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Table of contents Page
Installation concepts 16
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Valve terminals – offering numerous advantages
Created in 1989 as an innovative Reduced complexity – increased Enhanced modularity and Reduced costs
idea, Festo valve terminals are practical use flexibility If you are looking to reduce the
a milestone in the development The valve terminal was the single Made for a broad range of overall costs of a system you
of easy to use pneumatics; most decisive step in reducing applications. The individual should consider using cost-
so much so that it is hard to complexity and costs in automa- combination of different func- saving and comprehensive solu-
imagine the world of automation tion. The benefits are: tions on one terminal enables tions such as valve terminal
without them. • simple installation, configura- precise configuration of the valve technology. Thanks to fully
tion and commissioning, terminal to the application. pre-assembled and tested units,
• low maintenance and service, ordering and logistics costs are
• very adaptable – mechanically, Minimised error quota drastically reduced.
pneumatically and electrically. Previously, each individual valve
and each individual component
part such as coils and silencers
had to be ordered and installed
individually. The error quota in
orders, assembly and commis-
sioning fell dramatically with the
introduction of valve terminals.
4
The structure of a modular valve
terminal shows why valve
terminals reduce costs: there no
longer is any need to order and
install individual components.
Or:
6 - 8 valve terminals, each with
25 - 30 valve slices
5
Festo – number 1 in valve terminal technology
Past, present and future: As the first supplier of IP65/67 Valve terminals for every auto-
pioneers in the field of valve remote I/Os for M12 mation concept
terminal technology inputs/outputs on the fieldbus, Valve terminals from Festo are
Festo defined valve terminal Festo defined this market too. ideal for all automation con-
technology and continues to Something that sounds quite cepts, be they simple applica-
do so. Thanks to its: complicated is actually made tions or complex systems.
• innovation quality, very easy, because only Festo Thanks to remote I/O and instal-
• know-how, offers so many services for lation systems, their bandwidth
• excellent manufacturing simple design, commissioning and functionality – in practically
quality and and maximum process reliability. every conceivable application in
• program quality with maximum pneumatics, electrics and net-
variety worldwide working – cannot be beaten.
It’s a combination of
Festo is the number 1 in valve • maximum performance,
terminal technology. • very high process reliability
and
• an impressive
price/performance ratio.
The potential for minimising
overall costs in terms of the Total
Cost of Ownership (TCO) is yet
another plus.
6
Different connection techniques, The simple and quick solution
only one favourite: fieldbuses for these requirements is inno-
The number of pneumatic and vative fieldbus technology. It
electric drive and control ele- even enables the networking
ments is growing at a very fast of different automation compo-
rate. With parallel wiring of ever nents, which is often required in
larger and more complex contemporary system concepts.
systems and interlinked pro-
cessing centres over larger net-
worked processing cells, the
cabling is becoming immensely
complex. The number of input
and output points is driving
installation work and costs sky-
high, while the likelihood of
errors is increasing considerably. 1989 1995 2000 2005
2002 2008
More flexibility Your future with Festo
• First completely modular • More function integration of
electrical periphery with pneumatics and electrics
8 selectable connection • Integration of IT technology
technologies • Simplified engineering
• M8 3-pin, M12 5-pin, etc. • Integration of safety tech-
• Diagnostics level 3: individual nology
channel diagnostics for I/O • Integrated diagnostic concepts
and valves
7
Savings potential with fieldbus – comparing technologies
Starting point:
Conventional concept
8
Valve terminal with multi-pin • Quick electrical connection of Valve terminal with fieldbus • Internal wiring on the valve
plug connection the valves via pre-assembled connection terminal
A multi-wire cable connects the multi-pin plug and cable Coded switching signals re- • Signal transmission takes
valve terminal and a controller. • Connection to every controller present a further important place serially via the fieldbus
It provides one wire for every possible reduction in the number of wires connection: long distances can
valve coil, and additionally one • All electrical connections to the consuming devices. The be bridged
wire for the ground connection integrated coding of the signal composition • Inputs and outputs are moved
of all valve coils. • Ideal for compact machines and transmission is defined in from the control cabinet to the
with short lines so-called protocols. valve terminal
• Saves: costs, space, installa- • Ideal for complex systems and
tion and testing time machines with several stations
• Saves: costs, space and
installation, commissioning
and testing time
• Function integration (axis con-
troller, positioning systems,
safety technology, pressure
regulation technology,
temperature recording etc.)
