Connection system for solenoid valves and spool valves designed for fieldbus systems PROFIBUS-DP, INTERBUS-S, DEVICE-NET

Transcription

1 Installation manual ValveConnectionSystem Connection system for solenoid valves and spool valves designed for fieldbus systems PROFIBUS-DP, INTERBUS-S, DEVICE-NET MS-P575-5.GB.Ra GB

2 ! CAUTION! To avoid malfunction of the automation system, please read and follow these instructions: Ensure that the address size is correctly set. It may only be changed by qualified personnel. Make sure the VCS connector is correctly wired. The VCS circuit must always be looped through. Only use approved profiled cables (see.). Only use approved power supplies (see.). Be sure the power supply is switched off prior to contacting the VCS cable. Risk of short circuit! To ensure personal safety and prevent damage to property, all maintenance and installation work must be carried out by qualified personnel. Make sure to meet the electrical specifications of the system when operating it together with third-party equipment and components. Install all power and signal cables such that inductive and capacitive interference of the automation functions is avoided. Take all safety precautions when coupling the inputs and outputs to the hardware and software to avoid undefined conditions on the signal side of the automation system in case of line or conductor break. To ensure safe operation of the product, provide for suitable transportation, storage, installation and assembly as well as proper operation and maintenance.! WARNING! In the case of equipment with permanently installed connections (fixed devices/systems) without all-pole mains disconnect switch and/or switch fuses, incorporate a mains disconnect switch or fuse in the building installation. The equipment must be connected to a ground conductor. In the case of line powered equipment, check that the set nominal voltage range is in compliance with the local supply voltage prior to putting the equipment in service. In the case of a V power supply, provide for safe electrical separation of low voltage. Only use power supplies manufactured in compliance with IEC 6--. Take precautions to ensure that a program interrupted due to drop or loss of voltage is properly resumed. Dangerous operating conditions must be avoided at all times. If necessary, provide for an emergency shutdown. To avoid operational failure, do not directly connect high frequency between 50 and 900 khz to the VCS cable. In all cases in which faults occurring in automation equipment may result in substantial material or even personnel damage, i.e. in which dangerous faults may occur, take additional external precautions or provide for additional external equipment to ensure and/or force safe operation in the case of a fault (e.g. independent limiting switches, mechanical interlocks etc.). ESD CAUTION OBSERVE PRECAUTIONS FOR HANDLING ELETROSTATIC SENSITIVE DEVICES This product contains electronic components sensitive to electrostatic discharge. An electrostatic discharge generated by a person or object coming in contact with the electrical components can damage or destroy the product. To avoid the risk of electrostatic discharge, please observe the handling precautions and recommendations contained in standard EN Do not connect or disconnect the device when it is energised. This product complies with the essential requirements of the EMC Directive 89/6/EEC and its amendments. It is CEapproved. A separate Declaration of Conformity is available on request. A separate Declaration of Incorporation relating to the EU Directive 89/9/EEC Annex II B is available on request. Please provide ordering code and serial numbers of products concerned. NOTICE The information in this manual is subject to change without notice. In no event shall ASCO/JOUCOMATIC be liable for technical or editorial errors or omissions. Neither is any liability assumed for accidental or consequential damages arising out of or in connection with the supply or use of the information contained herein. THIS MANUAL CONTAINS INFORMATION PROTECTED BY COPYRIGHT. NO PART OF THIS DOCUMENT MAY BE PHOTOCOPIED OR REPRODUCED IN ANY FORM OR MANNER WHATSOEVER WITHOUT PRIOR WRITTEN PERMISSION FROM ASCO/JOUCOMATIC. COPYRIGHT 00 - ASCO/JOUCOMATIC - All rights reserved.

3 CONTENTS Page. VCS - VALVE CONNECTION SYSTEM. Structure. Diagnostics 5. SYSTEM COMPONENTS 6. Description 6. VCS connector 8. VCS cable 9. VCS interface 0.5 VCS power supply: 7V/max.. A 7.6 Power supply: V/max. 0 A 7.7 Accessories 8. POWER SUPPLY ON VCS LOOP 0. Principle 0. Power supply of coils. W 0. Power supply of coils >. W (max. W) 5. Power supply of coils. W and >. W 7.5 Supply of VCS loop with a standard V power supply 8.6 Selection charts (summary) 0. INSTALLATION INSTRUCTIONS. Power supply connection. Subsequent extension of the system. VCS connector replacement 5. CONNECTION TO STANDARDISED FIELDBUS SYSTEM 5 5. Profibus-DP 5 5. Interbus-S 6 5. DeviceNet 7 6. START-UP 9 6. Start-up instructions 9 6. Automatic addressing 9 6. Test mode 0 6. Error mode 7. VCS DIAGNOSTIC SOFTWARE (VCS - DIAG) 7. Program installation 7. Connection of the VCS interface 8. TECHNICAL CHARACTERISTICS 8. Electrical characteristics 8. Dimensions and weights 9. MAINTENANCE AND CARE 6 0. MEGA 8 SPOOL VALVE ISLANDS WITH VCS CONNECTORS 7 0. Presentation 7 0. Dimensions and weights 7 0. Ordering information for MEGA island with VCS connectors 8 0. Accessories Pressure supply of pilot valves Mounting and pneumatic accessories Assembly of MEGAislands/VCS connectors Joinable solenoid air operated MEGA spool valves 5 VCS Application Requirements Form 55

