Festo CPX-AP-I User manual

CPX-AP-I
Automation system
Operating instruc-
tions
8168784
2022-06a
[8168786]

Translation of the original instructions
CiA®, DEVICENET®, EtherCAT®, IO-Link®, PI PROFIBUS PROFINET®, PROFIdrive®, SERCOS® are regis-
tered trademarks of the respective trademark owners in certain countries.

Festo — CPX-AP-I — 2022-06a
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Table of contents
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
2Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Training of qualified personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 UL certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Additional information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Product overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.1 System structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2.2 Product variants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2.3 LED displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2.4 Labelling elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5System communication and address assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Mounting distances and installation space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Direct mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1 Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1.1 Power supply concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1.2 Voltage drop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1.3 Electrical isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.2 Functional earth FE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.3 Connecting the lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.4 Disconnecting the cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.1 Checking assembly and connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.2 Configuring the settings at the interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3 Test the function of the automation system CPX-AP-I (without higher-order controller)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.4 Commissioning in network (with higher-order controller). . . . . . . . . . . . . . . . . . . . . . . . . 24
9 Parameterisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10 Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.1 Diagnostics options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.2 Diagnostic status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.3 Grouping and overview of the diagnostic messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.4 Load voltage monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.5 Diagnostic messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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11 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.1 General technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.2 Technical data for UL certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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About this document
5
1 About this document
1.1 Applicable documents
All available documents for the product è www.festo.com/sp.
Document Contents
Operating instructions for the modules in an
automation system CPX-AP-I
Information on using the modules
Tab. 1: Applicable documents
1.2 Product version
This document refers to the automation system CPX-AP-I.
The product version can be determined from the product labelling.
There may be an updated version of this document for this or later product versions
è www.festo.com/sp.
1.3 Product labelling
The product labelling and the Data Matrix Code are printed on the housings of the modules. Scanning
the Data Matrix Code with an appropriate device opens the Festo Internet page with documents
appropriate for the product. Alternatively, the Product Key (11-digit alphanumeric code on the product
labelling) can be entered in the search field 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

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Safety
2 Safety
2.1 Safety instructions
–Take the legal regulations for the installation location into account.
–Operate the product only within the defined values è 11 Technical data.
–Observe the identifications on the product.
–Observe further applicable documents.
–Store the product in a dry environment protected from UV and corrosion
–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
automation systems.
Use the product only as follows:
–Use only in an industrial environment. Outside 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 approved for the applicable
product variant è www.festo.com/catalogue.
–Only use the product if it is in perfect technical condition.
2.3 Training of qualified personnel
Work on the product should only be conducted by qualified personnel. The qualified personnel must
be familiar with installation of electrical control systems.
2.4 UL certification
In combination with the UL inspection mark on the product, the information in this section must also
be observed in order to comply with the certification conditions of Underwriters Laboratories Inc. (UL)
for USA and Canada.
UL approval information
Product category code NRAQ, NRAQ7
File number E239998
Considered standards UL 61010-1; UL 61010-2-201; CAN/CSA C22.2 No. 61010-1-12;
CAN/CSA-IEC 61010-2-201
UL mark
UL control number 29TS
Tab. 3: UL certification information
–Technical data and environmental conditions may be subject to change in order to comply with
Underwriters Laboratories Inc. (UL) certification requirements for the USA and Canada.
Deviating values è 11.2 Technical data for UL certification.

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Product overview
7
–The unit shall be supplied by a power source which fulfils the requirements on a limited-energy
circuit in accordance to IEC/EN/UL/CSA 61010-1 or on a Limited Power Source (LPS) in accordance
to IEC/EN/UL/CSA 60950-1 or IEC/EN/UL/CSA 62368-1 or a Class 2 circuit in accordance to NEC or
CEC.
–UL: The integrated semiconductor short-circuit protection does not protect the downstream power
circuit. The power circuit must be protected in conformity with the National Electrical Code and all
other local regulations.
cUL: The integrated semiconductor short-circuit protection does not protect the downstream power
circuit. The power circuit must be protected in conformity with the Canadian Electrical Code, part I.
–If the equipment is used in a manner not specified by the manufacturer, the protection provided by
the equipment may be impaired.
–External backup fuses: use UL-certified fuses that are designed in accordance with UL 61010-1.
3 Additional information
–Contact the regional Festo contact if you have technical problems è www.festo.com.
–Accessories è www.festo.com/catalogue.
4 Product overview
4.1 Function
The automation system CPX-AP-I is a decentralised system for connecting electrical peripherals.
Different 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 modules 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
accessing internal parameters, the behaviour of the automation system CPX-AP-I can be adapted
to the respective requirements. Various diagnostic functions are also available.

