Reduced wiring system

(PROFIBUS-DP compliant)

PRODUCT NAME

EX510-GPR1 Series

MODEL/ Series

No.EX##-OMI0032

Table of Contents

Safety Instructions

System configuration

Model no. of product and how to order

3

7

7

8

10

11

EMC directive 11

EX510 GW Unit

12

Installation

Wiring method

Setting

12

13

16

Specification 24

Dimensions 25

SI Unit

26

Installation

Wiring method

Setting

28

29

33

Specification

Dimensions

33

33

Output Unit

35

Installation

Wiring method

Specification

Dimensions

36

37

40

41

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No.EX##-OMI0032

Input Unit

42

Installation

Wiring method

Specification

Dimensions

Procedure

Troubleshoot

Option

43

45

48

48

49

49

50

54

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No.EX##-OMI0032

Safety Instructions

This manual contains essential information to prevent possible injury and damage to (users and other people, and property) and to ensure correct handling.

Please confirm understanding the meaning of the following messages (signs) before reading the remaining the text, and always follow the instructions.

Also carefully read the instruction manual for any relevant equipment or apparatus before use.

Indications

IMPORTANT MESSAGES

Read this manual and follow the 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.

Indicates a potentially hazardous situation which if not avoided, may result in minor injury or moderate injury.

NOTE

Provides helpful information.

Operator

♦

This manual has been written for those who have knowledge of machinery and apparatuses that use pneumatic equipment and have full knowledge of assembly, operation and maintenance of such equipment.

♦

Please carefully read and understand this manual before assembling, operating or performing maintenance on the SI Unit.

Usage Restrictions

♦

This product is designed to be used in general equipment for factory automation. Never use this product with equipment or apparatus that directly concerns human lives*

1

, or in which a malfunction or failure can cause a great loss.

*1:Equipment or apparatus that directly concerns human lives refers to the following:

•

Medical equipment such as life support systems or equipment used in operating rooms

•

Compulsory equipment required by law such as the Fire Prevention Law, Construction Law

♦ and etc.

•

Equipment or apparatus that conforms with those mentioned above.

Contact our sales department when plans are made for the product to be used for the system* public. Such usage requires special consideration*

3

2 including equipment that concerns itself with the safety of persons or that seriously affects the

.

*2:A system or equipment that concerns itself with the safety of persons or that seriously affects the public refers to the following:

•

Nuclear reactor control systems in a nuclear power plants, safety protection systems or other systems important for safety in nuclear power facility

•

Driving control system for a mass transportation system, and flight control systems

•

Equipment or apparatuses that comes in contact with foods or beverages

*3:Special consideration refer to discussing usage with our engineers to establish a safe system designed as fool-proof, fail-safe, redundant and etc.

♦

Special consideration*

4

should be taken regarding safety or maintainability to prevent a failure or malfunction which can cause a hazard or less. That is likely to occur under certain environmental stress (deterioration).

*4:Special consideration means to fully review the equipment or apparatus in design stage and to establish a back up system in advance, such as a redundant system or fail-safe system.

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No.EX##-OMI0032

1.The compatibility of pneumatic equipment is the responsibility of the person who designs the pneumatic system or decides its specifications.

Since the products specified here are used in various operating conditions, their compatibility with the specific pneumatic system must be based on specifications or after analysis and / or tests to meet your specific requirements.

2.Only trained personnel should operate pneumatically operated machinery and equipment.

Compressed air can be dangerous if an operator is unfamiliar with it. Assembly, handling or repair of pneumatic systems should be performed by trained and experienced operators.

3.Do not service machinery / equipment or attempt to remove components until safety is confirmed.

•

Inspection and maintenance of machinery /equipment should only be performed after confirmation of safe locked-out control positions.

•

When equipment is to be removed, confirm the safety process as mentioned above. Cut the supply pressure for the equipment and exhaust all residual compressed air in the system.

•

Before machinery / equipment is re-started, take measures to prevent quick extensions of the cylinder piston rod etc. (Bleed air info the system gradually to create back-pressure.)

4.Contact SMC if the product is to be used in any of the following conditions:

•

Conditions and environments beyond the given specifications, or if product is used outdoors.

Installation on equipment in conjunction with atomic energy, railway, air navigation, vehicles, medical equipment, food and beverage, recreation equipment, emergency stop circuits, press applications, or safety equipment.

•

An application which has the possibility of having negative effects on people, property, or animals, requiring special safety analysis.

♦

Do not disassemble, modify (including printed circuit board changes) or repair.

An injury or failure can result.

♦

Do not operate the product outside of the specification range.

Operation in a range that exceeds the specification can cause a fire, malfunction, or damage to the unit. Verify the specifications before use.

♦

Do not use the product in an atmosphere containing combustible, explosive or corrosive gas.

It can cause a fire, explosion or corrosion.

The unit is not designed to be explosion-proof.

♦

The following instructions must be kept when using the product in an interlocking circuit:

•

Provide double interlocking thorough another system such as mechanical protection

•

Check the product regularly to ensure proper operation

Otherwise a malfunction can cause an accident.

♦

The following instructions must be kept while in maintenance:

•

Turn off the power supply

•

Stop the air supply, exhaust the residual pressure and verify that the atmosphere is released before performing maintenance work.

Otherwise the injury could be caused.

♦

Perform proper functional checks after maintenance work.

Stop operation when an abnormality is observed such as the unit not working properly.

Safety can not be assured due to unexpected malfunctions.

♦

Provide grounding for securing safety and noise resistance of reduced-wiring system.

Individual grounding is provided to the unit closely with short distance.

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No.EX##-OMI0032

NOTE

♦

Follow the instructions given below when handling reduced-wiring system:

To prevent the risk of being damaged and operating failure.

♦

The instructions on selection (installation, wiring, environment of use, adjustment, operation and maintenance) described below must also be followed.

∗

Product specifications

•

The direct-current power supply to combine should be UL authorized power supply.

(1)Limited voltage current circuit in accordance with UL508

A circuit which power is supplied by 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

No load voltage (V peak) Max. current rating (A)

0 to 20 [V] 5.0

Above 20 to 30 [V] 100 / peak voltage

(2)A circuit using max. 30Vrms or less (42.4V peak), which power is supplied by Class-2 power supply unit in accordance with UL1310 or UL1585

•

The reference of power supply for GW unit is 0V for both powers for output and control of GW unit.

•

Operate reduced-wiring system within the specified voltage.

Operation with a voltage beyond specifications could cause malfunction or damage of the unit.

•

Reserve a space for maintenance

Be sure to keep a space for maintenance when designing layout of the unit.

•

Do not remove nameplate.

Otherwise maintenance error and misreading of an operation manual could cause damage or malfunction.

It may also result in nonconformity to safety standards.

♦

Precautions on handling

∗

Installation

•

Do not drop, hit or apply excessive shock to the unit.

Otherwise the unit could be damaged so much as to result in.

•

Follow the specified tightening torque.

Excessive tightening torque can break screws.

The screw should be tighten with the specified torque, otherwise IP65 protection can not be guaranteed.

∗

Wiring (including plugging in/out of connector)

•

Do not bend the cables or apply excessive force to them by pulling or placing heavy load.

Wiring subject to bending or tensile stress could cause the cables to break.

•

Connect wires and cables correctly.

Incorrect wiring could break the reduced-wiring system to its extent.

•

Do not connect wires while the power is supplied.

Otherwise it can break the reduced-wiring system or I/O devices could be damaged or malfunction.

•

Do not connect power cable or high-voltage cable in the same wiring route as the unit.

