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5.4.4 Conversion to single solenoid or double solenoid valve

locations

The valves (single or double solenoid) which can be
fitted into a valve location are determined by the man-
ifold block.

In order to convert a valve location to single or double
solenoid, you must replace the manifold block on the
appropriate sub-base.

For conversion you will require:

– manifold block CPA..-EV1 for a single solenoid valve

location

– manifold block CPA..-EV2 for a double solenoid valve

location

By means of the identification on the manifold block,
you can ascertain which manifold blocks are fitted on
your CPA valve terminal (see diagram).

EV1: manifold block for single solenoid valve location
EV2: manifold block for double solenoid valve location

Fig. 5/7: Identification of the manifold blocks

AAAA

AAA

AAAA

5. Maintenance and conversion

5-22

CPA... 9808A

Summary of Contents for CPA VI Series

Page 1: ...AAA AAA AAA AAA AAA AAA AA AA AA AA AA AAA AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA...

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Page 3: ...1998 The copying distribution and utilization of this docu ment as well as the communication of its contents to others without expressed authorization is prohibited Of fenders will be held liable for...

Page 4: ...Order no 173 515 Title MANUAL Designation P BE CPA GB II CPA 9808A...

Page 5: ...2 3 2 1 1 Fitting onto a wall 2 4 2 1 2 Fitting onto a hat rail 2 5 3 Installation 3 1 General connecting principles 3 3 3 2 Connecting the CPA valve terminal 3 5 3 2 1 Auxiliary pilot air 3 5 3 2 2...

Page 6: ...sub base or manifold block 5 10 5 4 Conversion work on the CPA valve terminal 5 17 5 4 1 Conversion from pushing to pushing locking manual override 5 17 5 4 2 Conversion to internal or external pilot...

Page 7: ...ted use in their original state without modifications by the customer in a faultless technical state The specified limits for pressures temperatures electri cal data torques etc must be observed Pleas...

Page 8: ...ctograms Danger categories A distinetion is made between the following instructions WARNING This means that failure to observe this instruction may result in serious injury to personnel and or damage...

Page 9: ...or undefined voltage states of the electronic components with subsequent effects in con nected circuits Electrostatically vulnerable components These may be damaged if their contact surfaces are touc...

Page 10: ...A AAAA AAAA AAAA AAAA A A A A A A AAAA AAAA AAAA AAAA AAAA AAA AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA A A A A A AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AA...

Page 11: ...valve terminal pneumatics CP modules electronics Content Special information on commissioning programming and diagnostics related to the node used Information on fitting installing and commissioning...

Page 12: ...plates with Ident code B E G H J K M and N see chapter System summary Description of the components AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA AA AA AA AA AA AA AAA AAA...

Page 13: ...modules which can be combined in a CP system CP system Complete system consisting of CP field bus node and CP modules CPA valve terminal CPA valve terminal type 12 for field bus systems or with IC MP...

Page 14: ...he exhaust air as well as for connecting silencers HHB Manual override I O Input output modules Manifold base Block for electrical linking of the valve solenoid coils with the electrical sub base Pin...

Page 15: ...Chapter 1 System summary 1 System summary CPA 9808A 1 1...

Page 16: ...Contens 1 System summary 1 1 Summary of variants 1 3 1 2 Description of the components 1 6 1 System summary 1 2 CPA 9808A...

Page 17: ...or system Due to its compact structure the CPA valve terminal can be fitted very closely to the actuators to be control led As a result shorter compressed air tubing can be used Flow losses are there...

Page 18: ...AAAA AAAA AAAA AAAA AAAA AAAA AAAA AA AA AA AA AA AA AAAA AAAA AAAA AAAA AAAA AAAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA...

Page 19: ...minal with CP con nection This CPA valve terminal is connected to the AS i bus by means of a special AS i cable It is available with two types of electrical connections CPA valve ter minal with AS i c...

Page 20: ...enoid valves Sub base with work connections with without isolation of compressed air channel 1 and for additional pressure supply Left hand end plate with supply and exhaust connections and support fo...

