Valve terminal type 05 - Festo
Transcript of Valve terminal type 05 - Festo
E8NH
Valve terminal type 05 Pneumatics Manual
ISO-Valve
Only valid in agreement with the printed documentationaccompanying the product! Compare this edition code.
Authors: H.Simons
Editor: H.-J. Drung
Translation: Douglas Smith
Layout: Festo KG, Dept. PV-IDM
Type setting: DUCOM
E8NH
1994 Festo KG, 73726 Esslingen, Federal Republic of Germany
All rights reserved, including translation rights.No part of this publication may be reproducedor transmitted in any form or by any means,electronic, mechanical, photocopying or other-wise, without the prior written permission ofFesto KG.
ISO - 05
E8NH I
Part no.: 152 773
Title: MANUAL
Designation: P.BE-ISO-05-GB
ISO - 05
II E8NH
Contents
Chapter 1 USER INSTRUCTIONS AND SUMMARY OF SYSTEM
1.1 Important user instructionsDanger categoriesPictogramsInstructions on this manual
1.2 Detailed summary of system System structureDescription of components Description of functionCombination possibilities per valves location
Chapter 2 FITTING THE PNEUMATIC COMPONENTS
2.1 Fitting the componentsPneumatic componentsFitting a valve into a non-reserved locationFree valve locationsFitting additional componentsValve terminal with two oressurezonesEnd plates
2.2 Fitting the valve terminalWall fitting
ISO - 05
E8NH III
Chapter 3 CONNECTING THE PNEUMATIC COMPONENTS
3.1 General connecting methodsLaying the tubing General information
3.2 Connecting the valve terminalPreparing the sub-baseConnecting the supply linesConnecting the work linesAuxiliary pilot airConversion from internal to externalauxiliary pilot air
Chapter 4 COMMISSIONING
4.1 Commissioning testsChecking the valve functions Manual override Manual override designsTesting the valve-cylinder combination
4.2 Error analysisImpairment of functionsLED displays of the valves
Appendix A TECHNICAL APPENDIX
Appendix B INDEX
ISO - 05
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1. USER INSTRUCTIONS AND
SUMMARY OF SYSTEM
ISO - 05 1. User instructions
E8NH 1-1
Contents
1.1 IMPORTANT USER INSTRUCTIONS 1-3Danger categories 1-3Pictograms 1-4Instructions on this manual 1-5
1.2 DETAILED SUMMARY OF SYSTEM 1-7System structure 1-7Description of components 1-9Description of function 1-13Combination possibilities per valve location 1-15
ISO - 05 1. User instructions
1-2 E8NH
1.1 IMPORTANT USER INSTRUCTIONS
Danger categories
This manual contains instructions on thepossible dangers which can occur with valve ter-minal type 05.
A distinction is made between the following:
WARNING... means that personal injury or material dam-age can occur if the instructions are not fol-lowed.
CAUTION... means that material damage can occur ifthe instructions are not followed.
PLEASE NOTE ... means that this instruction must also be ob-served.
ISO - 05 1. User instructions
E8NH 1-3
Pictog rams
Pictograms and symbols supplement the dangerinstructions and draw the attention of the user tothe nature and consequences of the dangers.
The following pictograms are used:
Uncontrolled movement of loose tubing.
Undesired movements of the connected actua-tors.
High electric voltages or undefined switchingstates of the electronic components can affectconnected circuits.
Electrostatically vulnerable components.These components will be destroyed if the con-tact surfaces are touched.
The ISO valve terminal typ 05 is very heavy.Please ensure that it is sufficiently fastened.Always wear safety shoes.
ISO - 05 1. User instructions
1-4 E8NH
Instructions on this manual
The following product-specific abbreviations areused in this manual:
• The manual includes a description of the fol-lowing pneumatic components:
Abbreviation Meaning
Terminal Valve terminal type 05 with/without electrical I/Os
Node Field bus node or Control block SB202, SF202 SB50, SF50
Sub-base Ready-fitted manifold sub-base for 4, 8 or 12 valves (ISO 5599/1, size 1 or 2)
I O I/O
InputOutputInput/output
P-components Pneumatic components in general
I/O module Module with digital inputs or outputs in general (input/output modules)
4-input module8-input module4-output module
Module with 4 digital inputsModule with 8 digital inputsModule with 4 digital outputs
Components Common term for valves, throttle plate, pressure regulator intermediate plate, cover plate
Restrictor Throttle plate
Regulator Pressure regulator intermediate plate
Fig. 1/1: List of abbreviations
Product Design/fittings No. of valve locations
Valveterminaltype 05
ISO-valves size 1 or 2 with separate auxiliary pilot air• Single solenoid valves• Double solenoid valves• Mid-position valves blocked,
pressurized, exhausted
4, 8 or 124, 8 or 124, 8 or 12
Pressure switchDifferential pressure switch
Fig. 1/2: Pneumatic components type 05
ISO - 05 1. User instructions
E8NH 1-5
• The manual includes a technical appendixwith the pneumatic specifications.
• All information on power supply and on theelectronic modules are to be found in the ap-propriate manual (see below).