4 . VCS - VALVE CONNECTION SYSTEM The Valve Connection System, VCS in short, was designed to link together as many valves as possible in an easy, quick and economic way.. Structure fieldbus I P B 6 G Solenoid spool valve alone or installed on multiple subbase MEGA spool valve island General purpose solenoid valve General purpose valve 5 Air-operated valve actuator 5 (C) All combinations of spool valves for pneumatic or water applications, solenoid air operated valves or general purpose valves can be connected together in one V.C.S. loop. Up to 7 V.C.S. connectors and 5 sensor inputs up to a distance of.5 km! (C) 6 VCS module with 8 inputs I P G B VCS interface VCS power supply VCS cable (green) Power cable (black) C Sensor inputs With this new valve connection system, you can connect up to 7 valves with solenoid coils each (bistable valves) and up to 5 sensor inputs with a single cable and a quick-contact technology. Fieldbus systems (e.g. Interbus-S or Profibus-DP) are increasingly being used in installations and machines to connect sensors and actuators to a controller (PC or PLC). It is in this kind of structure that the VCS is integrated together with its VCS interface. The VCS interface communicates with the higher-level fieldbus system and transmits the switching information to the valves. The corresponding feedback (C) from the digital sensor inputs (limit switches) is transmitted over the line to the VCS interface and from there to the fieldbus system. The valves or nodes in the VCS line are connected with each other and to the VCS interface (I) over a profiled -wire VCS cable (G). Power as well as data are supplied to each valve over this VCS cable. To enable easy and quick connection of the valves to the VCS cable, ASCO/JOUCOMATIC s engineers have designed a special VCS connector which is fitted onto the valve and into which the profiled -wire VCS cable is placed. When the lid of the connector is snapped shut, the vampiretype plug automatically provides for immediate contact of the wires of the VCS cable which is also automatically cut to length. The node is connected. Each VCS connector is equipped with a data repeater to bridge a distance of up to 0 m between two valves. This allows for designing large valve systems. No tools are necessary to fasten the lid. You simply snap it shut. No cable cutting, stripping or screwing is required. In the basic version, the VCS interface is connected to a VCS power supply (P). Depending on the number of valves in the valve connection system and its size, additional power supplies can be clamped directly onto the cable to provide for an appropriate power output and compensate for any drop of voltage. In order to ensure the highest possible transmission protection, the VCS line is structured in the form of a loop system, i.e. the last valve in the line must again be connected to the VCS interface. The advantage is that the transmitted data is fed back to the VCS interface for comparison. The outputs are switched only after the transmitted data and the feedback data is 00 % identical.

5 VCS characteristics : Max. number of connectors in a line : 7 (for solenoid valves or monostable / bistable spool valves) Max. number of connectable sensors (ØM8) : 5 (data readback from sensors) VCS addressing : automatic :easy startup and operation Electrical connection / spool valve : special vampire-type VCS connector size 5 for quick connection Electrical connection of VCS/Interface loop : screw terminals Contact/electrical connection : no tools, no cable cutting / stripping Max. distance between two valves : 0 m Max. length of the line :.5 km Supply voltage / spool valve : V DC Current/Max. output power : Depending on the connector version proposed : - 00mA (,W) per output with green VCS cable to be used with,a power supply unit - A (W) per output with circuit and 0A auxiliary power supply unit circuit for control of solenoid valves with ratings greater than >,W, series and 9 and all fluid solenoid valves - or 00 ma (,W) per output with green cable and separate power circuit (black cable) for emergency shutdown management (see overleaf) Data protection : data readback and comparison, repeater in each VCS connector, parity check. Cycle time : approx., ms with 7 connectors Protection degree : VCS connector : IP65 - power supply and interface : IP0 Electromagnetic compatibility : in accordance with EU directive EMC/89/6/EEC. CE mark. Diagnostics The VCS has a fine-diagnostic feature. Each VCS connector cyclically transmits diagnostic information which is analysed by the VCS interface. As a result, the VCS system detects: valve low voltage, VCS connector overheating, overcurrent at valve output The VCS interface also has comprehensive error analysis features. It is provided with an RS- interface which can be connected to a PC. The system can be started up (even without fieldbus) and analysed with the supplied diagnostic software. The following functions are activated over PC: setting of valve outputs, reading of sensor inputs, reading of diagnostic information, checking of actual configuration, address allocation. The VCS system consists of four principle components (see following pages): A VCS connector to be mounted to a solenoid valve or spool valve (C) The VCS interface adapted to the protocols Profibus-DP, Interbus-S and Device-Net (I) The VCS power supply (P) The green VCS cable (G) + the black cable (b) for separate power supply for outputs (if required) Fieldbus P VCS Interface I C 5

6 . SYSTEM COMPONENTS. Description A. VCS connector (see chap..) Accessories Description Code VCS connector size 5, V DC with outputs max. 00 ma (connection exclusively over green cable) VCS connector size 5, V DC with outputs max. 00 ma and auxiliary power supply (connection with green and black cable) VCS connector size 5, V DC with output max. A and auxiliary power supply (connection with green and black cable) without input with inputs ØM8 without input with inputs ØM8 without input with inputs ØM8 Adapter 5/ for VCS connector mounting on coil size to industrial standard ( flat pins DIN6 + earth, distance between pins mm) single unit box of single unit box of single unit box of single unit box of single unit box of single unit box of Adapter 5/0 VCS connector mounting on coil with pins + earth to ISO 00 standard B. VCS interface (see chap..) Accessories Description Code Standard VCS interface for connection with protocol: VCS interface with analog inputs/outputs 0-0V (e.g. for Sentronic) for connection with protocol: 9 male pin SUB-D connector for Profibus-DP - IP0 Profibus-DP Interbus-S Device-Net Profibus-DP Interbus-S Device-Net ( * ) female pin SUB-D network input connector for Interbus-S - IP0 (BUS/IN) male pin SUB-D network output connector for Interbus-S - IP0 (BUS/OUT) Configuration diskette (.GSD /.EDS) for Profibus-DP and Device-Net Diagnostic software for VCS / PC ( * ) RS cable for VCS interface/pc connection. Length:.8 m (only for use with diagnostic software) VCS installation manual ( ) future product * 6