Otherwise the wires to the reduced-wiring system can be interrupted with noise or induced surge voltage from power lines or high-voltage lines and malfunction could be caused.

Separate wiring of the unit and each I/O device from that of power line and high voltage line.

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No.EX##-OMI0032

•

Verify the insulation of wiring.

Insulation failure (interference with other circuit, poor insulation between terminals and etc.) could introduce excessive voltage or current to the reduced-wiring system or each I/O device and damage them.

•

Separate power line for solenoid valves from power line for input and control unit.

Otherwise wires can be interrupted with noise or induced surge voltage causing malfunction.

•

Take proper measurements such as noise filter against noise when the reduced-wiring system is incorporated in equipment or devices.

Otherwise contamination with noise can cause malfunction.

∗

Environment

•

Consider operating environment suitable for protection class.

•

Take sufficient shielding measures when the unit is installed.

Insufficient measures could cause malfunction or failure.

Verify the effect of the measures after incorporation of the unit in equipment or devices:

(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 unit near by a place where electric surge is generated.

Internal circuit elements of the reduced-wiring system can deteriorate or break when equipment generating a large surge (electromagnetic lifter, high frequency induction furnace, motor, etc.) is located near the reduced-wiring system. Provide surge preventives, and avoid interference with line for the equipment.

•

Use the reduced-wiring system equipped with surge absorber when a surge-generating load such as solenoid valve is driven directly.

Direct drive of a load generating surge voltage can damage reduced wiring system.

•

Prevent foreign matter such as remnant of wires from entering the unit.

Take proper measures for the remnant not to enter the reduced-wiring system in order to prevent failure or malfunction.

•

Do not expose the reduced-wiring system to vibration and impact.

Otherwise failure or malfunction could be caused.

•

Keep the specified ambient temperature range.

Otherwise malfunction could be caused.

Do not use reduced-wiring system in a place where temperature suddenly changes even within the specified range.

•

Do not expose the reduced-wiring system to heat radiation from a heat source located nearby.

Malfunction could be caused.

∗

Adjustment and Operation

•

Use precision screwdriver with for small flat blade for setting Rotary switch.

∗

Maintenance

•

Perform maintenance and check regularly.

Otherwise an unexpected malfunction of components could of the unit occur due to a malfunction of the whole unit.

•

Perform a proper functional check.

Stop operation when an abnormality is observed such that the device doesn't work properly.

Otherwise an unexpected malfunction of the unit component can occur.

•

Do not use solvents such as benzene, thinner or other to clean the reduced-wiring system.

They could damage the surface of the body and erase the indication on the body.

Use a soft cloth to remove stains. For heavy stains, use a cloth soaked with diluted neutral detergent and fully squeezed, then wipe up the stains again with a dry cloth.

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No.EX##-OMI0032

Product Summary

System structure

•

Capable of decentralized control of 64 input points / 64 output points.

Decentralized control of 4 input branches (max. points of 16

×

4 branches) and 4 output branches

16

×

4 branches) per one GW unit is possible.

•

Easy setting and wiring

Slave side does not need switch settings, but GW unit needs them such as address setting.

It is possible to adjust length of branch cable and crimp branch cable without dedicated tool.

Each slave does not need individual power supply because the branch cable is 4-core flat cable including a power supply line.

•

Compact design

Small and compact design is applied for all of GW unit which realizes decentralized control, Input unit which connects input equipments such as sensor, and SI unit which connects output equipment such as solenoid valve.

•

Flexible setting of number of occupied station

Utilize I/O point effectively by setting number of occupied station of GW unit.

•

Applicable to each type of solenoid valves

SMC’s solenoid valves can be easily wired for serial communication.

(See Manifold Valve for applicable valve.)

The extra output of SI unit can be used to actuate 2-port valve etc, with a cable assembly for output.

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No.EX##-OMI0032

Terminology definition

No. Term Definition

2 Field bus communication line by aligning them in line.

A standard which uses digital communication to transmit a signal between an equipment running at factory and field (instrumentation and operation equipment) and controller.

3 PROFIBUS-DP

Fieldbus jointly developed by Siemens, Bosch, ABB, etc. in Germany in 1980’s.

PNO (PROFIBUS Nutzerorganisation e.V) starts for the PROFIBUS-DP spread.

4 PLC(Programmable

An abbreviation of Programmable Logic Controller. It controls timely along with a

5 Manifold

6 GW unit

7 SI unit

8 Enclosure (IP)

9 Branch wiring

10 DIN rail program for logic algorithm, sequential operation and arithmetic operation.

A component used to join many valves into one.

A unit used to connect protocols conforming with different standards in one network.

In this system, it is regarded as a unit to adjust between PROFIBUS-DP protocol and

SMC dedicated protocol and connect them.

An abbreviation of serial interface. It sends and receives data by bit through a couple of signal lines, convert it to parallel and correspondingly control connected load. (A serial-to-parallel converting unit)

An abbreviation of Ingress Protection. It is a standard related to protection of a product from foreign matters (hand, steel ball, steel wire, dust, water etc.).

A method to branch and connect a communication line and signal line from GW unit to SI unit and input unit.

A metallic rail conforming with DIN (German Federation) standard. prevents reflection of a signal at the end and subsequent disturbance of the signal.

A connecting part to transmit a communication signal which goes and returns between equipments in field bus.

A connecting part to apply power to a product.

14 Input point

15 Output point

The number of point which can receive information from an input equipment (sensor, switch etc.).

The number of point which can operate an output equipment (solenoid valve, light and motor starter etc.)

An output configuration of an input equipment which uses NPN transistor for signal outputting part. It sinks current with input and that is the reason why it is called sink.

17 Current source type

An output configuration of an input equipment which uses PNP transistor for signal

18 NPN output

19 PNP output

20 PE

21 FG

22 GND

23 LED

24 BF

25 DIA

27 Rated voltage outputting part. It sources current with input and that is the reason why it is called source.

An output configuration which operates an output equipment by using NPN transistor.

Referred to as positive common type because positive potential is applied to common wire of power supply.

An output configuration which operates an output equipment by using PNP transistor.

Referred to as negative common type because negative potential is applied to common wire of power supply.

An abbreviation of protective Earth. It is a ground to drop a hazardous voltage which is generated on a case (metallic conductive part) due to breakage of internal circuit

(to prevent electrical shock).

An abbreviation of frame ground meaning a body ground. Used to show a ground simply.

An abbreviation of ground meaning reference voltage for signal. It has a same potential level as a shield wire (sheath) of signal line and connector and is referred to as a reference potential to transmit an electrical signal.

An abbreviation of Light Emitting Diode meaning a kind of semiconductor element which emits light when current is applied.

Abbreviation of BUS FAULT. It shows the communication of the GW unit.

Abbreviation of Diagnosis. It shows the GW unit status.

A connection port to distribute a communication line and signal line from GW unit to

SI unit and input unit.

A optimum value of power supply voltage applied to a product. It can ensure normal operation of a product with this voltage in specified operating environment.

A range of power supply voltage to operate a product normally.

A current necessary to operate a product normally. In this case, the current applied to a load is not included.

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No.EX##-OMI0032

No.

38

Term

31 Short protection

33 SYNC function

35 ID number

36 GSD file

37 Class 2 master

Enhancing diagnosis information

40 Impedance

41 Data rate

Definition

A speed at which data is sent and received in field bus etc. It depends on an equipment (PLC etc.) at high side and is indicated by bps (bit per second).

A method to protect an internal circuit from being damaged when power supply and

GND terminal are shorted.

