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CPA VI
Series Manual
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Festo CPA VI, CPA10VI, CPA14VI, CPA Series Series Manual

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CPA pneumatics manual
Valve terminal with CPA pneumatics Type CPA..-VI
Manual
173 515 en 0207c
Contents and general instructions
Author M. Simons.................................
Editors H.-J. Drung, M. Holder........................
Original de.......................................
Translation transline Deutschland.....................
Layout Festo AG & Co., Dept. KG-GD...................
Type setting DUCOM................................
Edition en 0207c...................................
Designation P.BE-CPA-EN............................
Order no. 173 515.................................
AS-Interface
®
is a registered trademark of
AS-Interface Association
E (Festo AG & Co., D-73726 Esslingen, Federal Republic of Germany, 2002) Internet: http://www.festo.com e-mail: service_international@festo.com
The copying, distribution and utilization of this document as well as the communication of its contents to others without ex­pressed authorization is prohibited. Offenders will be held li­able for the payment of damages. All rights reserved, in par ticu­lar the right to carry out patent, utility model or ornamental design registration.
Festo P .BE-CPA-EN en 0207c
I
Contents and general instructions
II
Festo P.BE-CPA-EN en 0207c
Contents and general instructions
Contents
Designated use V........................................................
Tar g et g r o u p V..........................................................
Service V...............................................................
Notes on this manual VI...................................................
Important user instructions XI..............................................
1. System summary 1-1...............................................
1.1 Overview of variants 1-4.............................................
1.2 Description of components 1-7.......................................
2. Fitting 2-1........................................................
2.1 Fitting variants 2-4.................................................
2.1.1 Fitting onto a wall 2-5.......................................
2.1.2 Hat rail fitting 2-6...........................................
3. Installation 3-1...................................................
3.1 Preparing the compressed air 3-4.....................................
3.1.1 Operation with non-lubricated compressed air 3-4................
3.1.2 Operation with lubricated compressed air 3-5....................
3.2 General connecting methods 3-7......................................
3.2.1 Laying the tubing 3-7........................................
3.2.2 Basic information 3-8........................................
3.3 Connecting the CPA valve terminal 3-9.................................
3.3.1 Auxiliary pilot air 3-9........................................
3.3.2 CPA valve terminal with pressure zone separation 3-12.............
3.3.3 Connecting the supply, exhaust and work lines 3-14...............
3.3.4 Connecting the electric cables 3-20.............................
3.4 Address assignment of the valves 3-24..................................
Festo P .BE-CPA-EN en 0207c
III
Contents and general instructions
4. Commissioning 4-1................................................
4.1 Testing the valves 4-4...............................................
4.1.1 Checking the valve functions 4-5..............................
4.1.2 Checking the valve-cylinder combination 4-9....................
4.2 Eliminating faults 4-15...............................................
4.2.1 Impairment of function 4-15...................................
4.2.2 LED display of the valves 4-17..................................
5. Maintenance and conversion 5-1.....................................
5.1 General precautionary measures 5-4..................................
5.2 Dismantling the CPA valve terminal 5-5.................................
5.3 Replacing CPA valve terminal components 5-9...........................
5.3.1 Replacing valve sub-bases, blanking plates or
additional supply plates 5-9..................................
5.3.2 Replacing the large surface-mounted silencer 5-11................
5.3.3 Replacing the end plate, sub-base or manifold block 5-12...........
5.4 Conversion work on the CPA valve terminal 5-19..........................
5.4.1 Conversion from non-locking to locking/non-locking
manual override 5-19.........................................
5.4.2 Conversion to internal or external pilot air 5-21....................
5.4.3 Converting the CPA valve terminal to different pressure zones 5-22...
5.4.4 Conversion of valve location for actuating one or
two solenoid coils 5-24.......................................
5.5 Adding/removing valve locations 5-25..................................
A. Technical appendix A-1.............................................
A.1 Festo accessories A-3...............................................
A.2 T echnical specifications A-4..........................................
B. Supplementary component summary and installation instructions B-1.....
B.1 Overview of end plates B-3..........................................
B.2 Separating the CPA valve terminal from the CPX terminal B-6...............
C. Index C-1.........................................................
IV
Festo P.BE-CPA-EN en 0207c
Contents and general instructions
Designated use
The CPA valve terminals described in this manual are in­tended for fitting into a machine or automated system. Please observe the safety regulations specified in this manual as well as the instructions concerning the designated use of the relevant CPA valve terminal. CPA valve terminals may only be used as follows:
– in accordance with designated use
– in their original state
– without any modifications by the user
– in faultless technical condition.
When used together with commercially available compo­nents, such as sensors and actuators, the specified limits for pressures, temperatures, electrical data, torques etc. must be observed. National and local safety regulations must also be observed.
Targ et gro up
Service
Festo P .BE-CPA-EN en 0207c
This manual is directed exclusively at technicians trained in control and automation technology.
Please consult your local Festo service centre if you have any technical problems.
V
Contents and general instructions
Notesonthismanual
This manual contains specific information on fitting, installing, commissioning, servicing and converting the CPA valve ter­minal. This manual describes only the pneumatic components and refers to the valve terminal variants listed in the table below.
CPA valve terminal with CPX t erminal, type CPA..
Informationontheelectric/electroniccomponents: see manual “CPX system, installation and commis­sioning”
Tab. 0/1: CPA valve terminal with CPX terminal
VI
Festo P.BE-CPA-EN en 0207c
Contents and general instructions
Variants of the CPA valve terminal for incorporation in the CP system, type CPA..-VI
With IC connection: Information on the electric/electronic components: in thismanual
With MP connection: type CPA..-IMP Information on the electric/electronic components: see leaflet with product
With CP connection: types CPA..-IFB-CP and CPA..-IFB-DN Information on the electric/electronic components: see manual “CP system, installationand commissioning”
With AS-Interface connection; type CPA..-IFB-ASI or CPA..-IFB-ASI-Z Information on the electric/electronic components: see leaflet with product
Tab. 0/2: Connection variants of the CPA valve terminal
Festo P .BE-CPA-EN en 0207c
VII
Contents and general instructions
Information on further CP modules or CPX modules can be found in the manual for the relevant module. The tables below give an overview.
Manuals on the CPA valve terminal with CPX terminal
Manual “System manual,” type P.BE-CPX-SYS-..
Contents Overviewof structure, components and method of operation of CPX terminals; instruc-
Manual “CPX field bus node”
Contents Instructions on fitting,
tions on installation and commissioning as well as basic information on parametrizing.
type P.BE-CPX-FB...
installing, commissioning and diagnosing the appropriate field bus node
“CPX I/O modules” type P.BE-CPX-EA-...
Connection techniques and instructions on fitting, installing and commission­ing input and output modules of type CPX-... as well a s type CPA and Midi/ Maxi pneumatic interfaces
“Valve terminal with CPA pneumatics” type P.BE-CPA-... or “Valve terminal with Midi/Maxi pneumatics” type P.BE-MIDI/MAXI-03-...
Informationonfitting, installing and commission­ing the relevant pneumatic modules
Tab. 0/3: Manuals on the CPA valve terminal with CPX terminal
VIII
Festo P.BE-CPA-EN en 0207c
Contents and general instructions
Manuals on the CP system Periph-
erals
Manual “CP system, installation and commissioning” type P.BE-CPSYS-...
Contents General basic information on the method of operation, fitting, installation
Manual “CP field bus node,
Contents Special information on
and commissioning of CP systems.
programming and diagnosis” type P.BE-CP-FB... or P.BE-VIFB...-10...
commissioning, programming and diagnosing related to the node used
“CPV valve terminal, pneumatics” or ”CPA valve terminal, pneumatics” type P.BE-CPV-... or P.BE-CPA-...
Informationonfitting, installing and commis­sioning CPA or CPV valve terminals
“CP modules, electronics” type P.BE-CPEA-...
Informationonfitting, installing and com­missioning CP I/O modules
Tab . 0 / 4 : Manual s o n t h e C P s y s tem
Festo P .BE-CPA-EN en 0207c
IX
Contents and general instructions
The CPA valve terminal consists of the following pneumatic and electrical components: The most important pneumatic components are the valve sub-bases, connection sub-bases and end plates (see diagram).
1 Valve sub-bases
1
2 Connection
sub-bases
3 End plates
Fig. 0/1: Main components of the CPA valve terminal
This manual contains the documentation for the valve sub­bases with Ident. codes B, E, G, H, J, K, M and N (see chapter “System overview, description of components”).
233
X
Festo P.BE-CPA-EN en 0207c
Contents and general instructions
Important user instructions
Danger categories
This manual contains instructions on the possible dangers which may occur if the product is not used correctly. These instructions are marked (Warning, Caution, etc.), printed on a shaded background and marked additionally with a picto­gram. A distinction is made between the following danger warnings:
Warning
This means that failure to observe this instruction may result in serious personal injury or damage to property.
Caution
This means that failure to observe this instruction may result in personal injury or damage to property.
Festo P .BE-CPA-EN en 0207c
Please note
This means that failure to observe this instruction may result in damage to proper ty.
The following pictogram marks passages in the text which describe activities with electrostatically sensitive compo­nents.
Electrostatically sensitive components may be damaged if they are not handled correctly.
XI
Contents and general instructions
Marking special information
The following pictograms mark passages in the text contain­ing special information.
