conn ectio n (l eft/rig ht-h and e nd plate )
7
Supply connections (1 , 11, 12/14), exhaust connections (3 /5, 82/84):
8
with indiv idua l tubing o n left and/or rig ht-h and end plate
with ce ntra l tub ing on pn eu mati c mul tip le con ne ctor plat e
Work conn ectio ns (2, 4), p er valv e
9
Pneumatic multiple connecto r plate
0
Fig. 1/4: Pneumatic connections and operating elements on the
CP valve terminal
7
CPV... 9802 1-11
1. System overview
On the CP valve terminal with single electrical connections you will find the following electrical connections
and display elements:
7
6
5
4
3
2
Label fields (pe r cable socket)
1
Type plate
2
Connecting l ugs for pilot solen oid valve 14
3
Earth /gro un d co nne ct ion (pe r end p late )
4
Connecting l ugs for pilot solen oid coil 12
5
Yellow LEDs, signal stat us displ ays of pilot solenoi ds
6
(per cab le so cket)
Ready-m a de ca ble w ith sock et for ind ividu al con ne ction
7
(per pilo t sole noid ), ca n be turn ed 180°.
1
Fig. 1/5: Electrical connections and display elements
of the CP valve terminal with IC connection
1-12 CPV... 9802
1. System overview
On the CP valve terminal with MC connection you will
find the following connections and display elements:
1
2
3
5
4
SUB-D multipin plug ( 9-pin for terminals with 4 valves,
1
25-pin fo r termin als w ith 6 or 8 va lves)
La bel cli p
2
Yellow LEDs, signal status displays of the p ilot solenoids
3
Type plate
4
Earth/g rou nd co nnectio n (p er e nd pla te)
5
Fig. 1/6: Electrical connections and display elements
of the CP valve terminal with MC connection
CPV... 9802 1-13
3
1. System overview
On the CP valve terminal with CP connection you will
find the following electrical connections and display elements:
12
9
8
4
5
7
6
Inco min g CP ca ble
1
Cont inuin g CP cable
2
Label clip
3
Yellow LEDs, signal stat us displ ay of rela ys
4
Yellow LED s, signal sta tus displ ay of t he pil ot solen oids
5
Rela y conne cti ons wit h cab le
6
Type plate
7
Earth /gro un d co nne ct ion (pe r end p late )
8
Green LED, Statu s display of C P conn ectio n
9
Fig. 1/7: Electrical connections and display elements
of the CP valve terminal with CP connection
1-14 CPV... 9802
7
1. System overview
On the CP valve terminal with AS-i connection you will
find the following electrical connections and display elements:
4
3
5
2
1
0
9
8
Green LED status display of the in puts
1
(only CPV..-GE-ASI-4E4A-...)
Cable so cke t fo r ad ditio na l su pply with bla ck su pp ly ca ble
2
(only CPV..-GE-ASI-.-Z)
AS-i bus socket with yellow bus cable
3
Sensor cable with plug (only CPV..-GE-ASI-4E4A-...)
4
AS-i cable cap (only CPV..-GE-ASI-.-Z)
5
La bel cli p
6
Yellow LED status displ ays of the p ilot soleno ids
7
Type plate
8
Earth/g rou nd co nnectio n (p er e nd pla te)
9
BUS LED 1 (gre en) ,
0
BUS LED 2 (red) (only CPV..-GE-ASI-4E4A-...)
6
Fig. 1/8: Electrical connections and display elements
of the CP valve terminal with AS-i connection
CPV... 9802 1-15
1. System overview
1-16 CPV... 9802
2. Fitting
Chapter 2
Fitting
CPV... 9802 2-1
2. Fitting
Contents
2. Fitting
2.1 CP terminal with individual tubing . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.1 Fitting onto a wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.1.2 Fitting onto a hat rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.1.3 Fitting with feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.2 CP terminal with pneumatic multiple connector plate . . . . . . . 2-10
2.2.1 Fitting the pneumatic multiple connector plate. . . . . . . . . . . . . 2-11
2.2.2 Fitting the CP terminal onto the pneuma tic
multiple connector plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.3 Fitting the designation support . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-2 CPV... 9802
2. Fitting
WARNING
Before undertaking installation or maintenance work,
switch off the following:
•
the compressed air supply
•
the power supply to the valve solenoid coils
You thereby a void:
– uncontrolled movements of loose tubing
– unintentional movements of the connected actuators
– undefined switching states of the electronic compo-
nents
2.1 CP terminal with individual tubing
Fitting
variants
The CP terminal with individual tubing has been designed for integration in a system or machine which is to
be fitted as follow s:
– Fitting onto a wall
– Fitting on a hat rail
– Fitting with feet
PLEASE NOTE
If your application is subjected to vibration in excess
of the following values:
– 0.15 mm travel at 10-58 Hz
– 2 g acceleration at 58-150 Hz
the CPV14 or CPV 18 terminals should be mounted
on a wall or with feet.
CPV... 9802 2-3
2. Fitting
2.1.1 Fitting onto a wall
PLEASE NOTE
In order to fit the CP valve terminal onto a wall you
require the following fitting kit:
– for CPV10/14 terminals:
fitting kit CPV 10/14-VI-BG-RWL
– for CPV18 terminal:
fitting kit CPV18-VI-BG-RW
This kit consists of 2 profile sections and 4 selfcutting screws.
Proceed as follows:
• Make sure that your fastening surface can support
the weight of the CP valve terminal.
• Make sure that there is enough room to connect the
power cables and pneumatic tubing.
• Screw the 2 fastening profile sections onto the valve
terminal with the screws specified in the table below
as shown in Fig. 2/1. With the CPV10/14 terminals,
make sure that the fixing bolts of the profile sections
grip into the groove on the valve terminal.
CP terminal Self-cutting s crew Tightening torque
CPV10/14 M4 x 10 1.5 Mn
CPV18 M5 x 10 4 Nm
2-4 CPV... 9802
2. Fitting
• Then fasten the CP valve terminal onto the wall with
4 M4 screws of sufficient length.
1
4
3
M4 screws (CPV10/14) o r M5 screws (CPV18 ) for wall fitting
1
Fixing bolts (only CPV10/14 )
2
Self-cutting screws
3
Additiona l se lf-cutting screw s for CPV14/1 8 termin als
4
2
1
Fig. 2/1: Fitting the CP terminal onto a wall
CPV... 9802 2-5
2. Fitting
2.1.2 Fitting onto a hat rail
PLEASE NOTE
In order to fit the CP valve terminal onto a hat rail
you require the following fitting kit:
– For CPV10/14 terminals:
fitting kit CPV10/14-VI-BG-NRH-35
– For CPV18 terminals:
fitting kit CPV18-VI-BG-NRH-35
These kits consist of 2 brackets, 2 or 4 M4 x 10 selfcutting screws (CPV10/14) or M5 x 10 (CPV18) and
2 M4 x 10 screws with clamping pieces and springs.
Proceed as follows:
• Make sure that your fastening surface can support
the weight of the CP valve terminal.