• Device/periphery diagnostics
possible
9
Open communication and networking of machines and systems
In the early 1980s, fieldbuses The control technology pyramid Field level
represented a first and very Four levels of industrial commu- Complex equipment and data
important step in enabling com- nication are generally defined: within a machine component or
munication between machines a production segment are net-
and systems. Management level worked using a fast and robust
Nowadays, networking in control The main focus at this level is bus system.
technology has advanced signifi- clearly on integrated process
cantly and extends to the highest visualisation and tracking. It also Sensor and actuator level
levels within companies. The incorporates the interface to Very fast communication with
central components are field- production systems. In general, possbile real-time capability –
buses and Industrial Ethernet, complex but normally not within the machine and at the
which enable industrial com- particularly time-critical data lowest control level. Digital
munication from the machine to packages are often transmitted or analogue processing of signal
management level and vice over large distances. statuses and diagnostic messa-
versa. ges of all actuators and sensors.
Control level
Synchronisation of production
processes or data within indivi-
dual processes or system parts.
This generally happens between
different PLCs.
Management
level Management level
Message Variability of
density participants
Performance classes and their characteristics
The speed, size, validity and availability of data vary depending on the performance
class, specific requests and technical feasibility.
10
Making the most of smart the context of service life guar- Moreover, end users and opera-
advantages, e.g. diagnostics antees, full service contracts, tors can retrofit and integrate
These open communication or to protect against unfounded these Festo systems – the infor-
concepts are not only of interest recourse claims. They are also mation is provided via the
to OEMs, who need to have of interest to end users who standard interfaces to the higher-
solid condition monitoring and depend on having the highest order process and machine dia-
diagnostic information to hand in level of process reliability. gnostics.
PC 1 PC 2
PC
5
PLC-Ethernet HMI-Ethernet/Web
4.1 4
HMI PLC-Fieldbus
Stand Alone
3.1 3.2
Notebook
FED
2 2 2
Position controller
1 Cylinders
Axes
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More efficient production using fieldbuses
For more than 20 years, field- Fundamental reasons for the use • reduction in assembly expen- • substitute control cabinet,
buses have been revolutionising of fieldbus technology include: diture and costs for testing as installed directly on the
industrial communication. In the • reduced error quota, also • actuation and data trans- machine
1980s, the technical and finan- through automatic trouble- mission between selected • improvement in cost/benefit
cial development within the shooting during set-up and in components of a system ratio
automation industry made a operation • definable electronic control • permanent improvement in the
new, groundbreaking technical • improved productivity and systems enable the combina- time-to-market situation
solution absolutely essential. reduced downtimes, because tion of systems
Even today, its significance diagnostic information is • installation and use in the
continues to grow as it results in, accessible from the field different machines and
for example, ever more complex, devices systems
highly networked and above all, • reduction in installation effort
closely synchronised production. by more than 60 %
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From the office to production – Industrial Ethernet
For more than 20 years, Ethernet Increased efficiency Diagnostics Integrated advantages:
has revolutionised office com- • Manufacturing and logistics • No laborious programming of a CPX as an example
munication. This LAN technology benefit enormously from the PLC and machine operator unit An intelligent electrical periphery
has become a standard in this possibility to network commu- as it is now possible to call up such as the CPX terminal inte-
field. nication and information flows diagnostic information from grates these advantages. And for
worldwide without huge the field devices. Festo valve terminals it offers
This had also led to further inno- expense using the Internet • Remote diagnostics and main- • the most up-to-date communi-
vations and improvements in and/or Intranet. tenance also possible with cation methods, such as field-
productivity in production and • One technology for all net- normal PC/browser. bus and/or Ethernet,
manufacturing. works simplifies the training of • comprehensive diagnostic
network specialists and pro- IT infrastructure: services,
With the combination of the grammers. • An existing IT infrastructure • condition monitoring,
advantages of fieldbuses and • Communication is drastically and know-how can be used • pre-processing and
Industrial Ethernet, the second simplified – even for mixed many times. • the latest function integration.
revolution is about to com- hardware from different manu- • Extremely fast data transmis- • Furthermore, it is not just
mence: the Ethernet can send facturers, such as e.g. servo- sion up to 100 Gigabytes/sec. uniquely modular and flexible,
messages to participants of a pneumatic and electric drives, • Configuration and recording but also
common line network by a kind measurement stations or of data and controls remains • independent of all PLC manu-
of wireless system. modular valve terminals. consistent, even over several facturers
network levels. • and can be integrated seam-
lessly into all host systems.
