AVENTICS CL07 Single valve Instruction Manual

AVENTICS CL07 Single valve

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About this Documentation

These instructions contain important information on the safe and appropriate assembly, operation, and maintenance of the product and how to remedy simple malfunctions yourself.
Read these instructions carefully, especially chapter 2 “Notes on safety”, before you start working with the product.

Documentation validity
These instructions describe the following product:
CL03 single valve

Required and supplementary documentation

• Also follow the instructions for the other machine and system components.
• Observe the system documentation from the system manufacturer.
• Furthermore, observe general, statutory and other binding rules of the European and national laws.

Presentation of information

Warnings
In this document, there are safety instructions before the steps whenever there is a danger of personal injury or damage to the equipment. The measures described to avoid these hazards must be followed.

Structure of warnings

• SIGNAL WORD Hazard type and source Consequences of non-observance O Measures to avoid these hazards

Meaning of the signal words

• WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injuries.
• NOTICE Indicates that damage may be inflicted on the product or the environment.

Symbols Operation may be impaired if this information is disregarded.

Notes on safety

The product has been manufactured according to the accepted rules of current technology. Even so, there is a risk of injury or damage if the following general safety instructions and the specific warnings given in this instruction manual are not observed.

• Keep these instructions in a location where they are accessible to all users at all times.
• Always include the operating instructions when you pass the product on to third parties.

Intended use
The product is exclusively intended for installation in a machine or system or for combination with other components to form a machine or system. The product may only be commissioned after it has been installed in the machine or system for which it is intended.

• Use of the CL03 single valve is permitted only under the operating conditions and within the performance limits listed in the technical data.
• The CL03 single valve is only intended for industrial applications.
• Only use compressed air as the medium.

Improper use
It is considered improper use if the CL03 single valve

• is used for any application not stated in these instructions or
• is used under operating conditions that deviate from those described in these instructions.

Personnel qualifications
All tasks associated with the product require basic mechanical, pneumatic and electrical knowledge, as well as knowledge of the respective technical terms.
In order to ensure operational safety, these tasks may only be carried out by qualified personnel or an instructed person under the direction of qualified personnel. Qualified personnel are those who can recognize possible hazards and institute the appropriate safety measures, due to their professional training, knowledge, and experience, as well as their understanding of the relevant regulations pertaining to the work to be done. Qualified personnel must observe the rules relevant to the subject area.

Notes on safety

General safety instructions

• Observe the regulations for accident prevention and environmental protection in the country where the product is used and at the workplace.

• Only use the product within the performance range provided in the  technical data. You can find out more in the online catalog
  (www.aventics.com/pneumatics-catalog).

• Do not place any mechanical loads on the product under any circumstances. O This product may only be used for industrial applications (class A).

• Examine the product for obvious defects, such as cracks in the housing or  missing screws, caps, or seals.

During installation

• The warranty will not apply if the product is incorrectly assembled.
• Always make sure the relevant system component is not under pressure or voltage before carrying out assembly work on the machine or system.
• Ensure the system cannot be switched on accidentally during assembly work.
• Observe the following standards when installing the system:
  • DIN EN 50178, classification VDE 0160
  • VDE 0100

During commissioning

• Installation may only be performed in a voltage-free and pressure-free state and only by a qualified technician. Always carry out the installation in a pressure-free state to avoid dangerous movements.
• Make sure that attached system components are properly secured.
• Do not put the CL03 valve system into operation before it is completely assembled as well as correctly wired and configured, and after it has been properly tested.
• Before commissioning versions that are subject to the restrictions of the IP69K protection class, make sure that all the connection seals and plugs are leaktight to prevent fluids and foreign particles from penetrating the product.

During operation

• In certain applications there may be a risk of crush injuries. Always follow the site safety instructions.
• Ensure an adequate exchange of air and sufficient cooling if the solenoid valves are continuously loaded.

Delivery Contents

The delivery contents include:

• Operating instructions
• Base plate (without valve) and valve cover, IP69K
• Base plate with assembled valve and valve cover, IP69K

About This Product

The CL03 single valve has been developed with a focus on hygienic design, chemical resistance, protection class, modularity, and flexibility. It is intended for wash-down applications in, for example, food processing and packaging.