7 C. Power supplies (see chap..6) Accessories Description Code VCS power supply 7V DC -.A Power supply for black power cable, V DC adjustable - 0A D. Cables (see chap..) Accessories Description Code Flat profiled VCS cable, green, wires - lengths: Flat power cable, black, wires - lengths: 5 m 50 m 00 m 5 m 50 m 00 m VCS adapter (round/flat) for connection of additional VCS power supply right-angle outlet with cable gland for round cable dia. to 6mm Extension module for flat VCS cable or power cable (flat/flat) set of 0 self-adhesive flat cable mounting clips set of heat-shrinkable 0 end caps for flat cable ends to ensure IP65 protection set of 7 clip-on ID labels for spool valves and VCS connectors (Note: each component is supplied with ID labels at delivery) set of 0 guides for green VCS cable Note: each VCS connector is supplied with this guide + spare guide set of 0 guides for black power supply cable Note: each VCS connector is supplied with this guide + spare guide E. VCS input modules Accessories Description Code VCS input module, 8 PNP inputs, 8 x M8 connectors Straight male pin input connector M8 (cable dia..5 to 5mm) Right-angle male pin input connector M8 (cable dia..5 to 5mm)

8 . VCS connector View from bottom for monostable and bistable valves 5 LINK PE : OUT 0 : V DC ±0 % : OUT Nr. Description - Solenoid valve connection, 5 mm (), pins - Lever to contact the green VCS cable and the black power cable - Green VCS cable guide - Black power cable guide (depending on the VCS connector version) 5 - Green VCS cable 6 - Black power cable (depending on the VCS connector version) 7 - LED indicator for inputs 0 and : green light if input is connected. 8 - LED indicator for valve outputs 0 and : Output 0 pneumatic function (yellow) Output pneumatic function (green) 9 - Clip-on identification labels to indicate the valve function 0 - Lever catch - Screw to mount the VCS connector to the solenoid valve Connection for inputs (limit switches): M8 female panel connector (see below) - Input 0: depending on the VCS connector version - Input : depending on the VCS connector version - Clip-on identification labels to indicate the input function 5 - Seal for solenoid valve () Solenoid valve connection, 5mm, pins (space 9,mm) + PE for monostable and bistable valves.. Wiring diagram of inputs View on soldered side of male connector -wire sensor IN V Sensor -wire sensor (magnetoresistive position detector) IN V + Sensor wires GND - V ±0 % GND* IN 0/IN * not applicable for -wire sensor Cable inlet:.5-5 mm. 8

9 . VCS cable.. VCS cable installation! Be sure the power supply is switched off prior to contacting the VCS cable. Risk of short circuit! You can install it in just seconds!! Power off 6 before any connection/disconnection A A 5 A. VCS cable Open the lever by pressing the catch. Lift the lever until it snaps into the buffer. Mount the empty cable guide (A) into the cable tray. In case the cable guide snaps in at the bottom, pull it up with a screw driver. The cable guide must snap in at the top to ensure for proper contacting. 5 Insert the cable by first inserting the profiled side and then the opposite side. The arrow on the cable must show in the same direction as the arrow on the lever. 6 Press down the lid until the catch snaps in: the cable is cut to length and contacted. B. Black power cable i The same procedure as for the green VCS cable. But the black power cable is not cut to length. Insert the green VCS cable into the green cable guide (A) (see above illustration) and the black power cable into the black cable guide... Wiring instructions for the flat cables The VCS cable and the black power cable must only be bent towards the broad, flat side of the cable. Both cables must be mounted without strain. 9

10 . VCS interface 6 PROFIBUS-DP ERROR R POWER TERM DIA x0 x INTERFACE ADDRESS ON 00 0 RUN DATA > T SIZE ValveConnectionSystem OFF ON 7 7 V OUT <V ERR TEST 8 RSC 5 Ref. Description - Setting and connection for fieldbus interface. - RS-C interface for connection to a PC (VCS-DIAG). - DIP switches for configuration of interface and selection of operating mode. - LED indicators for display of operating state. 5 - VCS connecting terminals. 6 - Optional connecting terminals for analog inputs/outputs (Sentronic). 7 - Reset button, restart of VCS interface... VCS connecting terminals VCS SUPPLY STANDARD SUPPLY 7V 0V +U GND VCS OUT VCS IN _ + + _ blue brown brown blue POWER CONTROL IN V 0V Ref. Description 8 - Connection to ground: to be connected to the machine ground. 9 - VCS power supply connections (see chapter.). 0 - Beginning of VCS loop. - End of VCS loop (return). - Voltage control input for black power cable (see chapter.). To connect the VCS cable to the VCS interface, strip the profiled cable by approx. 0 mm and protect each wire end with a sleeve. 0

11 .. Analog input/output signals (Option) Connecting terminals for proportional valve (sentronic) 5 SENTRONIC SENTRONIC SENTRO SUPPLY SUP SET SUP SET V GND SET GND Feedbk V GND SET GND Feedbk V GND Ref. Description - Analog input/output signals for proportional valve connection (Sentronic etc.) - Analog input/output signals for proportional valve connection (Sentronic etc.) 5 - Power supply connection for analog inputs/outputs (must be connected for analog input/output option) Connection of SENTRONIC or PULSTRONIC to VCS interface terminals Signal Function SENTRONIC Pin assignment PULSTRONIC Pin assignment V Power supply SUP - GND common ground SET Setpoint (0-0V) SET - GND - - Feedbk Feedback value (0-0V) 6 * ) Only if the feedback (0-0V) option is used. *.. Assignment of RS-C interface Pin Signal Function T D Transmitted data R D Received data 5 GND Common ground A one-to-one cable in which R D and T D are not crossed is used for connection to a PC. Data transmission occurs without parity bit at a rate of 900 baud.

