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Installation manual

GBMS-P575-6.R3

PNEUMATIC SPOOL VALVE ISLANDSby field bus with the following protocol

MEGA - AS-Interfaceversion 3.0

NTERFACE

2

AS-Interface version 3.0

CAUTION

To avoid malfunction of the bus system, please check on any valve island

• for correct addressing and speed parameters.

• All installation, adjustment and maintenance operations must be carried out by qualified personnel.

A separate Declaration of Incorporation relating to EEC-Directive 89/392/EEC Annex II B is available on request.Please provide acknowledgement number and serial numbers of products concerned.This product complies with the essential requirements of the EMC-Directive 89/336/EEC and amendments. Aseparate Declaration of Conformity is available on request.

COPYRIGHT © 2001 - ASCO/JOUCOMATIC - All right reserved

CONTENTS Page

1. The BUSLINK MEGA system with the AS-Interface protocol ______________________________________ 3

2. Components of system ____________________________________________________________________ 5

2.1 Functional description ______________________________________________________________ 52.2 Arrangement of components _________________________________________________________ 52.3 Dimensions - Mounting______________________________________________________________ 62.4 MEGA island code with one AS-Interface unit ____________________________________________ 72.5 MEGA island code with 2 or 3 AS-Interface units _________________________________________ 82.6 Joinable solenoid air operated MEGA spool valves ________________________________________ 92.7 Auxiliary manual operator____________________________________________________________ 10

3. Mounting of MEGA BUSLINK with AS-Interface ________________________________________________ 12

3.1 Mounting ________________________________________________________________________ 123.2 Pneumatic connection ______________________________________________________________ 12

4. Electrical connection ______________________________________________________________________ 15

4.1 General ________________________________________________________________________ 154.2 Power supply _____________________________________________________________________ 154.3 Connection of inputs ________________________________________________________________ 164.4 Addressing _______________________________________________________________________ 174.5 Control signals ____________________________________________________________________ 20

5. AS-Interface ________________________________________________________________________ network22

5.1 Connection of AS-Interface network____________________________________________________ 225.2 Connection to power supply __________________________________________________________ 225.3 Programming instructions____________________________________________________________ 235.4 Startup of AS-Interface network _______________________________________________________ 235.5 Diagnostics _______________________________________________________________________ 235.6 Fuses ________________________________________________________________________ 235.7 Accessories for AS-Interface _________________________________________________________ 245.8 Dimensions of accessories for AS-Interface _____________________________________________ 24

This product contains electronic components sensitive to electrostaticdischarge. If a person or an object come in contact with the electricalcomponents of the product, there will be an electrostatic charge which candamage or destroy the product.To reduce the risk of electrostatic discharge, please observe the handlingprecautions and recommendations contained in standard EN100 015-1 atall times. Do not connect or disconnect this device when it is energised.E S D

WARNINGOBSERVE PRECAUTIONS

FOR HANDLINGELECTROSTATIC

DISCHARGESENSITIVE DEVICES

3


1. THE BUSLINK MEGA SYSTEM with the AS-Interface version 3.0 protocolSet of four to eight mono or bistable pneumatic spool valves (6 or 8 mm push-in fittings) with built-in means of connection toa programmable logic controller via a series link or fieldbus using the standardized AS-Interface (AS-Interface) communicationprotocol.

ADVANTAGESThe numerous features of the Buslink system enables it to meet the requirements of modern automated installations:• no bulky cable bundles,• less time and money spent on electrical and pneumatic connection• supplied as a pre-tested unit ready-equipped with control spool valves• maintenance facilitated

POSSIBLE CONFIGURATIONS• Islands can comprise:

- one AS-Interface system with one or two nodes and a maximum of eight monostable or four bistable MEGA spool valves- two or three AS-Interface systems with a maximum of fourteen or twelve spool valves

• Island with or without inputs for data feedback• Island mountable on rack or symmetrical rail to EN 50022• Components can be mixed and matched as desired:

- all spool valve functions- 6 or 8 mm push-in fittings- type of manual operator (impulse or latchable in hold position : push and turn)- internal or external supply to pilots- separation plate

1 Spool valves (maximum of eight monostable spool valves or four bistable spool valves)

2 ASi connection module

3 Four or eight inputs on request

FUNCTIONAL DIAGRAM

3

2

1

POWER

FAULT

Maximum of eight

outputs

MasterASI

ASi

24V =

Yellow cable

Black cable

ASI gateway to other protocols(Profibus-DP, FIPIO, Device Net, etc.)

ASI powersupply

4


COMMUNICATION CHARACTERISTICSCommunication protocol AS-Interface V3.0 (simple addressing)Profile version with inputs = FE78 / version without inputs = FE88Transmission Flat AS-Interface cable (2 wires) or cable (5 wires)Max. number of spool valve islands 31 nodesNumber of valves per island 4 to 8 spool valvesMax. number of inputs per interface 8 inputs for 2- or 3-wire PNP sensorsMax. bus cable length 100 m (300 m with repeater)Island addressing (participants) infrared control panel or jack plugCompatibility with control system no modification of current programmesStatus indication LED

ELECTRICAL CHARACTERISTICSSupply voltage 24 V DC, ±10% at the island (max. ripple ratio: 10 %).

Supply to the valves with an additional flat AS-Interface cable,(black, 2 wires) class 3 (PELV).

Max. consumption 75 mA per coil on power supply (black cable)<300mA per node on AS-Interface bus cable (yellow cable)

Protection IP65 (coil insulation class: F)Electrical insulation optocouplersPeak voltage suppression integrated in the island for each coilBus connection (IN/OUT) and 24 V supply vampire-type panel connector for yellow and black cableEarth connection earthing screw on the connection module with inputsElectromagnetic compatibility in accordance with EU directive EMC 89/336/EEC

CE markINPUT CHARACTERISTICSInput connection 5-pin female panel connector M12Supply voltage related to bus supplyProtection / short circuit by internal current limitationConsumption 9 mA per input with 24V DCConsumption maxi. sensors 40 mA per node

Indication 1 yellow LED per input (ON = input on)

PNEUMATIC CHARACTERISTICS (see page 9)

AS-Interfacemaster yellow cable

black cable

AS-Interface gateway to other protocols(Profibus-DP, FIPIO, Device Net etc.)

