Camozzi PRE Series Troubleshooting guide

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
1
Operation and maintenance instructions for Series PRE Electronic proportional
regulator
The products are designed and manufactured in conformity with the following directives:
- 2014/30/UE “Electromagnetic compatibility”
They also comply partially or totally with regard to the applicable parts of the following standards:
- EN 61000-6-2:2005 Electromagnetic compatibility (EMC) — Part 6-2:
Generic standards - Immunity for industrial environments
- EN 61000-6-4:2007 Electromagnetic compatibility (EMC) — Part 6-4: Generic standards -
Emissions for industrial environments
- UL 61010-1: Safety requirements for electrical equipment for measurement, control and
laboratory use Part 1: General requirements and the following technical standards
and to the following technical standards:
- EN ISO 4414:2010 Pneumatics - General rules and safety requirements for systems and their
components.
For more information regarding the declarations of conformity, see the Certifications section
on the website http://catalogue.camozzi.com.
Made in Italy

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
2
Sommario
1.!Product identification ................................................................................................................. 3!
2.!Introduction ................................................................................................................................ 4!
3.!General recommendations ......................................................................................................... 4!
4.!Product description: ................................................................................................................... 5!
5.!Pneumatic simbol: ...................................................................................................................... 6!
6.!General characteristics and conditions of use ............................................................................ 7!
7.!Electrical/Pneumatic circuit ...................................................................................................... 15!
8.!Product storage and transport ................................................................................................. 15!
9.!Installation and start-up ........................................................................................................... 15!
10.!CoilVision ............................................................................................................................... 19!
11.!Digital output ......................................................................................................................... 19!
12.!Universal visual interface X (UVIX) ........................................................................................ 21!
12.1.!Monitoring ..................................................................................................................... 21!
12.1.1.!Status information .................................................................................................. 21!
12.1.2.!Details ............................................................................................................................. 22!
12.2.!Configurator ................................................................................................................... 24!
12.2.1.!USER SETUP .................................................................................................................... 24!
12.2.2.!RANGE SETUP ................................................................................................................. 25!
12.2.3.!DIGITAL OUTPUT SETUP ................................................................................................. 26!
12.2.4.!PRESSURE SENSOR SETUP .............................................................................................. 26!
13.!Use ......................................................................................................................................... 27!
14.!Troubleshooting and/or exceptional circumstances ............................................................. 30!
15.!Limitations on use ................................................................................................................. 31!
16.!Maintenance .......................................................................................................................... 31!
17.!Environmental notes ............................................................................................................. 31!
18.!Contacts ................................................................................................................................. 33!

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
3
1. Product identification

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
4
2. Introduction
This manual illustrates how to properly use the Series PRE electronic pressure regulator in its
version with analog inputs and with digital inputs (preset).
This version of the Controller is identified with code 0118 xx xx xxx x xxxxx, where 0118 indicates
the analog version and is followed by year, week, machine, station and serial number.
For more information, refer to the manual dedicated to the Camozzi UVIX supervision software
(Universal Visual Interface X).
3. General recommendations
The recommendations regarding safe use in this document should be observed at all times.
• Some hazards can only be associated with the product after it has been installed on the
machine/equipment. It is the task of the final user to identify these hazards and reduced the
associated risks accordingly.
• The products dealt with in this manual may be used in circuits that must comply with the
standard EN ISO 13849-1.
• For information regarding component reliability, contact Camozzi.
• Before proceeding with use of the product, carefully read all information in this document.
• The instructions in this manual must be observed together with the instructions and
additional information regarding the product in this manual, available from the following
reference links:
o web site http://www.camozzi.com
o Camozzi general catalogue
o Technical assistance service
• Assembly and start-up operations must be performed exclusively by qualified and authorized
personnel on the basis of these instructions.
• It is the responsibility of the system/machine designer to ensure the correct selection of the
most suitable pneumatic component according to the intended application.
• For all situations not contemplated in this manual and in situations in which there is the risk
of potential damage to objects, or injury to persons or animals, contact Camozzi for advice.
• Never make unauthorized modifications to the product. In this case, any damage or injury
to objects, persons or animals will be the responsibility of the user.
• All relevant product safety standards must be observed at all times.
• Never intervene on the machine/system before verifying that all working conditions are safe.
• Before installation and maintenance, ensure that the specific envisaged safety locks are
active, and then disconnect the electrical mains (if necessary) and system pressure supply,
discharging all residual compressed air from the circuit and deactivating residual energy
stored in springs, condensers, recipients and gravity.