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Product overview
4.2 Structure
4.2.1 System structure
7
8
9
7
8
10
13
1
2
3 4 5 6
11
12
Fig. 1: System structure (example for PROFINET interface and electrical interface for VTUG)
1Higher-order controller
2Network
3Interface (example for PROFINET)
4Digital input/output module
5Digital input module or analogue input
module
6Electrical interface
(example for valve terminal VTUG)
7AP system communication
8Power supply
9Power transmission
10 Digital input/output modules
11 IO-Link master
12 IO-Link device
13 Digital input module (without transmission)

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Product overview
9
4.2.2 Product variants
Interfaces
Module Function
The interface between the automation system CPX-AP-I and the network per-
forms the following functions:
–Connection of the automation system CPX-AP-I to the network
–Data transfer between the automation system CPX-AP-I 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 diag-
nostic data (depending on the interface)
–Controller of the automation system CPX-AP-I
Example for
CPX-AP-I-PN-M12
Tab. 4: Interfaces
Input/output modules
Module Function
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.
–An analogue input module in an automation system CPX-AP-I receives ana-
logue input signals.
–A IO-Link master in an automation system CPX-AP-I includes multiple IO-
Link Ports for the integration of IO-Link Devices.
example for
CPX-AP-I-8DI-M8-3P
Tab. 5: Input/output modules

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Product overview
Electrical interfaces
Module Function
Valve terminals, e.g. VTUG or MPAL, can be controlled via the automation
system CPX-AP-I with electrical interfaces.
VAEM-L1-S-...-AP
VMPAL-EPL-AP
Tab. 6: Electrical interfaces
4.2.3 LED displays
Depending on the module, the modules have various LED displays for visualising status and diagnos-
tics.
Detailed information on the LED displays of the individual modules è Product-specific documentation
4.2.4 Labelling elements
The same clip-on inscription label is available for all modules. The inscription label is in two parts and
can be divided into two smaller units if necessary.

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System communication and address assignment
11
5 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 with connecting cables. The connecting cables are con-
nected to the individual modules via connection [XF10]. Connection [XF20] is available for transmission
to another module.
The addresses of the modules are assigned automatically every time the automation system CPX-AP-I
is started. 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].
1
2 3
6
7
2 3
4
5
Fig. 2: System communication and addressing
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]

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System communication and address assignment
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-order 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-order controller is rejected and a network-specific
error message is generated.
Behaviour when changing the configuration during operation
–If a module is removed during operation, process data is not transferred to the higher-order
controller for this module and all downstream modules. The failure of the module is signalled via a
diagnostic 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-order controller
or an existing module is replaced, this module is not included in the active configuration and data
exchange with this module is not possible.
In order for changes to the configuration to become active, the system must be restarted (switched
off/on).

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Assembly
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6 Assembly
6.1 Mounting distances and installation space
Certain minimum distances must be observed when installing the modules to ensure sufficient space
for the connecting cables. The minimum distances to be observed depend on the modules and the
type of connectors used (straight or angled).
1
2 3
4
5
13
7
9
10
6
8
11
12
Fig. 3: Mounting distances and installation space (example for CPX-AP-I-8DI-M8-3P)

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Assembly
Item no.
è Fig. 3
Interfaces Input/output modules
IO-Link Master
Connector plug Connector plug
straight angled straight angled
Minimum distances [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. 7: Mounting distances and installation space
Mounting distances of the electrical interfaces è Product-specific documentation

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Assembly
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6.2 Direct mounting
The modules are installed directly via the fastening interfaces with two M4 socket head screws with
internal hexagon in accordance with DIN EN ISO 4762.
When installing the modules, note the following:
–Always use two retaining screws.
–Use suitable washers.
–Observe a tightening torque of 1.2 Nm.
–Functional earth connection è 7.2 Functional earth FE

