Definox ICS Operation and maintenance manual

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 1/30 April 2010
ICS SIGNALING UNIT
www.definox.com
ICS housing
2I/1O terminal option
ICS housing
AS-I 2.1& 2.0 2I/1O module
ICS housing
Multi-voltage supply unit 2I/1O

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 2/30 April 2010
TABLE OF CONTENTS
1 CHANGE MANAGEMENT 4
2 SAFETY 5
2.1 Important information 5
2.2 General information 5
3 INTRODUCTION 6
3.1 Disassembling the signaling unit 6
3.1.1 Disassembling the unit/actuator 6
3.1.2 Disassembling the unit components 7
3.2 Reassembling the signaling terminal 8
3.2.1 Reassembling the unit components 8
3.2.2 Reassembling the unit/actuator 9
4 TERMINAL VERSIONS 10
4.1 Wiring 2 sensors/1 solenoid valve 10
4.2 Electrical specifications 10
5 MULTI-VOLTAGE MODULE VERSIONS 12
5.1 Module functions 12
5.2 Selecting the multi-voltage module version 12
5.3 24 V DC modules 13
5.3.1 Different input/output cabling 13
5.3.1.1. Description 13
5.3.1.2. Wiring diagrams: 14
5.4 24 V AC –48 V AC/DC modules 15
5.4.1 Different input/output cabling 15
5.4.1.1. Description 15
5.4.1.2. Wiring diagrams: 16
5.5 Wiring to the PLC 18
5.6 Wiring to the solenoid valves and sensors 18
5.7 Meaning of LEDs on the front of the modules 18
5.8 Technical specifications of the multi-voltage modules 19
5.9 1ST level maintenance 20
5.9.1 Power LED extinguished 20
5.9.2 Fault LED illuminated or flashing 20
5.9.3 Testing the solenoid valve 20
5.9.4 Testing the sensors 20

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 3/30 April 2010
6 AS-i MODULE VERSIONS 21
6.1 Wiring to AS-i network 21
6.2 Wiring to the solenoid valves and sensors 21
6.3 AS-i network 22
6.3.1 AS-i supplies 22
6.3.2 AS-i address programming 22
6.4 Meaning of LEDs on the front of the modules 23
6.5 Meaning of I/O bits via AS-i 23
6.6 Technical specifications of AS-i modules 24
7 CHANGING CONFIGURATION & PNEUMATIC CONNECTION 25
7.1 Switch from an NC unit (terminal or module) to NO (normally open) 25
8 PARTS FOR ICS UNIT 26
8.1 Exploded view of the (AS-i or multi-voltage) module version ICS unit 26
8.2 Exploded view of the terminal version ICS unit 27
8.3 List of ICS unit parts 28
8.4 Dimensions, assignment and reference of sensor cams for ICS units 29
8.4.1 For DPAX valves DN25 to 150 29
8.4.2 For DCX3 & 4 mini valves DN1/2” to 1” 29
8.4.3 For DCX3 & 4 valves DN25 to 76 29
8.4.4 For DMAX valves DN9 to 53 29

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 4/30 April 2010
1 CHANGE MANAGEMENT
CHANGES
INDEX
DATE
PAGE(S)
INITIALS
New version
1
April 2010
/
F. MERLET

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 5/30 April 2010
2 SAFETY
2.1 Important information
Always read the maintenance notice before manipulating the valve
Failure to observe these instructions can result in serious bodily injury or loss of life.
This can also result in less serious injuries or damage to the equipment.
Electricity can result in serious bodily injury or loss of life.
This can also result in less serious injuries or damage to the equipment.
2.2 General information
The following advice is given to ensure optimum use of the equipment.
The tasks must be performed in the order specified.
Forbidden or permitted actions:
NOTE !
DANGER !
NOTE !
DANGER !
CAUTION !
•
OK
<0.5 m
≥ 0.5 m
NO
Cleaning

