SMC Networks EX510-GPR1 Series User manual

1
Reduced wiring system
PROFIBUS-DP Compatible GW unit
Operation Manual
EX510 - GPR1
URLhttp://www.smcworld.com

12
Safety Instructions 2
Product Summary 6
Name of Parts / Accessories 7
Dimensions 8
Settings 8
Specifications 10
Wiring 11
Display/ Switch Setting 17
Troubleshooting 21
Table of Contents
Phone
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Thank you for purchasing the SMC reduced wiring system
EX510 series.
Please read this manual carefully before operating this product
and make sure you understand this product, its capabilities and
limitations.
Please keep this manual handy for future reference.
OPERATOR
•This operation manual has been written for those who have
knowledge of machinery and apparatuses that use reduced
wiring units and have full knowledge of assembly, operation and
maintenance of such equipment.
•Please read this operation manual carefully and understand it
before assembling, operating or providing maintenance service
to the actuator.

32
Safety Instructions
The reduced wiring system and this manual contain essential
information to protect users and others from possible injury and
property damage and to ensure correct handling.
Please check that you fully understand the definition of the
following messages (signs) before going on to read the text, and
always follow the instructions.
Please read the operation manual of related apparatus and
understand it before operating the actuator.
Read this manual and follow its instructions. Signal words such as
WARNING, CAUTION and NOTE, will be followed by important
safety information that must be carefully reviewed.
Indicates a potentially hazardous situation
which could result in death or serious
injury if you do not follow instructions.
Gives you helpful information.
Indicates a potentially hazardous situation
which if not avoided, may result in minor
injury or moderate injury.
Do not operate beyond specification range.
Fire, malfunction or switch damage can result.
Please use it after confirming the specification.
Do not disassemble, retrofit (including change of printed
circuit board) or repair.
An injury or failure can result.
Do not use the product in the environment with possible
presence of flammable, explosive or corrosive gas to
prevent fire, explosion or corrosion.
Note the reduced wiring system does not have explosion proof
construction.
These instructions must be followed when using the
product in an interlocking circuit:
•Provide double interlocking by another system such as
mechanical protection
•Check the product regularly to ensure proper operation
Otherwise malfunction can cause an accident.
These instructions must be followed while in maintenance:
•Turn off the power supply
•Stop the supplied air, exhaust the residual pressure and
verify the release of air before performing maintenance
Otherwise it can cause injury.
Execute a proper performance inspection after completing
the maintenance check.
Please stop driving for abnormality as neither the product not
work normally.
There is a possibility that safety cannot be secured due to the
unintentional malfunction.
Provide grounding for improving safety and noise
resistance of reduced wiring system.
Individual grounding is provided to the product closely with short
distance.
IMPORTANT MESSAGES

54
Safety Instructions (continued)
NOTE
The direct-current power supply to combine should be UL
authorization power supply.
1.Limited voltage current circuit in accordance with UL508
A circuit which power is supplied by the secondary coil of a
transformer that meets the following conditions
• Maximum voltage(with no load): less than 30Vrms(42.4V peak)
• Maximum current:(1)
less than 8A(including when short circuited)
(2)limited by circuit protector (such as fuse)
with the following ratings
2.A circuit using max. 30 Vrms or less (42.4V peak), which
power is supplied by Class-2 power supply unit in accordance
with UL1310 or UL1585
Follow the instructions given below when handling your reduced
wiring system. Or, it will have a risk of being damaged and
operating failure.
• Operate reduced wiring system with the specified voltage.
• Reserve a space for maintenance.
•Do not remove labels.
•Do not drop, hit or apply excessive shock to the product.
•Follow the specified tightening torque.
•Do not bend or apply tensile force to cables, or apply force by
placing heavy load on them.
•Connect wires and cables correctly.
•Do not connect wires while the power is on.
•Do not lay wires or cables with power line or high-voltage line
in the same wiring route.
• Verify the insulation of wiring.
• Separate power line for solenoid valves from power line for
Input and control unit.
•Take proper measurements against noise such as noise filter
when the reduced wiring system is incorporated in equipment
or devices.
• Select the proper type of protection according to the
environment of operation.
• Take sufficient shielding measures when installing at a
following place.
(1) A place where noise due to static electricity is generated
(2) A place where electric field strength is high
(3) A place where there is radioactive irradiation
(4) A place near power line
• Do not use the product nearby a place where electric surges
are generated.
• Use reduced wiring system equipped with surge absorber
when a surge-generating load such as a solenoid valve is
driven directly.
• Prevent foreign matter such as remnant of wires from entering
this product.
• Do not expose reduced wiring system to vibration and impact.
• Keep the specified ambient temperature range.
•Do not expose reduced wiring system to heat radiation from a
heat source located nearby.
• Use a precision screwdriver with small flat blade when setting
DIP switch.
• Perform maintenance and check regularly.
• Perform a proper functional check.
• Do not use the product with chemicals such as benzene and
thinner.
No load voltage (V peak)
0 to 20[V]
Above 20 to 30 [V]
Max. current rating (A)
5.0
100 / peak voltage

