Aventics HF03 User manual

Operating Instructions
1987765492/08.2014, Replaces: 06.2002, EN
Double Multiple Plug Connector
HF03 / HF02
English

Contents
AVENTICS | HF03 / HF02 | 1987765492–BDL–001–AB 3
English
Contents
1 Notes on safety .................................................................. 5
2 System architecture .......................................................... 6
2.1 Construction and design............................................................... 7
2.2 Function............................................................................................. 7
2.3 I/O connections ............................................................................... 7
3 Installation ......................................................................... 8
3.1 HF 03 mounting............................................................................... 8
3.2 HF 02 mounting............................................................................... 9
3.3 Marking and identification .........................................................10
3.4 Electrical connection ...................................................................10
3.4.1 M12×1 connections .................................................................... 11
3.4.2 Multiple plug connection for I/O modules ........................... 12
3.5 Making connections .....................................................................13
4 Testing and start-up ........................................................ 14
4.1 Testing .............................................................................................14
4.2 Start-up ...........................................................................................14
5 Conversion and extension .............................................. 14
5.1 Adding passive I/O modules......................................................14
6 Characteristics, service parts and accessories ........... 15
6.1 Characteristics ..............................................................................15
6.2 Service parts and accessories .................................................16

Notes on safety
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1 Notes on safety
Please observe the notes on safety.
This valve system may only be used for industrial applications.
Installation may only be performed in a voltage-free and pressure-
free state and only by a qualified technician.
In order to avoid accidents, electrical start-up is to be carried out
only in a pressure-free state.
Please familiarise yourself thoroughly with the contents of the
operating instructions before installing the valve system and
connecting it to the compressed air or electrical systems.
Validity These operating instructions apply to:
WThe passive I/O modules in conjunction with the series HF 03 /
HF 02 valve system with a double multiple plug connector.
WARNING
Ground the valve system. Please observe the following standards when installing the
system: VDE 0160 (DIN EN 50178) and VDE 0100
Do not put the valve system into operation before it is completely assembled as well as
correctly wired and tested.
NOTICE
Before connecting or disconnecting the plugs, switch off the operating voltage to prevent
damage to the electrical system.
If the valve system is occupied completely by components, or subject to continuous loading
of the solenoids, be sure to provide adequate exchange of air, or air cooling.

System architecture
6AVENTICS | HF03 / HF02 | 1987765492–BDL–001–AB
2 System architecture
The versatility and flexibility of this valve system enables
AVENTICS to support your automation tasks. The valves are
completely assembled and tested according to your requirements;
the electrical connection is made via multiple plug connectors.
I/O modules are in- stalled in the system as per your
specifications. The valve system in the local or external pilot
control versions is then ready for use. Its modular construction
allows existing systems to be expanded or converted at any time.
The valve system's operating instructions are composed of
individual components.
Fig. 1: System architecture
II I
I
Valve metsys s with
bus coupler:
– Series HF 03 / HF 02
– Bus couplers
series CMS
type M-Design:
PROFIBUS-DP
INTER BUS
DeviceNet
CANopen
– I/O modules
– Power module
– AS-Interface Master
Valve systems with a
multiple plug connector:
– Series HF 03 / HF 02
– Bus couplers
series BDC
type V-Design:
PROFIBUS-DP
INTERBUS
DeviceNet
CANopen
type A-Design:
AS-Interface
– Modules
series DDL
type V-Design:
DDL / DDL-E
Valve systems
with
double multiple
plug connector:
– Series HF 03 /
HF 02
– I/O modules
(passive)
BDC = Bus Direct Control
DDL = Drive & Diagnostics Link
CMS = Central Mounted System

System architecture
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2.1 Construction and design
valve system with
double multiple plug
connector and passive
I/O modules
The HF 03 / HF 02 valve system is composed of the following
components depending on the order:
Wright end plate for connecting the pneumatics,
Wvalve in expansion levels for 1 to 16 valves,
Wadapter plate for the pneumatic connection,
Wmultiple plug connector, double,
WI/O modules, passive (4 maximum),
Wleft side cover.
2.2 Function
M12×1 connections for
passive I/O modules
The passive I/O module makes it possible to connect a sensor or
an actuator to each of the eight M12×1 connections. Up to 32
sensors/actuators are possible per valve system with multiple
plug connector at a maximum of 4 I/O modules. The switching
state is displayed by a yellow LED on each I/O connection.
Multiple plug
connector II for
passive I/O modules
The M12×1 I/O connections are internally connected to the
multiple plug connector II. They are connected to the PLC via
mating plug II. See figure 2 and 3.
LED display for the
supply voltage
The supply voltage's presence is shown by a green LED.
2.3 I/O connections
I/O connection M12×1 Sensor/actuator connection, 8× connection socket with internal
M12×1 thread, for 4 or 5-pin plug
Accessories M12×1 mating plug
Multiple plug
connector II
I/O module connection to the controls
Accessories Mating plug II
Marking On the I/O module beneath each M12×1 connection