• Valve terminal type 05 can be connectedwith the following field bus nodes:
Festo fieldbus node
Field bus protocol PLC/I-PCmanufacturer
Appropriate Festomanual (electronics,field bus)
FB1 ET100SUCONET Kl.1Festo field bus
SIEMENSKlöckner-MoellerFesto
P.BE-VIFB1-03/05-GB
FB2 D-busModnet 1 SFBPrinta
ABBAEGHoneywell
P.BE-VIFB2-03/05-GB
FB3 PROFIBUS Open busas per DIN19245
P.BE-VIFB3-03/05-GB
FB4 MELSEC MININET Mitsubishi P.BE-VIFB4-03/05-GB
FB5 CS-31 ABB P.BE-VIFB5-03/05-GB
FB6 INTERBUS-S Phoenix,open field bus
P.BE-VIFB6-03/05-GB
FB7 II/O-busEDP-L
BeckhoffEberle
P.BE-VIFB7-03/05-GB
FB8 1771 Remote-I/O Allen-Bradley P.BE-VIFB8-03/05-GB
FB9 SINEC L2-DP SIEMENS,open field bus
P.BE-VIFB9-03/05-GB
FB10 Genius bus GE Fanuc P.BE-VIFB10-03/05-GB
SB202 No field bus Festo-PLC internal P.BE-SB202-03/05-GB
SF202 Festo field bus Festo-PLC internal P.BE-SF202-03/05-GB
SB50 No field bus SIMATIC PLC P.BE-SB50-05-GB
SF50 SINEC L2-DP SIMATIC PLC P.BE-SB50-05-GB
Fig. 1/3: Automation systems/field bus protocols
ISO - 05 1. User instructions
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1.2 DETAILED SUMMARY OF SYSTEM
System structure
Festo valve terminals can be used for solvingautomation tasks at the machine level. The valveterminals of type 05 are equipped on a modularbasis and permit combinations of pneumatic andelectronic modules. The following groups aretherefore possible on the field bus:
Industrial PC or PLC (I-PC)
Valve terminal type 05:pneumatic componentsand electronic modules
Valve terminal type 05:only pneumatic components
Valve terminals type 03:pneumatic andelectronic modules
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Further field bus slaves
Field bus
Fig. 1/4: System summary and possible variants of valve terminals
ISO - 05 1. User instructions
E8NH 1-7
Valve terminal type 05 with field bus connectionoffers the following advantages: • variable fitting of locations with electrical in-
puts and outputs and 4, 8 or 12 pneumaticvalves
• subsequent extension/conversion possible– pneumatic with components for vertical linking– electrical with I/O modules
• valve designs for specific purposes– ISO valves sizes 1 and 2
• can be connected to various control systems• simpler circuitry• easy-to-understand system structure with
physical separation of controller and machine• valves already fitted• wired pilot valve solenoid coils• central compressed air supply• central exhaust• device already tested
A field bus system offers the following advan-tages: • fewer output modules required in the control-
ler• economic data transmission over long dis-
tances• high baud rates • a large number of slaves can be connected• easier error diagnosis
ISO - 05 1. User instructions
1-8 E8NH
Description of components
Valve terminal type 05 is composed of individualmodules. Each module is assigned with differentfunctions and elements for connection, displayand operation. The diagram below summarizesthe modules.
Fig. Module
1 node
2 Adapter plate for sub-base as per ISO 5599/I size 1 or 2
3 Sub-base fitted with:• Pneumatic vavles with hole pattern as ISO 5599/I
- single-solenoid valves- double solenoid valves- mid-position valves
• Components for high-level linking (pressure regulator intermediate plates, throttle plates etc.)
• Cover plates
4 End plates right with mounting holes and thread for M8 ring screw
5 End plate left with hole for additional PE connection
6 Electronic modules (input/output modules), fitted with• digital inputs (modules with 4 or 8 inputs)• digital outputs (modules with 4 outputs)
1 326 45
Fig 1/5: Modules on valve terminal type 05
ISO - 05 1. User instructions
E8NH 1-9
The following connection, display and operatingelements are to be found on the pneumatic mo-dules of type 05:
Fig. Elements
1 Control block or field bus node with LEDs and connection, further detailssee product packing or chapter "Installation" in the appropriate node manual
2 Fuses for the inputs/sensors (pin 1)
3 Adapter plate
4 Operating voltage connection of terminal type 05
5 Fuses for the valves (pin 2)
6 Valve location inscription field
7 Yellow LEDs (per pilot solenoid)
8 Manual override (per pilot solenoid, pushing or locking)
9 Connection for external control air
10 Connections for common tubing
11 Work connections (per valve)
12 Adapter cable for operating voltage supply to the node and to the I/O modules
31 2 4
10
119
5 6 7 8
9
10
12
Fig. 1/6: Operating, display and connecting elements of the ISO modules type 05
ISO - 05 1. User instructions
1-10 E8NH
The following connection and operating elementsare to be found on the pneumatic modules oftype 05 for high-level linking:
1 1
4*
32
5*
Fig. Elements
1 Adjusting screw for throttle flow
2 Regulator button with latching lock (to adjust pull button out from lockingposition and turn)
3 Connection for pressure display
4 Adjusting screw pressure switch
5 Adjusting screw differential pressure switch
Throttle plate
Pressure regulator
Pressure switch
Differentialpressure switch
*) General schematic representation of these componentsFurther details see product packing.
Fig. 1/7: Operating and connecting elements for high-level linking
ISO - 05 1. User instructions
E8NH 1-11
The display and connection elements shownbelow are to be found on the electronic modules.Further information on their use is to be found inthe manual for the field bus node. Only thepneumatic modules are described here.