• Fit one of the following hat rails:
Hat rail for CPV10/14 te rminal Hat rail for CPV18 termi nal
support rail as per
EN 50022 - 35x7.5
(width 35 mm, he igh t 7 .5 mm )
support rail as per
EN 50022 - 35x15
(width 35 mm, height 15 mm)
• Make sure that there is enough room to connect the
power cables and the pneumatic tubing.
• Fasten the hat rail to the surface approximately every
100 mm.
2-6 CPV... 9802
2
2. Fitting
• Screw the 2 brackets onto the end plates with the
screws supplied, as shown in the diagram below.
With the CPV10/14 terminals, make sure that the
fixing bolts of the brackets grip into the recess on the
CP valve terminal.
CP terminal Self-cutting s crews Tightening torque
CPV10/14 M4 x 10 1.5 Nm
CPV18 M5 x 10 4 Nm
1
3
4
For each end plate one M 4 x 10 screw (CPV10 /14) or
1
two M5 x 10 screws (CPV18)
Hat ra i l
2
Hat rail cla mp ing u nit
3
Fixing bolts (only CPV10/14 )
4
Fig. 2/2: Fitting the valve terminal onto a hat rail
• Hang the valve terminal onto the hat rail. Fasten the
terminal on both sides with the hat rail clamping unit.
This will prevent it from tilting or slipping.
CPV... 9802 2-7
2
2. Fitting
2.1.3 Fitting with feet
PLEASE NOTE
In order to fit the CP valve terminal with feet (at the
level of work connections 2 and 4) you require the
following fastening screws:
•
•
•
4 M6 x 65 socket headscrews (CPV18)
Proceed as follows:
• First you must prepare your fastening surface, and
make a suitable bracket where necessary. The position and distances between the fastening holes of the
CP terminals are shown in the diagram below.
4 M4 x 45 socket head screws (CPV10)
4 M4 x 50 socket head screws (CPV14)
1
3
2
CPV 10 termin al CPV 14 terminal CPV 18 terminal
53 mm
1
4 mm
2
10 mm x nu mbe r
3
of plates
66 mm
5 mm
14 mm x nu mbe r
of plates
87 mm
8.1 mm
18 mm x nu mbe r
of plates
Fig. 2/3: Position of the fastening holes
2-8 CPV... 9802
2. Fitting
• Make sure that there is enough room to connect the
power cables and the pneumatic tubing.
• With CP terminals with IC connection, you must insert the 4 socket head screws supplied into the holes
intended for this purpose on the left and right-hand
end plates (see diagram).
CPV10 CPV14 CPV1 8
Socket hea d screw s M4 x 45 M4 x 50 M6 x 65
1
3
2
M4 x 45 or M4 x 50 or M6 x 65 socket head screws
1
End plate s
2
Faste ning b racke t
3
Fig. 2/4: Position of fastening screws
• Screw the CP valve terminal onto your fastening surface or onto a support bracket.
CPV... 9802 2-9
2. Fitting
2.2 CP terminal with pneumatic multiple connector plate
If you are using a pneumatic multiple connector plate,
the power supply and work lines will be connected at a
central point. This enables the supply and work lines to
be disconnected from the valve terminal easily and quickly.
PLEASE NOTE
Only CP terminals, which have been fitted with appropriate end plates, may be mounted on the pneumatic
multiple connector plate.
CP valve terminals, which have been fitted with end
plates for individual tubing, can be converted before
they are fitted onto the pneumatic multiple connector
plate.
In this case replace the end plates with multiple
connector end plates.
2-10 CPV... 9802
2. Fitting
2.2.1 Fitting the pneumatic multiple connector plate
Proceed as follows:
• Make sure that your fastening surface can support
the weight of the pneumatic multiple connector plate
and the valve terminal fastened to it.
• Make sure that there is enough room to connect the
power cables and the pneumatic tubing.
• Cut out a section of the fastening surface in order to
connect the pneumatic tubing (dimensions see Figs.
2/5 and 2/6).
• Drill four mounting holes in the fastening surface.
The position and distances between these holes is
shown in Figs. 2/5 and 2/6.
• Fasten the standard design of the pneumatic multiple
connector plate with 4 M4 screws (CPV10/14), or
with 4 M5 screws (CPV18), and the extended pneumatic multiple connector plate with 4 M6 screws of
appropriate length to the fastening surface.
CPV... 9802 2-11
2
4
2. Fitting
Wall cutout dimensio ns for CP valve te rminals with
standard pneuma tic mul tiple conne ctor plate
CPV10/14:
CPV18:
7
8
7
8
5
1
6
23
5
1
5
CPV10 termin al CPV14 terminal CPV18 termin al
29.5 mm +
1
60 mm
2
55 mm
3
R4
4
11.25 mm
5
10 mm x number of plates
6
31.5 mm
7
Diameter 4.3 mm
8
6
39.5 mm + 6
76.6 mm
68.6 mm
R4
12.75 mm
14 mm x number of plates
38.3 mm
Diamet er 4.3 m m
6
5
59.0 m m +
98 mm
-------------------------------------
-------------------------------------
25.5 m m
18 mm x number of plates
54 mm
Diam eter 5.5 m m
6
Fig. 2/5: Wall cutout dimensions for the standard pneumatic multiple
connector plate
2-12 CPV... 9802
3
2
2. Fitting
Wall cutout dimensions for CP valve terminals with
extended pneuma tic mul tiple conne ctor pl ate
CPV10/18:
1
"
!
3
0
4
8
CPV14:
8
9
1
"
7
!
6
2
0
5
88
CPV10 terminal CPV14 terminal CPV18 termi nal
30 mm +
1
73 mm
2
R12
3
6.3 mm
4
----------------------------------
5
----------------------------------
6
----------------------------------
7
21 mm
8
10 mm x numbe r of plates
9
21.5 mm
0
18.5 mm
!
