3839371

Installation manual
ValveConnectionSystem
Connection system for solenoid valves and

spool valves designed for fieldbus systems
PROFIBUS-DP, INTERBUS-S, DEVICE-NET
MS-P575-5.GB.R3a
GB
INSTALLATION
CAUTION !
To avoid malfunction of the automation system, please read and follow these instructions:
Ensure that the address size is correctly set. It may only be changed by qualified personnel.
Make sure the VCS connector is correctly wired. The VCS circuit must always be looped through. Only use approved
profiled cables (see 2.1).
Only use approved power supplies (see 2.1).
Be sure the power supply is switched off prior to contacting the VCS cable. Risk of short circuit!
To ensure personal safety and prevent damage to property, all maintenance and installation work must be carried out
by qualified personnel.
Make sure to meet the electrical specifications of the system when operating it together with third-party equipment and
components.
Install all power and signal cables such that inductive and capacitive interference of the automation functions is avoided.
Take all safety precautions when coupling the inputs and outputs to the hardware and software to avoid undefined
conditions on the signal side of the automation system in case of line or conductor break.
To ensure safe operation of the product, provide for suitable transportation, storage, installation and assembly as well
as proper operation and maintenance.
WARNING !
In the case of equipment with permanently installed connections (fixed devices/systems) without all-pole mains
disconnect switch and/or switch fuses, incorporate a mains disconnect switch or fuse in the building installation. The
equipment must be connected to a ground conductor.
In the case of line powered equipment, check that the set nominal voltage range is in compliance with the local supply
voltage prior to putting the equipment in service.
In the case of a 24V power supply, provide for safe electrical separation of low voltage. Only use power supplies
manufactured in compliance with IEC 364-4-41.
Take precautions to ensure that a program interrupted due to drop or loss of voltage is properly resumed. Dangerous
operating conditions must be avoided at all times. If necessary, provide for an emergency shutdown.
To avoid operational failure, do not directly connect high frequency between 250 and 900 kHz to the VCS cable.
In all cases in which faults occurring in automation equipment may result in substantial material or even personnel
damage, i.e. in which dangerous faults may occur, take additional external precautions or provide for additional external
equipment to ensure and/or force safe operation in the case of a fault (e.g. independent limiting switches, mechanical
interlocks etc.).
CAUTION
ESD
OBSERVE PRECAUTIONS
FOR HANDLING
ELETROSTATIC SENSITIVE
DEVICES
This product contains electronic components sensitive to electrostatic

discharge. An electrostatic discharge generated by a person or object
coming in contact with the electrical components can damage or destroy
the product.
To avoid the risk of electrostatic discharge, please observe the handling
precautions and recommendations contained in standard EN 100015-1.
Do not connect or disconnect the device when it is energised.
This product complies with the essential requirements of the EMC Directive 89/336/EEC and its amendments. It is CEapproved. A separate Declaration of Conformity is available on request.
A separate Declaration of Incorporation relating to the EU Directive 89/392/EEC Annex II B is available on request. Please
provide ordering code and serial numbers of products concerned.
NOTICE
The information in this manual is subject to change without notice.
In no event shall ASCO/JOUCOMATIC be liable for technical or editorial errors or omissions. Neither is any liability assumed for
accidental or consequential damages arising out of or in connection with the supply or use of the information contained herein.
THIS MANUAL CONTAINS INFORMATION PROTECTED BY COPYRIGHT. NO PART OF THIS DOCUMENT MAY BE PHOTOCOPIED
OR REPRODUCED IN ANY FORM OR MANNER WHATSOEVER WITHOUT PRIOR WRITTEN PERMISSION FROM
ASCO/JOUCOMATIC.
COPYRIGHT
2001 - ASCO/JOUCOMATIC - All rights reserved.
INSTALLATION
CONTENTS ________________________________________________________________ Page
1.
1.1
1.2
VCS - VALVE CONNECTION SYSTEM _______________________________________________________ 4

Structure _________________________________________________________________________________ 4
Diagnostics _______________________________________________________________________________ 5
2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
SYSTEM COMPONENTS __________________________________________________________________ 6

Description _______________________________________________________________________________ 6
VCS connector ____________________________________________________________________________ 8
VCS cable _______________________________________________________________________________ 9
VCS interface ____________________________________________________________________________ 10
VCS power supply: 27V/max. 3.1 A ___________________________________________________________ 17
Power supply: 24V/max. 10 A _______________________________________________________________ 17
Accessories _____________________________________________________________________________ 18
3.
3.1
3.2
3.3
3.4
3.5
3.6
POWER SUPPLY ON VCS LOOP __________________________________________________________ 20

Principle ________________________________________________________________________________ 20
Power supply of coils 2.4 W _______________________________________________________________ 20
Power supply of coils > 2.4 W (max. 24 W) _____________________________________________________ 25
Power supply of coils 2.4 W and > 2.4 W _____________________________________________________ 27
Supply of VCS loop with a standard 24V power supply ____________________________________________ 28
Selection charts (summary) _________________________________________________________________ 30
4.
4.1
4.2
4.3
INSTALLATION INSTRUCTIONS __________________________________________________________ 32

Power supply connection ___________________________________________________________________ 32
Subsequent extension of the system __________________________________________________________ 33
VCS connector replacement ________________________________________________________________ 34
5.
5.1
5.2
5.3
CONNECTION TO STANDARDISED FIELDBUS SYSTEM ______________________________________ 35

Profibus-DP _____________________________________________________________________________ 35
Interbus-S _______________________________________________________________________________ 36
DeviceNet _______________________________________________________________________________ 37
6.
6.1
6.2
6.3
6.4
START-UP _____________________________________________________________________________ 39
Start-up instructions _______________________________________________________________________ 39
Automatic addressing ______________________________________________________________________ 39
Test mode ______________________________________________________________________________ 40
Error mode ______________________________________________________________________________ 41
7.
7.1
7.2
VCS DIAGNOSTIC SOFTWARE (VCS - DIAG) ________________________________________________ 42

Program installation _______________________________________________________________________ 42
Connection of the VCS interface _____________________________________________________________ 42
8.
8.1
8.2
TECHNICAL CHARACTERISTICS __________________________________________________________ 43

Electrical characteristics ___________________________________________________________________ 43
Dimensions and weights ___________________________________________________________________ 44
9.
MAINTENANCE AND CARE ______________________________________________________________ 46
10.
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
MEGA 18 SPOOL VALVE ISLANDS WITH VCS CONNECTORS _________________________________ 47

Presentation _____________________________________________________________________________ 47
Dimensions and weights ___________________________________________________________________ 47
Ordering information for MEGA island with VCS connectors ________________________________________ 48
Accessories _____________________________________________________________________________ 49
Pressure supply of pilot valves ______________________________________________________________ 52
Mounting and pneumatic accessories _________________________________________________________ 52
Assembly of MEGAislands/VCS connectors ____________________________________________________ 53
Joinable solenoid air operated MEGA spool valves _______________________________________________ 54
VCS Application Requirements Form _______________________________________________________________ 55
INSTALLATION
1.
VCS - VALVE CONNECTION SYSTEM
The Valve Connection System, VCS in short, was designed to link together as many valves as possible in an easy, quick
and economic way.
1.1
Structure
fieldbus
1
I
3
P
B
4
All combinations of spool valves for pneumatic or water

applications, solenoid air operated valves or general
purpose valves can be connected together in one V.C.S. loop.
Up to 127 V.C.S. connectors and 254 sensor inputs
up to a distance of 2.5 km !
5
(C)
1 Solenoid spool valve alone or

installed on multiple subbase
2 MEGA spool valve island
3 General purpose solenoid valve

4
General purpose valve
5 Air-operated valve actuator
(C)
3
2
6 VCS module with 8 inputs

I
VCS interface
P VCS power supply

G VCS cable (green)
B Power cable (black)
C Sensor inputs
With this new valve connection system, you can connect up to 127 valves with 2 solenoid coils each (bistable valves) and
up to 254 sensor inputs with a single cable and a quick-contact technology.
Fieldbus systems (e.g. Interbus-S or Profibus-DP) are increasingly being used in installations and machines to connect
sensors and actuators to a controller (PC or PLC). It is in this kind of structure that the VCS is integrated together with its
VCS interface. The VCS interface communicates with the higher-level fieldbus system and transmits the switching
information to the valves. The corresponding feedback (C) from the digital sensor inputs (limit switches) is transmitted over
the line to the VCS interface and from there to the fieldbus system.
The valves or nodes in the VCS line are connected with each other and to the VCS interface (I) over a profiled 2-wire VCS
cable (G). Power as well as data are supplied to each valve over this VCS cable. To enable easy and quick connection of
the valves to the VCS cable, ASCO/JOUCOMATICs engineers have designed a special VCS connector which is fitted onto
the valve and into which the profiled 2-wire VCS cable is placed. When the lid of the connector is snapped shut, the vampiretype plug automatically provides for immediate contact of the wires of the VCS cable which is also automatically cut to length.
The node is connected. Each VCS connector is equipped with a data repeater to bridge a distance of up to 20 m between
two valves. This allows for designing large valve systems. No tools are necessary to fasten the lid. You simply snap it shut.
No cable cutting, stripping or screwing is required.
In the basic version, the VCS interface is connected to a VCS power supply (P). Depending on the number of valves in the
valve connection system and its size, additional power supplies can be clamped directly onto the cable to provide for an
appropriate power output and compensate for any drop of voltage.
In order to ensure the highest possible transmission protection, the VCS line is structured in the form of a loop system, i.e.
the last valve in the line must again be connected to the VCS interface. The advantage is that the transmitted data is fed
back to the VCS interface for comparison. The outputs are switched only after the transmitted data and the feedback data
is 100 % identical.
INSTALLATION
VCS characteristics :
Max. number of connectors in a line
: 127 (for solenoid valves or monostable / bistable spool valves)
Max. number of connectable sensors (M8) : 254 (data readback from sensors)
VCS addressing
: automatic :easy startup and operation
Electrical connection / spool valve
: special vampire-type VCS connector size 15 for quick connection
Electrical connection of VCS/Interface loop : screw terminals
Contact/electrical connection
: no tools, no cable cutting / stripping
Max. distance between two valves
: 20 m
Max. length of the line
: 2.5 km
Supply voltage / spool valve
: 24V DC
Current/Max. output power
: Depending on the connector version proposed :
- 100mA (2,4W) per output with green VCS cable to be used with 3,1A
power supply unit
- 1A (24W) per output with circuit and 10A auxiliary power supply unit
circuit for control of solenoid valves with ratings greater than > 2,4W,
series 107 - 189 - 190 and 192 and all fluid solenoid valves
- or 100 mA (2,4W) per output with green cable and separate power
circuit (black cable) for emergency shutdown management (see overleaf)
Data protection
: data readback and comparison,
repeater in each VCS connector, parity check.
Cycle time
: approx. 3,4 ms with 127 connectors
Protection degree
: VCS connector : IP65 - power supply and interface : IP20
Electromagnetic compatibility
: in accordance with EU directive EMC/89/336/EEC.
CE mark
1.2
Diagnostics
The VCS has a fine-diagnostic feature. Each VCS connector cyclically transmits diagnostic information which is analysed
by the VCS interface. As a result, the VCS system detects:
valve low voltage,
VCS connector overheating,
overcurrent at valve output
The VCS interface also has comprehensive error analysis features.
It is provided with an RS-232 interface which can be connected to a PC. The system can be started up (even without
fieldbus) and analysed with the supplied diagnostic software.
The following functions are activated over PC:
setting of valve outputs,
reading of sensor inputs,
reading of diagnostic information,
checking of actual configuration,
address allocation.
The VCS system consists of four principle components (see following pages):
A VCS connector to be mounted to a solenoid valve or spool valve (C)

The VCS interface adapted to the protocols Profibus-DP, Interbus-S and Device-Net (I)
The VCS power supply (P)
The green VCS cable (G) + the black cable (b) for separate power supply for outputs
(if required)
Fieldbus
VCS
Interface
INSTALLATION
2.
SYSTEM COMPONENTS
2.1
Description
A.
VCS connector (see chap. 2.2)

Accessories
Description
VCS connector size 15, 24V DC with 2 outputs max. 100 mA

(connection exclusively over green cable)
VCS connector size 15, 24V DC with 2 outputs max. 100 mA

and auxiliary power supply
(connection with green and black cable)
VCS connector size 15, 24V DC with 1 output max. 1A
and auxiliary power supply
(connection with green and black cable)
B.
Code
without input
single unit 881 57 803

box of 8 881 00 600
with 2 inputs M8

box of 8 881 00 601
without input
with 2 inputs M8
single unit
box of 8
single unit
box of 8
881
881
881
881
57
00
57
00
949
602
951
603
without input

box of 8 881 00 604
with 2 inputs M8

box of 8 881 00 605
Adapter 15/22 for VCS connector mounting on coil size 22

to industrial standard (2 flat pins DIN46244 + earth, distance between pins 11mm)
881 57 811
Adapter 15/30 VCS connector mounting on coil with 2 pins + earth to ISO 4400 standard
881 57 812
VCS interface (see chap. 2.4)

