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Chapter 4

Commissioning

4. Commissioning

CPA... 9808A

4-1

Содержание CPA VI Series

Страница 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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Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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Страница 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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Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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