KIESELMANN ASi-Bus ES/ABSL 5630 010-000 Series User manual

Operating instructions - Translation of the original -
25.4.12
KIESELMANN GmbH
Paul-Kieselmann-Str.4-10
D - 75438 Knittlingen
 [phone]Fax: [phone]
www.kieselmann.de[e-mail]
Control head ASi-Bus ES/ABSL
5630 xxx 010-000
with platine V4.x
for Double seat valve
Single seat valve
Butterfly valve
Ball valve

25.4.12
Operation instructions: Control head 5630xxx010-000
ASi-Bus ES/ABSL
2
1. List of contents ..............................................................................................................2
2. Information for your safety............................................................................................. 3
3. Marking of safety instructions in the operating manual ................................................. 3
4. Variants of control heads ASi-Bus ES/ABSL................................................................. 4
4.1 Double seat valve (pneum. Lifting valve) ............................................................ 4
4.2 Single seat valve (pneum. Lifting valve).............................................................. 4
4.3 Butterfly valve / Ball valve (pneum. Rotary valve).............................................. 4
5. Safety instructions........................................................................................................ 5
5.1 Field of application .............................................................................................. 5
5.2 General safety instructions.................................................................................. 5
5.3 General notes ..................................................................................................... 5
6. Function ........................................................................................................................ 5
6.1 Description of function ........................................................................................ 5
7. Maintenance.................................................................................................................. 5
8. Installation informations................................................................................................. 5
8.1 Installation instructions........................................................................................ 5
9. Initial operation .............................................................................................................. 6
10. Power supply / valve control.......................................................................................... 6
10.1 Standard variant.................................................................................................. 6
10.2 ES variant (plug P5)........................................................................................... 6
10.3 Switch-over Standard / ES (selector switch E).................................................... 6
10.4 JTAG Interface (plug P1) ................................................................................... 6
10.5 External inputs 1 (plug P4) and 2 (plug P3) ........................................................ 6
10.6 Valve interface (plug F)..................................................................................... 6
11. Electrical installation......................................................................................................7
11.1 Electrical connection of the control head ............................................................ 7
11.2 Terminal pin assignment ..................................................................................... 7
11.3 LED Indication of slave status / Selector switch (D)........................................... 7
11.4 Electrical connection design of control head ASi-Bus ES/ABSL......................... 8
12. Position control and position indication ......................................................................... 9
12.1 Lifting valve ......................................................................................................... 9
12.2 Rotary valve ...................................................................................................... 10
13. Electrical and pneumatical piloting ASi-Bus ES/ABSL................................................ 11
13.1 Valve piloting - Double seat valve ..................................................................... 11
13.2 Valve piloting - Lifting valve............................................................................... 12
13.3 Valve piloting - Rotary valve.............................................................................. 13
13.4 Bit-assignment external input............................................................................ 13
14. Demontage und Montage............................................................................................ 14
14.1 Disassembly...................................................................................................... 14
14.2 Assembly .......................................................................................................... 14
15. Spare parts list ............................................................................................................ 15
16. Technical data ............................................................................................................. 16
17. Fault clearance............................................................................................................ 16
1. List of contents

25.4.12
Operation instructions: Control head 5630xxx010-000
ASi-Bus ES/ABSL
3
2. Information for your safety
We are pleased that you have decided for a high-class KIESELMANN product. With correct application
and adequate maintenance, our products provide long time and reliable operation.
Before installation and initiation, please carefully read this instruction manual and the security advices
contained in it. This guarantees reliable and safe operation of this product and your plant respectively.
Please note that an incorrect application of the process components may lead to great material damages
and personal injury.
In case of damages caused by non observance of this instruction manual, incorrect initiation,
handling or external interference, guarantee and warranty will lapse!
Our products are produced, mounted and tested with high diligence. However, if there is still a reason
for complaint, we will naturally try to give you entire satisfaction within the scope of our warranty. We will
be at your disposal also after expiration of the warranty. In addition, you will also find all necessary instruc-
tions and spare part data for maintenance in this instruction manual. If you don't want to carry out the main-
tenance by yourself, our KIESELMANN service team will naturally be at your disposal.
3. Marking of safety instructions in the operating manual
Hintsareavailableinthechapter"safetyinstructions"ordirectlybeforetherespectiveoperationinstruction.
The hints are highlighted with a danger symbol and a signal word. Texts beside these symbols have to
be read and adhered to by all means. Please continue with the text and with the handling at the valve only
afterwards.
Symbol Signal word Meaning
DANGER Imminent danger which may cause
severe personal injury or death.
ATTENTION
Dangerous situation which may
cause slight personal injury or
material damages.
NOTE
Marks application hints and other
information which is particularly
useful.