Installation
8AVENTICS | HF03 / HF02 | 1987765492–BDL–001–AB
3 Installation
3.1 HF 03 mounting
Dimensions The valve system can be mounted in any desired position with 4
screws (e.g. M6) or placed on a DIN rail,
DIN EN 50022, 35 × 15.
Fig. 2: HF 03 dimensioned drawing
n = number of valve positions
View A
View C
View B
Mating plug
I
on multiple
plug connector
I
PE connection
Mating plug
II
on multiple
plug connector
II
II I
C = ~122 for cable
with Ø 9.0
C = ~132 for cable
with Ø 15.5
IO 1

Installation
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3.2 HF 02 mounting
Dimensions The valve system can be mounted in any desired position with 4
screws (e.g. M6) or placed on a DIN rail,
DIN EN 50022, 35 × 15.
Fig. 3: HF 02 dimensioned drawing
View A
View B
Mating plug
I
on multiple
plug connector
I
Mating plug
II
on multiple
plug connector
II I
C = ~122 for cable
with Ø 9.0
C = ~132 for cable
with Ø 15.5
IO 1
n = number of valve positions
PE connection

Installation
10 AVENTICS | HF03 / HF02 | 1987765492–BDL–001–AB
3.3 Marking and identification
I/O module, passive The I/O connections are inscribed directly on the I/O modules.
Fig. 4: I/O module, passive
3.4 Electrical connection
M12×1 connections for
passive I/O modules
The passive I/O module makes it possible to connect a sensor or
an actuator to each of the eight M12×1 connections. Up to 32
sensors/actuators are possible per valve system with multiple
plug connector at a maximum of 4 I/O modules.
LED display for M12×1
connections
The switching state is displayed by a yellow LED on each M12×1
connection.
Numbering the M12×1
connections
The M12×1 connections are numbered from 0 to 7. See figure 4.
Method for counting
the I/O modules
The maximum of 4 I/O modules are counted starting with the first
I/O module next to the multiple plug connector II. This I/O module
is marked as IO 1 according to the plug assignment count. See
figure 2 and 3.
Multiple plug
connector II for I/O
modules
The I/O connections are internally connected to the multiple plug
connector II. They are connected to the PLC via mating plug II. See
figure 2 and 3.

Installation
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LED display for the
supply voltage
The supply voltage's presence is shown by a green LED.
3.4.1 M12×1 connections
M12×1 connections for
the I/O modules
A sensor or an actuator can be connected to each of the eight
M12×1 connections of an I/O module via M12×1 plug (4 or 5-pin).
Fig. 5: M12×1 connection layout
WARNING
When connecting the peripheral equipment (I/O interface), the requirements for protection
against accidental contact must be observed in accordance with EN 50178, classification
VDE 0160.
NOTICE
There is no protection to prevent reverse polarization or feedback of the supply voltage.
Ensure that the permissible current load of 0.5 A per signal and supply line is not
exceeded, whereby the total current of all supply lines may not exceed 4 A per module!
Table 1: M12×1 connection layout
M12×1 connection layout
PIN
1+24 V
2- - -
3GND
4Signal
5- - -

Installation
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3.4.2 Multiple plug connection for I/O modules
Both the multiple plug connector I for the valve controls (right next
to the valves) and the multiple plug connector II for the I/O modules
(right next to the I/O modules) are located on the adapter plate.
See Figure 2 and 3.
Multiple plug
connector II for the I/O
modules
The I/O modules are connected to the PLC via the multiple plug
connector II on the I/O module side.
Fig. 6: Mating plug II assignment
NOTICE
24 V DC supply voltage with electrical isolation via a power supply unit according to DIN EN
60742, classification VDE 0551.
All GND pins and all +24 V pins are bridged in the multiple plug connector. There must be a
sufficient number of pins connected to supply and accept the total current of all
consumers. There should be at least 3 GND pins connected.
The total current of all I/O modules may not exceed the fuse value of 8 A!
The crimped contact connections fit wire cross sections of 0.14 ... 0.56 mm2.
Please only use multiple-strand cables with an external insulation diameter from 9.0 to
15.5 mm; use the appropriate mating plug sealing element to ensure that the IP 65 degree
of protection and the strain relief are guaranteed.