AS-Interfacepower supply

■ Pneumatic spool valve island for data exchange the standardisedAS interface version 3.0 protocol.

■ Up to 8 spool valves can be linked to one AS-Interface.■ Easy cabling with instant vampire-type connectors and flat profiled

2-wire cables.■ Connection of 4 to 8 inputs for sensor status readback.■ IP65 protection allowing for direct mounting on machines, close to

the actuators.■ High performance, modular, easy-to-install unit with LED indicators

for easy diagnostic analysis and maintenance.■ The MEGA-AS-Interface version 3.0 island is provided with individual

AS-Interface connectors for direct installation and piloting of spoolvalves with 3-pin solenoid coils to DIN 46244 or ISO 4400 (max. 7.2W).Pneumatically operated spool valves and general purpose valvescan be installed on one AS-Interface network.Individual AS-Interface connectors: see leaflet P522.

COMBINATIONS● MEGA-AS-Interface islands can be grouped as follows:

- 1 AS-Interface unit with 1 or 2 nodes and 4 bistable or max. 8monostable MEGA spool valves (see following page).

- 2 or 3 AS-Interface units with max. 14 or 12 spool valves.● Spool valve island with or without inputs for data feedback.● Frame or DIN EN 50022 rail mounting.● Optional mixing of:

- all spool valve functions,- 6 or 8 mm O.D. instant fittings.- Different types of manual override: impulse-type or locking push/turn type.- Internal and external pilot pressure supply.- Pressure separation plate and intermediate pressure supply module.

ASi

24V =

5


2. COMPONENTS OF SYSTEM

2.1 FUNCTIONAL DESCRIPTIONIslands are linked to controllers (PLCs) by an AS-Interface bus cable (yellow) for control of the spool valves, and for state datafeedback if the islands have inputs. A second connector is used to supply the spool valves with power (black cable).Pressure and exhaust ports are connected to common lines on the island. The spool valves control the pressure and exhaust flowsof pneumatic actuators. Actuators are pneumatically connected at the tops of the spool valves. On request, the island can be equippedwith inputs. The electrical sensors can thus be linked up with M12 connectors.

MAXIMUM CAPACITY OF ISLANDDepending on the configuration chosen, islands can be fitted with a maximum of eight outputs (one output per valve coil) and eight inputs.The maximum capacity of the island depends on the number of nodes (see table below).

Example for maximum configuration:

NOTE:- With one node, the maximum configuration of the island

is 4 outputs and 4 inputs- With two nodes, the maximum configuration of the island

is 8 outputs and 8 inputs- 1 output: 1 monostable spool valve- 2 outputs: 2 monostable spool valves or one bistable

spool valve or one 2x3/2 spool valve

2.2 ARRANGEMENT OF COMPONENTS

Item Description

1 MEGA island pneumatic connection fitting

2 AS-Interface bus connection module

3 2x3/2-5/2-5/3 monostables or bistables spool valves (8 max.)

4 push-in fittings for load ports "2-4"

5Threaded ports or push-in fittings for pneumatic supply "1"and exhaust "3-5"

6 Spool position indicator

7 AS-Interface; adapter for AS-Interface bus cable (yellow)

8 AS-Interface; adapter for additional AS-Interface power cable (black)

9 Link-up connectors

10 Address setting

11 Two LEDs for AS-Interface and power indication

12 Eight LEDs for input indication

13 Pilot power LED

14 Input link-up by M12 connectors (optional)

15 Ground terminal connection (with input option)

16 Collected, pipable exhaust from pilots 82-84

17 Pilot external supply (12-14)

14 14 14 14 14 14

5 3

1

2

4

2

4

2

4

2

4

2

4

2

4

82-84

12-14

14 1312 11

22 2124 23

14 14

2

4

2

4

ASi

24V

15

2

4

36

1

5

7

8

10

11

14

1217

139

16

Number ofnodes

1

2

Max. number ofspool valves

Max. number ofinputs

4 monostableor 2 bistable

or 2 double 3/2 NC4

8 monostableor 4 bistable

or 4 double 3/2 NCor 4 monostable +

2 bistable (1)

8

6


■■■■■ Islands consisting of several AS-Interface unitsIt is possible to assemble islands in all specified combinations up to a maximum of 3 AS-Interface units and 12 spool valves.

n = Number of spool valvesx = Number of AS-Interface modules - 1

Definition of lengths: L2 (±2) = 94 + (n x 18) + (x x 36)

L1 = L2 + 13

■■■■■ AS-Interface island with up to 8 spool valves(pressure supply from left side)

■■■■■ Version with pressure supplyfrom left and/or right side

2.3 DIMENSIONS - MOUNTING

Two mounting systems are available for islands:

- on frame/rack (two mounting holes at either end, in which case the distance between fastners centres L2 varies with the number of spool valves)- on symmetrical rail to DIN-EN 50022.

When mounting, check that there is sufficient room on the right to pneumatic connection and any exhaust silencers

L2* ±2 = 67 + (n x 18)33,5 18

L1* = L2 + 13

33,511

21,5

27 23

58

184926,5

5,5

14 14 14 14 14 14

5 3

1

2

4

2

4

2

4

2

4

2

4

2

4

82-84

12-14

108

6,5 6,5

5,5 1114

5

2028

4,2

==

240/

173

(3)

145

130

(2)

14 1312 11

22 2124 23

14 14

2

4

2

4

6

ASi

24V

14 14 14

27

ASi

24V

(1)

33,5 18L2L1

33,5

14 14 14 14

27

ASi

24V

6,56,5

12 12 12 12

927927

4,2

14 14 14 14

ASi

24V

12 12 12 1214 14 14 14

ASi

24V

12 12 12 12

n n n

4 5 6 7 8

L2* (±2) 139 157 175 193 211 + 27

L1* 152 170 188 206 224 + 27

Weight (kg) 0.940 1.070 1.200 1.380 1.460 +0.050

Number of spool valves Right sidepressure supply

(1)

