OPERATING INSTRUCTIONS 5630 Valve control INTERBUSLOOP version for pneum. lifting valves with board version V 2.0 or V 3.0

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1 Valve control versions IBU board for lifting Part No. valves V. Contr. LIFTV IBU 2STS THSA KAPG9 1MV V. Contr. LIFTV IBU 2STS THSA KAPG9 2MV V. Contr. LIFTV IBU 2STS THSA KAQS 1MV V. Contr. LIFTV IBU 2STS THSA KAQS 2MV V. Contr. LIFTV IBU 2STS EHOS KAPG9 1MV V. Contr. LIFTV IBU 2STS EHOS KAPG9 2MV V. Contr. LIFTV IBU 2STS EHOS KAQS 1MV V. Contr. LIFTV IBU 2STS EHOS KAQS 2MV PURPOSE-CONFORMANT USE IDENTIFICATION CODE V-CONTROL LIFTV IBU 2PS THSA KAPG9 1MV Product = valve control Application lifting valve Control board INTERBUS 2 position detectors transparent cap mechanical / LED position indication special steel cap without position indication KAPG9 cable connection PG9 cable connection Quickon plug Number of 3/2 way solenoid valves 1 2 EHOS KAQS 2MV The valve controls are used to control pneumatically actuated lifting valves in production lines of the beverage and foodstuff industry, in pharmaceutics, bio-engineering, and in the chemical industry. They encompass the complete actuation, sensing, and electronics required for their connection and integration into advanced, powerful control systems. DESCRIPTION OF THE VALVE CONTROL The valve control has a modular design. Depending on the type, the pneumatic (max. of 3 3/2 way solenoid valves) and electric control modules with 2 proximity detectors (Hall sensors on the board) are integrated into the valve control. The valve can also be pneumatically actuated by externally attached solenoid valves. The valve position is indicated mechanically and electrically (DUO LED) directly at the valve control. For heavyduty applications we recommend using a special steel cover (no indication of valve position). A pressure control valve effectively prevents the cover from bursting in case of air leakage. The electrical connection can be carried out directly by means of double-pole cables or with a plug connection. To protect the device against unauthorized tampering the cover can be sealed. In accordance with the valve control type, the following valve functions can be driven. NOTE Valve functions air-opening spring-closing air-closing spring-opening air-closing air-opening Personnel operating and maintaining the valve control are asked to read and observe these operating instructions and to use it in compliance with the specified technical data. The manufacturer does not assume liability for any damages arising from improper or not as directed use. All relevant regulations concerning accident prevention and safety of electric equipment have to be observed while operating, servicing, or repairing the valve control. MAINTENANCE The valve control does not require maintenance. However, we recommend checking the tightness of the air connections at set intervals. If air leakage occurs within the valve control, the compressed air escapes into the open by way of the pressure control valve. ELECTRICAL INSTALLATION (ILL. 6) 56304XXX00_000_E.DOC/ Page 1

2 The electrical connection of the valve control is carried out by means of two unscreened two-wire lines. We recommend using the BUS line of Phönix Contact. It is possible to connect the BUS input and BUS output line with the valve control by means of two PG9-screw fittings or two plug connections. 1 = brown = + 24 V 2 = black = ground / GND CAUTION: On principle electric installations are always to be carried out in idle condition. Ill. 3 Electrical connection of the valve control with PG9 screw fitting (17) ill Strip about 60 mm of the outer insulation off the control cable. 2. Strip the insulation of the control cable wires by about 10 mm and equip them with wire sleeves with 4-side crimping. Cut off projecting cable wires at the wire sleeves. CAUTION: Cable wires that have not been cut off lead to faulty contact making. Assembly drawing of the Quickon plugs: Socket cable plug seal bushing 3. Unbolt the housing cover (23) (24) by rotary motion (bayonet catch) and take it off in upward direction. Lead BUS input and BUS output line separately by PG screw fittings (17) into the housing. 4. Unscrew the slotted bolt (13/1) (2ea.). 