A number allocated to identify the unit connected on the PROFIBUS-DP network. It is not allowed to be duplicated.

A function that the output data of the GW unit synchronizes with the SYNC command from the master. master.

Number of 16bit allocated from PNO to identify product.

File which describes the master data of product.

Master for control, commissioning, and configuration functions.

Diagnosis information from GW unit. It is composed of standard diagnosis information provided with PROFIBUS-DP and peculiar diagnosis information to the GW unit.

Normally, indicated by dB/ft (decibel per feet).

A resistance generated when alternating current is applied to a circuit. Referred to as alternating current resistance.

An amount of data which can be sent from one equipment to the other equipment.

Referred to as transmission speed of data.

A electric resistance of a conductor. It is a value to show ease of current flow.

A method for insulation by converting an electric signal to an optic signal once and using an element called opt-coupler which shows “1” and “0” when turned on and off.

An opt-coupler has a part to convert an electric signal to an optic signal or opposite of it and so can be separated electrically and insulated.

45 Input delay time Refer to “Transmission delay”.

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No.EX##-OMI0032

Model no. of product and how to order

*For the detail of part no. of solenoid valve manifold and independent solenoid valve with SI unit, refer to Operation Manual or other equivalent documents of used solenoid valve.

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No.EX##-OMI0032

Common Specification

EX510 series common specification

Item

Rated voltage 24VDC

Allowable instantaneous electrical stop 1msec. or less

Protection class

Applicable standard

IP20

UL / CSA, CE

Specification

Withstand voltage

Insulation resistance

Ambient temperature

Ambient humidity

Vibration resistance

Impact resistance

500VAC 1min. (between PE and external terminal block)

10M

Ω

or more

(500VDC is given between PE and external terminal block)

Operating: -10 to 50

°

C Storage: -20 to 60

°

C

35~85%RH (No dew condensation)

10 to 57Hz (constant amplitude) 0.35mm

57 to 150Hz (constant acceleration) 50m/s

2

2 hours for each direction, X, Y and Z

(comply with JIS B 3502 and IEC61131-2)

147m/s

2

is given 3 times for each direction, X, Y and Z

(comply with JIS B 3502 and IEC61131-2)

Operating environment No corrosive gas

EMC directive (89/336/EEC)

EN61000-6-2: 2001, EN55011: 1998+A1+A2

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No.EX##-OMI0032

Installation

EX510 GW unit

Parts and functions description

No. Parts

1 Communication socket (BUS)

2 Power supply socket (PWR(V))

3 Power supply socket (PWR)

Purpose

Connect to PROFIBUS-DP line with a communication connector for

PROFIBUS-DP ( ). Connect a terminating resistor ( ) to both end units of a transmission route.

Supplying power for output instruments such as a solenoid valve with a power supply connector ( ).

Supplying power for controlling GW and for input instruments such as a sensor with a power supply connector ( ).

4

5

GW unit side branch connector

(for input)

GW unit side branch connector

(for output)

6 PE terminal

7 Mounting hole

8 DIN rail mounting slot

9 Display / switch setting part

Mounting/Installation

Connecting an input unit etc. by using branch cables (EX510-FC ).

Connecting SI unit (manifold valve) etc. by using branch cables

(EX510-FC ).

Used for grounding.

Used when an unit is mounted with two M4 screws.

Used when an unit is mounted to DIN rail.

Sets up the switch on such as LED display and address, I/O points.

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No.EX##-OMI0032

Wiring method

Internal circuit and wiring

The wirings are described in the following order.

1.Communication wiring:

Connection with PROFIBUS-DP

↓

2.Power supply wiring:

Connections of power supplies for output and input devices and controlling GW

↓

3.Branch wiring:

Connection from GW unit to SI unit or Input unit

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No.EX##-OMI0032

1.Communication wiring

The method to connect a PROFIBUS-DP detected cable and a GW unit PROFIBUS-DP communication connector is shown below.

Connecting cable

•

Make sure to connect the signal cables to designated pins (Refer to Fig.1).

•

Be sure to connect a terminating resistor to both

ends of transmission line. (Refer to Fig. 2).

Tighten the connector securely to 0.5 to 0.6Nm tightening torque.

Connecting terminating resistor

•

Be sure to connect a terminating resistor to both ends of transmission line (Refer to Fig. 3).

Tighten the connector securely to 0.5 to 0.6Nm

tightening torque.

•

The terminating resistor to be used differs depending on the specification of the cable. The following terminal resistance value is based on the specification of type A cable.

2. Power supply wiring

Connect power supply wiring to the two power supply 2-pin connectors. Power supply consists of

2 systems, but they it can be used with both of single power supply and separate power supplies.

Also, other units do not need individual power supply. Make sure of connection with the designated pin. Tighten the connector securely to 0.5 to 0.6 N

.

m tightening torque. Refer to Fig.4 about how to connecting.

When SI unit etc. (EX510-S 0 ) is used besides the external power supply type output unit, it is necessary to supply power for output to the GW unit and the output unit.

NOTE: Connect a ground cable of 100 ohm or less to PE terminal.

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No.EX##-OMI0032

3. Branch wiring

Each unit is wired with a branch cable, and connected with a branch connector.

Two branch connectors are attached to each of SI unit and Input unit.

Pressure welding for branch connector

The method of pressure welding for branch connector is explained.

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No.EX##-OMI0032

Wiring of branch cables

How to connect branch cable is shown below.

Connect the branch connectors for GW unit in order from the bottom one (COM A, B, C, and D).

Setting

Display for setting

Display Contents

PWR(V)

RUN

The power for output is supplied at specified voltage : Lights up

The power for output is not supplied at specified voltage : Goes off

The power for input and GW unit controlling part is supplied: Lights up

The power for input and GW unit controlling part is not supplied: Goes off

DIA

*1

DIA error: Lights up

Normal DIA: Goes off

BF

PROFIBUS-DP communication error: Lights up

Normal PROFIBUS-DP communication: Goes off

COM A is receiving data : Lights up

*2

COM A

COM A is having no data to receive : Goes off

COM B is receiving data : Lights up

*2

COM B

COM B is having no data to receive : Goes off

COM C is receiving data : Lights up

*2

COM C

COM C is having no data to receive : Goes off

COM D is receiving data : Lights up

*2

COM D

COM D is having no data to receive : Goes off

*1 DIA LED lights up in red when the input unit connected to the input port (COM A-D) is not in a normal status (open fuse, broken wire, miswiring, loosening of joint of the branch cable) or the input unit is not connected. DIA LED does not light up in red if the input unit is connected to the unused input port.

*2 Only when Input is connected and communicated normally.

COM A-D LED does not light up if the port is not set to be

“used” by input point setting.

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No.EX##-OMI0032

Switch setting

NOTE

1. Open the cover, and set DIP switch with a flat blade driver, etc.

2. Make sure that switch setting is performed with power supply turned off.

3. Be sure to perform this setting of the switch before use.

1.Setting of Address

.

UNIT STATUS

.

HOLD/CLR

Setting of address is performed with SW1.

.

HW/SW mode (SW1)

•

Address setting (Switch No.1 to 7)

All setting are turned OFF at shipment and the Address is set to 0.

Make sure to set the Address within the range of 0 to 125.

