SPX FLOW APV CU41-S Bedienungsanleitung

APV CU4 AS-interface

CONTROL UNIT

FORM NO.: H326406 REVISION: UK-5 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.

INSTRUCTION MANUAL

APV_CU4 AS-i_UK-5_072018.indd

Control Unit

CU4 AS-interface

Instruction manual: UK - rev. 5

APV

Content Page

1. AbbreviationsandDenitions   4

2. SafetyInstructions   4

2.1. Sentinels

2.2. Intended Use

2.3. General Regulations for Careful Handling

2.4. Welding instructions

2.5. Persons

2.6. Warranty

2.7 Important Safety Instructions for AS-interface networks

3. General Terms 7

3.1. Purpose of use

3.2. Design of CU4 AS-interface

3.3. Function of the individual components

4. MechanicsandPneumatics   10

4.1. Air connection for valves with turning actuator

4.2. Air connections for single seat and double seat mix proof valves

4.3. Pressure relief valve

4.4 Functional description - block diagrams

4.5. Technical Data / Standards

4.6. Solenoid valves

4.7. Throttling function

4.8. NOT element

5. Adapter 19

5.1. Valveswithturningactuator,e.g.butteryvalves

5.2. Single seat valves

5.3. Double seat mix proof valves DE3, DA3+

5.4 Double seat mix proof valves D4, D4 SL, DA4

6. Electronicmodule   20

6.1. Function / Block diagram

6.2. Functional description of connections

6.3. Use of data bits

6.4. Technical Data

6.5. Connections

6.6. LED indication

7. Feedback unit 26

7.1. General terms

7.2. Sensors

7.3. Adjustment of valve position feedback

7.4. Use of external sensors

8. CU Assembly and Startup 27

8.1. Valveswithturningactuator,e.g.butteryvalves

8.2. Single seat valves

8.3. Double seat mix proof valves DE3, DA3+

8.4. Double seat mix proof valves D4, D4 SL, DA4

8.5. Replacement of a CU3 control unit

9. AccessoriesandTools   40

10. Service   41

10.1. Dismantling

11. TroubleShooting   42

12. Spare Parts Lists

ITISESSENTIALTOREADTHISINSTRUCTIONMANUAL

BEFORE USE OF THE CONTROL UNIT!

APV_CU4 AS-i_UK-5_072018.indd

Control Unit

CU4 AS-interface

Instruction manual: UK - rev. 5

APV

1. AbbreviationsandDenitions

A ExhaustAir

AWG American Wire Gauge

CE Communauté Européenne

CU Control Unit

DI Digital Input

DO Digital Output

EMC ElectromagneticCompatibility

EU European Union

GND Ground

IP International Protection

LED Luminous Diode

N Pneumatic Air Connection NOT element

NEMA NationalElectricalManufacturersAssociation

P Supply Air Connection

PWM Pulse-WidthModulation

Y Pneumatic Air Connection

2. Safety Instructions

2.1. Sentinels

Meaning:

Danger! Direct danager which can lead to severe boldily

harm or to death!

Caution! Dangerous situation which can lead to bodily

harm and/or material damage.

Attention! Risk as a result of electric current.

Note! Important technical information or recommendation.

Thesespecialsafetyinstructionspointdirectlytothe

respectivehandlinginstructions.Theyareaccentuatedbythe

correspondingsymbol.Carefullyreadtheinstructionstowhich

thesentinelsrefer.Continuehandlingthecontrolunit

onlyafterhavingreadtheseinstructions.

DANGER

APV_CU4 AS-i_UK-5_072018.indd

Control Unit

CU4 AS-interface

Instruction manual: UK - rev. 5

APV

2. Safety Instructions

2.2. Intended Use

The CU4 control unit is only intended for use as

described in chapter 3.1. Use beyond that described in

chapter 3.1. is not according to the regulations and SPX FLOW

shall not be held responsible for any damage resulting from this

non-observance.

The operator bears the full risk. Conditions for the proper and

safe operation of the control unit are the appropriate transport

and storing as well as the professional assembly. Intended

use also means the observance of all operating, service and

maintenance conditions.