25.4.12
Operation instructions: Control head 5630xxx010-000
ASi-Bus ES/ABSL
4
4. Variants of control heads ASi-Bus ES/ABSL
4.1 Double seat valve (pneum. Lifting valve)
4.2 Single seat valve (pneum. Lifting valve)
4.3 Butterfly valve / Ball valve (pneum. Rotary valve)
Valve function Electrical connection Solenoid valves Article No.
without lifts
Plug M12 4-pin
Socket plug M12 5-pin
1 solenoid valve 5630 201 010–000
with upper seat lift 2 solenoid valves 5630 202 010–000
with lower seat lift 2 solenoid valves 5630 206 010–000
with upper + lower seat lift 3 solenoid valves 5630 203 010–000
Valve function Electrical connection Solenoid valves Article No.
air open / spring closed
air closed / spring open
Plug M12 4-pin
Socket plug M12 5-pin
1 solenoid valve 5630 501 010–000
air closed / air open 2 solenoid valves 5630 502 010–000
Valve function Electrical connection Solenoid valves Article No.
air open / spring closed
air closed / spring open
Plug M12 4-pin
Socket plug M12 5-pin
1 solenoid valve 5630 801 010–000
air closed / air open 2 solenoid valves 5630 802 010–000

25.4.12
Operation instructions: Control head 5630xxx010-000
ASi-Bus ES/ABSL
5
5. Safety instructions
5.1 Field of application
The control heads are used to pilot valves of production systems of the beverage and foodstuff industry,
pharmaceutical industry, bio-technology, and chemical industry.
They contain the complete actuator, sensory, and electronic technology for connection and integration
to up-dated and efficient control systems.
5.2 General safety instructions
5.3 General notes
6. Function
The control head has been constructed in a modular system. Depending on the performance the pneu-
matic (three solenoid valves at maximum) and the electric control module with 2 position response syn-
chros (hall sensors on the board) have been integrated into the control head.
6.1 Description of function
The valve positions are displayed electrically (DUO - LED) and directly at the control head. The valve
positions "OPEN" and "CLOSED" are in addition displayed mechanically.
For robust operating conditions we recommend the use of the option stainless cab.
A pressure relieve valve serves as a pressure reduction in case of air leakages. The electric connection
is carried out via a electrical connection plug or a flat cable adapter at the control head. As a protection
against external influences, the cab can be leaded (only possible in the version - plastic cab)
7. Maintenance
The control head is maintenance-free. However, it is recommended to check the density of the air con-
nections at fixed intervals, The air pressure escapes at air leakages through a pressure control valve
into the open air.
8. Installation informations
8.1 Installation instructions
Generally the assembly and disassembly of the control head must occur de-energized.
ATTENTION
• To avoid danger and damage, the fitting must be used in accordance with the safety instructions
and technical data contained in the operating instructions.
DANGER
• The personnel responsible for the service and maintenance is instructed to carefully read and follow
this operating manual and to maintain the prescribed technical data.
The manufacturer will not be liable for any damages caused by improper use or handling.
• Make sure that the prevailing requirements of accident prevention and safety for electrical appli-
ances are complied with during the maintenance and repair works.
• Never carry out electrical connections while the system is under energized.
ATTENTION
• Danger of injury by destruction of the housing cap, if the spindle cap is screwed in into the pulse generator
not completely (see Fig.2 /Page9). The spindle cap must be screwed in up to metallic limit stop on the
pulse generator.
NOTE
• All data are in line with the current state of development. Subject to change as a result of technical
progress.

25.4.12
Operation instructions: Control head 5630xxx010-000
ASi-Bus ES/ABSL
6
9. Initial operation
• Adjust the valve functions at the valve selector switch (D). (Tab. 2, page 7)
•
Connect power supply. (see “Electrical installation” on page 7)
•
Connect the control air pipe Ø 6x1 to the connection (17). (Fig.7 /Page14)
•
Connect the compressed-air pipe Ø 6x1 to the connection (11). (Fig.7 /Page14)
•
Check the pneumatic components for air leakages.
• Check the valve functions by activating manually the solenoid valves (20a). The manual activator is
provided as slide switch at the front side of the solenoid valves (20a).
10. Power supply / valve control
10.1 Standard variant
The power supply to the control board is taken from the 30V supply that lies close to the bus. All extra
components that can be switched on the control board are supplied directly via the bus and/or internally
generated voltage 24V DC. The valves are also controlled directly on the control board. Transient
diodes protect the electronics against voltages that are too high and peak voltages.
10.2 ES variant (plug P5)
In the ES variant, an additional 24V power supply for the solenoid valve is required. This voltage is fed
into the control board via a separate plug (P5). The internal power supply of the solenoid valves is then
cut off over the switch (E).
10.3 Switch-over Standard / ES (selector switch E)
In the back of the committee there is a counter with 2 positions. With this counter can be put whether
the committee should be pursued in the standard way or in the ES way. Encoding takes place from the
Kieselmann society. The counter is sealed after the choice. A suitable mark of the type of the manage-
ment is indicated on the frame.
10.4 JTAG Interface (plug P1)
The control board is equipped with a JTAG interface that allows the processor to be equipped with new
firmware at any time. Via this interface, the firmware on the control board can be changed easily and
at any time with a handheld programmer. Other solutions with the existing hardware are then easier to
realise.
10.5 External inputs 1 (plug P4) and 2 (plug P3)
There are two input channels for processing external signals that can be brought onto the control board
by inductive or capacitive sensors. The connectable sensors are also supplied via the control board
with 24V.
10.6 Valve interface (plug F)
The interface for the connection of a maximum of 3 solenoid valves is integrated on the control board.
The solenoid valves are inserted with the air distribution block onto the control board and screwed as
one complete unit within the TOP.