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 6/30 April 2010
MAINTENANCE NOTICE ICS signaling unit
3 INTRODUCTION
The ICS signaling unit is available in 3 configurations: AS-i 2.1 2I/1O module, multi-voltage 2I/1O module and
terminal module.
3.1 Disassembling the signaling unit
3.1.1 Disassembling the unit/actuator
IMPORTANT: Before starting any work on the unit, it is important to ensure that the mains
supply is switched off, that the air supply is closed and that the circuit is purged.
Disassembling the cover
Turn the cover to align the pin with the pictogram,
thenremove the cover by pulling upwards.
Disassembling connector - base / actuator
Disconnect the air pipes from the box.
Unscrew the stuffing box assembly, locate and
disconnect the wires on the terminal or on the
supply module, then remove the supply cable, or
disconnect and remove the cable from the AS-i
module.
Unscrewthe locking screw.
Turnthe connector (with or without the cover) to
release the three locking studs of the base.
Separateby pulling upwards.
Unscrew the two CHC screws.
Remove the actuatorcover.
DANGER !
Valve
actuator
Cover
Connector
Base





Keying studs
locking screw



MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 7/30 April 2010
3.1.2 Disassembling the unit components
Before disassembling the components, locate and disconnect the wires to the terminal or
disconnect the terminal from the module (AS-i or multi-voltage).
Disassembling the solenoid valve
Unscrew the two fastening screws on the solenoid
valve andremove it and the seal,
Disassembling the modules OR
Unscrew the fastening screw from the module (AS-i
or multi-voltage) and remove.
Disassembling the terminal
For low-level detection, slightly unscrew the upper
screw, then refit the detector.
For low- and high-level detection, completely
unscrew the upper screwsthat serve to secure
the position, then the lower screwsthat simply
hold the detectors in place.
Remove the lower screws and the guides.
Unscrew the supportscrews, and remove them.
Disassembling the terminal
Disassembling the terminal: hold the nuts, unscrew
the M3 screws, remove the terminal.
Disassembling the terminal support:
Unscrew the M4 screw, remove the terminal support
from the connector.
NOTE !
Nut
Connector
Terminal
M3 screw
Washer
M4 screw
screw
Connector
Multi-voltage
module
AS-i module
Connector
Solenoid
valve
assembly
Screw
NC Solenoid valve
Seal
Sensor support assembly
Upper sensor
Lower sensor
Sensor support assembly






Lower sensor support guide
Sensor support

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 8/30 April 2010
3.2 Reassembling the signaling terminal
3.2.1 Reassembling the unit components
Reassembling the terminal OR
As for removal, in reverse order:
Position the terminal on the terminal support, fit the
two M3 screws, the washers and the nuts.
oTightening torque: 0.1 Nm(1 kgf.cm)
Position on the connector, fit the M4 screw.
oTightening torque: 0.8 Nm(8 kgf.cm)
Reassembling the sensors
As for removal, in reverse order:
Position the detector supports on the connector, fit
the M3 screw.
oTightening torque: 0.8 Nm(8 kgf.cm)
Position the high-level or low-level detector on their
detector bracket ; position each detector support
guide; fit the two M3 screws.
Tighten the lowerscrews.
oTightening torque: 0.4 Nm(4 kgf.cm)
Adjust the high position and the low position.
Tighten the upper screws.
oTightening torque: 0.4 Nm(4 kgf.cm)
Reassembling the module
As for removal, in reverse order:
Position the AS-i or multi-voltage module into its
housing in the connector. Fit the M3 screw on the
attachment point corresponding to the configuration
of the module.
oTightening torque: 0.3 Nm(3 kgf.cm)
Reassembling the solenoid valve
As for removal, in reverse order:
Position the solenoid valve seal between the two
walls and align with the centering pin on the
connector seating plane.
Align the solenoid valve with the same centering
pin.
Fit the two M2.5 attachment screws.
oTightening torque: 0.4 Nm(4 kgf.cm)
New, more accessible
attachment point on new unit.
Existing attachment point on
new version and 2004 version
of unit.