12 .. LED indicators A flashing sequence is run as soon as the VCS interface is switched on. Subsequently, RUN and 7V are permanently lit. See chapter 6. if these controls do not light up. The DATA LED indicates a general communication problem. LEDs >T, <V and OUT indicate group errors. For detailed information, see chapter 6. (operative malfunction). LED Error description INSTALLATION 7 V flashes in case of internal error; lights up constantly during faultless operation; does not light up when supply voltage is not available. RUN lights up constantly during faultless operation; does not light up in case of internal error. DATA Too many errors when transmitting data in the VCS loop. No safe data transmission possible (see General error chapter 6.). >T Overheating in either one or several VCS connectors. The temperature inside the connector has Group error exceeded 85 C. Check VCS connector and valve. OUT Overcurrent at the output of either one or several VCS connectors. The output current is above Group error 00 ma. Check VCS connector and valve for short circuit. <V Low voltage at either one or several VCS connectors. The supply voltage of the VCS cable has Group error dropped below 9 Volt. Check the load, add another VCS power supply if necessary. For group errors, the number of the faulty VCS connector can be indicated by LEDs 00, 0,. For this purpose, set the ERR switch to ON (see chapter 6.)...5 DIP switches ERR Test 0 0 Fieldbus communication: Stop at errors <V, >T, OUT, DATA. The outputs are switched off. 0 Test mode 0 Error indication Fieldbus communication: Do not stop at errors <V, >T, OUT. The outputs are not switched off. Stop at error DATA. ERR - Error : indicates where the error is located with the help of the LED indicators (see above) TEST - Test mode : locates an interruption in the VCS loop (see chapter 6.) SIZE : defines the address space of the VCS interface in the fieldbus system and/or PLC. The address space can be adjusted to the number of VCS connectors used. Unoccupied address space can thus be set free for other control operations. i RUN DATA > T 7 V OUT <V The address space must always be larger than the number of VCS connectors in the loop; otherwise an error is reported on the LED indicators when the system is started. Size Address space (number of bytes occupied) Max. number Dec. 8 without analog input/output option with analog input/output option of VCS connectors ERR TEST SIZE 8 OFF (0) ON ()

13 Without analog input/output option: (A = Address space) A = (size + ) [in byte] Bytes are reserved for diagnostic purposes. With analog input/output option: A = (size + ) [in byte] Bytes are reserved for diagnostic purposes and another bytes for the analog input/output option. Max. number of connectable VCS connectors (VCS max ): VCS max = (size + ) 8 Address space assignment in the fieldbus system of the PLC: A. Without analog input/output option Rel. Address Bit 7 Bit 6 Bit 5 Bit Bit Bit Bit Bit 0 Function 0 VCS connector VCS connector VCS connector VCS connector VCS connector 8 VCS connector 7 VCS connector 6 VCS connector VCS connector VCS connector VCS connector 0 VCS connector VCS connector 6 VCS connector 5 VCS connector VCS connector x x VCS connector VCS connector VCS connector N- [(N-)]- [(N-)]- [(N-)]- (N-).7 (N-).6 (N-).5 (N-). (N-). (N-). (N-). (N-).0 N- (N-).7 (N-).6 (N-).5 (N-). (N-). (N-). (N-). (N-).0 N = (Size + ) (N).7 (N).6 (N).5 (N). (N). (N). (N). (N).0 x = unoccupied Diagnostic byte (inputs only) Error counter (inputs only) The above assignment is applicable for inputs and outputs. Exception: Byte N and byte N- are assigned for the inputs only of the diagnostic byte and the error counter. For Interbus-S: In case Interbus-S is used as fieldbus system, the address space is limited to 0 byte (max. relative address N = 9). Recommended setting of size for Interbus-S = max. 8 (7 with analog input/output option). Max. number of VCS connectors = 7 (6 with analog input/output option). i

14 Diagnostic byte: The diagnostic byte must be evaluated by the PLC program to be able to react differently to the various errors reported. DIAG. 7 DIAG. 6 DIAG. 5 DIAG. DIAG. DIAG. DIAG. DIAG. 0 Power Fail Power Fail Data n.u. OUT < V n.u. Sentro Outputs Error > T n.u. = not used Description: DIAG. 7: DIAG. 6: DIAG. 5: DIAG. : Power Fail analog signal (Option) If you have the analog input/output option: The power supply for the analog inputs/outputs (Sentronic valves) is not connected, too low, or has a short circuit. - Check the voltage of the VCS interface at the corresponding terminals (SENTRO SUPPLY). If you do not have the analog input/output option: DIAG. 7 always at "". Power Fail Outputs (Option) If the black cable (power cable) is used: The power supply for the black power cable is not connected to the Power Control IN terminals, or it is too low, or has a short circuit. - Check the voltage of the VCS interface at the corresponding terminals (Power Control IN). If the black cable (power cable) is not used: DIAG. 6 always at "". n.u. = not used. OUT, Overcurrent An overcurrent (above 00 ma) has occurred at one of the VCS connectors. Use the software VCS-DIAG (see chapter 7) for fine diagnostics. The communication on the fieldbus and the switching off of the outputs are treated according to the DIP switch settings. - Check the corresponding VCS connector and valve and eliminate the overcurrent. The faulty VCS connector can be detected with the DIP switch ERR (see chapter 6.). DIAG. : < U, Low voltage Low voltage is reported for at least one VCS connector. Use VCS-DIAG (see chapter 7) for fine diagnostics. The communication on the fieldbus and the switching off of the outputs are treated according to the DIP switch settings. - Check the voltage at the corresponding VCS connector. Fit an additional VCS power supply into the VCS loop, if necessary. The faulty VCS connector can be detected with the DIP switch ERR (see chapter 6.). DIAG. : DIAG. : DIAG. 0: n.u. = not used. Data Error Data transmission errors occur constantly. The VCS cannot be operated safely any more. Communication on the fieldbus is stopped. All outputs are switched off. - Check the VCS loop in the test mode (see chap. 6.). Replace a faulty VCS connector and/or cable interruptions (see also error counter), if necessary. > T, Overheating At least one VCS connector is overheated. Use VCS-DIAG (see chapter 7) for fine diagnostics. The communication on the fieldbus and the switching off of the outputs are treated according to the DIP switch settings. - Check the corresponding VCS connector for overload and the corresponding valve for excess generation of heat (coil short circuit). The faulty VCS connector can be detected with the DIP switch ERR (see chap. 6.).