Page 21: ...r of valve locati ons is limited by the tie rod to 22 By means of the identification code you can ascertain the plates which are fitted on your CPA valve terminal This code is printed on the front of...

Page 22: ...ion the flow from com pressed air supply 1 to output 2 is blocked The following valves are available Valve plates Valve plate Ident code M Function single solenoid 5 2 way valve PLEASE NOTE No of assi...

Page 23: ...d 3 2 way valve basic position open Ident code B Function 5 3 way valve in mid position pressurized Ident code G Function 5 3 way valve in mid position blocked Ident code E Function 5 3 way valve in m...

Page 24: ...AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA AAA AAA AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA...

Page 25: ...erminal with IC connection AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA...

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Page 28: ...A A A A A A A A AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA...

Page 29: ...Chapter 2 Fitting 2 Fitting CPA 9808A 2 1...

Page 30: ...Contents 2 Fitting 2 1 Fitting variants 2 3 2 1 1 Fitting onto a wall 2 4 2 1 2 Fitting onto a hat rail 2 5 2 Fitting 2 2 CPA 9808A...

Page 31: ...compo nents 2 1 Fitting variants The CPA valve terminal can be fitted into a system or machine in one of the following ways Fitting with wall Fitting onto a hat rail PLEASE NOTE If in the case of a CP...

Page 32: ...unting surface see diag ram for distance between holes CPA10 terminal CPA14 terminal 1 2 3 4 66 3 mm 23 mm 10 6 mm x number of sub bases 4 holes for fitting onto feet 76 1 mm 26 mm 14 6 mm x number of...

Page 33: ...o clamping el ements Proceed as follows 1 Make sure that the mounting surface can support the CPA valve terminal 2 Fit the hat rail support rail EN 50022 35x7 5 width 35 mm height 7 5 mm Make sure the...

Page 34: ...of the hat rail see arrow B Make sure that the clamp ing element lies horizontal parallel to the hat rail 7 Secure the CPA valve terminal against tipping or sliding by tightening the screws on both si...

Page 35: ...Kapitel 3 Installation 3 Installation CPA 9808A 3 1...

Page 36: ...3 2 Connecting the CPA valve terminal 3 5 3 2 1 Auxiliary pilot air 3 5 3 2 2 CPA valve terminal with separation of pressure zones 3 9 3 2 3 Connecting the supply exhaust and work lines 3 11 3 2 4 Con...

Page 37: ...voltage supply for the valve solenoid coils You can thereby avoid uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic com...

Page 38: ...erview of the system using either tube straps or multiple hose holders Disconnecting 1 Press down the locking ring A of the Pin type connector or of the screw connector 2 Pull out tube B 3 Seal non re...

Page 39: ...at high speeds when several valves are switched to through flow at the same time 3 2 1 Auxiliary pilot air The CPA valve terminal can be operated with either in ternal or external auxiliary pilot air...

Page 40: ...d blind plug see diagram 1 Connection sealed with blind plug Fig 3 2 Internal auxiliary pilot air AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AA...

Page 41: ...ensure reliable faultless operation of the CPA valve terminal If your CPA valve terminal is fitted with valve plates with Ident code H K or N 3 2 way valves the external auxiliary pilot air must be se...

Page 42: ...PA14 valve plates with Ident code N K or H Please note that the regulated external auxiliary pilot air for all the valve plates on the CP terminal is supplied is taken via common tubing on the right h...

Page 43: ...ure zones are operated with compressed air which is supplied on the left hand side of this sub base see Fig 3 5 The number of pressure zones with which your CPA valve terminal is equipped is indicated...

Page 44: ...he above mentioned sub bases must be sealed with blind plugs or threaded blind plugs 1 2 3 4 5 Additional pressure supply plate Identification of the sub bases with separate pressure zones grey point...

Page 45: ...ion 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 4NPT 2 or 4 12 14 82 84 With CPA14 terminal val...

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Page 47: ...AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA...