* Dimensions of island with pressure supply from left side.(1) Islands of 4 to 8 spool valves can be equipped with an additional pres-sure supply module on the right side (provide for overlengths).(2) 130 mm for AS-Interface island without input (types A1 - A2 - A5 - A6)(3) 173 mm with right-angle mono connectors M12

240 mm with straight mono or duo connectors M12

7


(1) Different spool valve versions can be mixed on an island. In this case:- indicate type “P” in the basic reference- fill in reference line

ORDERING EXAMPLE: 678A7E1IG00CJJMMMM

MEGA island with AS-Interface protocol, two nodes, with 8 inputs over 4 M12 connectors, one pressure inlet on left-hand side, G1/4 thread. Unitdesigned for mounting on DIN rail, supplied assembled, including six spool valves with 8 mm OD instant hose fittings, impulse-type manual override,internal pilot. Spool valve types:- four monostable 5/2 spool valves, type M, in positions 1 to 4- two bistable 5/2 spool valves, type J, in positions 5 and 6

How to fill in reference line:- Fill in only if different spool valve versions are to be

mixed on an island.- Use the spool valve position numbers

specified in reference.- Repeat the type of accessory in the same position

number as specified in reference.

Spool valve versions (with mixed connections)

TypePort connections2 - 4

Manualoverride

Pilots12/14

(▼) impulse

(●) locking

(▼) impulse

(●) locking

Instant fittings8 mm O.D.


Port connections: 1 - 3 / 5 Type

On frame(2 x Ø4.2)

On railEN 50022 - DIN

Spo

ol v

alve

ver

sion

s

One pressure inlet onleft-hand side

With pressure inlet on left-hand and right-hand side







Island versions

MEGA ISLAND

Without input

With inputs(ØM12)

■■■■■ 2 node AS-Interface:

Without input

With inputs(ØM12)

Spool valve position9(2) 8 7 6 5 4 3 2 1

Please indicate the type of spool valveor accessory required (2)

Spool valve position9(2) 8 7 6 5 4 3 2 1MEGA island with

1 x AS-Interface

!

3

2

1

A5

A6

A7

A8

-

▼ ▼ ▼ ▼ ▼ ▼

678

(2) Max. configuration of AS-Interface island: 8 monostable spool valves for 2-node AS-Interface to be mounted in 9 positions if a pressure separation plateis used.

▼

A1

A2

A3

A4

type

2.4 MEGA ISLAND CODE WITH ONE AS-INTERFACE UNIT (8 spool valves at maximum)For island assembly with 2 or 3 AS-Interface units see following page.

A

▼

NOTA: A computer application is availablefor generating full island part numbers forspecific applications, to facilitate ordering.The application is available on CD-ROMfrom your usual supplier.

Spool valves (functions) Type2 x 3/2 NC-NC K5/2 - Solenoid air operated pilot, spring return (monostable) S5/2 - Solenoid air operated pilot, differential return (monostable) M5/2 - Solenoid air operated pilot and return (bistable) J5/3 - Pressure held (W1) G5/3 - Pressure applied (W2) B5/3 - Exhaust released (W3) EReserve module (to be placed at the left end of the island) A

Accessories TypePressure separation plate (see page 14) :• Total blocking of 1, 3 and 5 (no connection) .................. X• Blocking of 1 (ports 3 and 5 connections maintained) .. W• Blocking of 3 and 5 (port 1 connection maintained) ...... Y• Blocking of 5 (ports 1 and 3 connections maintained) .. T• Blocking of 3 (ports 1 and 5 connections maintained) .. RPort connections: 2 - 4 Type

Instant fittings Ø8mm O.D. EInstant fittings Ø6mm O.D. SMixed (E & S) on island (1) P

Auxiliary manual override Type(▼) impulse 1(●) locking 2Mixed (1 & 2) on island (1) P

Pilots supply 12/14 TypeInternal IExternal EMixed (I & E) on island (1) P

Instant fittings 10 mm O.D. QG1/4 G

Optionwithout option 00

other options. .99

Assembled A

Assembled C

Island mounting Island delivery Type

Internal 1External 2Internal 3External 4Internal 5External 6Internal 7External 8


1

3

12

8


MEGA island with2 or 3 AS-Interfaces

With pressure inlet on left-hand andright-hand side




Island versions■ ■ ■ ■ ■ 1 node AS-Interface:

MEGA ISLAND

Without input

With inputs(ØM12)


Without input

With inputs(ØM12)

Spo

ol v

alve

ver

sion

s

On frame(2 x Ø4.2)

On railEN 50022 - DIN

Island mounting Island delivery Type

How to fill in reference line 3 :- Fill in only if different spool valve versions are to be

mixed on an island.- Use the spool valve position numbers

specified in reference 2 .- Repeat the type of accessory in the same position

number as specified in reference 2 .

Spool valve versions (with mixed connections)

TypePort connections

2 - 4Manualoverride

Pilots12/14

(▼) impulse

(●) locking

(▼) impulse

(●) locking



Spool valve position16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

(3) Specify the type of intermediate AS-Interface module (2 digits per mo-dule to be written in 2 positions as 1 intermediate AS-Interface moduleoccupies the place of 2 spool valves).The 1st AS-Interface module at the right-hand side of the island is specifiedin the basic reference 1 (A2 to A8). It is not to be written in reference line2 and must not be included in the number of positions available.

Intermediate AS-Interface modules (3)

1 node module

2 node module

Please indicate the type of spool valve,accessory or AS-Interface module required (2)

Spool valve position16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

!

3

2

1

-

▼ ▼ ▼ ▼ ▼ ▼

678

(2) For max. configuration of AS-Interface island see page 32

▼

2.5 MEGA ISLAND CODE WITH 2 or 3 AS-INTERFACE UNITSIt is possible to assemble islands in all specified combinations up to a maximum of 2 AS-Interface units and 14 spool valves or 3 AS-Interface units and12 spool valves.

