APV CU4 User manual

Operating Manual
CU4 AS-interface
Control Unit
Read and understand this manual prior to
operating or servicing this product.
NTERFACE

1
Control Unit CU4 AS-interface UK-0 / 31.05.2010
Control Unit
CU4 AS-interface
Operating Manual: UK-0
UK
Content Page
1. Abbreviations and Definitions 2
2. Safety Instructions 2 - 4
2.1. Sentinels
2.2. Conventional Use
2.3. General Regulations for Careful Handling
2.4. Welding Instructions
2.5. Persons
2.6. Warranty
2.7. Safety Instructions for AS-interface networks
3. General Terms 5 - 7
3.1. Purpose of use
3.2. Design of CU4 AS-interface
3.3. Functional description
4. Mechanics and Pneumatics 8 - 14
4.1. Function and connections for turning actuators
4.2. Function and connections for single and double seat valves
4.3. Pressure relief valve
4.4. CU41 AS-interface block diagram
4.4.1 CU41N AS-interface block diagram
4.4.2 CU43 AS-interface block diagram
4.5. Technical Data / Standards
4.6. Solenoid valves
4.7. Throttling function
4.8. NOT element
5. Adapter for valves 15
5.1. Adapter for valves with turning actuator, e.g. butterfly valves
5.2. Adapter for single seat and change-over valves (SW4, M4 etc.)
5.3. Adapter for double seat valves
6. Electronic module 16 - 21
6.1. Function and block diagram connections
6.1.1. Switchover of feedback signals
6.2. Function connections
6.3. Use of data bits
6.4. Technical data
6.5. Sensors for valve position indication
6.6. LED indicators
7. Feedback unit 22
7.1. General Terms
7.2. Sensors
7.3. Adjustment for valve position indication
7.4. Use of external sensors
8. CU assembly and start-up 23 - 31
8.1. Turning actuator, e.g. butterfly valves
8.2. Single seat valves
8.3. Double seat valves
9. Accessories and Tools 32
10. Servicing 33
10.1. Disassembly
11. Trouble shooting 34 - 35
12. Spare parts lists
IT IS ESSENTIAL TO READ THIS OPERATING MANUAL
BEFORE USE OF THE CONTROL UNIT!

2
Control Unit CU4 AS-interface UK-0 / 31.05.2010
Control Unit
CU4 AS-interface
Operating Manual: UK-0
UK
A Exhaust Air
AWG American Wire Gauge
CE Communauté Européenne
CU Control Unit
DI Digital Input
DO Digital Output
EMC Electromagnetic Compatibility
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
1. Abbreviations and Definitions
2. Safety Instructions
2.1. Sentinels
Symbol: Meaning:
Danger ! Direct danger which can
lead to severebodily 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
DANGER

3Control Unit
CU4 AS-interface
Operating Manual: UK-0
Control Unit CU4 AS-interface UK-0 / 31.05.2010
UK
2.2. Conventional Use
The DELTA 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 regulations and APV shall not be
responsible for any damage resulting from this non-observance.
The operator bears the full risk. Conditions for a proper and
safe operation of the control unit are the appropriate transport
and storing as well as the professional assembly. Conventional
use also means the observance of 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 operating manual as well as the
operating conditions and permissible data specified in the data
sheets of the control unit for process valves should 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 electrical 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 defined 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!
2. Safety Instructions

4
Control Unit CU4 AS-interface UK-0 / 31.05.2010
Control Unit
CU4 AS-interface
Operating Manual: UK-0
UK
2.4. Welding instructions
It is generally recommended to avoid welding work in process
installation 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
qualified personnel and by means of appropriate tools.
- Qualified personnel must get a special training with regard to
possible risks and must know and observe the safety instructions
indicated in the operating 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 specified 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
- Safety Instructions for AS-interface
Always use protective modules against excess voltage in the
AS-interface installation.
- Safety Instructions for AS-interface
Grounding
For the AS-interface network a potential-free operation must be
guaranteed. Observe the use of 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.)
!
!
2. Safety Instructions

5Control Unit
CU4 AS-interface
Operating Manual: UK-0
Control Unit CU4 AS-interface UK-0 / 31.05.2010
UK
3. General Terms
3.1. Purpose of use
The Control Unit Delta CU4 AS-interface has been
developed for the control of process valves used in the food
industry 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 APV 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 Control Units CU4 AS-interface 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. 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.
1.
5.
2.
3.
4.
6.
fig. 3.2.

6
Control Unit CU4 AS-interface UK-0 / 31.05.2010
Control Unit
CU4 AS-interface
Operating Manual: UK-0
UK
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. At 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 filter. Observance of the required compressed air
quality is imperative. 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 butterfly
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 handle which is easy to operate.
The electronic module installed in the control unit fulfills 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, Profibus 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 on 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.

7Control Unit
CU4 AS-interface
Operating Manual: UK-0
Control Unit CU4 AS-interface UK-0 / 31.05.2010
UK
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 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 indicators provide more details.
The complete control unit has been designed on 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.
(Attention: wiring needs also be changed.)

