Diagnostic Module GFDM...Contents and general instructions Festo GDCA−GFDM−EN en 0802a IX...

System Description

Installation andCommissioning ofthe DiagnosticModule GFDM

Diagnostic Module GFDM

Manual

724 699en 0802a

Contents and general instructions

IFesto GDCA−GFDM−EN en 0802a

Original de. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Edition en 0802a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Designation GDCA−GFDM−EN. . . . . . . . . . . . . . . . . . . . . . . . .

Order no. 724 699. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E (Festo AG�&�Co. KG, D�73726 Esslingen, Germany, 2008)Internet: �http://www.festo.comE−Mail: �[email protected]

The reproduction, distribution and use of this document aswell as the communication of its contents to others is pro�hibited without explicit authorisation. Offenders will beliable for damages. All rights reserved, in particular theright of patent application and the right of registration of autility model or design.


II Festo GDCA−GFDM−EN en 0802a


IIIFesto GDCA−GFDM−EN en 0802a

Contents

Designated use VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Target group VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important user information IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Notes on the use of this manual XI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. System overview 1−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Diagnostic module GFDM 1−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Structure of the diagnostic module GFDM 1−9 . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 Mode of operation of the diagnostic module GFDM 1−11 . . . . . . . . . . . .

2. Assembly 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General information on assembly and disassembly 2−4 . . . . . . . . . . . . . . . . . . . .

2.2 Assembly of the diagnostic module 2−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Installation 3−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General information on installation 3−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Connecting cables 3−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Connections of the diagnostic module GFDM 3−5 . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Connecting analogue signal cables 3−7 . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Connecting digital signal cables 3−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3 Connecting the controller to a PC 3−12 . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4 Connecting the controller to FED−500 3−13 . . . . . . . . . . . . . . . . . . . . . . .

3.2.5 Connecting a PC to the FED−500 3−13 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.6 Connecting a status indicator 3−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.7 Connecting a PLC (optional) 3−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.8 Connecting the controller to a power supply unit 3−15 . . . . . . . . . . . . . .

3.3 Installing the �FCT with GFDM Plug−In" software 3−16 . . . . . . . . . . . . . . . . . . . . . .


IV Festo GDCA−GFDM−EN en 0802a

4. Commissioning 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Commissioning 4−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Prerequisites for commissioning 4−4 . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Steps in commissioning 4−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Activating a GFDM project 4−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Configuring and commissioning the diagnostic module 4−5 . . . . . . . . .

4.3 Configuring the network connection 4−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Direct network connection between the PC and controller 4−8 . . . . . . .

4.4 Information on operating the diagnostic module 4−10 . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Control key (CTRL) 4−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Visualisation with �GFDM for VipWin" 5−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 System overview of �GFDM for VipWin" 5−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Connecting �GFDM for VipWin" to a controller 5−4 . . . . . . . . . . . . . . . .

5.1.2 Installing �GFDM for VipWin" 5−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.3 OPC IP Setup 5−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Starting �GFDM for VipWin" 5−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Basic operation of �GFDM for VipWin" 5−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Menu structure of �GFDM for VipWin" 5−8 . . . . . . . . . . . . . . . . . . . . . . .

5.4 Visualisation of the diagnostic module � Overview 5−9 . . . . . . . . . . . . . . . . . . . .

5.4.1 Main view of the visualisation 5−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 Main page of the diagnostic module 5−11 . . . . . . . . . . . . . . . . . . . . . . . .

5.4.3 Start signal for time selection 5−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Operation of the diagnostic module 5−13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.1 Display settings dialog 5−13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.2 Diagnostic settings dialog 5−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.3 Diagrams dialog 5−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.4 Statistics dialog 5−29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Details of the overall state 5−31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.1 Conditions for state calculation by the monitoring modules 5−32 . . . . .

5.6.2 Symbol representation of the diagnostic results 5−32 . . . . . . . . . . . . . . .

5.6.3 Archive for the overall state 5−34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


VFesto GDCA−GFDM−EN en 0802a

5.7 Data export from �GFDM for VipWin" 5−36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.1 Exporting from tables 5−37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.2 Exporting from diagrams 5−38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.3 Exporting from the archive for the overall state 5−39 . . . . . . . . . . . . . . .

5.8 Error messages of the controller 5−41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Visualisation with �GFDM for FED−500" 6−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 System overview of FED−500 6−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Information on the firmware of the FED−500 6−5 . . . . . . . . . . . . . . . . . .

6.2 Switching on the FED−500 6−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Starting the visualisation program 6−6 . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2 Transferring the FED visualisation program 6−7 . . . . . . . . . . . . . . . . . . .

6.2.3 Enabling configuration mode 6−8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Basic operation of �GFDM for FED−500" 6−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Menu structure of �GFDM for FED−500" 6−10 . . . . . . . . . . . . . . . . . . . . . .








6.5.3 Diagrams dialog 6−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5.4 Archive dialog 6−27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .








VI Festo GDCA−GFDM−EN en 0802a

A. Appendix A−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 Technical data A−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1.1 General technical data A−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1.2 Interfaces of the controller A−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Control configuration of the runtime system A−6 . . . . . . . . . . . . . . . . . . . . . . . . .

A.3 Error messages of the controller A−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.4 Index A−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


VIIFesto GDCA−GFDM−EN en 0802a

Designated use

The diagnostic module GFDM is designed for monitoring the

pressure, flow rate and air consumption in pneumatic sys�tems as a function of the system cycle.

GFDM is a standalone system and thus equally suited to re�trofitting in existing systems and installation in new systems.

Use the diagnostic module GFDM:

� only in industrial applications,

� in accordance with its designated use,

� in its original condition without unauthorised modifica�

tions; only the conversions or modifications described inthe documentation supplied with the product are per�mitted,

� in faultless technical condition.

Please comply with national and local safety laws and regula�tions.


VIII Festo GDCA−GFDM−EN en 0802a

Target group

This manual is intended exclusively for technicians trained in

control and automation technology.

Service

Please consult your local Festo repair service if you have anytechnical problems.


IXFesto GDCA−GFDM−EN en 0802a

Important user information

Danger categories

This manual contains information on the possible dangersthat can occur if the product is not used as designated. Thisinformation is marked with a signal word (warning, caution,etc.), placed on a shaded background and additionallymarked with a pictogram. A distinction is made between thefollowing danger warnings:

Warning... means that serious injury to persons and damage toproperty can occur if this warning is not observed.

Caution... means that injury to persons and damage to propertycan occur if this warning is not observed.

Note... means that damage to property can occur if this warningis not observed.

In addition, the following pictogram marks passages in thetext that describe activities involving electrostatic sensitivecomponents:

Electrostatic sensitive devices: inappropriate handling canresult in damage to components.


X Festo GDCA−GFDM−EN en 0802a

Marking special information

The following pictograms mark passages in the text that con�tain special information.

Pictograms

Information: Recommendations, tips and references to other sources ofinformation.

Accessory: Information on necessary or useful accessories for the Festoproduct.

Environment: Information on the environment−friendly use of Festo prod�ucts.

Text markings

· Bullets denote activities that may be carried out in anydesired order.

1. Figures denote activities that must be carried out in theorder specified.

� Hyphens denote general listings.


XIFesto GDCA−GFDM−EN en 0802a

Notes on the use of this manual

This manual contains general basic information on assem�

bling, installing and commissioning the diagnostic moduleGFDM.

It also contains information on monitoring and parameterisingthe diagnostic module using the visualisation systems

�GFDM�for�FED−500" and �GFDM�for�VipWin" with extendedinformation on evaluation options for stored archive data.

