Aventics 580 CHARM User manual

580 CHARM
Technical Manual
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Conditions For Use Of This Product
AVENTICSTM G3 Manifold ("the PRODUCT") SHALL NOT BE USED IN CONDITIONS where any problem, fault or failure
occurring in the PRODUCT may lead to any incident resulting in damage to property, serious injury or loss of life and where
the end user does not have appropriate external backups and fail-safe measures incorporated within the systems that the
PRODUCT is used.
The PRODUCT has been designed and manufactured for use in general industries. Therefore, the PRODUCT and related
document(s) are not for use in any nuclear and/or medical related applications.
For avoidance of doubt, AVENTICS and its affiliated companies shall have no responsibility or liability including but not
limited to any and all responsibility or liability based on contract, warranty, tort, product liability for any injury or death
to persons, loss or damage to property caused by the product that are operated or used in application not intended or
excluded by instructions, precautions or warnings contained in AVENTICS documentation including any Technical, User,
Instruction, Safety manuals or bulletins.
Safety Precautions
Before using this product, please read this manual and the relevant manuals carefully and pay attention to safety and
product application. The following symbols are used in the manual to identify important safety, installation, and application
information.
The CAUTION symbol indicates a possible hazard which may cause injury or equipment damage. Please review and take
appropriate action.
The NOTE symbol indicates important information regarding equipment installation and setup. Please review and take
appropriate action.
NOTE!
CAUTION
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Electrical Installation And Operational Guidelines
 AVENTICS valve systems with integrated fieldbus communications must only be connected to a
Class 2 power source.
 All AVENTICS communication nodes should be grounded during the installation process. Proper
grounding guidelines can be found in National Electrical code IEC 60204-1 or EN 60204-1.
 All AVENTICS G3 Electronics Products must only be installed or wired in accordance with ASCO
AVENTICS published instructions and applicable electrical codes.
 When using MULTIPLE CLASS 2 POWER SOURCES all sources shall be Listed and rated suitable
for parallel interconnection.
 All field wiring shall be suitable for Class 1, Electric Light and Power, or if Class 2, 3 wirings, such
wirings shall be routed separately and secured to maintain electrical and physical separation
between Class 2 wiring and all other class wiring and limited energy circuit conductors from
unlimited energy circuit conductors.
 When using Class 2 Device Wiring Only, you SHALL NOT Reclassify and Install as Class 1, 3 or
Power and Lighting Wiring.
 When using molded connector power cables, DO NOT RELY ON WIRE COLORS FOR PIN-OUT;
Always use pin number references.
 Wire connections shall be rated suitable for the wire size (lead and building wiring) utilized.
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Table of Contents
PAGE
About CHARM Overview ............................................................................................................................... 1-5
1.1 580 CHARM Features ........................................................................................................................... 1-5
1.2 Cabling ............................................................................................................................................. 1-5
580 CHARM Introduction .............................................................................................................................. 2-6
2.1 Coil Capability ................................................................................................................................... 2-7
2.2 Maximum Coil Capability ..................................................................................................................... 2-8
2.3 Multiple manifold CHARM Cable Sets: ................................................................................................... 2-9
2.4 Pneumatic Valve Manifold ................................................................................................................. 2-10
2.5 Solenoid Coil Connections using Z-BoardTM Technology ........................................................................... 2-11
2.6 Z-Board™ Connectors ........................................................................................................................ 2-12
CHARM Communication Node ...................................................................................................................... 3-13
3.1 CHARM Node Description ................................................................................................................... 3-14
3.2 Connector Pinouts ............................................................................................................................. 3-15
3.3 Chassis Ground ................................................................................................................................ 3-16
3.4 Power Consumption .......................................................................................................................... 3-17
3.5 Valve Power Isolator ......................................................................................................................... 3-18
3.6 580 CHARM Node LED Functions ......................................................................................................... 3-20
3.7 Valve Coil Short Circuit / Open Load Protection ...................................................................................... 3-21
CHARM Node Graphic Display ...................................................................................................................... 4-22
4.1 Bank Address Sub-Menu .................................................................................................................... 4-23
4.2 Model Number .................................................................................................................................. 4-24
4.3 Advanced Settings Menu – Flip Display ................................................................................................ 4-24
4.4 Advanced Settings Menu – Addressing Scheme..................................................................................... 4-25
4.5 36 Coil Optimization .......................................................................................................................... 4-27
4.6 PWM Control (Coils) .......................................................................................................................... 4-28
4.7 Advanced Settings Menu – Parameters ................................................................................................. 4-29