Pictograms
Information: Recommendations, tips and references to other sources of information.
Accessories: Information on necessary or sensible accessories for the Festo product.
Environment: Information on environment-friendly use of Festo products.
XII
Text markings
• The bullet indicates activities which may be carried out in
any order.
1. Figures denote activities which must be carried out in the numerical order specified.
– Hyphens indicate general activities.
Festo P.BE-CPA-EN en 0207c
Contents and general instructions
The following product-specific terms and abbreviations are used in this manual:
Ter m
Additional pressure supply plate
AS-Interface Actuator-Sensor-Interface
Blanking plate Plate without valve function for filling an unused location.
Components Common term for pneumatic Sub-bases, valve sub-bases, additional
Connecting the tubing Connecting the supply lines (tubing) to the CPA valve terminal.
CP Compact Performance
CP cable Special cable fo r coupling the various CP modules
CP modules Common term for various modules which can be incorporated in a
CP system Complete system consisting of CP field bus node and CP modules
CPA10 CPA14
CPA valve terminal CPA valve terminal (type 12) for CPX terminal, field bus systems, IC, MP,
Meaning
Plate for supplying pressure zones which are in the centre of the CPA valve terminal. In this plate the compressed air is diverted from work connection 2, so that the relevant valve sub-bases can be supplied with compressed air. The exhaust air can also be expelled through connection 4.
pressure supply plates, blanking plates, end plates, CPX adapters, electrical sub-bases (with IC, MP, CP or AS-Interface connection), electrical manifold blocks, cover blocks, end plate covers, silencers.
CP system
Designation of the CPA valve terminal sizes: CPA valve terminal with micro valve sub-bases CPA valve terminal with mini valve sub-bases
or AS-Interface connections.
CPA valve terminal with AS-Interface connection
CPA valve terminal with CP connection
CPA valve terminal with individual connection (IC connection)
Festo P.BE-CPA-EN en 0207c
CPA valve terminal variant with serial connections which enables the CPA valveterminaltobeconnectedtotheAS-Interfacebus.
CPA valve terminal variant with plug and socket which enables the CPA valve terminal to be connected to further CP modules.
CPA valve terminal variant on which every valve solenoid coil can be connected individually with a special cable.
XIII
Contents and general instructions
Ter m Me a n ing
CPA valve terminal with multipin connection (MP connection)
CPX modules Commontermforthevariousmoduleswhichcanbeincorporatedina
CPX terminal Modular electric terminal type 50
Electrical bridge Conducts the power supply from the manifold block to the solenoid coils
Electrical sub-base Block with multipin, CP or AS-Interface connection
End plate Outer left and right-hand end plates of the CPA valve terminal for supply-
I/O Input/output modules
Manifold block Block for the electrical linking of the valve solenoid coils with the
Manual override Manual override
Pin-type Plug connection (with/without inner thread) for connecting the supply
Pneumatic interface The pneumatic interface is the interface between the modular electrical
Pneumatic sub-base Pneumatic manifold sub-base for the valve sub-bases, with work
CPA valve terminal variant with sub-D plug via which all valve solenoid coils are centrally connected.
CPX terminal
on CPA valve terminals with MP, CP or AS-Interface connection.
ing the valves with compressed air and for conducting the exhaust air, as well as for connecting silencers.
electrical sub-base or the CPX pneumatic interface.
cables to the CPA valve terminal
periphery of the CPX terminal and the CPA pneumatics.
connections 2 and 4 and open or closed compressed air channel 1.
Sub-base Pneumatic manifold sub-base with open or closed compressed air
Val ve s ub- bas e Plate with single-solenoid, double-solenoid or mid-position valve.
channel for single-solenoid, double-solenoid or mid-position valves with work connections 2 and 4.
Tab. 0/5: Product-specific terms and abbreviations
XIV
Festo P.BE-CPA-EN en 0207c
System summary
Chapter 1
1-1Festo P .BE-CPA-EN en 0207c
1. System summary
Contents
1. System summary 1-1...............................................
1.1 Overview of variants 1-4.............................................
1.2 Description of components 1-7.......................................
1-2
Festo P.BE-CPA-EN en 0207c
1. System summary
Contents of this chapter This chapter provides an overview of the following for the
CPA valve terminal:
– the connection variants and components of the valve
terminal
– the maximum number of valve locations
– the identification code of the pneumatic components
– the connecting, display and operating elements.
Further information Information on the electric multipin can be found in the
brief description of the CPA valve terminal with multipin connection.
Festo P .BE-CPA-EN en 0207c
1-3
1. System summary
1.1 Overview of variants
Festo assists you in solving your automation tasks at machine level with CPA valve terminals. The modular structure of the CPA valve terminal for the CP system enables you to use the CPA valve terminals optimally in your machine or system.
Due to its compact structure the CPA valve terminal can be mounted close to the actuators to be actuated. Short com­pressed air tubing can therefore be used. System losses can therefore be minimized and the times required for pressuriz­ing and exhausting the tubing can be minimized. This enables very compact valves with high flow rate to be used, therefore helping to reduce costs.
CPA valve terminal with CPX terminal
This CPA valve terminal is available with 2 to max. 22 single­coil valve locations or up to max. 11 double-coil valve loca­tions. Maximum 22 valve coils can be actuated.
Fig. 1/1: CPA valve terminal with CPX terminal
1-4
Festo P.BE-CPA-EN en 0207c
1. System summary
Electrical connection variants of the CPA valve terminal
The CPA valve terminals are available with the following types of electrical connections:
1 MP connection
2 IC connection
1
3 CP connection
4 AS-Interface
connection
34
Fig. 1/2: Variants of the CPA valve terminal
2
CPA valve terminal with IC connection
Festo P .BE-CPA-EN en 0207c
This CPA valve terminal is available with 2 to max. 22 valve locations. The electrical connection of the valve solenoid coils is made via individual connector plugs. Maximum 44 valve coils can be actuated.
1-5
1. System summary
CPA valve terminal with MP connection
CPA valve terminal with CP connection
CPA valve terminal with AS-Interface connection
This CPA valve terminal is available with 2 to max. 22 single­coil valve locations or up to max. 11 double-coil valve loca­tions. Maximum 22 valve coils can be actuated. The electri­cal connection of the valve solenoid coils is made centrally via the multipin plug.
This CPA valve terminal is available with 2 to max. 16 single­coil valve locations or up to max. 8 double-coil valve loca­tions. Maximum 16 valve coils can be actuated. The connec­tion to the higher-order field bus node is made via special ready-to-use CP cables.
This CPA valve terminal is connected to the AS-Interface bus via special AS-Interfac e cables. It is available with two types of electrical connections:
– with additional power supply connection (load voltage
can be switched off separately).
– without additional power supply connection.
Both variants are available with 2 to max. 4 single-coil valve locations or up to max. 2 double-coil valve locations. Maxi­mum 4 valve coils can be actuated.
Sizes of the CPA valve terminal
1-6
All CPA valve terminal variants are available with micro valves (valve width 10 mm, CPA10) or with mini valves (valve width 14 mm, CPA14). Mixed operation with valves of both sizes in not possible on a CPA valve terminal.
Festo P.BE-CPA-EN en 0207c
1. System summary
1.2 Description of components
The CPA valve terminal consists of the following electrical components:
123
5
1
CPA valve terminal for the CP system: MP, CP or AS-Interface sub-base
2 The electrical manifold block
(manifold block EV1 occupies 1 address, EV2 occupies 2 addresses)
4
3 Electrical bridge with manual override
and LEDs
4 CPX adapter for fitting the CPX
pneumatic interface
5 CPA valve terminals for the CPX
terminal: CPX pneumatic interface
Fig. 1/3: Electrical components of the CPA valve terminal
Festo P .BE-CPA-EN en 0207c
1-7
1. System summary
The CPA valve terminal consists of the following pneumatic components:
1
9
3
78
Electrical bridge with manual
1
override and LEDs
2 Cover block
3 End plate cover or large surface-
mounted silencer
4 Right-hand end plate with supply
and exhaust connections
5 Additional supply plate or blanking
plate
2
3
4 5
6
6 Sub-base:
– with work connections – with/without pressure zone
separation
– in combination with supply plate
for the compressed air supply
7 Left-hand end plate with supply and
exhaust connections
8 CPX adapter for fitting the CPX
pneumatic interface
9 Valve sub-base with single-solenoid
or double-solenoid valves
Fig. 1/4: Pneumatic components of the CPA valve terminal
1-8
Festo P.BE-CPA-EN en 0207c
1. System summary
CPA valve terminal with
The max. number of valve locations on the CPA valve terminal variants is shown in the following table.
Max. number of valve locations
CPX terminalICconnectionMPconnectionCPconnection
AS-Inter­face connection
If only the manifold block E V1 is used (for valve sub-base with one solenoid coil)
If only the manifold block E V2 is used (for valve sub-base with two solenoid coils)
Maximum number of valve coils which can be actuated
*)InthecaseofCPAvalveterminalswithICconnection,themaximumnumberofvalvelocationsis
limited to 22 due to the tie rod.
22 —
11 —
22 44 22 16 4
*)
*)
22 16 4
11 8 2
Tab. 1/1: Maximum number of valve locations depending on the CPA valve terminal
variants
Festo P .BE-CPA-EN en 0207c
1-9
1. System summary
By means of the identification code, you can ascertain which valve sub-bases are fitted on your CPA valve terminal. This code is printed on the front of the valve sub-base.
