Festo MPAL-VI User manual

Description
Pneumatics
556354
2017-07a
[8025680]
MPAL-VI
Valve terminal

MPAL-VI
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Original instructions
MPAL-VI-EN
TORX®, IO-Link®are registered trademarks of the respective trademark owners in certain countries.
Identification of hazards and instructions on how to prevent them:
Danger
Immediate dangers which can lead to death or serious injuries
Warning
Hazards that can cause death or serious injuries
Caution
Hazards that can cause minor injuries
Other symbols:
Note
Material damage or loss of function
Recommendations, tips, references to other documentation
Essential or useful accessories
Information on environmentally sound usage
Text designations:
 Activities that may be carried out in any order
1. Activities that should be carried out in the order stated
– General lists
èResult of an action/References to more detailed information

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Inhaltsverzeichnis
Further relevant documents 7.......................................................
Service 7.......................................................................
Product labelling 8...............................................................
Production period 8..............................................................
Specified standards 8.............................................................
1 Safety 9..................................................................
1.1 Safety instructions 9........................................................
1.2 Intended use 9.............................................................
1.3 Requirements for product use 9...............................................
1.3.1 Technical prerequisites 9............................................
1.3.2 Requirements of specialised personnel 10................................
1.3.3 Range of applications and certifications 10...............................
2 Product overview 11.........................................................
2.1 Purpose 11.................................................................
2.2 Overview of components 12...................................................
2.3 Electrical connection 13.......................................................
2.3.1 Multi-pin plug connection 13..........................................
2.3.2 CPX terminal 15.....................................................
2.3.3 I-Port/IO-Link interface 16............................................
2.4 Pneumatic components 17....................................................
2.4.1 Sizes 17...........................................................
2.4.2 Valves 17..........................................................
2.4.3 Supply module 19...................................................
2.4.4 Right end plates 20..................................................
2.4.5 Sub-bases 21.......................................................
2.4.6 Pressure regulator plates 23...........................................
2.4.7 Vertical pressure shut-off plate 26......................................
2.4.8 Vertical pressure supply plate 26.......................................
2.4.9 Fixed flow restrictor 27...............................................
2.4.10 Check valves 28.....................................................
2.5 Connecting components 29....................................................
2.5.1 Pneumatic connecting components 29...................................
2.5.2 Electrical connecting components 29....................................
2.6 Display and operating elements 31..............................................
2.6.1 Valve terminal 31....................................................
2.6.2 Left end plate with I-Port/IO-Link interface 32.............................
2.6.3 Switching status indication of the valves 33...............................
2.6.4 Manual override 33..................................................
2.6.5 Cover cap for manual override VAMC-L1-CD 34............................

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2.6.6 Pressure regulator plate 34...........................................
2.6.7 Vertical pressure shut-off plate 35......................................
2.6.8 Pneumatic interface 35...............................................
2.7 Inscription system 36.........................................................
2.8 Functional description 37.....................................................
2.8.1 Main and auxiliary power supply 37.....................................
2.8.2 Exhaust air 37......................................................
2.8.3 Vacuum or low-pressure operation 37...................................
2.8.4 Pilot air supply 38..................................................
2.8.5 Reverse operation 39................................................
2.8.6 Creation of pressure zones 40.........................................
2.8.7 Vertical stacking 42..................................................
2.9 Address assignment of valve positions 43........................................
2.9.1 Valve terminal with multi-pin plug connection: 46..........................
2.9.2 Valve terminal with I-Port/IO-Link interface: 46............................
2.9.3 Valve terminal with CPX terminal 46.....................................
3 Mounting and installation 47..................................................
3.1 Mounting on H-rails and walls 47................................................
3.2 Inscription label holder, mounting/dismounting 47.................................
3.3 General installation instructions 49..............................................
3.4 Compressed air preparation 50.................................................
3.4.1 Operation with unlubricated compressed air 50...........................
3.4.2 Operation with lubricated compressed air 50.............................
3.4.3 Preventing back pressure 52...........................................
3.5 Connecting the pneumatic lines 53..............................................
3.5.1 Installing or replacing unthreaded cartridges 54...........................
3.5.2 Mounting the tubing 56...............................................
3.5.3 Dismounting the tubing connection 56...................................
3.6 Connecting the compressed air supply 57.........................................
3.6.1 Checking the type of pilot air supply 57..................................
3.6.2 Creating pressure zones 58............................................
3.6.3 Setting working pressure using the pressure regulator 58...................
3.6.4 Checking requirements for vacuum or low-pressure operation 58.............
3.7 Connecting electrical cables 59.................................................
3.8 Adapting the address assignment of valve positions 60..............................
4 Commissioning 61...........................................................
4.1 Prior to commissioning 61.....................................................
4.2 Testing the valves and the valve/actuator combinations 61...........................
4.2.1 Commissioning variants 61............................................
4.2.2 Commissioning the pneumatic components with manual override 62...........

