EXNER PROCESS EQUIPMENT - Insatech - forsiden of content III Table of content 1 Safety and...

EXNER PROCESS EQUIPMENT

EXMATIC 460

Control unit Operating instructions

All brand and product names are trademarks of the company EXNER PROCESS EQUIPMENT Imprint Editor: EXNER PROCESS EQUIPMENT OHG Werner-von-Siemens-Straße 1 76694 Forst Germany Date of issue: 26/01/2009 © 2007, Dipl. -Ing. Detlef Exner As of 10/11/2008 File: EXmatic 460 BA eng 081110.doc All rights, including the rights in the translation, are reserved. The content of these operating instructions may only be reproduced with the written consent of EXNER PROCESS EQUIPMENT OHG, Forst, Germany. All technical information, drawings etc. are subject to the copyright law. Subject to technical modifications. This document was printed on chlorine and acid-free paper.

Table of content

III

Table of content

1 Safety and protection measures........................................................ 1

1.1 General notes on safety .........................................................................1

1.2 Intended use........................................................................................1

1.3 Danger areas and residual dangers ..........................................................2

1.4 Resources............................................................................................2

1.5 Personnel............................................................................................3

1.6 Disposal..............................................................................................3

1.7 Symbols and icons ................................................................................3

2 Product description .......................................................................... 5

2.1 Control unit EXMATIC 460 ........................................................................5

2.2 Process integration................................................................................6

3 Program functions ............................................................................ 9

3.1 Automatic start of cleaning .....................................................................9

3.2 Seal water ......................................................................................... 10

3.3 Cleaning program ............................................................................... 10

3.4 Pre- and After-Cleaning........................................................................ 12

3.5 Output signals .................................................................................... 13

4 Delivery.......................................................................................... 15

4.1 Delivery scope.................................................................................... 15

4.2 Delivery inspection.............................................................................. 15

5 Assembly........................................................................................ 17

5.1 Wall mounting.................................................................................... 17

5.2 Electric connections ............................................................................. 18

5.3 Pneumatic connections......................................................................... 19

5.4 Rinse valve connections ....................................................................... 20

6 Quick Setup.................................................................................... 21

6.1 Initial Operation.................................................................................. 21

7 Parameterization............................................................................ 29

7.1 Main Menu......................................................................................... 29

7.2 Automatic Mode.................................................................................. 30

7.3 Manual Mode ..................................................................................... 31

7.4 Parameters ........................................................................................ 32

Table of content

IV

7.5 System ............................................................................................. 38

8 Maintenance................................................................................... 45

8.1 Important notes on maintenance ........................................................... 45

8.2 Maintenance work............................................................................... 45

8.3 Disposal............................................................................................ 45

8.4 Resetting to Factory Settings................................................................. 46

9 Technical data ................................................................................ 47

9.1 Standards .......................................................................................... 47

9.2 Material............................................................................................. 47

9.3 Connected loads ................................................................................. 47

9.4 Ambient conditions.............................................................................. 48

9.5 Pneumatics ........................................................................................ 48

9.6 Rinse valves (option) ........................................................................... 48

9.7 Dimensions ........................................................................................ 49

9.8 Order structure EXmatic 460 ................................................................. 49

10 Spare parts and accessories............................................................ 51

1

1 Safety and protection measures

1.1 General notes on safety

The control unit EXMATIC 460 is designed in such a way that the

product does not present any risk if the operating instructions are

adhered to.

4 Read the operating instructions first.

4 Only assemble and operate the control unit if you have read

and understood all notes on safe and proper use.

4 Keep the operating instructions in order to consult it any

time.

4 Only operate the control unit and its accessories if they are

in an impeccable condition.

4 In addition, also observe the la ws, ordinances, regulations

and standards applicable in the country of use and at the

place of use.

1.2 Intended use

The control unit EXMATIC 460 is used for controlling pneumatic

retractable holders. The EXmatic 460 controls the movement of

the holder from the measurement position to the service position

and the process of automatic rinsing of the sensor in the rising

chamber of the holder.

The design of the control unit must be adjusted to the used

retractable holder.

The control unit must be maintained on a regular basis.

4 Establish a maintenance plan which is adjusted to your

process.

4 Only carry out maintenance work which is described in the

operating instructions!


2

4 The control unit may only be modified after consulting the

manufacturer.

The manufacturer does not assume any liability for damages arising from improper or unintended use.

1.3 Danger areas and residual dangers

Control units control retractable holders which are connected to

containers and pipes which can be under pressure. Process fluid

can only escape in case of careless actions or improper operation.

4 Ensure prior to start-up that the connected retractable holder

is suited and able to function.

4 Read the operating instructions of the used retractable

holder carefully and observe the notes on safety contained in

it.

4 Take appropriate protection measures before starting the

control unit or connecting to the retractable holder.

1.4 Resources

Only use checked and approved accessories and resources.

4 Make sure you have the correct supply voltage and follow

the information in the chapter “technical data”.

4 Filter (40 µm), clean and deoil the compressed air.

4 Make sure that the pressure is between 4 and 6 bar.

4 Use rinsing fluids and cleaning agents which are both

adapted to the process, the retractable holder and the

sealing material and dispose of them properly.

!!!