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
5
• To reduce the noise levels caused by the discharge of air from the component, envisage the
use of silencers or convey the fluid to a zone where no personnel are envisaged during
normal operation.
• Avoid covering the equipment with paint or other substances that may reduce heat
dissipation.
• Avoid cleaning with aggressive agents such as to dull the plastics and make it difficult to
read the screen
• In the event of an electrical power failure and pneumatic supply at the port connection 1,
the regulated pressure on port connection 2 will not be maintained and can be
discharged.
4. Product description:
The Series PRE electronic pressure regulator is composed of:
• M12 8 pin connector (6): provides connection to power supply, command signal, feedback
signals and to the output signal (for more details refer to the paragraph “Installation and
Commissioning").
• LCD display (1): if present (depends on the code), it shows the measurement of the
regulated pressure and allows to configure some parameters.
• General diagnostic LED bar (3): provides a quick indication of the general status of the
device (for more details, refer to the "Use" paragraph).
• Function keys (2): if the LCD display is present (depends on the code), these keys allow to
access and navigate the Regulator menu (for more details, refer to the "Use" paragraph).
• Micro USB connector (5) and wireless communication LED (4) to connect to the UVIX: the
device can be connected to the UVIX supervision software via wireless (if present) or USB
that allows to configure and monitor the device.

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
6
The analog version of the Series PRE electronic pressure regulator is available with two
different command signal types:
• Analog Voltage: voltage command signal 0 - 10 V.
• Analog Current: current signal 4 - 20 mA.
The choice between the two models must be made when ordering the regulator.
The configuration of some features of the Series PRE electronic pressure regulator is done
through the UVIX supervision software.
Two operating modes have been implemented:
• Automatic: the pressure target is set via the analog input. At startup the Regulator is in this
mode.
• Manual: the pressure target is set using the function keys or through a special command of
the UVIX supervision software. The regulator must be set in this mode during the
configuration phase in order to avoid unwanted pressure adjustments.
5. Pneumatic simbol:
Version with integrated
exhaust valve and external
servo-pilot supply
Version with integrated
exhaust valve and internal
servo- pilot supply
3 ways N.C. version with external
servo-pilot supply
3 ways N.C. version with internal
servo- pilot supply

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
7
6. General characteristics and conditions of use
General characteristics and conditions of use
PRE1
PRE2
Reference standards
CE; RoHs
Materials
Body: Aluminum Cover: Technopolymer Seal:NBR and FKM
Assembly position
Any
Overall dimensions
L = 50 mm; W = 50 mm; H = 140 mm
L = 50 mm; W = 50 mm; H = 185 mm
Weight
350gr circa
630gr circa
Medium and its quality
Filtered and non-lubricated compressed air of class 7.4.4 according to
ISO 8573.1. Inert gases and oxygen only for OX1 versions.
Maximum free flow rate
(Pin 10 bar)
Measured at ±5% of Preg
Pout 6 bar: 1.100 l/min ANR (PRE104)
Pout 4 bar: 1.200 l/min ANR (PRE104)
Pout 6 bar: 4.500 l/min ANR (PRE104)
Pout 4 bar: 5.200 l/min ANR (PRE104)
Maximum system
pressure drop
50 cc/min
10 cc/min
Maximun inlet pressure
(refer to coding table)
2 bar (B) 5 bar (E) 11 bar (D); (G) and (F)
Regulated pressure range
0 - 1 bar (0-14,5 PSI)(B) 0,05 - 10,3 bar (0,72-150 PSI)(D)
0,05 - 6 bar (0,72-87 PSI)(F) 0,03 - 4 bar (0,43-58 PSI) (E)
0,05 - 7 bar (0,72-101,5 PSI) (G)
Number of ways
3
Ambient temperature
0 ÷ 50 °C
IP protection class
according to EN 60529
IP65 (according to EN 60529)
Pneumatic ports
Standard version: G1/4, 1/4 NPTF
Manifold version: G1/4; 1/4 NPTF
Standard version: G1/4, G3/8
Manifold version: G1/4
Vibrations sine
According to EN 60068
part 2-6:2009-11 (table
B.1)
Frequency range: 10-500Hz
Displacement 0-peak: 0,75mm or 100 m/s2
Number of cycle: 10
Continuous shock
According to DIN EN
60068-2-27:2010-02 (table
A.1)
Peak acceleration: 150 m/s2
Duration: 11ms
Pulse shape: half sine
Electric port
M12 8 Pin Male A-key
Input signal setpoint
Analog version: 0÷10V (2), 4÷20 mA (4)
(**) Preset version (D): 5 bit (32 different pressure values)