Communications links
Visualisation CPX/MPA CPX/MPA
Diagnosis
Program/process control
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An overview of bus technologies
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DeviceNet CC-Link
The fieldbus for industrial field Bus system from Mitsubishi for
devices such as limit switches, high-speed communication, for
optical sensors, valve terminals, example between the electrical
frequency converters and opera- CPX terminal and a higher-order
ting panels reduces the amount master for Control &
of expensive individual wiring Communication-Link (CC-Link).
required and improves device- The bus node is provided with
specific diagnostic functions. system supply via the inter-
DeviceNet communication on the linking block and processes
broadcast-oriented Controller communications via the I/O
Area Network (CAN) meets the modules.
extensive demands for transmis-
sion reliability and interference AS-interface
immunity in vehicle construction For optimised working with
and also operates in large tem- decentralised solutions at redu-
perature ranges. ced costs: the AS-interface is, at
actuator/sensor level, the ideal
Ethernet/IP complement for fieldbus systems
The open bus system based on or industrial Ethernet. Data
the Ethernet standard and and power transmission all take
TCP/IP technology is one of the place on only one cable.
most frequently used Ethernet-
based fieldbuses. It communi-
cates, for example, between the
electrical CPX terminal and the
Ethernet/IP network. The bus
node is provided with system
supply via the interlinking block
and processes communications
via the I/O modules. Access to
the data is possible directly from
the device.
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Four principles – four times the choice
Nowadays smart machine con- With smart machine concepts Centralised installation Decentralised installation system
cepts are based on three impor- everything is possible • Control of several drives and • Individual functions on a small
tant cornerstones: pneumatics, • Centralised installation functions via one valve terminal valve terminal
electrics and networking. Mixed • Decentralised installation • Short control chain, covering • Installation-saving hybrid cable
pneumatic and electrical systems • Upstream installation only a few metres for data and voltage for the
are linked for communication via • Hybrid installation • Typical I/O number between connection of up to 16 modules
Ethernet and fieldbus protocols, 16 … 128 via FB nodes
thus achieving new levels for Your system concept defines the • Typical I/O number between
productivity and process reliabi- ideal valve terminal solution Advantages 16 … 512
lity. Having the right product • Up to 60% improvement in
selection and the right machine 3 steps to achieve your efficiency thanks to function Advantages
and installation concept is also objective: integration • Up to 30% shorter cycle times
key if future requirements are to A Define the machine and • Up to 50% reduction in channel through very short tubes
be satisfied. Festo covers practi- installation concept. costs • Up to 70% reduction in installa-
cally every possible option in B Check our portfolio according • Up to 40% higher performance tion space
this respect. to the requirements of your density • Up to 50% less air consumption
sector: machine concept, • Up to 35% reduction in down- – smaller valves yielding the
electrical installation, special times thanks to condition moni- same performance are possible
applications and requirements toring/diagnostics • Optimum flow rates and
C Select the right valve terminal • Minimised effort for complete response times
according to function and energy supply • Highly flexible: 3 master con-
performance. • Minimised effort through cepts 32 … 512 I/O; 3 valve
The matrix on the next page centralised, easily accessible terminal platforms; 3 I/O plat-
provides an initial selection assembly forms
overview. • Central service point • Portable use possible thanks to
small dimensions
Festo solutions • Teach-in function for automatic
• Type 44 VTSA configuration
• Type 04 ISO • Simplified and shortened:
• Type 32 MPA service and maintenance
• Type 03 Midi/Maxi through short connections
• Type 50 CPX terminal
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Festo solutions Decentralised installation for Festo solutions Hybrid installation system
• Type 10 CPV upstream functions • Type 10 CPV (centralised/decentralised)
• Type 32 MPA (Fieldbus Direct) • Type 80 CPV-SC Only possible with Festo!
• Type 80 CPV-SC • Small valve terminals with • Type 82 CPA-SC
• Type 55 CPI installation system directly integrated FB connec- • Type 15 CDVI • Comprehensive combination
• 3 platforms of highly speciali- tions or AS-interface compo- of individual systems, which
sed CPI I/O modules nents Festo AS-interface solutions can be expanded as required
• 3 platforms for decentralised • For conversion, loading and • Type 10 CPV • Optimal also on the control
CPI valve terminals unloading outside the machine • Type 32 MPA cabinet or on the control
• Ideal for tools on robots or cabinet wall.
handling systems, upstream
stoppers and gates Advantages
• Typical I/O number between • Best mix
4/8 … 32 (48) • Short cycle times and high
machine performance
Advantages • Up to 20% reduction in system
• All advantages of decentralised costs in the context of TCO
installation • Maximised choice, centralised
• Graduated granularity for smal- or decentralised
ler, medium and separately • Selectable extent of diag-
mounted function groups nostics
• Comprehensive diagnostics
and condition monitoring per Festo solutions
slave • Type 32 MPA
• No subordinate subsystem: • Type 44 VTSA
FB configuration per slave • Type 50 CPX terminal
• Type 55 CPI installation system
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Valve terminal variety at a glance
Valve terminals Flow rate Electrical inputs Number of so
electrical periphery (litre/min per valve) (max. per valve terminal) (max. per val
decentralised
… helps you to find the right
valve terminal for your planned
machine concept, thus providing
8 16 72 92 144 512 8 16 24
you with the right solution.