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4.3 Mounting/dismounting the optional cover caps for the manual override 66..............
5 Diagnostics and fault clearance 68.............................................
5.1 Switching statuses of the solenoid coils 68........................................
5.2 Fault LED on the pneumatic interface 69..........................................
5.3 Status LED on the left end plate with I-Port/IO-Link interface 70.......................
5.4 Functional impairment 71.....................................................
5.5 Requirements for the operating statuses of the pneumatic system 72..................
6 Maintenance 73.............................................................
6.1 General safety measures 73...................................................
6.2 Check oil setting (operation with lubricated compressed air) 73.......................
6.3 Cleaning or replacing flat plate silencer 73........................................
6.4 Replacing a valve or blanking plate 74...........................................
6.5 Mounting valves on vertical stacking units 75......................................
7 Modification 76.............................................................
7.1 General safety measures 76...................................................
7.2 Tie rod system 77............................................................
7.2.1 Configuration 77....................................................
7.2.2 Shortening the valve terminal 77.......................................
7.2.3 Extending the valve terminal 77........................................
7.2.4 Special solutions 78.................................................
7.3 Replacing or extending the sub-base, supply module, and/or replacing the right end plate 79
7.3.1 Maximum number of sub-bases 79......................................
7.3.2 Dismounting 80.....................................................
7.3.3 Mounting 80.......................................................
7.4 Replacing electrical interlinking modules 82.......................................
7.5 Conversion to ducted or unducted exhaust air 82..................................
7.5.1 Converting power supply modules to unducted exhaust air 82................
7.5.2 Converting supply modules to ducted exhaust air 82.......................
7.5.3 Conversion with right end plate with supply ports 82.......................
7.6 Conversion to internal or external pilot air supply 83................................
7.6.1 Conversion with right end plate without supply ports 83.....................
7.6.2 Conversion with right end plate with supply ports 84.......................
7.7 Conversion of valve terminal to different pressure zones 85..........................
7.8 Conversion of left end plate from IP40 to IP65/67 cover 85...........................
7.8.1 Dismounting 85.....................................................
7.8.2 Mounting 85.......................................................
7.9 Conversion of output direction of multi-pin plug connecting cable 85...................
7.9.1 Preparatory steps 86.................................................
7.9.2 Conversion to lateral cable output 86....................................

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7.9.3 Conversion to straight cable output 87..................................
7.10 Conversion of left end plate between multi-pin or I-Port/IO-Link interface and CPX port 87..
7.10.1 Dismounting 87.....................................................
7.10.2 Mounting 88.......................................................
7.11 Replacing pneumatic interface 89...............................................
7.11.1 Dismounting 90.....................................................
7.11.2 Mounting 91.......................................................
8 Dismounting 92.............................................................
8.1 General instructions for dismounting 92..........................................
8.2 Dismounting from H-rails 92...................................................
8.3 Dismounting from walls 94....................................................
A Technical appendix 95........................................................
A.1 Technical data 95............................................................
A.1.1 General 95.........................................................
A.1.2 Operating and environmental conditions 97...............................
A.1.3 Pneumatics 98......................................................
A.1.4 Electrical 106........................................................
A.2 Accessories 108..............................................................
B Extended component description 109............................................
B.1 Valves 109..................................................................
B.2 Pressure regulator plates 114...................................................
B.3 Vertical pressure shut-off plate 116..............................................
B.4 Vertical pressure supply plate 116...............................................
C Glossary 117................................................................
Index 118........................................................................

