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

IV E8NH

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


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.


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.


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


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• 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


1-6 E8NH

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


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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


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


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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


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


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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


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


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.


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*


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Combination possibilities

Pressure regulatorPressure switchDifferential pressure switch

Permitted combinationpossibilities seemain pneumaticscatalogue

Fig: 1/11: Combination possibilities


1-16 E8NH

2. FITTING THE PNEUMATIC COMPONENTS

ISO - 05 2. Fitting pneumatic components

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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


2-2 E8NH

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.


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.


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


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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


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.


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.


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


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


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


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.


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.


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


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


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


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


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.


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


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


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4. COMMISSIONING

ISO - 05 4. Commissioning

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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


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


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


4-4 E8NH

Pilot valves

without manual override

Manual override locking

Manual override pushing

Fig. 4/3: Variations of the manual override


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


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


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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 screwdriver 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


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


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


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


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

Documents

Valve terminal type 05 - Festo