Accessories
Description
Standard VCS interface for connection with protocol:
VCS interface with 2 analog inputs/outputs 0 - 10V

(e.g. for Sentronic) for connection with protocol:
Code
Profibus-DP
881 57 840
Interbus-S
881 57 841
Device-Net
Profibus-DP
881 57 842
Interbus-S
881 57 922
881 57 921
Device-Net
881 57 923 ( )
9 male pin SUB-D connector for Profibus-DP - IP20
881 00 331
9 female pin SUB-D network input connector for Interbus-S - IP20 (BUS/IN)
881 57 925
9 male pin SUB-D network output connector for Interbus-S - IP20 (BUS/OUT)
881 57 926
Configuration diskette (.GSD / .EDS) for Profibus-DP and Device-Net
881 57 957
Diagnostic software for VCS / PC
881 57 852 ( )
RS232 cable for VCS interface/PC connection. Length: 1.8 m

(only for use with diagnostic software)
881 57 853
VCS installation manual
881 57 876
( ) future product
INSTALLATION
C.
Power supplies (see chap. 2.6)

Accessories
D.
Description
VCS power supply 27V DC - 3.1A
881 57 845
Power supply for black power cable, 24V DC adjustable - 10A
881 57 846
Cables (see chap. 2.3)

Accessories
E.
Code
Description
Code
Flat profiled VCS cable, green, 2 wires - lengths:
25 m
50 m
100 m
881 57 889
881 57 890
881 57 857
Flat power cable, black, 2 wires - lengths:
25 m
50 m
100 m
881 57 940
881 57 941
881 57 928
VCS adapter (round/flat) for connection of additional VCS power supply

right-angle outlet with cable gland for round cable dia. 4 to 6mm
881 57 855
Extension module for flat VCS cable or power cable (flat/flat)
881 57 854
1 set of 10 self-adhesive flat cable mounting clips
881 57 856
1 set of heat-shrinkable 10 end caps for flat cable ends

to ensure IP65 protection
881 57 927
1 set of 17 clip-on ID labels for spool valves and VCS connectors

(Note: each component is supplied with 4 ID labels at delivery)
881 57 851
1 set of 10 guides for green VCS cable

Note: each VCS connector is supplied with this guide + 1 spare guide
978 02 256
1 set of 10 guides for black power supply cable

Note: each VCS connector is supplied with this guide + 1 spare guide
978 02 257
VCS input modules

Accessories
Description
Code
VCS input module, 8 PNP inputs, 8 x M8 connectors
881 57 827
Straight 3 male pin input connector M8 (cable dia. 3.5 to 5mm)
881 57 813
Right-angle 3 male pin input connector M8 (cable dia. 3.5 to 5mm)
881 57 814
INSTALLATION
2.2
View from bottom

for monostable and bistable valves
VCS connector
3
LINK
PE
9
11
7
10
13
14
12
910 11 -
Description
Solenoid valve connection, 15 mm(1), 4 pins
Lever to contact the green VCS cable and the black power cable
Green VCS cable guide
Black power cable guide (depending on the VCS connector version)
Green VCS cable
Black power cable (depending on the VCS connector version)
LED indicator for inputs 0 and 1:
green light if input is connected.
LED indicator for valve outputs 0 and 1:
Output 0 pneumatic function 14 (yellow)
Output 1 pneumatic function 12 (green)
Clip-on identification labels to indicate the valve function
Lever catch
Screw to mount the VCS connector to the solenoid valve
12 13 14 15 -
Connection for inputs (limit switches): M8 female panel connector (see below)
Input 0: depending on the VCS connector version
Input 1: depending on the VCS connector version
Clip-on identification labels to indicate the input function
Seal for solenoid valve
8-
(1) Solenoid valve connection, 15mm, 3 pins (space 9,4mm) + PE for monostable and bistable valves
2.2.1
Wiring diagram of inputs
View on soldered side of male connector
2-wire sensor
3-wire sensor
(magnetoresistive position detector)
IN
IN
24V
+
Sensor
24V
Sensor
3 wires
GND
1 24V 10 %
3 GND*
4 IN 0/IN 1
* not applicable
for 2-wire sensor
Cable inlet: 3.5 - 5 mm.
1
3
15
Nr.
1234567-
1: OUT 0
2: 24V DC 10 %
3: OUT 1
INSTALLATION
2.3
VCS cable
2.3.1
VCS cable installation
Be sure the power supply is switched off prior to contacting

the VCS cable.
Risk of short circuit!
You can install it in just seconds !
!
Power
off
before any
connection/disconnection
3
A
A.
VCS cable
Open the lever by pressing the catch.
Lift the lever until it snaps into the buffer.
Mount the empty cable guide (A) into the cable tray. In case the cable guide snaps in at the bottom, pull it up with a
screw driver.
The cable guide must snap in at the top to ensure for proper contacting.
Insert the cable by first inserting the profiled side and then the opposite side. The arrow on the cable must show
in the same direction as the arrow on the lever.
Press down the lid until the catch snaps in: the cable is cut to length and contacted.
1
2
3
4
5
B.
Black power cable

The same procedure as for the green VCS cable. But the black power cable is not cut to length.
i
2.3.2
Insert the green VCS cable into the green cable guide (A) (see above illustration) and the black power cable into
the black cable guide.
Wiring instructions for the flat cables
The VCS cable and the black power cable must only be bent towards the broad, flat side of the cable. Both cables must
be mounted without strain.
INSTALLATION
2.4
VCS interface
6
ERROR
R POWER
TERM DIA
PROFIBUS-DP
INTERFACE
x10
x1
1
ADDRESS
ON
100
10
2
SIZE
RUN DATA > T

OFF
4
ERR
OUT <V
TEST
ON
27 V
4 2
RS232C
3
5
Ref.
Description
1-
Setting and connection for fieldbus interface.
2-
RS-232C interface for connection to a PC (VCS-DIAG).
3-
DIP switches for configuration of interface and selection of operating mode.
4-
LED indicators for display of operating state.
5-
VCS connecting terminals.
6-
Optional connecting terminals for analog inputs/outputs (Sentronic).
7-
Reset button, restart of VCS interface.
2.4.1
VCS connecting terminals

8
10
11
12
VCS OUT
VCS IN
POWER
CONTROL
IN
9
STANDARD
VCS
SUPPLY
SUPPLY
27V
Ref.
0V
+U
GND
+
blue brown
_
+
brown blue
24V
0V
Description
8-
Connection to ground: to be connected to the machine ground.
9-
VCS power supply connections (see chapter 4.1).
10 -
Beginning of VCS loop.
11 -
End of VCS loop (return).
12 -
Voltage control input for black power cable (see chapter 4.1).
To connect the VCS cable to the VCS interface, strip the profiled cable by approx. 20 mm and protect each wire end with a sleeve.
10
INSTALLATION
2.4.2
Analog input/output signals (Option)
Connecting terminals for proportional valve (sentronic)

13
14
15
SENTRONIC 1
SENTRONIC 2
SENTRO
SUPPLY
SUP
24V GND SET
SET
GND Feedbk
SUP
24V GND SET
SET
GND Feedbk
24V GND
Ref.
Description
13 -
Analog input/output signals 1 for proportional valve connection (Sentronic etc.)
14 -
Analog input/output signals 2 for proportional valve connection (Sentronic etc.)
15 -
Power supply connection for analog inputs/outputs (must be connected for analog input/output option)
Connection of SENTRONIC or PULSTRONIC to VCS interface terminals

Signal
Function
SENTRONIC
Pin assignment
PULSTRONIC
Pin assignment
24V
Power supply
SUP - GND
common ground
SET
Setpoint (0 - 10V)
SET - GND
Feedbk
Feedback value (0 - 10V)
) Only if the feedback (0-10V) option is used.
2.4.3
Assignment of RS-232C interface

Pin
Signal
Function
TD
Transmitted data
RD
Received data
GND
Common ground
A one-to-one cable in which RD and TD are not crossed is used for connection to a PC.
Data transmission occurs without parity bit at a rate of 19200 baud.
11
INSTALLATION
2.4.4
RUN DATA > T
LED indicators
A flashing sequence is run as soon as the VCS interface is switched on. Subsequently, RUN
and 27V are permanently lit. See chapter 6.1 if these controls do not light up. The DATA LED
indicates a general communication problem. LEDs >T, <V and OUT indicate group errors.
For detailed information, see chapter 6.1 (operative malfunction).
27 V
OUT <V
LED
Error description
27 V
flashes in case of internal error;

lights up constantly during faultless operation;
does not light up when supply voltage is not available.
lights up constantly during faultless operation;
does not light up in case of internal error.
Too many errors when transmitting data in the VCS loop. No safe data transmission possible (see
chapter 6.2).
RUN
DATA
General error
>T
Group error
Overheating in either one or several VCS connectors. The temperature inside the connector has
exceeded 85 C. Check VCS connector and valve.
Overcurrent at the output of either one or several VCS connectors. The output current is above
200 mA. Check VCS connector and valve for short circuit.
Low voltage at either one or several VCS connectors. The supply voltage of the VCS cable has
dropped below 19 Volt. Check the load, add another VCS power supply if necessary.
OUT
Group error
<V
Group error
For group errors, the number of the faulty VCS connector can be indicated by LEDs 100, 10, 1. For this purpose, set
the ERR switch to ON (see chapter 6.4).
DIP switches
ERR
Test
0
1
1
0
Fieldbus communication: Stop at errors <V, >T, OUT, DATA.

The outputs are switched off.
Test mode
Error indication
Fieldbus communication: Do not stop at errors <V, >T, OUT.
The outputs are not switched off. Stop at error DATA.
ERR - Error
SIZE
OFF (0)
ON (1)
ERR
TEST
2.4.5
8 4 2
: indicates where the error is located with the help of the LED indicators (see above)
TEST - Test mode : locates an interruption in the VCS loop (see chapter 6.3)
SIZE
: defines the address space of the VCS interface in the fieldbus system and/or PLC. The address
space can be adjusted to the number of VCS connectors used. Unoccupied address space can
thus be set free for other control operations.
The address space must always be larger than the number of VCS connectors in the loop; otherwise an
error is reported on the LED indicators when the system is started.
Dec.
Size
4
2
0
1
2
3
4
.
8
.
12
13
14
15
0
0
0
0
0
0
0
0
0
1
0
0
1
1
0
0
1
0
1
0
1
1
1
1
1
1
1
1
0
0
1
1
0
1
0
1
12
Address space (number of bytes occupied)

without analog input/output option
with analog input/output option
4
6
8
10
12
.
20
.
28
30
32
34
6
8
10
12
14
.
22
.
30
32
34
36
Max. number
of VCS connectors
8
16
24
32
40
.
72
.
104
112
120
127
INSTALLATION
Without analog input/output option:
(A = Address space)
A = 2 (size + 2) [in byte]
2 Bytes are reserved for diagnostic purposes.
With analog input/output option:

A = 2 (size + 3) [in byte]
2 Bytes are reserved for diagnostic purposes and another 2 bytes for the analog input/output option.
Max. number of connectable VCS connectors (VCSmax):

VCSmax = (size + 1) 8
Address space assignment in the fieldbus system of the PLC:

A. Without analog input/output option
Rel. Address
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
VCS connector 4
0.7
0.6
VCS connector 3
0.5
0.4
VCS connector 2
0.3
0.2
VCS connector 1
0.1
0.0
VCS connector 8
1.7
1.6
VCS connector 7
1.5
1.4
VCS connector 6
1.3
1.2
VCS connector 5
1.1
1.0
VCS connector 12
2.7
2.6
VCS connector 11
2.5
2.4
VCS connector 10
2.3
2.2
VCS connector 9
2.1
2.0
VCS connector 16
3.7
3.6
.
.
.
.
.
.
VCS connector 15
3.5
3.4
.
.
.
.
.
.
VCS connector 14
3.3
3.2
.
.
.
.
.
.
VCS connector 13
3.1
3.0
.
.
.
.
.
.
VCS connector
[4(N-2)]-2
(N-2).3
(N-2).2
VCS connector
[4(N-2)]-3
(N-2).1
(N-2).0
3
.
.
.
(N-2).7
(N-2).6
VCS connector
[4(N-2)]-1
(N-2).5
(N-2).4
N-1
(N-1).7
(N-1).6
(N-1).5
(N-1).4
(N-1).3
(N-1).2
(N-1).1
(N-2).0
N = 2(Size + 2)
(N).7
(N).6
(N).5
(N).4
(N).3
(N).2
(N).1
(N).0
N-2
Function
Diagnostic byte
(inputs only)
Error counter
(inputs only)
x = unoccupied
The above assignment is applicable for inputs and outputs.