8
Control Unit CU4 AS-interface UK-0 / 31.05.2010
Control Unit
CU4 AS-interface
Operating Manual: UK-0
UK
4. Mechanics and Pneumatics
4.2.1. Function
CU41-S-AS-i / CU41-M-AS-i
design for seat valves and double seat mixproof valves
without seat lift.
Pair supply.
Y1 control air connection for main actuator.
A1 exhaust air, with exhaust silencer.
CU41N-S-AS-i
design for seat valves with NOT element.
Pair supply with integrated particle filter.
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
design for double seat mixproof valves with seat lift.
Pair supply with integrated particle filter.
Y1 pneumatic air connection for main actuator.
Y2 pneumatic air connection for seat lift actuator of upper seat lifting.
Y3 pneumatic air connection for seat lift actuator of lower seat lifting.
A1/A2 exhaust air, with exhaust silencer.
4.1.1. Function
CU41-T-AS-i
design for valve with turning actuator, e.g. butterfly valves.
Pair supply with integrated particle filter.
Y1 bore to transfer control air to turning actuator
A1 exhaust air, with exhaust silencer.
4.1. Air connections for turning actuator
4.2. Air connections seat valves and double seat mixproof valves
A1 A2
P
AIR IN
Y1 Y2 (N) Y3
Y1
A1
P
AIR IN

9Control Unit
CU4 AS-interface
Operating Manual: UK-0
Control Unit CU4 AS-interface UK-0 / 31.05.2010
UK
4. Mechanics and Pneumatics
4.3. Pressure relief valve
The base of the control unit is equipped with a pressure relief
valve. Which prevents an inadmissible pressure build-up in the
inner control unit.
If required, the pressure relief vents into the clearance between
the base and the adapter of the control unit.
The pressure relief valve must not be mechanically blocked
under any circumstances.
DANGER
DANGER

10
Control Unit CU4 AS-interface UK-0 / 31.05.2010
Control Unit
CU4 AS-interface
Operating Manual: UK-0
UK
4. Mechanics and Pneumatics
4.4. CU41 AS-interface
Functional description - block diagram
Picture shows a standard NC
(spring to closed) valve.
If NO (spring to open) valve is used,
the sensor wiring can be different.
NTERFACE
1AS-i-Bus +
AS-i-Bus -
5 VDC
Sensor 1
GND
5 VDC
Sensor 2
Sensor 1
(“Valve closed”)
Sensor 2
(“Valve open”)
GND
Normal
Feedback
Reverse
Solenoid valve
Throttle valves
P / Air supply
A / Exhaust
2
3
4
5
6
7
8
10
11
12

11 Control Unit
CU4 AS-interface
Operating Manual: UK-0
Control Unit CU4 AS-interface UK-0 / 31.05.2010
UK
4. Mechanics and Pneumatics
4.4.1. CU41N - AS-interface
Functional description - block diagram
Picture shows a standard NC
(spring to closed) valve.
If NO (spring to open) valve is used,
the sensor wiring can be different.
NTERFACE
1
Sensor 1
(“Valve closed”)
Sensor 2
(“Valve open”)
Solenoid valve
Throttle valves
P / Air supply
A / Exhaust
2
3
4
5
6
7
8
NOT-Element
5 VDC
Sensor 1
GND
5 VDC
Sensor 2
GND
10
11
12
Normal
Feedback
Reverse
AS-i-Bus +
AS-i-Bus -

12
Control Unit CU4 AS-interface UK-0 / 31.05.2010
Control Unit
CU4 AS-interface
Operating Manual: UK-0
UK
4. Mechanics and Pneumatics
4.4.2. CU43 AS-interface for double seat valve DA3
Functional description - block diagram
seat lift cylinder lower valve seat
main cylinder and integrated seat lift cylinder upper valve seat
Picture shows a standard NC
(spring to closed) valve.
If NO (spring to open) valve is used,
the sensor wiring can be different.
NTERFACE
EMV
/solenoid 1
EMV
/solenoid 2
EMV
/solenoid 3
Sensor 1
(“Valve closed”)
Sensor 2
(“Valve open”)
Abluft /
Exhaust
Abluft /
Exhaust
IN
Luft / air
1
2
3
4
5
6
7
8
AS-i-Bus +
AS-i-Bus -
5 VDC
Sensor 2
GND
10
11
12
Normal
Feedback
Reverse
5 VDC
Sensor 1
GND

13 Control Unit
CU4 AS-interface
Operating Manual: UK-0
Control Unit CU4 AS-interface UK-0 / 31.05.2010
UK
4. Mechanics and Pneumatics
4.5. Technical Data / Standards
Material: PA6.6
Ambient temperature: -20°C bis +70°C
CE: EMC 89/336/EEC
Standards and
environmental audits: protection class IP 67 EN60529 /
complies with NEMA 6
EMV interference resistance
EN61000-6-2
EMV emitted interference
EN61000-6-4
vibration/oscillation EN60068-2-6
safety of machinery
DIN EN ISO 13849-1
air hose: 6 mm / ¼” OD
pressure range: 6-8 bar
compressed air quality: quality class according to
DIN/ISO 8573-1
-content of solid
particles: quality class 3,
max. size of solid particles per m³
10000 of 0,5µm <d<1,0µm
500 of 1,0µm <d<5,0µm
-content of water: quality class 4,
max. dew point temperature + 3°C
For installations at lower temperatures
or at higher altitudes, additional
measures must be considered to reduce
the pressure dew point accordingly.
-content of oil: quality class 1,
max. 0,01mg/m3
(The oil applied must be compatible with Polyurethane
elastomer materials.)