Product description
The CL03 single valve is available in protection class IP69K.
An A-coded M12 round plug is used to provide the electric supply and control. The available versions of the product may change over time. See the online catalog (www.aventics.com/pneumatics-catalog) for a current description of available versions.

Overview of CL03 single valve with base plate and valve cover

1. Base plate
2. Valve
3. Valve cover
4. M12 round plug, A-coded, for control
5. Pneumatic connections
6. Mounting screws for valve on base plate
7. Seal for valve cover
8. Mounting screws for valve cover

Base plate overview

1. Base plate
2. Port R for pilot exhaust air
3. Port X for external pilot control
4. Connection 1
5. Connections 2 and 4
6. Connections 3 and 5
7. VENT connection for pressure equalization
8. M12 round plug, A-coded, for control
9. Pneumatic connections
10. Thread for mounting base plate to mounting surface, M5

Valves

• The valves direct the air to the pneumatic connections.
• 2×3/2 directional valves
• 5/2 directional valves
• 5/3 directional valves

Each valve has yellow LEDs indicating activation of:

• Solenoid 14 on valves with one solenoid
• Solenoid 14 or solenoid 12 on other valves.

The solenoid coils are controlled via the M12 plug. A yellow LED on the valve indicates the current-carrying solenoids. The switch position assignment can be recognized via the numbers 12 and 14.
You can find out more information about the valve options at “Technical Data” and in the online catalog (www.aventics.com/pneumatics- catalog).

Manual override
Each valve has a manual override, “turn and detent” (yellow knob) or “turn” (red knob) depending on the version. In both cases it is activated by a turning motion. Do NOT press! The switch position assignment can be recognized via the numbers 12 and 14.

Assembly

Check that the minimum or maximum values stated in the technical specifications are not exceeded.

CAUTION

Danger of injury if assembled under pressure or voltage!
Assembling when under pressure or electrical voltage can lead to injuries and damage to the product or system components.

• Make sure that the relevant system part is not under voltage or pressure before you assemble the product.
• Protect the system against being restarted.

Uncontrolled movements of incorrectly connected compressed air lines.
Incorrectly assembled compressed air lines with plug connections could come loose when pressure is applied to the single valve, resulting in injuries or damage to the device.

• Always check that the plug connections are effective.

NOTICE Risk of damage to the single valve
Incorrect screws, or too high torque, may damage the threaded mounting holes.

• Always use the screws supplied on delivery.
• Ensure correct assembly and the correct torque.

Assembling the CL03 single valve with base plate and valve

The single valve may be mounted in any orientation.

Mounting base plates
Mount the base plate of the single valve on a flat, firm surface using the threaded mounting holes (10).

Positioning the valve and assembling the valve cover

1. Place the valve (2) on the base plate. Press gently on the valve’s electrical connector end, making sure the contacts are straight and that the seal is seated correctly. Make sure the contacts are straight and that the seal is seated correctly.
2. Fasten the valve (2) by means of two self-tapping Pozidrive screws (6). Tightening torque 1.1 … 1.3 Nm screwdriver PZD no. 1.
3. Make sure that the manual override is in position 0. Carefully turn it into the zero position, if required.
4. Mount the valve cover (3). Make sure the seal (7) is correctly positioned. Tighten the three hexagon screws (8) with 1.0 … 1.2 Nm.

Connecting the pneumatics on the CL03 single valve

NOTICE Risk of valve damage due to congested exhaust!
Closed exhaust outlets will lead to air congestion and valve damage. The connection “VENT” in the base plate must also not be closed.

• Make sure that connection R is open and preferably provided with a silencer.
• Connect the “VENT” connection to a tube that exhausts the air outside the zone. Alternatively, if the valve is mounted in a protected area, for example in a cabinet, you can also fit a silencer to “VENT”.
• Ensure adequate ventilation through the exhaust air connection and connection R.

The single valve is connected to the compressed air system via connections in the base plate. Pilot air is supplied externally via connection X, which is always present on the base plate. The pilot control valves are always exhausted via channel R.

