Service Test Unit for ROSS Proportional Valves · · 2017-04-10 Service Unit for Proportional...

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Service Unit for Proportional Valves– Technical Description –

Page 1 04.08.2015

ROSS EUROPA GmbH • Robert-Bosch-Strasse 2 • D-63225 Langen Phone: 0049 6103 7597 0 • Fax: 0049 6103 74694e-mail: [email protected] • www.rosseuropa.com

ROSS®

Service Test Unit for ROSS® Proportional Valves

Technical Description V 1.0 / 2015

RESK 4591.40

For all Prop Valve Models Connections on both Sides Measuring Pressure Transformer included

Iss.: August 4, 2015

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Page 2 04.08.2015

Contents: Page

The Touch Screen .................................................. 3

General Information ................................................ 4

Test Preparation ..................................................... 5

Indications / Displays .............................................. 6

Test AUTOMATIC.................................................... 6

Graphics Analysis ............................................... 7, 8

Components needed for testing a ROSS® Proportional Valve:

For comprehensive information, please refer to Technical Leaflet RESK 4591.0

Test Unit RESK 4591.0 (see photo on the left)

Adapter Plate

Electronic Service Unit (as described in this document)

Adapter Cable

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Page 3 04.08.2015

The Touch Screen Basic Setting Options:

Set Value (V, mA) Actual Value

(V, mA)

bar/psi (switchable)

Measured Times (ms)

Reference Sensor

Power Supply Valve

Type

Valve Type

Pressure Range Valve

Step Quantity

STEP-Chart Edit

Actual Y-Scale

Measured Cycle Time

STEP Result

Test Mode

X-Axis Pre-Select

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General Information The Service Unit consists of two components: one pneumatic and one electronic. Through a simple exchange of sub-bases in connection with a 2 liter test volume, gauge and electronic pressure sensor, all ROSS proportional valves can be tested. Voltage is supplied by the electronic element (Service Box) which secures the testing procedure following a defined analysis. Optionally, the Service Box can be combined with a valve and connected directly to the IS machine. In that case, all relevant data, such as set value, actual value, operation voltage and actuation times are measured and indicated.

Through a 7“ Touch Screen all valve-specific parameters can be set, these are: — Valve Type (Nominal Diameter) — Pressure Range of the Valve — Set Value — Actual Value presetting (current, voltage)

Graphic Representation of Set and Actual Value. For the X-axis (time), a fixed setting ( 600 ms, 1.2 sec. 2.4 sec. 6.0 sec. ), or an automatic adjustment guided by the previous measuring results, can be selected.

The Y-axis (pressure) will automatically readjust to an optimal graphic representation.

On the test bench three test modes can be selected. For a functional test, the set value needs to be set to 50% of the nominal value, the inlet pressure must be set to +0.1 bar in the „valve segment“ on the screen.

Test AUTOM: Use the Test Selector (upper, middle touch field) to select „Test AUTOM“. Shifting the toggle switch towards MANUAL, a pilot control impulse of 350 ms is triggered. At this fixed time, the full cycle can be graphically represented. Test MANUAL: Preparations as described above, however, in this case cycle time (respectively ON-time) is solely defined through the position of the toggle switch. In this mode all measured values are readable.

STEP: On the Step-Page, time steps (in ms.) as well as assigned pressures can be set. On the Main Page the number of steps is defined. Start the procedure by shifting the toggle switch towards

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Page 5 04.08.2015

STEP. Repeat running through the Time/Pressure chart until the step counter has achieved NULL (ZERO) or the toggle switch has been moved to the neutral position. EXTERNAL Mode: This mode involves the use of both connectors X10 and X11, located on the right hand side of the service box.

X10 is connected with the connector removed from the valve. X11 is connected with the valve. The toggle switch is absolutely required to be in the neutral position. The process is controlled through the valve’s set value.

Test Preparation: The information given on the label must be transfered to the unit, i.e.: Pressure Range in terms of „bar“ (not max. pressure!), Set Value / Actual Value mode (V or mA) and Type (Nominal Diameter). All fields framed in blue and white are adjustable. Connect the service box with the external pressure sensor, Port X12 at the right-hand side.

Use the switch above the IEC connection to apply mains voltage. Inlet Pressure: Set valve‘s pressure range +0.1 bar using the gauge. For valves with pressure range exceeding 0 - 5 bar, inlet pressure must be set to 5 bar. Wrongly set inlet pressures directly influence actuation time analysis.

Type of Set / Actual Value: Use soft switch ( „Set“ ) to set mode (to be read from the nameplate): „Electronic Piloting“. Type: Use soft switch („Type“) to set nominal diameter (ND) given on valve‘s data sheet. Range: Use soft switch („Span“) to set pressure range (not max. pressure range) given on the nameplate. Set Value: In the upper, left-hand, blue touch field, 50% of reference value must be set:„Set Value“: 0-10 V -> 5.00 to be set.„Set Value“: 0-20 mA -> 10.0 to be set.„Set Value“: 4-20 mA -> 12.0 to be set.