ADDRESS

64(No.1) 32(No.2) 16(No.3) 8(No.4) 4(No.5) 2(No.6) 1(No.7)

0 OFF OFF OFF OFF OFF OFF OFF

1 OFF OFF OFF OFF OFF OFF ON

2 OFF OFF OFF OFF OFF ON OFF

3 OFF OFF OFF OFF OFF ON ON

4 OFF

: : : : : :

OFF OFF

: :

24 OFF OFF ON ON OFF OFF OFF

25 OFF OFF ON ON OFF OFF ON

: : : : : : : :

125

126

127

ON ON ON ON ON OFF

ON

ON ON ON ON ON ON OFF

ON ON ON ON ON ON ON

*Setting of 126 and 127 are invalid.

•

UNIT STATUS setting (Switch No.8)

The setting is as follows.

Refer to P.18 for detail.

At the time of shipment from the factory, the switch is set to off and the GW unit status information is not sent to master side as an input data.

UNIT STATUS

OFF

No.8 Function

OFF The GW unit status information is not sent to master side as an input data.

*If the address setting is turned on, an input setting for PLC is required.

•

HOLD/CLR setting (Switch No.9)

The setting is as follows.

The setting at shipment is turned OFF, set to CLR.

HOLD/CLR

CLR

No.9 Function

OFF Output is cleared when an communication error occurs.

HOLD

ON

Output is held when an communication error occurs.

*HOLD/CLR setting is made available per one point by parameter setting.

Refer to P.21 for detail.

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No.EX##-OMI0032

•

HW/SW mode setting (Switch No.10)

The setting is as follows.

Refer to P.22 “Supplementary explanation“ for detail.

The setting at shipment is turned OFF, set to HW mode.

Mode

HW

SW

No.10

OFF

ON

Set Address with No.1 to 7 (SW1).

Function

Addresses are set by network. Class 2 master is required for the setting via network. It is set at 126 when delivery .

* No.1 to 7 (SW1) are ignored.

Supplementary explanation

•

UNIT STATUS

Enhanced diagnosis information is prepared for PROFIBUS-DP to monitor the slave status between master and slave. The GW unit sends the master error condition as diagnosis information when entering states other than the normal, and the DIA display lights at the same time.

The self-diagnosis functions of this product are as follows.

Function Contents

Solenoid valve open fuse surveillance

Surveillance of solenoid valve power supply voltage

Input unit open fuse surveillance

It detects when the fuse for valve in the GW unit is broken.

It detects when the voltage of the solenoid valve lowers to approximately 19V or less.

It detects when the fuse of the input unit is broken and the power source to the sensor is OFF.

Diagnosis information is composed of 11 bytes. The first seven bytes are information provided by

PROFIBUS, and the other four bytes are peculiar information to the unit.

Please refer to PROFIBUS specifications and the manual of the master etc. for how to refer to diagnosis information on the master side.

The composition of diagnosis information is as follows. The value when it is normal is indicated: X is changeable.

Byte0 : Station Status 1

Bit 7 0

0 0 0 0 X 0 0 0

Diag. Master_Lock

“1” when SI unit is set as the other master

Diag. Prm_Fault

“1” when the parameter regarding the slave is wrong

Diag.

Invalid_Slave_Response

“1” when the response from, the slave is wrong

Diag. Not_Support

“1” when the diagnosis is not supported

Diag. Station_Non_Existent

“1” when SI unit is not recognized by the master

Diag. Station_Not_Ready

“1” when the unit is not prepared for data transmission

Diag. Cfg_Fault

“1” when the SI unit configuration information transmitted from the master is wrong

Diag. Ext

Indicates the status of enhanced diagnosis region (bytes 6 to 12)

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No.EX##-OMI0032

Byte1 : Station Status 2

Bit 7 0

0 X X X 0 1 0 X

Diag. Deactivated

“1” when SI unit is stopped

“1” when Sync command is received

“1” when Freeze command is received

Reserved

Diag. Sync_Mode

Diag. Freeze_Mode

Diag. Prm_Req

“1” when the SI unit setting is rewritten by the master

Diag. Stat_Diag

“1” when it has a diagnosis error

Diag. WD_on

The watchdog is in active state

Byte2 : Station Status 3

Bit 7 0

0 X X X X X X X

Diag. Ext_Overflow

“1” when the enhancing diagnosis data causes overflow

Byte3：Diag.Master_Add

Indicates the master address.

Byte4,5：Ident_Number

Indicates ID No. of SI unit.

Byte6：Diag.Header

Indicates how many bits the enhancing diagnosis data has (fixed value).

Byte7：GW unit diagnosis information

Bit 7 0

0 0 0 0 0 0 0 0

SOLV (F)

“1” when the fuse for valve is broken.

SOLV

Reserved

“1” when the solenoid valve power voltage decreases.

Reserved

-19-

No.EX##-OMI0032

Always “1” and status for output power source SOLV(F) and SOLV are invalid when equipment connected to GW are all output unit with external power source for all 4 ports (EX510-DY4) and no power for output is supplied to the GW.

Byte8：GW unit diagnosis information

Bit 7 0

0 0 0 0 0 0 0 0

“1” when COM D port of the output unit is abnormal

“1” when COM C port of the output unit is abnormal

“1” when COM B port of the output unit is abnormal

“1” when COM A port of the output unit is abnormal

“1” when COM A port of the input unit is abnormal

“1” when COM B port of the input unit is abnormal

“1” when COM C port of the input unit is abnormal

“1” when COM D port of the input unit is abnormal

Byte9 ∼ Byte10：Reserved（all 00h）

-20-

No.EX##-OMI0032

•

Precautions for setting with SIMATIC STEP7

When UNIT STATUS setting for DIP_SW1 is ON, select Unit Status from the EX510-GPR1 in the hardware catalog and add the enhanced diagnosis information to the module to be used.

* PLC software STEP7 manufactured by Siemens AG is shown above. STEP7 is a registered trademark of Siemens AG.

•

HOLD/CLR

When HOLD/CLR setting is to be done in every point for the parameter allocation setting of the module, it can be set for every valve from the slot “1” in the following screen.

2 : HOLD/CLR setting for every valve can be done.

1 : Click the OUTPUT.

* PLC software STEP7 manufactured by Siemens AG is shown above. STEP7 is a registered trademark of Siemens AG.

-21-

No.EX##-OMI0032

•

HW/SW mode

How to remove the exchange number change prohibition

When the exchange number change is set to be prohibited for the class 2 master, take the procedure below to cancel the setting.

1. Set up the address at 127 (turn the 1-7th bit of DIP_SW on) in HW mode.

2. Turn the power source (power source for communication) ON.

(Turn the power source for micro computer ON.)

3. Set the address at 126. (Turn the 7th bit of DIP_SW1 OFF.)

(Operation becomes invalid unless it is set within 10 seconds.)

4. Check that the RUN_LED blinks.

5. Turn the power source (power source for communication) OFF.

2.Flexible setting of I/O point (SW2)

I/O point can be changed with SW2.

Input setting (switch No.1 to 3)

The setting at shipment is turned OFF, set to 64.

No.1

OFF

No.2

OFF

No.3

OFF

Input point COM A COM B COM C COM D

64 16 16 16 16

OFF

OFF

OFF

ON

OFF

ON

ON

OFF

ON

OFF

ON

OFF

0 - - - -

16 8 8 - -

24 8 8 8 -

32 8 8 8 8

ON

ON

OFF

ON

ON

OFF

ON

ON

ON

It cannot be set to 0 for input and output point.

48 16 16 16 -

Reserve

Output setting (switch No.4 to 6)

The setting at shipment is turned OFF, set to 64.