Page 48: ...erminal 1 Common 3 5 Central 82 84 4 5 6 Central 3 5 CPA valve terminal 2 Common 82 84 Fig 3 8 Common lines with non return valves In the case of CPA valve terminals with two or more pressure zones an...

Page 49: ...valve plates 5 2 way valve single solenoid type M 5 2 way valve double solenoid type J 5 3 way valve pressurized in mid position type B blocked type G or exhausted type E PLEASE NOTE Valve plates wit...

Page 50: ...electric shock protection against di rect and indirect contact is guaranteed on Festo valve terminals by the use of PELV power units in accord ance with EN 60204 1 IEC 204 The valve terminals must be...

Page 51: ...24 AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA A A A A A A A A A A AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AA...

Page 52: ...Fitting the individual connecting sockets AA AA AA AA AA AA AA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA AAA AAA AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA...

Page 53: ...tipin or AS i connections can be found on the information sheet supplied with the product CPA valve terminals with CP connection Connecting the CP cable Detailed instructions on connecting the CPA val...

Page 54: ...3 Installation 3 20 CPA 9808A...

Page 55: ...Chapter 4 Commissioning 4 Commissioning CPA 9808A 4 1...

Page 56: ...Contents 4 Commissioning 4 1 Commissioning and testing the valves 4 3 4 2 Locating faults 4 11 4 Commissioning 4 2 CPA 9808A...

Page 57: ...he valve cylinder combination by means of manual override Full commissioning of complete system Install and connect the complete system Program control by PLC industrial PC Commissioning of the pneuma...

Page 58: ...ating voltage When manual override functions are in the switched position actuators can perform sudden undesired movements resulting possibly in injury to humans and damage to property Make sure that...

Page 59: ...rride variants are available on the CPA valve terminal with MP CP or AS i connection Locking manual override Automatic reset manual override Slide of locking manual override to pilot solenoid 14 Slide...

Page 60: ...ual overrides to the valve solenoid coils is shown in the following diagram Locking and automatic reset plunger of manual override to pilot solenoid 14 Locking and automatic reset plunger of manual ov...

Page 61: ...en cause injury to humans Supply the auxiliary pilot air separately via the right hand end plate 3 to 8 bar The auxiliary pilot air must be applied at full pressure immediately after switching on in o...

Page 62: ...ut test 1 Switch on the compressed air supply 2 Check the functioning and effect of each individual valve cylinder combination by actuating the manual override as shown in the following diagrams PLEAS...

Page 63: ...ot turn the pressed down plunger on CPA valve terminals with IC connection Otherwise the manual override will lock in The valve assumes the switch position Hold the plunger of the manual override pres...

Page 64: ...ains in switch position CPA valve terminal with MP CP or AS i connection Push the plunger of the manual override as far as possible into the inner position CPA valve terminal with IC connection Turn t...

Page 65: ...ition Switch position Basic position Check the tubing Check the tubing After switching on regulate external pilot air to 3 to 8 bar Valve or pneumatic system does not react as expected does not react...

Page 66: ...ssure zones Limitation of pressure zones by isolation plate Can be fitted at a later stage Vacuum low pressure operation Separately supplied regulated auxiliary pilot air 3 8 bar Controller can only b...

Page 67: ...e the assignment of the LEDs to the appropriate manual override left hand LED in the electrical bridge for the front ma nual override 12 right hand LED in the electrical bridge for the rear manual ove...

Page 68: ...PA valve terminals with IC connection The LEDs show the switching status of the valve sole noid coils The meanings are explained in the table below LED Switching status of valve Meaning Yellow out Bas...

Page 69: ...Chapter 5 Maintenance and conversion 5 Maintenance and conversion CPA 9808A 5 1...

Page 70: ...er 5 9 5 3 3 Replacing the end plate sub base or manifold block 5 10 5 4 Conversion work on the CPA valve terminal 5 17 5 4 1 Conversion from pushing to pushing locking manual override 5 17 5 4 2 Conv...

Page 71: ...sources of power the compressed air supply the voltage supply to the valve solenoid coils You will thereby avoid uncontrolled movements of loose tubing undesired movements of the connected actuators...