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Assembly
1
2
3
4
5
2
3
6
3
2
7
4
3
2
8
Fig. 4: Direct mounting
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

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Installation
17
7 Installation
7.1 Power supply
7.1.1 Power supply concept
The automation system CPX-AP-I uses two separate voltages:
–Logic supply PS: power supply for the internal electronics and sensors
–Load supply PL: power supply for the electrical outputs and valves
The voltages can be supplied jointly by one fixed power supply or separately by two fixed power
supplies.
1
2
3
456
7
Fig. 5: Power supply concept
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)
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 7.1.2 Voltage
drop.
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.

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Installation
Supply
Power is supplied to each module at connection [XD1]. The voltages can be forwarded to other
modules 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 maximum 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.
1 2 3 4 5
6
7 8
Fig. 6: Voltage zones
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

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Installation
19
7.1.2 Voltage drop
The connecting cables for the power supply and power transmission between the modules and the
modules themselves cause a voltage drop that must be taken into account in the project engineering.
Determination of the voltage drop based on the cable length and current è Tab. 8 Determination
of voltage drop in the cables. The values specified here are valid for approved cables with a core
cross-section of 0.5 mm² from the Festo catalogue.
Information for the exact calculation è 7.1.2.1 Calculating the voltage drop.
Cable length [m]
0.3 0.5 1.0 2.0 5.0 7.5 10.0 15.0 20.0
Voltage drop at 1 A [V] 0.0 0.1 0.1 0.2 0.4 0.5 0.7 1.1 1.4
Voltage drop at 2 A [V] 0.1 0.1 0.2 0.3 0.7 1.1 1.4 2.1 2.8
Voltage drop at 3 A [V] 0.1 0.2 0.3 0.5 1.1 1.6 2.2 3.2 4.3
Voltage drop at 4 A [V] 0.2 0.2 0.4 0.6 1.5 2.2 2.9 4.3 5.7
Tab. 8: Determination of voltage drop in the cables

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Installation
7.1.2.1 Calculating the voltage drop
With the steps described, the specific voltage drop for PL and PS can be calculated for each string. To
do this, the power requirement of the modules with peripherals and the line resistance in the cable are
combined.
The specification of the line resistance in the table comprises the forward and return line including the
forward resistance of the modules. The specified values are valid for approved connecting cables with
a core cross-section of 0.5 mm² from the Festo catalogue.
Cable length [m]
0.3 0.5 1.0 2.0 5.0 7.5 10.0 15.0 20.0
Line resistance [Ω] 0.04 0.06 0.09 0.16 0.37 0.55 0.72 1.07 1.42
Tab. 9: Line resistance depending on the cable length
1. Calculate the current consumption of the modules in the string for PL and PS.
2. Calculate the line resistance of the supply cable or connecting cable to the module.
3. Calculate the expected power requirements of the external sensors, the electrical outputs and the
valves.
4. From the previous steps calculate the resulting sum of the power requirements of each module.
5. Add the power requirements of the modules in the string. The values result from adding the power
requirement of the module itself to the power requirement of the following modules in the string.
6. Determine the voltage drop per cable. The voltage drop on the cable can be calculated from the
current consumption of a module.
Formula: voltage drop = line resistance × current
7. Determine the minimum voltage at the module from the voltage of the fixed power supply.
8. Compare the result with the permitted voltage range of the last module in the string from the
technical data. The voltage drops of every connecting cable must be added up to the last module
and subtracted from the minimum voltage of the power supply.
Sample calculation è 7.1.2.2 Example for calculation of the voltage drop.
7.1.2.2 Example for calculation of the voltage drop
In the example, the voltage drop on a string with 3 modules is calculated.
The current consumption of the VTUG valve terminal at PL for step 3 was calculated separately as
follows:
–Inrush current (0 … 20 ms): 47 mA
Holding current (> 20 ms): 15.5 mA
–Number of valve solenoids: 12
–Maximum current consumption when switching on, here assuming that all coils are switched on at
the same time: 12 × 47 mA = 564 mA