Operating Manual for the RE-19 Multi-pin Valve Terminal Version: RE 19M/05/99 Order no. 54-RE-19-M-GB
Contents Introduction...3 RE-19 valve terminal with multi-pin connection...4 Components of the RE-19 valve terminal...5 Assembly of the valve terminal...6 Commissioning...6 Preliminary steps...7 Connection of the supply and operating lines...8 Starting up the multi-pin terminal...8 General notes...9 Pin assignments...9 Cable connection...10 Testing the valve terminal...11 Maintenance and conversion...12 Removing the valves...12 Fitting the valves...13 Conversion into several pressure zones...14 Possible pressure separator positions...14 Technical data...15 Valves...16 Troubleshooting...18 2
Introduction With the AIRTEC valve terminals of the RE-19 series, you have decided in favor of a highly flexible, sturdy and durable system. It can be used as a versatile link between your PLC and the pneumatic actuators and can be adapted to your specific requirements. This operating manual is intended solely for control engineering and automation engineering specialists with experience in the assembly, installation, commissioning, maintenance and conversion of pneumatic components. For your own safety, please bear in mind that the RE-19 valve terminals are intended only for the control of pneumatic actuators. This requires that you use your system for the purpose intended in the original condition without making unauthorized modifications in a technically flawless condition. Ensure compliance with the limit values for pressures, temperatures, electrical data, torques, etc. specified by AIRTEC. Please comply with the regulations of the professional social insurance bodies, the TÜV (German technical inspection authority) and the VDE standards or the corresponding national regulations. 3
RE valve terminal with multi-pin connection RE-19/n-M-1 The valve terminal with multi-pin connection can be obtained with a manifold having an even number of stations between 4 and 22. It can be equipped with any combination of G 1/8 valves (each one station wide) and G 1/4 valves (each two stations wide). The electrical connection is via a 25-pin D-sub plug, from which the signals are transmitted in parallel over a multi-core cable (ordered separately) to the control electronics. Fig. 1: RE-19 valve terminal with multi-pin connection 4
Components of the RE-19 valve terminal The RE-19 valve terminal comprises the following components: Fig. 2: Components of the RE-19 valve terminal 1 Valves with one or two solenoids (1a) 2 Manifold with pneumatic connections and electronics as well as various electrical connections, here with D-sub plug (2a) Contact spacing All RE-19 valve terminals can be equipped with G 1/8 valves (5/2-way valves, 18 mm contact spacing) and G 1/4 valves (5/2-way and 5/3-way valves, 36 mm contact spacing) or a combination thereof. 5
Assembly of the valve terminal Before beginning installation or maintenance work, depressurize the system and switch off the power supply to the valve solenoids. Attachment holes The RE -19 valve terminals are attached with standard screws to a firm, flat backing in the control cabinet or directly to the machine. Any fitting position can be chosen. This requires four or six (for valve terminals with 12 or more stations) M5 screws. 6 mm diameter attachment holes are provided in each terminal). Attachment holes Fig. 3: Attachment of the RE-19 valve terminal Proceed as follows: Ensure that the attachment surface chosen can support the valve terminal. Ensure sufficient space for the cables and the air pressure air lines / hoses. Attach the valve terminal at the required position using a minimum of four or five screws. 6
Commissioning Before beginning installation or maintenance work, depressurize the system and switch off the power supply to the valve solenoids. Preliminary steps Connection: 1. Slide the hose up to the stop in/over the hose connection of the screw fitting. 2. Tighten the clamping screw (A) or pull back on the hose (in the direction indicated by the arrow) to securely center the hose. Removal: 1. Undo the clamping screw or release ring. 2. Pull out the hose. 3. Replace the screw fitting with a dummy plug. Connection A Removal Screw fitting with clamping screw (A) B Connection with release ring (B) Fig. 4: Connection and removal of hose lines Group the hoses laid for a better overview, avoiding kinks or constrictions of the hoses. Provide the screw fittings with suitable sealing rings to prevent leakage. Long hose lines and undersized screw fittings, particularly elbow joints, restrict air flow and slow down your system. 7