Page 72: ...s Procedure CP connection Loosen the union nut of the incoming and if necessary of the continuing CP cables MP connection Loosen the diagonally offset fastening screws of the SUB D multipin plug Pull...

Page 73: ...wn the blue clamping ring of the Pin type connector or of the screw connector 3 Pull off the pneumatic tubing of the Pin type connector or of the screw connector Loosening the CPA valve terminal on a...

Page 74: ...terminal AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA A...

Page 75: ...ode M can be fitted into a valve location with manifold block EV1 without the need to convert the manifold block 5 3 2 Replacing valve reserve or additional pressure supply plates Before a valve plate...

Page 76: ...h MP CP or AS i connection carefully clip the electrical bridge onto the new valve plate Make sure that the plugs of the solenoid coils do not break off AAA AAA AAA AAA AAA AA AA AA AA AAAA AAAA AAAA...

Page 77: ...s with 0 2 Nm 5 3 2 Replacing fitting the surface silencer Proceed as follows 1 Loosen the four fastening screws of the surface silencer or end plate cover 2 Remove the surface silencer or the end pla...

Page 78: ...serts from the sub base to be replaced Unlock the pin type inserts by removing the clamping spring with a screwdriver Pull the pin type inserts out of the sub base see diagram Use a screwdriver for th...

Page 79: ...e components on the sub bases to be re placed see this chapter Replacing valve reserve or additional pressure supply plates AAA AAA AAA AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAA AAA AAA AAA AAA AAA...

Page 80: ...A AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AA AA AA AA AA AA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AA AA AA AA AA AAA AAA AAA AAA A...

Page 81: ...from the sub base Fig 5 8 Dismantling the manifold block 1 AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AA AA AA AA AA AA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA...

Page 82: ...the guide rail of the new sub base until it locks into place 2 Check the free seals for damage Replace damaged seals Place the seals in the appropriate grooves of the sub base and the manifold plate...

Page 83: ...se 5 Place the end plate on the tie rod and screw the tie rod screws a few turns into the tie rod 6 Place the CPA valve terminal on a flat surface so that the components are not offset AAAA AAAA AAAA...

Page 84: ...0 Tighten the fastening screws of all components on the sub bases again with CPA10 0 2 Nm 0 05 Nm CPA14 0 3 NM 0 1 Nm 11 Place the pin type inserts in the sub bases see chapter 3 Installation section...

Page 85: ...e or double solenoid valve locations 5 4 1 Conversion from pushing to pushing locking manual override You can convert CPA valve terminals with MP CP or AS i connection from pushing to pushing locking...

Page 86: ...ew driver as shown in Fig 5 10 2 The locking clip will then bend and can be removed from its fixing Removing the locking clip by lifting it out clip can be re used Removing the locking clip by pressin...

Page 87: ...lot air Right hand end plate Description for internal pilot air Connection 12 14 in right hand end plate is not marked and is sealed with a blind plug The auxiliary pilot air is taken internally from...

Page 88: ...l pressure supply plate CPA10 DP U AW or CPA14 DP U AW In the case of CPA valve terminals with MP CP or AS i connection we recommend that the conversion be car ried out from the right hand side The ti...

Page 89: ...AAA AAA AAA AAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA AAA...

Page 90: ...valve location EV2 manifold block for double solenoid valve location Fig 5 7 Identification of the manifold blocks AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA...

Page 91: ...ifold block CPA EV1 occupies 1 address manifold block CPA EV2 occupies 2 addresses How to replace a manifold block is described under Replacing the end plate sub base or manifold block in this chapter...

Page 92: ...ew for extending this CPA valve terminal to 8 valve locations Long tie rod screw for extending this CPA valve terminal to 9 valve locations Fig 5 14 Extending the CPA valve terminal AA AA AA AA AA AAA...

Page 93: ...ew for valve terminals with an odd number of valve locations CPA ZA SL The table below shows the tie rod components which you will require for adding valve locations Number Starting basis valve termin...