76
Communication
connector for
PROFIBUS-DP(1pc)
Power supply
connector(2 pcs)
Accessory
1
34
2
5
6
7
8
9
10
11
Te rminating
resistor
(1 pc)
12
No. Parts Purpose
1
Communication
socket (BUS)
Connect to PROFIBUS-DP line with a
communication connector for PROFIBUS-
DP( ).Connect a terminating resistor( ) to
both end units of a transmission route*.
2
Power supply
socket
(PWR(V))
Supplying power for output instruments
such as a solenoid valve with a power
supply connector () .*
3
Power supply
socket
(PWR)
Supplying power for controlling GW and
input instruments such as a sensor with a
power supply connector () .*
4
GW unit side
branch connector
(for input)
Connecting an input unit etc. by using
branch cables (EX510-FC ).
5
GW unit side
branch connector
(for output)
Connecting SI unit (manifold valve) etc. by
using branch cables (EX510-FC ).
6PE terminal Used for grounding.
7Mounting hole Used when a unit is mounted with two M4 screws.
8Used when a unit is mounted to DIN rail.
9Display/ setting
switch area
Switch setting such as LED display in unit
state, Address and I/O point.
*For wiring method, see "Wring" in the "Operation manual".

DIN rail
mounting slot
Product Summary
System structure
( )
Power supply
for output
Power supply
for input and
controlling GW
DC24V
DC24V
GW unit
Input unit
1 connector
2 inputs type
Input unit
(1 connector 1 input type)
(connecting to 4 sets maximum)
Branch cable
(EX510-FC )
Valve manifold
with SI unit
connecting to
4 sets maximum
Connecting to bus
at upper level
(PROFIBUS-DP)


( )
The system which realizes wiring saving and distributed
installation by connecting to PROFIBUS-DP. The signal to
PROFIBUS-DP is transmitted by GW unit, and the signal to
input/output device which is installed discretely is collected by
GW unit.
Name of Parts/ Accessories
12

98
Dimensions (in mm)
RemovalMounting
Claw 1
Claw 2
DIN rail
fixing plate
64
25.7
COMA
COMB
COMC
COMD
OUTPUTINPUT
60 80
16
PWR
(V)
PWR
BUS
Perspective drawing
(tolerance 0.2)
16
PWR
(V)
PWR
BUS
OUTPUT INPUT
70 5
54 5
2xM4
*Tightening torque:0.8N.m
Settings
Mounted by screw
Mounted on DIN rail
Put claw 1 at the body under DIN rail and push it upward. Push
down claw 2 to the opposite rail until the claw clicks securely on
to rail. (Mounting procedure and )
For removing, lever up the DIN rail fixing plate at the body with a
flat screwdriver, and remove it by tilting claw 2 side forward.
(Removal procedure and )
Settings (continued)