Indexing hole
Locating pin
Low-level
detection:
cable
gland
side
High-level
detection:
locking
screw side
Cam / detector target adjustment:
The cam can be set anywhere
within a range extending from the
centre of the target to the full
target.
Adjust as needed !
Full target
Centre of target

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 9/30 April 2010
3.2.2 Reassembling the unit/actuator
Reassembling the connector - base /
actuator
As for removal, in reverse order:
Position the base on the actuator.
Fit the two CHC screws (M4 for 32 interaxial, and
M8 for 50 interaxial)
oTightening torque: 0.6 Nm(6 kgf.cm) for
M4 screws.
oTightening torque: 1 Nm (10 kgf.cm) for M8
screws.
Position the connector (with or without its cover)
on thekeying studs on the base.
Turn the connector to lock it onto the base
Tighten the locking screw to lock it in place.
Connect the pneumatic circuit.
Remove the cover if necessary, and electrically wire
according to the type of unit and in accordance with
the wiring diagrams provided herein.
Tighten the cable gland.
In order to ensure that it is
mounted on the keying
studs, position the shape
with the letter "A" on the
connector relative to the
base as shown in the
figure below:
Reassembling the cover
As for removal, in reverse order:
Align the pin of the cover with the "open cover"
pictogram, and bring the cover into contact with the
connector.
Turn the cover in the direction of its locking arrow
until the pin is above the "cover locked" pictogram.
Note:
Under normal operation, the base, the connector and
the cover can, if necessary, be lead-sealed by means
of a wire or a screw in a hole passing through the
entire signaling unit.
Keying studs



locking screw

Valve actuator
Cover
Connector
Base



NOTE !


MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 10/30 April 2010
4 TERMINAL VERSIONS
The terminal versions allow you to connect the sensors and the solenoid valves directly to the PLC.
In this case the operating voltage of the sensors and the solenoid valves is only 24 V DC +/- 10%.
4.1 Wiring 2 sensors/1 solenoid valve
Part name
Function
V+
+ Sensor supply (+24 V DC)
V-
Sensor earth
I1
Retro data valve closed (PNP)
I2
Retro data valve open (PNP)
EV1
Solenoid valve control 1 (+24 V DC)
(main actuator)
EV-
Solenoid valve earth
Part name
Function
V+
+ Sensor supply (+24 V DC)
V-
Not connected
I1
Retro data valve closed (PNP)
I2
Retro data valve open (PNP)
EV1
Solenoid valve control 1 (+24 V DC)
(main actuator)
EV-
Solenoid valve earth
4.2 Electrical specifications
General specifications
Supply voltage
Sensors
Solenoid valves
Current consumed for 1 active solenoid valve and 1 active sensor
Temperature
Operating
storage/transport
24 V DC +/- 10%
24 V DC +/- 10%
40 mA DC
-10 to +60 °C
-40 to +85 °C
Sensors
Supply voltage
Output current
2 wire and 3 wire inductive sensor connection
24 V DC +/- 10%
50 mA max
Yes
Wiring for 2 wire sensors and solenoid valve on 2I/1O terminal (Version on request)
White
Black
Black
Lower
sensor
Upper
sensor
SV1 (Main
actuator)
Red
White
Black
Brown
Blue
Brown
Blue
Red
Black
Lower
sensor
Upper
sensor
SV1 (Main
actuator)
Black
Black
Wiring for 3 wire sensors and solenoid valve on 2I/1O terminal (Standard version)

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 11/30 April 2010
Solenoid valves
Supply voltage
Current consumed
Switching frequency on inductive load
24 V DC +/- 10%
30 mA max
0.5 Hz
Electrical connections to PLC
Connection type
Conductor section
Spring cage terminal
0.75 mm² max.
A 0.5 mm² cross section is sufficient.
Cable diameter: 4 to 8 mm.

