SPX FLOW APV CU4plus AS-i User manual

APV CU4plus AS-interface
CONTROL UNIT
FORM NO.: H333978 REVISION: UK-3 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
INSTRUCTION MANUAL

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Control Unit
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Instruction Manual UK-3
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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 10
3.1. Purpose of use
3.2. Design of CU4plus AS-interface
3.3. Function of the individual components
4. Mechanics and Pneumatics 13
4.1. Air connections for turning actuator
4.2. Air connections seat valves 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 24
5.1. Valveswithturningactuator,e.g.butteryvalve
5.2. Single seat valve
5.3. Double seat mix proof valve DE3, DA3+
5.4. Double seat mix proof valves D4, D4 SL, DA4
6. Electronic Module 25
6.1. Function/block diagram
6.2. Functional description of connections
6.3. Technical data / AS-interface
6.4. Connections
6.5. LED indications
6.6. Adjustementofvalveproles
6.7. AS-i communication / Data signals
6.8. Service and Maintenance Software CU4plus Toolbox
7. Valve Position Indication 38
7.1. Continuously measuring valve position measuring system
7.2. Tolerance band of the valve position measuring system
7.3. Adjustment of valve position indication / Teach-in
7.4. Use of external sensors
8. CU Assembly and Startup 41
8.1. Valveswithturningactuator,e.g.forbutteryvalve
8.2. Single seat valve
8.3. Double seat valve DA3+ with activated Seat Lift Detection (SLD)
8.4. Double seat mix proof valves D4, D4 SL, DA4
8.5. Replacement of CU3 versions
9. Accessories and Tools 55
10. Service 56
10.1. Dismantling
11. Trouble Shooting 57
12. Spare Parts Lists 59

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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
EMV Electromagnetic Compatibility
EU European Union
GND Ground/mass potential
IP International Protection
LED Luminous diode
N Pneumatic Air Connection NOT element
NEMA National Electrical Manufacturers Association
P Supply Air Connection
PELV Protected Extra-Low Voltage
PWM Pulse-width modulation
Y Pneumatic Air Connection
SLD Seat Lift Detection / Seat Lift Gathering
2. Safety Instructions
2.1. Sentinels
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

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2. Safety Instructions
2.2. Intended use
The CU4plus AS-i control unit is only intended for use as described
in chapter 3.1. Use beyond that described in chapter 3.1. do not
comply with the regulations and SPX FLOW shall not be
responsible for any damage resulting from this non-observance.
The operator bears the full risk. Prerequisites for 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 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 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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
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
qualiedpersonnelandbymeansofappropriatetools.
- 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 specialized 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.
Note! This warranty only applies to the Control Unit.
No liability will be accepted for consequential
damage of any kind arising from failure or
malfunction of the device.
!
!

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2. Safety Instructions
2.7. Important safety instructions for AS-interface networks
Aside from complying with the Installation Guidelines according to
AS-iSpecication,observethefollowinginstructions!
2.7.1 Earthing
- The PE connection of the AS-i power supply (protective earth) must
(if existent) be grounded.
- The symmetry point of the AS-i network (GND, ground, shield) must
be connected with the plant ground).
- Neither AS-i – nor AS-i + must be grounded.
- Use of earth-leakage relay, insulation monitoring modules is
recommended.
- Use of surge protection modules is recommended.
2.7.2. Network design and voltage supply
- UseonlyAS-icertiedpowersupplies.
- Output voltage 26.5 to 31.6 VDC
- AS-i power supplies deliver up to 8A.
- The voltage drop between power supply and bus device must not
exeed 3V. If required, the power supply must be set closer to the
slaves. Alternatively power supplies with repeaters can be extended
to such an extent that up to 3 power supplies can be distributed
overthewholebus,seeg.
- An AS-i segment including all stubs must not be longer than 100 m.
- Additional 100 m AS-i cable may be connected to each repeater,
whereas not more than 2 repeaters (max. 2 connected in series)
may be set between a slave and the master.
- A galvanically isolated AS-i power supply must be connected in
every segment.
Extension with repeater
Master
PS PS PSS
100m 100m 100m
SS
R
R