2.3. General Regulations for Careful Handling

To ensure a faultless function of the unit and a long service life,

the information given in this instruction manual as well as the

operatingconditionsandpermissibledataspeciedinthedata

sheets of the control unit for process valves must be strictly

adhered to.

- The operator is committed to operating the control unit in faultless

condition, only.

- Observe the general technical rules while using and operating the

unit.

- Observe the relevant accident prevention regulations, the national

rules of the user country as well as your company-internal operating

and safety regulations during operation and maintenance of the unit.

- Switch off the electric power supply before carrying out any work on

the system!

- Note that piping or valves that are under pressure must not be

removed from a system!

- Take suitable measures to prevent unintentional operation or

impermissible impairment.

- Following an interruption of the electrical or pneumatic supply,

ensureadenedandcontrolledre-startoftheprocess!

- If these instructions are not observed, we will not accept any liability.

Warranties on units, devices and accessories will expire.

APV_CU4 AS-i_UK-5_072018.indd

Control Unit

CU4 AS-interface

Instruction manual: UK - rev. 5

APV

2. Safety Instructions

2.4. Weldinginstructions

It is generally recommended to avoid welding work in process

installations in which control units are installed and connected.

If welding is nonetheless required, earthing of the electrical

devices in the welding area is a necessity.

2.5. Persons

- Installation and maintenance work may only be carried out by

qualiedpersonnelandbymeansofappropriatetools.

- Thequaliedpersonnelmustgetaspecialtrainingwithregardto

possible risks and must know and observe the safety instructions

indicated in the instruction manual.

- Work at the electrical installation may only be carried out by

personnel specialised in electrics!

2.6. Warranty

This document does not contain any warranty acceptance.

We refer to our general terms of sale and delivery.

Prerequisite for a guarantee is the correct use of the unit in

compliancewiththespeciedconditionsofapplication

Attention! This warranty only applies to the control unit.

No liability will be accepted for consequential

damage of any kind that could arise from the failure

or malfunction of the device

2.7 ImportantSafetyInstructionsforAS-interfacenetworks

- Always use protective modules against excess voltage in the AS-

interface installation.

- Grounding

For the AS-interface network a potential-free operation must be

guaranteed. Use isolation monitoring modules to provide for proper

grounding conditions.

Grounding of the bus cable or connected components or their

charging with external voltage leads to malfunction in the bus

system.

APV_CU4 AS-i_UK-5_072018.indd

Control Unit

CU4 AS-interface

Instruction manual: UK - rev. 5

APV

3. General Terms

3.1. Purpose of use

The CU4 AS-interface Control Unit was developed for the control of

process valves used in the food and related industries.

The CU4 control unit operates as interface between process control

and process valve and controls the electric and pneumatic signals.

The pneumatic control of valves is undertaken via the solenoid

valves. The control unit controls the valve positions, open and

closed, via integrated and external sensors. The electronic module

undertakes the task to process the switching signal from the control

and to control the corresponding solenoid valves. The electronic

module also provides potential-free contacts.

The corresponding light signals in the control unit provide for an

external indiciation of the valve positions.

3.2. DesignofCU4AS-interface(fig.3.2.)

The CU4 AS-interface control unit mainly consists of the following

components:

1. The control unit base with integrated air channels and electric and

pneumatic connections as well as viewing windows with type label.

2. 1 or 3 solenoid valves for the control of the valve actuators and for

the seat lifting of double seat valves.

1 solenoid valve with 1 logic NOT element for the control of the

valve actuators.

3. Sensor module with 2 integrated Hall sensors or 2 external

proximity switches to detect the valve position.

4. The electronic module for the electric supply, communication with

control, evaluation of feedback signals and control of solenoid

valves as well as valve position indication through LED.

5. Clamp ring to fasten the CU4 on the adapter.

6. Cover with LED optics.

The cable/s by means of which the solenoid valves are connected

with the electronic module must be guided through the cable guide

attherearsideoftheelectronicmodule(g.3.2.1).

cable guide

fig. 3.2.

fig. 3.2.1

APV_CU4 AS-i_UK-5_072018.indd

Control Unit

CU4 AS-interface

Instruction manual: UK - rev. 5

APV

3. General Terms

3.3. Functionoftheindividualcomponents

The installation of the control unit is undertaken by special adapters

which are available for the different valves types, see chapter

5. Adapter. The snap connectors for supply air and pneumatic air

to the individual cylinders at the valves are located at the outside of

the control unit. In case of the control units for valves with turning

actuator, the pneumatic air is transferred internally to the actuator.