Ident. code
B Valve sub-base, 5/3-way, mid position pr essurized
D Additional supply plate, for compressed air supply of three and more pressure
I Valve sub-base, 5/3-way, mid position exhausted
G Valve sub-base, 5/3-way, mid position blocked
H Valve sub-base, two 3/2- way, control side 12 in basic position open, control
J Valve sub-base, 5/2- way, double-solenoid
K Valve sub-base, two 3/2-way, single-solenoid, in basic position blocked
M Valve sub-base, 5/2-way, single-solenoid
N Valve sub-base, two 3/2-way, single-solenoid, in basic position open
T Sub-base for pressure zone separation, compressed air channel (1) blocked
Y Valve sub-base, 5/2-way, single-solenoid on two-coilvalve location
Pneumatic components
zones
side 14 in basic position closed
T ab. 1/2: Ident. code of the pneumatic components
Further information on the valve sub-bases can be found in Appendix A.
1-10
Festo P.BE-CPA-EN en 0207c
1. System summary
You will find the following connecting, display and operating elements on the CPA valve terminal:
CPA valve terminalwith IC connection
CPA valve terminal with MP, CP or AS-Interface connection or with CPX terminal
1 1
5
4
1
Manual override (per pilot solenoid, locking or non-locking)
3
2 Clip (only with non-locking manual override)
5
2
4
3
3 Supply connections (1, 12/14) and exhaust connections (3/5) on the right-hand
end plate
4 Work connections (2, 4) per valve sub-base
5 Supply connection (1) and exhaust connections (3/5, 82/84) on the left-hand
end plate
Fig. 1/5: Pneumatic connecting and operating elements of the CPA valve terminal
Festo P .BE-CPA-EN en 0207c
1-11
1. System summary
You will find the following electrical connecting and display elements on the CPA valve terminal:
1
5
1 Ready-to-use cable with socket for connectong a valve
solenoid coil
2 Clip with identification field (per cable socket)
3 Yellow LED per cable socket, shows signal status of the
pilot solenoids
4 Terminal lugs of pilot solenoid coil 12
5 Terminal lugs of pilot solenoid coil 14
2
3
4
1-12
Fig. 1/6: Electrical connecting and display elements of the
CPA valve terminal with IC connection
Festo P.BE-CPA-EN en 0207c
1. System summary
You will find the following electrical connecting and display elements on the CPA valve terminal with MP connection:
1 2
Festo P .BE-CPA-EN en 0207c
3
1 Identification clips
2 Yellow LED, signal status displays of the pilot solenoids
3 Sub-D multipin plug (25-pin)
Fig. 1/7: Electrical connecting and display elements of the
CPA valve terminal with MP connection
1-13
1. System summary
You will find the following electrical connecting and display elements on the CPA valve terminal with CP connection:
12
3
6
5
4
1 Green LED, status display of the CP connection
2 Incoming CP cable
3 Yellow LED, signal status display of the pilot solenoids
4 Continuing CP cable
1-14
5 Earth/ground connection
6 Identification clips
Fig. 1/8: Electrical connecting and display elements of the
CPA valve terminal with CP connection
Festo P.BE-CPA-EN en 0207c
1. System summary
You will find the following electrical connecting and display elements on the CPA valve terminal with AS-Interface con­nection:
1
2
3
8
7
6
5
Festo P .BE-CPA-EN en 0207c
4
1 AS-Interface cable cap
2 Identification clips of the valve sub-bases
3 Yellow LED, signal status display of the pilot solenoids
4 Identification clips of the AS-Interface connection
5 AS-Interface bus socket with yellow bus cable
6 Earth/ground connection
7 Green LED, status display of the CP connection
8 Cable socket for additional supply with black additional
supply cable (optional)
Fig. 1/9: Electrical connecting and display elements of the
CPA valve terminal with AS-Interface connection
1-15
1. System summary
You will find the following electrical connecting and display elements on the CPA valve terminal with CPX terminal:
1 23 4
1-16
1 Red LED, fault display of the pneumatic interface
2 DIL switch for setting the number of valve addresses
3 Identification clips
4 Yellow LED, signal status displays of the pilot solenoids
Fig. 1/10: Electrical connecting and display elements of the
CPA valve terminal with CPX terminal
Detailed instructions on the CPX pneumatic interface can be found in the supplementary manual for the CPX I/O modules (P.BE-CPX-EA-..).
Festo P.BE-CPA-EN en 0207c
Fitting
Chapter 2
2-1Festo P .BE-CPA-EN en 0207c
2. Fittin g
Contents
2. Fitting 2-1........................................................
2.1 Fitting variants 2-4.................................................
2.1.1 Fitting onto a wall 2-5.......................................
2.1.2 Hat rail fitting 2-6...........................................
2-2
Festo P.BE-CPA-EN en 0207c
2. Fitting
Contents of this chapter This chapter explains how you should fit and dismantle the
complete CPA valve terminal.
Further information Special information on replacing or adding pneumatic compo-
nents can be found in chapter 5.
CPA valve terminal with CPX terminal:
– Information on fitting the CPA valve terminal with CPX
terminal can be found in the CP system manual.
– Information on fitting and dismantling the module elec-
tronics and sub-bases can be found in the manual “CPX I/O modules” and in the leaflet supplied with the product in the case of modules and components ordered at a later stage.
Festo P .BE-CPA-EN en 0207c
2-3
2. Fittin g
2.1 Fitting variants
Warning
Switch off the following power supplies before undertaking installation and/or maintenance work:
• the compressed air supply
• the power supply for the valve solenoid coils.
You can thereby avoid:
– uncontrolled movements of loose tubing,
– unexpected movements of the connected actuators,
– non-defined switching states of the electronic compo-
nents.
The CPA valve terminal has already been p repared for incor­poration in a system or machine using one of the following fitting variants:
2-4
– fitting onto a wall
– fitting onto a hat rail.
Please note
Hat rails fitted with CPA14 valve terminals can break if they are subjected to vibration which exceeds the following values:
– 0.15 mm path at 10...58 Hz – 2 g acceleration at 58...150 Hz. This can cause damage to the CPA valve terminal or to your
machine or system.
• Use the wall fitting for CPA14 valve terminals.
Festo P.BE-CPA-EN en 0207c
2. Fitting
2.1.1 Fitting onto a wall
Fitting the CPA valve terminal with CPX terminal onto a wall is
described in the system manual P.BE-CPX-SYS-... .
Proceed as follows:
1. Make sure t hat the fastening surface can supp or t the weight of the CPA valve ter min al (weights see Appendix A).
2. Make sure there is sufficient space for connecting the power cables and compressed air tubing.
3. Drill four mounting holes in the fastening surface (distance between holes see table).
4
4
CPA10 t erminal
1 66.3 mm
2 23 mm
3 10.6 mm x number of sub-bases
4 4 holes for fitting onto a wall
Fig. 2/1: Position of the fastening holes
Festo P .BE-CPA-EN en 0207c
1
32
CPA14 terminal
2
1 76.1 mm
2 26 mm
3 14.6 mm x number of sub-bases
4 4 holes for fitting onto a wall
4
2-5
2. Fittin g
2.1.2 Hat rail fitting
4. Fasten the CPA valve terminal with four M4 screws of sufficient length to the fastening surface (tightening torque 0.8 Nm).
Fitting the CPA valve terminal with CPX terminal onto a hat rail
is described in the system manual P.BE-CPX-SYS-... .
For fitting the CPA valve terminal onto a hat rail you will re­quire fitting kit type CPA-BG-NRH. This kit consists of 2 M4x10 screws and 2 clamping elements.
Proceed as follows:
1. Make sure tha t the fastening surface can supp ort the weight of the CPA valve ter mi n al (weights see Appendix A).
2-6
2. Fit the hat rail (support rail as per EN 50022 – 35x7.5; width 35 mm, height 7.5 mm). Make sure there is suffi­cient space for connecting the power cables and com­pressed air tubing.
3. Fasten the hat rail to the fastening surface at intervals of approx. every 100 mm.
4. Mount the hat rail clamping units on the end plates of the CPA valve terminal (see diagram).
5. HangtheCPAvalveterminalontothehatrail(seearrowA).
6. Swing the CPA valve terminal onto the hat rail (see arrow B). Make sure that the clamping element lies horizontally to the hat rail.