Connection of the supply and operating lines Install the necessary screw fittings and silencers as in the table below. Valve KF-10 Valve KF-09 Fig. 5: Connection of the supply and operating lines Connection code number (ISO 5599) Line Connection size (ISO 228) Connection (recommended) 1 Compressed air (inlet) 2, 4 Operating air (outlet) G 3/8 Screw fitting G 3/8, hose 12/9 G 1/8 (KF 09) G 1/4 (KF 10) Screw fitting for G 1/4: hose 10/8 for G 1/8: hose 8/6 3, 5 Exhaust G 3/8 Screw fitting for silenced exhaust line or for silencers 82/84 Pilot exhaust M 5 Screw fitting for silenced exhaust line or for silencers 8
Starting up the multi-pin terminal General notes Before startup: Switch off power before attaching or disconnecting the plug connector. The RE-19/n-M1 multi-pin terminals are designed for operating voltages of 24 V -10% + 15%. Higher voltages can cause damage and lower voltages can cause malfunctions. Pin assignments The pin assignments for the 25-pin D-sub plug are shown in the diagram below: Pin Function 1 to 22 Valves 1 to 22 (24 Volt) 23, 24 and 25 GND (0 Volt) Fig. 6: View of connectors from the pin side 9
Cable connection The valve terminal is connected to power via a 25-pin D-sub plug. Protection classification IP 65 is only obtained when a cable with the corresponding specification is properly connected and fixed with two screws. The GND connections are short-circuited internally. One GND pin must be assigned for every eight valve solenoids. For the following cables, which must be ordered from AIRTEC with the order numbers below, a pin assignment reference list is included: ST-68-M-105 - multi-pin terminal connector with 5 m cable, 25-pin ST-68-M-110- multi-pin terminal connector with 10 m cable, 25-pin Polarity reversal protection All multi-pin terminals are equipped with polarity reversal protection in the form of a power diode in the GND line. 10
Testing the valve terminal There are two possibilities for testing the valve terminal: Testing the individual valve-cylinder combinations via the manual override Testing the entire system via the programmed control. Testing via the manual override will be described here. For starting up the entire system see page 9, Starting up the multi-pin terminal. Testing via the manual override is especially well suited for testing the functioning and the effectiveness of an individual valve or valve-cylinder combination. This requires only switching on the compressed air supply. In the interest of safety, before testing disconnect the power supply in order to ensure that the solenoids and the electronics are not unintentionally activated. Following testing, make sure that all manual overrides are again in their original positions. Manual override HN off HN on Fig. 7: Manual override The manual override (HN) of the valve solenoid is self-locking, i.e. it remains active until reset to its original position. It is actuated e.g. by turning 45 with a screwdriver. Proceed as follows: 1. Switch on the compressed air supply. 2. Switch on the HN. The valve goes to the switching position. 3. Switch off the HN again. The valve returns to the initial position. 11
Maintenance and conversion Before beginning installation or maintenance work, depressurize the system and switch off the power supply to the valve solenoids. Removing the valves For maintenance and conversion work, the valves can be removed very easily from the manifold. Removal direction Fig. 8: Removal of valves Proceed as follows: 1. Undo the two screws attaching the valve to the manifold (C). For KF-09 valves, these are an M4 screw (A) and an M3 screw (B). For KF-10 valves, these are two M4 screws (A, B). 2. Then pull out the valve together with its valve solenoid(s) from the manifold in the removal direction. 12