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Page 6 04.08.2015

X-Scale: Four time ranges can be preset: 1:1 defined 600 ms, 1:2 corresponds to 1.2 sec.,1:4 corresponds to 2.4 sec., 1:10 corresponds to 6.0 sec.

Use „Automatic“ to select the optimal measuring range from previous measuring.

Y-Scale: For a distinct and clear representation of measuring results, the unit self-adjusts on three ranges, guided by previous measurements. Normally, the valve range is selected. In case of smaller set values, the Y-axis is set on ½ of the set value, or ¼ of the set value, to be read in the upper area above the Y-axis.

Connect valve with Port X1 (left side of the device), using the cable supplied with the unit.

For the initial test, the AUTOMATIC mode is recommended. This mode can be set via the touch field above the graphics area.

By shifting the toggle switch towards „Manual“, the test cycle will be started.

The result will be shown in the INFO line and in the yellow displays in the upper area. To the upper left, the cycle time is shown. In this mode, 351 ms should be shown. This indication is of particular relevance for a valve test on the IS machine.

Analysis of the measured results:

Indications:

SV: adjustable set valueAV: measured actual value (in terms of V or mA, respectively)Bar: measured actual value (in terms of bar)T10: time in ms, until actual value reaches 50 mbar T95: time in ms, until the actual value reaches 95% of set value T-Exhaust: time in ms, until actual value falls below 100mbar after shut-off Ref.AV: measured value of external pressure sensor, in terms of bar Power supply: internal/external voltage supply of valve Puls active cycle time during measuring process

Test AUTOMATIC: This test procedure focuses primarily on repeatability. Indications for actual values (V, mA, bar) as well as externally measured pressure values cannot be displayed due to the short measuring time. Priority is on the graphic representation of the complete cycle.

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Page 7 04.08.2015

Rise time, fall time and control behavior are available for the analysis. The info line will show the analysed result.

As only one information item can be represented, the deviation having occurred first will be indicated. 1) Pressure deviation in regulating mode 2) Rise time too small or too large 3) Fall time too large Rise time too fast: Indicative of changed parameters or mechanical problems in the valve. If regulating behavior is within a range of ±20 mbar, valve operation may continue, otherwise repair will be necessary. Rise time too slow: Indicative of changed parameters or mechanical problems in the valve. Repair will be necessary.

Fall time too slow: Indicative of changed parameters or mechanical problems in the valve. Repair will be necessary. Pressure deviation (in regulating mode) This fault will be indicated, when the pressure difference between the valve’s actual value and the external pressure sensor is larger ±25 mbar. In that case repair is necessary.This fault is mainly caused by the valve pressure sensor, or by leakage in the valve at the inlet or the outlet. The graphic representation shows clear control variations. External mode: In this mode all indications are active. Basic requirement for starting a measuring cycle is a zero phase of the set value, at least 10 ms.

Graphics Analysis: For the analysis of the measuring result the displayed graphic is of particular help.

On the Test Bench: 1. The actual value should not vary more than ±30 mbar around the set value. If the inlet pressure is stable and the tolerance level is exceeded, an abnormal regulating behavior may be assumed.

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Page 8 04.08.2015

2. If the actual value shows a zigzag curve below the set value, leakage in the exhaust area of the valve is likely to be the cause. If no leakage can be identified on the test bench, the valve is defective.

3. If the actual value shows a zigzag curve above the set value, leakage in the pressurizing area of the valve is likely to be the cause. If the test pressure is set correctly, the valve is defective. On the IS-Machine:

1. The „Power Supply“ field shows the supply voltage of the valve. It should be within the maximum tolerance of ±10%. If this is not the case, valve behavior is too fast or too sluggish. 2. The actual value should not vary more than ±50 mbar around the set value. If the inlet pressure is stable and the tolerance level is exceeded, an abnormal regulating behavior may be assumed.3. If the actual value shows a strongly varying curve around the set value, leakage in the cylinder system or insufficient air supply may be the cause. 4. Should blow-out processes with high volume flow be involved, the occurrence of such a phenomenon is possible. 5. The pulse time is analogous to the piloting procedure. If several impulses are visible in the machine cycle, the respective time will always refer to the last impulse.

For further information, our Standard Worksheet is available, including step-by-step, illustrated testing instructions.