5. Remove the plug (13) from the board (2) and connect the control cable wires acc. to the connection layout (ill. 2) CAUTION: Push the wire sleeves of the control cable up to the end stop into the bushing of the plug, and clamp them afterwards. Pin connection of plugs (13) Hexagon nut clamping piece PUTTING INTO OPERATION IN 4 BIT MODE If different valve control generations are used in one system, appropriate measures have to be taken in accordance with the description INTERBUS valve control generations (page 5). Ill. 4 Ill Push the plug (13) onto the connecting board and tighten it with slotted screws (13/1). 7. Place the control cable in the valve control free of contact to the piston rod of the drive unit and clamp it free of tension by the PG9 screw fitting (17) (carry out tensile test by hand). Electrical connection of the valve control with the Quickon socket (25 (26) ill. 4: Strip about 15 mm of the outer insulation off the 2-wire control cable. Push hexagonal nut, clamping piece, seal bushing according to assembly drawing onto the control cable. Affix the control cable wires, acc. to connection layout, (ill. 3), up to stop to the outer cable insulation in the socket. Place socket upon cable plug and screw down with hexagonal nut. If the drive of the valves is realized in 4 bit mode, the valve type can be adjusted directly via the valve - selection switch BCD (ill. 6). Programming by means of the CMD software of Phönix Contact is not necessary. 1. Adjust the valve type via the valve - selection switch 2. Remove the plug-in bridge (14) from the board (2) (ill. 6). By this the valve - selection switch and the 4 bit mode are activated. 3. Apply service voltage (Techn. data, chart 8) 4. Connect compressed air hose Ø 6 x 1 to fitting (11) 5. Check components for air leakage. 6. Check the valve function by manual operation of the 3/2 way solenoid valves (22). The manual actuation in the form of a slide switch is placed at the front side of the 3/2 way solenoid valves (22). Pin connection of the Quickon socket: ELECTRICAL ACTUATION 56304XXX00_000_E.DOC/ Page 2

3 The drive of the valves is realized by means of the drive signal MVA (chart 1). 2. Maximum running time - Opening the valve 3. Maximum running time - Closing the valve 1. Switch on operating voltage and cut in control air. 2. Check the valve functions according to the drive signal MVA (chart 1) Valve function valve drive valve codification: Valve functions Drive signal MVA 3/2 way solen. v. Valve codification switching position valve - selection switch air-opening 0 MV1 4 spring-closing 1 air-opening 0 MV1 5 air-closing 1 MV3 air-closing 1 MV1 4 spring-opening 0 CHART 1 PUTTING INTO OPERATION IN 16 BIT MODE see use of valve control versions, page 5 Adjusting the valve type: Before putting into operation and when exchanging the board (2), in general the valve type is to be programmed by means of the CMD software according to the specifications in chart 1. Two bytes of data are available for adjusting the valve type as well as the special functions. Byte 0 serves for driving the solenoid valves and switching over into the planning mode, and byte 1 for input of the values of the function adjusted in byte 0. For adjusting the valve type, bit 4 (valve type) is to be set in byte 0. In addition to it, the relevant bits 0-3 (BCD coded) are set in byte 1. The valve code can be gathered from chart 1. Thus, the valve type has been programmed. Now the bits set before must be reset again. CAUTION: The value of bit 0 of byte 0 must be 0. The complete occupancy of the input / output bytes can be gathered from the charts 2 through 6. Additional functions: The transmission protocol of the Interbus enables the following additional functions: 1. Counter for the switching cycles of the valve (By this, possible maintenance records can be generated by means of logging the operational data). 2. Monitoring the maximum switching cycles of the valve. (By this, possible service messages can be generated by means of logging the operational data). 3. Running time monitoring Opening. By this, the running time required for opening the valve can be monitored and error messages be generated. 