Supply voltage

Compressed air

Rinsing fluid/

cleaning agent


3

1.5 Personnel

Trained skilled workers may operate and maintain the control unit

only!

The operating personnel must wear suitable protective clothing

during start-up and maintenance work.

Observe the rules and regulations concerning safety at work

applicable in the country of use and at the place of use!

1.6 Disposal

Observe the rules and regulations concerning waste disposal

applicable in the country of use and at the place of use.

1.7 Symbols and icons

Icons and symbols in these operating instructions ensure a better

orientation.

Safety signs using the signal word DANGER! point out to danger

for life and limb as well as to the risk of considerable material

damages if the instructions are not observed.

Safety signs using the signal word CAUTION! point out to the

fact that materia l damages must be expected if the instructions

are not observed.

This is an important note!

This sign indicates that the working steps must be carried out in

the given order.

Qualification

Protective clothing

Accident

prevention rules

DANGER!

CAUTION!

!!!

R

5

2 Product description

2.1 Control unit EXMATIC 460

1 Operating panel

2 Function keys

3 Return button

4 ESC button

5 Main switch

Figure 1: Control unit outside

6 Terminal board

7 Indicator/pressure switch

8 Pilot valve

9 Input multi hose

Figure 2: Control unit inside

The control unit EXMATIC 460 can fully automatically control and

monitor the measuring and cleaning cycles of a pneumatic

retractable holder. For doing this, the cleaning times, measuring

intervals and the starting times can be parameterized and

adjusted to the respective specification.

The control unit monitors the respective position indication of the

retractable holder via integrated inputs.

View from outside

View from inside

Function

Input


6

Automatic cleaning can be started via an enlarged input.

The respective condition of the retractable holder and of the

control unit can be transmitted to a higher process control system

via three contact outputs.

The retractable holder and the cleaning valves for controlling the

cleaning solutions are connected to the control unit by means of

pneumatic hoses. This should be done with the adjusted

EXconnect multi hose.

2.2 Process integration

The control unit EXMATIC 460 is supplied with 24V DC and with

compressed air 4-6 bar. The connection of the retractable holder

and the cleaning and drain valves is realized by pneumatic hoses

which are gathered in a multi hose.

Figure 3: Process sequence

The respective status of the measuring unit (alarm status,

measuring status, cleaning status) can be transmitted to a higher

process control system by means of contacts.

A cleaning cycle can be started via an external trigger, e.g. from

the pH transmitter.

Output

Retractable holder


7

The control unit EXmatic 460 is a completely independent control

unit and can principally be operated without any connection to a

transmitter or a process control system.

The control unit has a manual as well as an automatic mode. The

manual mode is for manually triggering the movement of the

retractable holder and the individual cleaning valves.

In automatic mode, a parameterized cleaning process is running

after starting a cleaning cycle. After completion, the retractable

holder moves to the measurement position.

9

3 Program functions

3.1 Automatic start of cleaning

In principal, there are 3 different ways of starting an automatic cleaning cycle. They can also be combined in a useful manner. A recurring cycle is run via the internal clock (loop). In doing so,

after a parameterized measuring time, cleaning is started

automatically, e.g. every four hours. After completion of the

cleaning process, the retractable holder moves to the

measurement position and the cycle runs again.

Automatic cleaning is started at a specif ic point in time which can

be parametrized (Real Time Event), e.g. every day at 8.15 a.m.,

12 noon and 4.30 p.m.. After completion of the cleaning process,

the retractable holder moves to the measurement position and

stays there until the next Real Time Event starts.

Cleaning is started via an external trigger. After completion of the

cleaning and after opening the external trigger, the retractable

holder moves to the measurement position and stays there until

the external trigger is closed again.

As described, cleaning is carried out in a defined cycle (loop).

Further cleaning processes can additionally be started via an

external trigger and the retractable holder can be kept in the

cleaning position. This function is used if the sensor is to be

watered during operating lives and if the defined cycle is to be

interrupted, or if the sensor is to be pulled back into the rinsing

chamber for being protected while a strong agitator is running in

the container.

As described, cleaning is carried out at defined points in time

(Real Time Event). In addition, further cleaning processes can be

started via an external trigger and the retractable holder can be

kept in the cleaning position. This function is used if the sensor is

to be watered during operating lives and if the cycle is to be

interrupted. Or if the sensor is to be pulled back into the rinsing

Loop

Real Time Event

External Trigger

Loop + Trigger

Event + Trigger

3 Program functions

10

chamber for being protected while a strong agitator is running in

the container.

3.2 Seal water

For the short time during which the measuring window moves

over the sealing elements, when the retractable holder moves

from the measurement position to the cleaning position or back,

there is a connection between the process fluid and the rinsing

chamber. To ensure that as little process fluid as possible can

access the rinsing chamber and that the sealing elements are

additionally rinsed during this time, a seal water function can be

parameterized.

If the seal water function is active, the “Cleaning I” valve always

opens before the retractable holder is moved. This means that if

the water pressure connected to the “Cleaning I” valve is higher

than the process pressure, the water (seal water) runs through

the rinsing chamber to the process during the movement of the

retractable holder and thus prevents process fluid from accessing

the rinsing chamber. The sealing elements of the rinsing chamber

are rinsed at the same time.