14
Control Unit CU4 AS-interface UK-0 / 31.05.2010
Control Unit
CU4 AS-interface
Operating Manual: UK-0
UK
4. Mechanics and Pneumatics
4.6. Solenoid valves
In the base of the control unit max. 3 solenoid valves are installed.
The 3/2-way solenoid valves are connected with the electronic
module by moulded cables and plug connectors.
control: effected by pwm-signal
handle: rotary switch at valve
4.7. Throttling function
The operating speed of the valve actuator can be varied or
reduced. This may be necessary to slacken the actuation of the
valve in order to prevent pressure hammers in the piping
installation. For this purpose, the supply and exhaust air of the
first solenoid valve can be adjusted via the throttling screws
respectively allocated in the interface of the solenoid valve.
4.8. NOT element
The closing force of the valve actuator can be increased by
additional compressed air.
Through the installation of the logic NOT element, compressed
air is guided via a pressure reducing valve on the spring side of
the valve actuator.
The NOT element is also used for air/air actuators.
throttling screws

15 Control Unit
CU4 AS-interface
Operating Manual: UK-0
Control Unit CU4 AS-interface UK-0 / 31.05.2010
UK
5. Adapter
Adapter for different process valves
5.1. Valves with turning actuator, e.g. butterfly valves
5.3. Double seat valves
5.2. Single seat valves

16
Control Unit CU4 AS-interface UK-0 / 31.05.2010
Control Unit
CU4 AS-interface
Operating Manual: UK-0
UK
6. Electronic module
6.1. Function / Block diagram
The Control Unit DELTA CU4 AS-interface is a
slave for the fieldbus system AS-Interface.
It complies with the specification V3.0. The profile is S-7.A.*.E
(3 outputs and 2 inputs).
By means of a connecting terminal, the inputs can either be
connected with internal APV Hall effect sensors or with external
inductive proximity switches (compare 6.5.).
The AS-Interface DELTA CU4 is designed for the
extended address range. With these devices in the extended
address range up to 62 slaves (formerly known as 2.1) can be
connected with one AS-Interface cable (Attention: Consider
cumulative power input and simultaneity factor!)
For reasons of compatibility with older versions, a version with
the profile S-7.F.F.F (formerly known as 2.0) is alternatively
available.
All operating ranges within the electronic module such as the
control of the solenoid valves, position feedback and LED
indication are separated galvanically and can, thus, be operated
with different voltages. Control of the solenoid valves is effected in
energy-saving manner via pwm-signals.
1
6
10
4
3
2
5
7
11
8
12
CU4
AS-interface
NTERFACE
hall
sensor
5 VDC
hall
sensor
Extended
address mode
max. 62 slaves
Sensor 1
+ AS-i-Bus
- AS-i-Bus
5 VDC
GND
CU4 AS-interface
Spec. V3.01
black
GND
Sensor 2
Normal
Reverse
Feedback
black
blue
blue
brown
white
black
red
brown
white
black
feedback bridge
red
NI5-K11K-AN5X/5
NI5-K11K-AN5X/5 2
1
3

17 Control Unit
CU4 AS-interface
Operating Manual: UK-0
Control Unit CU4 AS-interface UK-0 / 31.05.2010
UK
6. Electronic module
6.1.1. Switchover of feedback signals
The signals to the control can be switched over via the bridge
between the terminals 10, 11 and 12.
If a bridge is located between the terminals 10 and 11 (normal),
the signal is transferred from sensor 1 (closed valve position)
to input DI0 of the control. The signal of sensor 2 (open valve
position) is sent to input DI1.
In case of a bridgte between terminals 11 and 12 (reverse),
the signal of sensor 1 (closed valve position) is sent to
input DI1 of the control. At input DO0, the signal of sensor 2
(open valve position) switched.
If there is no bridge between the terminals 10, 11 and 12,
this will lead to an error message.
The two LEDs 'valve open' and 'valve closed' will flash
in this case.
6.2. Functional description of connections
Terminal Designation Functional description
1 AS-i + AS-i network connection
2 AS-i - AS-i network connection
3 5 VDC voltage supply for valve sensor
4 Sensor 1 sensor signal 1 (closed valve position)
5 GND ground for sensor supply
6 5 VDC voltage supply for valve sensor
7 Sensor 2 sensor signal 2 (open valve position)
8 GND ground for sensor supply
10 Normal normal allocation of feedback signals
11 Feedback tie point for cable bridge
12 Reverse reverse allocation of feedback signals