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
8
Analog Output signal
(feedback)
0÷5 V DC and 4÷20 mA (both present in the analog version (2) and (4))
Electrical power supply
24Vdc ±10%
Current consumption
Max 0.5A (envisage a power supply unit of at least 1.0A)
Hysteresis (*)
0,5% FS
0,7% FS
Repeatability (*)
0,4% FS
0,4% FS
Linearity (*)
0,3% FS
0,3% FS
Resolution (*)
0,3% FS
0,6% FS
Overpressure discharge
With relieving
Modularity
With Series MD
(*) measured with Inlet pressure = Maximum regulated pressure + 1bar and a volume
connected to the outlet without any loss.
(**) Digital input Type 1 according CEI EN 61131-2: OFF from 0V to 5V, ON from 15V to 24V

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
9
• Efficiency curve
y"="0,1033x
0
1
2
3
4
5
6
7
8
9
10
11
010 20 30 40 50 60 70 80 90 100
Regulated pressure [bar]
Electrical control signal [%]
Efficiency curve 10,33 bar
y = 0,04x
0
1
2
3
4
010 20 30 40 50 60 70 80 90 100
Regulated pressure [bar]
Electrical control signal [%]
Efficiency curve 4 bar

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
10
• FLOW CHARTS SIZE 1 - Standard version (1/4G)
Working pressure 1 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 4 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 6 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 7 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 10,33 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
11
• FLOW CHARTS SIZE 1 – Manifold version (1/4G)
Working pressure 1 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 4 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 6 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 7 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 10,33 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
DECAY FACTOR
N° = number of regulators in manifold configuration
D(%) = relative percentage decay of the maximum flow rate
Note: the air inlet is only from one side, in case it should be on the
right and on the left, only consider the positions as from 1 ÷ 3..

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
12
• FLOW CHARTS SIZE 2 - Standard version (1/4G)
Working pressure 1 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 4 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 6 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 7 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 10,33 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
13
• FLOW CHARTS SIZE 2 - Standard version (3/8G)
Working pressure 1 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 4 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 6 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 7 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal
Working pressure 10,33 bar
P = Regulated outlet pressure and exhaust pressure
Q = Flow
% = Percentage of the command signal

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
14
• Step response (Values determined according to ISO 10094-1)
PRE-104
Type of Dynamic tests
Dynamic Characteristics
No tank
Volume 0,4L
Volume 2L
Step 0% to 100%
Shifting Time [ms]
36
82
175
Response Time [ms]
260
372
1.261
Settling Time [ms]
179
247
934
Step 100% to 0%
Shifting Time [ms]
39
64
177
Response Time [ms]
678
957
4.152
Settling Time [ms]
470
708
3.170
PRE-238
Type of Dynamic tests
Dynamic Characteristics
No tank
Volume 0,4L
Volume 2L
Step 0% to 100%
Shifting Time [ms]
60
60
95
Response Time [ms]
350
465
850
Settling Time [ms]
250
325
650
Step 100% to 0%
Shifting Time [ms]
60
60
80
Response Time [ms]
850
860
870
Settling Time [ms]
600
590
565