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Further relevant documents
For all available product documentation èwww.festo.com/pk
This document contains information about the mounting, installation, commissioning, maintenance and
conversion of the product.
The following documents contain further details:
Name, type Table of contents
System description CPX terminal Detailed description of the CPX system, overview of
descriptions of the CPX modules
Brief description VMPAL-EPL-
SD.../-FL.../-KL...
Valve terminal with multi-pin plug connection:
Brief description VMPAL-EPL-IPO32 Valve terminal with I-Port/IO-Link interface:
Assembly
instructions
Valve terminal MPA Wall mounting and H-rail mounting of the valve
terminal MPA with multi-pin plug connection
Assembly
instructions
Terminal CPX with
valve terminal MPA
Wall mounting and H-rail mounting of the valve
terminal MPA with CPX terminal
Assembly
instructions
VMPA...-B8-R...C2-C... Mounting the pressure regulator plates
Assembly
instructions
VMPA1-HS Mounting the vertical pressure shut-off plates
Assembly
instructions
VMPA1-FT-NW...-10 Mounting the fixed restrictors
Assembly
instructions
VMPA...RV Mounting the check valves
Assembly
instructions
ASLR-D-L1 Mounting the inscription label holders
Assembly
instructions
VMPA-HB...-B Mounting the cover caps VMPA-HB...-B
Assembly
instructions
VAMC-L1-CD Mounting the cover caps VAMC-L1-CD
Assembly
instructions
VMPAL-LW Using the releasing tool for electrical interlinking
Tab. 1 Documents relating to the product
Service
Contact your regional Festo contact person if you have technical questions èwww.festo.com.

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Product labelling
Product labelling (example) Significance
MPAL-VI
569926 H7XX
P1234567
1: -0.9 -10 bar
12, 14: 3 -8 bar
T: -5 -50 °C
Proc. Cont. Eq.
E322346
1: -0.9 -8 bar
12, 14: 3 -8 bar
24 V I max: 6 A
DE-73734 Esslingen
1
2
3
4
5
6
1Order code
2Serial number with production period
(encrypted èChap.Production period)
3Technical data èAppendix A.1
4Product designations and certification-specific
technical data
5Test number (serial number)
6Part number
Tab. 2 Product labelling (rating plate) of the product
Production period
In the product labelling, the first two characters of the serial number indicate the production period in
encrypted form èTab. 2, 2. The letter indicates the production year and the next characters (numeral
or letter) indicates the production month.
Production year
H = 2016 J = 2017 K = 2018 L = 2019 M = 2020 N = 2021
P = 2022 R = 2023 S = 2024 T = 2025 U = 2026 V = …
Tab. 3 Production year
Production month
1 January 2 February
3 March 4 April
5 May 6 June
7 July 8 August
9 September O October
N November D December
Tab. 4 Production month
Specified standards
Version status
IEC60204-1:2005-10 EN60529:1991-10
ISO228-1:2000-09 EN61000-6-2:2005-08
ISO5599-1:2001-08 EN61000-6-4:2007-01 + A1:2011-02
ISO8573-1:2010-04 DIN51524-13:2006-04
Tab. 5 Specified standards

1 Safety
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1 Safety
1.1 Safety instructions
 Switch off the power supply before mounting and installation work. Only switch on the power supply
when mounting and installation work is completely finished.
 Never unplug or plug in a product when it is energised!
 Observe the handling specifications for electrostatically sensitive devices.
1.2 Intended use
Valve terminal MPAL-VI is intended for installation in machines and automation technology systems and
must be used exclusively as follows:
– In perfect technical condition
– In its original state without unauthorised modifications; the conversions or modifications described
in the documentation are permitted
– Within the product's limits as defined by the technical data èAppendix A.1,
– Only in combination with approved components (e.g. valves, drive/displacement encoder combina
tions)
– In an industrial environment
Use for intended purpose is described completely in the documentation. Every other use is considered
not intended.
1.3 Requirements for product use
 Make the documentation available to the design engineer, installer and personnel responsible for
commissioning the machine or system in which this product is used.
 Make sure that the specifications of the documentation are always complied with. Also consider
the documentation for the other components and modules.
 Take into consideration the legal regulations for the destination:
– Regulations and standards
– Regulations of the testing organisations and insurers
– National specifications
1.3.1 Technical prerequisites
General conditions for the correct and safe use of the product, which must be complied with at all
times:
 Comply with the connection and ambient conditions of the product and all connected components
specified in the technical data èAppendix A.1.
Only full compliance with the limit values and load limits permits operation of the product in accord
ance with the relevant safety regulations.
 Observe the instructions and warnings in the documentation.

1 Safety
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1.3.2 Requirements of specialised personnel
The product may be commissioned only by a qualified electrical technician who is familiar with
the following topics:
– Installation and operation of control and automation systems
– Applicable regulations for operating safety-engineering systems
– Applicable regulations for accident prevention and occupational safety
– Documentation for the product
1.3.3 Range of applications and certifications
Safety-related standards and test values with which the product complies and which it satisfies can be
found in the Technical Data 
èAppendix A.1. Product-relevant EC directives are itemised in the declaration of conformity.
Certificates and declaration of conformity for the product èwww.festo.com/sp
The product fulfils the requirements of EU directives and is marked with the CE marking.
Certain configurations of the product have been certified by Underwriters Laboratories Inc. (UL) for
the USA and Canada. These configurations bear the following mark:
UL Listed Mark for Canada and the United States
Note
Observe the following if the UL requirements are to be complied with:
– Rules for complying with the UL certification are itemised in the separate UL-specific
special documentation.
– The technical data listed there takes precedence. This data may vary from the tech
nical data mentioned here.