Fig. Elements
1 Output socket for an electrical output
2 Yellow status LED (per output)
3 Red error LED (per output)
4 Input socket for an electrical input
5 Green status LED (per input)
6 Input socket for two electrical inputs
7 Two green status LEDs (one LED per input)
8 Node with LEDs and field bus connection, further details in chapter "Installation" in the appropriate node manual
9 Right-hand end plate
10 Fuse for inputs/sensors
11 Operating voltage connection
12 ASI-master for peripheral I/Os
31
A4 A4 E4 E8
2 4 5 6 7 8
10 91112
ASI-master
Fig. 1/8: Display and operating elements of the electronic modules
ISO - 05 1. User instructions
1-12 E8NH
Description of function
The node/control block controls the followingfunctions:
• connection of the terminal to the field bus mo-dule of the control system and to furtherslaves via the field bus interface
• adaption of field bus baud rate and field busprotocol to the control system
• control of data transfer to/from the field busmodule of the control system
• internal control of the terminal
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Digitale I/O-modules Field bus
Node
Pneumatic componenten
Cylinder
Sensors
} Signal direction
Compressed air
Work air
Fig. 1/9: Function summary of valve terminal type 05
ISO - 05 1. User instructions
E8NH 1-13
The pneumatic sub-base contains:
• common channels for supply and exhaust air
• electrical channel for passing on the signalsfrom all valve solenoid coils.
Work connections 2 and 4 are provided for eachvalve location on the side of the sub-base.
The valves are supplied with compressed air andthe exhaust air and pilot air from the valves arevented via the common channels of the right-hand end plate or the adapter plate.
There are two possibilities of supplying the S-valves with auxiliary pilot air:
• Auxiliary pilot air taken from the main supply.
• separately regulated auxiliary pilot air(3 - 12 bar)
The terminal can be ordered with two pressurezones. If desired, isolating discs can be insertedat the factory e.g. in order to create two differentworking pressures.
The digital input/output modules process inputsignals (e.g. from sensors) and transmit thesesignals via the field bus to the controller. Allelectrical outputs control low-current consumingdevices with positive logic.
ISO - 05 1. User instructions
1-14 E8NH
Combination possibilities per valve location
Further pneumatic components can be fitted ineach valve location between the sub-base andthe valve. This high-level linking enables theuser to implement certain additional effects. Thediagram below shows the components available.
Available components
Valve
Throttle plate,actuator speedcan be adjusted
Pressure regulator (1*)actuator forcescan be adjusted
Pressure switch (1*)directed pressure enquiry(with signal output)
Differential pressure switch (1*)directed differential pressure enquirywith signal output)
Sub-base
(1*) Please note the instructions on the combination possibilities on thefollowing page.
(2*) General schematic representation of these components
Fig. 1/10: Components for high-level linking
2*
2*
ISO - 05 1. User instructions
E8NH 1-15
Combination possibilities
Pressure regulatorPressure switchDifferential pressure switch
Permitted combinationpossibilities seemain pneumaticscatalogue
Fig: 1/11: Combination possibilities
ISO - 05 1. User instructions
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2. FITTING THE PNEUMATIC COMPONENTS
ISO - 05 2. Fitting pneumatic components
E8NH 2-1
Contents
2.1 FITTING THE COMPONENTS 2-3Pneumatic components 2-4Fitting a valve into a non-reserved location 2-5Free valve locations 2-6Fitting additionalcomponents 2-6Valve terminal with two pressure zones 2-7End plate 2-8
2.2 FITTING THE VALVE TERMINAL 2-9Wall fitting 2-9
ISO - 05 2. Fitting pneumatic components
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2.1 FITTING THE PNEUMATIC COMPONENTS
WARNINGBefore fitting the components switch off thefollowing:• compressed air supply• operating voltage supply to the outputs
(pin 2)• operating voltage supply to the electronic
components (pin 1)
You can thereby avoid:
• uncontrolled movement of loose tubing
• undesired movement of the connected actua-tors
• undefined switching states of the electroniccomponents
WARNINGThe modules of the valve terminal containelectrostatically vulnerable components.• Do not therefore touch any contact surfaces
on the side plug connectors of the modules. • Please observe the regulations for dealing
with electrostatically vulnerable components.
You can thereby avoid damage to the valve ter-minal modules.
ISO - 05 2. Fitting pneumatic components
E8NH 2-3
PLEASE NOTETreat all modules and components of the valve terminal with the utmost care. Pay special attention to the following:• Screw connectors must not be distorted or
subjected to mechanical stress.• Screws must fit correctly (otherwise the
threads will be damaged).• The modules must not be offset (IP 65).• Connecting surfaces must be clean
(avoid leakage and contact errors).
With components ordered at a later stage,please observe the fitting instructions in-cluded in the package.
Pneumatic components
Before the valve terminal can be extended orconverted, it must first be dismantled.
Dismantling the terminal
• Switch off the power and compressed air sup-plies to the terminal.
• Remove the terminal from the fastening sur-face and place it on a flat surface.
• Clean the valve terminal before removing thecomponents. You thereby avoid dirt enteringthe air channels of the components.
ISO - 05 2. Fitting pneumatic components
2-4 E8NH
Fitting a valve into a non-reserved valvelocation
Non-used valve locations are sealed with coverplates. This guarantees the following:
• Hollow spaces in the sub-base are protectedfrom dirt.
• Pressure-tight seal of valves or coil con-nection level.