Standard Work Sheet • Testing InstructionsUpdated: 31.01.2017

Work Station: Testing Facility

Product: Proportional Valve

Job: Step-by-Step Testing

No. Action Photo Remark

1 Mount Adapter Plate

on test unit

2 Mount valve on

Adapter Plate

3 Inlet Pressure:

Set valve‘s pressure

range +0.1 bar using

the gauge

For valves with

pressure range

exceeding 0-5 bar,

inlet pressure must

be set to 5 bar

Important:

Wrongly set inlet pressures

directly influence actuation

time analysis

Note:

If pressure builds up at outlet

side too, valve is defective,

due to leak at inlet side.

4 Connect service box

to IEC connection

Note:

Several connecting adaptors

are supplied with the test unit






5 Use the switch above

the IEC connection

to apply mains

voltage

6 Use soft switch

( „Set-V.“ ) to set

mode (to be read

from the nameplate:

“Electronic

Piloting”).

7 Use soft switch

( „Type“ ) to set

nominal diameter

(ND)

Note:

Nominal diameter is given on

valve‘s data sheet

Data on request. Please

contact ROSS Europa

8 Use soft switch

(„Span“) to set

pressure range (not

max. pressure range)

given on the

nameplate.

Use format „X.Y0“ and

confirm with „Ret“

(For example: „4.00“ for

„0 – 4 bar“)






9 In the upper, left-

hand, blue touch

field a 50% set value

reference must be

set

Set-V.: 0-10 V

-> 5.00 to be set

Set-V.: 0-20 mA

-> 10.0 to be set

Set-V.: 4-20 mA

-> 12.0 to be set

10 Normal Mode:

Connect valve with

Port X1 (left side of

the device), using the

cable supplied with

the unit

Important:

Switch off mains voltage prior

to this step!

11 Connect the service

box with the external

pressure sensor, Port

X12 at the right-hand

side






12 For the initial test,

the AUTOMATIC

mode is

recommended. This

mode can be set via

the touch field above

the graphics area

Note:

Apply mains voltage prior to

Step 13

13 X-Scale:

Four time ranges can

be preset:

1:1 defined 600 ms,

1:2 corresponds to 1.2

sec.,

1:4 corresponds to 2.4

sec.,

1:10 corresponds to

6.0 sec

Note:

Use „Automatic“ to select the

optimal measuring range from

previous measuring

14 By shifting the toggle

switch towards

„Manual“, the test

cycle will be started

Note:

Initial cycle is required. After

second time shifting the

toggle result info will be

correct

15 The result will be

shown in the INFO

line and in the yellow

displays in the upper

area. To the upper

left, the cycle time is

shown

Note:

In this mode, 351 ms should

be shown. This indication is of

particular relevance for a

valve test on the IS machine






16a Rise time too fast: If regulating behavior is within a

range of ±20 mbar, valve

operation may continue,

otherwise re-calibrating will be

necessary by ROSS

16b Rise time too slow: Case A:

Mechanical Problems

Check of mechanical blocking at

inlet port and inlet solenoid will

be necessary

Case B:

Changed Parameters

Re-calibrating will be necessary

by ROSS

16c Fall time too slow: Case A:

Mechanical Problems

Check of mechanical blocking at

exhaust port and exhaust

solenoid will be necessary

Case B:

Changed Parameters

Re-calibrating will be necessary

by ROSS

16d Pressure deviation Case A: Leakage

Check and possibly exchange of

both solenoid armatures will be

neccesary

Case B:

Defect Pressure Sensor

Exchange of pressure sensor

will be necessary by ROSS

17 For further

information about

graphics analysis,

manual test and

external mode (on IS

Machine), please refer

to our Technical

Description „Service

Unit for Proportional

Valves“

Test Unit for ROSS®-Proportional ValvesRESK 4591.0Page 1 of 6E - 04-2016

ROSS®ROSS EUROPA GmbH • Robert-Bosch-Strasse 2 • D-63225 LangenTel.: 0049-6103 - 7597-0 • Fax: 0049-6103 - 74694 e-mail: [email protected] • www.rosseuropa.com

SPECIFICATIONSMaximum Pressure: 5 bar.

Test pressure (pressure supply at G 1 inlet), must be set to nominal valve pressure. For valves with nominal pressure exceeding 5 bar, test pressure must be set to 5 bar.