Fitting the valves Valves can be very easily mounted on the manifold of the valve terminal: Mounting direction Fig. 9: Mounting of valves Proceed as follows: 1. Insert the O-rings into the manifold (E): for an 18 mm wide valve (KF-09) 3x 11 x 1.5 (D) 1x 2 x 1.5 (F) for a 36 mm wide valve (KF-10) 6x 11 x 1.5 (D) 2x 2 x 1.5 (F) 2. Ensure the correct fitting direction. Press the valve onto the manifold (E), threading the contacts (C) securely into the contact clips (G). The shaped seal is permanently installed at the factory and prevents direct metallic contact to the housing. 3. Secure each valve with two screws: for an 18 mm wide valve (KF-09) 1 M3 screw (B) with 0.6 Nm 1 M4 screw (A) with 1.1 Nm for a 36 mm wide valve (KF-10) 2 M4 screws (A, B) with 1.1 Nm. Tighten the screws to the correct torques. 13
Conversion of the RE-19 valve terminal into several pressure zones In the RE-19 valve terminal, the collecting channels 1 for the air pressure supply and 3 and 5 for the exhaust air can be divided into separate pressure zones. The pressure separator (Figure 10) is inserted via a front face connection and placed between two valve positions. Fig. 10: Fitting the pressure separator Fix the separator in this position with a locknut, using an Allen wrench and a screwdriver. It provides secure sealing and is held in position by the serrated washer. The required tightening torque is 3,6 Nm. Different pressures can e.g. now be fed in or large volumes vented without affecting other consumers. Possible pressure separator positions +n x 18,3 (contact space) +n x 18,3 (contact space) Valve terminal RE-19/n Fig. 11: Pressure separation 14
Technical data All valve terminals Degree of protection IP 65 according to VDE 0470/EN 60529 Operating voltage 24 V DC - 10%... + 15% Power consumption per solenoid Output circuits Status indication: LED yellow Materials 2.5 Watt Polarity reversal protection Suppressor circuit No short-circuit protection Valve solenoid Al, stainless steel, PET; seals ABR, PU Multi-pin Weight with four stations (without valves) Extra weight of two additional stations (without valves) 0.930 kg 0.330 kg Temperature range - 10 C... + 50 C Connector plug Sub D, 25-pin 15
Valves 5/2-way valves G 1/8, single solenoid Order no. KF-09-510-HN KF-09-511-HN Connection G 1/8 for 2 and 4, flange for 1, 3, 5 Nominal size 6 mm Nominal flow rate 950 l/min 810 l/min Operating pressure 3... 8 bar Switching time at 6 bar on 11 ms, off 20 ms on 10 ms, off 26 ms Temperature range - 10 C... + 50 C Medium Materials Standard voltage Power consumption Pressurized air, filtered (40 µm), oiled or non-oiled Housing Al, inner parts Al, stainless steel, brass, plastic, seals ABR 24 V DC 2.5 W (104 ma) DC Degree of protection IP 65 according to VDE 0470/EN 60529, with ST-02 plug or installed on RE-19 Weight 0.200 kg 5/2-way valves G ¼, single solenoid Order no. KF-10-510-HN KF-10-511-HN Connection G 1/4 for 2 and 4, flange for 1, 3, 5 Nominal size 9 mm Nominal flow rate 2100 l/min 1800 l/min Operating pressure 2.5... 8 bar Switching time at 6 bar on 13 ms, off 26 ms on 18 ms, off 29 ms Temperature range - 10 C... + 50 C Medium Pressurized air, filtered (40 µm), oiled or non-oiled Materials Housing Al, inner parts Al, stainless steel (only 511), brass, plastic, seals ABR Standard voltage Power consumption 24 V DC 2.5 W (104 ma) DC Degree of protection IP 65 according to VDE 0470/EN 60529, with ST-02 plug or installed on RE-19 Weight 0.370 kg 16
5/2-way double solenoid and 5/3-way valves G 1/4 Order no. KF-10-520-HN KF-10-530-HN KF-10-533-HN KF-10-534-HN Connection G 1/4 for 2 and 4, flange for 1, 3, 5 Nominal size 9 mm Nominal flow rate 2100 l/min 1500 l/min Operating pressure 2.5... 8 bar 3... 8 bar Switching time at 6 bar 16 ms on 16 ms, off 26 ms Temperature range - 10 C... + 50 C Medium Pressurized air, filtered (40 µm), oiled or non-oiled Materials Housing Al, inner parts Al, stainless steel (only 530, 533, 534), brass, plastic (only 530, 533, 534), seals ABR Standard voltage Power consumption 24 V DC 2.5 W (104 ma) DC Degree of protection IP 65 according to VDE 0470/EN 60529, with ST-02 plug or installed on RE-19, IP 65 according to VDE Weight 0.430 kg 17
Troubleshooting Pneumatic system Fault Remedy Leakage from system Check plug connections Check connections Check seals Replace missing or defective seals Undefined valve switching states Check supply pressure (min. 3 bar) Valve does not operate Override is activated Check supply pressure (min. 3 bar) Electrical system Fault Valve operates via manual override, but not via electrical signal Remedy Check electrical connections (yellow LED must light up when solenoid is activated) Check power supply 18