The seal water function ensures a better cleaning of the sensor,

maintenance of the sealing elements and increases the operating

life of the sensor and of the sealings. The function should always

be active, if possible.

If you do not want seal water running to the process fluid or if this

is not admitted, the seal water function can also be deactivated.

The general function of the retractable holder and the control unit

is not impaired by that.

3.3 Cleaning program

As soon as a cleaning program is started (see 3.1), the following

functions are running one after the other:

Function

3 Program functions

11

Figure 4: Program sequence

Cleaning with 1. cleaning solution, e.g water.

„Cleaning I“ valve and drain valve are opened and close again

after the preset time (10…300 seconds).

By opening the „Cleaning I“ valve, a delivery pump can be

triggered via an outlet trigger (no. 21 + 22).

Cleaning with 2. cleaning solution, e.g. acid.

„Cleaning II“ valve and drain valve are opened and close again

after the preset time (0…300 seconds). If this time is set to "0",

this program step is let out completely.

By opening the “Cleaning II” valve, a delivery pump can be


Reaction Time for 2. cleaning solution

Cleaning II RT is a reaction time for the 2. cleaning solution and

provided so that the cleaning acid, which was put into the rinsing

chamber, is able to react, for example.

All cleaning valves and the drain valve stay closed. After the

preset time (0…300 seconds), the next program step follows. If

this time is set to “0”, this program deactivated.

Cleaning with 1. cleaning solution, e.g. water.

Cleaning I/1

Cleaning II

CLeaning II RT

CLeaning I/2

3 Program functions

12

“Cleaning I” valve and drain valve are opened and close again

after the preset time (0…300 seconds). If this time is set to “0”,

this program deactivated.

By opening the “Cleaning I” valve, a delivery pump can be


If the sensor is not to be moved again into the process directly

after cleaning, the pause time is activated.

This is particularly recommended if the measuring medium is

especially aggressive and therefore the lifetime of the sensor is

especially short. In this case, short measuring intervals and long

pause times can minimize the dipping time of the sensor and thus

increase the lifetime.

The sensor remains in the rinsing chamber, all cleaning valves and

the drain valve remain closed. After the preset time (0…999

minutes), the sensor moves to the measurement position.

If the time is set to “0”, this program deactivated.

Measuring interval at parameterization “loop” or “loop + trigger”.

The sensor is moved to the measurement position and stays there

for the preset time (1…999 minutes). This time can be interrupted

in case of parameterization “loop + trigger” by an external trigger.

After this time has lapsed, the next cleaning cycle begins.

3.4 Pre- and After-Cleaning

The functions “Pre- and After – Cleaning“ serve to pre- and after-

clean the holder rinsing chamber respectively, in addition to the

normal cleaning cycle.

The function Pre-Cleaning is a rinsing function, which (pre-) cleans

the rinsing chamber, while the sensor is still in the measurement

position. Thus, it can be ensured during a hot water rinsing

procedure that the rinsing chamber is already heated before the

actual cleaning takes place and that hot rinsing medium is

Pause

Measure

Pre - Cleaning

3 Program functions

13

availa ble immediately. Cleaning the area of the rinsing chamber

before the process medium makes direct contact with the housing

parts is another application, at which the contact results from the

movement of the holder. This makes particular sense when the

function “Sealing water” cannot be used, e.g. with certain food

and pharmaceutical applications.

The function After-Cleaning is a rinsing function, which (after-)

cleans the rinsing chamber, while the sensor is already back at the

measurement position upon a normal cleaning procedure.

3.5 Output signals

The control unit has 3 output signals that can be used to signal

status messages to a superior process control system. The

following functions can be assigned to the corresponding output

signals.

Measurement / Hold

Measurement : This contact is used to signal that the current

measurement value can be used. The signal is set (+24VDC, max

100mA at contact terminal 31/32) when the holder is in

measurement position.

The signal is set when the holder has reached the measurement

position and the sealing water function has been terminated.

The signal is reset, 2 seconds before the beginning of a

cleaning cycle, including the sealing water function, or when the

holder is removed from the measurement position manually.

Hold : This contact serves for freezing the measurement value,

while the holder is not in the measurement position and, thus, the

measurement value displayed is not up-to-date. The signal is set

(+24VDC, max 100mA at contact terminal 31/32) when the holder

is not in the measurement position.

After- Cleaning

Output signal I

3 Program functions

14

The signal is set, 2 seconds before the beginning of a cleaning

cycle, including the sealing water function, or when the holder is

removed from the measurement position manually.

The signal is reset when the holder has reached the

measurement position and the sealing water function has been

terminated.

It is not possible to use both functions simultaneously!

Cleaning in operation

The signal shows that the unit is implementing a cleaning

function.

normal : The signal is set (+24VDC, max 100mA at contact

terminal 33/34) when the cleaning function is being implemented,

even during the pre- and after-cleaning functions.

inverse : Selecting this functions results in the signal being

inverted, i.e. the signal is not set when a cleaning function is

being implemented, even during the pre- and after-cleaning

functions. In all other cases the signal is set, active.

Alarm / Malfunction

The signal shows that a malfunction is present.

normal : The signal is set (+24VDC, max 100mA at contact

terminal 35/36) when the holder has not reached the

corresponding final position at this point in time or in case the

compressed air fails completely.

inverse : Selecting this functions results in the signal being

inverted, i.e. the signal is not set when a malfunction is present.