15 Error counter: The error counter counts the number of faulty VCS cycles per time unit (error rate). This must not necessarily be controlled by the PLC program. Communication on the fieldbus is stopped and the diagnostic bit DIAG. (DATA ERROR) is set as soon as the admissible error limit is exceeded. All outputs are switched off. The admissible error limit depends on the number of VCS connectors in the VCS loop. ERROR. 7 ERROR. 6 ERROR. 5 ERROR. ERROR. ERROR. ERROR. ERROR The error counter can show the decimal values 0-55 (0 - FF Hex). Number of VCS connectors Error limit The error counter is updated every 5 msec. Communication is stopped as soon as more than 50% of the VCS cycles are faulty. 5

16 B. With analog input/output option Rel. Address Bit 7 Bit 6 Bit 5 Bit Bit Bit Bit Bit 0 function 0 VCS connector VCS connector VCS connector VCS connector VCS connector 8 VCS connector 7 VCS connector 6 VCS connector VCS connector VCS connector VCS connector 0 VCS connector VCS connector 6 VCS connector 5 VCS connector VCS connector VCS connector VCS connector VCS connector N- x x [(N-)]- [(N-)]- [(N-)]- (N-).7 (N-).6 (N-).5 (N-). (N-). (N-). (N-). (N-).0 N- N- Setpoint.7 Setpoint.6 Setpoint.5 Setpoint. Setpoint. Setpoint. Setpoint. Setpoint.0 Feedback.7 Feedback.6 Feedback.5 Feedback. Feedback. Feedback. Feedback. Feedback.0 Setpoint.7 Setpoint.6 Setpoint.5 Setpoint. Setpoint. Setpoint. Setpoint. Setpoint.0 Feedback.7 Feedback.6 Feedback.5 Feedback. Feedback. Feedback. Feedback. Feedback.0 Sentronic Sentronic x = unoccupied N- DIAG. 7 DIAG. 6 DIAG. 5 DIAG. DIAG. DIAG. DIAG. DIAG. 0 N= (size+) N.7 N.6 N.5 N. N. N. N. N.0 Diagnostics (inputs only) Error counter (inputs only) The setpoint and the feedback value for the analog signal pressure regulator are transmitted with an 8-bit resolution. The output pressure is calculated as follows: Pout = Set PMR 55 Set = decimal setpoint ( ) PMR = maximum output pressure of the analog signal valve. The above assignment is applicable for inputs and outputs. Exception: Byte N and byte N- are assigned for diagnostics and error counter. Setpoint and feedback value function in response to the same address. The setpoints are output data and the feedback values are input data. For Interbus-S: In case Interbus-S is used as fieldbus system, the address space is limited to 0 byte (max. relative address N = 9). Max. reasonable setting of size for Interbus-S = 7 (8 without analog signal option). Max. number of VCS connectors = 6 (7 without analog signal option). i 6

17 .5 VCS power supply: 7V max. /, A (with integrated "data/voltage" decoupling) This unit is for power supply to the VCS interface and VCS loop over the green cable. ValveConnectionSystem Ref. Description - POWER LED ON : Output voltage OK OFF : Output voltage below 6. Volt or current above.a. - 7 V DC terminals, max..5 mm² - 0 V terminals, max..5 mm² - Shield: to be connected to machine ground 5 - Internal PE screw. Do not unscrew from outside! 6 - Grounding PE: max..5 mm². Do not operate the equipment without grounding! 7 - Power supply L, max..5 mm², 0V AC / 0V AC 8 - Power supply N, max..5 mm², 0V AC / 0V AC 9 - Voltage selector 5 V: 00-7 V/AC 0 V: 0-0 V/AC Frequency: 7-6 Hz 0 - Latch for symmetrical DIN EN 500 rail. The output is protected against idle running, sustained short circuit and overload. Connection by screw terminals - Protection: IP0 A PELV power supply is used which is equivalent to a safety transformer to VDE 0550/IEC 6--. The power supply must be mounted on a horizontal DIN rail TS 5 to allow for adequate air circulation.! i Do not operate the power supply without grounding. Do not attempt to gain access to the inside of the power supply: dangerous voltage inside. DANGER TO LIFE! When connecting with stranded wires use end sleeves (without isolation). The VCS power supply has an output voltage of 7 V and an integrated data decoupling feature to ensure that the solenoid valves are always supplied with V ± 0 % and the communication over the green VCS cable is not disturbed..6 Power supply: V max. / 0 A (without decoupling) This unit supplies the power (see chapter ) to pilot coils with higher current ratings over the black cable. ValveConnectionSystem 5V AC 0V AC 5/0V AC 8.0/.8A 50/60Hz N L -8V V DC / 0A Electronically protected Ref. Description - Voltage selector 5V: 00-7 V AC 0V: 0-0 V AC Frequency: 7-6 Hz - Power supply N, max,5mm 0V AC / 0V AC - Power supply L, max,5mm 0V AC / 0V AC - Grounding PE: max..5 mm². Do not operate the equipment without grounding! 5 - Adjustment of output voltage, to 8V 6 - V DC terminal, max.,5 mm 7-0V terminal, max.,5 mm The output is protected against idle running, sustained short circuit and overload. Connection by screw terminals - Protection: IP0 A PELV power supply is used which is equivalent to a safety transformer to VDE 0550/IEC 6--. The power supply must be mounted on a horizontal DIN rail TS 5 to allow for adequate air circulation. Connect the power supply in compliance with the applicable electrical safety regulations. Do not operate the power supply without grounding.! Do not attempt to gain access to the inside of the power supply: dangerous voltage inside. DANGER TO LIFE! When connecting with stranded wires use end sleeves (without isolation). 7