Special information on configuring the diagnostic module andsetting basic parameters using the �FCT with GFDM Plug−In"software package can be found in the accompanying online

Help.

The following table contains an overview of further docu�ments for the diagnostic module GFDM.


XII Festo GDCA−GFDM−EN en 0802a

Type Title Description

System de�scription

�Diagnostic ModuleGFDM"

This manual: Overview of the assembly, in�stallation and commissioning of the diagnosticmodule GFDM.

Quick refer�ence

�Diagnostic ModuleGFDM"

Quick reference for the diagnostic moduleGFDM.

Electronicsmanual

�Controller CECX−K−D1" Overview of structure, components, assemblyand installation.

Operating in�structions

�Pressure Sensor SDE1" Connection technology as well as informationon assembly, installation and commissioning.

�Flow Sensor SFE1−LF"

�Flow Sensor MS6−SFE"

Online Help �Festo ConfigurationTool � GFDM Plug−In"

Configuration, parameterisation and commis�sioning of the diagnostic module.

Manual �Operator Unit FED" Connection technology as well as informationon assembly, installation and commissioning.

Table.�0/1: Documents related to the diagnostic module


XIIIFesto GDCA−GFDM−EN en 0802a

Term/abbreviation Meaning

0 signal 0 V applied at the input, or output supplying 0 V.

1 signal 24 V applied at the input, or output supplying 24 V.

AI Analogue input

AO Analogue output

DI Digital input

DO Digital output

Condition monitoring Process or activity for ascertaining the status of systems

Ethernet Physical network for connecting various devices

FCT Abbreviation for the Festo Configuration Tool. Software with uniform pro�ject and data management for all supported device types. The specialrequirements of a device type are supported with the necessary descrip�tions and dialogs by means of plug−ins.

FDC Abbreviation for the controller CECX−K−D1. The controller acceptsmeasured values from sensors and controls the forwarding of the diag�nostic results to a visualisation system.

LSB Least significant bit

MSB Most significant bit

OPC server An OPC server provides OPC objects and thus forms a link between theinformation base of the OPC server and an OPC client connected to theserver.For the �GFDM for VipWin" visualisation program, the �3S OPC server"accesses the parameters of the controller via the CoDeSys interface andmakes them available to the VipWin project as OPC objects.VipWin must be installed as a client on the same computer for this.

Monitoring module A monitoring module calculates measured values on the basis of sensorsignals and using digital signals. The monitoring module compares thesevalues with predefined reference values to ascertain results that are madeavailable to the diagnostic module.


XIV Festo GDCA−GFDM−EN en 0802a

Term/abbreviation Meaning

PLC/IPC Programmable logic controller/industrial PC

Trigger signal Digital signal (specified via an edge if applicable) for determining the startand stop of consumption measurement by the �Cycle consumption" moni�toring module.

Table.�0/2: Product−specific terms and abbreviations

System overview

1−1Festo GDCA−GFDM−EN en 0802a

Chapter 1

1. System overview

1−2 Festo GDCA−GFDM−EN en 0802a

Contents

1.1 Diagnostic module GFDM 1−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Structure of the diagnostic module GFDM 1−9 . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 Mode of operation of the diagnostic module GFDM 1−11 . . . . . . . . . . . .

1. System overview


Contents of this chapter This chapter provides you with an overview of the function,structure and components of the diagnostic module GFDM.

1. System overview


1.1 Diagnostic module GFDM

The diagnostic module GFDM undertakes status monitoringof a pneumatic system for early detection of malfunctions.

As part of this process, pressure and flow rate values arecontinuously recorded and the cycle consumption calculated.

These values are compared with stored reference values.Values exceeding the tolerance ranges are immediately sig�nalled.

Calculation of the reference values is either automaticallyperformed by means of a teach−in function or manually

adapted to the special requirements of system operation.

Controller CECX−K−D1

Diagnosis is performed in the controller CECX−K−D1. Threemonitoring modules are implemented to this end. Each ofthese modules calculates and monitors one of the followingcharacteristics:

� pressure,

� flow rate,

� cycle consumption.

1. System overview


Determination of the measured values

Pressure and flow rate values are determined directly fromthe analogue signals of the sensors.

Cycle consumption is determined by integrating the flow rateover a system cycle. The system cycle is read in to the con�troller via �start" and �stop" trigger signals.

The following diagram shows as an example how cycle con�sumption is calculated on the basis of the measured valuesfor flow rate. The diagnostic result for cycle consumption isavailable during the respective subsequent system cycle.

1 Trigger signal

2 Error in the sys�tem

3 Flow rate [l/min]

4 Cycle consump�tion [l]

1 2 1 1

3

4

[l/min]

[l]

t

t

Fig.�1/1: Example of a system with a defective cylinder

1. System overview


Example of how limits are set

In many systems, the flow rate fluctuates very strongly. It can be helpful in these cases to disable the lower limits ofthe �Flow rate" monitoring module. This is done by definingthese limits in a range that can never be reached.

Reference value 150 l/min

Upper limit yellow + 40 l/min

Upper limit orange + 60 l/min

Upper limit red + 90 l/min

Lower limit yellow � 200 l/min

Lower limit orange � 200 l/min

Lower limit red � 200 l/min

Table�1/1: Example of how limits are set

1 Upper limit red

2 Upper limitorange

3 Upper limit yel�low

4 Reference value

5 Flow rate in l/min

6 Lower limits yel�low, orange andred

t

[l/min]

1 2

5

3

6

4

Fig.�1/2: Limit settings for the �Flow rate" monitoring module

1. System overview


Determination of the module state

Each monitoring module determines the deviation of the cur�rent value from a stored reference value. As soon as the devi�ation falls below or exceeds one of the six limits, this is out�put as a new module state.

The following diagram shows the result for module state withchanging measured values:

1 Currentmeasured value

2 Reference value

3 Module state as afunction of themeasured value

t

1

2

3

Fig.�1/3: Module state for cycle consumption

Module state Colour Meaning

Green Normal operation

Yellow Warning

Orange Maintenance advisable

Red Alarm

Table�1/2: Module state and meaning

1. System overview


Determination of the overall state

The overall state is derived from the results of the monitoringmodules. The result for overall state is given by the more sig�nificant of the states of the active monitoring modules.

The overall state is provided at the digital outputs of the con�troller. You have the following options:

� transfer the overall state to a PLC,

� display the overall state using a status indicator.

Locking

If the supply pressure is out of the tolerance range (out of redthreshold), the �Flow rate" and �Cycle consumption" monito�ring modules no longer display results and their modulestatus is displayed as �Interlocked".

Operating state and product number

To adapt diagnosis to different conditions, the option exists tomodify reference values and limits during operation.

The following defaults can be read in at the digital inputs ofthe controller:

� operating state,

� product number.

As soon as one of these defaults changes, a new diagnosticparameter set is automatically loaded for all three monitoringmodules.

Diagnosis by the controller is only performed in the operatingstates 1 (Automatic) and 2 (Stop). Since operating state andproduct number are chosen independently of each other,there are 32 different diagnostic parameter sets.

1. System overview


1.2 Structure of the diagnostic module GFDM

The diagnostic module GFDM consists of a pressure sensorand a flow sensor for recording measured values, a controller

for calculating states as well as a visualisation system on thebasis of an operator unit directly at the system or on the basisof PC−based software for the office area.

GFDM is supplied with different sensors and visualisationsystems. The representations of the components in this man�ual may therefore differ from the equipment you are using.