7. Fasten the CPA valve terminal against tilting or sliding by tightening the locking screws on both sides with 1.3 Nm.
Festo P.BE-CPA-EN en 0207c
2. Fitting
1 Hat rail
2 Self-cutting
M4x10 screw of the hat rail clamping unit
3 Clamping
element of the hat rail clamping unit
Fig. 2/2: Fitting the CPA valve terminal onto a hat rail
(A)
1
(B)
2
3
Festo P .BE-CPA-EN en 0207c
2-7
2. Fittin g
2-8
Festo P.BE-CPA-EN en 0207c
Installation
Chapter 3
3-1Festo P .BE-CPA-EN en 0207c
3. Installation
Contents
3. Installation 3-1...................................................
3.1 Preparing the compressed air 3-4.....................................
3.1.1 Operation with non-lubricated compressed air 3-4................
3.1.2 Operation with lubricated compressed air 3-5....................
3.2 General connecting methods 3-7......................................
3.2.1 Laying the tubing 3-7........................................
3.2.2 Basic information 3-8........................................
3.3 Connecting the CPA valve terminal 3-9.................................
3.3.1 Auxiliary pilot air 3-9........................................
3.3.2 CPAvalveterminalwithpressurezoneseparation 3-12.............
3.3.3 Connecting the supply, exhaust and work lines 3-14...............
3.3.4 Connecting the electric cables 3-20.............................
3.4 Address assignment of the valves 3-24..................................
3-2
Festo P.BE-CPA-EN en 0207c
3. Installation
Contents of this chapter This chapter describes the tubing and cabling of the CPA
valve terminal. The following belong here:
– General instructions on preparing the compressed air and
on connecting the tubing
– Instructions on operation with external/internal auxiliary
pilot air
– Instructions on operating CPA valve terminals with pres-
sure zone separation
– Fitting the pin-type inserts and QS screw connectors
– Connecting the power supply
– Earthing the CPA valve terminal with CP or AS-Interface
connection
– Address assignment of the valves
Further information Information on power supply to the CPA valve terminal with
CPX terminals can be found in the CPX system manual.
Instructions on the electrical connections of the CPA valve terminal with multipin or AS-Interface connection can be found in the leaflet supplied with the product.
Information on connecting the CPA valve terminal with CP connection can be found in the CP system manual.
Information on connecting the CPA valve terminal with CPX terminal can be found in the CP system manual.
Festo P .BE-CPA-EN en 0207c
3-3
3. Installation
3.1 Preparing the compressed air
Caution
Dirty or incorrectly lubricated compressed air will reduce the service life of the valve terminal.
3.1.1 Operation with non-lubricated compressed air
Caution
Too much residual oil content in the compressed air will reduce the service life of the valve terminal.
– If bio-oils are used (oils with synthetic ester or true ester
basis, e.g. rape oil methylester) the residual oil content must not exceed 0.1 mg/m
– If mineral oils are used (e.g. HLP oils as per DIN 51524
parts 1 to 3) or corresponding oils on a polyalphaolefine basis (PAO), the residual oil content must not exceed
3
5mg/m
(see ISO 8573-1 class 4).
You will thereby avoid functional damage of the valves.
3
(see ISO 8573-1 class 2).
3-4
Excessive residual oil cannot be permitted irrespective of the compressor oil, as otherwise the basic lubrication will be washed out d uring the course of time.
Festo P.BE-CPA-EN en 0207c
3. Installation
3.1.2 Operation with lubricated compressed air
Please note
Please use non-lubricated air in your system if possible in order to protect the environment. Festo pneumatic valves and cylinders have been designed so that, if used as in­tended, they will not require additional lubrication and will still achieve a long service life.
Please note the following instructions if lubricated com­pressed air must be used. The compressed air prepared with the compressor must correspond in quality to non-lubricated compressed air. If possible, do not operate the complete system with lubricated compressed air. If possible, always install the lubricators di­rectly in front of the consuming cylinder.
Festo P .BE-CPA-EN en 0207c
Caution
Incorrect additional oil and too much residual oil content in the compressed air will reduce the service life of the valve terminal.
– Use Festo special oil OFSW-32 or the other oils listed in
the Festo catalogue (as per DIN51524-HLP32, basic viscosity 32cST at 40 °C).
– The additional lubrication must not exceed 25 mg/m
(ISO 8573-1 class 5).
– Make sure that the lubricator setting is correct
(see following section).
You will thereby avoid functional damage of the valves.
Setting the lubricator
With the machine running (typical operating status) 0.2 to max. 1 drop/min. or 0.5 to 5 drops/1000 l air.
3
3-5
3. Installation
Checking the lubricator setting
Proceed as follows:
• Check the service unit in respect of condensate and lubri-
cator setting twice a week.
1. Ascertain the cylinder which is furthest from the lubricator.
2. Ascertain the valve terminal which controls this cylinder.
3. Remove the silencer, if fitted, from connection 3/5.
4. Hold a piece of white cardboard 10 cm in front of the exhaust port.
5. Let the system run for a short period.
– There must only be a slight yellow colouring on the
cardboard. If oil drops out, this is an indication that too much oil has been used.
3-6
A further indication of excessive lubrication is the colouring or status of the exhaust silencer. A distinctly yellow colouring of the filter element or drops of oil on the silencer indicate that the lubricator setting is too high.
Festo P.BE-CPA-EN en 0207c
3. Installation
3.2 General connecting methods
Warning
Switch off the following power supplies before undertaking installation and/or maintenance work:
• the compressed air supply
• the power supply for the valve solenoid coils.
You can thereby avoid:
– sudden uncontrolled movements of loose tubing,
– unexpected movements of the connected actuators,
– non-defined switching states of the electronic compo-
nents.
3.2.1 Laying the tubing
Festo P .BE-CPA-EN en 0207c
If elbow screw connectors or multiple distributors are used, the airflow will be reduced slightly.
3-7
3. Installation
3.2.2 Basic information
Connecting
1. Push tubing (B) as far as possible into the tubing connec­tion of the pin types or screw connector. If necessary, press down locking ring (A).
2. For reasons of clarity, group the tubing together with:
–tubingstrapsor
– multiple hose holders.
Removing
1. Press down the blue locking ring (A) of the screw con­nector.
1 Pin-type insert
2 Pin-type adapter
(with threaded connection)
3 QS screw
connector
Fig. 3/1: Tubing variants
3-8
2. Pull out tubing (B).
3. Seal unused connections with blind plugs or threaded blind plugs (C).
Connecting
1 2
3
Removing
Festo P.BE-CPA-EN en 0207c
3. Installation
3.3 Connecting the CPA valve terminal
Seal the work connections (2 or 4) with blind plugs or threaded blind plugs on sub-bases fitted with blanking plates.
In order to guarantee the optimum efficiency of your CPA valve terminal, we recommend in the following cases that you connect the compressed air tubing and, if necessary, also the exhaust air tubing on both sides:
– when large volume cylinders are operated at high speeds,
– when several valves are switched simultaneously to the
flow position.
3.3.1 Auxiliary pilot air
Festo P .BE-CPA-EN en 0207c
Caution
– If possible, operate the CPA valve terminal with non-
lubricated auxiliary pilot air (connections 12/14). Other­wise observe the instructions in the section “Preparing the compressed air.”
– With CPA valve terminals with internally branched auxili-
ary pilot air, the above mentioned instruction also applies to the supply air (connection 1).
With CPV valve terminals with two pressure zones and in­ternally branched auxiliary pilot air:
– Due to the internally branched auxiliary pilot air in the
right-hand end plate, the pressure in the right-hand pressure zone must be 3...8 bar.
The CPA valve terminal can be operated with internal or exter­nal pilot air, depending on the right-hand end plate. You can ascertain the auxiliary pilot air variant for which your CPA valve terminal is equipped by the type designation on the right-hand end plate (see table).
3-9
3. Installation
CPA valve terminal Right-hand end plate type
With external pilot air CPA..-EPR-S
With internal pilot air CPA..-EPR
Tab. 3/1: End plates for internal or external pilot air
Internal pilot air If the supply pressure of your CPV valve terminal lies between
3...8 bar, you can operate the terminal with internally
branched auxiliary pilot air. In this case the auxiliary pilot air will be taken from connection 1 in the right-hand end plate.
If the CPA valve terminal with internal pilot air is used, the centre connection must be fitted with a blind plug (see dia­gram).
3-10
1
1 Seal connection with a blind plug
Fig. 3/2: Internal pilot air
Festo P.BE-CPA-EN en 0207c
3. Installation
External pilot air If the supply pressure of your CPA valve terminal does not lie
between 3...8 bar, you must operate the terminal with exter­nal pilot air. In this case, the auxiliary pilot air is supplied ex­ternally via connection 12/14.
Please note
• Used regulated pilot air (3...8 bar). Reliable and faultless
operation of the CPA valve terminal is then possible.
• If your CPA valve terminal is fitted with valve sub-bases
with Ident. code H, K or N (3/2-way valves), the external pilot air must be set to correspond with the supply pres­sure at which these valve are operated (see diagrams).
1 Control pressure
12/14 (bar)
3
2 Work pressure P1
(bar)
3 Start-up pressure
1
2
Fig. 3/3: External pilot air diagram for valve sub-bases CPA10 with Ident. codes N, K, H
Festo P .BE-CPA-EN en 0207c
3-11
3. Installation
1 Control pressure
12/14 (bar)
2 Work pressure P1
(bar)
3 Start-up pressure
1
2
Fig. 3/4: External pilot air diagram for valve sub-bases CPA14 with Ident. codes N, K, H
Note that the regulated external pilot air for all valve sub­bases on the CPV valve terminal is supplied or branched via common tubing on the right-hand end plate. This also applies if the CPA valve terminal is operated with different pressure zones (see Fig. 3/5).
3.3.2 CPAvalveterminalwithpressurezoneseparation
The CPA valve terminal can be fitted with the following number of pressure zones depending on the connection variant:
3
3-12
Electrical connection variants
Pressure zones 1...12 1...9 1...3
Tab. 3/2: Maximum number of pressure zones
The pressure zones are implemented by means of special sub-bases which block the compressed air channel (1).
