Festo CPX-AP Series User manual

8099720
CPX-AP
Automation system
8099720
2019-06
[8099722]
Instructions| Operat-
ing

Translation of the original instructions
IO-Link® is a registered trademark of its respective trademark holder in certain countries.
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1 About this document................................................................................................... 5
1.1 Applicable documents.................................................................................................. 5
1.2 Product version............................................................................................................ 5
1.3 Product labelling.......................................................................................................... 5
1.4 Specified standards...................................................................................................... 5
2 Safety........................................................................................................................... 6
2.1 Safety instructions........................................................................................................ 6
2.2 Intended use................................................................................................................ 6
2.3 Training of qualified personnel..................................................................................... 6
3 Additional information................................................................................................ 6
4 Service..........................................................................................................................6
5 Product overview......................................................................................................... 6
5.1 Function....................................................................................................................... 6
5.2 Configuration................................................................................................................ 7
5.2.1 System structure.....................................................................................................7
5.2.2 Product variants......................................................................................................8
5.2.3 LED displays........................................................................................................... 9
6 System communication and address assignment........................................................ 10
7 Mounting..................................................................................................................... 12
7.1 Mounting distances and installation space................................................................... 12
7.2 Direct mounting............................................................................................................ 14
8 Installation.................................................................................................................. 15
8.1 Power supply................................................................................................................ 15
8.1.1 Power supply concept.............................................................................................15
8.1.2 Voltage drop........................................................................................................... 17
8.1.2.1 Calculating the voltage drop................................................................................... 18
8.1.3 Electrical isolation...................................................................................................19
8.2 Functional earth FE....................................................................................................... 19
8.3 Connecting the lines..................................................................................................... 19
8.4 Disconnecting the cables.............................................................................................. 20
9 Commissioning............................................................................................................ 20
9.1 Checking assembly and connections............................................................................ 20
9.2 Configuring the settings on the interface...................................................................... 20
9.3 Check the function of automation system CPX-AP (without higher-level control).......... 20
9.4 Commissioning in network (with higher-order controller)..............................................20
10 Parameterisation......................................................................................................... 21
11 Diagnostics.................................................................................................................. 21
11.1 Diagnostics options...................................................................................................... 21
11.2 Diagnostic status.......................................................................................................... 21
11.3 Grouping and overview of the diagnostic messages......................................................22
Table of contents

11.4 Load voltage monitoring................................................................................................24
11.5 Diagnostic messages.....................................................................................................27
12 Disposal........................................................................................................................30
13 Technical data.............................................................................................................. 31
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1 About this document
1.1 Applicable documents
All available documents for the product èwww.festo.com/pk.
Document Contents
Instructions for the modules in an
automation system CPX-AP
Information on using the modules
Tab. 1 Applicable documents
1.2 Product version
This document refers to the automation system CPX-AP.
The product version can be determined using the product label.
There may be an updated version of this document for these or later product versions
èwww.festo.com/sp.
1.3 Product labelling
The product label and the Data Matrix Code are printed on the housing of the modules. Scanning the
Data Matrix Code with an appropriate device opens the Festo Support Portal with information appro-
priate for the product. Alternatively, the Product Key (11-digit alphanumeric code on the product
labelling) can be entered in the search field of the Support Portal èwww.festo.com/sp.
1.4 Specified standards
Version
IEC60204-1:2016-10 DIN46211:1965-03
EN60068-2-6:2008-02 DIN46225:1976-12
EN60068-2-27:2009-05 DIN46234:1980-03
EN60204-1:2018-09 DINENISO4762:2004-06
EN60529:1991-10 –
Tab. 2 Standards specified in the document
About this document

2 Safety
2.1 Safety instructions
– Take into consideration the legal regulations for the respective destination.
– Use the product only within the defined values è 13 Technical data.
– Observe labelling on the product.
– Observe further applicable documents.
– Store the product in a dry, UV- and corrosion-protected environment.
– Before working on the product:
Switch off the power supply and secure it against being switched on again.
2.2 Intended use
The product described in this document is intended exclusively for control tasks on machines or auto-
mation systems.
Use the product only as follows:
– Use only in an industrial environment. Outside of industrial environments, e.g.in commercial and
residential/mixed-use areas, it may be necessary to take measures to suppress radio interference.
– Use only in combination with modules and components that are permissible for the respective
product variant èwww.festo.com/catalogue.
– Only use the product if it is in perfect technical condition.
2.3 Training of qualified personnel
Installation, commissioning, maintenance and disassembly should only be conducted by qualified per-
sonnel. The qualified personnel must be familiar with installation of electrical control systems.