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 12/30 April 2010
5 MULTI-VOLTAGE MODULE VERSIONS
The 24 VDC and 24 VAC-48 VAC/DC multi-voltage modules provide an interface between the peripheral devices
(solenoid valves, sensors) and the command control system (PLC). Two different voltages can be used at the
same time on the module.
Terminology:
The input signals correspond to the solenoid valve commands.
The output signals correspond to the retro data signals from the sensors.
5.1 Module functions
Electronic module:
Adapts the electrical signals between the PLC and the sensors/solenoid valve that only operate
at 24 V DC.
Allows you to select the type of signals PNP, NPN or NO (using jumpers).
Displays the states of the I/O, supply and faults.
In order for the module to be permanently supplied, it must be ensued that the
connecting cable has sufficient conductors! (6 conductors min for the unit, 1 solenoid
valve and 2 sensors: 2 for the module power supply, 2 for the sensor retro data, 2 for the
solenoid valve).
5.2 Selecting the multi-voltage module version
According to the voltages used on the installation, different module versions are available:
I/O PLC
MULTI-
VOLTAGE
MODULE
Output
s
Inputs
Sensors
Solenoid
valve
Permanent 24 V DC
supply available?
Module with permanent 24 V AC -
48 V AC/DC supply
Signal voltages
Solenoid valve
24 V AC, 48 V AC or 48 V
DC and Retro data
sensors 24VAC, 48VAC
or 48V DC
N.B.: The supply voltage
must be common to the
solenoid valve voltages or
sensors.
Module with
permanent 24V DC
supply
Retro data sensors
24 V DC?
Signal voltages
Solenoid valve 24V DC
and
Retro data sensors 24VDC, 24VAC,
48VAC or 48V DC
Signal voltages
Solenoid valve 24VDC, 24VAC, 48V
AC or 48V DC
and
Retro data sensors 24 V DC
NO
NO
YES
YES
Multi-voltage module:
Ref. 7708050 (2I/1O)
Multi-voltage module:
Ref. 7708052 (2I/1O)
IMPORTANT

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 13/30 April 2010
5.3 24 V DC modules
The electrical supply of the multi-voltage module must be 24 V DC, and permanent.
The solenoid valve signals or ,the sensor signals can have a different voltage (24 V AC, 48 V DC or 48 V AC) to
24 V DC, but never at the same time.
5.3.1 Different input/output cabling
5.3.1.1. Description
The table below gives the following 8 possible wiring diagrams:
Different voltages,
Signal types (PNP, NPN, NO, common used).
Example:
- Solenoid valve signals: 48 V AC + common independent,
- Sensor signals + fault: 24 V DC output PNP.
The diagram to be used is number 5.
Comments: :
Initially, the module is configured to be wired according to diagram number 3.
The bold marks on the wiring diagrams represent the jaws of the CO and CI connectors (use
tool 7708097 to remove or move the jaws).
Table of the 8 possible wiring diagrams
SOLENOID VALVE SIGNALS
Connector (CO)
24 V DC
Independent
SENSOR SIGNALS + FAULT
Output
Voltage
V+
V-
PNP
24 V DC
Diagram No. 1
Diagram No. 3
Diagram No. 5
48 V DC
Diagram No. 8
Diagram No. 7
NPN
24 V DC
Diagram No. 2
Diagram No. 4
Diagram No. 6
48 V DC
Diagram No. 8
Diagram No. 7
NO
24 V AC, 48 V
AC
Diagram No. 8
Diagram No. 7
CAUTION!
2-point wiring jaws that links the CI and CO
connectors to V+ or V-.
NOTE !