Exception: Byte N and byte N-1 are assigned for the inputs only of the diagnostic byte and the error counter.
For Interbus-S:
In case Interbus-S is used as fieldbus system, the address space is limited to 20 byte (max. relative address N = 19).
Recommended setting of size for Interbus-S = max. 8 (7 with analog input/output option).
Max. number of VCS connectors = 72 (64 with analog input/output option).
13
INSTALLATION
Diagnostic byte:
The diagnostic byte must be evaluated by the PLC program to be able to react differently to the various errors reported.
DIAG. 7
DIAG. 6
DIAG. 5
DIAG. 4
DIAG. 3
DIAG. 2
DIAG. 1
DIAG. 0
Power Fail
Sentro
Power Fail
Outputs
n.u.
OUT
<V
n.u.
Data
Error
>T
n.u. = not used
Description:
DIAG. 7:
Power Fail analog signal (Option)

If you have the analog input/output option:
The power supply for the analog inputs/outputs (Sentronic valves) is not connected, too low, or has a short circuit.
- Check the voltage of the VCS interface at the corresponding terminals (SENTRO SUPPLY).
If you do not have the analog input/output option: DIAG. 7 always at "1".
DIAG. 6:
Power Fail Outputs (Option)

If the black cable (power cable) is used:
The power supply for the black power cable is not connected to the Power Control IN terminals, or it is
too low, or has a short circuit.
- Check the voltage of the VCS interface at the corresponding terminals (Power Control IN).
If the black cable (power cable) is not used: DIAG. 6 always at "1".
DIAG. 5:
n.u. = not used.
DIAG. 4:
OUT, Overcurrent
An overcurrent (above 200 mA) has occurred at one of the VCS connectors. Use the software VCS-DIAG
(see chapter 7) for fine diagnostics. The communication on the fieldbus and the switching off of the outputs
are treated according to the DIP switch settings.
- Check the corresponding VCS connector and valve and eliminate the overcurrent. The faulty VCS
connector can be detected with the DIP switch ERR (see chapter 6.4).
DIAG. 3:
< U, Low voltage

Low voltage is reported for at least one VCS connector. Use VCS-DIAG (see chapter 7) for fine diagnostics.
The communication on the fieldbus and the switching off of the outputs are treated according to the DIP
switch settings.
- Check the voltage at the corresponding VCS connector. Fit an additional VCS power supply into the VCS
loop, if necessary. The faulty VCS connector can be detected with the DIP switch ERR (see chapter 6.4).
DIAG. 2:
n.u. = not used.
DIAG. 1:
Data Error
Data transmission errors occur constantly. The VCS cannot be operated safely any more. Communication
on the fieldbus is stopped. All outputs are switched off.
- Check the VCS loop in the test mode (see chap. 6.3). Replace a faulty VCS connector and/or cable
interruptions (see also error counter), if necessary.
DIAG. 0:
> T, Overheating
At least one VCS connector is overheated. Use VCS-DIAG (see chapter 7) for fine diagnostics. The
communication on the fieldbus and the switching off of the outputs are treated according to the DIP switch
settings.
- Check the corresponding VCS connector for overload and the corresponding valve for excess generation of
heat (coil short circuit). The faulty VCS connector can be detected with the DIP switch ERR (see chap. 6.4).
14
INSTALLATION
Error counter:
The error counter counts the number of faulty VCS cycles per time unit (error rate). This must not necessarily be controlled
by the PLC program. Communication on the fieldbus is stopped and the diagnostic bit DIAG. 1 (DATA ERROR) is set as
soon as the admissible error limit is exceeded. All outputs are switched off.
The admissible error limit depends on the number of VCS connectors in the VCS loop.
ERROR. 7
ERROR. 6
ERROR. 5
ERROR. 4
ERROR. 3
ERROR. 2
ERROR. 1
ERROR. 0
27
26
25
24
23
22
21
20
The error counter can show the decimal values 0 - 255 (0 - FF Hex).
Number of VCS connectors
Error limit
1 - 15
16 - 31
62
51
32 - 47
48 - 63
43
38
64 - 79
80 - 95
96 - 111
112 - 127
33
30
27
25
The error counter is updated every 225 msec. Communication is stopped as soon as more than 50% of the VCS cycles are
faulty.
15
INSTALLATION
B.
With analog input/output option

Rel. Address
Bit 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
VCS connector 4
0.7
0.6
VCS connector 3
0.5
0.4
VCS connector 2
0.3
0.2
VCS connector 1
0.1
0.0
VCS connector 8
1.7
1.6
VCS connector 7
1.5
1.4
VCS connector 6
1.3
1.2
VCS connector 5
1.1
1.0
VCS connector 12
2.7
2.6
VCS connector 11
2.5
2.4
VCS connector 10
2.3
2.2
VCS connector 9
2.1
2.0
VCS connector 16
3.7
3.6
.
.
.
.
.
.
VCS connector 15
3.5
3.4
.
.
.
.
.
.
VCS connector 14
3.3
3.2
.
.
.
.
.
.
VCS connector 13
3.1
3.0
.
.
.
.
.
.
x
(N-4).7
VCS connector
VCS connector
VCS connector
[4(N-4)]-1
[4(N-4)]-2
[4(N-4)]-3
(N-4).5
(N-4).4
(N-4).3
(N-4).2
(N-4).1
(N-4).0
3
.
.
.
N-4
x
(N-4).6
function
N-3
Setpoint 1.7 Setpoint 1.6 Setpoint 1.5 Setpoint 1.4 Setpoint 1.3 Setpoint 1.2 Setpoint 1.1 Setpoint 1.0
Feedback 1.7 Feedback 1.6 Feedback 1.5 Feedback 1.4 Feedback 1.3 Feedback 1.2 Feedback 1.1 Feedback 1.0
Sentronic 1
N-2
Setpoint 2.7 Setpoint 2.6 Setpoint 2.5 Setpoint 2.4 Setpoint 2.3 Setpoint 2.2 Setpoint 2.1 Setpoint 2.0
Feedback 2.7 Feedback 2.6 Feedback 2.5 Feedback 2.4 Feedback 2.3 Feedback 2.2 Feedback 2.1 Feedback 2.0
Sentronic 2
N-1
DIAG. 7
DIAG. 6
DIAG. 5
DIAG. 4
DIAG. 3
DIAG. 2
DIAG. 1
DIAG. 0
Diagnostics
(inputs only)
N=2(size+3)
N.7
N.6
N.5
N.4
N.3
N.2
N.1
N.0
Error counter
(inputs only)
x = unoccupied
The setpoint and the feedback value for the analog signal pressure regulator are transmitted with an 8-bit resolution.
The output pressure is calculated as follows:

Pout = Set PMR
255
Set
= decimal setpoint (0 ... 255)
PMR = maximum output pressure of the analog signal valve.
The above assignment is applicable for inputs and outputs.
Exception: Byte N and byte N-1 are assigned for diagnostics and error counter.
Setpoint and feedback value function in response to the same address. The setpoints are output data and the feedback
values are input data.
For Interbus-S:
In case Interbus-S is used as fieldbus system, the address space is limited to 20 byte (max. relative address N = 19).
Max. reasonable setting of size for Interbus-S = 7 (8 without analog signal option).
Max. number of VCS connectors = 64 (72 without analog signal option).
16
INSTALLATION
2.5
VCS power supply: 27V max. / 3,1 A

(with integrated "data/voltage" decoupling)
This unit is for power supply to the VCS interface and VCS loop over the green cable.
Ref.
Description
1-
POWER LED ON : Output voltage OK

OFF : Output voltage below 26.1 Volt
or current above 3.1A.
2-
27 V DC terminals, max. 2.5 mm
3-
0 V terminals, max. 2.5 mm
4-
Shield: to be connected to machine ground
5-
Internal PE screw. Do not unscrew from outside!
6-
Grounding PE: max. 2.5 mm.

Do not operate the equipment without grounding!
7-
Power supply L, max. 2.5 mm, 120V AC / 230V AC
8-
Power supply N, max. 2.5 mm, 120V AC / 230V AC
9-
Voltage selector
115 V: 100 - 127 V/AC
230 V: 220 - 240 V/AC
Frequency: 47 - 63 Hz
10 -
Latch for symmetrical DIN EN 50022 rail.
The output is protected against idle running, sustained short circuit and overload.
Connection by screw terminals - Protection: IP20
A PELV power supply is used which is equivalent to a safety transformer to VDE 0550/IEC 364-4-41.
The power supply must be mounted on a horizontal DIN rail TS 35 to allow for adequate air circulation.
Do not operate the power supply without grounding.

Do not attempt to gain access to the inside of the power supply: dangerous voltage inside. DANGER TO LIFE!
When connecting with stranded wires use end sleeves (without isolation).
The VCS power supply has an output voltage of 27 V and an integrated data decoupling feature to ensure that
the solenoid valves are always supplied with 24 V 10 % and the communication over the green VCS cable is
not disturbed.
2.6
Power supply: 24V max. / 10 A (without decoupling)

This unit supplies the power (see chapter 3) to pilot coils with higher current ratings over the black cable.
Ref.
Description
1-
Voltage selector
115V: 100 - 127 V AC
230V: 220 - 240 V AC
Frequency: 47 - 63 Hz
2-
Power supply N, max 2,5mm2 120V AC / 230V AC
3-
Power supply L, max 2,5mm2 120V AC / 230V AC
4-
Grounding PE: max. 2.5 mm.

Do not operate the equipment without grounding!
5-
Adjustment of output voltage, 24 to 28V
6-
24V DC terminal, max. 2,5 mm2
7-
0V terminal, max.2,5 mm2
115V AC
230V AC
24V DC / 10A
Electronically protected
115/230V AC
8.0/2.8A 50/60Hz
24-28V
The output is protected against idle running, sustained short circuit and overload.
Connection by screw terminals - Protection: IP20
A PELV power supply is used which is equivalent to a safety transformer to VDE 0550/IEC 364-4-41.
The power supply must be mounted on a horizontal DIN rail TS 35 to allow for adequate air circulation.
Connect the power supply in compliance with the applicable electrical safety regulations.
Do not operate the power supply without grounding.
Do not attempt to gain access to the inside of the power supply: dangerous voltage inside. DANGER TO LIFE!
When connecting with stranded wires use end sleeves (without isolation).
17
INSTALLATION
2.7
Accessories
2.7.1
Adapters
These adapters are used to mount the VCS connector to solenoid valves with a mounting pad to ISO 4400 (size 30) or
industrial standard (size 22).
Since these valves usually have a rating of more than 2.4 Watt, the VCS connector with additional power connection
(881 57 807 or 881 57 809) must be used. In this case, one output (output 1) remains unoccupied.
Only the monostable valve function is supported.
Adapter 15/22 mm (881 57 811)
Adapter 15/30 mm (881 57 812)
LINK
LINK
1 - Connector seal
2 - Adapter
3 - Adapter seal
4 - Coil
5 - VCS connector
Size 22
Industrial standard
2 flat pins
(spacing 11mm) + PE
Size 15
2 pins + PE
Size 30
ISO 4400
2 pins + PE
Size 15
2 pins + PE
Install the adapter with its seal onto the solenoid coil and screw it down tightly.
Place the seals on the pins of adapter, mount the VCS connector and screw it down tightly.
2.7.2
VCS adapter round/flat (881 57 855)

2
The VCS adapter is used to supply voltage over an additional

VCS power supply (881 57 845) directly to the VCS cable (see
chap. 3.2.1.2) to reduce voltage drops and/or increase the
supply current. The flat cable is contacted with a vampire-type
plug. A round cable with 4-6 mm outer diameter can be
connected with max. 2.5 mm2 screw terminals (IP65 protection).
Connection :
To connect the flat cable: Loosen both screws on the lid.
1 : VCS cable
Remove the lid. Insert the flat cable. Check the cable profile to
2 : additional VCS power supply
avoid mismating. Replace the lid (check for correct orientation)
and screw it down carefully.
To connect the round cable: Turn the threaded ring clockwise. Insert the cable into the angled cover. Protect both wire ends
with sleeves and screw them down. Fasten the cover carefully with the threaded ring. Tighten the PG cable gland to ensure
IP 65 protection.
Fastening with 2 screws max. 4 mm.
Assignment round/flat VCS adapter:
Pin no.
1
3
18
Signal
+27 V
0V
Flat cable color

brown
blue
INSTALLATION
2.7.3
VCS extension module flat/flat (881 57 854)
This extension module is used to lengthen the distance between two VCS connectors
without having to remove the existing cable segment.
The two flat cables which must be connected are contacted by the vampire-type plug
(IP65 protection).
To connect the cables : loosen the screws on the lid. Remove it. Insert the two flat
cables. Check the cable profile to avoid mismating. Seal the cable ends with the enclosed
seals. Replace the cover and screw it down carefully to ensure IP65 protection.
Installation is on DIN rail or with two screws 5 mm.
2.7.4
VCS cable end caps (881 57 927)
These caps are used to seal off open cable ends (black power cable) to ensure IP65
protection and prevent short circuit.
Adaptation : Place the cap on the end of the flat cable and heat it at a temperature above
135 C (air heater). The adhesive liner in the end cap melts to seal and encapsulate the
components contained within.
2.7.5
VCS input module M8 (881 57 827)
The VCS loop can be equipped with an M8 input module. With this module, eight electrical
sensors (with 2 or 3 wires) are connected to eight 3-pin M8 connectors.
The module is connected to the VCS system with a lead (1 m long) fitted with a connector
with vampire-type plug for direct connection of the flat VCS cable.
The lead and vampire-type connector (C) are supplied with the input module.
Wiring diagram of inputs
View on soldered side of male connector
2-wire sensor
3-wire sensor
(magnetoresistive position detector)
IN
IN
24V
Sensor
24V
+
Sensor
3 wires
GND
1 24V 10 %
3 GND*
4 IN 0/IN 1
* not applicable
for 2-wire sensor
Cable inlet: 3.5 - 5 mm.
C
LED
P4
: LED indicator of input state
27V : VCS power supply 27V is on the module
TEST : LED control during "Testmode" (see chapter 6.3)
19
INSTALLATION
3.
POWER SUPPLY ON VCS LOOP
3.1
Principle
On principle, valve connection systems can be designed with a single cable (green VCS cable) or with two cables (separate
black power cable).
In a single cable structure, the inputs and valve outputs are supplied over the VCS power supply. Power supply and
communication is made over the green VCS cable.
In a two-cable structure, the outputs are supplied over the black power cable (power supply). The inputs and the electronics integrated
in the VCS connectors are supplied over the green VCS cable (VCS power supply) which is also used for communication.
Mixed systems, in which VCS connectors with and without black power cable connection are used, can also be set up (see chapter 1.1)
Separate power supply for the VCS loop
and for MEGA spool valve solenoid coils
BUS
Direct power supply for islands to the VCS loop