18 .7 Accessories.7. Adapters These adapters are used to mount the VCS connector to solenoid valves with a mounting pad to ISO 00 (size 0) or industrial standard (size ). Since these valves usually have a rating of more than. Watt, the VCS connector with additional power connection ( or ) must be used. In this case, one output (output ) remains unoccupied. Only the monostable valve function is supported. Adapter 5/ mm ( ) Adapter 5/0 mm ( ) LINK LINK Connector seal - Adapter - Adapter seal - Coil 5 - VCS connector Size Industrial standard flat pins (spacing mm) + PE Size 5 pins + PE Size 0 ISO 00 pins + PE Size 5 pins + PE Install the adapter with its seal onto the solenoid coil and screw it down tightly. Place the seals on the pins of adapter, mount the VCS connector and screw it down tightly..7. VCS adapter round/flat ( ) The VCS adapter is used to supply voltage over an additional VCS power supply ( ) directly to the VCS cable (see chap....) to reduce voltage drops and/or increase the supply current. The flat cable is contacted with a vampire-type plug. A round cable with -6 mm outer diameter can be connected with max..5 mm screw terminals (IP65 protection). Connection : To connect the flat cable: Loosen both screws on the lid. : VCS cable Remove the lid. Insert the flat cable. Check the cable profile to avoid mismating. Replace the lid (check for correct orientation) : additional VCS power supply and screw it down carefully. To connect the round cable: Turn the threaded ring clockwise. Insert the cable into the angled cover. Protect both wire ends with sleeves and screw them down. Fasten the cover carefully with the threaded ring. Tighten the PG cable gland to ensure IP 65 protection. Fastening with screws max. Ø mm. Assignment round/flat VCS adapter: Pin no. Signal Flat cable color +7 V brown 0 V blue 8

19 .7. VCS extension module flat/flat ( ) This extension module is used to lengthen the distance between two VCS connectors without having to remove the existing cable segment. The two flat cables which must be connected are contacted by the vampire-type plug (IP65 protection). To connect the cables : loosen the screws on the lid. Remove it. Insert the two flat cables. Check the cable profile to avoid mismating. Seal the cable ends with the enclosed seals. Replace the cover and screw it down carefully to ensure IP65 protection. Installation is on DIN rail or with two screws Ø 5 mm..7. VCS cable end caps ( ) These caps are used to seal off open cable ends (black power cable) to ensure IP65 protection and prevent short circuit. Adaptation : Place the cap on the end of the flat cable and heat it at a temperature above 5 C (air heater). The adhesive liner in the end cap melts to seal and encapsulate the components contained within..7.5 VCS input module M8 ( ) The VCS loop can be equipped with an M8 input module. With this module, eight electrical sensors (with or wires) are connected to eight -pin M8 connectors. The module is connected to the VCS system with a lead ( m long) fitted with a connector with vampire-type plug for direct connection of the flat VCS cable. The lead and vampire-type connector (C) are supplied with the input module. -wire sensor IN V Wiring diagram of inputs View on soldered side of male connector -wire sensor (magnetoresistive position detector) Sensor IN V + Sensor wires GND - V ±0 % GND* IN 0/IN * not applicable for -wire sensor Cable inlet:.5-5 mm. C LED P : LED indicator of input state 7V : VCS power supply 7V is on the module TEST : LED control during "Testmode" (see chapter 6.) 9

20 . POWER SUPPLY ON VCS LOOP. Principle On principle, valve connection systems can be designed with a single cable (green VCS cable) or with two cables (separate black power cable). In a single cable structure, the inputs and valve outputs are supplied over the VCS power supply. Power supply and communication is made over the green VCS cable. In a two-cable structure, the outputs are supplied over the black power cable (power supply). The inputs and the electronics integrated in the VCS connectors are supplied over the green VCS cable (VCS power supply) which is also used for communication. Mixed systems, in which VCS connectors with and without black power cable connection are used, can also be set up (see chapter.) Direct power supply for islands to the VCS loop BUS Separate power supply for the VCS loop and for MEGA spool valve solenoid coils BUS 7V = (.A) VCS INTERFACE 7V = VCS INTERFACE V = i ( ) It is recommended that the end of the black cable loop is connected to the POWER CONTROL terminals of the VCS interface (fig.) to enable control of the voltage level on the black cable. The type of electrical power supply and the required quantity depend on the number, type and consumption of spool valves/solenoid air operated valves in the VCS loop and on the length of the VCS loop. The components can be defined in the following ways: Directly according to the type of application (see chapters.,. &.5) with the help of the diagrams in accordance with the number of connectors in the loop and its length. With selection charts (see chapter.6) for coils. W or for.6 W coils of for MEGA spool valve islands. The required quantity of power supplies can quickly and easily be estimated over these two methods provided that the system is equipped with one connector type and coils at one consumption level. Systems with many different types of components require a detailed estimation of the necessary quantity of power supplies. To request an estimation, please fill in the VCS Application Requirements Form on page 55 and consult us. The supply of power to the VCS loop mainly depends on the rating of each coil in the application. The following diagrams show the different supply options: for coils. W (wattage value of coil in cold state) for coils >. W (wattage value of coil in cold state) for systems with a mixture of coils rated. W and >. W. Power supply of coils. W.. VCS connector without black power cable 7V = (,A) VCS INTERFACE 578 The outputs and inputs and the electronics of the VCS connectors are supplied with power exclusively over the green VCS cable