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2 Product overview
2.1 Purpose
The valve terminal is based on a modular structure and creates the following connections:
– Common ducts for supply and exhaust air
– Electrical connections for supply and communication between all solenoid coils
Working lines (2) and (4) are provided for each valve position on the individual sub-bases. The valves
are supplied with compressed air (operating pressure and pilot pressure) via the common ducts and
connections in the supply modules. The exhaust air (from the valves and the pilot exhaust) is also ex
hausted via these common ducts and connections.
The valve terminal can be supplemented by additional supply modules, e.g. to supply pressure zones.
The functional scope of a valve position can be extended by vertical stacking, e.g. for pressure regulation.
Depending on the types of valve used, the following valve terminal operating modes can be used:
– Standard operation with one or more pressure zones
– Reversible operation with compressed air supply via connections (3), (5) and exhaust via port (1)
– Low-pressure operation at 0…3bar
Further information on the valve operating modes èAppendix B

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2.2 Overview of components
13
46
2
5
1Electrical connection - left end plate
2Supply module
3Sub-base with electrical interlinking module
and valve or blanking plate
4Combination of sub-bases with 4-way
electrical interlinking module and valves
or blanking plates
5Vertical stacking
6Right end plate
Fig. 2.1 Electrical connection and pneumatic components on the valve terminal - example

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2.3 Electrical connection
2.3.1 Multi-pin plug connection
The electrical connection of the valve terminal is made centrally via a multi-pin plug connection in
the left end plate.
Depending on the type of connector on the multi-pin plug connection, a maximum of 32 solenoid coils
can be controlled inside the valve terminal èTab. 2.1. Each solenoid coil occupies a pin on the multi-
pin plug connection.
2
1
1Multi-pin plug connection
(here: Sub-D connector with 25 pins)
2Multi-pin connection cable
(here: with IP65/67 cover)
Fig. 2.2 Electrical connection for the valve terminal via multi-pin plug - example

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Connector types
Pin assignment and core colours on the multi-pin connection line differ depending on
version èBrief description VMPAL-EPL-SD.../-FL.../-KL...
Multi-pin plug connection Plug type Number of controllable
solenoid coils
Sub-D connector with 9 pins 8
Sub-D connector with 25 pins 24
Sub-D connector with 44 pins 32
Terminal strip with 33 pins 32
Flat cable plug connector with
40 pins
32
Tab. 2.1 Types of plugs on the multi-pin connection

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Cover types
The following types of cover are available for the multi-pin plug connections with Sub-D plugs:
Type of cover Characteristics
IP65/67 – Closed cover with seal
– Degree of protection IP65/67
– Connection on side or at front
– Preconfigured cable or can be configured by customer
The IP65/67 cover is only available for the following types
of connector on the multi-pin plug connection:
– Sub-D connector with 25 pins
– Sub-D connector with 44 pins
IP40 – Open cover
– Degree of protection IP40
(here: Sub-D plug with 25 pins)
The IP40 cover is available for all types of connector on
the multi-pin plug connection èTab. 2.1.
Tab. 2.2 Types of cover for multi-pin connections with Sub-D plugs
2.3.2 CPX terminal
The electrical connection from the valve terminal to the CPX terminal takes place through the pneumat
ic interface. The pneumatic interface replaces the left end plate on the valve terminal.
Depending on the switch setting of the rotary switch on the pneumatic interface, within the valve ter
minal a maximum of 32 solenoid coils can be controlled.
1
2
3
4
1CPX bus node
2Pneumatic interface
3Optional: other CPX modules
4Left end plate on the CPX terminal
Fig. 2.3 Electrical connection of valve terminal via CPX terminal - example

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2.3.3 I-Port/IO-Link interface
The electrical connection of the valve terminal is provided by the I-Port/IO-Link interface and by 5-pin
connecting cables. Via the I-Port/IO-Link interface, a maximum of 32 solenoid coils can be activated
in the valve terminal.
The valve terminal can be installed centrally or decentrally:
1
2
3
5
4
1Bus nodes CTEU
2End plate with I-port/IO-Link interface
3Connecting cable
4Electrical connecting plate with bus node
CTEU
5Valve terminal
Fig. 2.4 Electrical connection of valve terminal via I-Port/IO-Link interface - example
Central installation
A bus node CTEU is mounted directly on the end plate with I-Port/IO-Link interface.
Decentralised installation
A bus node CTEU is mounted on an electrical sub-base. The electrical sub-base is connected to the end
plate with I-Port/IO-Link interface by a connecting cable.
This connecting cable must not be longer than 20 m.