1110
Specifications
Basic specifications
Compatible system
Bus Interface
PROFIBUS-DP V0
EIA RS-485
Rated voltage
Range of
power supply
voltage
24VDC
Power supply for input and controlling GW :
24VDC 10%
Power supply for output : 24VDC+10%/-5%
(Warning for voltage drop is given at approx. 20V)
Rated current
Input/ output
point
Power supply for input and controlling GW : Max.4.1A
(Inside GW unit: 0.1A, Input unit: 4A)
Power supply for output:Max.6A
Input point: Max. 64 / Output point: Max. 64
(Changeable by switch settings)
Upper level bus
Communication speed [kbps]
Max. wiring length [m] *
Freeze function Available
9.6
1200
19.2 45.45 93.75 187.5
500 1500 3000 6000 12000
1000
400 200
Synchronous function Available
Address setting range 0 to 125
*
Max. wiring length differs depending on the specification of a cable.
The specification
of wiring length is based on type A cable.
Number of branches for
input/ output
4 branches for input
4 branches for output
Communication type
Communication protocol: Dedicated for SMC
Communication speed: 750kbps
Lower level bus
Branch current for input Max. 1A per branch
Branch current for output
Max. 1.5A per branch
Branch cable length
At 0.75A per branch : 20m or less
At 1.0A per branch : 16m or less
At 1.5A per branch : 10m or less
Internal circuit
DC-DC
Converter
(Insulation)
+ 24 V
0V
COM D
INPUT
OUTPUT
+24V
RD+
RD
-
0V
+ 24 V
0V
Power supply
for output
Power supply
for input and
controlling GW
+24V
TD+
TD
-
0V
COM A
INPUTOUTPUT
+24V
RD+
RD
-
0V
+24V
TD+
TD
-
0V
(Brown)
VP
RxD/TxD-N
DGND
RxD/TxD-P
SHIELD
PE
○
+5V
GND
GND
Internal circuit
Wiring
100
Max. wiring length [m] *
Communication speed [kbps]
+
-
ID no. 140d HEX
Device data file GSD file*
*This file is necessary for automatic device setting.

1312
Wiring of branch cables
4 branches for input
4 branches for output
Branch cable
To SI unit
To Input unit
Branch connector
at GW unit side
Branch connector
at cable side
COM D
COM C
COM B
COM A
Insert branch connector on the table side from the bottom (COM
A, B, C, D of branch connector of GW unit side).
EX510
4
3
2
1
Insulating cap
Pin no.
display
Cover Body Branch cable
Brown Black
White
Blue
Hold for
fixing latch Latch
Pin no.1:
Brown wire
Press fitting
Press the cover to the body with plier etc.
Confirmation
It is completed with a check on 4 latches engaging.
Branch wiring
The wiring between each unit should use branch cables, and be
connected with branch connectors.
SI unit and Input unit have 2 branch connectors for each.
Pressure welding for branch connector
The method of pressure welding for branch connector is
explained.
(1)Components
(2)Working procedure
Set a branch cable to the cover.
1)Set the brown wire of the branch cable
so that it comes to the pin no.1.
2)Meet the cable end to the insulating
cap at the cover.
3)Fold the cover so that the branch cable
can be put between the cover.
4)Fix the latch tip by inserting to a hole
for fixing latch.
Note)Check the color of wire written on
a branch connector and the color
of branch cable are same.
Fix to a body tentatively.
Fit 4 latches on a body to 4 ditches on
the cover, and press them until the
latch engages to the level 1.
Wiring (continued)

15
14
Wiring (continued)
Communication wiring
Connect PROFIBUS-DP dedicated cables to the communication
connector for PROFIBUS-DP.
(1)Make sure to connect the signal cables to designated pins
(Refer to Drawing 1). And tighten the connector surely to 0.5
to 0.6 N.m tightening torque.
(3)Refer to Drawing 4 about how to connect to the unit.
VP
RxD/
TxD-N
DGND
RxD/
TxD-P
SHIELD
Green Red Shield
Green Red Shield
VP
390
RxD/TxD-P
Data Line
Data Line RxD/TxD-N
220
390
DGND
Communication connector
for PROFIBUS-DP
Te r minating
resistor
Drawing1
Specification of type A cable
135 to 165
Capacitance
between conductors 30 pF/m or less
Impedance
110 /km or less
Cable diameter 0.64 mm or more
Conductor resistance
0.34 mm2or more
Conductor area
Drawing3
Drawing4
The value of terminating resistor changes with cable specification.
This value of terminating resistor is based on
type A cable (Refer
to Drawing 3).
Connect the pin with VP mark
on terminal resistance to VP
of the communication connector.
VP
RxD/
TxD-N
DGND
RxD/
TxD-P
SHIELD
VP
Drawing2
(2)Make sure to connect a "terminating resistor" to the units at
the both ends of the system (Refer to Drawing 2). For firmly
tightening, give a torque of 0.5 to 0.6 N.m.
*The terminating resistor attached to this unit as an accessory
is recommended.