The air supply of the control unit is equipped with an exchangeable

airlter.Observetherequiredcompressedairquality!Pleasealso

see chapter 4.5.

The number of the solenoid valves installed in the CU4 depends on

thevalveactuatorstobecontrolled.Singleseatandbutteryvalves

and double seat valves without seat lift function require 1 solenoid

valve. Control units for double seat valves are equipped with

3 solenoid valves. For the manual actuation, the solenoid valves are

provided with a safe lever which is easy to operate.

Theelectronicmoduleinstalledinthecontrolunitfulllsthetaskto

process the electric signals from the control, to control the solenoid

valves and to evaluate the feedback signals from the feedback unit.

Moreover, the signalling and indication of the valve positions as well

as additional diagnostic functions are undertaken via the electronic

module.

The electronic module is the interface between control actuators

or sensors. Depending on the control type, different modules

areavailable,e.g.DirectConnect,AS-interface,Probusand

DeviceNet.

A feedback unit is required to detect the valve position. The CU4

AS-interface is equipped with 2 adjustable Hall effect sensors.

These are activated by a valve control rod installed at the operating

cam. In this way, the open and closed valve position can be

detected.

The 2 Hall effect sensors are continuously adjustable over an

additional range. Thus, feedback messages for different valves with

different stroke lengths can be adjusted properly. As an alternative,

external proximity switches can be connected instead of the

integrated Hall effect sensors when the valve position indication is

undertaken direct at the process valve.

APV_CU4 AS-i_UK-5_072018.indd

Control Unit

CU4 AS-interface

Instruction manual: UK - rev. 5

APV

3. General Terms

3.3. Functionoftheindividualcomponents

The luminous diodes are located on the front side of the electronic

module. Their signals are visibly indicated to the outside by an

optical window in the cover of the control unit. Beside the open and

closed valve position, the existence of the operating voltage as well

as different diagnostic information are indicated. Chapter 6.6. LED

indication provides more details.

The complete control unit is designed according to the building

block principle. By exchange of the electronic module, the control

typecanbechanged,e.g.fromdirectcontrol(DirectConnect)to

communication with AS-interface.

Note! Wiring must be changed.

AIR IN

A1 A2

Y1 Y2(N) Y3

AIR IN

APV_CU4 AS-i_UK-5_072018.indd

Control Unit

CU4 AS-interface

Instruction manual: UK - rev. 5

APV

4. MechanicsandPneumatics

4.1. Airconnectionforvalveswithturningactuator

4.1.1. Function

CU41-T-AS-i

designforvalvewithturningactuator,e.g.butterflyvalves

P airsupplywithintegratedparticlelter

Y1 bore to transfer control air to turning actuator

A1 exhaust air with exhaust silencer

4.2. Airconnectionsforsingleseatanddoubleseatmixproofvalves

4.2.1. Function

CU41-S-AS-i/CU41-M-AS-i/CU41-D4

design for seat valves and double seat mix proof valves

withoutseatlift

P  irsupplywithintegratedparticlelter

Y1 control air connection for main actuator

A1 exhaust air with exhaust silencer

CU41N-S-AS-i

designforseatvalveswithNOTelement

P airsupplywithintegratedparticlelter

Y1 pneumatic air connection for main actuator

Npneumatic air connection for the spring support of the actuator

by compressed air, via NOT element

A1 exhaust air with exhaust silencer

CU43-M-AS-i/CU43-D4

designfordoubleseatmixproofvalveswithseatlift

P airsupplywithintegratedparticlelter

Y1 pneumatic air connection for main actuator

Y2 pneumatic air connection for seat lift actuator of upper seat lift

Y3 pneumatic air connection for seat lift actuator of lower seat lift

A1/A2 exhaust air with exhaust silencer

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