No.4 No.5 No.6

Output point

COM A COM B COM C COM D

OFF OFF ON

OFF

ON

0 - - - -

OFF 16 8 8 - -

OFF

ON

ON

ON

ON

OFF OFF 32

OFF

ON

ON

ON

OFF

24 8 8 8 -

8 8

Reserve

8 8

48 16 16 16 -

ON ON ON

It cannot be set to 0 for input and output point.

-22-

No.EX##-OMI0032

3.Setting I/O Memory map

GW unit occupies memory area as follows according to the number of I/O point set up on the front page.

Ex.) Input point : 64, Output point : 64 (Setting at shipment)

In case of the input data, the sensor signal data of the Input unit which was connected with the COM A port, occupies "Word (a)" of the input area.

If a sensor signal is stored in the "0 bit" of the Input unit, it becomes like the figure below.

In the same way, in the case of the output data, the contents displayed in "Word (c)" of the output area.

•

Memory map of input data

Input area

Branch connector

(INPUT)

Data(2 byte)

MSB LSB MSB LSB

15 8 7 0 byte (b+1) byte (b) byte (b+3) byte (b+5) byte (b+7) byte (b+2) byte (b+4)

: :

byte (b+6)

(a,b=0 to)

•

Memory map of output data

Input area

Branch connector

(INPUT)

Data(2 byte)

MSB LSB MSB LSB

15 8 7 0 byte (d+1) byte (d+3) byte (d) byte (d+2) byte (d+5) byte (d+7) byte (d+4) byte (d+6)

: :

NOTE

Read carefully the user manual of PLC which is used as a master.

The method of PLC setup, reading from or writing to memory differ from one PLC manufacturer to another.

(c,d=0 to)

-23-

No.EX##-OMI0032

Specification

Specification

•

Basic specification

Rated voltage

Power supply voltage

Rated current

24VDC

Power supply for input and controlling : 24VDC

±

10%

Power supply for output : 24VDC+10% / -5%

(Warning for voltage drop is given at approx. 20V)

Power supply for input and controlling : Max.4.1A

Inside GW unit: 0.1A

Input unit: 4A

Power supply for output : Max. 6A

Input/Output point Input point : Max.64 / Output point : Max.64 (Changeable by switch settings)

•

Higher-level bus

Bus interface

Freeze function

Synchronous function

Address setting range

EIA RS-485

Available

Available

0 to 125

ID No.

Device data file

140d HEX

GSD file *

* This file is necessary for automatic device setting.

•

Lower-level bus

Number of branches for input/output 4 branches for input, 4 branches for output

Communication type

Communication protocol: dedicated for SMC

Communication speed: 750kbps

Current for input branch* Maximum 1 [A] per branch

Current for output branch

Branch cable length

Maximum 1.5 [A] per branch

Within 20m (See diagram below for details.)

*Maximum value in total of current consumption and load current of connected input equipments.

•

Transmission speed

PROFIBUS-DP communication line uses a twist pair cable with a shield. The maximum cable length is determined by transmission speed. Also, the specifications of the cable length is based on type A cable.

•

Network length

Communication speed [kbps]

Max. cable length [m]*

Communication speed [kbps]

9.6

500

19.2

1500

1200

45.45

3000

93.75

6000

187.5

1000

12000

Max. cable length [m]* 400 200 100

*Maximum cable length differs depending on the specifications of a cable. The above cable length is based on type A cable.

•

Cable specification

Impedance

Capacitance between conductors 30pF/m or less

Conductor resistance 110

Ω

/km or less

Cable diameter

Conductor area

135 to 165

Ω

0.64mm or more

0.34mm

2

or more

-24-

No.EX##-OMI0032

Dimensions

•

GW unit (EX510-GPR1)

-25-

No.EX##-OMI0032

SI unit

Parts and functions description

SI unit is the unit to be combined with manifold solenoid valves to communicate with GW unit. It can be used with a plug lead type and plug in type solenoid valves.

Single solenoid valve can be operated by using empty ports. (Only for EX510-S 01 )

-26-

No.EX##-OMI0032

No. Parts

1 Branch connector at Output unit

2 Load mounting connector

5 Mounting hole

6 Connector locking pin inserted hole

Purpose

Used to crimp branch connector ( ) into branch cable

(EX510-FC ) and connected them to GW unit.

Connecting output equipment such as solenoid valve.

Lights up: Power ON (Normal)

Goes off: Power OFF

Lights up: Data received

Goes off: No data received

Used to mount the unit with two M3 screws.

Receiving connector locking pin ( ).

Possible to mount on DIN rail. (Only for EX510-S 02 )

8 Adapter cable assembly Connects a plug-in valve manifold.

NOTE

Only mounting direction of the SI unit to the mounting bracket is different between

EX510-S A and EX510-S B. Mounting direction can be changed from horizontal to vertical by changing the screws which construct the mounting bracket. Mounting direction of the EX510-S 02C cannot be changed to vertical as the its mounting bracket is exclusive for horizontal mounting.

-27-

No.EX##-OMI0032

Mounting/Installation

Installation method

Each SI unit is mounted and removed as shown on the following figure.

-28-

No.EX##-OMI0032

Wiring method

1.Internal circuit

-29-

No.EX##-OMI0032

-30-

No.EX##-OMI0032

2. Wiring of the branch cable and connector for connecting load (Connector for connecting load: Applicable only to EX510-S 01 )

•

Wiring of branch cables and load mounting connector are shown below.

(Insert load mounting connector with pinsette. After insertion at all load mounting connectors is completed, insert connector locking pin. The output no. of each load mounting connector can be found on the below.

*For crimping of a branch connector, refer to page 15.

(Load connecting connector pin assignment (EX510-S 01 )

EX510-S001

No.

Name

Function

4 COM

CN0 CN1 CN2 CN3 CN4 CN5 CN6 CN7

Load actuating common (+)

3 Output OUT2 OUT4 OUT6 OUT8

2 Output OUT3 OUT5 OUT7 OUT9 OUT11 OUT13 OUT15

1 COM Load actuating common (+)

EX510-S101

No. Function

Name

CN0 CN1 CN2 CN3 CN4 CN5 CN6 CN7

4 COM OUT0 OUT2 OUT4 OUT6 OUT8 OUT12 OUT14

3 Output (n)

2 Output (n+1)

Load actuating common (

−

)

Load actuating common (

−

)

1 COM OUT1 OUT3 OUT5 OUT7 OUT9 OUT13 OUT15

-31-

No.EX##-OMI0032

•

Output connector(MIL20pin) pin assignment(EX510-S 02 )

EX510-S002

Terminal 1 3 5 7 9 11 13 19

Output No.

0 2 4 6 8 10 14 - 24V

Terminal 2 4 6 8 10 12 14 16 18 20

Output 15 - 24V

EX510-S102

Terminal 1 3 5 7 9 11 13 19

Output 0 2 4 6 8 10

Terminal 2 4 6 8 10 12 14 16 18 20

Output 15 - 0V

Note : Only a flat cable type manifold (P kit) can be connected to EX510-S 02 . It cannot be connected to PCW type (G/J kit) according to the different pin assign.

Use of remaining output (Only for EX510-S 01 )

Remaining output of SI unit can be used by using a cable assembly for output. (Refer to the figure below.)

Refer to “SI unit specification” on page 33 for the load current restriction of SI unit.

Power consumption of each valve series is shown in the table below.

Refer to the catalog of each valve series for detail.