3 Additional information
– Accessories èwww.festo.com/catalogue.
4 Service
Contact your regional Festo contact person if you have technical questions èwww.festo.com.
5 Product overview
5.1 Function
The automation system CPX-AP-I is a decentralised system for connecting electrical peripherals. Differ-
ent module types with different connection technology are available. An automation system CPX-AP-I
consists of an interface and at least one other module. For system communication, the individual mod-
ules in an automation system CPX-AP-I are connected to each other by connecting cables. The process
data is exchanged cyclically.
The automation system CPX-AP-I is connected to a higher-level controller via an interface. By access-
ing internal parameters, the behaviour of the automation system CPX-AP-I can be adapted to the
respective requirements. Various diagnostic functions are also available.
Safety
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5.2 Configuration
5.2.1 System structure
1Higher-order controller
2Network
3Interface (example for PROFINET)
4Digital input/output module
5Digital input module
6Electrical interface
(example for valve terminal VTUG)
7AP system communication
8Power supply
9Voltage forwarding
10 Digital input/output modules
11 IO-Link Master
12 IO-Link device
13 Digital input module (without forwarding)
Fig. 1 System structure (example for PROFINET interface and electrical interface for VTUG)
Product overview
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5.2.2 Product variants
Interfaces
Module Function
Example for
CPX-AP-I-PN-M12
The interface between the automation system CPX-AP and the network per-
forms the following functions:
– Connection of the automation system CPX-AP to the network
– Data transfer between the automation system CPX-AP and the higher-
order controller
– Transmission of control signals to the connected modules
– Monitoring the functionality of the connected modules
– Access to system parameters (read/write), input/output signals and dia-
gnostic data (depending on the interface)
– Controller of the automation system CPX-AP
Tab. 3 Interfaces
Input/output modules
Module Function
Example for
CPX-AP-I-8DI-M8-3P
The input/output modules include various module types:
– Digital input/output modules can be used, for example, to query sensor
signals or to control actuators.
– In an automation system CPX-AP, an analogue input module acquires ana-
logue input signals.
– In an automation system CPX-AP, a IO-Linkmaster provides several IO-Link
Ports for the connection of IO-Link Devices.
Tab. 4 Input/output modules
Product overview
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Electrical interfaces
Module Function
VAEM-L1-S-...-AP
VMPAL-EPL-AP
With electrical interfaces, valve terminals, e.g. VTUG or MPAL, can be con-
trolled via the automation system CPX-AP.
Tab. 5 Electrical interfaces
5.2.3 LED displays
Depending on the module, the modules in an automation system CPX-AP have various LED displays for
visualising status and diagnostics.
Detailed information on the LED displays of the individual modules èProduct-specific documentation
Product overview
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6 System communication and address assignment
For internal system communication between the modules, two strings can be implemented via the
connections [XF20] and [XF21] of the interfaces by means of connecting cables. The connection of the
connecting cables to the individual modules is made via connection [XF10]. The connection [XF20] is
available for forwarding to another module.
The addresses of the modules are assigned automatically each time the automation system CPX-AP is
started up. The interface is assigned address1. The modules are addressed at terminals [XF20] and
[XF21] in ascending order for each string, starting with the string at terminal [XF20].
1Interface
2Connection for system communication
[XF10]
3Connection for system communication
forwarding [XF20]
4String 2
5String 1
6Connection for system communication string
2 [XF21]
7Connection for system communication string
1 [XF20]
Fig. 2 System communication and addressing
System communication and address assignment
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NOTICE!
Loss of function due to incorrectly connected or impermissible connecting cables.
• Always connect the connecting cables for the modules to the connection [XF10].
• Always connect the forwarding of the connecting cables to the connection [XF20].
• Only use permissible connecting cables from the Festo catalogue èwww.festo.com/catalogue.
Behaviour in the event of incorrect configuration after restart
When establishing a connection with the higher-level controller, the configuration is checked for the
following criteria, depending on the network protocol of the interface:
– Total number of input and output bytes
– Module codes and sequence of modules
– Length and format of the start-up parameterisation
If there are deviations, the connection to the higher-level controller is refused and a network-specific
error message is generated.
Behaviour when changing the configuration during operation
– If a module is removed during operation, no process data is transferred to the higher-level control-
ler for this module and all subsequent modules. The failure of the module is signalled via a dia-
gnostic message and, if necessary, network-specific status bytes in the process data.
– If an additional module is added after the connection is established with the higher-level control-
ler or an existing module is exchanged, this module is not included in the active configuration and
no data exchange with this module is possible.