The following components are required for GFDM:

Component Brief description

Controller CECX−K−D1Control unit for configuring a diag�nostic module for pneumatic sys�tems.The device configuration must not bechanged.

A pressure sensor for monitoringchanges in pressure in pressure linesystems or terminal devices:� SDE1−..−D10−..−PI/NI/2I−.. 1)

� SDE1−..−V1−..−PI/NI/2I−.. 1)

� SDE1−..−D6−..−PI/NI/2I−.. 1)

� SDE1−..−D2−..−PI/NI/2I−.. 1)

� SDE1−..−B2−..−PI/NI/2I−.. 1)

1) One component in each case included in the scope of delivery as alternatives.

1. System overview


Component Brief description

A flow sensor for monitoring changesin flow rate and consumption in pres�sure line systems or terminal devices:� MS6−SFE−F5−..−P2I/N2I−.. 1)

� SFE1−LF−F200−..−PI/NI/2I−.. 1)

�FCT with GFDM Plug−In" configura�tion system software for configuring,commissioning and parameterisingthe diagnostic module. 2)

A visualisation system for displayingand parameterising the diagnosticmodule:� Operator unit FED−500 with

�GFDM for FED−500" 1)

� �GFDM for VipWin" software 1),2)

1) One component in each case included in the scope of delivery asalternatives.

2) PC/laptop not included in the scope of delivery.

Table�1/3: Components of the diagnostic module

The software packages for the configuration system(�FCT�with�GFDM�Plug−In") and visualisation system(�GFDM�for�VipWin") can be installed and used in parallel onone PC/laptop.

1. System overview


1.2.1 Mode of operation of the diagnostic module GFDM

The following diagram explains the mode of operation of thediagnostic module.

1 Visualisation sys�tem, either:�GFDM for Vip�Win" or �GFDMfor FED−500"

2 PC with �FCT withGFDM Plug−In"configurationsoftware

3 Controller

4 Status indicator(not included inthe scope of de�livery of GFDM)

5 Monitored sys�tem

1 2

3

6

7

8

4

5

6 PLC of the monitored system (notincluded in the scope of delivery ofGFDM)

7 Flow sensor (here MS6−SFE)

8 Pressure sensor (here SDE1)

Fig.�1/4: Diagnostic module GFDM

Integrated in the system to be monitored 5 are the sensors7 and 8, whose measurement data is provided to the diag�nostic module. The measurement data is transferred to thecontroller 3 together with system−specific signals from thePLC 6 (cycle trigger, operating state and product number)and evaluated there by monitoring modules.

Configuration and commissioning of the diagnostic module isperformed using the �FCT with GFDM Plug−In" software pack�age 2.

1. System overview


The results are displayed using a visualisation system 1.

The overall state is optionally indicated by a status indicator4.

Assembly


Chapter 2

2. Assembly


Contents

2.1 General information on assembly and disassembly 2−4 . . . . . . . . . . . . . . . . . . . .

2.2 Assembly of the diagnostic module 2−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Assembly


Contents of this chapter The diagnostic module GFDM is supplied as individual com�ponents. This chapter describes the assembly and disassem�bly of the components, insofar as not described in the hard�ware documentation.

Further information If you want to replace individual components of the diagnos�tic module, please refer to the respective documentation (seeTable.�0/1).

2. Assembly


2.1 General information on assembly and disassembly

CautionInappropriate handling can result in damage to the compo�nents of the diagnostic module.

Before carrying out assembly, installation and mainten�ance work, switch off the following:

� compressed air supply,

� operating and load voltage supplies.

NoteDamage to components.

Handle all the components of the diagnostic module withgreat care. Please note the following in particular:

� Screw connections must be free of offset and mechan�ical tension. Screws must be positioned accurately(otherwise threads will be damaged).

� The specified torques must be observed.

� Electrostatic sensitive devices.Do not touch the contact surfaces of the sensor con�nectors.

2. Assembly


2.2 Assembly of the diagnostic module

CautionInappropriate handling can result in damage to the compo�nents of the diagnostic module.

· Observe the handling specifications for electrostaticsensitive devices.

· Discharge yourself before installing or removing mod�ules to protect the modules from static discharges.

· Assemble all the components of the diagnostic module inaccordance with the information on assembly in the re�spective accompanying documentation (see Table.�0/1).

2. Assembly


Installation


Chapter 3

3. Installation


Contents

3.1 General information on installation 3−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Connecting cables 3−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Connections of the diagnostic module GFDM 3−5 . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Connecting analogue signal cables 3−7 . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Connecting digital signal cables 3−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3 Connecting the controller to a PC 3−12 . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4 Connecting the controller to FED−500 3−13 . . . . . . . . . . . . . . . . . . . . . . .

3.2.5 Connecting a PC to the FED−500 3−13 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.6 Connecting a status indicator 3−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.7 Connecting a PLC (optional) 3−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.8 Connecting the controller to a power supply unit 3−15 . . . . . . . . . . . . . .

3.3 Installing the �FCT with GFDM Plug−In" software 3−16 . . . . . . . . . . . . . . . . . . . . . .

3. Installation


Contents of this chapter This chapter contains general information on installing theelectrical components of the diagnostic module GFDM. Thisincludes information on the following in particular:

� electrical or electronic connections between the compo�nents of the diagnostic module,

� connection accessories (connecting cables and sockets).

Note· Refer to the current technical documentation for theindividual components.

Further information Information on installing the pneumatic components can befound in the operating instructions for the sensors (seeTable.�0/1).

Information on setting up the network connection betweenthe controller and PC can be found in Section 4.3 of this sys�tem description.

3. Installation


3.1 General information on installation

WarningSudden unexpected movement of the actuators of the sys�tem to be monitored and uncontrolled movements of loosetubing can cause injury to persons or damage to property.

Before carrying out installation and maintenance work,switch off the following:

� compressed air supply,

� operating and load voltage supplies.

3.1.1 Connecting cables

Warning· Use only power supplies that guarantee reliable electrical isolation of the operating voltage to IEC/DIN EN 60204−1.Take into account also the general requirements forPELV circuits as per IEC/DIN EN 60204−1.

· Protect all modules with front power supply using a fusein series. This fuse must not exceed 10 A under any cir�cumstances.

NoteLong signal cables reduce interference immunity.

· Make sure the signal cables are no longer than 30 m.

· Do not lay the signal cables near or parallel to cableswith high levels of interference.

· Earth the system properly.

3. Installation


3.2 Connections of the diagnostic module GFDM

The following connections are available for the components ofthe diagnostic module GFDM:

1 2 3 4 5

6

7 8

1 Analogue connection between the flowsensor and controller for transferringmeasured values

2 Analogue connection between thepressure sensor and controller fortransferring measured values

3 Digital connection between the PLC ofthe monitored system and controller(PLC and digital connection notincluded in the scope of delivery ofGFDM)

4 LAN connection between the PC andcontroller for configuring andcommissioning the diagnostic modulewith the FCT GFDM plug−in

5 Serial connection between the FED andcontroller for visualising the diagnosticmodule with �GFDM for FED−500" (alternative to 7)

6 Serial connection for transferringdiagnostic results and �GFDM forFED−500" visualisation software

7 LAN connection between the PC andcontroller for visualising the diagnosticmodule with �GFDM for VipWin"(alternative to 5)

8 Digital connection between thecontroller and the status indicator (notin the scope of delivery of GFDM).

Fig.�3/1: Connections between the components of GFDM

3. Installation


· Use the following connecting cables to establish the elec�trical connections of GFDM.