Diameter 6.5 mm
"
9
40 mm +
89 mm
R14
9.0 mm
4.7 mm
5.55 mm
R8
26 mm
14 mm x number of plates
29.5 mm
29.5 mm
Diameter 6.5 mm
9
9
4
60 mm + 9
118 mm
R22
15 mm
-----------------------------------
-----------------------------------
-----------------------------------
35.5 mm
18 mm x number of plates
44 mm
44 mm
Diamet er 6.5 mm
Fig. 2/6: Wall cutout dimensions for the extended pneumatic multiple
connector plate
CPV... 9802 2-13
2. Fitting
2.2.2 Fitting the CP terminal onto the pneumatic multiple connector plate
Proceed as follows:
• In the case of CP terminals with individual connection, insert the socket head screws supplied into the
fastening holes of the CP terminal. In the case of CP
terminals with MP, AS-i or CP connection, the socket
head screws are already inserted with a retaining device in the fastening holes under the electrical
connector plate.
• Place the 3-seal or 4-seal strips for sealing the supply channels into the grooves in the left or right-hand
end plate.
• In order to seal the work channels, carefully press
the 2 individual seals into the threads of the work
connections.
• Screw the CP terminal onto the pneumatic multiple
connector plate with the 4 socket head screws. Tighten the screw s in diagonally opposite sequence with
2 Nm (CPV10/14) or 4 Nm (CPV18).
Fig. 2/7: Fitting the CP terminal onto the
pneumatic multiple connector plate
2-14 CPV... 9802
2. Fitting
2.3 Fitting the designation support
As a protection against unauthorized operation of the
manual override and for mounting the designation clips
for the valves, the CP terminal has a designation support. This is fitted on the front above the manual override.
PLEASE NOTE
The designation support cannot be fitted onto CP terminals which are equipped with relay plates.
Proceed as follows:
• Clip the designation support into the grooves in the
left and right-hand end plates (see diagram).
Fig. 2/8: Fitting the designation support
• Press the designation clips into the recesses on the
designation support (see Fig. 2/8).
CPV... 9802 2-15
2. Fitting
2-16 CPV... 9802
3. Installation
Chapter 3
Installation
CPV... 9802 3-1
3. Installation
Contents
3. Installation
3.1 General connecting principles . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Connecting the CP valve terminal . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.1 Auxiliary pilot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.2 Connecting the supply and work tubing. . . . . . . . . . . . . . . . . . . 3-8
3.2.3 Connecting the electrical cables. . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-2 CPV... 9802
3. Installation
3.1 General connecting principles
WARNING
Before undertaking installation or maintenance work,
switch off the following:
•
the compressed air supply
•
the power supply to the valve solenoid coils
You thereby a void:
– uncontrolled movements of loose tubing
– unintentional and sudden movements of the connec-
ted actuators
– undefined switching states of the electronic compo-
nents
Laying the pneumatic tubing
PLEASE NOTE
•
If necessary, place a seal under the screw
connectors or silencers in order to avoid leakage.
– If elbow connectors or multiple distributors are
used, the air flow will usually be reduced.
CPV... 9802 3-3
3. Installation
Basic installation
– Connecting
1. Push the tubing as far as it will go over the port
on the screw connector.
2. If necessary, pull the locking ring (A) over the
tubing connection and tighten clamping screw (B).
3. G roup the tubing together for reasons of
clarity with:
- tubing connectors or
- multiple hose holders
– Disconnecting
1. Loosen the locking screw or locking ring of the
screw connector.
2. Pull the tubing out.
3. Replace non-required tubing with blind plugs (C).
Connecting
(A)
Discon ne cting
(C)
(B)
Fig. 3/1: Tubing variants
3-4 CPV... 9802
3. Installation
3.2 Connecting the CP valve terminal
PLEASE NOTE
•
If valves are not used, seal the work connections
2 and 4 with blind plugs.
•
Depending on the tool you are using, observe
the following sequence when you connect the
work lines:
- if using a socket head wrench, you can connect
the work lines in any sequence.
- if using an external socket head wrench, you
must connect the work lines from left to right
(room for wrench).
In order to guarantee optimum efficiency of your CP
valve terminal, we recommend that the compress ed air
and, if necessary, the exhaust lines be connected on
both sides in the fo llowing cases:
– when large-volume cylinders are to be operated at
high speed
– when several valves are switched simultaneously to
through flow
PLEASE NOTE
•
Connect the supply pressure to both sides of the
end plates or pneumatic multiple connector plate,
if the CP terminal is operated with two pressure
zones.
CPV... 9802 3-5
3. Installation
3.2.1 Auxiliary pilot air
CAUTION
Operate the CP valve terminal only with the medium
described below.
– If possible, use non-lubricated auxiliary pilot air
(connection 12/14). Otherwise the oil content must
not exceed 3-5 drops per 1000 l of air consumed.
Use hydraulic oil of type DIN 51524-HLP32.
Observe the instructions on special oil for maintenance units in the Festo Pneumatics Catalogue.
– In the case of CP valve terminals with internally
branched auxiliary pilot air, the above mentioned
instruction also applies to the supply air (connection
1/11).
The CP valve terminal is intended for internal or external pilot air, depending on the end plates. Refer to your
order documentation or to the table in chapter 5.3 "Internal/external pilot air" to see which end plates are fitted on your CP terminal.
Internal
pilot air
If the supply pressure o f your CP terminal is between 3
and 8 bar, you can work with internal auxiliary pilot air.
In this case the auxiliary pilot air is taken from port 1 or
11 on the left or right-hand end plate.
PLEASE NOTE
If you are using a CP terminal with internal pilot air,
– port 12/14 must be sealed with a blind plug.
3-6 CPV... 9802
3. Installation
External
pilot air
If the supply pressure of your CP terminal is in the
range 3 to 8 bar, you must operate the terminal with
external pilot air. In this case the external pilot air is
supplied via port 12/14 on the CP terminal.
PLEASE NOTE
•
Use regulated external pilot air (3 to 8 bar).
This will ensure reliable faultless operation of the
CP terminal.
•
Ensure that the regulated external pilot air is
supplied or taken at only one point by means of
common tubing for all valve plates on the
CP terminal. This also applies when the CP
terminal is operated with different pressure zones
(see diagram).
1
2
34
Isolatin g p late
1
Blind plu g
2
Pressure zone 2
3
Pressure zone 1
4
Fig. 3/2: Auxiliary pilot air
CPV... 9802 3-7
11
12/14
3. Installation
3.2.2 Connecting the supply and work tubing
Fit the screw connectors or silencers as shown in the
table below. Then connect the tubing.