In all other cases the signal is set, active.

Output signal II

Output signal III

4 Delivery

15

4 Delivery

4.1 Delivery scope

The control unit is inspected in the factory and delivered ready for

installation in a packaging which optimally protects the control

unit.

The delivery consists of:

§ control unit EXMATIC 460

§ key for control cabinet

§ operating instructions

Depending on the version you have ordered, you also receive:

§ EXconnect multi hose (installed)

§ mounting angle for multi hose (installed)

Keep the control unit in the packaging. There, it is protected best until being assembled.

4.2 Delivery inspection

Before releasing the control unit for assembly, you must ensure

that:

Ø packaging and control unit are in an impeccable condition.

Ø the identification plate of the control unit corresponds to the

data in the order form.

!!!

R

4 Delivery

16

Figure 5: Identification plate

The identification plate is affixed to the inside of the cabinet door!

In case of questions, please contact your dealer.

17

5 Assembly

5.1 Wall mounting

Ensure that

Ø there is enough working space for operating the control unit.

Ø possible voltage-supplying units are disconnected from the

mains.

Ø you only use approved tools.

Mount the control cabinet as shown below:

Figure 6: Wall mounting

R

5 Assembly

18

5.2 Electric connections

The control unit must be disconnected from the mains and the

compressed air must be pressureless!

There is the risk for life and limb if the voltage supply is not

disconnected!

Connect the control unit according to the circuit diagram:

Ø6mm red

Ø6mm yellow

Ø6mm green

D1

D2

D3

D4

A1

A2

A3

A4

A5 A6Ø

4mm

blue

Ø4m

mbl

ack 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83

AS

EXmatic460

Cle

an.p

ump

II

conn

ectin

g ho

seE

Xco

nnec

t 150

digital control unit

Ø6mm black

Ø6mm blue

Co 2 Co2

MS

1 2 11 12 21 22 23 24 31 32 33 34 35 36

+- +- +- +- +- +- +-

power distribution

Out

puts

igna

l IM

easu

rem

ent /

Hol

d

Out

puts

igna

l II

Cle

anin

g in

ope

ratio

n

Out

puts

igna

l III

Ala

rm /

mal

func

tion

exte

rnal

ST

AR

T

Pow

er s

uppl

y24

VD

C 3

0VA

Cle

an.p

ump

I

electrical wiring

pneumatical tubing

cleaning fluid tubing

Figure 7: Connection diagram

R

DANGER!

5 Assembly

19

Pin allocation:

Contact Description

1 Main Power supply 24VDC 30VA -

2 Main Power supply 24VDC 30VA +

11 Input Start signal (24VDC - selfpowered)

12 Input Start signal (24VDC + selfpowered)

21 Output 24VDC - max.80mA Clean Pump I

22 Output 24VDC + max.80mA Clean Pump I

23 Output 24VDC - max.80mA Clean Pump II

24 Output 24VDC + max.80mA Clean Pump II

31 Output 24VDC - max.100mA Measurement / Hold

32 Output 24VDC + max.100mA Measurement / Hold

33 Output 24VDC - max.100mA Service in operation

34 Output 24VDC + max.100mA Service in operation

35 Output 24VDC - max.100mA Alarm / Malfunction

36 Output 24VDC + max.100mA Alarm / Malfunction

5.3 Pneumatic connections

Multi hose

Control

connection

Hose

dim./colour

EXtract

connection Note

A1 black 6mm black 1 maintenance

A1 blue 6mm blue 2 measurement

A2 6mm red D4 drain valve

A3 6mm yellow D2 Cleaning I

A4 6mm green D3 Cleaning II

A5 4mm black 3 indicator

measurement

A6 4mm blue 4 indicator

maintenance

5 Assembly

20

Supply

Control

connection

Hose

Dimension Note

AS 4/6mm Filtered air 40µm, water and oil-free 4-6 bar

5.4 Rinse valve connections

Rinse valves (option)

Connection Dimension Designation

Compressed air 4/6mm A

Input rinse

medium

Threaded hose connection

4/6mm or 3/8“ B

Output rinse medium

Threaded hose connection 4/6mm or thread 3/8“

C

Figure 8: Cleaning Valve

The valves are to be mounted at a distance to the holder of 0.5 m

at a maximum.

6 Quick Setup

21

6 Quick Setup

$$

There is the risk of damaging the system or of the process

fluid or the cleaning solution leaking in an uncontrolled

manner!

Ø Wear suitable protective clothing

Ø Read the operating instructions

Ø Only have trained specialist personnel implement the

commissioning procedure of the system!

Ø Check all seals and all connections of the holder before moving

the same into the process

Please wear protective glasses and protective clothing when

commissioning the system!

The quick setup serves for quick parameterization of the control

unit during the commissioning procedure. The menu may be

completed once only. All settings can be retrieved and modified at

a later point in time in the Main Menu at Parameter and System.

(See chapter 7.)

6.1 Initial Operation

When activating the control unit for the first time, you will have

access to the Quick Setup menu.

Ø Using the Quick Setup you can implement all required

parameterization actions of the unit

Ø You will have access to the Quick Setup menu when

activating the control unit for the first time or when resetting

the unit back to factory settings. (Chapter 8.4)

Ø Instructions regarding the operation can be found in chapter

7

DANGER!