21 Up to 7 VCS connectors can be fit into one cable loop (with and without inputs). The cable length between two VCS connectors and between a VCS connector and a VCS interface must not exceed 0 m. All inputs/outputs are supplied over the green VCS cable. The output rating is limited to max.. Watt (00 ma) per output. Depending on the length of the line, the output current, the simultaneity factor (simultaneous switching of outputs) and the number of VCS connectors, one or more additional VCS power supplies may have to be used for intermediate power supply. The following applies (worst case calculation):... VCS connectors with inputs Required number of VCS power supplies: All valves are supplied with power over the green VCS cable. All VCS connectors are provided with inputs and max. output is switched per VCS connector ( ). Distance between connectors: 0m Solenoid coils : =, W. Number of simultaneously switching outputs Example with VCS power supplies (7V -.A) cable length / m : VCS power supply number 7V = (,A) VCS INTERFACE m 8m 0m 7V = (,A) island n 6 island n 5 island n 6m VCS adapter round/flat ( ) 0m 5m 0m m 7m m island n island n island n This application, in which 7 VCS connectors are connected to a loop m long, requires two 7 V.A power supplies (see diagram below). The nd power supply must be connected to the green VCS cable with a VCS adapter round/flat (see chapter.7.) It must be placed in the middle of the loop. The additional power supplies must be divided up equally between the number of connectors in the VCS loop (see table on following page).

22 ... VCS connectors without inputs Required number of VCS power supplies: All valves are supplied with power over the green VCS cable. All VCS connectors are without inputs and max. output is switched per VCS connector ( ). Distance between connectors: 0m Solenoid coils : =. W. INSTALLATION... Feeding point of intermediate VCS power supply In case the output current must be increased on the whole system or the voltage drop is to high, intermediate power is supplied over the round/flat adapter ( ) and additional VCS power supplies (with integrated data decoupling feature). Choose the optimal feeding point according to the number of VCS power supplies required. Number of additional VCS power supplies Feeding point VCS power supply N/ VCS power supplies N/, / N VCS power supplies N/, N/, / N VCS power supplies /5 N, /5 N, /5 N, /5 N 5 VCS power supplies /6 N, /6 N, /6 N, /6 N, 5/6 N N = Total number of VCS connectors One VCS power supply is always directly connected to the VCS interface. To bridge more than 0 m between two VCS connectors, an additional VCS connector without valve is to be used as repeater. In this case, two outputs remain unoccupied. The same applies if more inputs than outputs are required. For more, use the 8 inputs module (see chapter.7.5) Number of simultaneously switching outputs cable length / m : VCS power supply number

23 .. VCS connector with black power cable (two cable structure) V = (0A) 7V = (,A),A 0A VCS INTERFACE This configuration allows for an emergency switch to be fitted in order to interrupt the power supply to the solenoid coils in the loop if necessary. The power supply feeds 0A to the black cable to supply the coils with power. In case of power failure on the black cable, the VCS interface continues transmitting position sensor and diagnostic data over the green VCS cable The output current is limited to 00mA per solenoid coil. All valves with a 5 mm pad mounting and max.. Watt can be directly piloted in this manner. To pilot valves with a higher size coil, adapters of 5 mm to mm (industrial standard) and 5 mm to 0 mm (ISO 00) are available. To realise an emergency shutdown with bistable valves with max.. Watt, the VCS connector is available with an additional power connection (black power cable) and two outputs of max. 00 ma. The outputs of the VCS connectors with black power cable connection are supplied over the black power cable. The output rating is limited to. Watt (00 ma) per output. Depending on the length of the VCS line, you may have to use either one or several additional VCS power supplies for intermediate power supply.... VCS connectors with inputs Required number of VCS power supplies: All valves are supplied with power over the black cable. All VCS connectors are provided with inputs and an additional power connection ( ). Distance between connectors: 0m Solenoid coils : =. W. Number of simultaneously switching outputs : VCS power supply number cable length / m

24 ... VCS connectors without inputs Required number of VCS power supplies: All valves are supplied with power over the black cable. All VCS connectors are without inputs and with an additional power connection ( ). Distance between connectors: 0m Solenoid coils : =. W. Number of simultaneously switching outputs INSTALLATION : VCS power supply number cable length / m

25 . Power supply of coils >. W (max. W) 7V = (,A) VCS INTERFACE 90 9 ISO (5) ISO (5) V = (0A) The VCS interface is supplied with power from the VCS power supply, and the VCS cable is used for data transmission in the VCS loop and for power supply to the coils. W (see description in previous chapter). To connect the coils >. W (max. W), use VCS connectors or , the 0A power supply and the black power cable. In this configuration, the number of VCS connectors which can be connected to the loop depends on the power available on the green cable over the main VCS power supply (.A). To pilot valves with a higher wattage, adapters of 5 mm to mm (industrial standard) and 5 mm to 0 mm (ISO 00) are available. You must use a VCS connector with additional power connection for this purpose. The outputs of the VCS connectors with black power cable connection are supplied over the black power cable. The output rating is limited to Watt (.0 Ampere) per output. Depending on the length of the VCS loop, you may have to use either one or several additional VCS power supplies for intermediate power supply (see next pages). 5