IC, MP or
CPX
CP AS-Interface
Festo P.BE-CPA-EN en 0207c
3. Installation
Valve sub-bases, which are fitted onto sub-bases with pres­sure zone separation, are supplied with compressed air which is provided to the left of this sub-base (see Fig. 3/5).
You can ascertain the number of pressure zones with which your CPA valve terminal is equipped by the designation on the special sub-base (grey dot above work connection 2).
CPA valve terminal with two pressure zones
These CPA valve terminals have a sub-base with pressure zone separation. The left-hand pressure zone is supplied with compressed air via connection 1 on the left-hand end plate; the right-hand pressure zone is supplied via connection 1 on the right-hand end plate.
CPA valve terminal with more than two pressure zones
Festo P .BE-CPA-EN en 0207c
A sub-base with pressure zone separation is required for each pressure zone. The outer pressure zones are supplied with compressed air via connection 1 on the end plates, the remaining pressure zones are supplied with compressed air via connection 2 on the sub-bases which are fitted with addi­tional supply plates (see diagram). As an additional aid to remove the exhaust air, a silencer can be fitted at connection 4 on these sub-bases. If connection 4 is not used, it must be sealed with a blind plug.
3-13
3. Installation
1
2
4
5
3
Additional pressure supply plate
1
2 Designation of the sub-bases with pressure zone separation (grey dot)
3 Pressure zone 1 (compressed air supply via connection 1 on the left-hand
end plate)
4 Pressure zone 2 (compressed air supply via connection 2 on the sub-base
with additional pressure supply plate)
5 Pressure zone 3 (compressed air supply via connection 1 on the right-hand
end plate)
Fig. 3/5: Example: Pressure zone separation and external pilot air
3.3.3 Connecting the supply, exhaust and work lines
Fit the tubing as described below. Then lay the pneumatic tubing.
3-14
Festo P.BE-CPA-EN en 0207c
3. Installation
Proceed as follows:
1. Use the following table for selecting the correct pin-type inserts:
Connection code ISO 5599
1 3/5
With threaded connection also connec­tions 12/14 and 82/84
2or4 12/14 82/84
CPA14 terminal: Values in brackets for 12/14 or 82/84
With threaded connection not 12/14 or 82/84
Tubin g CPA 10 terminal
Pin-type size
Compressed air/vacuum, exhaust
Work air/ vacuum, additional pressure supply, pilot air exhaust
Tubing connections:
QSP14-6 QSP14-8 QSP14-1/4-U QSP14-5/16-U
Blind plug:
QSP14-PTB
Threaded connection:
CPA10-PTE-1/8-M5 CPA10-PTE-1/8NPT-10-32-UNF
Blind screw:
B-1/8 B-1/8NPT
Tubing connections:
QSP10-4 QSP10-6 QSP10-5/32-U QSP10-3/16-U
Blind plug:
QSP10-PTB
Threaded connection:
CPA10-PTA-M5 CPA10-PTA-M7 CPA10-PTA-10-32-UNF
Blind screw:
B-M5-B B-M7 (only connection 2/4)
Silencer:
UC-QS-6H UC-QS-..H
CPA14 terminal Pin-type size
Tubing connections:
QSP18-8 QSP18-10 QSP18-5/16-U QSP18-3/8-U
Blind plug:
QSP18-PTB
Threaded connection:
CPA14-PTE-1/4-M5 CPA14-PTE-1/4NPT-10-32-UNF
Blind screw:
B-1/4 B-1/4N PT
Tubing connections:
QSP14-6 (QSP10-4) QSP14-8 (QSP10-6) QSP14-1/4-U (QSP10-5/32-U) QSP14-5/16-U (QSP10-3/16-U)
Blind plug:
QSP14-PTB (QSP10-PTB)
Threaded connection:
CPA14-PTA-1/8 CPA14-PTA-1/8NPT
Blind screw:
B-1/8 (B-M5-B) B-1/8N
Tab. 3/3: Pin-type inserts
Festo P .BE-CPA-EN en 0207c
3-15
3. Installation
2. Check that the seal of the pin-type is greased. If necess­ary, grease the seal with Festo F2 grease.
3. Press the pin type inserts into the holes in the sub-base.
4. Make sure that the pin-type inserts are seated as far as possible in the holes. Measure here the distance between the connecting level and the locking ring of the pin-type inserts (see diagram).
1
3-16
1 5.5 mm (CPA10) or 6.5 mm (CPA14)
Fig. 3/6: Checking the pin-type fitting
Festo P.BE-CPA-EN en 0207c
3. Installation
5. Secure the pin type inserts with the clamping springs (see diagram).
1 Clamping springs
12
2 Pin-type inserts
Fig. 3/7: Fitting and removing the pin-type inserts
6. In the case of pin type inserts with threaded connection, screw in the connectors.
7. Fit the tubing as shown in Fig. 3/1.
Festo P .BE-CPA-EN en 0207c
3-17
3. Installation
Observe the following instructions on installing the pneu­matic components. Only then can you guarantee faultless operation.
– If you have several systems with central ducted exhaust
air, use non-return valves in the common exhaust lines in order to prevent functional impairment due to back pressures.
1 CPA valve
terminal 1
1
2 Common 3/5
3 Central 82/84
4 Central 3/5
5 CPA valve
terminal 2
6 Common 82/84
Fig. 3/8: Common lines with non-return valves
– In the case of CPA valve terminals with two or more pres-
sure zones and auxiliary pilot air branched internally on the right-hand side, the pressure for the pressure zone on the outside right must be 3...8 bar.
34 5
2
6
2
6
2
3-18
Festo P.BE-CPA-EN en 0207c
3. Installation
Vacuum/low pressure operation
The CPA valve terminal can be operated with vacuum or low pressu re > – 0.9 ... < 3 bar under the following conditions:
– regulated auxiliary pilot air must be supplied separately.
– the CPA valve terminal must be fitted with the following
valve sub-bases:
– 5/2-way valve, single-solenoid (Ident. code M)
– 5/2-way valve, double-solenoid (Ident. code J)
– 5/3-way valves in mid-position pressurized
(Ident. code B), blocked (Ident. code G) or exhausted (Ident. code E).
Please note
Valve sub-bases with 3/2-way valves (Ident. code N, K or H) cannot be used for vacuum or low-pressure operation. If your CPA valve terminal is fitted with these valve sub­bases, a separate pressure zone must be provided for these valves (supply pressure see Fig. 3/3 for CPA10 or Fig. 3/4 for CPA14).
Festo P .BE-CPA-EN en 0207c
3-19
3. Installation
3.3.4 Connecting the electric cables
Information on the connection procedure as well as on cables and current requirements can be found in the manual “CP System, installation and commissioning.”
Warning
Use only power units which guarantee reliable isolation of the operating voltages as per IEC 742/EN 60742/VDE 0551 with at least 4 kV isolation resistance (Protected Extra Low Voltage PELV). Switch power packs are permitted, provid­ing they guarantee reliable isolation in accordance with EN 60950/VDE 0805.
Please note: By the use of PELV power units, protection against electric shock (protection against direct and indirect contact) is guar­anteed with the Festo valve terminals in accordance with EN 60204-1/IEC 204. Safety transformers with the adjacent symbol must be used for supplying PELV networks. The valve terminals must be earthed to ensure that they function cor­rectly (e.g. EMC).
3-20
Please note
Check within the framework of your EMERGENCY STOP circuit, to ascertain the measures necessary for putting your machine/system into a safe state in the event of an EMERGENCY STOP (e.g. switching off the operating voltage for the valves and output modules, switching off the com­pressed air).
Earthing the CPA valve terminal with CPX terminal
Instructions on earthing the CPA valve terminal with CPX terminal can be found in the CPX system manual.
Festo P.BE-CPA-EN en 0207c
3. Installation
EarthingtheCPAvalveterminalwithCPorAS-Inter­face connection
Please note
Earth your CPA valve terminal.
• Connect the earth connection on the electrical sub-base
(see diagram) with low impedance (short cable with large cross-sectional area) to the earth potential.
In this way, you will avoid interference caused by electro­magnetic influences.
Festo P .BE-CPA-EN en 0207c
1
1 Earth/ground connection
Fig. 3/9: of the CPA valve terminal with CP connection
CPA valve terminal with IC connection
With this variant of the CPA valve terminal each valve solenoid coil is connected separately .
3-21
3. Installation
Use the ready-to-use connector socket KMYZ-7-24-...-LED from Festo for connecting the valve solenoid coils. The hold­ing current reduction for the valve solenoid coil and an LED are incorporated in the transparent plug of this connector socket. The LED indicates the switching status of the valve solenoid coils.
Please note
If the CPA valve terminal with IC connection is used at maximum operating temperature and 100 % switch-on duration, it must be operated wth current reduction. Use here the connector socket KMYZ-7-24-...-LED.
Connect the valve solenoid coils as follows:
1. Insert the socket onto the terminal lugs of the appropriate pilot solenoid or intermediate plug. The socket can be fittedturned180°.Makesurethatthecentringboltbe­tween the terminal lugs grips into the hole in the socket (see diagram).