BUS
27V =
(3.1A)
VCS
INTERFACE
27V =
VCS
INTERFACE
24V =
() It is recommended that the end of the black cable loop is

connected to the POWER CONTROL terminals of the
VCS interface (fig.1) to enable control of the voltage level
on the black cable.
The type of electrical power supply and the required quantity depend on the number, type and consumption
of spool valves/solenoid air operated valves in the VCS loop and on the length of the VCS loop.
The components can be defined in the following ways:
Directly according to the type of application (see chapters 3.2, 3.3 & 3.5) with the help of the diagrams in
accordance with the number of connectors in the loop and its length.
With selection charts (see chapter 3.6) for coils 2.4 W or for 1.6 W coils of for MEGA spool valve islands.
The required quantity of power supplies can quickly and easily be estimated over these two methods provided
that the system is equipped with one connector type and coils at one consumption level.
Systems with many different types of components require a detailed estimation of the necessary quantity of power
supplies. To request an estimation, please fill in the VCS Application Requirements Form on page 55 and consult us.
The supply of power to the VCS loop mainly depends on the rating of each coil in the application.
The following diagrams show the different supply options:
2.4 W (wattage value of coil in cold state)
for coils
for coils > 2.4 W (wattage value of coil in cold state)
for systems with a mixture of coils rated 2.4 W and > 2.4 W
3.2
Power supply of coils
3.2.1
VCS connector without black power cable

27V =
(3,1A)
2.4 W
VCS
INTERFACE
The outputs and inputs and the electronics of

the VCS connectors are supplied with power
exclusively over the green VCS cable.
578
578
20
302
302
520
INSTALLATION
Up to 127 VCS connectors can be fit into one cable loop (with and without inputs).
The cable length between two VCS connectors and between a VCS connector and a VCS interface must not exceed 20 m.
All inputs/outputs are supplied over the green VCS cable. The output rating is limited to max. 2.4 Watt (100 mA) per output.
Depending on the length of the line, the output current, the simultaneity factor (simultaneous switching of outputs) and the
number of VCS connectors, one or more additional VCS power supplies may have to be used for intermediate power supply.
The following applies (worst case calculation):
3.2.1.1 VCS connectors with inputs

Required number of VCS power supplies:
All valves are supplied with power over the green VCS cable.
All VCS connectors are provided with inputs and max. 1 output is switched per VCS connector (881 57 805).
Distance between 2 connectors: 20m
Solenoid coils : = 2,4 W.
Number of simultaneously
switching outputs
127
124 125
127
121
6
103 100
101
5
82
80
75
62
3
50
37
42
20
: VCS power supply number
60
40
25
20
500
400
131
1000
800
1500
1200
2000
1600
2020
2500
cable length / m
2420
3.2.1.2 Example with 2 VCS power supplies (27V - 3.1A)
27V =
(3,1A)
VCS
INTERFACE
27V =
(3,1A)
12m
18m
20m
VCS adapter round/flat
(881 57 855)
island n6
island n5
15m
2m
10m
16m
island n4
7m
11m
20m
island n1
island n2
302
302
520
island n3
This application, in which 37 VCS connectors are connected to a loop 131 m long, requires two 27 V 3.1A power supplies
(see diagram below). The 2nd power supply must be connected to the green VCS cable with a VCS adapter round/flat
881 57 855 (see chapter 2.7.2) It must be placed in the middle of the loop.
The additional power supplies must be divided up equally between the number of connectors in the VCS loop (see table
on following page).
21
INSTALLATION
3.2.1.3 Feeding point of intermediate VCS power supply
In case the output current must be increased on the whole system or the voltage drop is to high, intermediate power is supplied
over the round/flat adapter (881 57 855) and additional VCS power supplies 881 57 845 (with integrated data decoupling feature).
Choose the optimal feeding point according to the number of VCS power supplies required.
Number of additional
VCS power supplies
Feeding point
1 VCS power supply
N/2
2 VCS power supplies
N/3 , 2/3 N
N/4 , N/2 , 3/4 N
1/5 N , 2/5 N , 3/5 N , 4/5 N
1/6 N , 2/6 N , 3/6 N , 4/6 N , 5/6 N
N = Total number of VCS connectors
One VCS power supply is always directly connected to the VCS interface.
To bridge more than 20 m between two VCS connectors, an additional VCS connector without valve is to be used as repeater.
In this case, two outputs remain unoccupied. The same applies if more inputs than outputs are required. For more, use the
8 inputs module (see chapter 2.7.5)
3.2.1.4 VCS connectors without inputs

All valves are supplied with power over the green VCS cable.
All VCS connectors are without inputs and max. 1 output is switched per VCS connector (881 57 803).
Solenoid coils : = 2.4 W.
switching outputs
127
127
125
6
5
112
103 100
90
77 75
67
52 50
45
2
1
22
500
440
22
1910
25 25
1000
1500
2000
2500
900 1340 1800 2240
cable length / m
INSTALLATION
3.2.2
VCS connector with black power cable (two cable structure)
27V =
(3,1A)
This configuration allows for an emergency

switch to be fitted in order to interrupt the
power supply to the solenoid coils in the loop
if necessary. The power supply feeds 10A to
the black cable to supply the coils with power.
In case of power failure on the black cable,
the VCS interface continues transmitting
position sensor and diagnostic data over the
green VCS cable.
VCS
INTERFACE
578
578
3,1A
24V =
(10A)
10A
578
578
302
302
520
The output current is limited to 100mA per solenoid coil. All valves with a 15 mm pad mounting and max. 2.4 Watt can be
directly piloted in this manner.
To pilot valves with a higher size coil, adapters of 15 mm to 22 mm (industrial standard) and 15 mm to 30 mm (ISO 4400)
are available.
To realise an emergency shutdown with bistable valves with max. 2.4 Watt, the VCS connector is available with an
additional power connection (black power cable) and two outputs of max. 100 mA.
The outputs of the VCS connectors with black power cable connection are supplied over the black power cable. The output
rating is limited to 2.4 Watt (100 mA) per output.
Depending on the length of the VCS line, you may have to use either one or several additional VCS power supplies for
intermediate power supply.
3.2.2.1 VCS connectors with inputs

All valves are supplied with power over the black cable.
All VCS connectors are provided with inputs and an additional power connection (881 57 951).
switching outputs
127
127
125
4
3
100
75
105
70
62
50
35
1
25
1595
124
500
700
1000
1500
1400
2000
2500
cable length / m
2100
23
INSTALLATION
3.2.2.2 VCS connectors without inputs
All VCS connectors are without inputs and with an additional power connection (881 57 949).
switching outputs
127
125
3
108
100
75
54
50
25
500
85
24
1000
1080
1500
2000
1715 2160
2500
cable length / m
INSTALLATION
3.3
Power supply of coils > 2.4 W (max. 24W)

27V =
(3,1A)
VCS
INTERFACE
192
190
ISO4 (544)
ISO1 (541)
24V =
(10A)
320
370
238
The VCS interface is supplied with power from the VCS power supply, and the VCS cable is used for data transmission in
the VCS loop and for power supply to the coils 2.4 W (see description in previous chapter).
To connect the coils > 2.4 W (max. 24 W), use VCS connectors 881 57 807 or 881 57 809, the 10A power supply and the
black power cable.
In this configuration, the number of VCS connectors which can be connected to the loop depends on the power available
on the green cable over the main VCS power supply (3.1A).
To pilot valves with a higher wattage, adapters of 15 mm to 22 mm (industrial standard) and 15 mm to 30 mm (ISO 4400)
are available. You must use a VCS connector with additional power connection for this purpose.
The outputs of the VCS connectors with black power cable connection are supplied over the black power cable. The output
rating is limited to 24 Watt (1.0 Ampere) per output.
Depending on the length of the VCS loop, you may have to use either one or several additional VCS power supplies for
intermediate power supply (see next pages).
25
INSTALLATION
3.3.1
VCS connectors with inputs

All VCS connectors are provided with inputs and an additional power connection (881 57 809).
Solenoid coils: > 2.4 W.
switching outputs
127
124
127
125
4
3
100
75
105
70
62
50
35
1595
25
500
1000
700
3.3.2
1500
1400
2000
2500
cable length / m
2100
VCS connectors without inputs

All VCS connectors are without inputs and with an additional power connection (881 57 807).
Solenoid coils: > 2.4 W.
switching outputs
127
125
3
108
100
75
54
50
25
500
85
26
1000
1080
1500
2000
1715 2160
2500
cable length / m
INSTALLATION
3.4
Power supply of solenoid coils 2.4 W and > 2.4 W
3.4.1
General application
27V =
(3,1A)
VCS
INTERFACE
578
302
578
520
302 520
578
2,4W
24V =
(10A)
2,4W
320
370
238
370
Figure 1
238
Figure 2
Components with a consumption of 2.4 W and > 2.4 W can be connected to the same loop. This is the typical application
described in chapter 1.1 Structure which allows for spool valves and solenoid valves with coil sizes 15, 22, 25, 30 and 40
with 3 or 4 pins to DIN 46244 or ISO 4400 to be controlled over a single cable.
Only coils > 2.4 W are supplied with power from the black cable (use connectors 881 57 807 or 881 57 809). The low power
coils 2.4 W are fed over the green cable (use connectors 881 57 803 or 881 57 805).
Connection of the black power cable to the VCS interface (fig. 1) or the sealing of the wire strands with heat-shrinkable end
caps (fig. 2) is described in chapter 2.7.4, 3.1 and 4.1.
2.4 W and > 2.4 W) with control of emergency shutdown

3.4.2 Power supply of solenoid coils (
27V =
(3,1A)
VCS
INTERFACE
578
302
578
520
2,4W
24V =
(10A)
2,4W
320
370
238
Changing the VCS connector type on the solenoid coils 2.4 W (new connectors 881 57 949 or 881 57 951) and modifying
the wiring of the black power cable allows for emergency shutdowns in the VCS loop to be controlled whilst information from
the sensors and the status of the data on the green cable are retained.
To define the number of VCS power supplies in accordance with the number of VCS connectors, consider that all connector
used are VCS connector with 2x100mA outputs with 2 sensor inputs (see diagram in chapter 3.2.1.1 or selection chart in
chapter 3.6.1).
The number of VCS power supplies has been defined for connectors placed at 20 m from each other. More VCS
connectors can be used if they are placed at shorter intervals. (To request an estimation, please see chapter
3.6.1 or fill in the VCS Application Requirements Form on page 55 and consult us.)
27
INSTALLATION
3.5
Supply of VCS loop with a standard 24V power supply
3.5.1
Supply of solenoid coils 2.4 W
3.5.1.1
Direct supply of solenoid coils 2.4 W with a standard 24V power supply
24V =
(2A)
VCS
INTERFACE
578
302
302
520
A standard power supply with a max. current of 2 A connected to the standard supply terminals on the VCS interface is
sufficient to operated up to 13 VCS connectors 2.4 W. The number of VCS connectors which can be fed over a standard
power supply in accordance with the VCS connector version used has been defined in the following table.
VCS connector version
VCS connector with 2 outputs max. 100mA
(green cable)
3.5.1.2
Code
without input
881 57 803
1 . . . 13
with 2 inputs
881 57 805
1 . . . 12
Separate supply of VCS loop and solenoid coils 2.4 W
VCS
INTERFACE
24V =
(10A)
578
Fuse
578
2A
8A
578
578
302
302
520
This configuration allows for an emergency switch to be fitted in order to interrupt the power supply to the solenoid coils
in the loop if necessary. The power supply feeds 2A to the green VCS cable over the VCS interface and 8A to the black cable
for the electrical supply of the coils. In case of power failure on the black cable, the VCS interface continues transmitting
position sensor and diagnostic data.
The number of solenoid coils which can be connected to the loop is given in the table below.
Code
VCS connector with 2 outputs max. 100mA and without input

auxiliary power supply (with green and black cable) with 2 inputs
881 57 949
1 . . . 32
881 57 951
1 . . . 21
i
28
These quantities have been defined for VCS connectors placed at 20 m from each other. More VCS connectors
can be used if they are placed at shorter intervals. (To request an estimation, please see chapter 3.6.2 or fill in
the VCS Application Requirements Form on page 55 and consult us.)
INSTALLATION
3.5.2
Supply of solenoid coils > 2.4 W
In this configuration, solenoid coils > 2.4 W (max. 24W) are always connected with a separate power supply of the VCS
loop as shown in the diagram below.
An emergency switch can be connected at option.
VCS
INTERFACE
24V =
(10A)
Fuse
192
190
2A
ISO4 (544)
ISO1 (541)
8A
320
370
238
The number of solenoid coils which can be connected to the VCS loop is given in the table below.
Code
without input
VCS connector with 1 output max. 1A and
auxiliary power supply (with green and black cable) with 2 inputs
881 57 807
1 . . . 32
881 57 809
1 . . . 21
These quantities have been defined for VCS connectors placed at 20 m from each other. More VCS connectors
can be used if they are placed at shorter intervals. (To request an estimation, please see chapter 3.6.2 or fill
in the VCS Application Requirements Form on page 55 and consult us.)
29
INSTALLATION
3.6
Selection charts (summary)
The charts provided below allow for defining the number of main power supplies in accordance with the quantity and type
of VCS connectors for coils = 2.4 W connected to the loop, and the distance between VCS connector.
3.6.1 VCS power supply (27V - 3.1A)