Connection between ... Connecting cable

1 ... controller analogue input and flow sensor Screened cable (3−wire, twisted)

2 ... controller analogue input and pressure sensor

Screened cable (3−wire, twisted)

3 ... controller digital input and PLC of the machine/system

Cable set for PLC connection or for other trigger signal cables

4 ... controller and PC with �FCT with GFDM Plug−In" software

RJ−45 network cable

5 ... controller and FED−500 Festo cable: FEC−KBG8

6 ... FED−500 and PC with �FCT with GFDM Plug−In" software

Festo cable: NEBC−S1G15−K−2.5−N−B−S1G9

7 ... controller and PC with �GFDM for VipWin" software

RJ−45 network cable

8 ... controller and status indicator Cable (5−wire)

Table�3/1: Connecting cables for GFDM components

3. Installation


3.2.1 Connecting analogue signal cables

Analogue signals from the sensors are read in at the analogueinput of the controller (CECX−A−4E4A−A).

For this you need:

� 2 screened cables, at least 3−wire, twisted (not included in the scope of delivery),

� 2 plug sockets FBSD−GD−9−5POL,

� 1 plug NECC−L1G6−C1 (6−pin).

· Connect the sensors to the controller and to the powersupply.

· Refer to the information in the chapter �Installation" inthe Electronics Manual �Controller CECX−K−D1".

24 V DC

Pressure sensor plug(4−pin)

Out A

0 V

Flow sensor plug(5−pin)

24 V DC

0 V

Controller CECX−K−D1Analogue input/output CECX−A−4E4A−A

24 V DC

0 V

Out C

Fig.�3/2: Circuit diagram for the cabling of pressure and flow sensors

· Connect the pins of the plug sockets FBSD−GD−9−5POL asfollows:

3. Installation


Plug socket FBSD−GD−9−5POL for pressure sensor

Pin Allocation Controller AI (CECX−A−4E4A−A)

1 +24 V DC �

2 � �

3 0 V AI0� Pin 02

4 Analogue output AI0+ Pin 01

5 � �

Table�3/2: Cable connection for pressure sensor

Plug socket FBSD−GD−9−5POL for flow sensor

Pin Allocation Controller AI (CECX−A−4E4A−A)

1 +24 V DC �

2 � �

3 0 V AI1� Pin 04

4 � �

5 Analogue output AI1+ Pin 03

Table�3/3: Cable connection for flow sensor

3. Installation


3.2.2 Connecting digital signal cables

Digital signals (cycle trigger and machine state) from the sys�tem to be monitored are read in at the digital input of thecontroller (CECX−D−16E).

For this you need:

� 10 I/O cables,

� 3 plugs NECC−L1G4−C1 (each 4−pin).

Cycle triggerstart signal

Cycle triggerstop signal

24 V DC

0 V

Controller CECX−K−D1Digital inputCECX−D−16E

Operatingstate

Product number

Fig.�3/3: Circuit diagram for the cabling of digital signals

· Connect the signal cables as follows:

CECX−D−16E Allocation

DI0 Cycle trigger � �Start signal" 1)

DI1 Cycle trigger � �Stop signal" 1)

DI2 ... DI5 Operating state 1 ... 16 � binary−coded

3. Installation


CECX−D−16E Allocation

DI6 ... DI9 Product number 1 ... 16 � binary−coded

DI10 ... DI15 �

1) Use depending on the parameterisation of the diagnostic module (see online Help for the GFDM plug−in).

Table�3/4: Connecting digital signal cables

Coding of the operating states

There are four digital inputs reserved on the controller fordetecting 16 different operating states. Evaluation of the sen�sor data by the monitoring modules is only performed in thefirst two operating states (�Automatic" and �Stop").

Operating state CECX−D−16E

DI5MSB

DI4 DI3 DI2LSB

1 = Automatic 0 0 0 0

2 = Stop 0 0 0 1

3 = Manual 1) 0 0 1 0

4 = Setup1) 0 0 1 1

5 = Alignment in normal position 1)

0 1 0 0

6 = Release 1) 0 1 0 1

7 = Emergency stop 1) 0 1 1 0

8 ... 16 = Free 1) ... ... ... ...

1) There is no calculation of states by monitoring modules in these operating states.

Table�3/5: Operating states of the monitored system

3. Installation


Coding of the product numbers

There are four digital inputs reserved on the controller fordetecting 16 different product numbers.

Product number CECX−D−16E

DI9MSB

DI8 DI7 DI6LSB

1 0 0 0 0

2 0 0 0 1

3 0 0 1 0

4 ... 14 ... ... ... ...

15 1 1 1 0

16 1 1 1 1

Table�3/6: Coding of product numbers

You can enter a meaningful product name for each productnumber using the FCT GFDM plug−in (see GFDM online Help,section Configuring the diagnostic module � Triggers).

3. Installation


3.2.3 Connecting the controller to a PC

1 2 3 4 5 6

10 A

1 Protective earth

2 Power supply unit (24 V DC)

3 Operating voltage connectionof the controller

4 RS−232 serial connection

5 RJ−45 Ethernet connection (10/100Mbit/s)

6 Functional earth

Fig.�3/4: Connections of the controller

For a network connection between the controller and PC youneed:

� 2 RJ−45 Ethernet/LAN cables(not included in the scope of delivery)

· Connect both the PC and controller (connection 5) to yourcompany’s network system or to a local hub/switch.

3. Installation


3.2.4 Connecting the controller to FED−500

For this you need:

� operator unit FED−500 (optional),

� Festo cable: FEC−KBG8.

· Connect the controller to the FED−500.(See also Fig.�3/4 � connection 4.)

3.2.5 Connecting a PC to the FED−500

For this you need:

� operator unit FED−500 (optional),

� PC with �FCT with GFDM Plug−In"software package incl. visualisation software for FED−500,

� Festo cable: NEBC−S1G15−K−2.5−N−B−S1G9.

· Connect the PC to the operator unit FED−500.

3. Installation


3.2.6 Connecting a status indicator

To connect a status indicator to the digital output of the con�troller you need:

� status indicator with 4 signal lights (24 V DC) green, yellow, orange and red(not included in the scope of delivery of GFDM),

� I/O cables,

� plug NECC−L1G6−C1 (6−pin).

Statusindicator green

Controller CECX−K−D1Digital outputCECX−D−14A−2

Statusindicatoryellow

Statusindicatororange

Statusindicator red

0 V

24 V DC

Fig.�3/5: Circuit diagram for the connection of the statusindicator

Only the current overall state of the monitored system is out�put on the digital output CECX−D−14A−2 of the controller.

3. Installation


CECX−D−14A−2 Status indicator Overall state

DO0 Green Normal operation

DO1 Yellow Warning

DO2 Orange Maintenance advis�able

DO3 Red Alarm

Table�3/7: Allocation of digital outputs to the status indica�tor

3.2.7 Connecting a PLC (optional)

To connect a PLC to the digital output of the controller youneed:

� I/O cables,

� plug NECC−L1G6−C1 (6−pin).

NoteThe time the controller needs to disable a digital output islonger than the time needed to enable another digital out�put. This means that potential (high) may be briefly pres�ent at two digital outputs at the same time.

· Make sure on the PLC used in your system that theswitch in potential is completed at the digital output ofthe controller before the signals are detected, forexample by programming delay times.

3.2.8 Connecting the controller to a power supply unit

· Connect the controller to the operating voltage.(See also Fig.�3/4 � connection 3.)