3-22
2. Screw the socket together with the locking screw with
0.2 Nm.
Festo P.BE-CPA-EN en 0207c
3. Installation
1 Connector socket
2 Terminal lug of
valve solenoid
1
2
Fig. 3/10: Fitting the individual connector sockets
Festo P .BE-CPA-EN en 0207c
3-23
3. Installation
3.4 Address assignment of the valves
CPA valve termina l with MP, CP, AS-Interface connection or CPX terminal
– The addresses must be assigned in ascending order
without gaps.
– Depending on the manifold block, a valve location
occupies one address (CPA..-EV1) or two addresses (CPA..-EV2). You can ascertain which manifold blocks are fitted on your CPA valve terminal by means of the identification marking on the manifold block (see diagram).
3-24
1
Fig. 3/11: Marking the manifold blocks
– Counting begins from left to right, on the individual valve
plates from the rear to the front (see diagram).
Festo P.BE-CPA-EN en 0207c
3. Installation
– If a manifold block occupies 2 addresses, the following
applies:
– solenoid coil 14 occupies the lower-value address;
– solenoid coil 12 occupies the higher-value address.
1 Valve sub-base
with two solenoid
1
11
2
coils
2 Blanking plate
with manifold block EV2
3 Blanking plate
with manifold block EV1
4 Valve sub-base
with one solenoid coil
5 Addresses of
coil 12
6
5
14
14
14
12
12
12
101112
875402
14
14
12
9613
6 Addresses of
coil 14
4
Fig. 3/12: Example: Address assignment of CPA valve terminal with MP connection and
8 valve locations (top view)
CPA valve terminal with MP or AS-Interface connection
Connecting the MP or AS-Interface cable
34
Festo P .BE-CPA-EN en 0207c
Instructions on the electrical connections can be found in the leaflet supplied with the product.
3-25
3. Installation
CPA valve terminal with IC connection
• The addresses must be assigned in ascending order
without gaps
• Counting begins from left to right, on the individual valve
plates from the rear to the front (see diagram).
1 Valve sub-base
with two solenoid coils
0
42
7
5
8
2 Valve sub-base
with one solenoid coil
3 Blanking plate
1
3
6
9
12 3
Fig. 3/13: Address assignment of a CPA valve terminal with IC connection and 8 valve
locations (top view)
CPA valve terminal with CP connection
Connecting the CP cable
Instructions on the electrical connections can be found in the manual “CP system, general installation and commissioning,” chapter 3.
3-26
CPA valve terminal with CPX terminal
Instructions on the electrical connections can be found in chapter 3 of the system manual.
Festo P.BE-CPA-EN en 0207c
Commissioning
Chapter 4
4-1Festo P.BE-CPA-EN en 0207c
4. Commissioning
Contents
4. Commissioning 4-1................................................
4.1 Testing the valves 4-4...............................................
4.1.1 Checking the valve functions 4-5..............................
4.1.2 Checking the valve-cylinder combination 4-9....................
4.2 Eliminating faults 4-15...............................................
4.2.1 Impairment of function 4-15...................................
4.2.2 LED display of the valves 4-17..................................
4-2
Festo P.BE-CPA-EN en 0207c
4. Commissioning
Contents of this chapter This chapter describes the commissioning of the CPA valve
terminal. The following belong here:
– Checking the valve functions
– Operating the manual override
– Checking the valve-cylinder combination
– Eliminating faults
–TheassignmentoftheLEDs
Further information Commissioning of the CP system is described in the appropri-
atemanualfortheCPnode.
Commissioning of the CPX terminal is described in the ap­propriatemanualfortheCPXfieldbusnode.
Festo P .BE-CPA-EN en 0207c
4-3
4. Commissioning
4.1 Testing the valves
The CPA valve terminal should be commissioned as follows:
Commissioning variants
Preliminary test of the pneumatic tubing
Complete commissioning of the complete system
Actiivity
T esting the valve- cylinder­combination by meansof the manualoverride
Installing and connecting thecompletesystem. Program control via PLC/ industrial PC.
Tab. 4/1: Commissioning variants
Commissioning the pneumatic components by means of the manual override is described below.
4-4
Festo P.BE-CPA-EN en 0207c
4. Commissioning
4.1.1 Checking the valve functions
Manual override
Warning
Before actuating the manual override: Uncontrolled actuation of the valve solenoid coils can
cause the actuators to perform sudden unexpected movements which may cause injury to human beings and damage to property.
• Disconnect the power supply for the valve solenoid coils
from the relevant connections on the CPA valve terminal.
You will thereby avoid undesired actuation of the valve solenoid coils.
Before switching on the power supply: During commissioning, manual override actuations which
are in the switched state can cause actuators to perform sudden unexpected movements. These movements can cause injury to human beings and damage to proper ty.
• Make sure that all manual override actuations are in
their basic positions.
You will thereby avoid undefined switching states of the valves.
Festo P .BE-CPA-EN en 0207c
You should use the manual override especially when commis­sioning the pneumatic system, in order to check the function and operation of the valve or the valve-cylinder-combination.
By actuating the manual override, you can switch the valve without an electric signal. You only need to switch on the compressed air supply.
4-5
4. Commissioning
Type s of manual override
The manual override has been designed to be used as follows:
Types of manual override
Manual override with automatic reset (non-locking)
Locking manual override The manual override remains
Manualoverride covered No ma nual override function
Method of operation
After actuation the manual override is reset by a pneumatic spring.
actuated until it is reset by hand.
Tab. 4/2: Variants of the manual override
The following manual override variants are available for CPA valve terminals with MP, CP, AS-Interface connection or CPX terminal:
4-6
Festo P.BE-CPA-EN en 0207c
4. Commissioning
Locking manual override Non-locking manual override
1
3
2
1 Slide of locking manual override to
pilot solenoid 14
2 Slide of locking manual override to
pilot solenoid 12
Fig. 4/1: Manual override variants of the CPA valve terminal with MP, CP, AS-Interface
connection or CPX terminal
Both the locking and the non-locking types of manual over­ride can be used with CPA valve terminals with IC connection.
3 Push button of non-locking manual
override to pilot solenoid 14
4 Push button of non-locking manual
override to pilot solenoid 12
4
Festo P .BE-CPA-EN en 0207c
4-7
4. Commissioning
The diagram below shows the assignment of the manual over­ride to the valve solenoid coils.
1
2
1 Locking or non-locking push button of the manual
override to pilot solenoid 14
4-8
2 Locking or non-locking push button of the manual
override to pilot solenoid 12
Fig. 4/2: Position of the manual override on CPA valve
terminals with IC connection
Festo P.BE-CPA-EN en 0207c
4. Commissioning
4.1.2 Checking the valve-cylinder combination
Warning
If the build-up in pressure of the auxiliary pilot air is too slow or delayed, this may cause the actuators to perform sudden unexpected movements under the following condi­tions:
– when the compressed air is switched on with a safety
start-up valve (slow build up of pressure) and
– when there are electric signals (e.g. after EMERGENCY
STOP).
This can cause damage to the machine or system and even injury to human beings.
• Supply the auxiliary pilot air via the right-hand end plate
(3...8 bar).
The auxiliary pilot air must reach a pressure of 3...8 bar as soon as it is switched on, otherwise the valve cannot be guar­anteed to switch (see diagram). Ifthepressureislessthan3bar,theremaybeadelaybefore the valve is switched, in spite of an electric signal being pres­ent. The slow increase in pressure of the complete supply does not then affect the cylinder. Depending on the valve function, the cylinder would extend or retract suddenly.
Festo P .BE-CPA-EN en 0207c
4-9
4. Commissioning
82/84
42
14 12
1
12/14
53
2
3
1
12/14
1
1 Externally supplied auxiliary pilot air (3 to 8 bar),
branched from the safety start-up valve
2 Safety start-up valve (slow build up of pressure of
complete supply)
Fig. 4/3: Example of valve-cylinder combination with slow
increase in pressure of the complete supply
2
4-10
Festo P.BE-CPA-EN en 0207c
4. Commissioning
The table below shows the effects of slow start-up pressuriza­tion when there are electric signals.
External auxiliar y pilot air
Branched after the safety start-up valve
Branched in front of the safety start-up valve
Pressure increase in complete supply
slow slow after pressure
slow fast before pressure
Pressure increase in the auxiliary pilot air (12/14)
Tab. 4/3: Effects of slow start-up pressurization
Carrying out the test Proceed as follows:
1. Switch on the compressed air supply.
2. Check the functioning and operation of each individual valve-cylinder combination by actuating the manual override as shown in the following diagrams.
Please note
Incorrect actuation of the non-locking manual override can lead to malfunctioning or damage to the manual override.
• Use a blunt pencil for actuating the non-locking manual
override.
• Actuate the manual override only with max. 30 N.
Time point when a valve switches
increase with (1)
increase with (1)
Movement of the cylinder
fast
slow
Festo P .BE-CPA-EN en 0207c
3. In the case of the CPA valve terminal with locking manual override: After testing the valves, make sure that all man­ual override actuations are in their basic positions.
4. Switch off the compressed air supply after checking the valves.
4-11
4. Commissioning
Actuating the manual override with automatic reset (non-locking)
CPA valve terminal with MP, CP, AS-In­terface connection or CPX terminal
CPA valve terminal withIC connection
Operation Reaction of the
valve
Press down t he plunger of the manualoverride until the valve switches.