Temperature: 0 to 85°C

Port Size: G 1

Model Number: RESK 4591.0

Dimensions - mm

20

136

43

5

Inlet

ca. 246

Manual

Exhaust

200

419

240

250

175

G 1

Sensor with Connector

for Electronic Test Box

0 to 5 bar, 0 to 5 volts

Cable - 3 m



Adapter Plate Proportional Valve Adapter Plate Illustration Model Numbers Model Number 01-SOP-03-00-0-0 01-SOP-03-00-0-1 01-SOP-03-00-0-3 ND 9,5 - ND 10,5, GPS-version 120P190002 120P190003 120P190006 120P190010 120P190011 120P190012 120P190014 120P190016 ND 12, Bosch-version 095P090000 095P090001 115P200000 115P200001 115P200002 115P200003 115P200006 115P200010 115P200012 115P200013 ND 7,0, Bosch-version

120P210000 Valve 120P21, Sklostroj-version

120P140002 120P140003 120P140012 120P140022 120P140023 120P140024 ND 12, 120P14, Heye-version

RESK 4152.17

RESK 4152.19

RESK 4152.20

RESK 4152.21

RESK 4152.22



Illustration Proportional Valve Model Number Adapter Plates Numbers Adapter Plates 01-SOP-01-00-0-2 01-SOP-01-00-0-3 01-SOP-01-00-0-4 01-SOP-01-00-0-5 01-SOP-01-00-0-6 01-SOP-01-00-0-7 01-SOP-01-00-0-9 01-SOP-01-00-1-0 01-SOP-01-00-1-2 01-SOP-01-00-1-4 01-SOP-01-00-1-6 01-SOP-01-00-1-7 01-SOP-01-00-1-8 01-SOP-01-00-2-2 01-SOP-01-00-2-4 01-SOP-01-00-2-6 ND 14, ROSS Proportional Valve 200P160002 ND 20, ROSS Proportional Valve 095P140002 095P140012 095P140022 ND 9,5, ROSS Proportional Valve

RESK 4152.23

RESK 4152.24

RESK 4152.25


Test Unit for ROSS®-Proportional Valves RESK 4591.0Page 4 of 6E - 04-2016

Required Accessories

Electronic test box for all proportional valve models. Connecting/porting options at both sides, power cable included.

Model Number: RESK 4591.40

Shut-off Valve, G 1Model-No.: YD1523C6002

Ambient/Media Temperature: 4° to 80° C.

Flow Medium: compressed air, filtered.

Pressure Regulator, G 1Model-No.: C5213K6017

Ambient/Media Temperature: 0° to 60° C.

Flow Medium: compressed air, filtered.

Regulated Pressure: 0.5 to 12 bar.

765

43

21

0

89

1011

1213

14

10080

60

40

20

0

120140

160

180

200

bar

lb/in2

�� fi

Pressure Gauge, G 1/4Model-No.: W5400A2011

Housing: ø 54 mm.

Pressure Range: 0 to 14 bar.

Ref. No. Connector for Valve

RESK 4591.60 Harting, square-type (with gold contacts) 120P140002 120P140002.V2 120P140022 120P140022.V2 120P140023 120P140024 120P140025.V2

RESK 4591.61 Wieland, square-type 01-SOP-01-00-0-2 01-SOP-01-00-0-3 01-SOP-01-00-1-2 01-SOP-01-00-2-2 095P140002 095P140012 095P140012.V2 095P140022 01-SOP-01-00-0-1 140P170000 200P160002 095P140000 095P140001 120P140004 200P160000 200P160001 200P160003 200P160004

RESK 4591.63 Harting, square-type (Sklostroj-wiring) 120P210000

RESK 4591.64 (2x) M12, 5-pin 01-SOP-03-00-0-0 01-SOP-03-00-0-0.V2 01-SOP-03-00-0-3 01-SOP-03-00-0-2 01-SOP-01-00-0-4 01-SOP-01-00-1-4 01-SOP-01-00-1-9 01-SOP-01-00-2-6 01-SOP-01-00-0-6 01-SOP-01-00-1-6 120P190016

RESK 4591.65 M12, 5-pin 01-SOP-01-00-1-7 01-SOP-01-00-0-5 01-SOP-01-00-1-5 01-SOP-01-00-1-0 120P190014 120P190012 115P200012 120P190002 115P200013

RESK 4591.68 M12, 8-pin 01-SOP-01-00-1-8 115P200000 115P200001 120P190010 120P190011 115P200010

Adapter Cable


Test Unit for ROSS®-Proportional Valves RESK 4591.0Page 5 of 6E - 04-2016



Safety Precautions

Before exchanging a valve, air supply must be shut off.

All equipment to be used by trained staff only.

Spare Parts

Port Size: G 1/2, radial, bottom-ported

Pressure Range: 0 to 10 bar

Pressure GaugeModel-No.: RESK 4591.8

Pressure Transmitter, incl. 3 m Cable with Connector

Model-No.: RESK 4591.43

ORDERING INFORMATION:

For testing a ROSS® Proportional Valve, the following components are required:

• Test Unit RESK 4591.0

• Adapter Plate (see Pages 2 and 3 for appropriate design)

• Electronic Test Box RESK 4591.40 (see Page 4 for details)

• Adapter Cable (see Page 4)

• Pressure Regulator (see Page 4)

• Shut-off Valve, (see Page 4)

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