SPX APV CU4 User manual

Instruction Manual
Read and understand this manual prior
to operating or servicing this product.
CU4 Direct Connect
Control Unit
Form No.: H323871
Revision: UK-3 Translation of original manual

1
Control Unit CU4 Direct Connect U -3 / 20.04.2011
Control Unit
CU4 Direct Connect
Instruction Manual: U -3
UK
APV
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
3. General Terms 5 - 7
3.1. Purpose of use
3.2 Design of CU4 Direct Connect
3.3 Functional description
4. Mechanics and Pneumatics 8 - 14
4.1 Connections
4.2 Function
4.3 Pressure relief valve
4.4. CU41 Direct Connect block diagram
4.4.1 CU41 Direct Connect block diagram
4.4.2 CU43 Direct Connect 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
6.2 Function connections
6.3 Technical data
6.4 Sensors for valve position indication
6.5 LED indicators
6.6 Wiring examples
7. Feedback unite 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 ESSE TIAL TO READ THIS OPERATI G MA UAL
BEFORE USE OF THE CO TROL U IT!

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Control Unit CU4 Direct Connect U -3 / 20.04.2011
Control Unit
CU4 Direct Connect
Instruction Manual: U -3
UK
APV
A Exhaust Air
AWG American Wire Gauge
CE Communauté Européenne
CU Control Unit
DI Digital Input
DO Digital Output
EMC Electromagnetic Compatibility
IP International Protection
LED luminous diode
Pneumatic Air Connection OT element
EMA ational 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 Direct Connect
Instruction Manual: U -3
Control Unit CU4 Direct Connect U -3 / 20.04.2011
UK
APV
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

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Control Unit CU4 Direct Connect U -3 / 20.04.2011
Control Unit
CU4 Direct Connect
Instruction Manual: U -3
UK
APV
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. Safety Instructions

5Control Unit
CU4 Dir ct Conn ct
Instruction Manual: UK-3
Control Unit CU4 Dir ct Conn ct UK-3 / 20.04.2011
UK
APV
3. General Terms
3.1. Purpose of use
Th Control Unit D lta CU4 Dir ct Conn ct has b n
d v lop d for th control of proc ss valv s us d in th food
industry and r lat d industri s.
Th CU4 control unit op rat s as int rfac b tw n
proc ss control and proc ss valv and controls th l ctric and
pn umatic signals.
Th pn umatic control of APV valv s is und rtak n via th
sol noid valv s. Th control unit controls th valv positions,
open and closed, via int grat d and xt rnal s nsors. Th
l ctronic modul und rtak s th task to proc ss th switching
signal from th control and to control th corr sponding
sol noid valv s. Th l ctronic modul also provid s
pot ntial-fr contacts.
Th corr sponding light signals in th control unit provid for an
xt rnal indiciation of th valv positions.
3.2. Design of CU4 Direc Connec (fig. 3.2.)
Th Control Units CU4 Dir ct Conn ct mainly consists
of th following compon nts:
1. Th Control Unit bas with int grat d air chann ls and l ctric
and pn umatic conn ctions as w ll as vi wing windows with
typ lab l.
2. 1 or 3 sol noid valv s for th control of th valv actuators and
for th s at lifting of doubl s at valv s.
- 1 sol noid valv with 1 logic NOT l m nt for th control of th
valv actuators.
3. S nsor modul with 2 int grat d Hall s nsors or 2 xt rnal
proximity switch s to d t ct th valv position.
4. l ctronic modul for th l ctric supply, communication with
control, valuation of f dback signals and control of sol noid
valv s as w ll as valv position indication through LED.
5. clamp ring to fast n th CU4 on th adapt r.
6. cov r with LED optics.
Th cabl /s by m ans of which th sol noid valv s ar conn ct d
with th l ctronic modul must b guid d through th ar at th
r ar sid of th l ctronic modul (fig. 3.2.1).
1.
5.
2.
3.
4.
6.
fig. 3.2.
2.
3.
ear
fig. 3.2.1

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Control Unit CU4 Direct Connect U -3 / 20.04.2011
Control Unit
CU4 Direct Connect
Instruction Manual: U -3
UK
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. 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 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 fulfils 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. The CU4 Direct Connect module described
here provides for the direct parallel wiring of the control.
A feedback unit is required to detect the valve position.
The CU4 Direct Connect 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 Direct Connect
Instruction Manual: U -3
Control Unit CU4 Direct Connect U -3 / 20.04.2011
UK
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 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 6.4. 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.)

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Control Unit CU4 Direct Connect U -3 / 20.04.2011
Control Unit
CU4 Direct Connect
Instruction Manual: U -3
APV
4. Mechanics and Pneumatics
4.1. connections
4.2.1. Function
CU41-S-DC / CU41-M-DC
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.
CU41 -S-DC
design for seat valves with OT element.
Pair supply with integrated particle filter.
Y1 pneumatic air connection for main actuator.
pneumatic air connection for the spring support of the actuator
by compressed air, via NOT element.
A1 exhaust air, with exhaust silencer.
CU43-M-DC
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. Funktion
CU41-T-DC
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 I
Y1 Y2 ( ) Y3
Y1
A1
P
AIR I