Connector type
Code
Nr of
VCS
supplies

20 m (1)
10 m (1)
5 m (1)
1 m (1)
881 57 803
1
2
3
4
5
6
1
23
46
68
91
113
...
...
...
...
...
...
22
45
67
90
112
127
with 2 inputs 881 57 805
1
2
3
4
5
6
7
1
21
41
61
81
102
122
...
...
...
...
...
...
...
20
1 ...
40
20 . . .
60
41 . . .
80
61 . . .
101 82 . . .
121 107 . . .
127
-
1
2
3
1 . . . 54
55 . . . 108
109 . . . 127
1 . . . 71
72 . . . 127
-
1
2
3
4
1
36
71
106
1 . . . 58
1 . . . 58
1 . . . 46
59 . . . 116 59 . . . 120
47 . . . 92
93 . . . 127 117 . . . 127 121 . . . 127
-
without input
VCS connector with 2 outputs
max. 100mA
(connection only over green cable)
881 57 949
or
max. 100mA and auxiliary power without input
881 57 807
supply (with green and black cable)
or
881 57 951
VCS connector with 1 output
with
2
inputs
or
max. 1A and auxiliary power
881 57 809
...
...
...
...
35
70
105
127
1
25
51
77
103
...
...
...
...
...
-
24
1
50
25
76
51
102 77
127 113
...
...
...
...
...
-
24
1 ...
50
25 . . .
76
52 . . .
112 103 . . .
127
-
24
51
102
127
1 ...
19
40
20 . . .
60
41 . . .
81
68 . . .
106 101 . . .
127
-
19
1 ...
20 . . .
40
67
46 . . .
100 92 . . .
127
-
19
45
91
127
1 . . . 122
1 . . . 89
90 . . . 127 123 . . . 127
-
(1) distance between 2 VCS connectors = 20 m
3.6.2
Standard power supply (24V - 2A)

Connector type

max. 100mA
Code
without input
Nr of
VCS
supplies

20 m (1)
10 m (1)
5 m (1)
1 m (1)
881 57 803
1 . . . 13 ( ) 1 . . . 15 ( ) 1 . . . 15 ( ) 1 . . . 15 ( )
1 . . . 12 ( ) 1 . . . 12 ( ) 1 . . . 12 ( ) 1 . . . 12 ( )
881 57 949
or
881 57 807
1 . . . 32 ( ) 1 . . . 42 ( ) 1 . . . 53 ( ) 1 . . . 73 ( )
881 57 951
or
881 57 809
1 . . . 21 ( ) 1 . . . 27 ( ) 1 . . . 34 ( ) 1 . . . 36 ( )

max. 100mA and auxiliary power without input
or
VCS connector with 1 output
with 2 inputs
max. 1A and auxiliary power
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
(1) distance between 2 VCS connectors = 20 m
( ) If the number of connectors to be used is above this limit, install the system with a VCS power supply (see chapter
3.6.1 above).
30
The number of VCS power supplies has been defined for different distances between each VCS connector.
For another distance, please fill in the installation definition sheet page 55, consult us.
INSTALLATION
For your order of joinable MEGA 18 spool valves of 1.6W, the charts provided below allow for defining the number of VCS
power supplies in accordance with the quantity and type of VCS connectors used.
3.6.3
VCS power supply (27V - 3.1A)

Connector type
Code
Number of
Number of
VCS supplies MEGA 18 islands(
without input 881 57 803
1
2
3
1
2
3
4
5

VCS connector with 2 outputs max. 100mA and

auxiliary power supply (with green and black cable)
or
3.6.4
881 57 949
or
881 57 807
881 57 951
or
with 2 inputs
881 57 809
without input
1 ...4
5 ...8
9 . . . 15
1
4
7
10
14
...
...
...
...
...
**)
3
6
9
13
15
1 . . . 15
1
2
1 ...7
8 . . . 15
Number of
standard supplies
1
1
Number of
MEGA 18 islands( )
1 ...2( )
1 ...2( )
Standard power supply (24V - 2A)

Connector type
Code

VCS connector with 2 outputs max. 100mA and
or
without input 881 57 803

881 57 949
without input
or
881 57 807
881 57 951
with 2 inputs
or
881 57 809
**
*
*
...9( )
*
1 ...4( )
(*) If the number of spool valve islands to be used is above this limit, install the system with a VCS power supply (see
chapter 3.6.3 above).
(**)These quantities have been estimated for MEGA18 islands of 8 spool valves with the islands placed at
2 m from each other and all pilots 14 activated simultaneously (consult us for other estimations).
Application example:
27 V
3,1 A
VCS
INTERFACE
2m
MEGA island MEGA island MEGA island MEGA island
2m
2m
2m
2m
A complete piloting system for process valves in the textile industry requires 32 bistable 5/2 spool valves. All joinable MEGA
spool valves with 1.6W coils are provided with VCS connectors for green cable only and are without M8 inputs (code
881 57 803). The island structure and the short distances between the islands as shown in the above diagram allow for the
32 connectors to be fed over a single VCS power supply (3.1A).
31
INSTALLATION
4.
INSTALLATION INSTRUCTIONS
Mounting of VCS connectors on a MEGA 18 spool valve island: see chapter 10.
Mounting of VCS connectors on solenoid valves
Solenoid coil size 15 with 2 pins + earth to DIN 46244 (centre distance: 9.4mm): direct assembly
Solenoid coil size 22 with 2 pins + earth to DIN46244 (centre distance: 11mm): assembly with a 15/22 adapter.
Solenoid coil with 2 pins + earth to ISO4400 (size 30): assembly with a 15/30 adapter (see chapter 2.7.1).
4.1
Power supply connection
VCS power supply

A VCS power supply (max. 3.1 A output current) must be connected to the VCS-SUPPLY terminals of the VCS interface
(see below). A data decoupling feature is integrated in the VCS power supply
Standard power supply
Alternatively, a standard power supply may also be connected to the STANDARD SUPPLY terminals. The standard power
supply should be provided with an adjustable output voltage set to 27 Volt. This allows for compensation of the voltage drop
in the green VCS line. In this case, the integrated data decoupling feature in the VCS interface is used and the current is
limited to a maximum of 2 A.
When using the "Standard Supply" terminals, the current is limited to a maximum of 2A!
bl
br
br
bl
max. 2 Ampere
VCS power
supply
Power
supply for
black cable
Std. power
supply
(optional)
The connection between the power supplies and the VCS interface must be made with a cable with a cross-section of
1.5 mm or 2.5 mm.
Diagnostics of 24V error on black power cable
The black 24V power cable can be connected in two different ways.
27V =
(3,1A)
Fig.1
VCS
INTERFACE
Fig.2
578
578
578
3,1A
24V = 10A
(10A)
578
578
302
302
520
302
302
520
It is recommended that the end of the black cable loop is connected to the POWER CONTROL terminals of the VCS
interface (fig.1) to enable control of the voltage level on the black cable. If the voltage drops below 18V, an error signal is
sent to the controller over the fieldbus.
If the loop cannot be closed (e.g. because of the extent of the loop), the ends of the black flat cable must be fitted with heatshrinkable end caps (fig. 2) available as accessory (set of 10 pieces - code: 881 57 927) to prevent short circuit and ensure
IP65 protection (see chapter 2.7.4).
32
INSTALLATION
4.2
Further evolution of the installation
It is possible to modify the installation later by adding or suppresing connectors.
!
4.2.1
Disconnect the power on the VCS loop before working on equipment.
Fitting in of VCS connectors

n-1
Fitting in of an additional VCS connector

into the system (new number n).
Procedure:
This can be done in two different ways
depending on the length of the VCS
cable connecting connectors n-1 and
n in the existing system.
VCS
New Address
"n+1"
If the cable between two VCS connectors is long enough, simply contact the new VCS connector.
- Insert the cable into the new VCS connector.
- Snap the lid shut.
If the cable is not long enough, part of it must be replaced.
- Open the lids of the two adjacent VCS connectors.
- Remove the cable connecting these two VCS connectors.
- Mount the new component n and its VCS connector in the appropriate place.
- Define a new VCS cable long enough to connect connectors n-1 through n+1 over the new connector n.
- Make sure that the 2 cable ends have a clear cut, vertical to their axes (we recommend using a VCS connector to cut
the VCS cable).
- Place the ends into the cable guides of the adjacent VCS connectors and make sure that they touch the ends of the VCS
cable still in place.
- Close the lids of both VCS connectors n-1 and n+1.
- Insert the cable into the cable guide of the new VCS connector n and proceed with installation as described in chap.2.3.1.
- Close the lid and number the new VCS connector.
In fitting in a new VCS connector the following addresses in the VCS loop are displaced by +2 bits. This must
be included in the address assignment list in the control program.
4.2.2 Removal of a VCS connector

n
n-1
n+1
VCS
Removal of a VCS connector n

Procedure:
The 2 pieces of VCS cable must be
removed and replaced with a new piece
of cable connecting n-1 to n+1.
New address
"n"
Both old pieces of VCS cable must be removed and replaced by a corresponding longer one.
- Open the lid of the VCS connector to be removed and the lids of the two adjacent VCS connectors.
- Remove the 2 pieces of VCS cable connecting these 3 VCS connectors.
- Remove component n and its VCS connector.
- Define a new VCS cable long enough to connect VCS connector n-1 to the new VCS connector n.
- Make sure that the 2 VCS cable ends have a clear cut, vertical to their axes (we recommend using a VCS connector to
cut the VCS cable).
- Place the ends into the cable guides of the adjacent VCS connectors and make sure that they touch the ends of the VCS
cable still in place.
- Close the lids of the two VCS connectors.
- Change the number(s) of the VCS connector(s).
In removing a VCS connector the following addresses in the VCS loop are displaced by -2 bits. This must be
included in the address assignment list in the control program.
33
INSTALLATION
4.3
Replacement of a VCS connector
On a single solenoid coil on the VCS loop

- Disconnect the power on the VCS loop.
- Open the lid of the VCS connector to be replaced (you do not need to open the lids of the adjacent VCS connectors).
- Remove the cable from the cable guide.
- Change the VCS connector.
- Place the 2 ends of the VCS cable back into the cable guide. The vampire-type marks left from the first connection will
allow you to place the cable ends in their original position.
- Close the lid of the VCS connector.
- Connect the power to the VCS loop.
On a solenoid coil installed on a spool valve island
- Disconnect the power on the VCS loop.
- Open the lid of the VCS connector to be replaced (a) as well as the lids of the 2 adjacent VCS connectors (b and c) (fig.1).
- Remove the 2 pieces of VCS cable (fig.2).
- Remove the VCS connector (a) (fig.3) and replace it with a new one (fig.4).
- Though you can still put the 2 old pieces of VCS cable in their original place, we recommend using a new piece of VCS
cable long enough to connect VCS connectors b through c.
- Make sure that the 2 VCS cable ends have a clear cut, vertical to their axes (we recommend using a VCS connector
to cut the cable).
- Lift the 3 cable guides and insert the new VCS cable (fig.4).
- Close the lids (fig.5).
- Connect the power to the VCS loop.
2
3
fig.1
fig.2
1
fig.3
34
fig.4
fig.5
INSTALLATION
5.
CONNECTION TO STANDARD FIELDBUS SYSTEM
5.1
PROFIBUS-DP
881 00 331
2
PROFIBUS-DP
to the following
receiver
ERROR
R POWER
TERM DIA
INTERFACE
x10
x1
ADDRESS
ON
PLC
B A BA
coming from the

controller (PC or
PLC)
SUB-D
Pin no.
8
3
Function
A-Line
B-Line
GND
+5V-Bus
RTS
Housing
Cable shield
Nr.
Description
1-
9-pin SUB-D female panel connector for standardised Profibus connection. For Profibus connector connection
(e.g. 881 00 331).
2-
Switchable terminating resistor. Only to be switched on if the node is the last in the Profibus line and there is no
terminating resistor in the Profibus connector.
3-
Error LED (ERROR): Constant red in case of an interruption in the communication to the Profibus master
(controller) or error in data transmission.
4-
Power LED (POWER): Constant green when the power supply of the Profibus module is ON and the interface
is not in a reset condition.
5-
Diagnostic LED (DIA): Constant green in case of error-free communication with the Profibus master (controller).
6-
Address switch: To set the node addresses 00 - 99. Addresses 00, 01, 02 are reserved for the masters.
Recommended setting: 03 - 99.
Description:
The incoming and outgoing Profibus cable can be connected over the Profibus VCS connector.
The baud rate is adjusted automatically to the master (PLC) and is between 9.6 KBaud and 12 MBaud.
The Profibus diagnostic function is not supported.
The number of input and output data transmitted in the Profibus system can be changed with the DIP switch Size (see
chapter 2.4.5).
Configuration with the configuration disk (881 57 957):