Dismantling the cover plates
• Loosen the screws of all cover plates on thisvalve location. Remove the cover platesfrom the sub-base.
Fitting the valve
• Insert new seals.
• Place the new components on the sub-baseor on the already fitted components.
• Use the accompanying screws to fasten thepilot solenoids and the valve.
Fig. 2/1: Fitting the valves
ISO - 05 2. Fitting pneumatic components
E8NH 2-5
Free valve locations
PLEASE NOTESeal the free valve locations and pilot valvelocations with the appropriate cover plates(these must be ordered separately).
Fitting additional components
Decide in which positions you wish to insert theadditional components.
Dismantling the components
• Loosen the screws of all components abovethis position.
• Remove these components.
Fig. 2/2: Fitting additional components
ISO - 05 2. Fitting pneumatic components
2-6 E8NH
Fitting new components
• Insert new seals.
• Place the new components on the sub-baseor on the already fitted components.
• Screw tight the new components.
• Replace the dismantled components as be-fore.
Valve terminal with two pressure zones
The terminal can be fitted with different pressurezones at the factory if desired. Whether or notyour terminal has two pressure zones can be as-certained from the order documentation for theterminal. Subsequent conversion to two pressurezones is only possible by Festo service person-nel.
ISO - 05 2. Fitting pneumatic components
E8NH 2-7
End plates
CAUTIONThe right-hand end plate must always beearthed before it is fitted. You thereby avoidhigh voltages on the metal surfaces in theevent of a fault.
You will require a right-hand and a left-hand endplate as a mechanical termination of the termi-nal. These end plates fulfill the following func-tions:
• They comply with protection class IP65
• They contain connections/holes for the pro-tective earthing
• They contain holes for the wall fitting.
Earth the end plate as follows:
• Right-hand end plateInsert the earthing plate into the rear groove.Screw the earthing plate to the terminal bymeans of the threaded holes intended for thispurpose.
• Left-hand end plateThis is connected conductively to the othercomponents by means of ready fitted springcontacts.
PLEASE NOTEInstructions on earthing the complete valveterminal are to be found in the chapter "Instal-lation" in the relevant node manual.
ISO - 05 2. Fitting pneumatic components
2-8 E8NH
2.2 FITTING THE VALVE TERMINAL
Wall fitting
WARNINGIn the case of long terminals with several I/Omodules, use additional support brackets forthe modules (approx. every 200 mm).Youthereby avoid: • overloading the fastening eyes on the
left-hand end plate• the terminal sagging (I/O side) • natural resonance
Proceed as follows:
• Calculate the weight of your terminal weigh orestimate). General rule:
• Make sure that the fastening surface can sup-port this weight.
Fasten the terminal as follows:
• two M10 screws on the adapter plate see (Fig. 2/3: 2)
• one M10 screw on the right-hand end platesee (Fig. 2/3: 2).
• two M6 screws on the left-hand end platesee (Fig. 2/3: 1).
Size 1 Size 2
Pumatic components with4 valve locations 8 valve locations 12 valve locations
8.0 kg14.0 kg20.0 kg
12.0 kg20.0 kg28.0 kg
Per node 1.0 kg 1.0 kg
Per electronic module 0.4 kg 0.4 kg
ISO - 05 2. Fitting pneumatic components
E8NH 2-9
If necessary, use the following additional fasten-ing methods:
• hole at the bottom of the right-hand end platewith M10 thread (blind hole)
• support bracket for the I/O.modules (see fit-ting instructions in product packing with sup-port bracket)
The terminal can be fitted in any position. Ifnecessary, use spacers for compensating for theunevenness of the fastening surface and use thethread for the M8 ring screw (e.g. for cranehooks).
21 Thread for M8ring screw
3
M6
M10
Fig. 2/3: Wall fitting of an ISO terminal type 05
ISO - 05 2. Fitting pneumatic components
2-10 E8NH
3. CONNECTING THE PNEUMATIC
COMPONENTS
ISO - 05 3. Connecting components
E8NH 3-1
Contents
3.1 GENERAL CONNECTION METHODS 3-3Laying the tubing 3-3General information 3-4
3.2 CONNECTING THE VALVE TERMINALPreparing the sub-base 3-5Connecting the supply lines 3-6Connecting the work lines 3-8Auxiliary pilot air 3-9Conversion from internal to externalauxilary pilot air 3-10
ISO - 05 3. Connecting components
3-2 E8NH
3.1 GENERAL CONNECTION METHODS
WARNING Before installation or maintenance work is car-ried out, the following must be switched off:• the compressed air supply • the operating voltage supply to the outputs
(pin 2) • the operating voltage supply to the
electronic components (pin 1)
You thereby avoid:
• uncontrolled movement of loose tubing
• undesired movements of the connected actu-ators
• undefined switching states of the electroniccomponents
Laying the tubing
PLEASE NOTE• Place a suitable seal under each screw
connector or silencer in order to prevent leakage.
• If elbow connectors or multiple distributorsare used, the air flow will usually be reduced.
ISO - 05 3. Connecting components
E8NH 3-3
General information
• Connecting 1. Push the tubing as far as it will go into or
over the screw connector. 2. If necessary, pull the locking ring over the
tube coupling or tighten the locking screw.3. For reasons of clarity, group the tubing
together with: - tube straps or - multiple tube holders.
• Disconnecting 1. Where applicable, loosen the locking
screw or locking ring on the screw connector.