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- AS-i power cables must be separated from the energy cables and
must be as short as possible.
- External proximity switches must be connected to the slave as close
as possible.
- Floating sensors/actuators: Grounding of galvanic peripheral
devices connected with AS-i potential is not permitted. It must be
avoided in terms of immunity to interference.
2.7.3. Selection of the appropriate power supply:
The max. electricity demand in the AS-i net (sum of all consumers)
per segment must be smaller than the admissible current carrying
capacity of the AS-i network (max. 90 %).
- The electricity demand of the individual slave results from the
instruction manual. For the design of the networks a simultaneity
factor can be integrated if necessary. A max. assignment of e.g. 62
slaves should be taken as a basis.
- At the end of each segment under full load, the AS-i voltage must be
withinthespecication26.5to31.6V.
2.7.4. What has to be observed if a 8A AS-i power supply is used?
If more than the standard current of 2 A is transferred via the AS-i
cables, the following boundary conditions must be considered when
planning the net:
- The voltage drop along the AS-i line increases. For orientation
purposes: If 2 A are transferred via one 100 m-long-cable with wire
cross-section of 1.5 mm, the voltage drop amounts to 5 V.
- The contacts of the penetration technology are desiged only for
certain maximum permanent current which are partially below 8 A.
Refer to the manufacturer datasheet!
2. Safety Instructions
Extension with repeater to max. 500 m (central positioning)
Master
PS
PS
PS PS PS PS S
S
100m 100m 100m 100m 100m
SSSS
RRR
R
RRepeater Power Supply Slave

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2. Safety Instructions
2.7.5. Increase in interference resistance
- The connection „Schirm“ (shield) at the AS-i power supply unit
must be connected directly and with good RF characteristics with
the potential equalization of the machine or plant. This is not a
grounding measure for safety reasons, but a functional grounding
so that the AS-i line can be operated symmetrically against
the earth. If a shielded cable is used, the cable shield must be
connected there - and there only, as well.
- A good symmetrie must also be observed towards other electrical
sources of interference (speed-controlled actuators, welding units
etc.). The length of the connecting cables between the active slaves
(CU4, CU4plus etc.) and the proximity switches connected to them
must be limited to max. 2 m.
- When high electrostatic charge is expected (e.g. polishing
machines, injection moulding machines, wrapping foils for plastic
materials etc.) it may be required to take additional protective
measures, such as the installation of arresters for static loads.
2.7.6. May the AS-i cable be laid in parallel to power cables?
- Although the communication via AS-i cable is not sensitive to
EMC, it should be laid separately from line cables - also in control
cabinets.
- Maximum distance to potential sources of interference (e.g.
frequency converter) must be observed.
- Every AS-i wiring harness should have its own cable, i.e. AS-i
cables should not be laid together with other cables in the same
common cable.
- If it is required to lay single conductors (e.g. in control cabinets),
parallel conductors must be laid. In case of standard stranded wires,
lay and twist single coductors together.

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3. General Terms
3.1. Purpose of use
The control unit CU4plus AS-i has been developed for the control
of process valves in food processing industry as well as related
industries.
The CU4plus AS-i 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 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 for potential-free contacts. The corresponding light
signals in the control unit provide for an external indication of the
valve positions.
3.2. Design of CU4plus AS-interface (fig. 3.2.)
The CU4plus AS-interface control unit consist 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 integrated position measuring system for the
detection of the valve position.
4. Electronic module for the electric supply, for the AS-i communication
with the 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).
fig. 3.2.
3.
1.
5.
2.
4.
6.
cable guide
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. 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lter.Observanceoftherequiredcompressedair
quality is imperative. Please also see chapter 4.5 Technical Data.
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 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fulls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. Commnication is undertaken via the standard AS-interface
busprotocolaccordingtospecicationV3.0.
Valve position detection is realized via a linear sensor which is
integrated in the sensor module.
Control is effected via the solenoid switch cam mounted to the valve
actuator rod. The measuring range of the linear sensor detects
the complete valve stroke. By means of the teach-in function,
the corresponding position for closed and open valve position
are detected and seat lift positions are permanently saved in the
electronic module if required. (see chapter 7.3 Teach-in function)
For DA3+ double seat valves with active seat lift detection (SLD)
additionally to the linear sensor integrated in the CU, two external
proximity switches installed at the valve actuator are required.
The corresponding signals of the linear sensor as well as external
proximity switches are evaluated in an internal logic circuit and,
thus, the corresponding valve position indications are generated.
(see chapter 6.7. Data signals, AS-i communication)
For the D4 valve generation, additionally to the linear sensor
integrated in the control unit, 1 or 2 internal hall sensors are
installed at the CU4 feedback tower.