The GSD file (device master file) HMS1002.GSD is supplied with the configuration disk. This file is copied into the
configuration tool of the PLC (e.g. S5/S7 controller) or the PC. The GSD file is normally copied into the controller's
subdirectory \GSD (Siemens S7).
Call "additional field devices" / "AB-DT-PDF" in the "hardware catalog". It is recommended to select "universal module"
and "output - input" for the I/O type.
Please follow the instructions of the manufacturer of the controller.
The number of activated bytes must correspond with the table in chapter 2.4.5.
The address on the Profibus module must correspond to the configuration.
35
INSTALLATION
5.2
INTERBUS-S
SUB-D
Pin no.
1
6
BUS-IN
BUS-OUT
DO 1
/DO 1
DO 2
/DO 2
2
7
DI 1
/DI 1
DI 2
/DI 2
3
9
GND
-
GND
RBST
5
Housing
Rep. LED
Signal
RBDA
: Remote bus disable:

Constant red if the outgoing bus is switched off because of an error
: Transmit/Receive:
Constant green if PCP communication takes place (is not used in the VCS system).
: Bus active:
Constant green if data transfer is error-free
: Cable check:
Constant green if the signal level at the bus cable is OK and there is no reset.
TR
BA
CC
+5V
Cable shield
Pin 9 and pin 5 of the BUS-OUT connector must be bridged. No BUS-OUT connector is connected to the last node in the
Interbus line.
Description:
The baud rate is fixed at 500 Kbaud. The bus cable is a shielded cable with 3 twisted pairs.
The number of input/output data transmitted in the Interbus can be changed with the DIP switch Size (see chapter 2.4.5).
Unlike with other fieldbus systems, only max. 20 bytes can be transmitted in this system. This means that with the "analogic
signal" it is recommended to set a size of max. 7 with the DIP switches. Without "analogic signal" a size of max. 8 is
recommended. All larger settings are limited to the corresponding maximum.
Configuration:
No special configuration required: the size of each node (address space) is automatically recognised and the fieldbus
address is fixed in compliance with the physical position in the Interbus loop.
36
INSTALLATION
5.3
DEVICE NET
1
Terminal no.
Function
V- (GND)
CAN-L
Shield
CAN-H
V+ (24V)
The DeviceNet must receive
power through the V- and V+
of the screw terminals.
Connect the standard DeviceNet cable here.

Screw terminals: 3.83 mm pitch, max. 1.5 mm2)
(Plug can be disconnected)
Ref.
Description
1-
Fieldbus connection terminal block
2-
LED indicators
3-
DIP switch for module configuration

LED
Error description
POWER
Green light when the power supply (V+) is ON.

Red blinking:
Constant red:
Green blinking:
Constant green:
MOD
Module status
recoverable module error

critical module error
during configuration
error-free configuration and no module error
Red blinking:
Constant red:
Green blinking:
recoverable network error

critical network error
Module is on-line (is recognised) but not connected (no cyclical data exchange)
Constant green: error-free data transfer
NET
Network status
DIP switches for module configuration:

0
MSB
1
1
Baud rate
DIP
12
00
01
10
11
Remark: DIP switch numbers 1 - 8 do not

correspond to the significance.
LSB
(ON)
Baud rate (Kbaud)

125
250
500
reserved (not used)
Address (MAC-ID)
DIP
5 6
0 0
0 0
0 0
.
.
.
.
1 1 1 1
1 1 1 1
3
0
0
0
4
0
0
0
7
0
0
1
8
0
1
0
1 0
1 1
Address
0
1
2
62
63
37
INSTALLATION
Description:
The DeviceNet cable consists of a twisted pair for data transmission and a twisted pair with a large cross-section for power
supply.
A transmission speed of either 125, 250 or 500 Kbaud can be selected.
The maximum length of the network is limited in accordance with the baud rate.
Data transmission occurs as Group 2 only server and the preset protocol is master/slave connection set for polled I/O.
External terminating resistors (121 Ohm) must be fitted to both ends of the DeviceNet line. The number of input/output data
transmitted in the DeviceNet can be changed with the DIP switch Size (see chapter 2.4.5).
Configuration with the configuration disk (881 57 957):

An EDS file (electronic data sheet), dt1.eds is supplied on the configuration disk. This file is used in the configuration tool
of DeviceNet to include the VCS system.
Please follow the instructions of the controller manufacturer.
Addressing :
The physical addressing of the data exchanged ("size" Dip switches on VCS interface) must be the same as the
configuration of data exchanged into the configuration software (DeviceNet manager or RSNetWorx). Otherwise the VCS
interface won't communicate with the PLC.
38
INSTALLATION
6.
6.1
START-UP
Start-up instructions
Connect all VCS connectors and make sure that the VCS loop is closed. The VCS loop begins at the
VCS interface at the VCS OUT terminals. Insert the cable as indicated with the arrow (observe the
marking on the cable) through the VCS connectors. It ends at the VCS IN terminals. When
connecting valve batteries (multiple valve blocks), open all the VCS connectors and insert the cable.
Shut the VCS connectors one after the other from the left to the right. This order must be observed to prevent the VCS cable from being crushed.
On starting up the system, the LED indicators blink in a certain sequence. In the end only the RUN and 27V LEDs light
up green. If this is not the case, errors are indicated by a blinking or constantly lit up LEDs.
Error no.
RUN
27V
DATA
OUT
>T
<V
0
1
1
0
1
1
Internal hardware error. Send interface to manufacturer for repair.
0
1
1
1
1
0
Interruption in the VCS loop.

Switch on the test mode with the DIP switch TEST and look for the
interruption (see chap. 6.3).
1
1
0
0
1
1
Internal hardware error. Send VCS interface to manufacturer for repair.
1
1
1
0
0
1
The number of VCS connectors in the loop is above the figure set in the
address space. Correct the setting with the DIP switch SIZE. Put the VCS
into service again.
1
1
1
0
1
0
1
1
1
0
1
1
1
1
1
1
1
0
1
1
0
0
0
0
Cyclical operation. Faultless operation of VCS loop.
0: LED OFF
Error description
1: LED ON
*) Recoverable error / regular operating conditions

6.2
Automatic addressing
After the supply voltage has been switched on, the VCS interface tests the length of the VCS loop. On successful
completion of the test, a consecutive VCS number is allocated to each VCS connector. This results in a fixed allocation
of the VCS numbers and relative addresses according to the tables on page 13 (without analog input/output option) and page
16 (with analog input/output option). The
Address Address Address
absolute PLC address assignment is made
11
10
9
over the configuration of the fieldbus
system.
Address Address Address Address Address Address Address Address

1
2
3
4
5
6
7
8
39
INSTALLATION
6.3
Test mode
100
10
1
SIZE
RUN DATA > T

OFF
OUT <V
ERR
27 V
TEST
ON
8
4 2
Switch off pressure supply, because all coils will be energised during the test mode.
The test mode can be switched on in the two following ways:

1. De-energise the VCS loop (switch off all VCS power supplies).
Set the DIP switch TEST to ON and the DIP switch ERR to OFF.
Switch on all VCS power supplies.
2. Set the DIP switch TEST to ON and the DIP switch ERR to OFF.
Press the Reset test button.
- In this phase of the test, the VCS connectors are switched on in consecutive groups of 8 (1 to 8, then 9 to 16, then 17
to 24 etc.) in an activation cycle of 2 seconds for the whole loop.
This enables you to check the piloting and function of each VCS connector.
- Check the piece of VCS cable between the last blinking VCS connector and the first VCS connector that does not blink,
and check the contacts.
- Replace, if necessary, the first VCS connector that does not blink or the last blinking VCS connector.
- Switch on the VCS power supply.
- If all VCS connectors blink, set the DIP switch TEST to OFF. The system restarts. The error should be recovered.
- In case one or more than one VCS connector does not work, the corresponding VCS cable connections and VCS
connectors must be checked and possibly replaced.
40
INSTALLATION
6.4
Error mode
100
10
1
SIZE
RUN DATA > T

OFF
OUT <V
ERR
27 V
TEST
ON
8
4 2
During the operation of the VCS loop, the LEDs also indicate errors in the individual VCS connectors. The following errors
can be reported for each VCS connector: low voltage, overcurrent, overheating. These are group errors, i.e. either one or
several VCS connectors can be at fault.
- Set the DIP switch TEST to OFF and ERR to ON.
- All LEDs (except the 27V-LED) are off.
- The kind of error is indicated first (error LED lights up for a short time), and then the number of the faulty VCS connector.
The LED RUN, DATA and >T are used to indicate the number of a VCS connector in the error mode. They have the following
significance:
RUN ___________ 100 (hundreds digit)
DATA ___________ 10 (tens digit)
>T ___________
1 (units digit)
- Count the number of flashes of each LED.
- Add up the number of flashes of all LEDs to reveal the number of the faulty VCS connector.
Several VCS connectors having the same error are displayed in ascending order. The flashing rate of each LED must be
counted to reveal the connector number of the faulty VCS connector. A maximum of three errors and the corresponding
connector number are indicated.
Up to three pairs (errors and VCS numbers) are shown.
After this display procedure, all group errors are indicated again.
You can repeat the display procedure several times by switching the DIP switch ERR from OFF to ON.
41
INSTALLATION
7.
PC DIAGNOSTIC SOFTWARE (VCS - DIAG)
7.1
Program installation
Insert the disk VCS-DIAG (881 57 852) into your disk drive. Open the file
README.TXT with a text editor and follow the installation instructions given in this file.
After successful installation: Change to the directory C:\VCS and execute
VCS DIAG.EXE.
Minimum configuration:
PC: Pentium II
Memory: 32 MByte
Free disk space: 10 MByte
Operating system: Windows 95 or higher, Windows NT 4.0
7.2
Connection of the VCS interface
The online functions of VCS-DIAG can only be used if the VCS interface is connected to the PC with the RS-232 cable
(881 57 853). Plug one side of the cable into the RS-232C socket of the VCS interface and the other side of the cable into
the serial interface (COM 1 ... COM 2) of your PC.
Supply the VCS interface with voltage.
42
INSTALLATION
8.
TECHNICAL CHARACTERISTICS
8.1
VCS electrical characteristics
Max. number of connectors in a line

Max. number of connectable sensors (M8)
Max. distance between 2 VCS connectors
Max. length of the VCS loop
Max. cycle time
VCS power supply (881 57 845)

Input voltage
Max. input current
Output voltage
Max. output current
Integrated data decoupling feature
Protection degree
Assembly
: 127 (for solenoid valves or monostable / bistable spool valves)

: 254 (data readback from sensors)
: 20 m
: 2500 m
: 0.4 ... 3.44 msec. linearly increasing with the number of VCS connectors
in the loop
: 88 ... 132 V
187 ... 264 V
: 1.8 A
1.1 A
: 27 V 3 %
: 3.1 A
(115 Volt range)

(230 Volt range)
(115 Volt range)
(230 Volt range)
(short circuit proof)
: IP20
: DIN EN 50022 symetrical rail
Power supply for black power cable (881 57 846)

Input voltage
: 85 ... 132 V
(115 Volt range)
176 ... 264 V
(230 Volt range)
Max. input current
: 6.0 A
(115 Volt range)
2.8 A
(230 Volt range)
Output voltage
: 24 to 28 V
(adjustable by potentiometer)
Max. output current
: 10 A
(short circuit proof)
Protection degree
: IP20
Assembly
: DIN EN 50022 symetrical rail
Green VCS cable and black power cable
Max. current capacity
Cross-section
Specific resistance
Min. bending radius
Cable material
VCS connector
Max. output current
Inputs
Supply voltage
Protection degree
Operating temperature
VCS interface
Fieldbus systems
Control input
Admissible supply current
Protection degree
Operating temperature
Assembly
: 16 A
: 1.5 mm
: 14 /km
: 18 mm to the flat side
: EM3 rubber mixture in conformity with DIN VDE 0207 part 21
: 2x100 mA with VCS green cable only (short circuit proof)