17
16
Wiring (continued)
Power supply wiring
Connect power supply wiring to the two power supply 2pin
connectors. Power supply structure consists of 2 systems, but it
can be used with both single power supply and separate power
supply.
Individual power supply for other units is not necessary. Make
sure of connection with the designated pin. Tighten the connector
securely to 0.5 to 0.6N.m tightening torque.
Power supply connector
Power supply
for output
Power supply
for input and
controlling GW
Power supply connector detail
PWR
(V)
PWR
0V
24V
24V
0V
Note
A secure earth connection (Protection class 3) should be performed
for PE terminal.
Display / Switch Setting
SW1
OFF
ON
OFF
ON
COM C COM DCOM A COM B
SW2
DIA BFPWR(V) RUN
INPUT
Setting for Display
DC
24V
DC
24V
A. For separate power supply use
DC
24V
B. For single power supply use
Display Meaning
PWR
(V)
The power for output is supplied with specified voltage: Lights up
The power for output is not supplied with specified voltage: Goes off
RUN
Power supply for input and controlling GW is supplied: Lights up
Power supply for input and controlling GW is not supplied: Goes off
COM A COM A is receiving data: Lights up*2
COM A is having no data to receive: Goes off
COM B COM B is receiving data: Lights up*2
COM B is having no data to receive: Goes off
COM C COM C is receiving data: Lights up*2
COM C is having no data to receive: Goes off
COM D COM D is receiving data: Lights up*2
COM D is having no data to receive: Goes off
*1:Refer to "Technical Specification" for the extension diagnosis
information.
*2:It is lit when Input unit is connected and communicating
normally. LED of COM A-D does not light up if the port is not
set to be "used" by input point setting.
BF PROFIBUS-DP communication is abnormal: Lights up
PROFIBUS-DP communication is normal: Goes off
DIA With extension diagnosis information*1: Lights up
Without extension diagnosis information: Goes off

1918
Display/ Switch Setting (continued)
Address setting (switch No.1 to 7)
At the time of shipment from the plant, all settings are turned off
and the address is set to 0. Make sure to set the address in the
range of 0 to 125.
10987654321
2148163264
ON
SW1
OFF
ON
Address
UNIT STATUS HOLD/CLR
HW/SW
Switch setting
Make sure that switch setting is performed with power supply
turned off.
The switch setting is mode available by opening a cover and
using a flat driver.
Setting of Address, UNIT STATUS, HOLD/CLR,
HW/SW mode (SW1)
These setting are done with SW1.
64(No.1)
1
Address
2
3
4
:
24
25
:
125
126
32(No.2) 16(No.3) 8(No.4) 4(No.5) 2(No.6)
OFF OFF OFF OFF OFF OFF
OFF OFF OFF OFF OFF ON
OFF OFF OFF OFF OFF ON
OFF OFF OFF OFF ON OFF
::::::
OFF OFF ON ON OFF OFF
OFF OFF ON ON OFF OFF
: : :: : :
ON ON ON ON ON OFF
ON ON ON ON ON ON
1(No.7)
ON
OFF
ON
OFF
:
OFF
ON
:
ON
OFF
*If the address setting is turned on, an input setting for PLC is
required. Refer to "Technical Specification" for detail.
HOLD/CLR setting (switch No. 9)
The setting is as follows.
The settings when shipped from plant is turned OFF, set to CLR.
HOLD/CLR
CLR
Function
Output is cleared when a communication
error occurs.
HOLD Output is held when a communication
error occurs.
No.9
OFF
ON
Mode
HW
Function
Set Address with SW1 to 7.
SW
Address are set by network. The setting
when shipped from plant is 126.
Note : SW1 to 7 are ignored.
No.10
OFF
ON
*HOLD/CLR setting is made available per one point by parameter
setting. Refer to "Technical Specification" for detail.
HW/SW mode setting (switch No. 10)
The setting is as follows.
The setting when shipped from plant is turned OFF, set to
HW
mode.
0OFF OFF OFF OFF OFF OFF OFF
*Setting of the address 126 and 127 are invalid.
UNIT STATUS setting (switch No. 8)
The setting is as follows.
The settings when shipped from plant is turned OFF, GW status
information is not sent to master side as an input data.
UNIT STATUS
OFF
Function
GW status information isn't sent to master
side as an input data.
ON GW status information is sent to master
side as an input data.
No.8
OFF
ON
127 ON ON ON ON ON ON ON