In order for changes to the configuration to become active, the system must be restarted (switched
off/on).
System communication and address assignment
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7 Mounting
7.1 Mounting distances and installation space
In order to guarantee sufficient space for the connection cables, certain minimum distances must be
observed when installing the modules. The minimum distances to be observed depend on the mod-
ules and the type of connectors used (straight or angled).
Fig. 3 Mounting distances and installation space (example for CPX-AP-I-8DI-M8-3P)
Mounting
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Interfaces Input/output modules
IO-Link Master
Connector plug Connector plug
Item no.
è Fig.3
Straight Angled Straight Angled
Minimum distance [mm]
1103 62 108 66
235 56 35 54
335 56 35 54
464 64
Distance between mounting holes [mm]
5155 155
87.5 (CPX-AP-I-4DI-M8-3P)
6170 170
102.5 (CPX-AP-I-4DI-M8-3P)
722.5 15
845 30
98 8
aJ 7 7
aA 20.5 20.5
aB 35.5 20.5
aC 13.8 13.8
Tab. 6 Mounting distances and installation space
Mounting distances of the electrical interfaces èProduct-specific documentation
Mounting
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7.2 Direct mounting
The modules are mounted directly via the mounting interfaces with two hexagon socket head screws
M4 according to DIN EN ISO 4762.
Observe the following when installing the modules:
– Always use two retaining screws.
– Use suitable washers.
– Observe a tightening torque of 1.2Nm.
– Functional earth connectionè 8.2 Functional earth FE
1Mounting interface connection side top
2Washer
3Socket head screw M4
4Module
(example for CPX-AP-I-8DI-M12-5POL)
5Mounting interface connection side bottom
and connection functional earth FE
6Cable lug with earthing cable (optional)
7Mounting interface, lateral bottom and con-
nection for functional earth FE
8Mounting interface, lateral top
Fig. 4 Direct mounting
Mounting
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8 Installation
8.1 Power supply
8.1.1 Power supply concept
The automation system CPX-AP-I uses two separate voltages:
– Logic supply PS: power supply for internal electronics and sensors
– Load supply PL: power supply of the electrical outputs and valves
The voltages can be supplied jointly by one fixed power supply or separately by two fixed power sup-
plies.
1SELV/PELV fixed power supply
2Fuse for line protection logic supply PS
(max. 4 A)
3Fuse for line protection load supply PL
(max. 4 A)
4Interface
5Digital input module
6Digital input/output module
7Voltage forwarding (if necessary)
Fig. 5 Power supply concept
NOTICE!
Property damage due to overload of the cables.
• Observe the maximum acceptable current load of the cables.
• Only use permissible cables from the Festo catalogue for the power supply
èwww.festo.com/catalogue.
NOTICE!
Loss of function due to voltage drop.
• Take into account the voltage drop at the supply feed and in the voltage forwarding
è 8.1.2 Voltage drop.
Installation
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The load supply PL can be switched on and off at any time. When switched off, the electrical outputs or
valves are not active, even if they are controlled.
Supply
Power is supplied to each module at connection [XD1]. The voltages can be forwarded to other mod-
ules via the connection [XD2].
Each module can also be powered directly from the fixed power supply, e.g.
– to reduce voltage drops,
– to form voltage zones,
– if the max. current is exceeded.
NOTICE!
Loss of function if logic supply PS is switched on late.
If the modules are supplied by different fixed power supplies, the interface must be switched on last,
as otherwise they will not be detected by the interface when the automation system CPX-AP starts up.
1Interface
2Digital input module
3Digital input/output module
4Digital input module
5Electrical interface
(example for valve terminal VTUG)
6Voltage forwarding (if necessary)
7SELV/PELV fixed power supply for feeding
the power supply to the interface
8SELV/PELV fixed power supply for separate
feed of the power supply
Fig. 6 Voltage zones
Installation
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8.1.2 Voltage drop
The cables between the modules and the modules themselves cause a voltage drop, which must be
taken into account in the project engineering.
Determination of the voltage drop based on the cable length and current
è Tab. 7 Determining the voltage drop.
Information for the exact calculation of the voltage drop è 8.1.2.1 Calculating the voltage drop.
Cable length [m]1)
0.3 0.5 1.0 2.0 5.0 7.5 10.0 15.0
Voltage drop at 1A [V] 0.0 0.1 0.1 0.2 0.4 0.5 0.7 1.1
Voltage drop at 2A [V] 0.1 0.1 0.2 0.3 0.7 1.1 1.4 2.1
Voltage drop at 3A [V] 0.1 0.2 0.3 0.5 1.1 1.6 2.2 3.2
Voltage drop at 4A [V] 0.2 0.2 0.4 0.6 1.5 2.2 2.9 4.3
1) The specified values are valid for permissible cables with a core cross-section of 0.5mm² from the Festo catalogue.