1x1.0 A/output with black power cable connection (no short circuit protection)
2x1.0 A with black power cable connection (no short circuit protection)
: High: U 11 Volt or I 6.5 mA
Low: U 5 Volt or I 2.6 mA
Input resistance: 2.4 k
Operating voltage: 21.6 Volt ... 26.7 Volt
Operating current: max 20 mA
: 22.4 ... 27.1 Volt
: IP65
: -10 ... +50 C
: Profibus-DP, Interbus-S, DeviceNet

: Voltage control on black power cable: UPower < 18 Volt
: VCS supply: 3,1 A
Standard supply: 2,0 A
: IP20
: 0 ... +50 C
: DIN EN 50022 rail mounting or direct screw fastening ( 4 mm).
43
INSTALLATION
8.2
Dimensions and weights
VCS connector
Weight: 50 g
VCS interface
Weight: 320 g
GND
VCS OUT
VCS IN
_
+
blue brown
_
+
brown blue
POWER
CONTROL
IN
24V
0V
100
ERROR
R POWER
TERM DIA
INTERFACE
x10
x1
PROFIBUS-DP
EN 50022
ADDRESS
75
ON
100
10
1
SIZE
OFF
44
ERR
OUT <V
TEST
ON
27 V
4 2
RS232C
116
+U
86
0V
127
VCS
STANDARD
SUPPLY
SUPPLY
27V
INSTALLATION
49
130,5
115,5
VCS power supply, 27V/3.1A

Weight: 560 g
EN 50022
65
135
70
Power supply for black power cable, 24V adjustable/10A

Weight: 960 g
118
102
120
EN 50022
124
115V AC
230V AC
24V DC / 10A
Electronically protected
115/230V AC
8.0/2.8A 50/60Hz
24-28V
45
INSTALLATION
15
15
39
29
68
68
VCS input module

Weight: 0.150 kg
IN-5 IN-4
IN-3 IN-2
129
138
4,5
4,5
26
= =
4,5
IN-1 IN-0
29
IN-7 IN-6
26
VCS
13
4,5
55
31
70
Cable length: 1m
9.
129
4,5
MAINTENANCE AND CARE
No special maintenance or care required for the VCS products described in this installation manual.
46
67
67
LINK
LINK
39
29
52
Adapter 15 / 30
Weight: 0.015 kg
52
Adapter 15 / 22
Weight: 0.014 kg
INSTALLATION
10
10.1
MEGA ISLANDS + VCS CONNECTORS
MEGA 18 SPOOL VALVE ISLANDS WITH VCS CONNECTORS

Presentation
1
Ports 1 - 3/5 : with instant fittings for flexible hose O.D. 10 mm

or G1/4 thread
Ports 2 - 4 : with instant fittings for flexible hose O.D. 6 or 8 mm
Ports 12/14 - 82/84 : with instant fittings for flexible hose O.D. 4 mm
or M5 thread
Frame (2 4,2) or DIN rail mounting
Electrical connection with VCS connector
Green flat profiled VCS cable
Connection of inputs with M8 connector (upon request)
(1 connector per input)
1
2
3
5
4
5
6
Combinations
Islands with up to 16 MEGA spool valves for frame or DIN EN50022 rail mounting can be grouped together.
Optional mixing of:
- All spool valve functions.
- 6 or 8 mm O.D. instant fittings.
- Different types of manual override: impulse-type or locking push/turn-type.
- Internal and external pilot pressure supply.
- Pressure separation plate and intermediate pressure supply module.
OUT-1 OUT-0
OUT-1 OUT-0
OUT-1 OUT-0
OUT-1 OUT-0
OUT-1 OUT-0
OUT-1 OUT-0
OUT-1 OUT-0
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
IN
OUT
12 14 12 14 12 14 12 14
14
14
14
18
33,5
23
4,2
27
14
58
OUT-1 OUT-0
110
141
180
10.2
21,5
33,5
L2 2 = 67 + (n x 18)
L1 = L2 + 13
6,5
11
6,5
122
n : number of spool valves
82-84
12-14
12-14
14
1
IN-1
IN-1
IN-0
6
12
IN-1
IN-0
IN-1
IN-0
IN-1
IN-0
IN-1
IN-0
4
IN-1
IN-0
122
15 26,5
5
82-84
108
28
= =
65
20
11
18
49
26,5
5,5
5,5
IN-1
IN-0
IN-0
18
Number of spool valves

4
10
11
12
13
14
15
16
L2 (2)
139
157
175
193
211
229
247
265
283
301
319
337
355
L1
152
170
188
206
224
242
260
278
296
314
332
350
368
0.810
0.960
1.110
1.260
1.410
1.560
1.710
1.860
2.010
2.160
2.310
2.460
2.610
Weight (kg)
47
INSTALLATION

10.3
Ordering information for MEGA island with VCS connectors
To order please specify references
and, if applicable,
followed by the required quantity and code of VCS connectors.

2
MEGA island with

VCS connectors
Spool valve versions
Port connections: 2 - 4
Instant fittings 8mm O.D.
Instant fittings 6mm O.D.
Mixed (E & S) on island (1)
Type
E
S
P
Auxiliary manual override

() impulse
() locking (push-turn)
Mixed (1 & 2) on island (1)
Type
1
2
P
Pilots supply 12/14

Internal
External
Mixed (I & E) on island
(1)
Port connections: 1 - 3 / 5
Instant fitting 10 mm O.D.
G1/4
Spool valve position

6 7 8 9 10 11 12 13 14 15 16
Please indicate the type of

spool valve or accessory required
Type
VS
( ) The VCS connectors must be ordered separately

(see preceding page)
Island version
Island for VCS connectors ( )
678 V S
MEGA ISLAND
Type
I
E
P
Type
Q
G
Spool valves (functions)

Type
2 x 3/2 NC-NC
K
5/2 - Solenoid air operated pilot, spring return (monostable) S
5/2 - Solenoid air operated pilot, differential return (monostable) M
5/2 - Solenoid air operated pilot and return (bistable)
J
5/3 - Pressure held (W1)
G
5/3 - Pressure applied (W2)
B
5/3 - Exhaust released (W3)
E
Reserve module (to be placed at the left end of the island) A
For detailed information on spool valves see page 6
Accessories (see page 9)

Type
Intermediate pressure supply module
D
(connection is identical to that selected for ports 1 - 3/5
of end covers, see opposite)
Pressure separation plate:
Total blocking of 1, 3 and 5 (no connection) .................. X
Blocking of 3 and 5 (port 1 connected) ......................... Y
Blocking of 1 (ports 3 and 5 connected) ....................... W
Option
without option
00
..
99
other options
Island mounting
On frame
(2 x 4.2)
On rail
EN 50022-DIN
Island delivery
Assembled
Unassembled
Assembled
Unassembled
Type
A
B
C
D
(1) Different spool valve versions can be mixed on an island. In this case:
- indicate type P in the basic reference 1
- fill in reference line 3
ORDERING EXAMPLE:
: 678VSE1IQ00C
: M MM J J GW J J J
MEGA island designed for DIN rail mounting, supplied assembled,
pneumatic supply with 10 mm OD instant hose fittings. Unit comprising
9 spool valves for VCS connectors. Pneumatic connection of ports 2 to 4
by 8 mm OD instant hose fittings, impulse-type manual override, internal
pilot.
Spool valve types:
- three monostable 5/2 spool valves, type M, in positions 1, 2 and 3
- five bistable 5/2 spool valves, type J, in positions 4, 5, 8, 9 and 10
- one 5/3 spool valve (W1), type G, in position 6
- one pressure separation plate, blocking 1, type W, in position 7
( ) The VCS connectors must be ordered separately in accordance with
*
the configuration of the VCS loop (see chapters 2.1 & 3).
48
1
2
Spool valve position

6 7 8 9 10 11 12 13 14 15 16
Spool valve versions (with mixed connections)

Connection
Manual
Pilots
Type
ports 2 - 4
override
12/14
Internal
1
() impulse
Instant fittings
External
2
8 mm O.D.
Internal
3
() locking
External
4
Internal
5
() impulse
External
6
Instant fittings
Internal
7
6 mm O.D.
() locking
External
8
How to fill in reference line 3 :

- Fill in only if different spool valve versions are
to be mixed on an island.
- Use the spool valve position numbers
specified in reference 2 .
- Repeat the type of accessory in the same
position number as specified in reference 2 .
INSTALLATION
10.4
Accessories
10.4.1 End covers
The end covers assure the following functions:

- Island assembly: the bolts are fixed into the covers. The island is
tightened by hand with the knurled screws (S). There is no need for
tools.
- Choice of island mounting:
on machine frame (2 4.2),
on DIN EN 50022 rail (for cabinet installation).
- Pneumatic connection of the channelled ports of the island
(1 3/5 12/14 etc.)
Island assembly (see chapter 10.7)

Choice of island mounting
On machine frame
On DIN EN 50022 rail
L1
2 M4
Pneumatic connection
3/5
12/14
82/84
3/5
82/84
3/5
82/84
12/14
12/14
1
3/5
12/14
82/84
Port 1
Port 3/5
Port 12/14
Connection size
Port nos.
Type: Q
Type: G
Instant fittings for

flexible hose
10mm O.D.
G1/4
Instant fittings for

flexible hose
4mm O.D.
M5
Port 82/84
1
: Pressure supply for island
: Exhausts 3 and 5 channelled and connectable
: External pilot pressure supply. Necessary for use with
vacuum or if the general supply pressure is below
3 bar.
: Channelling and connection of the pilot exhausts for
installation of the island in protected environments
(food-processing industries, laboratories etc.)
Possibility of direct connection of a
silencer to each exhaust 3/5
Order codes for end covers

Description
Port connections 1 - 3/5 ( )
Type
Code
1 set of 2 end covers for

islands for frame
mounting
Instant fittings for 10mm O.D. hose
881 57 901
G1/4 thread
881 57 903
1 set of 2 end covers for

islands for DIN rail
mounting
Instant fittings for 10mm O.D. hose
881 57 859
G1/4 thread
881 57 861
10
G1/4
( ) For port connections 12/14 and 82/84 see above table
49
INSTALLATION
10.4.2 Supply with 1, 2 or 3 different pressures

A MEGA island is especially designed to be supplied with more than one pressure level.
Supply with 1 pressure (P1)
3
P1
P1
P1
P1
The island are provided with 2 end covers for choice

of pressure supply side (left or right side).
For more than 8 spool valves or for simultaneous
operation of 5 spool valves, the unit must be supplied
with pressure from both sides.
P1
All other island versions are provided with 2 end covers

for choice of pressure supply side.
For more than 8 spool valves or for simultaneous
operation of 5 spool valves, the unit must be supplied
with pressure from both sides.
Units with more than 12 spool valves must be supplied

with pressure from three sides using an intermediate
P1 pressure supply module which should be placed in
the middle.
P1
Supply with 2 different pressures (P1-P2)
A pressure separation plate must be used (see different types)
Supply with 2 different pressures with separate exhausts
Supply with 2 different pressures with common exhausts
E1
E
5
P1
E2
3
P1
P2
Pressure separation
plate for blocking flow
path 1
(type: W)
P2
Pressure separation
plate for blocking flow
paths 1-3-5
(type: X)
Supply with 3 different pressures (P1-P2-P3)
E2
B
E1
P1
A
3
P2
Spool
valves
supplied at
pressure P1
50
Spool
Spool
valves
valves
supplied at supplied at
pressure P2 pressure P3
E3
P3
For this configuration use:

- 1 intermediate pressure supply module A .
- 2 pressure separation plates B . Choose between the
following versions:
Ports 1 3 5 blocked to separate off the exhausts
(type X).
Port 1 blocked to channel the exhaust of the whole
island (type W).
INSTALLATION
10.4.3 Pressure separation plate and intermediate pressure supply module

To obtain the configurations described on the opposite page, these accessories must be incorporated in the right order.
Intermediate pressure
supply module
(width: 27 mm)
Pressure
separation plate
(width: 9 mm)
STANDARD VERSIONS FOR ISLANDS WITH CONNECTORS SIZE 15, MULTIPOL IP20 AND VCS
Type
Code
Ports 1 and 3 / 5 with instant fittings 10 mm O.D. (1)
881 57 819
Ports 1 and 3 / 5 with G1/4 thread (1)
881 57 821
Total blocking of ports 1 - 3 - 5 (no connection)
881 57 815
Blocking of ports 3 - 5 (port 1 connected)
881 57 817
Blocking of port 1 (ports 3 and 5 connected)
881 57 816
No blocking (ports 1, 3 and 5 connected)
881 57 818
Description
Intermediate
pressure
supply module
Pressure
separation
plate
(1) An exhaust silencer can be mounted to port 3 / 5 (see following page)

Construction details of pressure separation plate
Pressure
separation plate
Codes
pressure
separation plate
Type
881 57 815
881 57 817
881 57 816
881 57 818
: blocked
Flow path Flow path Flow path Flow path

1
3/5
12/14
82/84
: remains opened
82/84
3/5
3
82/84
3/5
3
12/14
12/14
Port 1
Port 3/5
Ports 12/14
Ports 82/84
:
:
:
:
pressure supply
exhausts 3 and 5
external pilot pressure supply
connection of exhausts of pilot loop
51
INSTALLATION