3. Installation


3.3 Installing the �FCT with GFDM Plug−In" software

The GFDM plug−in is installed on your PC together with theinstallation program of the FCT.

Administrator rights are required for installing the software.

Note· Uninstall the old version of the GFDM plug−in if necess�ary before installing a new version.

Proceed as follows when installing from CD−ROM:

1. Close all programs.

2. Place the installation CD−ROM in the drive. If the installa�tion starts automatically, you can skip Steps 3 and�4.

3. Change to the CD−ROM drive, for example in Explorer.

4. Double−click to start �Setup.exe".

5. Select the desired language and confirm your selectionwith �OK".

6. Follow the instructions in the installation program. Clickon �Continue" to proceed to the next step or �Return" toreturn to the previous step.

When installation is completed, you will find the entry �FCT"in the start menu under �Programs\Festo Software".

Commissioning


Chapter 4

4. Commissioning


Contents

4.1 Commissioning 4−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Prerequisites for commissioning 4−4 . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Steps in commissioning 4−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Activating a GFDM project 4−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Configuring and commissioning the diagnostic module 4−5 . . . . . . . . .

4.3 Configuring the network connection 4−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Direct network connection between the PC and controller 4−8 . . . . . . .

4.4 Information on operating the diagnostic module 4−10 . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Control key (CTRL) 4−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Commissioning


Contents of this chapter This chapter contains information on commissioning the diag�nostic module GFDM.

Included are preparations for establishing the connectionbetween the PC and controller, installation of the commission�ing software as well as an explanation of the first steps in�volved in setting up the diagnostic module.

4. Commissioning


4.1 Commissioning

The �FCT with GFDM Plug−In" software package is used tocommission the diagnostic module. This software offers aconvenient user interface with the following functions:

� configuration of the diagnostic module,

� commissioning of the diagnostic module,

� parameterisation of the diagnostic module.

4.1.1 Prerequisites for commissioning

� All the components of the diagnostic module are correctlyassembled and installed.

� The �FCT 1.0 with GFDM Plug−In" software package isinstalled on the PC (see Section 3.3).

� The network connection is correctly installed and confi�gured (see Section 4.3).

� The diagnostic module is switched on.

4. Commissioning


4.2 Steps in commissioning

· Start the FCT software on your PC: Start menu\Programs\Festo Software\Festo ConfigurationTool.

4.2.1 Activating a GFDM project

To configure and parameterise a diagnostic module with theFCT GFDM plug−in, a project must be created or opened inthe�FCT.

A new project must have at least one component added to it.

Fig.�4/1: Selecting a component for a new project

1. Highlight the entry �GFDM" in the component selection.

2. Enter a component name (e.g. the name of the system tobe monitored by the diagnostic module).

Information on working with projects and adding componentsto a project can be found in the Help for the FCT ([Help] menu,[General FCT Contents]).

4.2.2 Configuring and commissioning the diagnostic module

You can configure the diagnostic module step−by−step usingthe tabs in the workspace of the GFDM plug−in.

To commission the diagnostic module you need an onlineconnection to the controller.

· Change the configuration of the network connection ifnecessary (see Section 4.3).

4. Commissioning


Further information can be found in the online Help for the�FCT with GFDM Plug−In" software package.

1. Enable the online Help for the GFDM plug−in via the menuHelp\Contents of installed PlugIns\Festo\GFDM.

2. In the Help, switch to the chapter: � Setting up a diagnostic module� Starting a GFDM project.

3. Following the further information and instructions onconfiguring and commissioning the diagnostic module.

4. Commissioning


4.3 Configuring the network connection

Stations in a network can only communicate with each other ifthe IP addresses and network mask match.

· To adapt the network settings of the controller to yournetwork for the first time, use either:

� a direct network connection between a PC and thecontroller using a hub/switch or a crossover networkcable or

� the CF card (Compact Flash memory card) of the con�troller.

The scope of delivery of the diagnostic module GFDM doesnot include a card reader for Compact Flash memory cards.

Proceed as follows:

1. Adapt the IP configuration of your PC to that of the con�troller (only with a direct network connection between thePC and controller, see Section 4.3.1).

2. Change the IP configuration of the controller using the�FCT with GFDM Plug−In" software.

· Select the command [IP Configuration ...] in the menu [Component].

· Follow the instructions in the dialogs.

· Make sure that the new IP configuration of the con�troller matches the network settings of your PC. If youhave any questions about this, please consult yoursystem administrator.

3. Restore the IP configuration of your PC to the originalsettings (only after a direct network connection betweenthe PC and controller, see Section 4.3.1).

4. Commissioning


Enable the online Help for the GFDM plug−in if necessary viathe menu Help\Contents of installed PlugIns\Festo\GFDM orusing the F1 function key.

In the online Help, switch to the sections: � Setting up a diagnostic module� IP configuration.

4.3.1 Direct network connection between the PC and controller

· Select an IP address and network mask for your PC suit�able to the controller settings.

Network setting Value

IP address of the controller on delivery 192.168.5.20

Suitable IP address for the PC 192.168.5.21

Suitable network mask for the PC 255.255.0.0

Table�4/1: Sample IP configuration for PC and controller

Administrator rights are required for configuring the networksettings of your PC.

You change the network settings of your PC as follows (Win�dows 2000/XP):

1. Select [Settings][Network Connections] in the Windowsstart menu.The �Network Connections" window opens.

2. In the �Network Connections" window, double−click thenetwork connection intended for the diagnostic module.The � Status" dialog opens.

3. Click the �Properties" button on the �General" tab.The � Properties" dialog opens.

4. Commissioning


4. Highlight the �Internet Protocol (TCP/IP)" item on the�General" tab in the � Properties" dia�log and click the �Properties" button.The �Internet Protocol (TCP/IP) Properties" dialog opens.

Fig.�4/2: Selecting a component for a new project

5. Set the network properties of your PC in the �InternetProtocol (TCP/IP) Properties" dialog and confirm with OK.

4. Commissioning


4.4 Information on operating the diagnostic module

4.4.1 Control key (CTRL)

CautionPressing the control key on the controller CECX−K−D1 dur�ing operation can influence the program flow and thus leadto incorrect diagnostic results.

· Avoid changes of any kind to the controller.

If the control key is accidentally pressed:

· Perform a restart on the controller.

· Transfer the software for the controller in the default con�figuration if necessary.

Enable the online Help for the GFDM plug−in via the menuHelp\Contents of installed PlugIns\Festo\GFDM or using theF1 function key.

In the online Help, switch to the sections:� Setting up a diagnostic module� Updating the controller.

Further information Information on the controller can be found in the ElectronicsManual �Controller CECX−K−D1".

Visualisation with �GFDM for VipWin"


Chapter 5

5. Visualisation with "GFDM for VipWin"


Contents

5.1 System overview of �GFDM for VipWin" 5−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Connecting �GFDM for VipWin" to a controller 5−4 . . . . . . . . . . . . . . . .

5.1.2 Installing �GFDM for VipWin" 5−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.3 OPC IP Setup 5−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Starting �GFDM for VipWin" 5−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Basic operation of �GFDM for VipWin" 5−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Menu structure of �GFDM for VipWin" 5−8 . . . . . . . . . . . . . . . . . . . . . . .








5.5.3 Diagrams dialog 5−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






5.7 Data export from �GFDM for VipWin" 5−36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.1 Exporting from tables 5−37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.2 Exporting from diagrams 5−38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.3 Exporting from the archive for the overall state 5−39 . . . . . . . . . . . . . . .