4.8 Factory Defaults ............................................................................................................................... 4-30
4.9 Diagnostic Menu ............................................................................................................................... 4-30
4.10 Coil “Self Test” Mode .......................................................................................................................... 4-31
4.11 Error Messages .................................................................................................................................. 4-32
CHARM Output Configuration ....................................................................................................................... 5-33
5.1 Charm Configuration Options ............................................................................................................. 5-34
CHARM Mapping......................................................................................................................................... 6-35
6.1 Outputs (Valves) .............................................................................................................................. 6-35
6.2 Output Mapping ................................................................................................................................ 6-35
6.3 Mapping Example for 36 Coils ............................................................................................................. 6-36
6.4 Mapping Example for 48 Coils ............................................................................................................. 6-37
6.5 Mapping Example for 64 Coils ............................................................................................................. 6-38
Mapping Example for 64 Coils Cont. .................................................................................................... 6-39
6.6 Mapping Example for 96 Coils ............................................................................................................. 6-40
6.7 Commissioning CHARM Node with DeltaV Software ................................................................................ 6-42
6.8 580 CHARM Module Changes .............................................................................................................. 6-47
Firmware Upgrade ...................................................................................................................................... 7-49
7.1 Procedure to upgrade the 580 Charm node firmware ............................................................................. 7-49
Appendix................................................................................................................................................... 8-52
8.1 System Specifications ........................................................................................................................ 8-52
8.2 Factory Default Settings .................................................................................................................... 8-52
8.3 Troubleshooting ................................................................................................................................ 8-53
8.4 Glossary of Terms ............................................................................................................................. 8-53
8.5 Technical Support ............................................................................................................................. 8-53
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About CHARM Overview
Electronic Marshalling – part of Emerson Process Management’s “I/O on Demand” was developed to focus on the
areas of commissioning process automation systems that are the most complex, involve many hours of labor, or
that can disrupt a project the most. Electronic Marshalling offers some unique value propositions, which can help
alleviate the pains previously discussed. As in wired marshalling, the multi core cables from the field still land on
the right side of the terminal blocks in the marshalling cabinet, so there are no changes to the work done by
technicians that wire up the multi core cables from the field. However, there are no cross-marshalling wires; all of
the work, design, and engineering associated with cross-marshalling simply go away, because each individual I/O
channel will be “Electronically Marshalled” to any controller in the system. This means that the I/O can be bound to
specific controllers at any stage in the project. If late changes are made to I/O types, or new I/O is added, no
adjustments to existing wiring or the cabinets must be made. New I/O can be added to the marshalling cabinets
and Electronically Marshalled to the controllers that need the I/O.
Now an exciting technology from Aventics extends Electronic Marshalling, and for the first time allows integrated
control of pneumatic valve manifolds on one network. The Aventics 580 CHARM node, attached to an Aventics
501/502/503 Series valve manifold, can interface directly with the DeltaV Characterization Module (CHARM) I/O
card from Emerson.
1.1 580 CHARM Features
Features Description
Termination Resistor Terminating Resistor is built into the Aventics CHARM module
Conformance Tested Tested by Emerson Process Management for conformance
1.2 Cabling
CHARM Power and Communication cables:
Part number: P599AF519387001 – 1.5M Length (set of 2 cables)
Part number: P599AF519387002 – 0.5M Length (set of 2 cables)
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580 CHARM Introduction
The 580 CHARM Node is an electronic interface that features an integrated graphic display for simple
commissioning and displaying of diagnostic information. The 580 CHARM Node connects to a variety of valve
series including, the 501, 502, and 503. The 580 CHARM Node is capable of addressing a total of (48) coil outputs
in the 501 Series and (32) coil outputs in the 502 & 503 Series, with diagnostic functionality built in. With proper
assembly and termination, the 580 CHARM Node has an IP65 rating.
This manual details specific information for configuring and commissioning the Aventics 580 CHARM Node. For
more information relating to pneumatic valves and valve manifold assemblies, please refer to the Aventics 501,
502 & 503 Series Catalogs at www.emerson.com.
580 CHARM Node
Valve Side
Drives up to 48 coils in 501 Series
Drives up to 32 coils in 502 & 503 Series
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2.1 Coil Capability
Valve Series Max. number of coils per manifold
501 48*
502 32
503 32
* In order to achieve 48 coils using the CHARM module the user will be required to use a 24 Station (48
Coil) 501 Series manifold.
This manifold will utilize a special manifold block that includes another valve driver that is in addition to
the driver in the 580 CHARM module.