A

▼

type

A6

A8

A2

A4

typeSpool valves (functions) Type

2 x 3/2 NC-NC K5/2 - Solenoid air operated pilot, spring return (monostable) S5/2 - Solenoid air operated pilot, differential return (monostable) M5/2 - Solenoid air operated pilot and return (bistable) J5/3 - Pressure held (W1) G5/3 - Pressure applied (W2) B5/3 - Exhaust released (W3) EReserve module (to be placed at the left end of the island) A

without input 2Vwith inputs ØM12 4Vwithout input 6Vwith inputs ØM12 8V

Internal 1External 2Internal 3External 4Internal 5External 6Internal 7External 8

head module defined in reference 1

Intermediate AS-Interface modules defined in reference 2

(1) Different spool valve versions can be mixed on an island. In this case:

- indicate type “P” in the basic reference 1- fill in reference line 3

Optionwithout option 00

other options. .99

Assembled A

Assembled C

Instant fittings 10 mm O.D. QG1/4 G

Port connections: 1 - 3 / 5 Type

Port connections: 2 - 4 TypeInstant fittings Ø8mm O.D. EInstant fittings Ø6mm O.D. SMixed (E & S) on island (1) P

Auxiliary manual override Type(▼) impulse 1(●) locking 2Mixed (1 & 2) on island (1) P

Pilots supply 12/14 TypeInternal IExternal EMixed (I & E) on island (1) P

Accessories TypePressure separation plate (see page 14) :• Total blocking of 1, 3 and 5 (no connection) .................. X• Blocking of 1 (ports 3 and 5 connections maintained) .. W• Blocking of 3 and 5 (port 1 connection maintained) ...... Y• Blocking of 5 (ports 1 and 3 connections maintained) .. T• Blocking of 3 (ports 1 and 5 connections maintained) .. R

9


2.6 JOINABLE SOLENOID AIR OPERATED MEGA SPOOL VALVESGENERAL■ Space saving due to new patented design and integral twin pilot.■ High flow rate, reduced dimensions.■ Low power consumption.■ Quick installation and easy maintenance with visual indication of the spool

position, identification and reference labels as well as manual override.■ Low weight for block installation.

SPECIFICATIONSFLUIDS : Air or neutral gas, filtered at 30µm, lubricated ornotOPERATING PRESSURE : -0.95 to 8 bar (with external supply)

: 3 to 8 bar (with internal supply)ALLOWABLE TEMPERATURE : -10°C to +50°CCONNECTION

- Spool valve (ports 2 - 4) : instant fittings for flexible hose 6 or 8 mm O.D.- End covers (ports 1 - 3 - 5) : G1/4 thread or instant fittings 10 mm O.D.

FLOW (Qv at 6 bar) : see table belowFUNCTION : 2x3/2 NC, monostable or bistable 5/2, 5/3PILOT CONTROL : solenoid air operated with internal or external pressure supplyPILOT PRESSURE : 2 or 3 bar to 8 bar (see table below)VIBRATION FATIGUE LIMIT : to EN 60068-2-6 standard

CODES (24 V DC)Spool valve without connectorports 2-4 with instant fittings

▼ 57800041 57800013

● 57800042 57800014

▼ 57800030 57800002

● 57800036 57800008

▼ 57800031 57800003

● 57800037 57800009

▼ 57800029 57800001

● 57800035 57800007

▼ 57800032 57800004

● 57800038 57800010

▼ 57800033 57800005

● 57800039 57800011

▼ 57800034 57800006

● 57800040 57800012

Solenoid air Solenoid air

Electrical connectionSpool valve

monostable

bistable

Protectiondegree

Insulationclass ConsumptionVoltage (*)

2 flat terminals + earth

3 flat terminals + earthIP 65F24 V DC

CHOICE OF EQUIPMENT

Return(12)

Pilot(14)

5/2

5/3

Centre closedW1

solenoid air operated

Centre open to exhaustW3


Centre open to pressureW2


900(550)

Solenoid air Differential

FunctionsSymbols

Flowat 6 bar(l/min)(ANR)

Operators(M)

14 2

35

4

182/8412/14

Solenoid air Spring

14 2

35

4

182/84

12

12/14

12

12/14

2

35

4

182/84

14

24

182/84

1214

1412

35

24

182/84

1214

1412

35

24

182/84

1214

1412

35

(M) Manual override ▼ : impulse-type ● : locking, push/turn-type(550) : Max. flow rate of 550l/min for the version with instant fittings for flexible hose O.D. 6mm.

6mm O.D. 8mm O.D.

1.5 W

2x3/2NC

Solenoid air Spring

Pilotpressure

(bar)

450

600(550)

700(550)

750(550)

4...8

3...8

3...8

2...8

3...8

3...8

3...8

5/2

5/2

5/3

5/3

M

B

S

G

E

K

Type

J

ELECTRICAL CHARACTERISTICS

CONSTRUCTIONBody and end covers: glass-fibre reinforced synthetic material.Internal parts: aluminium, stainless steel, zinc-plated steel, brassand synthetic material.Sealings: nitrile (NBR) and PUR.Internal or external pilot pressure supply by selecting sealImpulse-type or locking push/turn-type manual override.

Integral electrical pilot to NFC79300 (VDE 0580).Encapsulated coil with flat terminals to DIN 46244 A 2.8 x 0.5(spacing: 9.4 mm).The bistable version is provided with an integral twin pilot placedon one side of the valve with a single electrical connector forreduced dimensions.

1.6 W

(*) Monostable version, in alternative current, available

10


2.7 AUXILIARY MANUAL OPERATORMEGA Series 578 spool valves are equipped with momentary-actionoperators (A) and locking operators (B).Monostable spool valves Bistable spool valves

Typeof

spool valve

Manual operator actionSpool valve function

5/2monostable

2x3/2or

5/2bistable

or

5/3with neutral

position

The valve is in the working position as long as the operator isheld in the working position**

Returns to rest position when the manual operator is released

Spool valve is in the working position** (as whenoperator 14 is activated).