With pneu mati c m ultip le co nne ctor plat e With ou t pne um ati c multip le conn ector pla te
1
3/5
11
1
82/84
3/5
2
4
Connection
code
ISO 55 99
1 or 11 Com pre ssed air/
2 or 4 Work air/vac uu m M7 G 1/8 G 1/ 4 Screw con necto r
3/5 Exhaust ri ght/
12/1 4
or
82/8 4
Tubing Conne ctio n size ISO 22 8,
vacuum
left-hand end pla te
Pne um. mul ti p le
connecto r p late
Auxiliary p ilo t a i r/
exhaust right/
left-hand end pla te
Pne um. mul ti p le
connecto r p late
12/14
M5
2
G1/2
G3/8
G 1/8
G 1/8
4
1
G 1/2
G 1/2
G 1/4
G 1/4
Connection
plates or pneum ati c
multiple connector plate
Screw con necto r
- for ducted exhaust ai r
- for silencers
Screw connector on
connection 8 2/ 84
- for ducted exhaust ai r
- for silencers
82/84
11
Specific ations i n bracke ts
for exte nded pn eum .
multiple con nector plate
CPV10 CPC14 CPV18
G 1/8 G 1/4 G 3/8 Screw co nnecto r in en d
G 3/8
G 1/4
M7 (M5)
Fig. 3/3: Assigning the connections
3-8 CPV... 9802
5
3. Installation
PLEASE NOTE
If there are several systems with ducted exhaust
air, use non-return valves in the common exhaust
tubing, in order to avoid impairment of function
as a result of back pressures.
1
2 3 4
6
2
6
2
CP te rm inal 1
1
Common 3/5
2
Centra l 82 /84
3
Centra l 3/5
4
CP te rm inal 2
5
Common 82/84
6
Fig. 3/4: Common tubing with non-return valves
CPV... 9802 3-9
3. Installation
PLEASE NOTE
In the case of CP terminals with two pressure zones
and auxiliary pilot air taken internally on the righthand side, the pressure on the right-hand side must
be between 3 bar and 8 bar.
PLEASE NOTE
In the case of CP terminals with ducted supply air,
connections 11 and 12/14 must be sealed with blind
plugs.
Vacuum/low pressure operation
The CP terminal can be operated with vacuum or low
pressure (< 3 bar), providing regulated auxiliary pilot air
is supplied separately (summary see "Conversion from
internal to external auxiliary pilot air").
3-10 CPV... 9802
3. Installation
3.2.3 Connecting the electrical cables
Earthing the CP terminals
There is a connection for earthing the CP terminal on
both the left and right-hand end plates (see diagram).
1
1
Earth/g rou nd co nn ectio n
1
Fig. 3/5: Earth/ground connection of CP terminal
PLEASE NOTE
•
Earth the CP terminal with MP, CP or AS-i
connection.
You thereby avoid electromagnetic interference
(EMC).
CPV... 9802 3-11
3. Installation
Connecting current-consuming devices to the
relay plate
PLEASE NOTE
Use only the ready made cable KRP-1-24-... from
Festo for connecting current-consuming devices to
the relay outputs.
Connect the current-consuming devices to the relay
outputs as follows:
• Carefully insert the socket first onto the connecting
lug of the lower relay output (see diagram).
• Screw the socket tight with the central locking screw
(tightening torque 0.15 Nm).
• Fit the second socket to the upper relay output in the
same manner.
Fig. 3/6: Fitting the relay output sockets
3-12 CPV... 9802
3. Installation
CP terminal with single connection
With this CP terminal variant each valve solenoid coil is
connected separately.
PLEASE NOTE
•
Use only the pre-assembled Festo connecting
sockets KMYZ-3-24-...-LED for connecting the valve
solenoid coils. There is an LED in the transparent
plug of the socket. This LED shows the switching
status of the valve solenoid coil.
Connect the valve solenoid coils as follows:
• Insert the socket onto the connecting lugs o f the appropriate pilot solenoid. The socket can be turned
180°. Make sure that the centring bolt grips into the
hole on the socket between the connecting lugs (see
diagram).
• Fasten the socket with the central locking screw
(tightening torque 0.3 Nm).
Fig. 3/7: Fitting the single connecting sockets
CPV... 9802 3-13
3. Installation
CP terminal with multipin or AS-i connection
PLEASE NOTE
Detailed instructions on the electrical installation of
the CP terminal with multipin or AS-i connections
can be found with the relevant product.
CP terminal with CP connection
Connecting the CP cable
PLEASE NOTE
Detailed installation instructions on the CP terminal
with CP connection can be found in the manual "CP
system – General installation and commissioning",
chapter 3.
3-14 CPV... 9802
4. Commissioning
Chapter 4
Commissioning
CPV... 9802 4-1
4. Commissioning
Contents
4. Commissioning
4.1 Commissioning – Testin g the valves . . . . . . . . . . . . . . . . . . . . . 4-3
4.2 Locati n g faul t s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-2 CPV... 9802
4. Commissioning
4.1 Commissioning – Testing the valves
PLEASE NOTE
Before commissioning the CP valve terminal,
observe the specifications on medium, see chapter
"Installation", section 3.2.1 Auxiliary pilot air.
Commiss ioning of the CP valve terminal should be undertaken as follows:
Commissio ning va riants Activity
Preli mi nary te st of t he
pneumatic tubing
Complete commissioning of the
comple te sy ste m
Test the va lve-cy li nder
combina tio n with t he ma nual
override.
Instal l and co nne ct the co mple te
syste m.
Progra m co ntro l b y PL C/
industria l PC.
There now follows a description of how to commission
the pneumatic components with the manual override.
Commissioning the CP system is described in the appropriate manual for the CP node.
CPV... 9802 4-3
4. Commissioning
Checking the valve functions
Manu al ov err ide
WARNING
Before operating the manual override:
•
Disconnect the operating voltage supply to the
valve solenoid coils by unplugging the contact
(IC, MP AS-i or CP connection).
You then avoid undesired actuation of the valve
solenoid coils.
•
Before applying the operating voltage, make sure
that all manual overrides are set again at their
basic positions.
You then avoid undefined switching states of the
valves.
You should use the manual override principally when
commissioning the pneumatic system, in order to check
the functioning and effectiveness of the va lve or valvecylinder combination.
By actuating the manual override, you can switch the
valve without an electrical signal. Only the compressed
air supply need be switched on.
4-4 CPV... 9802
4. Commissioning
Different types of manual override
The manual override is intended for use as follows:
Manual override design Mode of operation
Manual ov erride w ith
automatic reset (pushi ng)
Manual ov errid e lockin g Manual ove rride remains active,
Manua l ove rride is rese t by spring
force.
until it i s re set by ha nd.
The following types of manual override can be used
with the CP terminal.