2. Pull the tubing out. 3. If necessary, replace the screw connector
with blind plugs.
ISO - 05 3. Connecting components
3-4 E8NH
3.2 CONNECTING THE VALVE TERMINAL
Preparing the sub-base
There are connections on both sides of the sub-base for common tubing. The common tubingcan therefore be connected on the right, on theleft or on both sides depending on requirements.
• If two pressure zones are used, pressuremust be supplied to each side separately.
In order to guarantee the optimum efficiency ofyour terminal, we recommend that the air supplyand the exhaust tubing be connected on bothsides in the following cases:
• with large-volume cylinders which operate athigh speed
• simple-acting cylinders
• with terminals with more than 8 valves Prepare the connections as follows:
Connection of common tubing Procedure
Only on adapter plate Remove all adhesive foils
Only on right-hand end plate Remove all adhesive foils; remove all blind plugs and fit adapter plate
On adapter and right-hand endplate
Remove all adhesive foils and blind plugs
Adapter plate Right-hand end plate
Connections forcommon tubing
(blind plugs)
Connections forcommon tubing(adhesive foils)
Fig. 3/1: Supply connections on adapter and right-hand end plate
ISO - 05 3. Connecting components
E8NH 3-5
Connecting the supply lines
Fit the screw connectors or silencers with theappropriate seals according to the table below.Then connect the tubing.
Commontubing
Connectioncode ISO 5599
Connecting size ISO 228
Connection
Compressed air 1 G 1/2 (G 3/4) Screw connector
Exhaust 35
G 1/2 (G 3/4) Screw connector with:• non-return valve• silencer
Auxillary pilot air EXT G 1/8 (G 1/8) Screw connector• in right-hand end plate• in adapter plate
Please note: values in brackets are for ISO size 2
EXT
Connection forexternal pilot air
13
5Air supply connectionsright-hand end plate
Air supply connections for adapter plate
EXT
Connection forexternal pilot air1
3
5
Fig. 3/2: Connecting the supply lines
ISO - 05 3. Connecting components
3-6 E8NH
PLEASE NOTE If there are several systems with centrallyducted exhaust air, use non-return valves inthe common exhaust connections so that thefunction is not impaired as a result of backpressures.
System 1 System 2
Central 3/5
Common 3/5
Common 3/5
Common 3/5Valveterminal
Valveterminal
Fig. 3/3: Common tubing with non-return valves
ISO - 05 3. Connecting components
E8NH 3-7
Connecting the work lines
PLEASE NOTERemove the adhesive foils or the blind plugsand fit the screw connectors with seals asshown in Fig. 3/4.Then connect the tubing.If a fitted valve is not used, seal connections 2and 4 with appropriate blind plugs.
Tubing ConnectioncodeISO 5599
ConnectionsizeISO 228
Connection
Work air 24
G 1/4 (G 3/8) Screwconnector ormultipledistributor
Please note: values in brackets are for ISO size 2
2
4
2
4
Workconnections
Sub-base
Fig. 3/4: Assignment of linking plate
ISO - 05 3. Connecting components
3-8 E8NH
Auxiliary pilot air
Valve terminal type 05 can be operated with in-ternal or external auxiliary pilot air.
If the supply pressure is in the range 3 to 12 bar,the correct functioning of all valves is guaran-teed. If the pressure is less than 3 bar, the auxi-liary pilot air must be supplied externally.
Operation with internal pilot air: • The auxiliary pilot air is taken from P1.
Operation with external pilot air: • Use the external pilot connections EXT. The-
se connections are sealed at the factory withblind plugs.
PLEASE NOTE • Use controlled auxiliary pilot air.
This ensures reliable, faultless operation ofthe valve terminal.
Please note that controlled auxiliary pilot air forall pneumatic components via common tubing issupplied or taken at only one position.
This also applies if the valveterminal is operatedwith two pressure zones.
ISO - 05 3. Connecting components
E8NH 3-9
Conversion from internal to externalauxiliary pilot air
CAUTIONSwitch off the compressed air supply beforeundertaking conversion.
With the aid of a dividing bolt, which must beinserted into the end plate (must be ordered sep-arately), you can convert the terminal to externalpilot air. The auxiliary pilot air is then no longertaken from air connection 1.
Fitting the dividing bolt• Unscrew blind plug "a". • Push the O-ring into the groove of the divi-
ding bolt. • Screw in blind plug "a" again. • Remove blind plug "b" and connect the exter-
nal auxiliary pilot air.
Blind plug b
Blind plug a
Dividing bolt
O-Ring
Fig. 3/5: Conversion to external auxiliary pilot air
ISO - 05 3. Connecting components
3-10 E8NH
Dismantling the dividing bolt
PLEASE NOTEAn M4x25 screw is required for dismantlingthe dividing bolt.
• Unscrew blind plug "a".
• Screw the M4x25 screw into the dividing boltand pull the dividing bolt out by means ofthe screw.
• Screw in blind plug "a" again.
• Remove the external pilot air and screw inblind plug "b".
WARNING If one pressure zone is exhausted (e.g. duringEMERGENCY OFF), the external regulatormust never be without pressure, otherwisethere is no auxiliary pilot air for the otherpressure zones.