5/25/3

5/2 Remains in the working position

5/3 Returns to central neutral position

5/25/3

5/2 Remains in the return position

5/3 Return to central neutral position

* Locking operators have no rotation stop and can be turned in either direction. It is therefore activated by turning a quarter turn clockwiseor anticlockwise.

** These state changes only occur when the spool valve is under pressure.Supply pressure at Port 1

spool valve is in the working position** (as whenoperator 12 is activated).

3 1 5

12 14

2 4

(A) (A)

momentary locking*

(B) (B)

1

2

1

2

Bistable spool valve

11


INT

EX

T

INT

EX

T

MOUNTING AND PNEUMATIC ACCESSORIES

Accessory Description Code

DIN EN50022 rail

Set of 10 connecting bolts 18 mm long (for 5 spool valves)(Note: Each spool valve is delivered with connecting bolts)

Set of 10 instant reducing fittings 8 / 6 mm O.D. (1)

Exhaust silencer, male thread (2)

Sintered bronze exhaust silencer for direct mounting to ports withinstant fittings 10 mm O.D. (3)

Set of 17 clip-on ID labels for spool valves and VCS connectors(Note: each component is supplied with 2 ID labels at delivery)

88157858

33400033

88157893

88157887

34600407

34600002

88157826

88157851

1 m

5 x 1 m

1m

(1) For mounting to ports 2 – 4 of spool valves with 8 mm O.D. instant fittings for 6 mm O.D. flexible tube(2) Exhaust silencer for ports 3/5 of G1/4 threaded end covers (see page 7)(3) Exhaust silencer for ports 3/5 of end covers with instant fittings 10 mm O.D. (see page 7)

x10

x10

PRESSURE SUPPLY OF PILOT VALVESA MEGA spool valve is equipped on one side with a spacer sealing which also provides for aselecting function:- The spool valve can be adapted to either internal or external pilot pressure supply simply by

rotating this sealing.- The position selected for each spool valve can be identified from the outside even after the spool

valves have been assembled to islands.- Internal and external pressure supply can be mixed on one island.- If the components are supplied separately, the spool valves are delivered with the sealing placed

in INT for internal pressure supply.■ Internal pressure supply to pilot valves ■ External pressure supply to pilot valves

Identification underneath the spool valve

In this configuration:The pilot valves are directly supplied with pressure by using thesupply pressure (1) in the middle of the spool valve.The common pressure supply (spool valve and pilot valves) is3 to 8 bar (2 to 8 bar with bistable 5/2 spool valves).

In this configuration:- The spool valves on an island can be supplied with low pressure

and vacuum.- The pilots and the spool valves on an island can be supplied with

pressure over 2 separate lines.Supply pressure of pilot valves: 3 to 8 bar(2 to 8 bar with bistable 5/2 spool valves)Supply pressure of spool valves: -0.950 bar to +8 bar.Connection of pilot pressure supply 12/14 at either one of the 2 endcovers.

Identification underneath the spool valve

Sintered bronze body

Plastic body

12


- Island with eight spool valves

If six spool valves are to operate simultaneously, it isrecommended to supply the island from both sides to avoid airsupply disturbance.

5 3

1

2

4

2

4

2

4

2

4

2

4

2

4

82-84

12-14

14 1312 11

22 2124 23

2

4

2

4P1

53

1

82-84

12-14

P1

3 MOUNTING OF MEGA BUSLINK with AS-Interface version 3.0

3.1 MOUNTINGSecure the island in place (see §2.3)When mounting, check that there is sufficient room for the wiring, connectors and any exhaust silencers. Then make thepneumatic and electrical connections.

A Supply pressure 1and exhausts 3-5

Outlet 2-4

Connection of bus (yellow cable)

Spool valve power 24 V DC (black cable)

Sensor inputs (on request)

B

C

D

E

3.2 PNEUMATIC CONNECTION3.2.1 GENERAL■■■■■ On islandThe island is provided with passages for common pneumatic signals: supply pressure (1), exhausts (3) and (5), external supply of pilots (12/14) and pilot solenoid valve exhaust (82/84). In versions with a pressure inlet, the ports are located on the LH side of the island. In otherversions of the island (A2, A4, A6 and A8) the ports are on the RH and LH sides of the spool valves (see overleaf)■■■■■ On the spool valvesConnection of working ports (2-4) on upper surface:- push-in fittings for 6 or 8 mm OD tube

■■■■■ Connection procedure- Remove all plastic protective fittings.- Fit any exhaust silencers.- Connect the pneumatic lines. Tie the tubes together to form neat, easily-accessible bundles.

■ Recommendation concerning pressure supply (see next section)

3.2.2 PRESSURE SUPPLY CONNECTIONAll MEGA-AS-Interface can be supplied with one or two different pressures.

■ Supply with one pressure (P1)

5 3

1

2

4

2

4

2

4

2

4

82-84

12-14

14 1312 11

22 2124 23

2

4

2

4P1

- Island with 4 to 6 spool valves, connection of supply on LH side.

Recommandation concerning installation:Five spool valves at a maximum can operate simultaneously,without pneumatic disturbance.

13


■ Supply with two different pressures (P1 - P2)Insert a special set of two separation plates (total width 2 x 9 mm = 18 mm) type X or W for AS-Interface (see overleaf)- Type X (separation of ports 1 - 3 - 5 - 12 - 14) ........................................................ code 88157847- Type W (separation of ports 1 - 12 - 14, connection between 3 - 5) ....................... code 88157848

P2

E

P1

E3

1

5 3

1

5

W

P2

E2

P1

E13

1

5 3

1

5

X

Supply with two different pressures withcommon exhausts

Supply with two different pressures withseparate exhausts

Code:Code:

■ External supply for pilots- Place distributor seals in position EXT (see previous pages). To be done before installing the island.

- Supply port 12 - 14 with pilot pressure "Pp".