25.4.12
Operation instructions: Control head 5630xxx010-000
ASi-Bus ES/ABSL
7
11. Electrical installation
11.1 Electrical connection of the control head
➣Plug 4-pin (14A)
• The electrical connection of the ASI-Bus control head occurs through a plug 4-pin
(LUMBERG PRSFM4). (see Tab.1 Pin assignment)
➣Socket plug 5-pin (14C)
• The electrical connection of the ASI-Bus control head occurs through a plug socket 5-pin (LUMBERG
PRKFM5). (see Tab.1 Pin assignment)
➣Electrical connection on the board
• The installation of power cables from the plugs to the board is carried out by the manufacturer.
11.2 Terminal pin assignment
Tab. 1
11.3 LED Indication of slave status / Selector switch (D)
Tab. 2
Plug
(14A)
Pin No. Colour code Assignment Plug
P2 P5
1braun
brown Inputsignal Bus ASI (+)
2weiß
white ext. voltage ES 24 Volt (-)
3blau
blue Inputsignal Bus ASI (-)
4schwarz
black ext. voltage ES 24 Volt (+)
Socket plug Pin No. Colour code Assignment Plug
(14C) P3 P4
1braun
brown 24 Volt (+)
2weiß
white Sensor control line 2
3blau
blue GND
4schwarz
black Sensor control line 1
5grün/gelb
green/yellow -
1
3
+
-
+
-
2
4
-
+
2
1
4
3
LED 1Green LED 2 Red Descriptions Selector switch (D) functions
off off No main voltage present
0 = Double seat valve with both lifts
1 = Double seat valve without lifts
2 = Double seat valve with upper lift only
3 = Not used
4 = Single seat valve air open/spring closed
air closed/spring open
5 = Single seat valve air open/air close
6 = Not used
7 = Double seat valve with inverse both lift
8 = Butterfly / Ball valve air open/spring closed
9 = Butterfly / Ball valve air open/air closed
A = Butterfly / Ball valve air closed/spring open
C = reserved KIESELMANN
D = reserved KIESELMANN
E-F = Not used
on off Correct operation
off on No data exchange
Flashing on Incorrect slave address
Flashing Alternating flash
with LED1 Hardware error actuator/sensor
off Flashing Overload
LED3 - LED 6
LED 3 Green External input 2
LED 4 Green External input 1
LED 5 Red Valve closed
LED 6 Green Valve open
LED 5 / LED 6 Flashing alternately indicates
Valve in motion / error

25.4.12
Operation instructions: Control head 5630xxx010-000
ASi-Bus ES/ABSL
8
11.4 Electrical connection design of control head ASi-Bus ES/ABSL
D = Valve selector switch for valve type
see Tab.1
E = Selector switch: Position 1 Standard
Position 2 ES-mode
F=Plug
electrical connection for solenoid valve (MV)
P1 = JTAG Interface (Onbord programming)
P2 = Plug ASi-Bus
24V (+) braun/brown
GND (-) blau/blue
P3 = Plug - External input 2
Sensor control line weiß/white
P4 = Plug - External input 1schwarz/black
24V (+) braun/brown
GND (-) blau/blue
P5 = Plug - External voltage for solenoid valve
(ES)
24V (+) schwarz/black
24V (-) weiß/white
LED1= ASi-Bus Status
LED2= ASi-Bus Status
LED3= External input 2
LED4= External input 1
LED5= Actuator Status closed
LED6= Actuator Status open
7=Housing
14A = Plug M12 4-pin
14B = Compression gland M12
14C = M12Plug M12 5-pin
15 = Seal
16 = Signboard (optional)
Fig. 1

25.4.12
Operation instructions: Control head 5630xxx010-000
ASi-Bus ES/ABSL
9
12. Position control and position indication
12.1 Lifting valve
The repeat signal message ‘valve opened‘ or ‘valve closed‘ occurs contactless through the magnet field
of the pulse initiator‘s toric magnets at coverage of the Hall sensors on the board.
Valve Position Indicator
➣ELECTRICAL - through the DUO - LED on the board
• valve ’’OPEN’’ = Signal DUO-LED GREEN
• valve ’’CLOSED’’ = Signal DUO-LED RED
➣MECHANICAL - Lifting position of spindle
• valve ’’OPEN’’ = Valve position indicator - green
• valve ’’CLOSED’’ = Valve position indicator - red
NOTE
The installation position of the pulse generator is characterized by a marking in the spindle.
The distances of the measures " A" and " B" are valve-specifically and adjusted by the factory. These
must not be adjusted.
Puls generator Fig. 2