Service Test Unit for ROSS Proportional Valves RESK

Service Unit for Proportional Valves Page 1 Technical Description ROSS 04.08.2015 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 ROSS EUROPA GmbH Robert-Bosch-Strasse 2 D-63225 Langen Phone: 0049 6103 7597 0 Fax: 0049 6103 74694 e-mail: info@rosseuropa.com www.rosseuropa.com www.rosseuropa.com

Service Unit for Proportional Valves Technical Description 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: Test Unit RESK 4591.0 (see photo on the left) Adapter Plate Electronic Service Unit (as described in this document) Adapter Cable For comprehensive information, please refer to Technical Leaflet RESK 4591.0 www.rosseuropa.com

Service Unit for Proportional Valves Technical Description 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 Valve Type Type Pressure Range Valve Step Quantity STEP-Chart Edit Actual Y-Scale Measured Cycle Time STEP Result Test Mode X-Axis Pre-Select www.rosseuropa.com

Service Unit for Proportional Valves Technical Description Page 4 04.08.2015 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 www.rosseuropa.com

Service Unit for Proportional Valves Technical Description 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. www.rosseuropa.com

Service Unit for Proportional Valves Technical Description 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 value AV: 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. www.rosseuropa.com

Service Unit for Proportional Valves Technical Description 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. www.rosseuropa.com

Service Unit for Proportional Valves Technical Description 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. www.rosseuropa.com

Standard Work Sheet Testing Instructions Updated: 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 Instructions Updated: 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 Instructions Updated: 31.01.2017 Work Station: Testing Facility Product: Proportional Valve Job: Step-by-Step Testing No. Action Photo Remark 9 In the upper, lefthand, 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 Instructions Updated: 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 14 By shifting the toggle switch towards Manual, the test cycle will be started Note: Use Automatic to select the optimal measuring range from previous measuring 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 Instructions Updated: 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 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 Case B: Defect Pressure Sensor Exchange of pressure sensor will be necessary by ROSS

Test Unit for ROSS -Proportional Valves RESK 4591.0 Page 1 of 6 E - 04-2016 SPECIFICATIONS Maximum 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 Sensor with Connector for Electronic Test Box 0 to 5 bar, 0 to 5 volts Manual Exhaust 20 136 435 Cable - 3 m Inlet ca. 246 240 G 1 175 250 419 200 ROSS EUROPA GmbH Robert-Bosch-Strasse 2 D-63225 Langen Tel.: 0049-6103 - 7597-0 Fax: 0049-6103 - 74694 e-mail: info@rosseuropa.com www.rosseuropa.com ROSS

Test Unit for ROSS -Proportional Valves Adapter Plate Proportional Valve Illustration Model Numbers 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 RESK 4591.0 Page 2 of 6 E - 04-2016 Adapter Plate Model Number RESK 4152.17 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 RESK 4152.22 120P140023 120P140024 ND 12, 120P14, Heye-version ROSS EUROPA GmbH Robert-Bosch-Strasse 2 D-63225 Langen Tel.: 0049-6103 - 7597-0 Fax: 0049-6103 - 74694 e-mail: info@rosseuropa.com www.rosseuropa.com RESK 4152.19 RESK 4152.20 RESK 4152.21 ROSS

Test Unit for ROSS -Proportional Valves Illustration Proportional Valve Adapter Plates Numbers 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 RESK 4591.0 Page 3 of 6 E - 04-2016 Model Number Adapter Plates RESK 4152.23 200P160002 ND 20, ROSS Proportional Valve 095P140002 095P140012 095P140022 RESK 4152.25 ND 9,5, ROSS Proportional Valve ROSS EUROPA GmbH Robert-Bosch-Strasse 2 D-63225 Langen Tel.: 0049-6103 - 7597-0 Fax: 0049-6103 - 74694 e-mail: info@rosseuropa.com www.rosseuropa.com RESK 4152.24 ROSS

2 Test Unit for ROSS -Proportional Valves RESK 4591.0 Page 4 of 6 E - 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 1 Model-No.: YD1523C6002 Pressure Regulator, G 1 Model-No.: C5213K6017 Pressure Gauge, G 1/4 Model-No.: W5400A2011 3 4 1 5 0 6 80 60 40 20 0 7 100 ROSS fi 8 9 120 140 160 180 200 lb/in2 bar 14 10 11 13 12 Ambient/Media Temperature: 4 to 80 C. Flow Medium: compressed air, filtered. Ambient/Media Temperature: 0 to 60 C. Flow Medium: compressed air, filtered. Regulated Pressure: 0.5 to 12 bar. Housing: ø 54 mm. Pressure Range: 0 to 14 bar. ROSS EUROPA GmbH Robert-Bosch-Strasse 2 D-63225 Langen Tel.: 0049-6103 - 7597-0 Fax: 0049-6103 - 74694 e-mail: info@rosseuropa.com www.rosseuropa.com ROSS

Test Unit for ROSS -Proportional Valves RESK 4591.0 Page 5 of 6 E - 04-2016 Adapter Cable 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 ROSS EUROPA GmbH Robert-Bosch-Strasse 2 D-63225 Langen Tel.: 0049-6103 - 7597-0 Fax: 0049-6103 - 74694 e-mail: info@rosseuropa.com www.rosseuropa.com ROSS

Test Unit for ROSS -Proportional Valves RESK 4591.0 Page 6 of 6 E - 04-2016 Spare Parts Pressure Gauge Model-No.: RESK 4591.8 Pressure Transmitter, incl. 3 m Cable with Connector Model-No.: RESK 4591.43 Port Size: G 1/2, radial, bottom-ported Pressure Range: 0 to 10 bar Safety Precautions Before exchanging a valve, air supply must be shut off. All equipment to be used by trained staff only. 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) ROSS EUROPA GmbH Robert-Bosch-Strasse 2 D-63225 Langen Tel.: 0049-6103 - 7597-0 Fax: 0049-6103 - 74694 e-mail: info@rosseuropa.com www.rosseuropa.com ROSS