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 14/30 April 2010
5.3.1.2. Wiring diagrams:
24VDC x x
24VAC
48VDC
48VAC
24VDC x x
24VAC
48VDC
48VAC
24VDC x x
24VAC
48VDC
48VAC
24VDC x x
24VAC
48VDC
48VAC
24VDC x
24VAC x
48VDC x
48VAC x
24VDC x
24VAC x
48VDC x
48VAC x
24VDC x
24VAC x
48VDC x
48VAC x
24VDC x
24VAC x
48VDC x
48VAC x
V+
V-
I2
I1
O1
CO
V+
V-
I2
I1
O1
CI
V+
V-
I2
I1
O1
CO
V+
V-
I2
I1
O1
CI
V+
V-
I2
I1
O1
V+
V-
I2
I1
O1
V+
V-
I2
I1
O1
V+
V-
I2
I1
O1
PNP OUTPUT SENSORS
NPN OUTPUT SENSORS
DIAGRAM NO. 1
Signals:
- Solenoid valve: Connector (CO) to 24 V DC
- Sensors: 24 V DC output PNP
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 2
Signals:
- Solenoid valve: Connector (CO) to 24 V DC
- Sensors: 24 V DC outputs NPN
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO.3
Signals:
- Solenoid valve: Connector (CO) to GND
- Sensors: 24 V DC output PNP
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator (O1)
Common Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 4
Signals:
- Solenoid valve: Connector (CO) to GND
- Sensors: 24 V DC outputs NPN
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
PNP OUTPUT SENSORS
NPN OUTPUT SENSORS
DIAGRAM NO. 7
Signals:
- Solenoid valve: Connector (CO) to GND
- Sensors: PNP, NPN OR NO outputs
connector independent.
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 8
Signals:
- Solenoid valve: Connector (CO) to 24 V DC
- Sensors: PNP, NPN OR NO outputs
connector independent.
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
PNP, NPN OR NO OUTPUT SENSORS
DIAGRAM NO. 5
Signals:
- Solenoid valve: Connector (CO) independent
- Sensors: 24 V DC output PNP
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 6
Signals:
- Solenoid valve: Connector (CO) independent
- Sensors: 24 V DC outputs NPN
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 15/30 April 2010
5.4 24 V AC –48 V AC/DC modules
The electrical supplyof the multi-voltage module must be 24 V AC, 48 V AC or 48 V DC, and permanent.
The solenoid valve signals or the sensor signals can have a different voltage (24 V AC, 48 V AC or 48 V DC) to
the supply, but never at the same time.
5.4.1 Different input/output cabling
5.4.1.1. Description
The table below gives the following 14 possible wiring diagrams:
Different voltages,
Signal types (PNP, NPN, NO, common used).
Example:
- Power supply 48 V AC,
- Solenoid valve signals: 48 V AC,
- Sensor signals + fault: 24 V AC NO outputs.
The diagram to be used is number 6.
Comments: :
Initially, the module is configured to be wired according to diagram number 1 or 2.
The bold marks on the wiring diagrams represent the jaws of the CO and CI connectors (use
tool 7708097 to remove or move the jaws).
Table of the 14 possible wiring diagrams
SOLENOID VALVE SIGNALS
Connector (CO)
SENSOR SIGNALS + FAULT
Output
Voltage
24 V AC
48 V AC
48 V DC
Independent
V+
V-
NO
24 V AC
Diagram No. 1
Diagram No. 6
Diagram
No. 13
Diagram
No. 14
Diagram No. 3
NO
48 V AC
Diagram No. 5
Diagram No. 2
Diagram
No. 13
Diagram
No. 14
Diagram No. 4
PNP
48 V DC
Diagram No. 5
Diagram No. 6
Diagram
No. 7
Diagram
No. 8
Diagram No. 11
NPN
Diagram No. 5
Diagram No. 6
Diagram
No. 9
Diagram
No. 10
Diagram No. 12
2-point wiring jaws that links the CI and CO
connectors to V+ or V-.
CAUTION!
NOTE !

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 16/30 April 2010
5.4.1.2. Wiring diagrams:
24VAC x x
48VDC
48VAC
24VAC
48VDC x x
48VAC
x
24VAC x
48VDC x
48VAC
x
24VAC x
48VDC x
48VAC
24VAC x
48VDC x
48VAC x
24VAC x
48VDC x
48VAC x
48
V ac
I2
I1
O1
CI
24
V ac
I2
I1
O1
CI
CO
48
V ac
I2
I1
O1
CO
24
V ac
I2
I1
O1
48
V ac
I2
I1
O1
24
V ac
I2
I1
O1
NO OUTPUT SENSORS
DIAGRAM NO. 1
Signals:
- Solenoid valve: Connector (CO) to V+
- Sensors: 24 V AC NO outputs
(V+)
(V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
24 V
AC
DIAGRAM NO. 2
Signals:
- Solenoid valve: Connector (CO) to V+
- Sensors: 48 V AC NO outputs
(V+)
(V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
48 V
AC
DIAGRAM NO.3
Signals:
- Solenoid valve: Connector (CO) independent
- Sensors: 24 V AC NO outputs
(V+)
(V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
24 V
AC
DIAGRAM NO. 4
Signals:
- Solenoid valve: Connector (CO) independent
- Sensors: 48 V AC NO outputs
(V+)
(V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
48 V
AC
DIAGRAM NO. 5
Signals:
- Solenoid valve: Connector (CO) to V+
- Sensors: 48 V DC PNP or NPN outputs
48V AC NO outputs
(V+)
(V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
24 V
AC
DIAGRAM NO. 6
Signals:
- Solenoid valve: Connector (CO) to V+
- Sensors: 48 V DC PNP or NPN outputs
24 V AC NO outputs
(V+)
(V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
48 V
AC
PNP, NPN OR NO OUTPUT SENSORS (connector independent)