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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 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 provides 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.
Note! Wiring must be changed!

Y1
A1
P
AIR IN
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4. Mechanics and Pneumatics
4.1. Air connections for turning actuator
4.1.1. Function
CU41plus-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 seat valves and double seat mix proof valves
4.2.1. Function
CU41plus-S AS-i
design for seat valves
P  airsupplywithintegratedparticlelter
Y1 pneumatic air connection for main actuator
A1 exhaust air with silencer
CU41Nplus-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 silencer
CU41plus-M AS-i
design for DE3 double seat valves without seat lift function
P airsupplywithintegratedparticlelter
Y1 pneumatic air connection for main actuator
A1 exhaust air with silencer
CU43plus-M AS-i
design for DA3+ double seat valves with seat lift function
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 lifting
Y3 pneumatic air connection for seat lift actuator of lower seat lifting
A1/A2 exhaust air with silencer
A1
A1
A2
Y1
Y1
Y2 (N) Y3
P
AIR IN
P
AIR IN

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4. Mechanics and Pneumatics
4.2.1. Function
CU41plus-D4-V1
design for D4 double seat mix proof valves
without seat lift function
P airsupplywithintegratedparticlelter
Y1 control air connection for main actuator
A1 exhaust air, with exhaust silencer
CU43plus-D4-V1
design for D4 SL, DA4 double seat mixproof valves
with seat lift function
P airsupplywithintegratedparticlelter
Y1 control 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
A1
A2
Y1
Y2
Y3
P
AIR IN

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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 valve 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

R
1
2
3
4
5
6
7
8
9
10
11
12
Linear
Sensor
AS-i Bus +
AS-i Bus -
Z+
Z-
PELVE+
PELVE-
5 VDC
Sensor 3
GND
5 VDC
Sensor 4
GND
AS-i Bus +
AS-i Bus -
LED 9
LED 8
LED 7
LED 1
LED 3/4
LED 5
LED 6
LED 2
Y1
Y2
Y3
P
Cu4plus AS-interface/ Spec. V3.0
Teach
Service
Port
linear sensor
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4. Mechanics and Pneumatics
4.4. Functional description - block diagrams
4.4.1. CU41plus AS-interface
(internal position measuring system)
Valve types: SW4, MS4, SV1, SVS1F
The illustration shows a valve in standard design NC (normally closed). The valve in the design NO (normally open) can also be used. The respective valve limit position is detected via the teach function and saved in the control unit.
solenoid valve
throttle valves
P / air supply
A / exhaust

R
1
2
3
4
5
6
7
8
9
10
11
12
Linear
Sensor
AS-i Bus +
AS-i Bus -
Z+
Z-
PELVE+
PELVE-
5 VDC
Sensor 3
GND
5 VDC
Sensor 4
GND
AS-i Bus +
AS-i Bus -
LED 9
LED 8
LED 7
LED 1
LED 3/4
LED 5
LED 6
LED 2
Y1
Y2
Y3
P
Cu4plus AS-interface/ Spec. V3.0
Teach
Service
Port
self-lock
connector
linear sensor
pressure
reducing valve
(locked to 5 bar)
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4. Mechanics and Pneumatics
4.4. Functional description - block diagrams
4.4.2. CU41Nplus AS-interface
(internal position measuring system)
Valve type: SD4
solenoid valve
throttle valves
P / air supply
A / exhaust
NOT element
The illustration shows a valve in standard design NC (normally closed). The valve in the design NO (normally open) can also be used. The respective valve limit position is detected via the teach function and saved in the control unit.