Externallycontrolledauxiliarypilot air
Pressure zone 1 Pressure zone 2
Fig. 3/6: Terminal with external pilot air and two different pressure zones
ISO - 05 3. Connecting components
E8NH 3-11
4. COMMISSIONING
ISO - 05 4. Commissioning
E8NH 4-1
Contents4.1 COMMISSIONING TESTS 4-3
Checking the valve functions 4-4Manual override 4-4Checking the valve-cylinder combination 4-6Carrying out the test 4-7
4.2 ERROR DIAGNOSIS 4-9Impairment of function 4-9LED displays of the valves 4-11
ISO - 05 4. Commissioning
4-2 E8NH
4.1. COMMISSIONING TESTS
The following procedure should be adopted forcommissioning the valve terminal:
Commissioning with the manual override is de-scribed overleaf. Commissioning by program isdescribed in the relevant manual for the node.
Commissioning variants Activity
Preliminary test ofpneumatic tubing
Move valve cylindercombination by means ofmanual override
Complete commissioningof whole system
Fit and connect the wholesystem (all field busslaves). Program controlby PLC/industrial PC.
Fig. 4/1: Commissioning variants
ISO - 05 4. Commissioning
E8NH 4-3
Checking the valve functions
Manual override
WARNINGThe manual override must be operated onlywhen the electrical power supply to the valvesis switched off. Before the valves are operatedagain with electrical signals, make sure thatthe manual override is in the basic position.
The manual override is used principally duringcommissioning of the pneumatic system, in orderthat the user can check the function and effec-tiveness of the valve or of the valve-cylindercombination. By operating the manual override, the user canswitch the valve without the electrical signal.Only the compressed air supply needs to beswitched on.
The manual override has been designed to beused as follows:
Manual override design Method of operation
Manual override withautomatic reset (pushing)
After operation the manual override is resetby spring force.
Manual override locking Manual override remainsactive until reset by hand
Fig. 4/2: Designs of manual override
ISO - 05 4. Commissioning
4-4 E8NH
Pilot valves
without manual override
Manual override locking
Manual override pushing
Fig. 4/3: Variations of the manual override
ISO - 05 4. Commissioning
E8NH 4-5
Checking the valve-cylinder combination
WARNING When pressurizing or repressurizing the valveterminal under the following conditions:• by means of the safety start-up valve
(slow pressurization) and• when electrical signals are present
(e.g. after EMERGENCY OFF);
Feed the auxiliary pilot air separately via anend plate without regulator (3-5 bar).
The auxiliary pilot air must be available at fullpressure as soon as it is switched on, otherwisethe slow pressurization of the complete supplywill have no effect with the following cylinders:
• control by mid-position valve with basic posi-tion exhausted
• control by mid-position valve with basic posi-tion blocked
• control by single solenoid valves
• control by double solenoid valves which arereversed during the pressureless phase.
Separatelysuppliedauxiliary pilotair
Pressureincrease ofcompletesupply
Pressureincrease inauxiliary pilotair (12,14)
Time ofreversal ofvalve
Movement ofthe cylinder
with regulator slowly slowly after pressureincrease at (1)
quickly
withoutregulator
slowly quickly beforepressureincrease at (1)
slowly
Fig. 4/4: Effects of slow switch-on pressurization with electrical signals
ISO - 05 4. Commissioning
4-6 E8NH
Carrying out the test
1. Switch on the compressed air supply.
2. Test the functioning and effectiveness ofeach individual valve-cylinder combination byoperating the manual override as described inthe following diagrams.
3. Switch the compressed air supply off againwhen the valves have been tested.
Operating the manual override with automatic reset (pushing)
Reaction of the valve
Press the plungerof the manual override as far as it will go
The valve:• switches
Hold plunger presseddown
• remains switched
Release plunger.A spring returnsthe plunger of themanual overrideto the basic position.
• returns to basic position
Fig. 4/5: Manual override with automatic reset
ISO - 05 4. Commissioning
E8NH 4-7
CAUTION Before operating the valve terrminal, return themanual override to the basic position.
Operating the manual override with stop (locking)
Reaction of the valve
Insert the screw- driver into the grooveof the plunger.Press the plunger ofthe manual overrideas far as it will go and turn it to the right.
The valve: • switches
Remove screwdiver • remains switched
Insert the screw-driver into the grooveof the plunger.Press the plungerdown, turn it to the left and remove the screwdriver.
• returns to basic position
Fig. 4/6: Manual override with stop
ISO - 05 4. Commissioning
4-8 E8NH
4.2 ERROR DIAGNOSIS
Impairment of function
When the compressed air supply is switched onor during the subsequent test of the individualvalves, the following can be ascertained aboutthe operating status of the pneumatic system:
Operating status ofpneumatic system
Valve position Error treatment whencompressed air is switchedoff
Air comes out...• of common tubing
connections• of work tubing
connections• between the modules
• Basic position
• Switch position
• Basic position
• Check the seal or tubing
• after switching on again, limit auxiliary pilot air to 3-12 bar
Valve or pneumatic system...• does not react as
expected
• does not react
• Switch position
• Switch position
• Check the tubing
• After switching on againcheck operating pressure (e.g. pressure zones)
• Service case
• does not react • Basic position • Check control connection(apply > 3 bar pressure to regulator)
Fig. 4/7: Operating status of the pneumatic system
ISO - 05 4. Commissioning
E8NH 4-9
If the operating status of the pneumatic systemdiffers from the desired pneumatic status, thefollowing conditions are probably not fulfilled:
Desired pneumatic operating status
Condition Remarks
No leaks • correctly laid tubing• controlled auxiliary pilot air
_
Immediate reaction Sufficient air supply via airsupply module
Exhaust valve terminal atright-hand end plate andadapter plate
No faults Non-return valves incommon exhaust tubing
Applies when severalsystems with centrally-ducted exhaust are used
Two pressure zones Limitation of pressure zonesby an isolating disc
Subsequent conversion onlyby Festo service personnel.