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 17/30 April 2010
24VAC
48VDC x x
48VAC
24VAC x x
48VDC
48VAC
24VAC x x
48VDC
48VAC
24VAC x x
48VDC
48VAC
24VAC x
48VDC x
48VAC x
x
24VAC x
48VDC x
48VAC
x
24VAC x
48VDC x
48VAC
24VAC x
48VDC x
48VAC x
V+
V-
I2
I1
O1
CI
V+
V-
I2
I1
O1
CO
V+
V-
I2
I1
O1
CO
V+
V-
I2
I1
O1
V+
V-
I2
I1
O1
V+
V-
I2
I1
O1
V+
V-
I2
I1
O1
DIAGRAM NO. 7
Signals:
- Solenoid valve: Connector (CO) to 48 V DC
- Sensors: 48 V DC outputs PNP
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
PNP OUTPUT SENSORS
NPN OUTPUT SENSORS
DIAGRAM NO. 8
Signals:
- Solenoid valve: Connector (CO) to 48 V DC
- Sensors: 48 V DC outputs NPN
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 9
Signals:
- Solenoid valve: Connector (CO) to GND
- Sensors: 48 V DC outputs PNP
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 10
Signals:
- Solenoid valve: Connector (CO) to GND
- Sensors: 48 V DC outputs NPN
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 12
Signals:
- Solenoid valve: Connector (CO) independent
- Sensors: 48 V DC outputs NPN
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 11
Signals:
- Solenoid valve: Connector (CO) independent
- Sensors: 48 V DC outputs PNP
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 14
Signals:
- Solenoid valve: Connector (CO) to GND
- Sensors: NO outputs connector independent
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
DIAGRAM NO. 13
Signals:
- Solenoid valve: Connector (CO) to 48 V DC
- Sensors: NO outputs connector independent
24 V DC (V+)
GND (V-)
Open (I1)
Closed (I2)
Cde_Main Actuator_ (O1)
Common_Command (CO)
Common_Info (CI)
Power
supply
Valve
position
Valve
control
SV
Sensor
NO OUTPUT SENSORS
V+
V-
I2
I1
O1
CI

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 18/30 April 2010
5.5 Wiring to the PLC
5.6 Wiring to the solenoid valves and sensors
5.7 Meaning of LEDs on the front of the modules
The front of each module is fitted with LEDs that display the states of the inputs/outputs, as well as the
presence of the power supply or a local fault.
: Status of the sensor valve open
Yellow LED illuminated –Valve open
: Status of the sensor valve closed
Yellow LED illuminated –Valve closed
: Status of the main actuator solenoid valve
Yellow LED illuminated –Solenoid valve controlled
PWR:Power supply on
Green LED illuminated = Power supply on
FAULT: Indicates the status of the module.
Red LED illuminated = Supply voltage too low or overload
or short-circuit on a peripheral of the unit (faulty solenoid
valve, ….).
Red LED flashing = Overload or short-circuit on a
peripheral.
Part name
Function
V+
+ Power supply
V-
- Power supply
O1
Solenoid valve control 1 (main actuator)
CO
Solenoid valve connector command
See the wiring table
I1
Retro data valve closed
I2
Retro data valve open
FLT
Retro data error
CI
Common retro data
See the wiring table
V+
V+
V-
V-
I1
I2
O1
V-
2I/1O modules
White
Black
White
Black
Red
Black
Lower
sensor
Upper
sensor
SV1 (Main
actuator)
Wiring for sensors and solenoid valve on 2I/1O modules
MAIN
ACTUATOR
Tool location for opening spring cage
and inserting cable(s)
Module supply
I2
I1
V-
CI
V+
V+
V-
O1
FLT
V-
CO
V+