■ Common supply / separate exhausts- Type Y (separation of ports 3 - 5, connection maintained between 1 - 12 - 14) .... code 88157849

P1

E2

P1

E13

1

5 3

1

5

Y

PP

18

Front view

Connectorsfor electrical

link-up

Spool valvesand pneumatic

connections

SUPPLY OF AS-INTERFACE MEGA ISLANDS WITH TWO DIFFERENT PRESSURESMEGA-AS-Interface can be supplied with two different pressures. Theymust then be supplied with a special set of separation plates. The nomi-nal width of a MEGA spool valve is 18 mm and this version has stackableconnectors of the same width providing electrical continuity up to themain connection module, on the RH side of the island (see opposite). Ifany pneumaitc accessories are added between the spool valves, theymust be of the nominal width of 18 mm and a link-up connector must beprovided for electrical continuity.

Method of installation of a MEGA-AS-Interfaceisland with pressure (P) from both sides

AS-Interfaceconnection

Top view of islands

5 3

1

2

4

2

4

2

4

2

4

82-84

12-14

14 1312 11

22 2124 23

2

4

2

4

Pp

14


VERSIONS FOR AS-Interface islands

Description CodeType

Set of two separation

plates (1)+

1 connectorfor electrical link-up

complete blanking 1 - 3 - 5 (no connection) X 88157847

blanking of 3 - 5 (port 1 connection maintained) Y 88157849

blanking 1 (port 3-5 connections maintained) W 88157848

SEPARATION PLATEThe MEGA-AS-Interface requires a special set of separation plates to provide electrical continuity between the connectors oppositethe fitting. To obtain the different configurations shown opposite, these accessories must be inserted at the correct positions.

Separation plate construction detail

Separatingplatecode

Type Connection1

Connection3/5

Connection12/14

Connection82/84

88157847 X ✶✶✶✶✶ ✶✶✶✶✶ ✶✶✶✶✶ ∇∇∇∇∇

88157849 Y ∇∇∇∇∇ ✶✶✶✶✶ ∇∇∇∇∇ ∇∇∇∇∇

88157848 W ✶✶✶✶✶ ∇∇∇∇∇ ✶✶✶✶✶ννννν

Separationplates

Port 1 : pressure supplyPort 3/5 : exhausts 3 and 5Port 12/14 : external pilot pressure supplyPort 82/84 : connection of pilot circuit exhausts

3/5

1

12/14

82/84

3 5

1

3 5

1

82/84 3/5

1

12/14

(1) In this case it is necessary to have a configuration with pressure supplies on the LH and RH sides

Example: Complete blanking off (Type X)

Connectorfor electrical link-up(width: 18 mm)

one set of two separation plates(width 2 x 9 mm = 18 mm)

✶✶✶✶✶ : connection blanked ∇ ∇ ∇ ∇ ∇ : connection maintained

15


MEGA-AS-Interface ISLAND without inputs(types A1 - A2 - A5 - A6)

with 4 inputs (*)(types A3 - A4)

with 8 inputs (*)(types A7 - A8)

V N.N

GND

4 ELECTRICAL CONNECTION

4.1 GENERALThe components are connected to a control system (PLC) with a AS-Interface bus cable (yellowflat cable "Y") to pilot the spool valves. A second adapter (X) is used to supply the spool valves with24V DC power (black flat cable "B"). Upon request, the AS-Interface connection module (G) canbe equipped with 5-pin ØM12 connectors for the inputs to transmit status information from thesensors.

Coil

Spule

A ground terminal is provided on the versionwith a casing with inputs.The ground connection for preventing injuryis made on the island at the screw providedfor the purpose.

Built-in electrical protection for each coil. Grounding

4.2 POWER SUPPLY- The yellow cable supplies ASI interface and the inputs

• Power supply : as per AS-Interface specification• Consumption : 280 mA max per node (varies with the condition of the inputs and outputs)• Max consumption specific to sensors: 40 mA per node

- The black cable powers the coils of the valves• Power supply : 24 V DC, ±10%• Consumption : 80 mA per coil powered

Check power voltage while installation is in service and make sure that the tolerance limitsare complied with (±10%)

Details of connections: see chapter 5

GY

B

X

G

(*) two inputs per M12 connector

16


CONNECTION TO M12 CONNECTORTwo types of M12 connectors are available:- Twin straight connector (A) for connecting two individual cables (one per sensor)- Single straight connector (B) for connecting a sensor or cable bundle

(B) 88100330(A) 88100253

4.3 CONNECTION OF INPUTS (Inputs on request)

Connection of plug-in IP65 M12 connectors.Two and three wire sensors can be connected up.

Sensor Sensor Sensor Sensor Sensor

Connector to be procured:

(A) Straight twin M12 connectorwith five male contactsentry for each 3 to 5 mm dia cablecode: 88100253

(B) Straight single M12 connectorfor one 4 to 6 mm cable entrywith five male contactscode: 88100330

Contact Name Description1 24V DC IN Input power2 IN x +1 Positive logic input x + 13 GROUND Common (3-wire sensors)4 IN x Positive logic input x5 PE grounding

Input connection diagramMarking seen from male connector screw-on side

● 2-wire sensors ● 3-wire sensors (e.g. solid state)

1

2

4

3

5

+

-

+

-

INx+1

IN xSensorx

Sensorx+1

24V 24V

GND GND

1

2

4

3

5Sensor x

IN x IN x+1

Sensor x+1

24V 24V

NOTE:The state of the sensors connected can be determined via the inputs. The inputs have positive logic, they can be operated togetherwith the PNP output sensors. The inputs are low and must be switched to +24 V (high) to be activted.Compatibility of inputs with IEC 1131-2 for Type 1 sensors, as follows:- low logic state for Vi < 5V and Ii < 0.5 mA- high logic state for Vi > 15V and Ii > 2 mAMaximum voltage of inputs 30 V DC, maximum input current at this value < 15 mA.Typical input current: 9 mA at 24V DCMax consumption specific to sensors: 40 mA per nodeWhen connecting 2-wire connectors, the residual current in the low state must be < 1 mA.