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2.4 Pneumatic components
2.4.1 Sizes
The components of the valve terminal are available in the following sizes:
– MPA1: Size 10 mm
– MPA14: Size 14 mm
– MPA2: Size 20 mm
2.4.2 Valves
The valve terminal can be equipped with the following valves:
– 2x 2/2-way valves
– 2x 3/2-way valves
– 3/2-way valves
– 5/2-way valves
– 5/3-way valves
Unassigned valve locations can be sealed with blanking plates.
Identification of the valves
ID codes are printed on the tops of the valves. These ID codes enable equipment items on the valve
terminal to be identified.
ID code Valve assembly
B5/3-way valve, mid-position open, mechanical spring return
DTwo single solenoid 2/2-way valves, normally closed, pneumatic spring return
DS Two single solenoid 2/2-way valves, normally closed, mechanical spring return
E5/3-way valve, mid-position exhausted, mechanical spring return
G5/3-way valve, mid-position closed, mechanical spring return
HTwo single solenoid 3/2-way valves, control side 12 normally open, control side
14 normally closed, pneumatic spring return
HS Two single solenoid 3/2-way valves, control side 12 normally open, control side
14 normally closed, mechanical spring return
HU Two 3/2 polymer poppet valves, control side 12 normally open, control side 14
normally closed, mechanical spring return
ITwo 2/2-way valves, normal position closed, pneumatic spring return
– In 2-pressure operation:
Operating pressure via port (1) or port (5)
– For vacuum operation:
Operating pressure via port (1), vacuum at port (5)
J5/2-way double solenoid valve
KTwo single solenoid 3/2-way valves, normally closed, pneumatic spring return
KS Two single solenoid 3/2-way valves, normally closed, mechanical spring return
KU Two 3/2 polymer poppet valves, normally closed, mechanical spring return
LBlanking plate for sealing an unused valve position

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ID code Valve assembly
MSingle solenoid 5/2-way valve, pneumatic spring return
MS Single solenoid 5/2-way valve, mechanical spring return
MU Single solenoid 5/2-way polymer poppet valve, mechanical spring return
NTwo single solenoid 3/2-way valves, normally open, pneumatic spring return
NS Two single solenoid 3/2-way valves, normally open, mechanical spring return
NU Two 3/2 polymer poppet valves, normally open, mechanical spring return
WSingle solenoid 3/2-way valve, normally open, external compressed air supply
via port (2), pneumatic spring return
XSingle solenoid 3/2-way valve, normally closed, external compressed air supply
via port (4), pneumatic spring return
Tab. 2.3 ID codes of the valves
– Display and operating elements èChap.2.6.3
– Circuit symbol èAppendix B.1
– Pressure ranges èAppendix A.1.3

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2.4.3 Supply module
1
23
1Supply module
2Flat plate silencer
3Exhaust plate for ducted exhaust air
Fig. 2.5 Supply module
The supply module can be used for the following applications:
– Main supply of operating pressure to the valve terminal
– Additional supplies, e.g. to increase pressurisation and exhaust performance
– Common exhausting of exhaust air ducts (3) and (5) for working air via a flat plate silencer or an
exhaust air plate for ducted exhaust air
The exhaust air plate for ducted exhaust air can be used in reversible mode to supply pressure.
– Main and auxiliary power supply èChap.2.8.1
– Exhaust air èChap.2.8.2
– Pressure zone formation èChap.2.8.6
– Address assignment èChap.2.9

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2.4.4 Right end plates
12
1Right end plate
without supply ports
2Right end plate
with supply ports
Fig. 2.6 Right end plates
The right end plate without supply ports can be used for the following purposes:
– Internal and external pilot air supply
– Exhausting of pilot air (82/84) via a silencer or as ducted exhaust air
If a right end plate without supply ports is used, a separate supply module is needed for
the main supply of operating pressure to the valve terminal.
The right end plate with supply ports can be used for the following purposes:
– Main supply of operating pressure to the valve terminal
– Internal and external pilot air supply
– Separate exhausting of exhaust air ducts (3) and (5) for working air
– Exhausting of pilot air (82/84) via a silencer or as ducted exhaust air
– Main and auxiliary power supply èChap.2.8.1
– Exhaust air èChap.2.8.2
– Pilot air supply èChap.2.8.4
– Pressure zone formation èChap.2.8.6