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 19/30 April 2010
5.8 Technical specifications of the multi-voltage modules
General specifications
Supply voltage
24 V DC modules
24 V AC –48 V AC/DC modules
Current consumed for 1 active solenoid valve and 1 active
sensor
Electromagnetic compatibility
Temperature
Operating
storage/transport
24 V DC +/- 5%
24 V AC –48 V AC/DC +/- 10%
60 mA DC (24 V DC supply)
≤ 110 mA AC (24 V AC supply)
≤ 55 mA DC (48 V DC supply)
≤ 75 mA AC (48 V AC supply)
EN61000-6-2 , EN61000-6-4
-10 to +60 °C
-40 to +85 °C
Diagnostic functions
Supply voltage display
Unit status display
Green “POWER” LED
Red “FAULT” LED
Sensor inputs
Nominal input voltage
2 wire and 3 wire inductive sensor connection
24 V DC
Yes
Solenoid valve output
Output voltage
Output current
Switching frequency on inductive load
Short-circuit protection
24 V DC
50 mA max
0.5 Hz
Yes
Electrical connections to PLC
Connection type
Conductor section
Spring cage terminal
0.75 mm² max.
A section of 0.5 mm² is sufficient. Refer to the cable gland
specifications for the maximum routing diameter of the
cable.
Solenoid valve signals from the PLC
Number
Nominal input voltage +/- 10%
Minimum current
Signal type
1
24 V AC/DC to 48 V AC/DC
≥ 6mA
PNP or NPN
Sensor signals to PLC
Number
Fault signal
Output voltage +/- 10%
Output current
Signal type
1 à 3
Yes
24 V AC/DC to 48 V AC/DC
50 mA max
PNP, NPN or NO

MAINTENANCE NOTICE
IT-TDFX-245 revision 1 Page 20/30 April 2010
5.9 1ST level maintenance
5.9.1 Power LED extinguished
Check that the supplyfrom the module is wiredcorrectly.
Check that the voltage between V+ and V- (two stage terminal) is equal to 24 V DC +/- 5% or 24 V AC
–48 V AC/DC +/- 10% depending on the unit used.
If the result of these actions is negative, replace the unit.
5.9.2 Fault LED illuminated or flashing
Red LED flashing = Overload or short-circuit on sensor or solenoid valve.
Disconnect the sensor/solenoid valve connector and check that the fault has disappeared. Check the
sensors andsolenoid valve one by one.
Red LED illuminated = Supply voltage too low or overload or short-circuit on a peripheral of the unit
(faulty solenoid valve, ….).
Check that the voltage between V+ and V- (two stage terminal) is equal to 24 V DC +/- 5% or 24 V AC –
48 V AC/DC +/- 10% depending on the unit used.
Disconnect the sensor/solenoid valve connector and check that the fault has disappeared. Check the
sensors andsolenoid valve one by one.
5.9.3 Testing the solenoid valve
The green LED on the unit mustbe illuminated.
Control the solenoid valve coil using the PLC.
Measure the voltage on the peripheral connector using a voltmeter between terminals O1 and CO.
Check that this voltage corresponds to the solenoid valve control voltage. If the result of this stage is
negative, check the wiring between the unit and the PLC.
If the “Main actuator” LED is illuminated, measure the voltage on the peripheral connector between
terminals SV1 and SV-. This voltage must be between 20 and 24 V DC.
If this voltage is correct, change the solenoid valve.
Otherwise, disconnect the peripheral connector. If the “Main actuator” LED is extinguished, change the
unit.
5.9.4 Testing the sensors
The unit must be connected electrically to the PLC.
Use a voltmeter to check that the voltage between terminals V+ and V- on the sensor side of the
terminal is between 20 and 24 V DC.
Place a metallic object in front of sensor target to check that the LED on the sensor illuminates correctly.
The LED does not illuminate: Change the sensor and restart the tests from step 1.
LED illuminates = Measure the voltage using a voltmeter between terminals V- and I1 or I2 on the
peripheral terminal of the unit and check that the voltage is 12 V DC.
Check that the LED on the unit corresponding to the sensor is illuminated correctly.
LED extinguished -> Change the module.
LED illuminated = Check the voltage on the two stage connector between the terminals I1 and CI or I2
and CI depending on the sensor tested.
If the voltage is correct, check the wiring between the module and the PLC, otherwise change the unit.