• Fit exhaust air connections that are not connected to an exhaust air line with a silencer.
• Provide unused connections with blanking plugs.

Pneumatic connections on the base plate

1. External pilot control connection
2. Pilot control exhaust air connection
3. Ventilation connection

Connecting the single valve CL03 electrics

CAUTION Dangerous voltage
A power pack without safe isolation may lead to dangerous voltages in the event of a malfunction. Injuries from electric shock and system damage may be the consequences.

• Only use a power pack with safe isolation according to EN 60747, VDE 0551 classification! The corresponding electrical circuits are thus SELV/PELV circuits in accordance with IEC 60364-4-41.

NOTICE High current load
Current loads over 1 A per connector pin will damage the system.
Do not exceed the permissible current load of 1 A per connector pin.
The CL03 single valve is supplied and controlled via the A-coded M12 round plug 1(,4 ).

Assignment of the M12 plug, A-coded, on the single valve CL03

Proceed as follows:

1. Ensure that enough free space is left for the electrical connections so that the permissible minimum bending radii are adhered to.
2. Insert the cable onto the round plug connector.

There are two controls (connector pins) permanently assigned to valve solenoids 12 and 14 for the valve position.

1. Only solenoid 14 must be connected for single solenoid valves. The second control for solenoid 12 remains unused.
2. The following assignments are made in the 3/2 directional valves:
   • Solenoid 14 and pneumatic connection 4
   • Solenoid 12 and pneumatic connection 2

Commissioning and Operation

Commissioning may only be carried out by qualified electrical or pneumatic personnel or an instructed person under the direction and supervision of qualified personnel.

Step-by-step commissioning (step 1 … 4)

Step 1: Checking the number of ports

1. Check the correct position of all fittings and connections.
2. Check the correct assembly of the electrical connection.

Step 2: Check assignment of the control signals

1. Make sure that the system is not under voltage or pressure.
2. Turn all manual overrides to the 0 position (see “Operating the manual override”).
3. Switch on the operating voltage.
4. Check the assignment of the control signals to the single valve. The yellow LED is illuminated if the valve is being properly controlled.
   If the LED is not illuminated, check the assignment of the control signal and the plug.

Step 3: Check the pneumatic functions

CAUTION Undefined system state!
Danger of injury if the system is in an undefined state and if the manual overrides are not set to zero. Before switching the system on, ensure that it is in a defined state!

1. Make sure that the system is not under voltage or pressure.

2. Turn the manual override to position 0 (see “Operating the manual override”).

3. Make sure that all actuators are in their home positions and that there is no danger from moving actuators.
   CAUTION Before applying compressed air to the system, check the stability of the compressed air connections and make sure that no personnel are within the hazardous zone when the compressed air supply is switched on.

4. Apply the compressed air to the system.

5. Examine the connected valve (and all other valves connected in the system if necessary) using the manual override (see “Operating the manual override”).

6. Replace the valve cover (see “Positioning the valve and assembling the valve cover”).

Step 4: Switch on the system

CAUTION Undefined system state!
Danger of injury if the system is in an undefined state and if the manual overrides are not set to zero.

• Before switching the system on, ensure that it is in a defined state!
• Set all manual overrides to zero.
• Make sure that no personnel are within the hazardous zone when the compressed air supply is switched on.

1. Switch on the compressed air supply.
2. Switch on the operating voltage.

Operating the manual override

NOTICE Manual override damage due to improper operation
The manual override will be damaged if it is operated improperly or with excessive force.

• Exercise care and caution when actuating the manual override.
• Observe the following information for operation.
  The manual override is a rotary switch. DO NOT press!
  The valve control’s functional reliability and method of operation can be checked before start-up by activating the valve functions using the manual override (instead of the electrical signal). The electrical signal is disabled when the manual override is used.

Turn and detent (yellow knob):
Insert a screwdriver blade in the slot of the manual override and turn it from position 0 to position 1 using slight force until it clicks into place.
The valve switches. The manual override remains in the switched position until it is turned back to position 0. Depending on the valve construction, the valve then either returns to the initial position or remains in the selected position.