Tab. 7 Determining the voltage drop
Installation
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8.1.2.1 Calculating the voltage drop
1. Determine the current consumption of a module.
Current PS [A] Current PL [A]
Power consumption èTechnical data of the module
Power consumption PS/PL of the sensors/actuators
Current consumption of the following module at
connection [XD2]
Sum of current consumption
Tab. 8 Determination of the current consumption at connection [XD1]
2. Determine line resistance è Tab. 9 Determining the line resistance.
Cable length [m]1)
0.3 0.5 1.0 2.0 5.0 7.5 10.0 15.0
Line resistance [Ω] 0.04 0.06 0.09 0.16 0.37 0.55 0.72 1.07
1) The specified values are valid for permissible cables with a core cross-section of 0.5mm² from the Festo catalogue.
Tab. 9 Determining the line resistance
The specification of the line resistance comprises the forward and return line including the for-
ward resistance of the modules.
3. Calculate voltage drop (starting with the last module).
Formula: voltage drop = line resistance × current
Line resist-
ance [Ω]
Current PS
[A]
Voltage
drop PS [V]
Current PL
[A]
Voltage
drop PL [V]
Last module (n) –––
Cable between
Modules n and n–1
Cable between
Module n–1 and n–2
…
Supply line to the inter-
face
Total
Tab. 10 Calculating the voltage drop
Installation
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8.1.3 Electrical isolation
In the modules of the CPX-AP-I automation system, there is potential separation between the internal
electronics and
– the network interfaces of the interfaces,
– the system communication,
– the load supply PL.
Information on the potential separations of the inputs and outputs of the modules
èTechnical data of the product-specific documentation
8.2 Functional earth FE
NOTICE!
Malfunction due to electromagnetic interference.
Depending on the substrate of the mounting surface, the modules must be connected to the function-
al earth with low impedance.
The general rule is:
• Remove paint, corrosion and anodised layers.
• Earthing cables should be as short as possible.
• Screws, slot nuts, profiles etc. must have a high electrical conductivity.
For installation on conductive substrates:
• Establish a low impedance connection between the module and conductive substrate as well as
between the conductive substrate and functional earth.
• Establish equipotential bonding between different system components on which the modules are
mounted.
• Avoid interference voltages on the conductive substrate.
For installation on an insulated substrate:
• Establish a low impedance connection between the module and functional earth via an earthing
cable.
• Use an earthing cable with a nominal cross section of 4…6mm2.
• Use a suitable cable lug according to DIN 46234, DIN 46225, DIN 46211.
8.3 Connecting the lines
WARNING!
Risk of injury due to electric shock.
• For the electric power supply, use SELV or PELV circuits that guarantee a reliable electric discon-
nection from the mains network.
• Observe IEC60204-1/EN60204-1.
1. Switch off the power supply.
2. Observe the tightening torque of the cables (e.g. hook spanner with torque adjustment).
3. Seal unused connections with cover caps.
Installation
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8.4 Disconnecting the cables
1. Switch off the power supply.
2. Disconnect the cables.
9 Commissioning
In order to avoid connecting and addressing errors, commissioning of the automation system CPX-AP
must be carried out as follows:
1. Check assembly and connections.
2. Configure the settings on the interface.
3. Check the function of the automation system CPX-AP (without higher-level control).
4. Commissioning in network (with higher-order controller).
9.1 Checking assembly and connections
1. Check the mounting of modules to ensure they are firmly seated.
2. Check connection of functional earth FE.
3. Check that connected lines are seated firmly.
9.2 Configuring the settings on the interface
• If necessary, configure the settings using the control elements on the interface.
Detailed information on the control elements of the respective interface
èProduct-specific documentation
9.3 Check the function of automation system CPX-AP
(without higher-level control)
1. Switch on power supplies PS and PL.
2. Check the behaviour of the automation system CPX-AP:
– Connected actuators
– LED displays
The following LED displays must be illuminated green:
– [SD] System diagnostics (only available for interfaces)
– [MD] Module diagnostics (available for all modules)
– [PL] Voltage PL (only available for interfaces, electrical interfaces and modules with out-
puts)
9.4 Commissioning in network (with higher-order controller)
Information on commissioning on the network èInstructions for the respective interface
Commissioning
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