Contents of this chapter This chapter explains how to operate the �GFDM for VipWin"visualisation system for parameterising the diagnostic mo�dule�GFDM.



5.1 System overview of �GFDM for VipWin"

VipWin is a software module for visualising process data. Inaddition to providing basic visualisation and data acquisitionfunctions, VipWin also handles networking, data archiving oralerting tasks. VipWin also enables the development of ap�plication−specific projects.

�GFDM for VipWin" is a special visualisation project devel�oped by Festo for the diagnostic module GFDM.

�GFDM for VipWin" fulfils the following functions:

� parameterisation of the diagnostic module,

� recording of measured values and diagnostic results (log�ging),

� visualisation of current and archived measured valuesand diagnostic results.

5.1.1 Connecting �GFDM for VipWin" to a controller

�GFDM for VipWin" is physically connected to a controller viaa local network.

�GFDM for VipWin" is connected to a 3S OPC server, that is inturn connected to the controller, with the help of OPC com�munication.



5.1.2 Installing �GFDM for VipWin"

· Make sure there is no other VipWin version installed onthe�PC.

Administrator rights are required for installing the software.

Proceed as follows when installing from CD−ROM:

1. Close all programs.

2. Place the �GFDM for VipWin" installation CD−ROM in thedrive. If the installation starts automatically, you can skipSteps 3 and 4.

3. Change to the CD−ROM drive, for example in Explorer.

4. Double−click to start �Autorun.exe".

5. Select the desired language and confirm your selectionwith �OK".

6. Follow the instructions in the installation program. Clickon �Continue" to proceed to the next step or �Return" toreturn to the previous step.

When installation is completed, you will find two entries in thestart menu under �Festo Software\GFDM\".

� OPC IP Setup: Dialog for accepting the IP address of thecontroller (see 5.1.3).

� GFDM for VipWin: Visualisation system for the diagnosticmodule.



5.1.3 OPC IP Setup

A connection between �GFDM for VipWin" and the controllercan only come about if the IP address of the controller isstored in the OPC server. The IP address of the controller isstored in the PC using the �OPC IP Setup" dialog.

After initial commissioning of the controller and any changeto the IP address of the controller:

1. Start the dialog: Start menu\Programs\Festo Soft�ware\GFDM\OPC IP Setup.

Fig.�5/1: Dialog for accepting the IP address of the con�troller

2. Enter the correct IP address of the controller and pressthe �Accept" button.

The IP address of the controller can only be changed with thehelp of the �FCT with GFDM Plug−In" software package (seeSection�4.3).



5.2 Starting �GFDM for VipWin"

The �GFDM for VipWin" visualisation program needs a li�censed dongle (WIBU key) plugged into the USB port to runon a PC/laptop.

Without a dongle, the program only runs in demo mode andis terminated after 30 minutes.

· Start �GFDM for VipWin" via Start menu\Programs\FestoSoftware\GFDM\GFDM for VipWin.

After a short delay, the main view of the visualisation appearswith current information on the connected diagnostic module.

The connection with the controller is automatically estab�lished provided the IP address of the controller has been cor�rectly accepted (see Section 5.1.3).

5.3 Basic operation of �GFDM for VipWin"

The �GFDM for VipWin" visualisation program is operatedusing buttons and dialogs.

When using a screen with touch−sensitive interface:

· With your finger, gently touch the screen in the area of thebutton to be pressed.

When using a standard screen without a touch−sensitive inter�face:

· With your mouse, click in the area of the button to bepressed.

The �Menu" button brings you to the main menu of the visua�lisation.



5.3.1 Menu structure of �GFDM for VipWin"

Main�menu

Footer

Display�settings

Details�(of�the�overall�state) Overall�state�−�Archive

Diagnostic�settings−�Pressure−�Flow�rate−�Cycle�consumption

Refs.�and�limitsEntry�in�percent

Refs.�and�limitsEntry�of�the�difference

Diagrams Pressuremonitoring�module

Flow�ratemonitoring�module

State�archive

Cycle�consumptionmonitoring�moduleStatistics

(displaysettings)

Create�table

Create�table

Create�table

Create�table

Fig.�5/2: Menu structure of the visualisation program

The menu structure shows all the submenus and dialogs inthe visualisation program.

· Press the respective button for the desired dialog orsubmenu.

· Press the �{" button (Back) to return to the next−highermenu in the visualisation program.



5.4 Visualisation of the diagnostic module � Overview

5.4.1 Main view of the visualisation

1

2

3

Fig.�5/3: Main view of the visualisation of the diagnostic module

The visualisation of the diagnostic module is basically dividedinto three areas:

1 Header containing the designation of the view and menu−dependent button.

2 Main area for measured values, dialogs, submenusand/or further information.

3 Footer showing the overall state and two buttons.



Buttons in the main view

Area Button Function

Header Jumps to the main menu

Returns to the next−higher menu ordialog

Footer Jumps to the view �Details of the overall state"

Jumps to the dialog �Display settings"

Table�5/1: Buttons in the main view

Symbols for the overall state

Symbol Colour Meaning

Grey All monitoring modules are inactive.

Green All active monitoring modules signalling�Normal operation", the deviations arewithin the permissible range.

Yellow At least one active monitoring modulesignalling �Warning".

Orange At least one active monitoring modulesignalling �Maintenance advisable".

Red At least one active monitoring modulesignalling �Alarm".

Table�5/2: Symbols for the overall state



5.4.2 Main page of the diagnostic module

The main page of the visualisation contains current resultsfrom three monitoring modules, displayed both numericallyand graphically.

1 Numerical displayof the last result

2 Graphical displayof the currentresult

3 Marker indicatingthe referencevalue

4 Name of themonitoredsystem

1

2

3

4

Fig.�5/4: Main page of the visualisation

The diagnostic results and the graphical display in the visua�lisation are refreshed every second. The diagnostic results atthe digital output of the controller, on the other hand, areavailable in real−time.

· Press the �Menu" button in the header to go to the mainmenu of the visualisation (see Section 5.3.1).



5.4.3 Start signal for time selection

The diagnostic module can be configured without externalcycle triggers. In this case, a time trigger with recordingperiod is defined that is used to calculate the cycle consump�tion. The time trigger can be started automatically or man�ually.

The �Start trigger automatically" option can only be set withthe help of the �FCT with GFDM Plug−In" software (see onlineHelp: Configuring the diagnostic module � Triggers).

�Start trigger automatically" option

Option active The time trigger starts immediately once switch−on of thecontroller is completed.

Option inactive The first cycle must be started manually after the controller isswitched on. The �Start time trigger" button appears on themain page of the visualisation.

Fig.�5/5: Main page with �Start time trigger" button

· Press the �Start time trigger" button at the moment whenthe �Cycle consumption" monitoring module is to be acti�vated.



5.5 Operation of the diagnostic module

5.5.1 Display settings dialog

In this dialog you can change all the basic settings for thedialog module or special display settings.

The settings are spread over two pages:

1 Buttons forchoosing a page

1

Fig.�5/6: Display settings

· Press the page with a grey background to bring thehidden options to the front.

You can enable or disable the following functions using thebuttons:

Button Function/setting

Language German Language selection for menu, dialogsand information

Englishand information



Button Function/setting

Units 1) SI Pressure [bar]

Flow rate [l/min] (litres per minute)

Cycle consumption [l] (litres)

US Pressure [psi]

Flow rate [cfm] (ft3 per minute)

Cycle consumption [cf ] (ft3)

Exit program Closes the visualisation program.