Locking m anual o verride Pushing m anual override
Slide of lo ckin g m anua l ove rride to pil ot
so lenoid 14
Button o f pushin g manu al overrid e to pi lot
solenoid 14
Slide of lo ckin g m anua l ove rride to
pilot solenoid 12
Button o f pushin g manu al overrid e to
pi lot s o lenoid 1 2
Fig. 4/1: Different types of manual override
CPV... 9802 4-5
4. Commissioning
Checking the valve-cylinder combination
WARNING
When exhausting or repressurizing the valve terminal
under the following conditions:
– with safety start-up valve
(slow pressure build-up) and
– when there is an electrical signal
(e.g. after EMERGENCY STOP)
Supply the auxiliary pilot air separately (3 to 8 bar).
The auxiliary pilot air must reach its full level immediately after being switched on, otherwise the slow pressure build-up of the overall supply will have no effect
with cylinders actuated as follows:
– by means o f single solenoid valves
– by means o f double solenoid valves which are
switched to flow-through during the pressureless
phase.
The effects of slow pressure build-up when there is an
electrical signal are shown in the table below.
Separatel y
supplied a uxilia ry
pilot air
tak e n behi n d s a f ety
start-up valve
taken in front of
safety sta rt -up valve
Pressure
increase i n
overall supply
slow slow after p res sure
slow fast before pressure
Pressure
increas e in
auxilia ry pilot
air (12/1 4)
Moment w hen
valve switches
over
increase at (1)
increase at (1)
4-6 CPV... 9802
Movement of
cylinde r
fast
slow
4. Commissioning
PLEASE NOTE
•
Use a blunt pointed object for actuating the
pushing manual override.
•
Actuate the manual override with max. 30 N.
you thereby avoid functional interference or damage
to the manual override.
Proceed as follows:Testing
• Switch on the c ompressed air supply.
• Check the functioning and mode of operation of each
individual valve cylinder combination with the manual
override as shown in the diagrams below.
• When the test is finished, switch off the compres sed
air supply again.
Actuate the man ual o verride with auto matic re set
(pushing)
Ca re fu lly press t h e
plunge r of the man ua l
override as far as it
will go.
Hold the plu nger o f
the manu al ove rride
pressed down.
Release plunge r.
Spring rese ts th e
plunge r to ba sic
positio n.
CPV... 9802 4-7
Reaction of valve
The valve:
– switch es.
– remains sw itch ed
– returns to basic position
(not with 5/2-way double
solenoid valv e, Ident.
code J)
4. Commissioning
CAUTION
Before commissioning the CP valve terminal, return
the manual override to basic position.
Actuate the m anual o verride with l ocking Reaction of valve
Push the slide of the
ma n ual o v er r i de down
as far as possible.
Leave slide in low er
position.
Push the slide of the
manual ov erri de up as
far as possible.
The va lve:
– switche s
– remains sw itche d
– returns to basic position
(not w ith 5/2 -w ay do uble
solen oid va lve, I dent.
cod e J )
4-8 CPV... 9802
4. Commissioning
4.2 Locating faults
Impairment of function
When you switch on the compressed air supply or
when you have tested the individual valves, you can
learn the following about the operating status of the
pneumatic system.
Operating statu s of the
pneumatic system
Air comes out.. .
– of common tubing
connections
– of work tubin g con ne ction s
– betw e en the m o dules
Valve or pneumatic sy stem
– does not re act as expe cted
– does not re act
– does not re act
Valve position Error treatment whe n compre ssed
– basic position
– swi tch po si tion
– basic position
– swi tch po si tion
– swi tch po si tion
– basic position
air has been switc hed off
• Che ck the seal or
tubing fi tting
• Whe n switchi ng on againrgu late
sepa ra te a u xi lia ry p ilot ai r 3 to 8
ba r
• Check tub in g
• When switching on again,
check ope rati ng pre ssure
(e.g. pressure zones)
• Retu rn fo r se rvi cing
– Check reg ula tor conn ectio n
(apply pre ssure > 3 ba r to
reg ulator)
CPV... 9802 4-9
4. Commissioning
If the operating status of the pneumatic system differs
from the desired pneumatic operating status, the following requirements are probably not fulfilled.
Desired
pneumatic
operating sta tus
Free of leaka ge – carefully laid tubing
Fast reaction Sufficien t pressure su pply
Free of inter feren ce Non-return va lves in
Two pressure
zones
Vacuum operatio n/
low pres sure ope ration
EMERGENCY STOP of
pressure zo nes
Slow switching on after
EMERGENCY STOP
Requireme nt Remarks
– regulated auxiliary pilot air
via intermediate pressure
modules
common exhaust tubing
Pressure zones are limited
by isolating plate
Se para tely re g ulate d
aux ilia ry pilot a ir
(3-8 bar)
Regula tor fu nctio n fo r
auxilary pilot ai r guara nte ed
in spite of co mple te su ppl y
being sw itche d o ff
When there are co ntro l
signals the aux iliary pilot a ir
must be at full level
immedia tely after it is
switche d on
—
• Exhaust v alve terminal at
left an d rig ht -ha nd end
plates (3/5 , 82/84)
– Applies whe n several
syste ms w ith ce nt ral
ducte d exh aust a re u sed
– Can be fitte d late r
– Regulator can only be
operat ed w ith pre ssure
(between 3 and 8 bar)
– Regulator regulates
auxili ary pil ot ai r for al l
valve plates on a terminal
4-10 CPV... 9802
4. Commissioning
LED display of valves
There is a yellow LED for each valve solenoid coil. This
LED shows the switching status of the valve solenoid
coil when the CP valve terminal is ready to operate.
PLEASE NOTE
Observe the assignment of the LED to the
appropriate manual override:
With IC connection:
– LED in front plug to
upper manual override (14)
– LED in rear plug to
lower manual override (12)
With MP, AS-i or CP connection:
– lower LED in plug cover to
upper manual override (14)
– upper LED in plug cover to
lower manual override (12)
CPV... 9802 4-11
1
1
4. Commissioning
2
The relationship of the LEDs to the manual override is
shown in the diagram below.
2
LEDs and manual override for pil ot so len oid 14
1
LEDs and manual override for pil ot so len oid 12
2
Fig. 4/2: Relationship of the LEDs to the manual override
4-12 CPV... 9802
4. Commissioning
The LEDs show th e switching status of the valve solenoid coils. The meaning of the LEDs is shown in the
table below.