9Control Unit
CU4 Direct Connect
Instruction Manual: U -3
Control Unit CU4 Direct Connect U -3 / 20.04.2011
UK
APV
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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Control Unit CU4 Direct Connect U -3 / 20.04.2011
Control Unit
CU4 Direct Connect
Instruction Manual: U -3
UK
APV
4. Mechanics and Pneumatics
4.4. CU41 Direct Connect
Functional description - block diagram
1
Power
Power
DO Valve closed
DO Valve open
DO Common
DI Main Valve
Not used
Not used
DI Common
5V DC
Sensor 1
Gnd
5V DC
Sensor 2
Sensor 1
(“Valve open”)
Sensor 2
(“Valve closed”)
Gnd
Solenoid valve
Throttle valves
P / Air supply
A / Exhaust
2
3
4
5
6
9
10
11
12
13
14
15
7
8
Picture shows a standard NC
(spring to closed) valve.
If NO (spring to open) valve is used,
the sensor wiring can be different.

11 Control Unit
CU4 Direct Connect
Instruction Manual: U -3
Control Unit CU4 Direct Connect U -3 / 20.04.2011
UK
APV
4. Mechanics and Pneumatics
4.4.1. CU41 Direct Connect
Functional description - block diagram
1
Power
Power
DO Valve closed
DO Valve open
DO Common
DI Main Valve
Not used
Not used
DI Common
5V DC
Sensor 1
Gnd
5V DC
Sensor 2
Sensor 1
(“Valve open”)
Sensor 2
(“Valve closed”)
Gnd
Solenoid valve
Throttle valves
P / Air supply
A / Exhaust
2
3
4
5
6
9
10
11
12
13
14
15
7
8
NOT-Element
Picture shows a standard NC
(spring to closed) valve.
If NO (spring to open) valve is used,
the sensor wiring can be different.

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Control Unit CU4 Direct Connect U -3 / 20.04.2011
Control Unit
CU4 Direct Connect
Instruction Manual: U -3
UK
APV
4. Mechanics and Pneumatics
4.4.2. CU43 Direct Connect for double seat valve DA3
Functional description - block diagram
Sensor 1
(“Valve open”)
Sensor 2
(“Valve closed”)
EMV 1
EMV 2
EMV 3
Abluft /
Exhaust
Abluft /
Exhaust
IN
Luft / air
1
Power
Power
DO Valve closed
DO Valve open
DO Common
DI Main Valve
DI upper Seat lift
seat lift cylinder lower valve seat
main cylinder and integrated seat lift cylinder upper valve seat
DI lower Seat lift
DI Common
5V DC
Sensor 1
Gnd
5V DC
Sensor 2
Gnd
2
3
4
5
6
9
10
11
12
13
14
15
7
8
Picture shows a standard NC
(spring to closed) valve.
If NO (spring to open) valve is used,
the sensor wiring can be different.

13 Control Unit
CU4 Direct Connect
Instruction Manual: U -3
Control Unit CU4 Direct Connect U -3 / 20.04.2011
UK
APV
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.)

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Control Unit CU4 Direct Connect U -3 / 20.04.2011
Control Unit
CU4 Direct Connect
Instruction Manual: U -3
UK
APV
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.
By turning the screws in anticlockwise direction, the inlet or
outlet air is throttled.
4.8. OT 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 Direct Connect
Instruction Manual: U -3
Control Unit CU4 Direct Connect U -3 / 20.04.2011
UK
APV
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

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Control Unit CU4 Direct Connect U -3 / 20.04.2011
Control Unit
CU4 Direct Connect
Instruction Manual: U -3
UK
APV
6. Electronic module
6.1. Function / Block diagram
The electronic module CU4 Direct Connect operates as
interface between superordinated control (PLC) and is connected
direct by parallel wiring, i.e. every individual signal is on a
separate line. The large input voltage range from 15 to 48VDC
provides for versatile connections. 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.
CU43
Direct Connect
DO Valve Closed
Power
DO Valve Open
DO Common
DI Main Valve
DI Lower Seat Lift
DI Common
5 VDC
hall
sensor
hall
sensor
NI5- 11 -AN5X/5
NI5- 11 -AN5X/5 Sensor 1
5 VDC
GND
GND
Sensor 2
DI Upper Seat Lift
Power
black
black
blue
blue
brown
white
black
red
brown
white
black
red
1
2
3

17 Control Unit
CU4 Direct Connect
Instruction Manual: U -3
Control Unit CU4 Direct Connect U -3 / 20.04.2011
UK
APV
6. Electronic module
6.2. Functional description of connections
Terminal Designation Functional description
1 Power Operating voltage
2 Power Operating voltage
3 DO Closed Valve Digital potential-free output for closed valve position
4 DO Open Valve Digital potential-free output for open valve position
5 DO Common Common potential for digital output to valve position indication
6 DI Main Valve Digital input to control 1st solenoid valve (valve open)
7 DI Upper Seat Lift Digital input to control 2nd solenoid valve
(seat lifting of upper valve seat)
8 DI Lower Seat Lift Digital input to control 3rd solenoid valve
(seat lifting of lower valve seat)
9 DI Common Common potential for digital inputs to control valve
10 5 VDC Voltage supply for valve sensor
11 Sensor 1 Sensor signal 1 (closed valve position)
12 GND Mass potential for sensor supply
13 5 VDC Voltage supply for valve sensor
14 Sensor 2 Sensor signal 2 (open valve position)
15 GND Mass potential for sensor supply