4. Running time monitoring Closing. By this, the running time required for closing the valve can be monitored and error messages be generated. In the CMD software the data allocation (2 bytes inputs and outputs) is assigned to the PLC inputs and outputs. If the functions are not desired, it will be unnecessary to assign every BIT to the PLC. Allocation of the functions: Output byte 0 CMD Bit no. Signal 0 MVA 1 MVB 2 Reserve 3 Reserve 4 Mode bit *1 5 Mode bit *1 6 Mode bit *1 7 Counter reset Chart 2 Bit, 6, 5, 4 Value Signal Normal operation Valve type Running time monitoring Opening in seconds Running time monitoring Closing in seconds Final value of counter in 1000-stepsvalues Reserve Reserve Reserve Chart 3 Output byte 1 Bit no. Signal CMD 0 Planning value 1 1 Planning value 2 2 Planning value 4 3 Planning value 8 4 Planning value 16 5 Planning value 32 6 Planning value 64 7 Planning value 128 Chart 4 Input byte Bit no. Signal 0 CMD 0 Proximity detection Valve closed 1 Proximity detection Valve open 2 Exceeding the running time 3 Reserve 4 Reserve 5 Exceeding the counter 6 Counter multiplexing 0 =bit =bit Counter value bit 16 in 1-step-values Chart 5 The additional functions are to be parameterized with the following data: 1. Maximum switching cycles of valve 56304XXX00_000_E.DOC/ Page 3 Input byte 1 CMD Bit no. Signal 0 Counter value bit 0 / 8 in 1-step-values 1 Counter value bit 1 / 9 in 1-step-values 2 Counter value bit 2 / 10 in 1-step-values

4 ELECTRICAL ACTUATION 3 Counter value bit 3 / 11 in 1-step-values 4 Counter value bit 4 / 12 in 1-step-values 5 Counter value bit 5 / 13 in 1-step-values 6 Counter value bit 6 / 14 in 1-step-values 7 Counter value bit 7 / 15 in 1-step-values Chart 6 The drive of the valves is realized by means of the drive signal MVA (chart 1). 1. Check valve functions according to the control signals. PROXIMITY DETECTION / VALVE POSITION INDICATION The proximity detection and the valve position indication should be checked along side the valve functions. PROXIMITY DETECTION The proximity detection for valve OPEN or CLOSED takes place without direct contact by the magnetic field of the ring magnets of the pulse generator with overlap of the Hall-sensors on the board (2) (ill. 5). In case of error messages, the mounting position of the pulse generator as well as the dimensions A and B (see data sheet) are to be checked acc. to valve size, or to be adjusted anew, respectively. Cap DANGER When assembling the pulse generator, screw the cap into the piston rod up to the metallic stop. A cap that has not been screwed in completely leads to destruction of the housing cover, because of the stroke motion of the piston rod (23) (24) > Danger of injury Valve position indication Mechanical: Valve "OPEN Valve "CLSD = lift position of the driving spindle = position indication "green (1) = position indication "red (1) DISASSEMBLY/ASSEMBLY OF THE VALVE CONTROL WHEN EXCHANGING THE VALVE ACTUATION 1. Do not unscrew the fresh air pipe and the control cable or the plug connection from the valve control. 2. Unbolt the housing cover (23) (24) by rotary motion (bayonet catch) and take it off in upward direction. 3. Close 3-/2 way solenoid valve (22) by manual operation 4. Detach the air pipe from the supply (19). 5. Screw out pan head screws (4) 2ea.. 6. Remove the housing (7) and close with housing cover (23) (24). 7. Disassemble valve actuation 8. Assemble in reverse order, steps 7 to 1. DISASSEMBLY/ASS. OF BOARD (2) AND CONNECTOR PLATES (27A,27B) 1 Unbolt the housing cover (23) (24) by rotary motion (bayonet catch) and take it off in upward direction. 2. Close 3-/2 way solenoid valve by manual operation 3. Unscrew screws (13/1) (2ea.) and pull off plug connector (13) from the board (2). 4. Unscrew the Torx screws (10) (2ea.) (spanner T20). 5. Expand the board holders (BH) slightly outward to both sides and remove the board (2) with the connector plate (27a) (27b) in an upward direction. CAUTION: The O-rings (8) (5 ea.) and 9 (1 ea.) are fixed to the bottom side of the connector plate (27). Check their position and number when assembling. 6. Press together the snap-in pin tips (PT) (2ea.) and release the board (2) from the plug connection (PC) at the connector plate (27). 7. Assemble in reverse order, steps 6 to 1. Ill. 5 Valve position indication Mode of indication: Electrical: = DUO LED on the board (2) Valve "OPEN = position indication "green Valve "CLSD = position indication "red 56304XXX00_000_E.DOC/ Page 4 DISASSEMBLY/ASSEMBLY OF THE 3/2 WAY SOLENOID VALVES (22) 1. Disassemble as described above, disassembly/assembly of the board (2) and connector plates (27a), (27 b), steps 1 through 6.