LED Switching po sition of va lve Meaning
Yellow out Basic position Logic 0 (signal not applied)
Yellow aligh t – Switch p ositio n
or
– basic position
Logic 1 (signal applied)
Logic 1 but:
– operati ng volta ge of out pu ts is
belo w pe rm itte d t ole ran ce ran ge
(DC 20.4 V to 26.4 V)
or
– compre ssed ai r su pply n ot corre c t
or
– pilot exhaust blocked
or
– return for se rvicing
CPV... 9802 4-13
4. Commissioning
4-14 CPV... 9802
5. Maintenance and conversion
Chapter 5
Maintenance and conversion
CPV... 9802 5-1
5. Maintenance and conversion
Contents
5. Maintenance and conversion
5.1 Fitting/removing CP terminal components . . . . . . . . . . . . . . . . . 5-3
5.1.1 Removing components from valve locations . . . . . . . . . . . . . . . 5-4
5.1.2 Fitting components into the valve locations . . . . . . . . . . . . . . . . 5-7
5.2 Conversion from pushing to locking manual override . . . . . . 5-12
5.3 Conversion from internal to external pilot air . . . . . . . . . . . . . 5-13
5.4 Conversion from individual to central tubing . . . . . . . . . . . . . . 5-18
5.5 Converting the CP terminal to two pressure zones . . . . . . . . . 5-19
5.6 Converting the CP valve terminal to
different electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-2 CPV... 9802
5. Maintenance and conversion
5.1 Fitting/removing CP terminal components
WARNING
Before starting the fitting, switch off the following:
•
the compressed air supply
•
the power supply to the valve solenoid coils
You thereby a void:
– Uncontrolled movements of loose tubing.
– Sudden and undesired movements of the connected
actuators.
– Undefined switching states of the electronic compo-
nents.
CPV... 9802 5-3
5. Maintenance and conversion
5.1.1 Removing components from valve locations
The components on the CP valve terminal can easily
be removed for maintenance and conversion work.
Proceed as follows:
1. Loose ning the electr ical connections:
– MP, AS-i or CP connections.
• Loosen the MP, AS-i or CP plug and carefuly
disconnect it.
• Then loosen the four fastening screws on the
electrical connector plate. Pull the electrical
connector plate away from the connecting lugs
on the valve plates.
• Remove, if necessary, the plugs on the relay
outputs of CP va lve te rminals with CP
connection. Loosen firs t the locking screws of
the upper plugs. Carefully pull the plug away
from the connecting lugs. Then loosen the
lower plugs in the same manner.
– IC connection of valve solenoid coils:
• Loosen the locking screws on the connector
plugs of the valve plates in order to remove
them.
• P ull the plugs carefully aw ay from the
connecting lugs. Mark the sockets.
• In the case of CP valve terminals with
pneumatic multiple connector plate, we
recommend that the connector plugs be
removed from each valve plate.
5-4 CPV... 9802
5. Maintenance and conversion
2. Loosen ing the pneumatic connections
• Individually wired CP terminals (without pneumatic
multiple connector plate):
Loosen th e work tubing of the valve plate which is to
be removed.
3. Loosening the CP valve terminal from the fastening
surface.
• CP valve terminals with pneumatic multiple
connector plate:
Loosen the fastening screws of the connector plate
in the left and right-hand end plates one turn in diagonally opposite sequence. Then remove the screws
completely. Now remove the CP valve terminal from
the pneumatic multiple connector plate.
• CP valve terminals with foot fastening:
Loosen the fastening screws in the right-hand end
plate and remove them.
• CP valve terminal fitted onto a wall or hat rail:
Loosen the right-hand wall fastening or hat rail clamping unit.
CPV... 9802 5-5
5. Maintenance and conversion
4. Remove the components.
• Loosen both lower tie rods one turn.
• Then loosen the upper tie rod and pull it over the
components which are to be replaced.
• Unscrew the two lower tie rods until the heads of the
screws are flush with the outer surface of the end
plate (do not remove the tie rod).
• Pull the valve terminal apart so that the distance between the component to be replaced and the next
component is in each case 2 mm.
1
2
33
Component to be replaced
1
Tie rod
2
Gap approx. 2 mm
3
Fig. 5/1: Removing the valves
5-6 CPV... 9802
5. Maintenance and conversion
• Turn the component forwards around the front tie
rod.
1
Front tie bolt
1
Rea r tie bo l t
2
Fig. 5/2: Position of the tie bolt
• Pull the component so that it snaps out of the front
tie bolt.
5.1.2 Fitting components into the valve locations
Proceed as follows:
1. Fitting components
• Check that the seals are fitted correctly between the
terminal components. They must lie accurately in the
appropriate seal grooves.
2
CPV... 9802 5-7
5. Maintenance and conversion
• Only CPV10/14 valve terminals: Check that the seals
are seated correctly when valve plates with pneumatic springs or double solenoid valves are fitted. The
seating is not symmetrical (see diagram).
Pneumatic spring valve (Ident code M):
Designation "L" on the seal
must point forwards.
The flat seal for valve pl ates with 3/2 -way
valves (Ident code C, H and N) as well as
for all end plates is symmetrical and marked
with 3/2 .
Double so len oid va lve (Id ent code J ):
Des ig na tio n " J" on the seal R must point
forwards.
Fig. 5/3: Position and designation of seals with pneumatic spring valves or
double solenoid valves (only CPV10/14 valve terminals)
PLEASE NOTE
There is only one version of the seal for all valve
plates of the CPV18 valve terminal. The position of
the seal is the same for all valve plates.
5-8 CPV... 9802
5. Maintenance and conversion
• Place the components on the front tie rod. Press the
components down so that they snap into the tie rod.
• Swing the components carefully backwards. Make
sure there is sufficient space for the flat seals.
• Push the upper tie rod as far as possible into the CP
terminal and screw it in a few turns.
• Align the components of the CP terminal on a flat
surface so that they are not offset against each other.
• Tighten first the upper tie rod and then the lower tie
rod with 0.3 Nm. Then tighten both tie rods with
2 Nm.
– With MP, AS-i or CP connections:
PLEASE NOTE
Replace the flat seals between the valve block and
the connecting plate if these seals are more than
one year old. You thereby guarantee reliable sealing
for your CP terminal.
The flat seals are seated at the bottom of the electrical
connector plate (see digram).
1
Fla t se al
1
Fig. 5/4: Position of the flat seal on the electrical
connector plate
CPV... 9802 5-9
5. Maintenance and conversion
• Remove the self-adhesive flat seal from the recess.
Use a screwdriver here to carefully loosen one corner of the seal (see Fig. 5/4). Then carefully pull the
seal away from the electrical connector plate.