Product Image Description Thread
Type Port Size Part Number
501 32+ Solenoid
4-Station Manifold
Block w/X32 Valve
Drivers
Metric
Thread
M7 H501AFM4BMA0010
Push-in
Fittings
1/4 K501AFM42MA0010
6mm K501AFM4FMA0010
4mm
(5/32) K501AFM4DMA0010
32+ Coil Valve Driver
Baseplate
#8
(12 points)
Baseplate
#7
(12 points)
Baseplate
#6
(12 points)
Baseplate
#5
(12 points)
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2.2 Maximum Coil Capability
If a user requires more coils than a single valve manifold can provide, multiple valve manifolds may be connected to a
single CIOC when using the appropriate cable sets
 In order to achieve the maximum number of coils available using a single CIOC and the CHARM module the user will
be required to use two valve manifolds in conjunction with each other.
 The first valve manifold will utilize base plates 8 through 5 and the second valve manifold will utilize base plates 4
through 1.
MANIFOLD #1
MANIFOLD #2
501 Series is capable of 96 coils max. (Uses two 501 24 station [48 Coil] manifolds).
502 & 503 Series are capable of 64 coils max. (Uses two 502 or 503 Series 16 or 32 station manifolds).
NOTE!
Baseplate
#8
(12 points)
Baseplate
#7
(12 points)
Baseplate
#6
(12 points)
Baseplate
#5
(12 points)
Baseplate
#4
(12 points)
Baseplate
#3
(12 points)
Baseplate
#2
(12 points)
Baseplate
#1
(12 points)
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2.3 Multiple manifold CHARM Cable Sets:

In order to attach multiple manifolds to one CIOC, two separate cable kits must
be used.
1) CHARM Power and Communication cables:
Part number: P599AF519387001 – 1.5M Length (set of 2 cables)
Part number: P599AF519387002 – 0.5M Length (set of 2 cables)
2) Multiple Manifold CHARM Power and Communication cables:
Part number: P599AF533776001 – Kit includes (2) M12 Tee’s, (2) .3M Sub Cables
& (2) 1.5M Trunk Cables
Multiple manifold CHARM
Cable Kit
CHARM Cable Kit
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2.4 Pneumatic Valve Manifold
The pneumatic valve manifold with internal circuit board technology is modular. The valve solenoid coil
connections are automatically made using Z-Board™ technology (plug together PC boards, which allow internal
connections from solenoid coils to output drivers without the use of wires). This allows easy assembly and field
changes.
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2.5 Solenoid Coil Connections using Z-BoardTM Technology
Z-Board™ plug together technology connects all valve solenoids to the valve coil output drivers, located in the 580
Node. There is a maximum of 48 coil outputs available on the complete manifold assemblies. The 48 available outputs
are accessed on the 501 series valves utilizing 3 or 4 station manifolds and on the 502 and 503 series utilizing 2 station
manifolds.
14 Solenoid,
Pin No. 1
Common,
Pin No. 4
12 Solenoid,
Pin No. 2
Not Used,
Pin No. 3
A single solenoid valve’s coil is always on the “14” end of the valve.
NOTE!
Pin out of integral plug is the same for 501, 502,
and 503 Series valves manifolds
Manifold Z-Boards
TM
580 Node Connection to Z-Boards
TM
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2.6 Z-Board™ Connectors
The 501/502/503 valve series utilize 3 different Z-Board™ designs to achieve the single and double solenoid
output functions. This yields the possible 48 single, 24 double, or various combinations of valve coil output
capabilities. The 501 Z-Board™ is minimum (3) station, the 502 and 503 Z-Board™ is minimum (2) stations.
501 Series
502 Series
503 Series
Each series Z-Board
TM
can be selected in either SINGLE or DOUBLE output (coil) versions.
The SINGLE and DOUBLE output function cannot be mixed on the Z-BoardsTM
NOTE!
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CHARM Communication Node
This module is the Communication Node to the manifold. It contains the communication electronics. It can be
configured via the graphic display or via software (DeltaV).
Communication Node Part Number
580 CHARM Node P580AECH2010A00
580 CHARM Node w/DIN Rail P580AECH2010DRM
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3.1 CHARM Node Description
Detail No. Description
1 5 Pin M12 Male Power & Communication (Primary)
2 Mounting Hole
3 5 Pin M12 Male Power & Communication (Secondary)
4 Module Status LED
5 Network Status LED
6 SET Button – used to navigate through user menus and to set parameters
7 Graphic Display – used to display parameter information
8 NEXT Button – used to navigate through user menus and to set parameters
1
2
3
8
7
6
5
4
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3.2 Connector Pinouts
Industry standard M12 connectors are used for communication and power.
