SPX FLOW APV CU41-S User manual

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

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Instruction manual: UK - rev. 5
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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!

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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
DANGER
!

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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.

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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.
!
!

5.
1.
6.
4.
3.
2.
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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
3.
2.

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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.

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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.

Y1
A1
P
AIR IN
A1 A2
Y1 Y2(N) Y3
P
AIR IN
S3
S2
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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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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

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1
2
3
4
5
6
7
8
10
11
12
AS-i-Bus +
AS-i-Bus -
5 VDC
Sensor 1
GND
5 VDC
Sensor 2
GND
Normal
Feedback
Reverse
4. MechanicsandPneumatics
4.4 Functionaldescription-blockdiagrams
4.4.1 CU41AS-interface
Sensor 1
(“Valveclosed”)
Sensor 2
(“Valveopen”)
Solenoid valve
Throttle valves
P / Air supply
A / Exhaust
The picture shows a standard NC (spring to
closed)valve.
IfNO(springtoopen)valveisused,thesensor
wiring can be different.

1
2
3
4
5
6
7
8
10
11
12
5 VDC
Sensor 1
GND
5 VDC
Sensor 2
GND
Normal
Feedback
Reverse
AS-i-Bus +
AS-i-Bus -
Self-lock
connector
Pressure
reducing valve
(lockedto5bar)
4. MechanicsandPneumatics
4.4.2 CU41N–AS-interface
Functionaldescription-blockdiagram
The picture shows a standard NC (spring to
closed)valve.
IfNO(springtoopen)valveisused,thesensor
wiring can be different.
Sensor 1
(“Valveclosed”)
Sensor 2
(“Valveopen”)
Solenoid valve
Throttle valves
P / Air supply
A / Exhaust
NOT element
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The picture shows a standard NC
(springtoclosed)valve.
1
Sensor 2
“Valve open”
Sensor 3
“Valve closed”
2
3
4
5
A / Exhaust air
P / Air supply
Solenoid valve
Throttle valves
6
10
11
12
7
8
4. MechanicsandPneumatics
4.4.3. CU41-D4AS-interfaceforD4doubleseatmixproofvalve
Functionaldescription-blockdiagram
M1 - magnet upper shaft
M2 - magnet lower shaft
M1
M2
5 VDC
Sensor 1
GND
5 VDC
Sensor 2
GND
Normal
Reverse
Feedback
AS-i-Bus +
AS-i-Bus -
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4. MechanicsandPneumatics
4.4.4 CU43AS-interfaceforDE3,DA3+doubleseatmixproofvalves
Functionaldescription-blockdiagram
Sensor 1
(“Valveclosed”)
Sensor 2
(“Valveopen”)
A/ Exhaust
A/ Exhaust
IN
Air
seat lift cylinder lower valve seat
main cylinder and integrated seat lift cylinder upper valve seat
The picture shows a standard NC
(springtoclosed)valve.
1
2
3
4
5
6
7
8
10
11
12
AS-i-Bus +
AS-i-Bus -
5 VDC
Sensor 1
GND
5 VDC
Sensor 2
GND
Normal
Feedback
Reverse
sol. 1
sol. 2
sol. 3
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The picture shows a standard NC
(springtoclosed)valve.
Exhaust air
Exhaust air
IN
air
Sensor 2
“Valve open”
Sensor 3
“Valve closed”
1
2
3
4
5
6
10
11
12
sol. 1
sol. 2
sol. 3
7
8
4. MechanicsandPneumatics
4.4.5. CU43-D4AS-interfacefürDA4/D4SLdoubleseatmixproof
valves
Functionaldescription-blockdiagram
M1
M2
M1 - magnet upper shaft
M2 - magnet lower shaft
5 VDC
Sensor 1
GND
5 VDC
Sensor 2
GND
Normal
Reverse
Feedback
AS-i-Bus +
AS-i-Bus -
seat lift cylinder lower valve seat
main cylinder and integrated seat lift cylinder upper valve seat
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4. MechanicsandPneumatics
4.5. TechnicalData/Standards
Material: PA6.6
Ambienttemperature: -20°C to +70°C
EU:  EMC2014/30/EU(89/336/EEC)
Standards and
environmentalaudits: Protection class IP 67 EN60529/
complies with NEMA 6
EMC interference resistance
EN61000-6-2
EMC emitted interference
EN61000-6-4
Vibration/oscillation EN60068-2-6
Safety of machinery
DIN EN ISO 13849-1
Airconnection: 6 mm / ¼" OD
Pressurerange: 6–8 bar
Compressedairquality: Quality class acc. to
DIN ISO 8573-1
- Contentofsolidparticles: Quality class 3,
max. size of solid particles per m³
    10000of0,5μm<d<1,0μm
    500of1,0μm<d<5,0μm
- Contentofwater: quality class 3,
max. dew point temperature -20 °C
For installations at lower
temperatures or at hight altitude,
additional measures must be
considered to adopt the pressure
dew point accordingly.
- Contentofoil: quality class 1,
max. 0,01 mg/m³
TheoilappliedmustbecompatiblewithPolyurethane
elastomer materials.

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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
Lever: 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 rstsolenoidvalve can
be adjusted via the throttling screws respectively allocated in the
interface of the solenoid valve.
By turning the screws in anticlockwise direction, the inlet or outlet air
is throttled
4.8. NOTelement
Through the installation of the logic NOT element, the closing force
of the valve actuator can be increased by additional compressed air.
The NOT element conveys the compressed air via an external
reducingvalve(max.5bar)tothespringsideofthevalveactuator.
Thepressurereducingvalveisxedto5bar.
Note:
The air connection of the NOT element is equipped with an
integrated non-return valve.
The air hose must be slided into the air connection until it stops in
order to open the non-return valve.
The NOT element is also used for air/air actuators.
throttling screws

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5. Adapter
Adapter for different process valves
5.1. Valveswithturningactuator,e.g.butterfly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

1
red
red
brown
+ AS-i-Bus
- AS-i-Bus
5 VDC
5 VDC
Sensor 1
Sensor 2
GND
GND
Normal
Feedback
Reverse
brown
white
white
black
black
black
blue
blue black
6
10
4
3
2
5
7
11
8
12
CU4
AS-interface
CU4 AS-interface
Spec. V3.01
Extended
adress mode
max. 62 slaves
NTERFACE
1
3
2
NI5-K11K-AN5X/5
NI5-K11K-AN5X/5
hall
sensor
hall
sensor
1
red
red
+ AS-i-Bus
- AS-i-Bus
5 VDC
5 VDC
Sensor 1
Sensor 2
GND
GND
Normal
Feedback
Reverse
white
white
black
black
6
10
4
3
2
5
7
11
8
12
CU4
AS-interface
CU4 AS-interface
Spec. V3.01
Extended
adress mode
max. 62 slaves
NTERFACE
1
3
2
hall
sensor
hall
sensor
S3
S2
Electronic module
with sensors for all
SPX FLOW APV valves
Electronic module
with sensors for
SPX FLOW APV / WCB D4 valves
APV_CU4 AS-i_UK-5_072018.indd
UK
Control Unit
CU4 AS-interface
Instruction manual: UK - rev. 5
APV
20
6. Electronic module
6.1. Function/Blockdiagram
TheControlUnitCU4AS-interfaceisaslavefortheeldbussystem
AS-interface.
ItcomplieswiththespecicationV3.0.Theprole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 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
prole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.
feedback bridge