Please note InthecaseofCPAvalveterminals with IC connection: do not turn the pressed-down plunger, as the manualoverride will otherwise lock.
Hold the plunger of the manual override pressed down.
Release the plunger. The spring resets the plunger of the manual override to the starting position.
The valve: – moves to the
switching position
–remainsinthe
switch position
–returnstobasic
position (not in the case of double-sole­noid valve type J)
Tab. 4/4: Non-locking actuation of the manual override
4-12
Festo P.BE-CPA-EN en 0207c
4. Commissioning
Caution
During commissioning, manual override actuations which are in the switched state can cause actuators to perform sudden unexpected movements. These movements can cause injury to human beings and damage to proper ty.
• Make sure that double-solenoid valves (Ident. code J)
are in their basic positions again. To do this actuate manual override 12 of the relevant valve or apply current to pilot solenoid 12.
• Bring the locking manual override actuations into the
basic position again. The valve sub-bases with Ident. codes H, K and N are each fitted with two valves. With manual override 14 you can actuate the valve on control side 14; with manual override 12 you can actuate the valve on control side 12 (see switching symbols of the valve sub-bases Appendix B).
In this way you will avoid undefined switching states when commissioning the machine/system.
Festo P .BE-CPA-EN en 0207c
4-13
4. Commissioning
Actuating the manual override with stop (locking)
CPA valve terminal with MP, CP, AS-In­terface connection or CPX terminal
CPA valve terminal withIC connection
Operation Reaction of the
CPA valve terminalwith MP, CP, AS-Interface connection or CPX terminal:
• Press down the plunger of the
manual override as far as possible.
CPA valve terminalwith IC connection:
• Press down the plunger of the
manual override until the valve switches.Thenturnthe plunger in a clockwise direction as far as possible.
• Leave the plunger in the lower
position.
valve
The valve: – moves to the
switching position
–remainsinthe
switch position
CPA valve terminalwith MP, CP, AS-Interface connection or CPX terminal:
• Press the plunger of the
manual override into the inner position as far as possible.
CPA valve terminalwith IC connection:
• Turn the plunger in an anti-
clockwise direction as far as possible. Then release the plunger.
T ab. 4/5: Locking actuation of the manual override
4-14
–returnstobasic
position (not in the case of double-sole­noid valve type J)
Festo P.BE-CPA-EN en 0207c
4. Commissioning
4.2 Eliminating faults
4.2.1 Impairment of function
After switching on the compressed air supply or when subse­quently testing the individual valves, you can learn the follow­ing about the operating status of the pneumatic system:
Operating status of the pneumatic system
Valve posit ion Error treatment when the
compressed air supply has been switched off
Air escapes from ... – the common line connections
– the work line c onnections
– between the modules
The valve or the pneumatic system does not react –asexpected
– does not react
– does not react
–Basicposition
–Switchposition
–Basicposition
–Switchposition
–Switchposition
–Basicposition
• Checking the tubing
• Checking the tubing
• After switching on again, regulate
external pilot air to 3...8 bar.
• Check the tubing
• After switching on again check t he
operating pressure (e.g. pressure zones)
• Bring the locking manual override into
the basic position.
• InthecaseofCPAvalveterminalswith
3/2-way valves, check the external pilot pressure (if necessary set as a factor of the work pressure).
• Servicing required
• Check the controller
(apply pressure>3 bar at controller)
Tab. 4/6: Function impairment of the pneumatic system
Festo P .BE-CPA-EN en 0207c
4-15
4. Commissioning
The following conditions should be fulfilled, in order that the desired pneumatic operating states listed below can be achieved:
Desired
Prerequisites Remarks pneumatic operating status
Free of leakage – Tubing connected with care
Fast reaction Sufficient pressure supply via
Faultless Non-return valves in common
Two or mo re pressure zones
Vacuum operation/ low-pressure operation
EMERGENCY STOP of pressure zones
Slow start-up after EMERGENCY STOP
– Regulated auxiliary pilot air
pressure supply points
exhaust line
Limiting the pressure zones with a
separator plate.
Externallysupplied regulated
auxiliary pilot air (3...8 bar)
Guaranteeing the controller function
for the auxiliary pilot air despite the
complete supply being switc hed off.
If there a re control signals, the auxi-
liarypilot air must have a pressure of
3...8 bar.
Tab. 4/7: Pneumatic operating states
—
• Exhaust the CPA valve terminal at
the left and right-hand end plates (3/5)
Applies when severalsystemswith centrally ducted exhaust are used
Subsequent conversion possible
Controller can only be operated with pressure (between 3...8 bar) Vacuum/low-pressure operation not with 3/2-way valves
The controller regulates the auxiliary pilot air of all the valves sub-bases onaCPAvalveterminal.
4-16
Festo P.BE-CPA-EN en 0207c
4. Commissioning
4.2.2 LED display of the valves
There is a yellow LED for every valve solenoid coil. This LED indicates the switching status of the valve solenoid coil.
The status of the LED for the manual override on CPA valve terminals with MP, CP, AS-Interface connection or CPX ter­minal.
Note the assignment of the LEDs to the relevant manual override:
– Left-hand LED in the electric bridge for the front manual
override (12)
– Right-hand LED in the electric bridge for the rear manual
override (14)
1 LED and manual
override for pilot solenoid 14
2 LED and manual
override for pilot solenoid 12
2
1
Fig. 4/4: Assignment of the LED for the manual override on CPA valve terminals with MP,
CP, AS-Interface connection or CPX terminal
Festo P .BE-CPA-EN en 0207c
4-17
4. Commissioning
The status of the LED for the manual override on CPA valve terminals with IC connection is shown in the following dia­gram:
1 LED and manual
override for pilot solenoid 14
2 LED and manual
override for pilot solenoid 12
Fig. 4/5: Assignment of the LED for the manual override on CPA valve terminals with
IC connection
1
2
The LED indicates the switching status of the valve solenoid coils. This is explained in the following table.
LED
Switching position of the
Meaning
valve
Yellow out Basic position Logical 0 (no signal)
Yellow alight
*) With double-solenoid valves (Ident code J) the LED lights up only when the signal is present.
*)
– Switch position
–Basicposition
or
Logical1(signalpresent)
Logical 1 but: – operating voltage of outputs below per-
mitted tolerance range (20.4...26.4 V DC)
– compressed air supply not OK
or
– pilot exhaust blocked
or
– servicing required
Tab. 4/8: Meaning of the LED display
4-18
Festo P.BE-CPA-EN en 0207c
Maintenance and conversion
Chapter 5
5-1Festo P .BE-CPA-EN en 0207c
5. Maintenance and conversion
Contents
5. Maintenance and conversion 5-1.....................................
5.1 General precautionary measures 5-4..................................
5.2 Dismantling the CPA valve terminal 5-5.................................
5.3 Replacing CPA valve terminal components 5-9...........................
5.3.1 Replacing valve sub-bases, blanking plates or
additional supply plates 5-9..................................
5.3.2 Replacing the large surface-mounted silencer 5-11................
5.3.3 Replacing the end plate, sub-base or manifold block 5-12...........
5.4 Conversion work on the CPA valve terminal 5-19..........................
5.4.1 Conversion from non-locking to locking/non-locking
manual override 5-19.........................................
5.4.2 Conversion to internal or external pilot air 5-21....................
5.4.3 Converting the CPA valve terminal to different pressure zones 5-22...
5.4.4 Conversion of valve location for actuating one or
two solenoid coils 5-24.......................................
5.5 Adding/removing valve locations 5-25..................................
5-2
Festo P.BE-CPA-EN en 0207c
5. Maintenance and conversion
Contents of this chapter This chapter deals with the maintenance and conversion of
the CPA valve terminal. The following applies here:
– Replacing or removing components in valve locations
such as valve sub-bases, blanking plates or additional pressure supply plates.
– Replacing the large surface-mounted silencer
– Replacing end plates, sub-bases or manifold blocks
– Modifying the type of manual override
– Conversion of the auxiliary pilot air to internal or external
pilot air
– Conversion of valve locations for actuating one or two
valve solenoid coils
– Adding or removing valve locations
Further information Information on fitting/dismantling the CPA valve terminal
with CPX terminals can be found in the CPX system manual.
Information on the electrical connections of the CPA valve terminal with a CPX terminal can be found in the CPX system manual.
Instructions on the electrical connections of the CPV valve terminal with multipin or AS-Interface connection can be found in the leaflet supplied with the product.
Information on connecting the CPA valve terminal with CP connection can be found in the CP system manual.
Festo P .BE-CPA-EN en 0207c
5-3
5. Maintenance and conversion
5.1 General precautionary measures
Warning
Switch off the following power supplies before undertaking installation and/or maintenance work:
• the compressed air supply
• the power supply for the valve solenoid coils.
You can thereby avoid:
– uncontrolled movements of loose tubing,
– unexpected movements of the connected actuators,
– non-defined switching states of the electronic compo-
nents.
5-4
Festo P.BE-CPA-EN en 0207c
5. Maintenance and conversion
5.2 Dismantling the CPA valve terminal
Providing the CPA valve terminal is easily accessible and if the following conditions are fulfilled, it is not necessary to dismantle the CPA valve terminal:
– when replacing or removing components in valve loca-
tions.
– when adding components, providing it is not necessary
to replace or insert sub-bases or manifold blocks.