Vacuum operation/low pressureoperation
Seperate supply of controlled auxiliary pilot air (3-12 bar)
Regulator can only beoperated with > 3 barpressure
EMERGENCY OFFin pressure zones
Regulator for the auxiliarypilot air must function evenwhen main supply isswitched off
Regulator controls theauxiliary pilot air for allpneumatic modules
Slow switch-onpressurization afterEMERGENCY OFF
With control signals applied,the auxiliary pilot air mustbe available at full pressureas soon as it is switched on
Fig. 4/8: Causes of possible deviations from the nominal status
ISO - 05 4. Commissioning
4-10 E8NH
LED displays of the valves
There is a yellow LED for each valve solenoidcoil. This LED shows the switching status of thevalve solenoid coil.
LED Switch position valve solenoid coil
Meaning
Yellow out Basic position Logic 0 (no signal)
Yellow alight • switch positionor
• basic position
Logic 1 (signal present)
Logic 1 but:• operating voltage of outputs below permitted tolerance range
(DC 21.6V...26.4V) or
• compressed air supply not correct or
• pilot line blocked or
• service case
12 14 12 14 12 14 1214
yellow LEDs unused LEDs
Fig. 4/9: LED display of switching status of the ISO valve solenoid coil
ISO - 05 4. Commissioning
E8NH 4-11
TECHNICAL APPENDIX
ISO - 05 Appendix A
E8NH A-1
Inhalt
TECHNICAL Appendix A-3Pneumatics A-3
ISO - 05 Appendix A
A-2 E8NH
Technical Data, Pneumatics
Medium Compressed air, filtered, lubricated or non-lubricated/vacuum
Mounting position As desiredDesign System for central control of valves and for
registering sensor signalsModule dimensionsvalve terminal:
Size 1 Size 2
• Sub-base with: 4 valve locations 8 valve locations12 valve locations
(H up to top of plug)• Node• Input/output modules• End plate leftHeight of individual components:Valves (single, double, mid-position)Pressure regulatorThrottle plateLength of individual components:Silencers
L W H290 x 230 x 151 (mm)490 x 230 x 151 (mm)690 x 230 x 151 (mm)
72 mm 36 mm 27 mm
45.7 mm
52 mm 26 mm
106 mm
L W H 321 x 230 x 151 (mm)545 x 230 x 151 (mm)769 x 230 x 151 (mm)
72 mm 36 mm 27 mm
55.7 mm
62.5 mm 40 mm
126 mmPressure range• With auxiliary pilot air
taken from P 1• With external auxiliary
pilot air
up to 12 barP 12, 14: 3 -12 bar P 1: (-0.9) +2 ... +12 bar (depending on valve)
Temperature range(pneumatic components)• Storage• Operation• Medium
-15 ... +50 °C-10 ... +50 °C -10 ... +60 °C
Voltage• Operation DC 24 V ±10 %Valve switching times Size 1 Size 2
ON OFF ON OFF• 5/2 single• 5/2 single (reset by spring)• 5/2 double• 5/3 mid-position (blocked)• 5/3 mid-position
(exhausted)• 5/3 mid-position
(pressurized)
17 ms10 ms 9 ms14 ms13 ms
14 ms
26 ms39 ms
43 ms47 ms
46 ms
25 ms13 ms10 ms16 ms18 ms
18 ms
42 ms42 ms
45 ms54 ms
48 ms
ISO - 05 Appendix A
E8NH A-3
Starting current consumption• per solenoid coil at approx. 24 V
(with LEDs) • total with max. no. of valve coils
(with LEDs)
approx. 260 mA
approx. 6.24 A
Power output per solenoid coil 6,0 W
Manual override of valves non-locking, locking, no manualoverride
Weights Size 1 Size 2• End plate left• Input modules • Output modules• Field bus node • Sub-base (incl. adapter plate
and right-hand end plate) with: 4 valve locations 8 valve locations12 valve locations
• Pilot solenoid valve• Cover plate (pilot solenoid valve)• Valves
(single, double, mid-position)
• Cover plate (valve location)• Throttle plate• Pressure regulator (P, B, A or A/B)
120 g 360 g 400 g
ca. 1000 g
6110 g 9830 g13580 g 115 g 15 g
290 g, 290 g, 320 g 100 g 265 g
520 g or 840 g
120 g 360 g 400 g
ca. 1000 g
app. 8000 gapp. 12800 gapp. 17600 g
115 g 15 g
550 g, 550 g, 620 g 140 g 870 g
960 g or 1490 g
ISO - 05 Appendix A
A-4 E8NH
Rated flows of the ISO valvessize 1 [l/min]
1 → 2 1 → 4 2 → 3 4 → 5
• 5/2 (single)operated/not operated
• 5/2 (double)operated/not operated
• 5/3 (mid-position), closedoperated/not operated
• 5/3 (mid-position), exhaustedoperated/not operated
• 5/3 (mid-position), pressurizedoperated/not operated
-/1200 1200/-
1200/-
1200/-
1200/-
1200/700
-/1200 1200/-
1200/-
1200/-
1200/700
1200/-
Rated flows of the ISO valvessize 2 [l/min]
1 → 2 1 → 4 2 → 3 4 → 5
• 5/2 (single)operated/not operated
• 5/2 (double)operated/not operated
• 5/3 (mid-position), closedoperated/not operated
• 5/3 (mid-position), exhaustedoperated/not operated
• 5/3 (mid-position), pressurizedoperated/not operated
-/2300 2300/-
2300/-
2300/-
2300/-
2300/2000
-/2300 2300/-
2300/-
2300/-
2000/2000
2000/-
Connections• Compressed air• Exhaust • Auxiliary pilot air • Work air
Size 1G1⁄2G1⁄2G1⁄8G1⁄4
Size 2G3⁄4G3⁄4G1⁄8G3⁄8