Send to back Moves the visualisation program to thebackground of the PC desktop. If there isanother program running in the back�ground, this appears on the desktop andis brought to the front.

Change export path Selects a directory for exported data.

Prepare for batterychange

Copies the current configuration and thestatistical information (see 5.5.4) to thememory card of the controller so theyare available once more after a batterychange.

1) Stored archive data is not converted if the units are changed

Table�5/3: Display settings of �GFDM for VipWin"



5.5.2 Diagnostic settings dialog

In this dialog you can set the parameters of the monitoringmodules.

1 Buttons forchoosing amonitoringmodule

1

Fig.�5/7: Diagnostic settings

· Press the button for the monitoring module whose para�meters are to be changed.

The following settings can be made for the selected monito�ring module:

� selecting the diagnostic function,

� changing reference values and limits,

� storing reference values and limits.



Diagnostic function

The working mode of the monitoring modules can be setusing these buttons. The switch in working mode is per�formed for the previously selected monitoring module.

Working mode Diagnostic function

Active The monitoring module records measured va�lues and evaluates diagnostic results.

Inactive The monitoring module does not perform anystate calculation.

Teach−in (learning)

The monitoring module records measured va�lues to calculate a reference value.

Table�5/4: Buttons for the diagnostic function

Teach−in

This diagnostic function enables the automatic generation ofa new reference value.

As long as a monitoring module is in �Teach−in" workingmode, the measured values are used for calculating referencevalues. The more measured values available, the more mean�ingful the new reference values as a rule.

1. Press the button for �Teach−in" working mode.

2. Wait the following minimum times:

� the length of time of one controller cycle (5 ms) for the�Pressure" monitoring module,

� the length of time of one controller cycle (5 ms) for the�Flow rate" monitoring module,

� the length of time until execution of at least one com�plete system cycle for the �Consumption" monitoringmodule.



3. Do not press the button for another working mode (�Ac�tive" or �Inactive") until the abovementioned lengths oftime have passed.

�Teach−in" working mode is exited, the measured values areaveraged and the result is accepted as a new reference value.

NoteWith the end of �Teach−in" working mode, the new refer�ence value is set but not saved.

· Save the changed reference value to the memory card ofthe controller (see the chapter �Saving reference valuesand limits).

Reference values and limits

· To change reference values or limits, press one of thefollowing buttons:

� In percent ...

� Rel. diff. ... (relative difference to the reference value in the unit of the reference value)

The following screenshot shows as an example the currentreference values and limits for the �Cycle consumption" moni�toring module.



Fig.�5/8: Reference values and limits for the �Cycleconsumption" monitoring module

The dialog for setting reference values and limits shows thefollowing for each monitoring module:

� the reference value,

� six input fields for limits that are displayed as differencesrelative to the reference value.

The column on the left shows all the negative differences(for low limits) while the column on the right shows all thepositive differences (for high limits).

Fig.�5/9 shows the connection between reference valuesand/or limits and the change in colour of the state signal.



Changing reference values and limits

1. Press the button for the reference value or limit to bechanged. A numeric keypad for entering a new parameterappears.

2. Enter the new reference value or limit using the numerickeypad displayed or directly using the keyboard. Adhereto the following conditions when doing so:

� A limit is entered as a difference relative to the refer�ence value.

� The value of the difference for the limit �red" is alwaysgreater than the difference for the limit �orange".

� The value of the difference for the limit �orange" isalways greater than the difference for the limit �yel�low".

3. Accept the newly entered value with �Return".



Colour changes when limits are exceeded or fallenbelow

The diagram below shows the connection between the para�meters of the reference values and/or limits and the changein colour of the associated state signal using the example ofthe �Cycle consumption" monitoring module and the refer�ence value 10 l. The colour of the state signal changes eachtime a specific limit is exceeded.

1 22 33 44

+ 6.0 l=

+ 60 %

5

6+ 4.5 l=

+ 45 %

+ 2.5 l=

+ 25 %

+ 10 l� 2.0 l=

� 20 %

� 3.5 l=

� 35 %

� 5.0 l=

� 50 %

1 Reference value

2 Reference value for �Warning" (yellow)

3 Reference value for �Maintenanceadvisable" (orange)

4 Reference value for �Alarm" (red)

5 Arrow representation for delayedswitching with sensitivity > 0

6 Arrow representation for immediateswitching

Fig.�5/9: Colour change of the state symbol for the �Cycle consumption" monitoringmodule

The �Sensitivity" setting enables an improvement in the dis�tinguishability of diagnostic results. Momentary exceeding ofthe limit is displayed for longer.The �sensitivity" must be set using the �FCT with GFDMPlug−In" software package (see online Help: Commissioningthe diagnostic module � Monitoring modules).



Invalid entry

A warning message is output if the conditions for entering thelimits are not observed.

· Acknowledge the warning message by pressing the �OK"button.

The visualisation once more shows the overview of the refer�ence values and limits for the previously selected monitoringmodules. The invalid entry was not accepted.

Saving reference values and limits

Changed reference valued and limits can be saved to thememory card of the controller.

1. Press the �Save reference values and limits" button forthis purpose.

2. Confirm the prompt that appears using the �Yes" button.

The parameters of all monitoring modules for the currentmachine state of the monitored system are saved.

NoteThe saved reference values and limits are reloaded in theevent of the following actions:

� following transfer of a configuration to the controllerusing the �FCT and GFDM Plug−In" software package(see online Help: Transferring a configuration),

� following a change in the machine states of the moni�tored system (see Section 3.2.2),

� following a controller restart.



5.5.3 Diagrams dialog

In this dialog you can display measured values and diagnos�tic results. You can access data that was saved during theexecution time of the visualisation program or that is cur�rently being recorded.

You can call up the following diagrams using the appropriatebutton:

Diagrams Storage capacity

Pressure, flow rate 1 month in each case

Cycle consumption, state archive 1 year in each case

Table�5/5: Storage capacity of �GFDM for VipWin"

Diagram view of an archive

1 Legend with dateand time of themeasured value(only visible whenthe cursor isactive)

2 Characteristic(s)

2

1

Fig.�5/10: �Cycle consumption" diagram view

Each newly recorded measured value is displayed in real−timeat the right margin of the diagram. The previously recordedmeasured values move to the left and ultimately out of thevisible area of the diagram.



Display range of the diagram axes

Archive(default display)

Max. displayrange of the X−axis

Display range ofthe Y−axis

�Pressure" monitoringmodule

5 minutes − 1 ... 10 bar

�Flow rate"monitoring module

5 minutes 0 ... 200 l/min 1)

0 ... 5000 l/min 1)

�Cycle consumption"monitoring module

1 hour 0 ... 200 l 1

0 ... 5000 l 1)

State archive 5 minutes 1 ... 16

1) Display range depends on the chosen sensor

Table�5/6: Display range of the diagram axes

Characteristics of the diagrams

Archive Characteristics

�Pressure" monitoring module

� Measured value 1)

� Reference value 1)

�Flow rate"monitoring module



�Cycle consumption"monitoring module



State archive � Overall state 1)

� Operating state� Product number� Module state, pressure� Module state, flow rate� Module state, cycle consumption

1) Characteristic visible in default setting



The values of the characteristics for module state and overallstate have the following meaning:

Value Module state Overall state

0 Monitoring module isinactive.

All monitoring modules are in�active.

1 Monitoring modulesignalling normaloperation, deviationwithin permissiblerange.

All active monitoring modulessignalling �Normal oper�ation", deviations within per�missible range.