Installation
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Mating plug II
assembly
1. Select a suitable sealing element and insert it into the mating
plug's terminal fitting:
red: cable Ø 9.0 ... 13.0 mm
white: cable Ø 11.5 ... 15.5 mm
2. Push the terminal fitting and mating plug casing over the cable.
3. Remove about 5 cm of the cable sheath. Remove about 5 mm
of insulation from the strands and mark them according to
their assignment and function.
4. Crimp the plug connections to the single cable strands.
5. Click the plug connections into the socket body according to the
assignment.
6. Screw the socket body to the mating plug casing; pay attention
to the orientation (different pin Ø on the mating plug provide
clarity).
7. Tighten the terminal fitting's lock nut until the sealing element
firmly holds the cable (IP 65 degree of protection, strain relief).
3.5 Making connections
Making connections 1. Make the PE connection (M5 screw on the adapter plate)
according to VDE 100 and VDE 160.
2. Connect the cable to the controlling electrical system.
3. Plug mating plug I onto the multiple plug connector I for valve
control and
4. mating plug II onto the multiple plug connector II for the I/O
modules and screw tightly.
NOTICE
Please ensure that enough free space is left for the electrical connections so that the
permissible minimum bending radii are adhered to.

Testing and start-up
14 AVENTICS | HF03 / HF02 | 1987765492–BDL–001–AB
4 Testing and start-up
4.1 Testing
The functional reliability and operating method of the
actuator/sensor controls should be checked before start-up.
4.2 Start-up
OSwitch on the operating voltage.
OSwitch on the compressed air supply.
5 Conversion and extension
5.1 Adding passive I/O modules
Adding I/O module(s) 1. Remove the left side cover from the valve system's last I/O
module (3 hexagon socket-head screws, DIN 912 M4 with
wrench width 3).
NOTICE
Before switching the system on, ensure that it is in a defined state!
Also ensure that all manual overrides are set to zero.
NOTICE
Please observe the following if additional passive I/O modules are to be added on at a later
date:
OTurn off the system operating voltage and compressed air.
OA maximum of 4 passive I/O modules can be connected!

Characteristics, service parts and accessories
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2. Put the additional I/O module in place. Ensure that the gasket
has been inserted properly and that the contacts have been
plugged in.
3. Screw the I/O module tight (3 hexagon socket-head screws,
DIN 912 M4, wrench width 3). Tightening torque: 2.5 ... 3.0 Nm.
4. Screw the left side cover back on after the last I/O module (3
hexagon socket-head screws, DIN 912 M4, wrench width 3).
Tightening torque: 2.5 ... 3.0 Nm.
5. Make connections. See section 3.
Fig. 7: Adding an I/O module (picture shows HF 03 with double multiple plug connector)
6 Characteristics, service parts and
accessories
6.1 Characteristics
II I
Table 2:
General
Degree of protection
EN60529 / IEC529
IP65 when assembled
Number of connections per unit 8

Characteristics, service parts and accessories
16 AVENTICS | HF03 / HF02 | 1987765492–BDL–001–AB
6.2 Service parts and accessories
* Delivery incl. 3 fastening screws and 1 gasket
Table 3:
Electrical
Rated voltage 24 V DC (-15& / +20%)
Max. current load:
Signal line
Supply line
0,5 A
0,5 A
Total supply line current 4.0 A/module
Fuse for I/O modules 8.0 A medium time lag
Table 4:
Order code Order number
I/O module, passive * IOP 1827030106
Table 5:
Accessories Order number
Mating plug II, straight, for I/O modules 1824484061
Mating plug II, angled, for I/O modules 1824484025
M12x1 plug, straight, for I/O connection 1834484222
M12x1 plug, angled, for I/O connection 1834484223

AVENTICS GmbH
Ulmer Straße 4
30880 Laatzen
Phone [phone]
Fax: [phone]
www.aventics.com
[email protected]
Further addresses:
www.aventics.com/contact
The data specified above only serve to
describe the product. No statements
concerning a certain condition or
suitability for a certain application can be
derived from our information. The given
information does not release the user from
the obligation of own judgement and
verification. It must be remembered that
our products are subject to a natural
process of wear and aging.
An example configuration is depicted on
the title page. The delivered product may
thus vary from that in the illustration.
Translation of the original operating
instructions. The original operating
instructions were created in the German
language.
1987765492–BDL–001–AB/08.2014
Subject to modifications. © All rights
reserved by AVENTICS GmbH, even and
especially in cases of proprietary rights
applications. It may not be reproduced or
given to third parties without its consent.