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
15
7. Electrical/Pneumatic circuit
+
+
+
+
+
+
+
+
+
+
8. Product storage and transport
• Adopt all measures possible to avoid accidental damage to the product during transport, and
when available use the original packaging.
• Observe the specified storage temperature range of -20 ÷ 70 °C.
9. Installation and start-up
• During unpacking, take great care not to damage the product.
• Check whether there are any faults caused by product transport or storage.
• Separate all packaging material to enable the recovery or disposal in accordance with current
standards in the country of use.
• Where possible avoid the risk of repeated pressure surges on the circuit where the
component is installed.
• The components must be fixed correctly using, where possible, the specific anchors and
ensuring that the fixture remains efficient even when the actuator is repeatedly used at a
high frequency and in the presence of strong vibrations.
• Once the component is installed, ensure that all air ways are securely connected to the
respective couplings.
• If the power supply is turned off, residual pressure may remain on the secondary side of the
regulators. The manufacturer must provide for additional exhaust components.
Recommended pneumatic circuit
• PRE series electronic regulator can be connected to DIN rails using the relative elements PCF-
E520 fitted on the rear of the body using two M4 threaded holes.

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
16
• The Series PRE electronic regulator can be directly fixed to a support using the 2 through
holes with diameter 4mm present on the body (not available in the PRE1 manifold version).
• The PRE1 electronic regulator can be fixed to the wall with the optional bracket code MD1-
ST/1 (if the two through holes in the body have a 34 mm center distance) or with the optional
bracket code PRE-ST (if the two through holes in the body have a 42 mm center distance);
the PRE2 electronic regulator can be fixed to the wall with the optional bracket code PRE-ST:
1. Fix the bracket to the wall with suitable screws
2. Connect the fittings G1/4; G3/8 or NPTF according to the PRE regulator size
3. Connect the regulator to the bracket with the two M4 x 55 screws supplied
• Connection of Manifold regulators with related Kit PRE-M-Pin-1-2
1. Insert the pins (1) in the seats on the regulator body
2. Insert the O-ring seal (3) into the special seat on the side face of the body
3. Bring the two modules sideways up until contact
4. Tighten the four grub screws (2) until they are locked (Tightening torque: 2,5 ± 0,5 Nm)

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
17
• There are 2 additional pneumatic ports on the PRE series electronic regulator:
o M5 to discharge the exhaust valve to the outside. It is important to keep this port
free and clean to ensure that air is discharged without obstructions that could limit
the flow. If necessary, remove the pre-assembled filter, connect a suitable coupling
and use a hose to convey discharged air to a suitable area.
o M5 for external servo-pilot supply. The regulator is supplied with a preassembled cap
for the versions with internal servo-pilot supply and with the fitting 6625 3-M5 for
the versions with external servo-pilot supply.
• In order to connect the regulator with MD series, use the PRE-1/4-C kit for regulator with
G1/4 pneumatic port or use the PRE-3/8-C kit for regulator with G3/8 pneumatic port.
• The board implements a protection against inversion of polarity on the power supply
voltage.
• The board is also fitted with a resettable 1A fuse to limit the maximum current absorption
of the servovalve. Use a power supply unit able to deliver a current of at least 0,5A
(recommended 1.0A).
• If UL/CSA standard compliance is required, the unit shall be supplied by an isolated power
source which fulfils at least one of the following the requirements of:
- Limited-Energy Circuit in accordance with UL/CSA 61010-1/ UL/CSA 61010-2-201
- Limited Power Source (LPS) in accordance with UL/CSA 60950-1
- a Class 2 supply source which complies with the National Electrical Code (NEC), NFPA 70,
Clause 725.121 and Canadian Electrical Code (CEC), Part I, C22.1. (typical examples are a
Class 2 transformer or a Class 2 power sources in compliance with, UL 5085-3/ CSA-C22.2
No. 66.3 or UL 1310/CSA-C22.2 No. 223).
• The power supply voltage must be within the range of 24V±10%.
• The board implements a protection against overload of the reference signal.
• The M12 8 pin male connector has the following pinout