R

6 Quick Setup

22

The following display will be shown:

Set Clock

12 : 15 : 45 HH : MM : SS

UP DOWN NEXT (Further explanations in chapter 7.5)

Set the current time and exit the menu item using the ESC key.


Set Date

31 . 03 . 08 DD : MM : YY

UP DOWN NEXT (Further explanations in chapter 7.5)

Set the current date and exit the menu item using the ESC key.


Time Setup Clean I/1

10…300 Sec

010 Sec

UP DOWN (Further explanations in chapter 7.4)

Set the rinsing time for Clean I/1 and exit the menu item using

the ESC key.

6 Quick Setup

23


Time Setup Clean II

0…300 Sec

000 Sec


Set the rinsing time for Clean II and exit the menu item using the

ESC key.


Time Setup Clean II RT

0…300 Sec

000 Sec


Set the reaction time for Clean II RT and exit the menu item using

the ESC key.



0…300 Sec

000 Sec


Set the rinsing time for Clean I/2 and exit the menu item using

the ESC key.

6 Quick Setup

24


Time Setup Pause

0…300 Min

000 Min


Set the pause time and exit the menu item using the ESC key.


Time Setup Measure

10…999 Min

060 Min


Set the measurement time and exit the menu item by using the

ESC key.


Sealwater

Sealwater : YES

YES NO (Further explanations in chapter 7.4)

Parameterize the sealing water function and exit the menu item by

using the ESC key.


Pre - Cleaning

Pre - Cleaning : NO

CL I CL I+II NO (Further explanations in chapter 3.4 /7.4)

6 Quick Setup

25

Parameterize the pre-cleaning function and exit the menu item

using the ESC key.


After - Cleaning

After - Cleaning : NO

CL I CL I+II NO (Further explanations in chapter 3.4 / 7.4)

Parameterize the after-cleaning function and exit the menu item

using the ESC key.


Operation Mode Real Time Event External Trigger ? Loop Event + Trigger Loop + Trigger


Parameterize the mode of operation and exit the menu item using

the ESC key.


Real TiIme Event Event No.1 00:00 Event No.2 00:00 Event No.3 00:00 Event No.4 00:00 Event No.5 00:00

UP DOWN ? (Further explanations in chapter 7.4)

Enter the start time for the corresponding real time event and exit

the menu item using the ESC key.

6 Quick Setup

26


Outputsignal I ? Measurement Hold

UP DOWN (Further explanations in chapter 3.5/ 7.5)

Parameterize output signal I and exit the menu item using the ESC

key.


Outputsignal II ? normal inverse

UP DOWN (Further explanations in chapter 3.5 / 7.5)

Parameterize output signal II and exit the menu item using the

ESC key.


Outputsignal III ? normal inverse

UP DOWN (Further explanations in chapter 3.5/ 7.5)

Parameterize output signal III and exit the menu item using the

ESC key.

6 Quick Setup

27


Main Menu Automatic Mode Manual Mode Parameter System

UP DOWN

With this, you completed the quick setup to the full extent.

Ø If you want to modify individual settings, this can be done in

the main menu at Parameter and System (see chapter 7.1)

Ø In order to re-run the quick setup you have to reset the unit to

the factory settings (see chapter 8.4). In doing so, all settings

implemented beforehand will be lost.

Ø You can view the current settings in automatic mode at Info.

29

7 Parameterization

$$

There is the risk of damaging the system or that process

fluid or cleaning solution issues in an uncontrolled

manner!

Ø Wear suitable protective clothing

Ø Have the system only parameterized by instructed skilled

personnel!

Ø Inspect all sealings and all connections of the holder prior to

running the process

Wear protective glasses and protective clothing when you start

the system!

The control unit is generally operated as follows:


UP DOWN

Ø The upper line shows the current menu.

Ø The lower line shows the functions of the soft keys.

Ø The function which can be selected is shown invertedly in

the respective case and selected by means of the Enter

button.

Ø The ESC button brings you back one menu each time.

7.1 Main Menu

In the Main Menu, you can choose between the individual

processes.

DANGER!

R

7 Parameterization

30


UP DOWN

Ø When you select the Automatic Mode, the parameterized

automatic process in the control unit starts (chapter 7.2).

Ø When you select the Manual Mode, you reach the level for

manual operation (chapter 7.3).

Ø When you select Parameters , you reach the

parameterization (chapter 7.4).

Ø When you select System, you reach the system control

(chapter 7.5).

7.2 Automatic Mode

The parameterized process runs in automatic mode and the

display shows the following:

Automatic 12:22:17

* Measuring *

In 45 Min. Service

Info Para Stop

Ø The first line shows Automatic and the current time in

HH:MM:SS.

Ø The middle shows the current function in big letters.

Ø Below, the time remaining until the next function or action

starts is shown.

Ø The soft keys are assigned to the following parameters:

Info Para Stop

7 Parameterization

31

Shows information relating to the control unit via preset times, the

total time of a cleaning cycle and the state of the software.

Leads you to the parameterization of the cleaning and interval

times (chapter 6.4).

Automatic can be interrupted here.

By pressing the stop button, you can select between an

Emergency Stop and a “gentle” Stop.