Oscillation(as per DIN/IEC 68 part 2-6 andIEC 721/part 2-3)Transport:
Operation:
Shock(as per DIN/IEC 68 part 2-27and IEC 721)
3.5 m travel at 2-8 Hz1 g acceleration at 8-25 Hz
0.35 mm travel by 25-57 Hz5 g acceleration at 57-150 Hz1 g acceleration at 150-200 Hz
30 g at 11 ms duration
ISO - 05 Appendix A
E8NH A-5
INDEX
ISO - 05 Appendix B
E8NH B-1
AAbbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Auxiliary pilot air . . . . . . . . . . . . . . . . . . 1-14, 3-9Auxiliary pilot air separately . . . . . . . . . . . . . . 4-6
CCombination possibilities . . . . . . . . . . . . . . . . 1-16Common exhaust connections . . . . . . . . . . . . 3-7Common tubing . . . . . . . . . . . . . . . . . . . . . . . . 3-5Connection element. . . . . . . . . . . . . . . 1-9 - 1-11Connections
code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6screw connectors . . . . . . . . . . . . . . . . . . . . 3-6size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6tubing . . . . . . . . . . . . . . . . . . . . . . . . 3-3 - 3-4work lines . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Cover plates . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
DDescription of function. . . . . . . . . . . . . . . . . . 1-13Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Differential pressure switch . . . . . . . . 1-15 - 1-16Display element . . . . . . . . . . . . . . 1-9 - 1-10, 1-12
PLEASE NOTEThe index is based on key words. It thereforesupplements the contents which are based ona function/action-orientated grouping.In the index you will not therefore find "Con-necting tubing" but the separate entries "Con-nections" and "tubing".
ISO - 05 Appendix B
E8NH B-3
EElectronics manual . . . . . . . . . . . . . . . . . . . . . 1-6EMERGENCY OFF . . . . . . . . . . . . . . . . 4-6, 4-10Error diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 4-9Exhaust
central. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7External pilot air. . . . . . . . . . . . . . . . . . . . . . . . 3-9
FFastening eyes . . . . . . . . . . . . . . . . . . . . . . . 2-11Function description . . . . . . . . . . . . . . . . . . . 1-13
HHigh-level linking
fitting additional components . . . . . . . . . . . 2-7
IInternal pilot air . . . . . . . . . . . . . . . . . . . . . . . . 3-9
LLED display
electronic modules . . . . . . . . . . . . . . . . . . 1-12valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Low pressure operation. . . . . . . . . . . . . . . . . 4-10
ISO - 05 Appendix B
B-4 E8NH
MManual
electronics . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Manual override. . . . . . . . . . . . . . . . . . . . . . . . 4-4
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7operation . . . . . . . . . . . . . . . . . . . . . 4-7 - 4-8position . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Modulessummary. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
NNon-return valves . . . . . . . . . . . . . . . . . . . . . . 3-7
OOperating element . . . . . . . . . . . . . . . . 1-9 - 1-10Operating status . . . . . . . . . . . . . . . . . 4-9 - 4-10
PPressure increase . . . . . . . . . . . . . . . . . . . . . . 4-6Pressure regulator . . . . . . . . . . . . . . . 1-15 - 1-16Pressure switch . . . . . . . . . . . . . . . . . 1-15 - 1-16Pressure zone . . . . . . . . . . . . . . . . . . . . . . . . 3-11Pressure zones . . . . . . . . . . . . . . . . . . . 2-8, 4-10
RRepressurizing. . . . . . . . . . . . . . . . . . . . . . . . . 4-6
ISO - 05 Appendix B
E8NH B-5
SSlow switch-on pressurization . . . . . . . . . . . . . 4-6Support brackets . . . . . . . . . . . . . . . . . . . . . . 2-11Switch-on pressurization . . . . . . . . . . . . . . . . 4-10Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6System structure . . . . . . . . . . . . . . . . . . . . . . . 1-7
TTesting the valves . . . . . . . . . . . . . . . . . . . . . . 4-3Throttle plate . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
VVacuum operation . . . . . . . . . . . . . . . . . . . . . 4-10Valve terminal
connections . . . . . . . . . . . . . . . . . . . . . . . . 3-5converting. . . . . . . . . . . . . . . . . . . . . . . . . . 2-4dismantling . . . . . . . . . . . . . . . . . . . . . . . . . 2-4extending . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Valvesfitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
WWall fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Wigh-level linking
components . . . . . . . . . . . . . . . . . . . . . . . 1-11regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
ISO - 05 Appendix B
B-6 E8NH