Page 94: ...below shows the tie rod components which you will require to adapt the length of the tie rod Number Starting basis valve terminals with an even number of valve locations Starting basis valve terminals...

Page 95: ...in this chapter 3 Dismantle the appropriate end plate and pull the valve locations away from the tie rods If necessary remove also the appropriate valve locations see section Replacing the end plate...

Page 96: ...ve reserve and addi tional pressure supply plates in this chapter 2 Fit the appropriate components into the empty valve locations see section Replacing the end plate sub base or manifold block in this...

Page 97: ...Technical appendix A Technical appendix CPA 9805NH A 1...

Page 98: ...Contents Technical appendix A 1 Accessories A 3 A 2 Technical specifications A 4 A 3 Index A 10 A Technical appendix A 2 CPA 9805NH...

Page 99: ...CNT 115 230 V AC ASI 1 5 Y 100 ASI 1 5 Z 100 ASI FK KK ASI KT FK CPA valve terminal with CP connection CP cable KVI CP 1 KVI CP 2 can be used with drag chain CPA valve terminal with IC connection Indi...

Page 100: ...m CPA14 0 2 Nm 0 05 Nm CPA14 0 3 Nm 0 1 Nm 0 7 Nm 0 1 Nm 1st stage 0 5 Nm CPA10 CPA14 2nd stage 1 5 Nm CPA10 or 2 0 Nm CPA14 Materials plates cover valve plate seal PPS PA6T X GF40 AL DD PPS ST AL NBR...

Page 101: ...14 2 8 bar Valve plate Ident code M N K H B G E 1 12 14 3 8 bar Valve plate Ident code B E G J M 12 14 3 8 bar Valve plate Ident code N K H 12 14 see diagram Valve plate Ident code B E G J M 1 0 9 10...

Page 102: ...l pressure 12 14 bar Working pressure P1 bar Startup control pressure Reset control pressure Fig A 2 External pilot air diagram for valve plates CPA14 Ident code N K or H 3 4 2 1 A Technical appendix...

Page 103: ...d 5 2 way valve double solenoid all 3 2 way valves 5 3 way valve pressurized 5 3 way valve closed 5 3 way valve exhausted 1 2 bzw 1 4 280 300 220 220 130 330 200 2 3 5 bzw 4 3 5 280 300 220 220 330 20...

Page 104: ...lves 5 3 way valve pressurized 5 3 way valve closed 5 3 way valve exhausted On 11 Switch 7 On 8 On 13 On 13 On 13 Off 18 Off 18 Off 17 Off 17 Off 20 Mini valves CPA14 M J N K H B G E 5 2 way valve sin...

Page 105: ...oltage Operating voltage Tolerance 24 V DC 20 4 26 4 V Current consumption per solenoid coil Rated current CPA valve terminal with CP connection Rated pickup current Rated current with current drop 30...

Page 106: ...al CP connection 1 13 electrical CPA valve terminal IC connection 1 11 electrical CPA valve terminal MP connection 1 12 pneumatic 1 10 Conversion manual override 5 17 CP connection 1 13 CPA valve term...

Page 107: ...1 11 CPA valve terminal MP connection 1 12 Double solenoid valve location conversion 5 22 E EMERGENCY STOP 4 12 External pilot air 3 8 5 19 F Fastening accessories fastening profile for wall fitting...

Page 108: ...gns 4 5 4 6 locking 4 10 pushing 4 9 Micro valves 1 5 Mini valves 1 5 Mounting kit for hat rail fitting 2 5 Mounting variants 2 3 MP connection 1 12 N Notes on this manual VIII O Operating elements pn...

Page 109: ...s A 4 R Rated flows A 6 Replacing the valve plate 5 7 Replacing the end plate 5 10 Replacing the manifold plate 5 10 Replacing the sub base 5 10 Replacing the surface silencer 5 9 Rplacing the additio...

Page 110: ...es A 4 Tubing variants 3 4 U User instructions VI V Vacuum operation 3 15 4 12 Valve locations adding 5 25 graduation 1 4 removing 5 26 Valve plates X 1 7 identification code 1 7 Valve switching times...

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