In case of an Emergency Stop, the holder immediately moves to

the maintenance position, stays there and is not rinsed.

In case of stop, the holder moves to the maintenance position and

finishes with a parameterized rinsing process.

7.3 Manual Mode

In Manual Mode, the individual functions can be chosen manually.

If you have chosen the Manual Mode, you must now enter a pass

code:

Input Manual Code

0 0 0 0

UP DOWN NEXT

Enter the pass code by setting the digits by means of the UP or

DOWN button and by skipping to the right by means of the NEXT

button.

As soon as the pass code has been entered completely and

correctly, you confirm with Enter and reach the menu of the

manual mode. The following display is shown:

Info

Para

Stop

7 Parameterization

32

Manual Mode Measure Clean I Clean II

UP DOWN

Select the desired function by means of the soft keys and confirm

with Enter.

Manual Mode

Measure OFF

ON Stop

With the soft key ON, you switch the function on, with the soft

key OFF, you switch it off again.

With the soft key Stop, you stop the function in its original state.

ESC brings you back to the menu.

Process correspondingly for the functions Clean I and Clean II! For

the detailed description of the function, please refer to chapter 3.3

7.4 Parameters

You can parameterize the times and the functions of the control

unit in the parameters menu.

If you have chosen Parameter in the main menu or during the

automatic mode, you must now enter the pass code:

Input Parameter Code

0 0 0 0

UP DOWN NEXT

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7 Parameterization

33

Enter the pass code by setting the digits by means of the UP and

DOWN buttons and by skipping to the right by means of the NEXT

button.


correctly, you confirm with Enter and reach the menu of the

parameters menu. The following display is shown:

Parameter Menu Service Time Setup Real Time Event Seal water Operation Mode

UP DOWN

Select the desired function via the soft keys and confirm with

Enter.

In the Service Time Setup the respective times of the functions

are set. The following display is shown:

Service Time Setup Clean I/1 010 Sec Clean II 000 Sec Clean II RT 000 Sec Clean I/2 000 Sec

UP DOWN ? The individual times are shown with the respective time which is

currently set. By means of the button ? you can access additional

times.

If you want to change times, select the desired time by means of

the soft keys and confirm with Enter. The following display is

shown:

Service Time

Setup

7 Parameterization

34


10…300 Sec

010 Sec

UP DOWN

The first line shows the admissible time range, the next line shows

the currently set value.

You can change this value by means of the soft keys. Keep a soft

key pressed for 2 seconds, then the value starts changing

automatically. By pressing the Enter button, you save the changed

value.

By pressing the ESC button, you leave the menu without saving!

Proceed correspondingly for the remaining times! For the detailed

description of the function please refer to chapter 3.3

In the Real Time Event the defined starting times for a rinsing

process are set. The following display is shown:

Real Time Event Event No.1 00:00 Event No.2 00:00 Event No.3 00:00 Event No.4 00:00 Event No.5 00:00

UP DOWN ?

The defined times for 5 starting times are shown. By means of the

? button you get access to further starting times (max. 15).

If you want to change the times, select the desired point in time

by means of the soft keys and confirm with Enter. The following

display is shown:

R

Real Time Event

7 Parameterization

35

Real Time Event

00 : 00

UP DOWN NEXT

The first line shows the currently set starting time.

You can change this value by pressing the soft keys. Keep one

soft key pressed for 2 seconds and then, the value starts changing

automatically. By pressing the NEXT button, you switch between

hours and minutes and vice versa.

By pressing the Enter button, you save the changed value.


Please proceed correspondingly for the remaining points in time!

For a detailed description of the function, please refer to chapter

3.1

In the menu point Seal water you can switch the seal water

function on and off.

Upon selection the following display is shown:

Seal water

Sealwater : YES

YES NO Switch the seal water function on (YES) or off (NO) by means of

the two soft keys.

By confirming with the Enter button, you save the changed value.


You will find the exact functional description in chapter 3.2.

R

Seal water

R

7 Parameterization

36

Using the menu item Pre – Cleaning, you can activate or

deactivate the pre-cleaning function (pre-cleaning of the rinsing

chamber, see chapter 3.4).

If selected, the following display will be shown:

Pre - Cleaning

Pre - Cleaning : NO

CL I CL I+II NO

Activate the pre-cleaning function using the two soft keys (CL I) or

(CL I+II).

CL I activates the pre-cleaning procedure of the rinsing chamber

with cleaning solution I and with the rinsing time set in the service

time setup for Clean I/1 (see chapter 7.4.)

CL I+II activates the pre-cleaning procedure of the rinsing

chamber with both cleaning solutions and with the rinsing times

set in the service time setup for Clean I/1, Clean II, Clean II RT,

and Clean I/2. Thus, the complete rinsing cycle is passed as pre-

cleaning procedure (see chapter 7.4.).

NO deactivates the pre-cleaning procedure of the rinsing

chamber.

By confirming your selection using the Enter key, you save the

modified value.

Using the ESC key, you leave the menu without saving the values!

Using the menu item After - Cleaning, you can activate or

deactivate the after-cleaning function (after-cleaning of the rinsing

chamber, see chapter 3.4).