10.5
Pressure supply of pilot valves
A MEGA spool valve is equipped on one side with a spacer sealing which also provides for
a selecting function:
- The spool valve can be adapted to either internal or external pilot pressure supply simply
by rotating this sealing.
- The position selected for each spool valve can be identified from the outside even after
the spool valves have been assembled to islands.
- Internal and external pressure supply can be mixed on one island.
- If the components are supplied separately, the spool valves are delivered with the sealing
placed in INT for internal pressure supply.
Internal pressure supply to pilot valves
External pressure supply to pilot valves
Identification underneath the spool valve
Identification underneath the spool valve

EXT
10.6
INT
INT
EXT
In this configuration:
The pilot valves are directly supplied with pressure by
using the supply pressure (1) in the middle of the spool valve.
The common pressure supply (spool valve and pilot valves)
is 3 to 8 bar (2 to 8 bar with bistable 5/2 spool valves).
In this configuration:
- The spool valves on an island can be supplied with low
pressure and vacuum.
- The pilots and the spool valves on an island can be supplied
with pressure over 2 separate lines.
Supply pressure of pilot valves: 3 to 8 bar
(2 to 8 bar with bistable 5/2 spool valves)
Supply pressure of spool valves: -0.950 bar to +8 bar.
Connection of pilot pressure supply 12/14 at either one of the
2 end covers.
Mounting and pneumatic accessories

Accessory
1m
Description
Code
1m
881 57 858
5x1m
334 00 033
DIN EN50022 rail
x10
Set of 10 connecting bolts 18 mm long (for 5 spool valves)

(Note: Each spool valve is delivered with connecting bolts)
881 57 893
Set of 10 instant reducing fittings 8 / 6 mm O.D. (1)
881 57 887
x10
Plastic body
346 00 407
Sintered bronze body
346 00 002
Exhaust silencer, male thread (2)
Sintered bronze exhaust silencer for direct mounting to ports with

instant fittings 10 mm O.D. (3)
881 57 826
Set of 17 clip-on ID labels for spool valves and VCS connectors

(Note: each component is supplied with 2 ID labels at delivery)
881 57 851
(1) For mounting to ports 2 4 of spool valves with 8 mm O.D. instant fittings for 6 mm O.D. flexible tube
(2) Exhaust silencer for ports 3/5 of G1/4 threaded end covers
(3) Exhaust silencer for ports 3/5 of end covers with instant fittings 10 mm O.D.
52
INSTALLATION
10.7
Assembly of MEGA island/VCS connectors
18
B1
J
2mm
D
5a
14
5b
12
5
3
14
12 82/84 1
578 00 004
P(1): _ 0.9/3...8 bar
5a
5b
12 14
12 14
12 14
6
1mm
1mm
1 - Screw the two rows of posts (B1) into the

LH end-fitting (A) fitting one post in each
row for each spool valve to be installed
(two 18 mm posts are supplied with each
spool valve).
2 - End with two male-male posts on the RH
side (supplied with the end-fittings) with the
short threaded end on the post side (C).
3 - Install the RH end-fitting, taking care to
properly seat the seal (J) and pre-tighten
with the two knurled knobs, leaving a play
of 2 mm for installing the spool valves.
4 - Identify each spool valve by its label with
the diagram, code, and letter of the type
(e.g. S, M, G etc.), then check that the
selector seal (J):
is in place,
properly oriented (INT or EXT) for the
desired piloting arrangement (see corresponding section), and
properly seated in its housing.
5 - Clip each spool valve (D) to the posts as
described in 5a and 5b.
6 - Place the spool valves against each other
beginning at the LH side.
Check that there is enough room and clearance to install the last spool valve.
Check that all spool valves are properly
clipped on and aligned.
7 - Secure the island assembly by screwing
tight with the knurled knobs. Do not use
pliers or any other tool!
- Fix the island to the support provided:
install on frame with two M4 screws or
directly to symmetrical DIN EN50022 rail
(see chapter 10.4.1).
8 - Identify the type of connector intended for
the MEGA spool valves (see chapters 2.1
& 3.1) and install them on the spool valves.
9 - Open all the lids of the connectors on the
island, connect the green VCS cable + the
(possible) black power cable, shut the lids
to ensure proper contacting (see chapter 2.3).
7
12 14 12 14 12 14 12 14 12 14
14
14
14
53
INSTALLATION

10.8
JOINABLE SOLENOID AIR OPERATED MEGA 18 SPOOL VALVES
GENERAL
Space saving due to new patented design and integral twin pilot.
High flow rate, reduced dimensions.
Low power consumption.
Quick installation and easy maintenance with visual indication of the spool
position, identification and reference labels as well as manual override.
Low weight for block installation.
SPECIFICATIONS
FLUIDS
OPERATING PRESSURE
: Air or neutral gas, filtered at 30m, lubricated or not

: -0.95 to 8 bar (with external supply)
: 3 to 8 bar (with internal supply)
: -10C to +50C
ALLOWABLE TEMPERATURE
CONNECTION
- Spool valve (ports 2 - 4)
- End covers (ports 1 - 3 - 5)
FLOW (Qv at 6 bar)
FUNCTION
PILOT CONTROL
PILOT PRESSURE
VIBRATION FATIGUE LIMIT
: instant fittings for flexible hose 6 or 8 mm O.D.

: G1/4 thread or instant fittings 10 mm O.D.
: see table below
: 2x3/2 NC, monostable or bistable 5/2, 5/3
: solenoid air operated with internal or external pressure supply
: 2 or 3 bar to 8 bar (see table below)
: to EN 60068-2-6 standard
CONSTRUCTION
Body and end covers: glass-fibre reinforced synthetic material.
Internal parts: aluminium, stainless steel, zinc-plated steel, brass
and synthetic material.
Sealings: nitrile (NBR) and PUR.
Internal or external pilot pressure supply by selecting seal
Impulse-type or locking push/turn-type manual override.
Integral electrical pilot to NFC79300 (VDE 0580).

Encapsulated coil with flat terminals to DIN 46244 A 2.8 x 0.5
(spacing: 9.4 mm).
The bistable version is provided with an integral twin pilot placed
on one side of the valve with a single electrical connector for
reduced dimensions.
ELECTRICAL CHARACTERISTICS
Voltage
Insulation
class
Protection
degree
24 V DC
IP 65
Spool valve
Consumption
Electrical connection
monostable
1.6 W
bistable
1.5 W
2 flat terminals + earth

3 flat terminals + earth
CHOICE OF EQUIPMENT
Operators
Functions
Symbols
Type
2x3/2
NC
4
14
5/2
5/2
5/3
5
12/14 82/84
5/3
14
2...8
Solenoid air
12
12
5
3
14
12 82/84 1
4
3...8
5
3
14
12 82/84 1
14
900
(550)
12
Solenoid air
Differential
3...8
Spring
14
4...8
Solenoid air
14
450
12
5/2
5/3
Spring
12/14 82/84
Solenoid air
Solenoid air
14
Return
(12)
CODES (24 V DC)

Pilot
pressure (M) Spool valve without connector
ports 2-4 with instant fittings
(bar)
6mm O.D.
8mm O.D.
12/14 82/84
Pilot
(14)
Flow
at 6 bar
(l/min)
(ANR)
5
3
14
12 82/84 1
12
Centre closed
W1
solenoid air operated
600
(550)
3...8
Centre open to pressure

W2
700
(550)
3...8
Centre open to exhaust

W3
750
(550)
3...8
(M) Manual override

: impulse-type : locking, push/turn-type
(550): Max. flow rate of 550l/min for the version with instant fittings for flexible hose O.D. 6mm.
54
578 00 041
578 00 013
578 00 042
578 00 014
578 00 030
578 00 002
578 00 036
578 00 008
578 00 031
578 00 003
578 00 037
578 00 009
578 00 029
578 00 001
578 00 035
578 00 007
578 00 032
578 00 004
578 00 038
578 00 010
578 00 033
578 00 005
578 00 039
578 00 011
578 00 034
578 00 006
578 00 040
578 00 012
VCS APPLICATION REQUIREMENTS FORM

To specify the proper quantity and type of VCS power supplies required for your application, please fill in this form and consult us.
Identification request
Society : ________________________________________________
Requested by : ___________________________________________
Adress : _________________________________________________
_______________________________________________________
_______________________________________________________
Tel. : ___________________________________________________
Fax : ___________________________________________________
Installation reference :
Which buslink protocol do you require?

Do you need the analog input/output option?
Profibus-DP
YES
Number of 2x100mA VCS connectors with green cable

Number of 2x100mA VCS connectors with green and black cables
Number of 1x1A VCS connectors with green and black cables
NO
Interbus-S
Device Net
if YES how many:
without input
881 57 803
with 2 inputs
881 57 805
without input
881 57 949
with 2 inputs
881 57 951
without input
881 57 807
with 2 inputs
881 57 809
Number of 8 PNP VCS input modules with M8 connectors
881 57 827
Maximum number of valves simultaneously switched on over green cable (1 output per VCS connector)
Coils power
(W)
Maximum power simultaneously switched on over black cable
(W)
Total length of the VCS loop (green cable)
(m)
Length of the black cable (if different from green cable)
(m)
Example:
Which buslink protocol do you require?
Do you need the analog input/output option?
Profibus-DP
YES
Number of 2x100mA VCS connectors with green cable

Number of 2x100mA VCS connectors with green and black cables
Number of 1x1A VCS connectors with green and black cables
Number of 8 PNP VCS input modules with M8 connectors
NO
Interbus-S
Device Net
if YES how many:
without input
881 57 803
12
with 2 inputs
881 57 805
without input
881 57 949
with 2 inputs
881 57 951
41
without input
881 57 807
with 2 inputs
881 57 809
10
881 57 827
Maximum number of valves simultaneously switched on over green cable (1 output per VCS connector)
35
Coil power
(W)
Maximum power simultaneously switched on over black cable
(W) 128
Total length of the VCS loop (green cable)
(m) 100
Length of the black cable (if different from green cable)
(m)
1.6
50
55

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Installation manual

Connection system for solenoid valves and

This product contains electronic components sensitive to electrostatic

2001 - ASCO/JOUCOMATIC - All rights reserved.

VCS - VALVE CONNECTION SYSTEM _______________________________________________________ 4

SYSTEM COMPONENTS __________________________________________________________________ 6

POWER SUPPLY ON VCS LOOP __________________________________________________________ 20

INSTALLATION INSTRUCTIONS __________________________________________________________ 32

CONNECTION TO STANDARDISED FIELDBUS SYSTEM ______________________________________ 35

VCS DIAGNOSTIC SOFTWARE (VCS - DIAG) ________________________________________________ 42

TECHNICAL CHARACTERISTICS __________________________________________________________ 43

MAINTENANCE AND CARE ______________________________________________________________ 46

MEGA 18 SPOOL VALVE ISLANDS WITH VCS CONNECTORS _________________________________ 47

VCS Application Requirements Form _______________________________________________________________ 55

VCS - VALVE CONNECTION SYSTEM

All combinations of spool valves for pneumatic or water

1 Solenoid spool valve alone or

3 General purpose solenoid valve

General purpose valve

5 Air-operated valve actuator

6 VCS module with 8 inputs

P VCS power supply

A VCS connector to be mounted to a solenoid valve or spool valve (C)

VCS connector (see chap. 2.2)

VCS connector size 15, 24V DC with 2 outputs max. 100 mA

VCS connector size 15, 24V DC with 2 outputs max. 100 mA

single unit 881 57 803

single unit 881 57 805

single unit 881 57 807

single unit 881 57 809

Adapter 15/22 for VCS connector mounting on coil size 22

VCS interface (see chap. 2.4)

Standard VCS interface for connection with protocol:

VCS interface with 2 analog inputs/outputs 0 - 10V

9 male pin SUB-D connector for Profibus-DP - IP20

Configuration diskette (.GSD / .EDS) for Profibus-DP and Device-Net

Diagnostic software for VCS / PC

RS232 cable for VCS interface/PC connection. Length: 1.8 m

VCS installation manual

Power supplies (see chap. 2.6)

VCS power supply 27V DC - 3.1A

Power supply for black power cable, 24V DC adjustable - 10A

Cables (see chap. 2.3)

Flat profiled VCS cable, green, 2 wires - lengths:

Flat power cable, black, 2 wires - lengths:

VCS adapter (round/flat) for connection of additional VCS power supply

Extension module for flat VCS cable or power cable (flat/flat)

1 set of 10 self-adhesive flat cable mounting clips

1 set of heat-shrinkable 10 end caps for flat cable ends

1 set of 17 clip-on ID labels for spool valves and VCS connectors

1 set of 10 guides for green VCS cable

1 set of 10 guides for black power supply cable

VCS input modules

VCS input module, 8 PNP inputs, 8 x M8 connectors

Straight 3 male pin input connector M8 (cable dia. 3.5 to 5mm)

Right-angle 3 male pin input connector M8 (cable dia. 3.5 to 5mm)

View from bottom

Wiring diagram of inputs

View on soldered side of male connector

VCS cable installation

Be sure the power supply is switched off prior to contacting

You can install it in just seconds !

Black power cable

Wiring instructions for the flat cables