2120
Input/Output Setting (SW2)
Input/Output Setting is performed with SW2.
654321
ON
SW2
OFF
ON
Number of output settingNumber of input setting
Troubleshooting
Display/ Switch Setting (continued)
Input setting (switch No.1 to 3), Output setting (switch
No.4 to 6)
The setting is as follows. At the time of shipment from the plant,
all settings are turned OFF, 64 Input/Output points.
1
2
3
Remedy / Disposal
•Check the power for output (24VDC) is
supplied.
•Check the branch cable is connected to SI
unit.
•Check the LED for power supply (PWR)
and the LED for communication (COM) at
SI unit are ON.
•Ensure output branch current does not
exceed the specification range.
•Program it after checking the wiring
specification of manifold block assembly.
•Check the power for input and controlling
GW (24VDC) is supplied.
•
Check the input unit indication LED is ON.
•Ensure input branch current does not
exceed the specification range.
•Check the connection of UNLIT COM port
branch to input unit.
•LED of unused COM port does not light up
when an input unit is connected. Check the
port is set to be "unused" by input point
setting.
4
LED of
COM A-D is
not LIT
Signals
cannot be
received
even with a
sensor
Solenoid
valve is not
working
Valve is not
working as
program
directs
No. Item
Overall system
Input point COM A COM B
OFF 64 16 16
ON 0
- -
OFF 16 88
ON 24 88
OFF 32 8 8
ON 48 16 16
OFF
ON Reserve
COM C COM D
16 16
- -
- -
8
-
8 8
16
-
No.3
OFF
OFF
ON
ON
OFF
OFF
ON
ON
No.2
OFF
OFF
OFF
OFF
ON
ON
ON
ON
No.1
Output point COM A COM B
OFF 64 16 16
ON 0
--
OFF 16 88
ON 24 88
OFF 32 88
ON 48 16 16
OFF
ON Reserve
COM C COM D
16 16
--
--
8
-
88
16
-
No.6
OFF
OFF
ON
ON
OFF
OFF
ON
ON
No.5
OFF
OFF
OFF
OFF
ON
ON
ON
ON
No.4
5
6
RUN LED
goes off
PWR(V)
LED goes
off
•Check the power for input and controlling
GW is supplied.
•Check the power for output (24VDC) is
supplied.
•Check the power supply voltage for output
is above 20V.
•Check the power for input and controlling
GW (24VDC) is supplied.
*Input/Output points set at PLC must be consistent with the
Input/Output points set at the GW unit.

22
Troubleshooting (continued)
PROFIBUS-DP compatible communication
1BF LED lights up
•Check the signal line from PLC is
correctly connected.
•Check the wiring and pin numbers.
•Check the address setting is correct.
•Check the connecting condition of the
terminating resistor.
•Check the number of input/output is set
correctly.
2 DIA LED lights up
•Check the power for output (24VDC) is
powered at a specified voltage.
•Check the power supply voltage for
output is above 20V.
•Check the input unit is connected after
the input port.
No. Item Remedy / Disposal
*Refer to "Technical Specification" for detail of troubleshooting.