The CHARM power & communication connector is a single keyway 5 pin male connector.
CHARM Power & Communication Connector Pin-Out (Primary and Secondary).
Pin No. Function Description
1 +24 VDC Valve Power
2 +6.3 VDC Node Power
3 Communication + Communication +
4 Communication - Communication -
5 0 V Valve and Node Power Common (0 VDC)
!
The draw of the +24VDC Valve pin cannot exceed 4 Amps, at any given moment in time.
The Node Power pins supply power to the node electronics. These pins must be powered at
all times for communication node to be functional.
Connect to Class 2 power source only.
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3.3 Chassis Ground
All Aventics manifolds should be grounded for safety. Grounding guidelines can be found in National Electrical
code IEC 60204-1 or EN 60204-1.
CHASSIS GROUNDCONNECTION POINT,
501 VALVES
CHASSIS GROUND CONNECTION POINT,
502 & 503 VALVES
When grounding to a machine frame, please ensure that the machine frame itself is
already properly grounded.
Better grounding can be achieved when larger diameter (lower gauge) wire is used.
CAUTION
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3.4 Power Consumption
Power Connection
Pin No. Function Description
1 +24 VDC Valve Power
2 +6.3 VDC Node Power
3 Communication + Communication +
4 Communication - Communication -
5 0 V Valve and Node Power Common (0 VDC)
Power Rating
 The maximum system current capability is 4 Amps. Care should be taken not to exceed 4 Amp draw
through the M12 Power connector pins.
Component Tolerance
+24VDC
(Valve)
Pins 1&5
+6.3VDC
(Node)
Pins 2&5
Current Per
Coil
Power
Per Coil Current Power
Solenoid Valve Coil 501 (Each) +10%/-15% 0.03 Amps* 0.8 Watts NA NA
Solenoid Valve Coil 502 (Each) +10%/-15% 0.05 Amps* 1.0 Watts NA NA
Solenoid Valve Coil 503 (Each) +10%/-15% 0.07 Amps* 1.7 Watts NA NA
580 CHARM Node +/- 10% 0.025 Amps 0.6 Watts 0.10 Amps 0.63 Watts
*Current is based on PWM control
NOTE!

The Node Power pins supply power to the node electronics. These pins must be powered at
all times for the communication node to be functional. See page 3-15 for reference.
 Reverse polarity protection is provided.
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3.5 Valve Power Isolator
 The Valve Power Isolator allows the user to separate the 24VDC valve power and the 6.3VDC
communication power.
 In a typical installation there would be an isolator used on each connector of the CHARM manifold
due to redundancy.
Description Part Number
Valve Power Isolator P599AF516881001
3
Male View
Female View
1
5
2
4
2
5
1
3
4
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Example layout using Valve Power Isolator
Network Power (6.3 VDC)
Valve Power (24 VDC)
DeltaV Communication Cable
24 VDC Power Supply
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3.6 580 CHARM Node LED Functions
Upon power up, the Module and Network Status LEDs indicate the state of the unit. There are two LEDs on the
580 CHARM Interface. The LEDs functions are described in the table below.
LED Name Color Pattern Description
NET
NETWORK
STATUS
Off OFF CHARM is unpowered or non-functional.
Green
ON The CHARM status is good, and the CHARM is configured.
Flashing twice
per second
The CHARM is not configured. If DeltaV Diagnostics displays
BAD status for this CHARM, a configuration error such as a
configuration mismatch, has occurred. If DeltaV Diagnostics
displays GOOD status for the CHARM, the CHARM has not
been configured.
Flashing
10 times per
second
A user has issued an “Identify” command from DeltaV
Explorer or DeltaV Diagnostics application. This is not a fault
and no action is required.
Red
ON No Communications on the bus or no address.
Flashing twice
per second Open/Shorted coil or field power missing.
Flashing
10 times per
second
Duplicate Address or CHARM cables swapped.
Green Red
Alternating
twice per
second
The CHARM is being upgraded or is in upgrade mode (no coil
control in this state).
Green then red
flashing four
times per
second
A CHARM fault (such as a bad address or a faulty CHARM
bus) exists that does not affect the coil status
Green then red
flashing briefly
once every 1.5
seconds
The CIOC has placed the CHARM is in fail safe state.
MOD
MODULE
STATUS
Off OFF Critical hardware fault. Microprocessor is not running.
Red ON
Green ON Normal operation. The device is operating properly.
Green Red FLASHING Module is in coil self-test mode. Cycle power to end coil self-
test mode.
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