Turn and release (red knob):

• Insert a screwdriver blade in the slot of the manual override and turn it from position 0 to position 1 using slight force.
• The manual override returns to position 0 when released.
  Depending on the valve construction, the valve then either returns to the initial position or remains in the selected position.

Service and Repairs

The CL03 single valve is maintenance-free and does not normally require any particular service or maintenance.

Cleaning and care

CAUTION Applied electric voltage and high pressure!
Danger of injury from electric shocks and sudden pressure drops.

• Make sure the system is not pressurized or connected to power before carrying out any service or maintenance work.
• Note the information on maintenance and cleaning in the overall system documentation.
• Only clean the single valve without valve cover using a dry cloth.
  Note: The IP69K version of the single valve has been designed for use in wet areas. After correct assembly, it can therefore be cleaned under high pressure and at high temperatures (IP69K conditions).

Maintenance

The single valve is maintenance-free.
However, observe any stipulated maintenance intervals and requirements for the entire system.

Checking the compressed air connections
Regularly check the compressed air connections and compressed air lines for leaks. Replace damaged or crushed lines.

Disassembly/Exchange

CAUTION Voltage and high pressure
Danger of injury from electric shocks and sudden pressure drops.
Make sure the system is not under pressure or voltage before performing the following tasks:

• Removing or connecting plugs
• Disassembling the system
• Exchanging individual components.

Disassembling the EV-CL03 from the mounting surface

1. Make sure the system is not under pressure or voltage before disassembly.
2. Loosen all connections.
3. Loosen all mounting screws on the CL03 single valve.
4. The valve can now be removed from the mounting surface.

Conversion and Extension

CAUTION Voltage and high pressure
Danger of injury from electric shocks and sudden pressure drops. Make sure the system is not under pressure or voltage before performing following tasks:

• Removing or connecting plugs
• Disassembling the system
• Exchanging individual components.

NOTICE Risk of damage to the CL03 single valve
Too high pressure when connecting compressed air to the exhaust air connection may damage the unit.
Do not exceed 0.3 bar when connecting compressed air to the “VENT” port.
Note: To ensure the IP69K protection after a modification, use the torques specified in these instructions and also make sure that all seals are correctly seated in their sealing slots. To check all seals, pressurize the ventilation port “VENT” up to 0.3 bar and then check for leakages by using soap water.

Exchange valve

1. Make sure the system is not under pressure or voltage before disassembly.
2. Remove the three hex head screws (8) on the valve cover (3) and then remove the cover, including the seal (7).
3. Remove the cross recessed screws (6) on the valve (2) and then remove the unscrewed valve from the base plate (1).
4. Place the new valve (5) on the base plate (1).
5. Press gently on the valve’s electrical connector end. Make sure the contacts are straight and that the seal is seated correctly.
6. Fasten the valve (2) by means of two self-tapping Pozidrive screws (6). Tightening torque 1.1 … 1.3 Nm screwdriver PZD no. 1.
7. Make sure that the manual override is in position 0. Carefully turn it into the zero position, if required.
8. Mount the valve cover (1). Make sure the seal (7) is correctly positioned. Tighten the three hexagon screws (8) with 1.0 … 1.2 Nm.

Disposal

Comply with national regulations regarding disposal.

Troubleshooting
See the section “Disassembly/Exchange” for information on how to replace a faulty product.

Technical Data

Spare Parts and Accessories

Information on spare parts and accessories can be found in the online catalog (www.aventics.com/pneumatics-catalog).

Figures: View varies according to the series.

Overview of CL03 single valve with base plate and valve cover

Base plate overview

Manual override

Assembling the CL03 single valve with base plate and valve – Dimensioned drawing

The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging.
An example configuration is depicted on the title page. The delivered product may thus vary from that in the illustration.
Translation of the original operating instructions. The original operating instructions were created in the German language.
R412018650–BAL–001–AF/2018-11 Subject to modifications. © All rights reserved by AVENTICS GmbH, even and especially in cases of proprietary rights applications. It may not be reproduced or given to third parties without its consent.

References

• AVENTICS – Smart, reliable solutions for pneumatic automation | Emerson DE

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