2 Monitoring modulesignalling �Warning".

At least one active monitoringmodule signalling �Warning".

3 Monitoring modulesignalling �Warningadvisable".

At least one active monitoringmodule signalling �Mainten�ance advisable".

4 Monitoring modulesignalling �Alarm".

At least one active monitoringmodule signalling �Alarm".

Table�5/7: Meaning of the values of the state characteristics

The characteristics for operating state and product numbercan assume the following values:

Characteristic Values

Operating state 1 = Automatic2 = Stop3 ... 16 (see Table�3/5)

Product number 1 ... 16

Table�5/8: Values of further characteristics



Buttons in the �Diagrams" dialog

Button Function

Cursor On/Off Enables or disables a vertical line in the displayeddiagram. The stored results are displayed withdate and time as a function of the cursor position.

Stop Disables the automatic display of new results.Recording of the results in real−time is continuedin the background.

Start Enables the automatic display of new results inreal−time.

Redraw The diagram results from the previous 5 minutesare redrawn. The default display range is enabledat the same time.

Characteristicsettings

Calls up a dialog for showing or hiding character�istics as well as for setting the colours of the se�lected characteristics.

Snapshot Stores the current diagram view on the Windowsclipboard.

Export Exports a text file containing the archive data fora particular day.· Select the directory for storing the text file in

the display settings (see Table�5/3)

Create table

Generates a table containing archive data for aperiod of time in the past (see the section �Diagrams in table form dialog").

.. Moves the visible area of the diagram to the leftby the displayed width.

,, Moves the visible area of the diagram to the rightby the displayed width.



Button Function

Zoom Enables the mouse pointer for selecting a zoomrange. This area is displayed full height and widthin the diagram.

Rezoom Restores the view of the diagram to default va�lues for the X− and Y−axes. The most recently dis�played time at the right margin of the diagramremains fixed.

Table�5/9: Buttons in the Diagrams dialog

Pressing a button executes the chosen function and at thesame time influences the display and the behaviour of theDiagrams dialog.

The following dependencies exist:

� Enabling the �Zoom" function stops the display of newresults in real−time, the �Stop" button is disabled.

� Pressing the �Rezoom" button starts the display of newresults in real−time, the �Start" button is disabled.

� Enabling the cursor disables the �Zoom" and �Rezoom"buttons.

� Disabling the cursor enables the �Zoom" and �Rezoom"buttons.

� Pressing the �Start" button disables the buttons for mov�ing the diagram view.

� Pressing the �Stop" button enables the buttons for mov�ing the diagram view.



Diagram in table form dialog

This dialog contains a table with archive data for a finiteperiod.

Archive Table capacity

�Pressure" monitoring module 15 minutes

�Flow rate" monitoring module 15 minutes

�Cycle consumption" monitoring mo�dule

60 minutes

State archive 60 minutes

Table�5/10: Table capacity of the archives

Fig.�5/11: Diagram in table form for the �Cycleconsumption" monitoring module



The following buttons are available:

Button Function

Page up Moves the visible area of the archive data up bythe displayed number of table rows.

Page down Moves the visible area of the archive data downby the displayed number of table rows.

Export Enables the �Report filter" dialog for saving afile containing the table of archive data.

Table�5/11: Buttons in the Diagrams in table form dialog

Report filter dialog

Fig.�5/12: Report filter dialog

· Enter a meaningful name for the export file.

· Choose a file format appropriate to the future use of theexport file:

� TXT,

� XRS,

� XML.



Further options:

Option Function

Generate name automatically

Generates a random file name from letters andnumbers.

Read archivefrom backup path

GFDM does not support this option.

Table�5/12: Options in the Report filter dialog

· Press the �OK" button to save the selected archive.

You can set the storage path for the export file (seeTable�5/3). Further information on the structure of the exportfile can be found in Section 5.7.

5.5.4 Statistics dialog

The statistical information is spread over two pages.

· Press the page with the grey background to display itscontents.

Fig.�5/13: Statistics dialog



· Press the �Reset statistic counter" button.

� The current date becomes the new validity date.

� The cycle and consumption counters are set to 0.

· Confirm the prompt that appears or cancel the operation.

The following information is available:

Designation Contents

Valid since Date and time when the statistic counters werelast reset.

Cycle counter Number of system cycles since the validity date.

Consumption Automatic

Overall air consumption in the operating state �Automatic" 1)

ConsumptionStop

Overall air consumption in the operating state�Stop" 1)

Overall con�sumption

Overall air consumption in all operating states 1)

1) All specifications refer to the period since the last validity date.

Table�5/13: Statistical information



5.6 Details of the overall state

This page contains all the information about the current diag�nostic results.

Fig.�5/14: Details of the overall state

Designation Information

Product Current product or current batch.

Operating state Current operating state.

FDC state Ready state of the controller: No connec�tion/Ok/error.

Pressure, Flow and Cycle consumption

Diagnostic result and diagnostic functionof the respective monitoring module.

Overall state(footer)

Diagnostic result for the monitored sys�tem.

Table�5/14: Details of the overall state

· Press the �Archive" button for further results (see Sec�tion�5.6.3).



5.6.1 Conditions for state calculation by the monitoring modules

The following conditions must be observed for state calcula�tion by the monitoring modules to take place:

� Controller started with no errors.

� Locking is inactive, i.e. �Pressure" monitoring modulestate is not �Red" (alarm).

� Operating status: �Automatic" or �Stop".

� Diagnostic function of the respective monitoring moduleis �Active" (see Section 5.5.2 �Diagnostic function").

� For the �Cycle consumption" monitoring module: At leastone system cycle has passed since the restart or since thechange in operating state.

� Entry of a limit ., 0.

5.6.2 Symbol representation of the diagnostic results

The result of the monitoring modules is displayed using sym�bols. These symbols have different colours and shapes.

Symbol Colour Meaning

Grey The monitoring module is inactive.

Green The active monitoring module is signalling�Normal operation", the deviation iswithin the permissible range.

Yellow The active monitoring module is signalling�Warning".



Symbol MeaningColour

Orange The active monitoring module is signalling�Warning advisable".

Red The active monitoring module is signalling�Alarm".

Table�5/15: Symbol representation for monitoring modules

Overall state of the diagnostic module

The overall state is derived from the results of the monitoringmodules. The result for overall state is given by the more sig�nificant of the states of the active monitoring modules.

Examples:

Pressure Flow rate Cycle con�sumption

Overall state

Table�5/16: Examples for overall state on the basis of re�sultsof the monitoring modules



5.6.3 Archive for the overall state

The archive contains max. 1024 entries relating to changes instate of the overall state. The most recent entry appears inthe bottom line. While this view is active, all new entries ap�pear in blue font.

Fig.�5/15: Archive for the overall state

Each entry contains the following information:

� date and time,

� designation for the new overall state and/or designation for the new module state,

� comment (initially without content).

The possible designations for overall state and module statecan be found in Section 5.7.



The following functions are available:

Button Function

Break/Continue

Interrupts or continues updating of the archive.

Export Exports the archive for the overall state as a textfile in ANSI format.

Scrollbar Moves the entire archive list up or down in the win�dow.

Table�5/17: Buttons in the archive for the overall state

Exporting the archive

The export path can be set (see the Section 5.5.1)

· Press the �Export" button.

· Confirm the prompt to export the file to the specified ex�port path using the �OK" button.

Further information on the structure of the export file can befound in Section 5.7.



5.7 Data export

Diagnostic Module GFDM...Contents and general instructions Festo GDCA−GFDM−EN en 0802a IX...

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