If selected, the following display will be shown:

Pre - Cleaning

After- Cleaning

7 Parameterization

37

Pre - Cleaning

After - Cleaning : NO

CL I CL I+II NO

Activate the after-cleaning function using the two soft keys (CL I)

or (CL I+II).

CL I activates the after-cleaning procedure of the rinsing chamber

with cleaning solution I and with the rinsing time set in the service

time setup for Clean I/1 (see chapter 7.4.)

CL I+II activates the after-cleaning procedure of the rinsing

chamber with both cleaning solutions and with the rinsing times

set in the service time setup for Clean I/1, Clean II, Clean II RT,

and Clean I/2. Thus, the complete rinsing cycle is passed as after-

cleaning procedure (see chapter 7.4.)

NO deactivates the after-cleaning procedure of the rinsing

chamber.


modified value.


In the menu point Operation Mode you can set the mode of

operation of the control.

Upon selection the following display is shown:

Operation Mode Real Time Event External Trigger ? Loop Event + Trigger Loop + Trigger

UP DOWN

The arrow shows you the currently set mode of operation.

Operation Mode

7 Parameterization

38

You can change the mode of operation by pressing the soft keys.

By confirming with the Enter button, you save the changed mode

of operation.


7.5 System

In the menu point System you can parameterize the system

settings.

Upon selecting System in the main menu, you must enter the pass

code:

Input System Code

0 0 0 0

UP DOWN NEXT

Enter the pass code by setting the digits via the UP and DOWN

buttons and skip to the right by means of the NEXT button.


correctly, confirm with Enter and you reach the menu of the

system menu. The following display is shown:

System Menu Outputsignal I Outputsignal II Outputsignal III Change Code

UP DOWN ?

Using the key ?, you will gain access to further selection functions.

7 Parameterization

39

System Menue Set Clock Set Date Test OUT / IN

UP DOWN ?


with Enter.

In the system mode Outputsignal I, the mode of operation of

output signal I can be set (see chapter 3.5)


Outputsignal I ? Measurement Hold

UP DOWN

The arrow is to indicate the currently set mode of operation.

You can change the mode of operation by using the soft keys.


modified mode of operation.


Measurement The signal is set when the holder has reached the

measurement position and when the sealing water function has

been terminated.

Hold The signal is set, 2 seconds before the start of a cleaning

cycle, including the sealing water function, or when the holder is

removed from the measurement position manually.

Output signal I

7 Parameterization

40

In the system mode Outputsignal II, the mode of operation of

output signal II can be set (cleaning in operation, see chapter

3.5).


Outputsignal II ? normal inverse

UP DOWN






normal The signal is set when a cleaning function is

implemented, even during the pre- and after-cleaning functions.

inverse The normal signal is set in an inverted manner.

In the system mode Outputsignal III, the mode of operation of

output signal III can be set (alarm / malfunction, see chapter 3.5).


Outputsignal III ? normal inverse

UP DOWN



Output signal II

Output signal III

7 Parameterization

41




normal : The signal is set when the holder does not reach its

corresponding extreme stop position or when the compressed air

fails completely.

inverse The normal signal is set in an inverted manner.

In the system mode Set Clock, the time can be set.

The following display is shown:

Set Clock

12 : 15 : 45 HH : MM : SS

UP DOWN NEXT

You can change the time by pressing the soft keys. Keep a soft

key pressed for 2 seconds and the value starts changing

automatically. By pressing the NEXT button, you switch from

hours to minutes and seconds and back.

By confirming with Enter, you save the changed value.


In the system mode Set Date, the date can be set.


Set Date

31 . 03 . 08 DD : MM : YY

UP DOWN NEXT

Set Clock

Set Date

7 Parameterization

42

You can change the date by means of the soft keys. Keep a soft

key pressed for 2 seconds and the value starts changing

automatically. By pressing the NEXT button you can switch from

day to month and to year and back.

By confirming with Enter, you save the changed value.


In the system mode Test OUT / IN, you can test the inputs and

the outputs of the control.


Test OUT / IN

Kanal : 1 2 3 4 5 6 7 OUT : 0 0 0 0 0 0 0

I

IN : 0 1 0 0 ON OFF ?

Select the channel via the ? button. The marking shows you the

channel you have selected. By pressing the soft keys ON and OFF,

you switch the outputs on (1) or off (0). The IN line shows you

the current status of the inputs.

By pressing ESC you leave the menu and the outputs are reset

again.

The outputs and the inputs are assigned as follows:

No. Output Connection

1 Holder drive 0=Service 1= Measurement 70/71

2 Drain valve 72/73

3 Cleaning valve I and Cleaning Pump I 74/75 21/22

4 Cleaning valve II and Cleaning Pump II 76/77 23/24

5 Output Measurement / Hold 78/79 31/32

6 Output Service 80/81 33/34

7 Output Alarm / malfunction 82/83 35/36

Test OUT / IN

7 Parameterization

43

No. Input Connection

1 Indication measurement 62/63

2 Indication service 64/65

3 Input Start signal 11/12 66/67

21/22 4 not assigned

In the system mode Change Code, the pass codes are set. The

following display is shown:

Change Code Code Manual Mode Code Parameter Code System

UP DOWN

If you change or forget a pass code, you block the system

access. Write the set values down and store them at a safe

place.


with Enter.