VSVA – ISO 15407-1
500
Modular, individual connections M8/M12,
Design C 1000
CPX/MPA/MPA-F 360
Universal, modular, versatile, serial valve 700
actuation, with electrical I/O
900
CPV 400
Standard, compact, powerful 800
1600
CPV-SC
Compact, Smart Cubic 170
CPA-SC
Modular, Smart Cubic 180
MH1 10
Miniature valve
14
VTOC 10
Compact, flexible 2x 3/2-way pilot valves
MHJ, MH2/3/4 10
50 100 150 MHJ
Fast-switching valve,
Individual connection 100 200 400 MH2/3/4
CDVI
Clean Design IP65/67 650
CPI-System
Decentralized installation system. Up to 16 I/O-modules and valve terminals.
3 platforms for each I/O-module, valve terminals and master modules.
18
4
1)
26
32
40
lve terminal)
olenoid coils
48
56
64 128 512
Pressure sensor
Function integration
Multi-axes interface for electrical axes
Safety valves
Soft-start/exhaust valve
Vertical stacking
2)
2)
2)
Multipin
AS-Interface
DeviceNet
Profibus
Electrical connection
Interbus
1)
CANopen
1)
Communication protocol
CC-Link
1)
EtherCat
1)
1)
1)
Ethernet/IP
1)
1)
Modbus/TCP
1)
1)
Profinet/IO RT
1)
1)
Integrated controller
1)
Directly actuated
Valve
Piloted
properties
Vacuum
IP40
class
IP65
Protection
IP67
Explosion-proof
Status bit
Module-/channel oriented
Diagnostics
Preventative maintenance
such as for example: manual pressure regulators, pressure gauges, flow control plates, shut-off plates (hot-swap), compressed air supply, integrated non-return functions/back pressure flaps
Web-based, Web monitor
210
207
251
206
211
226
213
227
210
210
210
232
243
204
248
242
244
(215,
xDKI)
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The trend: function integration
Two valve terminals and one These decentralised automation The examples Integrated functions:
electrical terminal not only work solutions save entire operation • Comprehensive diagnostics
together flawlessly, they also cycles, for example, in the CPX modular electrical terminal and condition monitoring
offer great potential for function subordinate system and thus For maximum modularity, • Integrated IT services:
integration. This is why actuator, permit fast processes on site. process reliability and quality. CPX web monitor for valve
sensor, open and closed-loop Neutral I/O platform for mini- terminals online
control technologies at Festo are mum installation effort. • Power supply for reliable
all blended together to form machine statuses
autonomous systems. • Motion function integration
• Multi-axis interface for
electrical and servopneumatic
drives
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Valve terminal MPA – Integrated functions: Standard valve terminal VTSA Integrated functions:
modularity redefined • Comprehensive diagnostics VTSA – total function and • Integrated diagnostics concept
MPA stands for seamless inte- and condition monitoring system integration through to • Standardisation “plus”: e.g.
gration into control systems with • Electropneumatic installation a complete installation solution vertical stacking
Ethernet, fieldbus, multi-pin or concept for maximum function with maximum flow. Standard • Safety@Festo: electrically actu-
individual valves. integration and flexibility combined. ated on-off valve for
• Integrated pressure sensors gradual pressure build-up
• Proportional pressure • Valves with switching position
regulators sensing for maximum relia-
• Electrical voltage zones for bility
new safety concepts • Reliability for lifting and semi-
• Shut-off plate (hot-swap): rotary cylinders and manual
valve replacement under clamping devices
pressure
• Sub-base with integrated
non-return valves
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Services for your success
cost saving
time saving
process security
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Assembly/commissioning … Courses … Customer-tailored solutions …
… fast, simple and reliable – … with individually tailored … whenever the extensive port-
thanks to Festo Plug and Work® content for public or in-house folio of 28,000 components is
and an optimally coordinated training. The focus of these not enough: from PrePack and
product portfolio. courses is activity-based PreAssembly to ready-to-install
learning with an industrial solutions, control cabinets, inte-
focus and a quick transfer to gration technology or modified
industrial practice. and newly constructed compo-
nents.
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Festo worldwide