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
18
PIN
ANALOG
PRESET
1
24 VDC
Power supply
Connect to the positive pole (24VDC) and to the negative pole (GND) of the power supply.
2
GND
3
IN+
Input of voltage (0-10V) or current (4-20mA) reference signal
Connect to the positive pole (IN+) and to the negative pole (IN-) of the
reference signal generator.
Internal resistance with voltage input: >10kΩ. Use reference signal generator
with low impedance and with output current >1mA@10V.
Internal resistance with current input: 100Ω.
It is mandatory to connect all negative poles of the power supply and the
reference signal generator together (pin 2 and pin 4).
IN1
First
digital
input.
4
IN-
IN2
Second
digital
input.
5
Vout+
Voltage analog feedback signal (0-5V)
Connect the positive pole (Vout+) and the negative pole (Vout-) to the voltage
input.
Output resistance: <10MΩ.
Do not connect the negative pole (Vout-) with other negative poles (pin 2 and
pin 4): as noise, input signal errors or feedback signal errors might occur.
IN3
Third
digital
input.
6
Vout-
IN4
Fourth
digital
input.
7
Iout+
Current analog feedback signal (4-20mA)
Connect to the positive pole of the current input.
Connect the negative pole of the current input to GND (pin 2).
IN5
Fifth
digital
input.
8
OUT
Digital output signal (0-24V)
Connect to a digital input.
If the input is of the NPN type, use pin 1 (24VDC) as reference of digital input; otherwise if
the input is of the PNP type, use pin 2 (GND) as reference of digital input.
Output resistance: >15MΩ. Max current: 50mA.

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
19
• For the electrical connection the following cable types are available:
CODE
DESCRIPTION
CS-LF08HB-C200
co-moulded connector M12 8 pole, female, straight with 2-metre cable unshielded
CS-LF08HB-C500
co-moulded connector M12 8 pole, female, straight with 5-metre cable unshielded
CS-LR08HB-C200
co-moulded connector M12 8 pole, female, bend with 2-metre cable unshielded
CS-LR08HB-C500
co-moulded connector M12 8 pole, female, bend with 5-metre cable unshielded
G11W-G12W-2
Micro USB cable (it may be used during the configuration phase)
10. CoilVision
With the integrated CoilVision technology the proportional regulator is able to
constantly monitor the operation of the coils inside it and prevent any malfunctions.
Depending on the model chosen, the proportional regulator can have three different levels of
diagnostics:
• Without diagnosticc: the CoilVision technology isn’t implemented.
• Basic diagnostics: CoilVision technology is active and will advice the user when the coils are
nearing the end of their life cycle
• CoilVision diagnostics: CoilVision technology is active and, in addition to advice the user
when the coils are nearing the end of their life cycle, constantly sends information about
their current health status to the UVIX environment.
11. Digital output
The digital output (OUT signal, pin 8) is a 0-24V digital signal. Through the UVIX configuration
software it is possible to set the logic of this output:
• Active – high level: if the output is activated, its value is brought to a high logic level.
• Active – low level: if the output is activated, its value is brought to a low logic level.

Operation and maintenance instructions
Series PRE proportional pressure regulator
Analog /preset version
5000024670
Ver. 01
20
Furthermore, based on the electrical connection made by the user, the following
configurations can be obtained:
• PNP: in this configuration the output signal refers to GND (pin 2), therefore the PNP digital
input of the control system must be connected between pin 8 (OUT) and pin 2 (GND).
• NPN: in this configuration the output signal refers to + 24V (pin 1), therefore the NPN digital
input of the control system must be connected between pin 8 (OUT) and pin 1 (+ 24V)
The operating mode of the digital output depends on what code is ordered. There are three
different operating modes:
• Error: the digital output changes state if the Regulator detects an error.
• Switch pressure: with this operating mode it is possible to set two fixed pressure thresholds,
a lower one and a higher one. The digital output changes state if the regulated pressure is
outside the range delimited by the two thresholds set. This is a useful way to check whether
the regulated pressure lies within the preset pressure range.
• Window pressure: with this operating mode it is possible to set two thresholds, a lower one
and a higher one, which determine a pressure range with respect to the target pressure
value.
The digital output changes state if the regulated pressure is outside the instantaneous range
(depending on the value of the target pressure at that moment) delimited by the two
thresholds set.
This is a useful way to check whether the regulated pressure lies within the pre-established
precision range.