ROSS EUROPA GmbH • Robert-Bosch-Strasse 2 • D-63225 Langen Phone: 0049 6103 7597 0 • Fax: 0049 6103 74694 e-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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Service Test Unit for ROSS Proportional Valves · · 2017-04-10 Service Unit for Proportional Valves – Technical Description – Page 2 04.08.2015 Contents: Page The Touch Screen
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Service Unit for Proportional Valves– Technical Description –
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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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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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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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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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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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
Standard Work Sheet • Testing InstructionsUpdated: 31.01.2017
Work Station: Testing Facility
Product: Proportional Valve
Job: Step-by-Step Testing
No. Action Photo Remark
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“)
Standard Work Sheet • Testing InstructionsUpdated: 31.01.2017
Work Station: Testing Facility
Product: Proportional Valve
Job: Step-by-Step Testing
No. Action Photo Remark
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
Standard Work Sheet • Testing InstructionsUpdated: 31.01.2017
Work Station: Testing Facility
Product: Proportional Valve
Job: Step-by-Step Testing
No. Action Photo Remark
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
Standard Work Sheet • Testing InstructionsUpdated: 31.01.2017
Work Station: Testing Facility
Product: Proportional Valve
Job: Step-by-Step Testing
No. Action Photo Remark
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
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.