Manual Mode

0 0 0 0

UP DOWN NEXT

Enter the pass code by setting the respective digits with the UP

and DOWN buttons and by switching to the right with the NEXT

button.

Change Code

CAUTION!

7 Parameterization

44


correctly, save the new code by confirming with Enter.


Proceed correspondingly for the remaining pass codes!

R

45

8 Maintenance

8.1 Important notes on maintenance

Ø Prepare a maintenance plan which is adjusted to your

process!

Ø Maintenance work may only be carried out by skilled

personnel.

Ø Always wear protective clothing during maintenance work.

Ø Only carry out maintenance work or repair which is described

in the operating instructions!

Ø Constructional modifications may only be carried out after

consulting the manufacturer.

8.2 Maintenance work

Yearly inspections.

Ø Check the compressed-air connections for tightness

Ø Check the multi hose connections for tightness and for a

stable fit at the holder and the control valves

Ø Retighten the clamps in the control cabinet

8.3 Disposal

Make sure that the control unit is free of hazardous and toxic

substances. The individual components must be disposed of

separately corresponding to their material.

Observe the rules and regulations relating to waste disposal which

are applicable in the country of use and at the place of use.

The packaging material is cardboard and can be disposed of as

waste paper.

R

Control unit

Packaging

8 Maintenance

46

8.4 Resetting to Factory Settings

By resetting the unit the factory settings, all settings and

parameterizations implemented beforehand will be lost!

Ø Switch off the control unit using the main switch.

Ø Hold the Enter key pressed for approx. 2 seconds while re-

activating the unit.

Ø You will automatically gain access the quick setup menu.

ATTENTION!

47

9 Technical data

9.1 Standards

Noise immune according to the standard EN 61000-6-2 Noise-suppressed according to the standard EN 61000-6-4 9.2 Material

Materials

Control cabinet

Casing glass-reinforced plastic

stainless steel option

Control unit glass-reinforced plastic

casing

plexiglass protection cover

9.3 Connected loads

Connected loads

Voltage supply 24V DC 30 VA

Input for external trigger 24V DC internal power supply for potential-free contact

Current consumption 0,65 A

Output for external relais, Cleaning Pump I and Cleaning Pump II

24V DC 80mA max.

Output for status and alarm contacts 24V DC 100mA max.

Triggering pneumatic valves 24V DC 80mA max.

9 Technical data

48

9.4 Ambient conditions

Temperature

Ambient temperature 0…+55°C

Transport and storage temperature -10…+60°C

Ambient

Relative humidity 10…95 % not condensing

Type of protection

Casing IP 54

Control unit with safety guard IP 54 with the safety guard closed

9.5 Pneumatics

Pneumatic hoses

outer ∅ inner ∅

for control air 6 mm 4 mm

for position indication 4 mm 2 mm

Compressed air

- filtered 40µm, water and oil-free

- 4 - 6 bar

- no permanent air consumption!

9.6 Rinse valves (option)

Connections

outer ∅ inner ∅

Compressed air 6 mm 4 mm

Rinse medium 6 mm 4 mm

9 Technical data

49

9.7 Dimensions

Dimensions

Plastic Stainless steel

Width 300 mm 300 mm

Height 400 mm 400 mm

Depth 250 mm 250 mm

9.8 Order structure EXmatic 460

EXMATIC 460

Design. Casing GF Plastic glass-reinforce plastic SS Stainless steel XX Special version

Design. Cleaning 1 for one cleaning solution 2 for two cleaning solutions X Special version

Design. Drain valve 0 Without drain valve 1 With drain valve

Design. Multi hose 00 Without multi hose 03 With 3m multi hose 05 With 5m multi hose 10 With 10m multi hose XX Special version Design. Mounting angle 00 Without mounting angle EX EXtract mounting angle RE Retractex mounting angle XX Special version

EXMATIC 460 - - - - - Order number

51

10 Spare parts and accessories

Spare parts

CONTROL Spare part Order number

EXmatic 460 Electronic control unit 9-110-00-002

Solenoid valve 5/2-way G ¼“ 24VDC 3,8W (without plug and cable)

9-091-10-001

Solenoid valve 3/2-way G ¼“ 24VDC 3,8W (without plug and cable)

9-091-10-002

Plug with cable for solenoid valve 7-098-20-001

Pressure switch (indication) 9-096-00-001

Accessories

CONTROL CABINET Accessory Order number

wall mounting set for plastic cabinet 2-083-70-001

wall mounting set for stainless steel cabinet 2-083-70-002

pipe mounting set for cabinet (plastic/stainless steel) 2-083-70-003

CLEANING VALVES Accessory Order number

1 valve for cleaning solution or drainage 2-095-70-001

2 valves for cleaning solution and drainage, mounted to mounting angles with all connections and PTFE hose

2-095-70-002

Membrane valve PVDF/FPM G 3/8“, DN12 PN6, pneumatic, pressureless closed (NC) 3 valves for two cleaning solutions and drainage,

mounted to mounting angles with all connections and PTFE hose

2-095-70-003

Figure 9: Membrane valves as accessories for the retractable holder

Please indicate the serial number of your unit if you order spare

parts or accessories. !!!

EXNER PROCESS EQUIPMENT - Insatech - forsiden of content III Table of content 1 Safety and...

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