26 .. VCS connectors with inputs Required number of VCS power supplies: All valves are supplied with power over the black cable. All VCS connectors are provided with inputs and an additional power connection ( ). Distance between connectors: 0m Solenoid coils: >. W. INSTALLATION Number of simultaneously switching outputs : VCS power supply number.. VCS connectors without inputs cable length / m Required number of VCS power supplies: All valves are supplied with power over the black cable. All VCS connectors are without inputs and with an additional power connection ( ). Distance between connectors: 0m Solenoid coils: >. W. 595 Number of simultaneously switching outputs : VCS power supply number cable length / m 6

27 . Power supply of solenoid coils. W and >. W.. General application 7V = (,A) VCS INTERFACE ,W V = (0A),W Figure Figure Components with a consumption of. W and >. W can be connected to the same loop. This is the typical application described in chapter. Structure which allows for spool valves and solenoid valves with coil sizes 5,, 5, 0 and 0 with or pins to DIN 6 or ISO 00 to be controlled over a single cable. Only coils >. W are supplied with power from the black cable (use connectors or ). The low power coils. W are fed over the green cable (use connectors or ). Connection of the black power cable to the VCS interface (fig. ) or the sealing of the wire strands with heat-shrinkable end caps (fig. ) is described in chapter.7.,. and.... Power supply of solenoid coils (. W and >. W) with control of emergency shutdown 7V = (,A) VCS INTERFACE ,W V = (0A),W Changing the VCS connector type on the solenoid coils. W (new connectors or ) and modifying the wiring of the black power cable allows for emergency shutdowns in the VCS loop to be controlled whilst information from the sensors and the status of the data on the green cable are retained. To define the number of VCS power supplies in accordance with the number of VCS connectors, consider that all connector used are VCS connector with x00ma outputs with sensor inputs (see diagram in chapter... or selection chart in chapter.6.). The number of VCS power supplies has been defined for connectors placed at 0 m from each other. More VCS connectors can be used if they are placed at shorter intervals. (To request an estimation, please see chapter.6. or fill in the VCS Application Requirements Form on page 55 and consult us.) i 7

28 .5 Supply of VCS loop with a standard V power supply.5. Supply of solenoid coils. W.5.. Direct supply of solenoid coils. W with a standard V power supply V = (A) VCS INTERFACE A standard power supply with a max. current of A connected to the standard supply terminals on the VCS interface is sufficient to operated up to VCS connectors. W. The number of VCS connectors which can be fed over a standard power supply in accordance with the VCS connector version used has been defined in the following table. VCS connector version Code Number of VCS connectors VCS connector with outputs max. 00mA without input (green cable) with inputs Separate supply of VCS loop and solenoid coils. W V = (0A) VCS INTERFACE Fuse A A This configuration allows for an emergency switch to be fitted in order to interrupt the power supply to the solenoid coils in the loop if necessary. The power supply feeds A to the green VCS cable over the VCS interface and 8A to the black cable for the electrical supply of the coils. In case of power failure on the black cable, the VCS interface continues transmitting position sensor and diagnostic data. The number of solenoid coils which can be connected to the loop is given in the table below. VCS connector version Code Number of VCS connectors VCS connector with outputs max. 00mA and without input auxiliary power supply (with green and black cable) with inputs i These quantities have been defined for VCS connectors placed at 0 m from each other. More VCS connectors can be used if they are placed at shorter intervals. (To request an estimation, please see chapter.6. or fill in the VCS Application Requirements Form on page 55 and consult us.) 8

29 .5. Supply of solenoid coils >. W In this configuration, solenoid coils >. W (max. W) are always connected with a separate power supply of the VCS loop as shown in the diagram below. An emergency switch can be connected at option. V = (0A) VCS INTERFACE Fuse A 90 9 ISO (5) ISO (5) 8A The number of solenoid coils which can be connected to the VCS loop is given in the table below. VCS connector version Code Number of VCS connectors VCS connector with output max. A and without input auxiliary power supply (with green and black cable) with inputs i These quantities have been defined for VCS connectors placed at 0 m from each other. More VCS connectors can be used if they are placed at shorter intervals. (To request an estimation, please see chapter.6. or fill in the VCS Application Requirements Form on page 55 and consult us.) 9

30 .6 Selection charts (summary) The charts provided below allow for defining the number of main power supplies in accordance with the quantity and type of VCS connectors for coils =. W connected to the loop, and the distance between VCS connector..6. VCS power supply (7V -.A) Connector type VCS connector with outputs max. 00mA (connection only over green cable) VCS connector with outputs max. 00mA and auxiliary power supply (with green and black cable) or VCS connector with output max. A and auxiliary power supply (with green and black cable) Connector type without input with inputs without input with inputs () distance between VCS connectors = 0 m.6. Standard power supply (V - A) VCS connector with outputs max. 00mA (connection only over green cable) VCS connector with outputs max. 00mA and auxiliary power supply (with green and black cable) or VCS connector with output max. A and auxiliary power supply (with green and black cable) without input with inputs without input with inputs () distance between VCS connectors = 0 m Code or or Code or or Nr of VCS supplies Nr of VCS supplies Number of VCS connectors ( ) If the number of connectors to be used is above this limit, install the system with a VCS power supply (see chapter.6. * above) m () 0 m () 5 m () m () ( * )... ( * )... ( * )... ( * ) Number of VCS connectors m () 0 m () 5 m () m ()... 5 ( * )... ( * )... ( * )... 7 ( * )... 5 ( * )... ( * )... 5 ( * )... ( * )... 5 ( * )... ( * )... 7 ( * )... 6 ( * ) i The number of VCS power supplies has been defined for different distances between each VCS connector. For another distance, please fill in the installation definition sheet page 55, consult us. 0