Addressing of inputs:

x: IN1-1, IN1-3, IN2-1, IN2-3X + 1: IN1-2, IN1-4, IN2-2, IN2-4(see following pages)

Equipped with four M12bulkhead connectors for eightinputs (two inputs per connector)

Addressing of inputs:

x: IN1-1, IN1-3X + 1: IN1-2, IN1-4(see following pages)

Equipped with two M12 bulkheadconnectors for four inputs(two inputs per connector)

17


Spool valve positions8 7 6 5 4 3 2 1

1st. node

4.4 ADDRESSING4.4.1 ADDRESSING OF SPOOL VALVESSpool valve control signals (see §4.5)Monostable and bistable spool valves are addressed differently

D3 D2 D1 D0 D3 D2 D1 D0_ _ _ _ _ _ _ _

■ Bistable valves (4 max.)Address weight increases from right to left

■ NOTE: With a 2-node configuration it is possible to mix monostable andbistable spool valves (maximum of six monostable and one bistable,four monostable and two bistable or two monostable and three bistable).There are no limitations on spool valve positioning.For addressing with all the possible combinations, please consult us.

4.4.2 ADDRESSING OF INPUTS

AS-Interface island with inputs

1st node

2nd node

Connect two sensors (two inputs) by M12 connector(see previous page)

2st. node

addressing:

■ Monostable spool valves (8 max.)progression of addressing: horizontal, from right to left

14 14 14 14 14

ASi

24V

mmmmmmmm

Control signalLED (14)

14 1312 11

22 2124 23

IN1-1

IN1-3

IN1-2

IN1-4

IN2-1

IN2-3

IN2-2

IN2-4

bbbb

bbmmb14 14 14 14 14

ASi

24V

12 12 12

Example: two monostable and three bistable

1 bistable2

monostable 2 bistable

1st node2nd node

Spool valve positions4 3 2 1

D2 D0 D2 D0

D3 D1 D3 D1

addressing: Control signals(14)

Returnsignals (12)

Spool valve positions5 4 3 2 1

1st node

D2 D1 D0 D2 D0

D3 _ _ D3 D1

2nd node

addressing:

14 14 14 14 14

ASi

24V

Control signalLED (14)

Return signal LED(12)

18


4.4.3 SUMMARY OF ADDRESSES

4.4.3.1 One node AS-Interface island

Numberof node

Data bit 4 monostable valves 2 bistable valves Island withoutinputs

(A1 - A2)

Island with fourinputs

(A3 - A4)

Addressing of valves Addressing of inputs

1/14 valve 1/14 valve -Input 1IN1-1




D0

D1

D2

D3

1

Valve X/14 = energization of "control" coil 14: Port 4 pressurized (1)Valve X/12 = energization of "return" coil 12: Port 2 pressurized(1) Except 2x3/2 NC valve on control side = 12 (Port 2 pressurized). Return by de-energization of coil 12 (see control signals, §4.5,following pages)

5 3

1

82-84

12-14

4 3 2 1

5 3

1

82-84

12-14

14 1312 11

4 3 2 1

■ 4 monostable or 2 bistable valvesor two double 3/2 NC valves, without inputs(island code: A1 or A2)

■ 4 monostable or 2 bistable valvesor two double 3/2 NC valves, with four inputs(island code: A3 or A4)

Example of configuration

1/14 valve

piloting code (control 14 or return 12)

valve serial number

▼ ▼

19


Island withoutinputs

(A5 - A6)

Island with eightinputs

(A7 - A8)

Numberof node

Data bit8 monostable valves 4 bistable valves

Addressing of valves Addressing of inputs

1/14 valve 1/14 valve - Input 1IN1-1








D0

D1

D2

D3

D0

D1

D2

D3

1

2

Valve X/14 = energization of "control" coil 14: Port 4 pressurized (1)Valve X/12 = energization of "return" coil 12: Port 2 pressurized(1) Except 2x3/2 NC valve on control side = 12 (Port 2 pressurized). Return by de-energization of coil 12 (see control signals, §4.5,following pages)

5 3

1

82-84

12-14

8 7 6 5 4 3 2 1

5 3

1

82-84

12-14

14 1312 11

22 2124 23

8 7 6 5 4 3 2 1

4.4.3.2 Two-node AS-Interface island

■ 8 monostable or 4 bistable valvesor four double 3/2 NC valves, without inputs(island code: A5 or A6)

■ 8 monostable or 4 bistable valvesor four double 3/2 NC valves, with eight inputs(island code: A7 or A8)

Example of configuration

1/14 valve

piloting code (control 14 or return 12)

valve serial number

▼ ▼

20


4.5 CONTROL SIGNALS

■ 5/2 MONOSTABLE VALVE (differential pneumatic return) - Type: M

■ 5/2 BISTABLE VALVE - Type: J

P

0

P

0

24 V

0 V

24 V

0 V

P

0

P

0

24 V

0 V

24 V

0 V

1

1

Port 2

Port 4

Coil 12 electrical signal not required (no coil 12, differential return)

Coil 14 signal (control)

14 1214 2

35

4

1

P = Pressure

These signals can bemomentary or constant untilthe desired state change.

1

Port 2

Coil 12 signal (return)

Port 4

Coil 14 signal (control)

14 1214 2

35

4

1

In Type W1 closed centre 5/3 type, the pressures at 2 and 4 are those that were present on de-energizing coils 12 and 14.2

P

0

P

0

24 V

0 V

24 V

0 V

2

2

W2 (B) W3 (E) W1 (G)

Port 2

Coil 14 signal

Coil 12 signal

Port 4

■ 5/3 VALVE - Types: B - E - G24

35

14 12

1

24

35

14 12

1

24

35

14 12

1

21


■ 3/2 NC MONOSTABLE VALVE - Type: K

P

0

24 V

0 V

P

0

P

0

24 V

0 V

24 V

0 V

P

0

P

0

24 V

0 V

24 V

0 V

Blanked off

14 1214 2

35

4

1

14 1214 2

35

4

1

BISTABLEMONOSTABLE

Port 2

Port 4

Coil 14 signal

Coil 12 signal not required (differential return)