AS-i Bus +
AS-i Bus -
R
1
2
3
4
5
6
7
8
9
10
11
12
Linear
Sensor
AS-i Bus +
AS-i Bus -
Z +
Z -
PELV E +
PELV E-
5 VDC
Sensor 3
GND
5 VDC
Sensor 4
GND
LED 9
LED 8
LED 7
LED 1
LED 3/4
LED 5
LED 6
LED 2
Y1
Y2
Y3
P
Cu4plus AS-interface/ Spec. V3.0
Teach
Service
Port
linear sensor (Y)
linear sensor (Y)
sensor 2 (TeachSignal)
sensor 1 (TeachSignal)
sol. valve 3
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4. Mechanics and Pneumatics
4.4. Functional description - block diagrams
4.4.3. CU43plus AS-interface for DA3+SLD double seat valve
(internal position measuring system
and 2 external proximity switches)
sensor 3
sensor 4
A / exhaust
A / exhaust
P / air supply
sol. valve 1
seat lift cylinder
lower valve seat
main cylinder and
integrated seat lift cylinder
upper valve seat
Y3
Y2
sensor 3
sensor 4
view X
Y3
Y2
Y1
Y1
X
sol. valve 2

AS-i Bus +
AS-i Bus -
R
1
2
3
4
5
6
7
8
9
10
11
12
Linear
Sensor
AS-i Bus +
AS-i Bus -
Z +
Z -
PELV E +
PELV E-
5 VDC
Sensor 3
GND
5 VDC
Sensor 4
GND
LED 9
LED 8
LED 7
LED 1
LED 3/4
LED 5
LED 6
LED 2
Y1
Y2
Y3
P
Cu4plus AS-interface/ Spec. V3.0
Teach
Service
Port
hall 2
(in sensor
tower, right)
(connected on
sensor 4
e-module)
linear
sensor
A / exhaust air
P / air supply
solenoid valve
throttle valves
4. Mechanics and Pneumatics
4.4. Functional description - block diagrams
4.4.4. CU41plus-D4-V1 for D4 double seat mix proof valves
M1 - magnet lower shaft
M2 - magnet upper shaft
M1
M2
sensor 3
not used
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AS-i Bus +
AS-i Bus -
R
1
2
3
4
5
6
7
8
9
10
11
12
Linear
Sensor
AS-i Bus +
AS-i Bus -
Z +
Z -
PELV E +
PELV E-
5 VDC
Sensor 3
GND
5 VDC
Sensor 4
GND
LED 9
LED 8
LED 7
LED 1
LED 3/4
LED 5
LED 6
LED 2
Y1
Y2
Y3
P
Cu4plus AS-interface/ Spec. V3.0
Teach
Service
Port
exhaust air
exhaust air
IN
air
sol. 1
sol. 2
sol. 3
main cylinder and integrated seat lift cylinder upper valve seat
seat lift cylinder lower valve seat
4. Mechanics and Pneumatics
4.4. Functional description - block diagrams
4.4.5. CU43plus-D4-V1 for D4 SL / PMO double seat mix proof
valves
M1
M2
M1 - magnet lower shaft
M2 - magnet upper shaft
linear
sensor
hall 1
(in sensor
tower, left)
(connected on
sensor 3
e-module)
hall 2
(in sensor
tower, right)
(connected on
sensor 4
e-module)
Operating directions of valve targets
main stroke down M1 + M2
upper seat lift up M2
lower seat lift down M1
APV_CU4plus_AS-interface_UK-3_062019.indd
UK
Control Unit
CU4plus AS-interface
Instruction Manual UK-3
APV
20