Valve series Power consumption

SY3000 / 5000 / 7000 /

9000

SYJ3000 / 5000 / 7000

Standard : 0.4W (approx. 17mA)

With power saving circuit : 0.1W (approx. 4mA)

Standard : 0.4W (approx. 17mA)

With power saving circuit : 0.1W (approx. 4mA)

VQZ1000 / 2000 / 3000

Standard : 1.0W (approx. 42mA)

Low wattage : 0.5W (approx. 21mA)

Refer to “Wiring of the diversion cable and connector for connecting load” on page 31 for how to wire the cable assembly for output.

NOTE

Do not pull the cable assembly for output strongly. It can cause defective connection or broken wire.

-32-

No.EX##-OMI0032

Setting

•

Setting of display

Display

Power supply LED

Communication

LED

Contents

Lights up: The power for output is supplied at specified voltage.

Goes off: The power for output is not supplied at specified voltage.

Lights up: Data is being received from a GW unit

Goes off: No data is being received.

Specification

Specification

•

SI unit specification

Item

Model No.

Output type

Number of output points

Rated load voltage

Maximum load current

Protection

Specification

EX510-S001 , EX510-S002 EX510-S101 , EX510-S102

NPN output(Sink type) PNP output(source type)

16 points

24VDC

Meet the three following conditions

0.25A or less/1 point 1.4A or less/1 unit Total current of OUT0 to

OUT7:1A or less, Total current of OUT8 to OUT15:1A or less

Built-in protection circuit for short circuit

Current consumption 50mA or less (inside of SI unit)

Weight

EX510-S 01:40g EX510-S 01A,B:80g EX510-S 02:50g

EX510-S 02A,B,C:90g (including accessories)

•

Applicable solenoid valve series

The following manifold valve can be used for EX510 series.

Valve series

SY

Model No.

3000, 5000, 7000, 9000

Refer to the catalogs and Technical Specification of each valve series for solenoid valve and manifold, etc.

Dimensions

•

EX510-S

•

EX510-S 01A

•

EX510-S 02A

-33-

No.EX##-OMI0032

Setting

Dimensions

•

EX510-S

•

EX510-S 02A

•

EX510-S

•

EX510-S 02C

Refer to the catalogs and Technical Specification of each valve series for dimensions of the manifold valve.

-34-

No.EX##-OMI0032

Output unit

Parts and functions description

No.

1

2

4

Parts Application

Branch connector at

Output unit

Used to crimp branch connector ( ) into branch cable (EX510-FC and connected them to GW unit.

Output terminal block

Used to connect output load, etc.

LED

Lights up : Power ON (normal)

Goes off : Power OFF

Communication

LED

Lights up : Receiving data

Goes off : No communication data

Lights up : Output signal ON

Goes off : Output signal OFF

6 Fuse Fuse is replace cable.

7 Mounting slot

8 Mounting hole

9 Cover

10

Terminal block for external power supply

Used to mount DIN rail on the unit.

The unit is mounted by two M4 screws.

Used to protect cable and provided with marker plate ( ) on the top.

Used to supply power.

(EX510-DYN4, EX510-DYP4)

-35-

No.EX##-OMI0032

Mounting/Installation

Installation method

Mounted by screw

Mounted on DIN rail (Common for EX510-DX 1 and 2)

Put claw 1 at the body under DIN rail and push it upward. Push down claw 2 to the opposite rail unit the claw clicks to be set stably. (Mounting procedure and )

For removing, push up DIN rail fixing plate at the body with a flat screwdriver, and remove it by tilting claw 2 side forward. (Removal procedure and )

-36-

No.EX##-OMI0032

Wiring method

1. Internal circuit

EX510-DYN3 : Output unit for NPN (Internal power supply type)

EX510-DYN4 : Output unit for NPN (External power supply type)

-37-

No.EX##-OMI0032

EX510-DYP3 : Output unit for PNP (Internal power supply type)

EX510-DYP4 : Output unit for PNP (External power supply type)

-38-

No.EX##-OMI0032

2. Branch wiring

Output unit and GW unit are connected with branch cable and branch connector.

SI unit and Output 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 #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 the body tentatively

Fit 4 latches on the body to 4 ditches on the cover, and press them until the latch engages to the level 1.

Press fitting

Press the cover to the body with pliers etc.

Confirmation

It is completed with check on 4 latches engaging.

Wiring of load electric wire and terminal block connector

•

Insert flat blade watch driver from slots on a terminal block connector to the end position.

•

Hold clamping part opened with a blade of the driver.

•

Insert electric wire into a clamping unit of a terminal block and pull the driver to finish wiring.

•

Applicable electric wire size is 0.08 to 1.5mm

2

(AWG

16 to 28).

•

Wire sheath stripped length is 5 to 6mm.

•

Too long stripped length might expose conductor and cause insulation failure, and too short stropped length might get the sheath caught or make the conductor unclamped or clamped improperly resulting in contact failure or disconnection of electric wire.

•

The flat blade watch driver shall have 2.5mm x

0.4mm blade end width and hold the clamp opened.

-39-

No.EX##-OMI0032

The terminal block connector can be connected with the following electric wires.

•

Solid wire, fine stranded wire, stranded conductor ultrasonically bonded, stranded conductor with ferrule, stranded conductor with pin terminal.

Wiring of power supply line and terminal block for external power supply.

•

Applicable electric wire size is 0.14 to 1.5mm

2

(AWG 16 to 26).

•

Wire sheath stripped length is 4 to 6mm.

•

Too long stripped length might expose conductor and cause insulation failure, and too short stripped length might get the sheath caught or make the conductor unclamped or clamped improperly resulting in contact failure or disconnection of electric wire.

•

The flat blade watch driver shall have 2.5mm x 0.4mm blade end width and hold the clamp opened.

•

Tightening torque for terminal block : 0.22Nm at minimum.

Maximum load current

Internal power supply type (EX510-DYN3, DYP3)

•

The following three requirements shall be satisfied. : 1) 0.5A or less per point. or

3) Total current from OUT0 to 7 and from OUT8 to 15 is 1A

respectively.

External power supply type (EX510-DYN4, DYP4)

•

The following three requirements shall be satisfied. : 1) 0.5A or less per point. or

3) Total current from OUT0 to 7 and from OUT8 to 15 is 1.5A

respectively.

For the load to the light, place an in-rush current restriction resistor to prevent potential fusing due to in-rush current.

Specification

Specification

Item

Model No.

Output type

Rated load voltage

Power supply type

Specification

EX510-DYN3

NPN

EX510-DYP3

PNP

EX510-DYN4

NPN

EX510-DYP4

PNP

24VDC

Internal power supply (from GW unit)

External power supply (from power supply connector)

Power supply connector acceptable electric wire

Output point

Output connector type

Acceptable electric wire

Maximum load current

- 0.14∼1.5mm

2

( AWG16∼26 )

16

Cage clamp type

0.08 to 1.5mm

2

( AWG16 to 28 )

The following three requirements shall be satisfied.

1) 0.5A or less per point.

2) 1A or less per unit.

3) Total current from OUT0 to 7 is 1A respectively.

The following three requirements shall be satisfied.

1) 0.5A or less per point.

2) 3A or less per unit.

3) Total current from OUT0 to 7 is 1.5A respectively.

Current consumption 50mA or less (Internal unit)

•

Applicable manifold valve series

The output unit can drive the 2-port valve of VX, VCW, VDW series, etc.

Refer to the catalogs and Technical Specification of each valve series for detail of the solenoid valve and manifold, etc.

-40-

No.EX##-OMI0032

Dimensions

-41-

No.EX##-OMI0032

Input unit

Parts and functions description

No.