■ 5/2 MONOSTABLE OR BISTABLE VALVE 3/2 NO FUNCTION (blank off port 4)

P

0

P

0

24 V

0 V

24 V

0 V

P

0

P

0

24 V

0 V

24 V

0 V

Blanked off Blanked off

14 1214 2

35

4

1

14 1214 2

35

4

1

MONOSTABLE BISTABLE

Port 4

Coil 14 signal

Coil 12 signal

Port 2

■ 5/2 MONOSTABLE OR BISTABLE VALVE 3/2 NC FUNCTION (blank off port 2)

not required (differential return)

Coil 12B

Port 2B

12B = 14 = control (B)12A = 12 = control (A)

P

0

24 V

0 VCoil 12A

Port 2A

Blanked off

22


5.2 CONNECTION TO POWER SUPPLYConnection to the power supplies made on the front of the island with the black AS-Interface cable and the vampire connector.Connection of the island is immediate, without using screws or stripping any cables, by clipping the adapter in place.

Black AS-Interface cable

Adapter for AS-Interface connectorThe adapter is supplied with the island.

NOTE: When connecting up the island, take care to orientatethe cable and the adapter correctly (the latter is polarizedby differential sizing of the lateral lugs)

■ ■ ■ ■ ■ Connection to power supply unit ■ Connection to island power supply

+_24V =

B

Brown

BluePower

BX

Y

5 AS-Interface version 3.0 NETWORK

5.1 CONNECTION OF AS-Interface BUSThe front face of the AS-Interface-compatible island is equipped with a vampire connector adapter for instant connection, withoutusing screws or stripping the flat yellow AS-Interface bus cable. This is used to carry input sensor data and power.

■■■■■ AS-Interface connection to island

+_

AS-interfaceY

Brown

BlueMaster

Yellow AS-Interface cable

Adapter for AS-Interface connectorThe adapter is supplied with the island.

NOTE: When connecting up the island, take care to orientatethe cable and the adapter correctly (the latter is polarizedby differential sizing of the lateral lugs)

■■■■■ Connection to AS-Interface master

■■■■■ Connection to AS-Interface bus

AS-interface

24V =

MasterAS-

Interface

GatewayY

X

Y

X

B

X

23


5.4 STARTUP OF AS-Interface NETWORK1 - Connect yellow cable2 - Connect black cable3 - Start AS-Interface master

5.5 DIAGNOSTICS

5.5.1 DISPLAY LEDON THE BUSLINK MODULE: The Buslink AS-Interface has 2, 6 or 10 diagnosis LEDs (depending on the version)

• POWER LED lights up as soon as the AS-interface module is powered on and ready for operation.• FAULT LED lights up permanently to indicate a communication error on the AS-interface.

flashes to indicate a fault on the node (e.g. short-circuit of the input supply).• IN1-1 .... IN1-4 4 LEDs (1-node island with 4 inputs) on when all sensors are activated• IN1-1 .... IN2-4 8 LEDs (2-node island with 8 inputs) on when all sensors are activated

5.5.2 DIAGNOSIS REGISTERSee AS-Interface information

5.5.3 FAILSAFE POSITIONThe AS-Interface islands have a reset to zero positionw when the power on AS-Interface yellow cableis shut off

5.6 FUSESThe power supply via the black cable is protected with a fuse (A) in the bus module box. It can be replacedby removing the module from the valves. Remove it with fine-nosed pliers.

Only use fuses of the same type and rating for replacement.

(A) Fuse type 20 x 5 mm, 250V / 1Aset of ten spare fuses (for outputs), code: 88100346

(A)

5.3 PROGRAMMING INSTRUCTIONSRefer to AS-Interface manufacturer manual

5.3.1 ADDRESS ADJUSTMENT

5.3.2 TRANSMISSION SPEED ADJUSTMENTThis is pre-set and given by the master AS-Interface

5.3.3 CONFIGURATION OF THE CONTROLLER CARD WITH THE ISLANDSIn the case of configuration of the AS-Interface network with a built-in AS-Interface coupler in the PLC, the identification codes for aJOUCOMATIC AS-Interface island are the following:

jack femalesocket

Using the jack socket at the front of the AS-interfacemodule allows you to accomplish programming taskswithout having to disconnect the yellow cable. The AS-interface master does not have to be powered off either.

The addressing unit and cable required for programmingare available from your IFM supplier:- Addressing unit: AC1144- Addressing cable: E70213

adressmodule

POWERFAULT

jack plug

M12 plug

island identification code

without input

with input

ID-code

FE88

FE78

Preconfigured addresses:1st node: 22nd node: 4

AS-Interfacemodule

jack plug

24


5.7 ACCESSORIES FOR AS INTERFACE

5.8 DIMENSIONS OF ACCESSORIES FOR AS Interface

INPUTS (M12)Straight single connector: 88100330

INPUTS (M12)Straight duo connector: 88100253

63

M12

Ø 2

0

M12

Ø 2

0

603-5 mm dia.

PG11

4-6 mm dia.

PG7

INPUTS / OUTPUTS (M12 - 90° elbow)88161927

M12x1

Ø 20

35

38

PG 7

Black profiled cable for 24V power supply, length:

1 set of 10 heat-shrinkable end caps for profiled cable endsto ensure IP65 protection

1 set of 10 self-adhesive flat cable mounting clips

Straight duo connector M12 with 5 male pins for 2 inputs Ø3 - 5 mm

Straight mono connector M12 (1 cable Ø4-6 mm) with 5 male pins for inputs

Right-angle mono connector M12 (1 cable Ø4 - 6 mm) with 5 male pins for inputs(rotatable by 180°)

881579408815794188157928

88157927

88157856

88100253

88100330

88161927

Description Code

25 m50 m

100 m

Accessory

Documents

MEGA - AS-Interface version 3 - ASCO | Home - Fluid ... · 2 ASi connection module ... The MEGA-AS-Interface version 3.0 island is provided with individual ... see leaflet P522. COMBINATIONS