5 2. Unscrew the recessed head screws (18) (2ea.) and remove the 3/2 way solenoid valve (22) with gasket (GPG) (crosstip screwdriver PH 100). 3. Assemble in reverse order, steps 2 to 1 / 6 to 1. ASSEMBLY INSTRUCTIONS FOR 3/2 WAY SOLENOID VALVES (22) * Insert the gasket (GPG) at the guide pins with the hole and bead positioned toward the top left. * Align the 3/2 way solenoid valve (22) by way of the guide pins and fasten with recessed head screws (18) (2ea.). * CAUTION: Tighten the recessed head screws (18) alternately and evenly, starting at top left. QUALITY OF CONTROL AIR PRESSURE Solids content: Particle size: max. of 5 µm Particle number density: max. of 5 mg/m 3 (grade 3) Water content: Dew point +2 C (grade 3) Oil content: Oil-free max. of 25 mg/m 3 oil (grade 3) ** Note: The current absorption of the board, with simultaneous drive of all valves, results in a possible number of valves of 21 per loop. Since only in very few cases all valves are driven simultaneously, the number of valves per loop increases because of the simultaneity factor. This factor varies, depending on the process application. TECHNICAL DATA Bus system: Interbus Loop Operational principle: Slave Evaluation options: Evaluation of valve position, switching cycles, running time monitoring Address range: ** 1 32 Operating temperature: 10 to +60 C Appliance classes: II (Control head with cap transparent) according to DIN EN61140 (VDE I (Control head with cap stainless ) steel) International protection rating: according to DIN EN60529 Supply voltage: Max. current drawn: electrical connecting line: Cable connection - valve control: Proximity sensor: Control air pressure: Air flow rate: Material for housing: Material for cover: Material for sealing gaskets: Weight: electromagnetic compatibility: Indication at device: IP 67 (Control head with cap transparent) IP 65 (Control head with cap stainless steel) V DC 70 ma INTERBUS bus line green Cable cross section 1.5 sq.mm. PG 9 direct wiring with connector plug (13) or Quick. plug 2 Hall effect sensors 0.1 to 8 bar 140 l/min. (6 bar) ABS 6F Standard: ABS transparent Optional: (special steel) NBR 0.5 kg Test report FS/57.00/ Mechanical and LED indication of the valve position, LED bus indicator Chart 7 INTERBUS VALVE CONTROL GENERATIONS If different valve control generations are installed in one compound control system, the relevant bit mode will have to be adjusted or board V 1.4 will have to be replaced. 1. Generation of horizontal board arrangement Turning valve 4136.xxx.xxx xxx (ao ac) 4236.xxx.xxx xxx (ao sc) (ac so) 2. Generation V 1.4 of vertical board arrangement Turning valve x1.xxx 000 (ao sc) (ac so) x2.xxx 000 (ao ac) xx.xxx xxx Lifting valve x1.xxx 000 (ao sc) (ac so) x2.xxx 000 (ao ac) Double seat valve x1.xxx 000 (DSV/NT) x2.xxx 000 (DSV/OT) x6.xxx 000 (DSV/UT) x3.xxx 000 (DSV/OUT) Identification of same type no. by designation on the board V1.4 or V Generation V 2.0 of vertical board