5 Fuse

8 Cover

Parts

1 Branch connector at Input unit

2 e-con socket

3

Power supply

LED

Application

Used to crimp branch connector ( ) into branch cable

(EX510-FC ) and connected them to GW unit.

Used to connects sensor.

Lights up : Power ON (normal)

Goes off : Power OFF

Lights up : Sensor signal input ON

Goes off : Sensor signal input OFF

Fuse is replaceable.

Used for mounting the unit on DIN rail and with attached bracket

( ) (thread mounting).

Used to mount the unit with two M4 screws. (EX510-DX only)

Used to protect sensor cable and provided with marker plate ( ) on the top.

-42-

No.EX##-OMI0032

Mounting/Installation

Installation

Mounted by screw

-43-

No.EX##-OMI0032

Mounted on DIN rail (Common to EX510-DX 1 and 2)

Put claw 1 at the body under DIN rail or bracket and push it upward. Push down claw 2 to the opposite rail until the claw clicks to be set stably. (Mounting procedure and )

For removing, push up DIN rail fixing plate at the body with a flat screwdriver, and remove it by tilting Claw 2 side forward. (Removal procedure and )

-44-

No.EX##-OMI0032

Wiring method

1.

Typical internal circuit and wiring

-45-

No.EX##-OMI0032

-46-

No.EX##-OMI0032

2. Wiring of branch cables and e-con

•

Insert the branch connector at cable side into mating connector at Input unit side.

•

Connect e-con after removal of cover.

*For crimping of a branch connector, refer to page 15.

3. Sensor connection

Utilize e-con to connect the sensor to the Input unit.

•

Strip the sensor wire as shown in the right figure.

(Refer to the table below for correspondence between connector and electrical wire gauge.)

Lead Wire Table

SMC Product No.

(1 pc)

ZS-28-CA-1

ZS-28-CA-2

ZS-28-CA-3

ZS-28-C

ZS-28-C-1

−

Color of cover

Orange

Red

Yellow

Red

Yellow

Applicable gauge of cable (

φ

)

0.6 to 0.9

0.9 to 1.0

1.0 to 1.15

0.8 to 1.0

1.0 to 1.2

Transparency

Nominal sectional area (mm

2

)

0.1 to 0.5

Product No.

3-1473562-4(AMP)

1-1473562-4(AMP)

1473562-4(AMP)

2-1473562-4(AMP)

0.14 to 0.3

4-1473562-4(AMP)

37104-3101-000FL(Sumitomo 3M)

(AWG26 to 24) 37104-3122-000FL(Sumitomo 3M)

0.08 to 0.5

XN2A-1430*(OMRON)

*Note: If given tensile force more than 12N, cable may separate from connector.

•

Insert the cable to the end with checking correspondence between color of cable and number stamped on e-con. (Refer to P.45 “Typical internal circuit and wiring”)

•

It checks that the above-mentioned preparation work has been performed correctly, and "A" part shown in the left figure is pushed by hand and makes temporary connection.

•

"A" part's center is straightly pushed in by tools, such as pliers.

• e-con is cannot be reused once crimped for connection. For the connection failure such as incorrect order of wire and incomplete insertion, please use the new e-con for sensor.

-47-

No.EX##-OMI0032

Specification

Specification

Item

Model No.

Applicable sensor

Number of input points

Supply voltage for sensor

Max. supply current for sensor

Current consumption

Input resistance

Rated input current

ON voltage / ON current

OFF voltage / OFF current

LED display

Weight

EX510-DXN

NPN output

Specification

EX510-DXP

PNP output

16 points (See diagram below for details.)

24VDC

0.2A/1 point, 0.9A/1unit

EX510-DXB1

2 wire type

100mA or less (inside of input unit)

5.6k

Ω

Approx. 4mA

17V or more / 2.5mA or more

(Between input terminal and

+24V for sensor)

17V or more / 2.5mA or more

(Between input terminal and 0V for sensor)

7V or less / 1mA or less

(Between input terminal and

+24V for sensor)

7V or less / 1mA or less

(Between input terminal and 0V for sensor)

Green LED (lights up during ON time)

EX510-DX 1:90g, EX510-DX 2:110g(including accessories)

Dimensions

-48-

No.EX##-OMI0032

Procedure

Maintenance Procedure

•

Mounting and wiring conditions

Check items

Confirm the connectors of each unit

(communication, power supply, input and output) is firmly connected.

Confirm the terminating resister is connected to both ends of network.

(If this system is located at termination of network.)

Confirm there is no breakage of connecting cable.

Condition

No looseness

No looseness

No defect on appearance

•

Service parts

Check items

PROFIBUS-DP compatible cable for moving parts (if used)

Display and operation

Condition

No defect on appearance and conductor resistance

No defect on operating conditions and display

•

Power supply

Check items

Measure the voltage at both ends of input and GW/SI controlling part power supply and confirm the voltage is within specifications.

Measure the voltage at both ends of solenoid valve/output power supply and confirm the voltage is within specifications.

Condition

DC24V±10%

DC24V+10%/-5%

-49-

Solution

Give an additional tightening.

Given an additional tightening.

Replace with a new one if there is a defect found on appearance.

Solution

Replace with a new one if there is a defect found on appearance and conductor resistance.

Replace with new unit if there is unintentional operation and defect found on display.

Solution

Investigate the cause of fluctuation of the voltage and take measure.

Investigate the cause of fluctuation of the voltage and take measure.

No.EX##-OMI0032

Troubleshoot

A reduced wiring system doesn’t operate normally.

A solenoid valve don’t operate normally.

Condition A

During check

Check the

LED of only condition of manifold solenoid valve. solenoid valve lights up. *

After check

Condition B

Check the condition of GW unit.

PWR_LED of

SI unit goes off.

COM_LED of

SI unit goes off.

A solenoid valve comes to operate normally.

Refer to Trouble

No.3

A solenoid valve fails.

Refer to Trouble

No.1

Refer to Trouble

No.2

SV solenoid valve manifold comes to operate normally.

To Condition B.

RUN_LED goes off.

BF_LED Light up

BF_LED Light up

DIA_LED Light up

GW unit comes to operate normally.

⇒To Condition D

Refer to Trouble

No.5

Refer to Trouble

No.6

A port COM_LED to show the connection with low side goes off.

PWR(V)_ LED goes off.

Refer to Trouble

No.9

Refer to Trouble

No.4

Refer to Trouble

No.7

Refer to Trouble

No.8

-50-

Yes

No

No.EX##-OMI0032

Condition C

The information about input equipment can’t be

During check

Check the condition of GW unit.

DIA_LED Light up recognized

After check

A reduced wiring system comes to operate normally.

GW unit comes to operate normally. to Condition D

A port COM_LED to show the connection with low side goes off.

GW unit fails.

Refer to Trouble

No.7

Condition D

Check the condition of Input unit.

LED for power supply of input unit goes off

Display LED corresponding to input signal goes off or mis-light up.

Refer to Trouble

No.10

Refer to Trouble

No.11

Input unit comes to operate normally

Input unit comes to operate normally.

⇒

A reduced wiring system comes to operate normally.

Refer to Trouble

No.12

* Some types of output equipment do not have LED display. For such equipment, check the output unit voltage to judge if it is normal or not.

Trouble No.1

Trouble Possible cause

PWR_LED of unit goes off.

Incorrect branch cable connection

Incorrect output power supply connection

Output power supply failure

Investigation method of cause Solution

Confirm there is no breakage, incorrect connection and looseness at connecting part of the branch cable.

Fix the connection of the branch cable.

There is no incorrect connection between output power supply and GW unit power supply connector.

Fix connection.