Loosening the electrical connections
Connecting variants Procedure
CP connection 1. Mark the incoming and the continuingCP cable.
2. Loosen the union nuts of the CP cable.
3. Pullthe CP cable away from the sub-base.
MP connection 1. Loosen the diagonally offset fastening screws of the sub-D multipin plug.
2. Pull the sub-D plug away from the sub-base.
AS-Interface connection 1. Loosen the fastening screws of the AS-Interface bus socket andif
applicable of the additional supply.
2. Pullthe socketsaway from the sub-base.
IC connection 1. Mark a ll the connector plugs of the valve solenoids.
2. Loosen the locking screws on the connector plugs.
3. Pull the plugs carefully away from the terminal lugs.
CPX terminal 1. Mark all electrical connection cables.
2. Loosen and remove these cables.
Tab. 5/1: Removing electrical connections
Festo P .BE-CPA-EN en 0207c
5-5
5. Maintenance and conversion
Loosening the pneumatic connections
Warning
If the pneumatic tubing is under pressure when the ter­minal is dismantled, it may perform sudden unexpected movements and thereby cause injury to anybody standing nearby.
• Switch off the compressed air supply before disconnect-
1. Mark all pneumatic tubing.
2. Press down the blue clamping ring of the pin type or
3. Pull the pneumatic tubing away from the pin type or
ing the pneumatic tubing on the CPA valve terminal.
screw connector.
screw connector.
5-6
Festo P.BE-CPA-EN en 0207c
5. Maintenance and conversion
Loosening the CPA valve terminal fitted onto a wall
1. Prevent the hanging CPA valve terminal from falling down
2. Loosen the fastening screws as shown in the following
before you loosen it from the fastening surface.
diagram.
CPA variants
Fastening
CPAvalve terminal: – 2 M6 screwson both the left and right-hand
end plates.
CPA te rminal with CPX terminal: – One screw on the left-hand end plate and 2
screws on the right-hand end plate of the CPA
valve terminal. – 2 screws on the CPX pneumatic interface – 2 screws on the left-hand end plate of the CPX
terminal.
T ab. 5/2: Removing the CPA valve terminal fitted onto a wall
3. RemovetheCPAvalveterminalfromthefastening surface.
Festo P .BE-CPA-EN en 0207c
5-7
5. Maintenance and conversion
Loosening the CPA valve terminal fitted onto a hat rail
1. Loosen the locking screw of the hat rail clamping unit on
2. Swing the CPA valve terminal forwards from the hat rail
3. Lift the CPA valve terminal off the hat rail (see diagram,
1 Hat rail
2 Clamping
element of the hat rail clamping unit
the left and right-hand end plates (see diagram). Make sure that the clamping element lies horizontally to the hat rail.
(see diagram, arrow A).
arrow B).
1
A
3 Locking screw of
the hat rail clamping unit
Fig. 5/1: Dismantling the CPA valve terminal
5-8
B
2
3
Festo P.BE-CPA-EN en 0207c
5. Maintenance and conversion
5.3 Replacing CPA valve terminal components
Components on the valve sub-bases can easily be removed for maintenance and conversion work.
The following components can be mounted on one sub-base:
–onevalvesub-baseor
–oneblankingplateor
– one additional supply plate.
Please note
Only one valve sub-base with a solenoid coil (single-sole­noid valve, Ident. code M) can be fitted in a valve location with manifold block EV1. Valve sub-bases with two sole­noid coils may only be fitted to a valve location with mani­fold block EV2.
5.3.1 Replacing valve sub-bases, blanking plates or additional supply plates
Before removing a valve sub-base from a CPA valve terminal with IC connection, you must first carry out the following:
1. Mark the valve sub-base to be removed with the valve solenoid coils to which the connector plug belongs.
2. Loosen the locking screws on the connector plugs of the valvesub-basetobereplaced.
3. Pull the plugs carefully away from the terminal lugs.
Festo P .BE-CPA-EN en 0207c
5-9
5. Maintenance and conversion
Loosening the components
1. Loosen the fastening screws of the relevant components
2. Remove the component from the sub-base of the CPA
(position of the fastening screws see diagram). Use a slim screwdriver to do this.
valve terminal.
1 CPA valve
terminal with MP, CP, AS-Interface connection or CPX terminal
12
2 CPA valve
terminal with IC connection
Fig. 5/2: Removing the valve sub-bases
Fitting the components
1. Make sure the seal is not damaged.
2. Replace the seal if it is damaged.
5-10
3. Make sure that the seal is seated correctly. It must lie in the recess in the sub-base.
Festo P.BE-CPA-EN en 0207c
5. Maintenance and conversion
4. Fitting valve sub-bases on CPA valve terminals with MP,
5. Place the component on the sub-base.
6. Screw the component at first only slightly and then
Beforefittingavalvesub-baseontoaCPAvalveterminalwith IC connection, you must first carry out the following:
1. Carefully insert the marked IC connector plug onto the
2. Tighten the locking screws on the connector plugs with
CP, AS-Interface connection or CPX terminal: Carefully clip the electric bridge onto the new valve sub­base. Make sure that the connector plugs of the solenoid coils do not break off.
tighten with: – CPA10: 0.2 Nm (+ 0.05 Nm) – CPA14: 0.3 Nm (+ 0.1 Nm)
terminal lugs of the relevant solenoid coils.
max. 0.2 Nm.
5.3.2 Replacing the large surface-mounted silencer
Proceed as follows:
1. Loosen the four fastening screws of the large surface­mounted silencer.
2. Remove the silencer from the end plate.
3. Replace the large surface-mounted silencer.
4. Check the seal between the end plate and the silencer for damage or dirt. Replace the seal if it is damaged.
5. Make sure that the seal is seated correctly. It must lie in the recess in the end plate.
6. Place the new silencer on the end plate.
7. Fasten the silencer only with the original screws. Tighten these screws with max. 0.7 Nm (± 0.1 Nm).
Festo P .BE-CPA-EN en 0207c
5-11
5. Maintenance and conversion
5.3.3 Replacing the end plate, sub-base or manifold block
Please note
Removal of the CPA valve terminal from the CPX terminal is described in Appendix A.
Removing
1. Loosen the electrical and pneumatic connections and removetheCPAvalveterminalfromitsfasteningsurface (see this chapter, “Dismantling the CPA valve terminal”).
2. Place the CPA valve terminal on a flat working surface.
3. Replacing a sub-base: Remove the pin-type inserts from the sub-base. Unlock the pin-type inserts by removing the clamping spring with a screwdriver. Pull the pin-type inserts out of the sub­base (see diagram). If necessary, use a screwdriver to do this.
1 Clamping spring
2 Pin-type inserts
Fig. 5/3: Removing the pin-type inserts
5-12
1
2
Festo P.BE-CPA-EN en 0207c
5. Maintenance and conversion
4. Loosen the fastening screws of all components on all sub-bases approx. 2 turns. You will then avoid stressing theCPAvalveterminalwhenthetierodsareloosened (see diagram).
1 CPA valve
terminal with MP, CP, AS-Interface connection or CPX terminal
12
2 CPA valve
terminal with IC connection
Fig. 5/4: Loosening components on sub-bases
5. Replacing a sub-base or a manifold block: Remove the component on the sub-base to be replaced (see this chapter, “Replacing a sub-base, blanking plate or additional supply plate”).
Festo P .BE-CPA-EN en 0207c
5-13
5. Maintenance and conversion
6. Depending on the component to be replaced, loosen the
Fig. 5/5: Loosening the tie rod screws
tie rod screws in the left or right-hand end plates (see diagram).
7. Remove the appropriate end plate from the tie rods.
8. Replacing an end plate:
Loosen the four fastening screws of the electrical sub­base or cover block and remove it from the relevant end plate(seediagram).
1 Fastening screws
of the electric sub-base
2 Fastening screws
of the cover block
Fig.5/6: Removingthesub-baseorcoverblock
5-14
1
2
Festo P.BE-CPA-EN en 0207c
5. Maintenance and conversion
9. Replacing a sub-base or a manifold block:
1 Sub-base to be
replaced
Usetheappropriatesub-basesofthetierod(see Fig. 5/7). Release and carefully remove the manifold block from the sub-base (see Fig. 5/8). Remove the seals from the sub-base or manifold block to be replaced.
1
Fig. 5/7: Removing sub-bases
1 Unlocking the
manifold block
12
2 Removing the
manifold block from the sub­base
Fig. 5/8: Removing the manifold block
Festo P .BE-CPA-EN en 0207c
5-15
5. Maintenance and conversion
Fitting
Fitting the sub-base and the manifold block:
1. Push the manifold block onto the guide rail of the new
2. Make sure the seal is not damaged. Replace the seal if it
3. Push the sub-bases onto the tie rod.
Fittingtheendplate
4. CPA valve terminal with MP, CP, AS-Interface connection or
sub-base until it clips in.
is damaged. Place the seals in the appropriate grooves of thesub-baseandthemanifoldblock.
CPX terminal: When you have replaced the end plate, screw the electri­cal sub-base or cover block onto the new end plate. Make sure that the electrical sub-base or cover block lies flush with the appropriate end plate (see Fig. 5/9). Tighten the screws with 0.7 Nm (± 0.1 Nm) (position see Fig. 5/6).
5-16
Festo P.BE-CPA-EN en 0207c
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