• Remove the protective foil from the new seal. Glue
the flat seal into the reces s .
• Place the end cover on the connecting lugs of the
valve block. Carefully press down the end c over.
• Tighten the screws of the electrical connector plate
in diagonally opposite sequence with 0.6 Nm
(CPV10/14) or with 3 Nm (CPV18).
– CP terminals with CP connection and relay plates:
• Fit the plugs onto the relay outputs as described under "Connecting current-consuming devices to the relay plate."
5-10 CPV... 9802
5. Maintenance and conversion
2. Fitting the CP terminal
CP terminals with pneumatic multiple connector plate
• Place the 3-seal and 4-seal strips in the recesses in
the left or right-hand end plate. Press the 2-seal
strips carefully into the threads of the work connections.
• Place the CP terminal on the pneumatic multiple
connector plate and tighten the fastening screws in
the left and right-hand end plates with 0.3 Nm. Then
tighten the screws in diagonally opposite sequence
with 2 Nm (CPV10/14) or with 4 Nm (CPV18).
CP terminal with foot fastening
• Insert the fastening screws in the right-hand end
plate and tighten the terminal.
CP terminal with wall or hat rail fastening
• Fix the right-hand fastening onto the wall with two
M4 screws or tighten the right-hand hat rail clamping
unit.
3. Fitting the pneumatic and electrical connections
• Fit the connections in the reverse sequence to that
described in "Removing CP terminal components".
CPV... 9802 5-11
2
5. Maintenance and conversion
5.2 Conversion from pushing to locking manual override
By removing a safety clip, you can convert your CP
terminal from pushing to locking manual override. Proceed as follows:
If you do not wish to use the safety clip again:
• Use a screwdriver to press in the centre of the safety
clip, as shown in 1. The safety clip will then bend
and can be removed from the fastening.
If you wish to use the safety clip again:
• Use a thin object (e.g. a spatula) to lift the safety clip
out of the fastening as shown in 2.
1
Remove the safe ty clip by pressin g it out
1
Remove the safe ty clip by liftin g it ou t (clip can be used agai n)
2
Fig. 5/5: Safety clip of the manual override
5-12 CPV... 9802
5. Maintenance and conversion
5.3 Conversion from internal to external pilot air
By fitting the appropriate left and right-hand end plates
you can convert your CP terminal to internal or external
pilot air.
PLEASE NOTE
Mixed operation of the CP terminal with internal and
external control air is not permitted. The auxiliary
pilot air channel is not divided into two pressure
zones by the optionally available isolating plate.
You can determine which end plates are fitted on your
CP valve terminal by means o f the part numbers (position see below). In the case of CP valve terminals with
AS-i, CP or MP connections, the electrical connector
plate must be dismantled.
Part number
Designa tion Part number
CPV10 CPV14 CPV18
CPV..-EPL
CPV..-EPL-E
CPV..-EPL-G
CPV..-EPL-PE
CPV..-EPL-PG
CPV..-EPR
CPV..-EPR-E
CPV..-EPR-G
CPV..-EPR-PE
CPV..-EPR-PG
CPV... 9802 5-13
161 378
161 374
161 376
161 370
161 372
161 379
161 375
161 377
161 371
161 373
162 548
162 544
162 546
162 540
162 542
162 549
162 545
162 547
162 541
162 543
163 280
163 196
163 198
163 194
163 192
163 281
163 197
163 199
163 195
163 193
5. Maintenance and conversion
PLEASE NOTE
With end plates CPV..-EPL-PG (part no. 161 372
and 162 542) as well as with CPV..-EPR-PG (part
no. 161 373 and 162 543), connection 12/14 is sealed internally.
All available end plate combinations are listed in the
table below. Check that the end plates, which you wish
to fit, can in fact be combined (see end plate pairs listed below).
End plate pairs with in ternal auxil iary pilot air for
single tubin g
CPV..-EPL-G CPV..-EPR Con nections only in le ft-hand
CPV..-EPL CPV..-EPR-G Connections only in right-
CPV..-EPL-E CPV..-EPR-G Connections in left a nd right-
Description
end pla te. Division into
pressure zo nes n ot pe rmi tte d.
Unuse d con nect ions m ust b e
sealed .
hand end plate. Division into
pressure zone s n ot pe rmi tted.
hand end plates.
Division into pressure zones
perm itted.
5-14 CPV... 9802
5. Maintenance and conversion
End plate pairs w ith exte rnal auxili ary pilot a ir
for single tubi ng
CPV..-EPL-E CPV..-EPR Connections only in
CPV..-EPL CPV..-EPR-E Connections only in
CPV..-EPL-E CPV..-EPR-E Connections in le ft and
End plate pa irs with interna l auxi liary pil ot air and
tubing via pneuma tic multi ple connector pla te
CPV..-EPL-PG CPV..-EPR-PG Connections on the
Description
left-hand end pla te.
Division i nto pressure
zones not permitted.
right-han d end plate.
Division i nto pressure
zones not permitted.
right-han d end plates.
Division i nto pressure
zones p ermitt ed . Unuse d
connectio n s mu st be seale d.
Description
pneumatic multiple
connecto r p late.
Right end plate s with
internal a uxili ary pilot a ir a re
marke d wi th INT.
End plate pairs w ith exte rnal auxili ary pilot a ir and
tubing via pneuma tic multi ple connector pla te
CPV..-EPL-PE CPV..-EPR-PE Connections on the
CPV... 9802 5-15
Description
pneumatic multiple
connecto r p late.
Division into pre ssure zo nes
permitte d.
5. Maintenance and conversion
Proceed as follows:
• Loosen the electrical and pneumatic connections
(see section "Remo ving components from valve locations" ).
• Loosen the CP terminal from the fastening surface.
Proceed in the reverse sequence to that described in
the sections "Fitting onto a wall", "Fitting onto a hat
rail" or "Fitting with feet" in the chapter "Fitting".
• In the case of CP valve terminals with CP, AS-i or
MP connections, remove the appropriate cover (see
section "Rem oving componen ts from valve locat ions").
• Place the CP terminal on the left-hand end plate.
Loosen the outer tie bolts max. 1 turn (see Fig. 5/1).
You thereby avoid overloading the centre tie bolt.
• Then loosen the centre tie bolt and remove it.
• Unscrew the outer tie bolts.
• Remove the end plate from the CP terminal. Make
sure that the other components on the CP terminal
remain together.
• Place the right-hand end plate on the CP terminal
and insert the tie bolts.
5-16 CPV... 9802
5. Maintenance and conversion
• Place the CP terminal on the right-hand end plate.