Confirm the condition of output power supply.

Supply DC24V+10%/-5% for

GW unit output power supply.

Trouble No.2

Trouble Possible cause

Incorrect branch cable connection

COM_LED of unit goes off.

Branch cable failure

Investigation method of cause Solution

Confirm there is no breakage, incorrect connection and looseness at connecting part of the branch cable.

Fix connection of the branch cable.

Confirm there is no equipment and high voltage line which might generate a noise around the branch cable.

Check the length of the branch cable and use of dedicated cable.

Take a proper measure such as by separating the branch cable from the noise source.

Fix connection.

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No.EX##-OMI0032

Trouble No.3

Trouble

Solenoid valve falls in failure.

Possible cause Investigation method of cause

Incorrect connection between unit and solenoid valve

Incorrect wiring

Incorrect solenoid valve power supply voltage

Solenoid valve failure

Unit failure

Confirm there is no looseness of the connector between unit and solenoid valve. between unit and solenoid valve

Confirm there is no breakage and failure of wiring between unit and solenoid valve.

System setting error Confirm the GW unit is set correctly.

Confirm the power supply voltage from the unit is within power supply voltage specified for the sensor. Also, confirm the length of a branch cable and current for the unit are within their specifications.

Replace with new one and check the operation again.

Replace with a new one and check the operation again.

Solution

Fix the connection between unit and solenoid valve.

Fix the wiring between unit and solenoid valve

Fix setting

Operate within the specifications.

Read the troubleshooting of solenoid valve

Replace unit.

Trouble No.4

Trouble

RUN_LED goes off or

BF_LED lights up.

(DIA_LED flashes.)

Possible cause

Incorrect address setting

Trouble No.5

Trouble

RUN_LED or BF_LED goes off.

(DIA_LED

Possible cause

Incorrect input and

GW unit controlling part power supply connection goes off.)

Input and GW unit controlling part power supply failure

Investigation method of cause

Confirm the address isn’t set to

126 or 127.

Investigation method of cause

Confirm there is no incorrect connection between input and GW unit controlling part power supply and GW unit power supply connector.

Confirm the condition of input and GW unit controlling part power supply.

Set the address between 0 and 125.

Solution

Solution

Fix connection.

Supply DC24V±10% for input and GW controlling part power supply of the GW unit.

Trouble No.6

Trouble

BF_LED lights up.

Possible cause

PROFIBUS communication error.

Investigation method of cause

Confirm the signal line from PLC is connected correctly.

Address setting error:

[In hardware mode]Confirm the address setting of DIP switch is performed correctly.

[In software mode]Confirm the address set through network is correct.

Confirm the number of I/O points are set correctly.

Check the length of communication line in respect to the communication speed, presence of the terminating resistor at both ends of transmission line and use of

PROFIBUS dedicated cable.

Confirm UNIT STATUS at GW unit side consists the one at master side.

Solution

Fix the connection.

Fix the setting of the GW unit.

Fix the setting.

Fix the connection and setting.

Fix the setting.

Confirm there is no equipment and high voltage line which might generate a noise around the communication line.

Take a proper measure such as by separating the communication line from the noise source.

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No.EX##-OMI0032

Trouble No.7

Trouble Possible cause

A port

COM_LED to show the connection with low side goes off.

(COM_LED of the port set as unused remains off.

Incorrect branch cable connection

Branch cable failure

Unconnected input unit

Broken input unit fuse

Investigation method of cause

Confirm there is no breakage, incorrect connection and looseness at connecting part of the branch cable.

Confirm there is no equipment and high voltage line which might generate a noise around the branch cable.

Check the length of the branch cable and use of dedicated cable.

Confirm the input unit is connected after the input port.

Confirm the fuse is not broken.

Trouble No.8

Trouble Possible cause

Incorrect output

PWR(V)_

LED goes off. power supply connection

Output power supply failure

Investigation method of cause

Confirm there is no incorrect connection between output power supply and GW unit power supply connector.

Confirm the condition of output power supply.

Solution

Fix connection of the branch cable.

Take a proper measure such as by separating the branch cable from the noise source.

Fix connection.

It is not breakage. However, if an input unit is used, incorrect connection is also possible cause. In that case, fix the connection.

Replace with a new one.

Solution

Fix connection.

Supply DC24V+10%/-5% for

GW unit output power supply.

Trouble No.9

Trouble Possible cause

Others

(DIA_LED lights up.)

Broken solenoid valve fuse (GW unit)

Investigation method of cause

Confirm the fuse for the solenoid valve is not broken. (The information of broken fuse is sent to PLC as extensive diagnosis result and so you can check on program software. The fuse is mounted on an internal board and this check method is recommended.)

Solution

Replace with new GW unit and check the operation again.

Trouble No.10

Trouble Possible cause

Input unit power supply

LED goes off.

Incorrect branch cable connection

Incorrect input and

GW unit controlling part power supply connection

Input and GW unit controlling part power supply failure

Broken input unit fuse

Investigation method of cause

Confirm there is no breakage, incorrect connection and looseness at connecting part of the branch cable.

Confirm there is no incorrect connection between input and GW unit controlling part power supply and GW unit power supply connector.

Confirm the condition of input and GW unit controlling part power supply.

Confirm the fuse is not broken. cable.

Solution

Fix connection.

Fix connection of the branch

Supply DC24V±10% for input and GW controlling part power supply of the GW unit.

Replace with a new one.

Trouble No.11

Trouble

Display

LED correspondi ng to input signal goes off.

Possible cause

Incorrect sensor cable connection

Sensor failure

Investigation method of cause

Confirm e-con connector does not have looseness at its connecting part.

Confirm there is no incorrect connection of the sensor cable.

Replace with new one and check the operation again.

Solution

Connect the sensor cable correctly.

Fix connection.

Replace sensor.

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No.EX##-OMI0032

Trouble No.12

Trouble

Input unit falls in an operating failure.

Possible cause

Inconsistence of used sensor’s polarity

Improper sensor power supply voltage

Investigation method of cause

Confirm the specification of the sensor is compatible to the one of the input block

(PNP, NPN).

Confirm the power supply voltage from the input unit is within power supply voltage specified for the sensor. Also, confirm the length of a branch cable and current for the input unit are within their specifications.

Solution

Remount the input block or sensor to make them compatible.

Operate within specifications.

Incorrect system setting

Confirm a GW unit is set correctly. Fix setting.

Input unit failure

Replace with new one and check the operation again.

Replace input unit.

Option

•

e-con

It is a connector used for connecting a sensor to the Input unit (EX510-DX ).

Refer to “Sensor connection” on page 47 for the connector part number and the applicable electric wire size.

•

Fuse for replacement

It is a fuse for replacement used for Input unit(EX510-DX ) and Output(EX510-DY ) unit.

•

Terminating resistor

Used to prevent signal reflections on the end of transmission line and to connect a communication connector with a GW unit.

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No.EX##-OMI0032

•

Branch cable

It is a 4-core flat cable used for connection between each unit.

•

Branch connector (Every 1 pc.)

It is a connector used to connect the branch cable to each unit.

SI unit and input unit are attached with the branch connector for 2 pcs. each.

Electric specification

Rated voltage

Rated current

Contact resistance

Withstand voltage

•

Cable assembly for output entry

It is a cable assembly to take the remaining output of the SI unit out of it.

AC / DC 160V or less

Max. 5.0A

20m

Ω

or less

AC1000V per 1 minute

(Leak current 1mA or less)

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No.EX##-OMI0032

Revision history

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No.EX##-OMI0032