arrangement Turning valve x1.xxx 000 (ao sc) (ac so) x2.xxx 000 (ao ac) Lifting valve x1.xxx 000 (ao sc) (ac so) x2.xxx 000 (ao ac) Double seat valve x1.xxx 000 (DSV/NT) x2.xxx 000 (DSV/OT) x6.xxx 000 (DSV/UT) x3.xxx 000 (DSV/OUT) 4. Generation V 3.0 of vertical board arrangement compatible with V 2.0 same item no. as V 2.0 Designation on the board with V 3.0 (s. drwg. page 6) Changes: Expanded to valve function DSV - opening upwards. Board potted INTERBUS board only turning valves INTERBUS board V Compatible in the compound control system. The valve - select. switch is inactive. The allocation of the valve types is carried out via the log. Compatible in the compound control system. The valve - selection switch is active. Replacement boards are no longer available. > will be replaced by complete valve controls type no xx.xxx 000 INTERBUS board V With valve - selection switch With plug-in bridge = 16 bit mode Without plug-in bridge = 4 bit mode Standard version 56304XXX00_000_E.DOC/ Page 5

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7 Valve control versions IBU board for lifting valves V. Contr. LIFTV IBU 2STS THSA KAPG9 1MV V. Contr. LIFTV IBU 2STS THSA KAPG9 2MV Part No. Valve function Spare parts, allocation - item acc. to chart Arrangem ent of solenoid valves ao sc / ac so 1 14,17(2x),18(2x),19,20,21,22,23,27a MV ac ao 1 14,17(2x),18(4x),19(2x),22(2x),23,27b MV1V,MV3 V. Contr. LIFTV IBU 2STS THSA KAQS 1MV ao sc / ac so 1 14,15(2x),16(2x),19,20,21,22,23,25(2x),26(2x),27a MV1 V. Contr. LIFTV IBU 2STS THSA KAQS 2MV ac ao 1 14, 15(2x),16(2x),19(2x),22(2x),23,25(2x),26(2x),27b V. Contr. LIFTV IBU 2STS EHOS KAPG9 1MV V. Contr. LIFTV IBU 2STS EHOS KAPG9 2MV ao sc / ac so 1 14,17(2x),18(2x),19,20,21,22,24,27a MV1 MV1V,MV ac ao 1 14,17(2x),18(4x),19(2x),22(2x),24,27b MV1V,MV3 V. Contr. LIFTV IBU 2STS EHOS KAQS 1MV ao sc / ac so 1 14,15(2x),16(2x),19,20,21,22,24,25(2x),26(2x),27a MV1 V. Contr. LIFTV IBU 2STS EHOS KAQS 2MV ac ao 1 14,15(2x),16(2x),19(2x),22(2x),24,25(2x),26(2x),27b MV1V,MV3 SPARE PARTS Ite Part name Material Part No. 1 Position indication ABS GN Coupling board / version V 2.0 (supersedes version V 1.4) O ring Ø 94 x 2.3 > supersedes Ø 96 x 2 NBR SW 70 Silicone Screw M6 x 16 DIN 912 (2ea.) O ring Ø 25 x 2.5 NBR black O ring Ø 44 x 2 NBR black Housing complete O ring Ø 3 x 2 (5ea.) NBR black O ring Ø 2 x 1.5 (1ea.) NBR black Screw JOT, WN 1451 K40 x 14 (2ea.) Plug connector Ger. RA 1/ Sound absorber special steel Connector piece, fourfold MC 1.5/4 STF 381 with screws /1 14 Short circuit plug-in bridge, bipolar Seal Ø 19 x Ø 15.2 x Cable connection adapter PA 6.6 sw Cable connection PG9 PA 6.6 sw Screw (2ea.) Plug connection pivoting RA 1/8, Ø 6 x Screw plug G 1/ Seal 13 x 1,5 PVC soft /2 way solenoid valve (new with slide switch) Housing cover, transparent MABS Housing cover, special steel Quickon IN plug Quickon OUT plug a Connector plate PA 6.6 sw b Connector plate PA 6.6 sw XXX00_000_E.DOC/ Page 7