Make sure that the tie rod, which has not yet been
tightened, does not fa ll out of the CP terminal.
• Remove the left-hand end plate from the CP terminal.
• Place the left-hand end plate on the CP terminal.
Swing the CP terminal onto the left-hand end plate.
• Screw in the tie rod and tighten it with 0.3 Nm.
• Then tighten first the centre and then the outer tie
rod with 2 Nm (CPV10/14) or with 4 Nm (CPV18).
• In the case of CP valve terminals with CP, AS-i or
MP connections, fit the appropriate connector plate
(see section " Fit ting com ponent s on to valve l ocat ions ").
• Fit the CP terminals onto their fastening surfaces
(see sections "Fitting onto a wall", "Fitting onto a hat
rail" or "Fitting with feet" in the chapter "Fitting").
• Finally connect the pneumatic tubing and the electrical cables (see chapter "Installation").
CPV... 9802 5-17
5. Maintenance and conversion
5.4 Conversion from individual to central tubing
In order to convert your CP terminal from individual to
central tubing with the pneumatic multiple connector
plate, you will require the following:
– the pneumatic multiple connector plate
– special end plates for the CP terminal
Proceed as follows:
• Replace the end plates of the CP terminal as described in the section "Conversion from internal to external control air".
• Fit the pneumatic multiple connector plate as described in chapter 2 in the section "Fitting the pneumatic
multiple connector plate".
5-18 CPV... 9802
5. Maintenance and conversion
5.5 Converting the CP terminal to two pressure zones
In order to convert your CP terminal to two pressure
zones, you will require an isolating plate (to be ordered
separately).
Fit the isolating plate as described in the section "Fitting
components in the valve locations".
PLEASE NOTE
•
When installing the CP terminal, you must supply
compressed air to both sides of the terminal.
•
Seal unused connections (supply and auxiliary pilot
air connections) with blind plugs.
CPV... 9802 5-19
5. Maintenance and conversion
5.6 Converting the CP valve terminal to different electrical connections
Due to the modular structure of the CP valve terminal,
you can convert it to IC, MP, AS-i or CP connections.
Proceed as follows:
CP terminals with IC connection
• Loosen the locking screws on the connecting
sockets.
• Pull the socket carefully away from the connecting
lugs on the pilot solenoid coil.
• Insert the MP, AS-i or CP connection onto the
connecting lugs of the pilot solenoid coils.
• Fasten the connector plate with the 4 socket head
screws. Tighten the screws in a diagonally opposite
sequence.
5-20 CPV... 9802
5. Maintenance and conversion
CP terminals with MP, AS-i or CP connection
• Loosen the 4 socket head screws o f
the connector plate.
• Pull the connector plate carefully away from the
connecting lugs of the pilot solenoid coils.
MP, AS-i or CP connector plate:
• Insert the connector plate onto the connecting lugs of
the pilot solenoid coils.
• Fasten the connector plate with the 4 socket head
screws.
• Tighten the screws in a diagonally opposite sequence.
IC connections:
• Insert the connector sockets onto the connecting lugs
of the pilot solenoid coils. Make sure that the guide
bolts grip into the connector socket.
• Fasten the socket with the central locking screw.
CPV... 9802 5-21
5. Maintenance and conversion
5-22 CPV... 9802
A. Technical appendix
Appendix A
Technical appendix
CPV... 9802 A-1
A. Technical appendix
Contents
Technical appendix
A.1 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
A.2 Technic al specificatio n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.3 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
A-2 CPV... 9802
A. Technical appendix
A.1 Accessories
General
CPV10/14 CPV18
Hat-ra il m ounti ng kit
Wall mount ing mkit
Identifie r clip
Manua l ove rride cove r
CP valve termina l with
AS-i connection
AS-i combi power uni t
AS-i bus cable (yellow)
AS-i additional suppl y cable (black)
Senso r ca ble
AS-i cable cap
AS-i cable sleeve
CP valve termina l with
CP connection
CP cable
Re la y c a bl e
CP valve termina l with
IC connection
Individual plug KMYZ-3-24-... -LED
CP valve term inal w ith
MP connection
Ready-to -use m ultip in ca ble
Multip in socke t
CPV10/14-VI-BG-NRH-35
CPV10/14-VI-BG-RWL
IBS6x 10
CPV..-VI-BZ-T...
ASI-CNT-115/230 V AC
ASI-1,5-Y-100
ASI-1,5-Z-100
KM8-M8-GSGD
ASI-FK-KK
ASI-KT-FK
KVI-CP-1...
KVI-CP-2... (for drag cha in use)
KRP-1-24...
KMP3-...P-...-X
SD-SUB-D-BU
CPV18-VI-BG-NRH-35
CPV18-VI-BG-RW
IBS9x20
CPV18-VI-BZ-T...
CPV... 9802 A-3
A. Technical appendix
A.2 Technical specifications
General
Permit ted te mp eratu re ra ng e:
–storage
– operation
– medium
- 20 to + 70
- 5 to + 50
- 5 to + 50
Protection cla s s as per E N 60 5 29 IP 65 (w ith FESTO accessories cable)
Relative humidity 90 % at 20
Corrosi on pro tectio n Against industrial clim at e (as p er FN9 4007 0)
Fitting p ositio n As desire d
Tightening torque s CPV10/14 CPV18
– Socket for IC connection
0.15 Nm
– Connect ing sock et f or re lay
outputs
0.15 Nm
– Fastening screw for wal l support
or hat rail
1.5 Nm
– Screws fo r fa st ening CP t erm inal
to pneumatic multipin
– Electri cal co nnector pla te
– Earth conne ction
– tie rod
2.0 Nm
0.7 Nm
1.0 Nm
1st. stage 0.3 Nm
2nd. st age 2 .0 Nm
o
C
o
C
o
C
o
C or 40 % at 50 oC
4.0 Nm
4.0 Nm
3.0 Nm
1.0 Nm
1st. stage 0.3 Nm
2nd. sta ge 4.0 Nm
Materi als
Plates, cover, pneuma tic multiple
connecto r plate :
Seal:
AL, AL-GD, Ms, PAXMD6, PET, POM, PPS, ST,
NBR, HNBR
Oscillation
(as per DIN/IEC 68 part 2–6)
– Transport:
3.5 mm trave l at 2– 9 Hz
1 g acceleration at 9–200 Hz
– Operati on/use :
0.35 mm travel at 10–60 Hz
5 g acceleration at 60–150 Hz
Sho ck :
(as per DIN/IEC 68 part 2–27 )
30 g accelera tion at 11 ms duratio n
A-4 CPV... 9802
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