APV CU4 Operating Manual

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Page 1

Operating Manual

CU4 AS-interface

Control Unit

Read and understand this manual prior to operating or servicing this product.

NTERFACE

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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!

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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

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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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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

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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.

fig. 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 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.

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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 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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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.

P air 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.

P air supply with integrated particle filter. Y1 pneumatic air connection for main actuator. N pneumatic 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.

P air 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.

P air 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

AIR IN

Y2 (N)

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 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

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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

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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

Sensor 1

(“Valve closed”)

Sensor 2

(“Valve open”)

Solenoid valve

Throttle valves

P / Air supply A / Exhaust

NOT-Element

5 VDC

Sensor 1

GND

5 VDC

Sensor 2

GND

Normal

Feedback

Reverse

AS-i-Bus +

AS-i-Bus -

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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

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

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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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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

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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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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.

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

brown

white

black

red

brown

white

black

feedback bridge

red

NI5-K11K-AN5X/5

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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

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6.3. Use of data bits

Communication data The use of the data bits shall be drawn from the following table:

6. Electronic module

Data bit Info Connection Level

DO0 0 main valve Low (no electr. current)

(Output) 1 High (current)

DO1 0 lower seat lifting (option ) Low (no electr. current)

(Output) 1 High (current)

DO2 0 upper seat lifting (option Low (no electr. current)

(Output) 1 High (current)

DO3 free

(Output)

Feedback bridge

Data bit normal reverse

DI0

valve position, Sensor 1 (closed valve position)

valve position, Sensor 2 (open valve position)

(Input)

DI1

valve position, Sensor 2 (open valve position)

valve position, Sensor 1 (closed valve position)

(Input)

DI2 Permanent "1" Permanent "1"

(Input)

DI3 Permanent "1" Permanent "1"

(Input)

(10 11 12)

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6. Electronic module

6.4. Technical Data

AS-Interface profile: S-7.A.*.E

(S-7.F.F.F as option)

Extended address range: is supported Serial communication mode: no Inverse-polarity protection: exists Indication "Power": LED3 (green) Indication "Fault": LED3 (red) AS-Interface Voltage range: 26,5...31,6 V Max. power input: <= 150 mA Input delay time: < 1 s AS-Interface specification: V3.0

Supply of solenoid valves: pwm-signals from

electronic module

Short-circuit protection: yes Excess voltage protection: 100mA Induction protection: yes Status indication of outputs: LED on board Response time of watchdog: --- (watchdog not activated)

Short-circuit or excess voltage of actuator supply or cable break at valves is signalled to the master via the peripheral failure bit (profile Profil S-7.A.*.Eonly). Simultaneously LED3 flashes according to AS-Interface specification alternately red/green.

Supply of sensors: 5 VDC (+/-5%)

Note: The sensor inputs and the

peripheral supply must not be connected with installationGND.

Connecting terminals: conductor cross section

0,5-1,5 mm² (with conductor sleeve) complying with AWG 20-16

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6. Electronic module

6.5. Connections

Sensors to detect the valve positions:

Internal sensors: Hall effect sensors,

APV type H 320385 UB 4,75-5,25 VDC operating distance according to APV specification

External sensors: Inductive proximity switches,

APV type H 208844 UB 4,75-5,25 VDC operating distance according to APV specification

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Valve Open

Valve Closed

Power Diagnose

Solenoid ○ upper seat ○○ lower seat

Solenoid Main

External luminous displays

Valve Open

colour: green, permanent light

valve in open position

Valve Closed

colour: orange, permanent light

valve in closed position

Valve Open colour: green, flashing

Bridge missing at terminals 10, 11, 12

Valve Closed colour: orange, flashing

Power Diagnose

colour: green, permanent light

operating voltage at module - faultless

colour: red /green

AS-i status + peripheral failure, e.g. shortcircuit, excess voltage, cable break (profile S-7.A.*.E only)

Soleniod Main

colour: blue, permanent light

1st solenoid valve (1) controlled

Soleniod Main ○ upper seat ○○ lower seat

colour: blue, 1 blink 2nd solenoid valve (2) controlled

colour: blue, 2 blink 3rd solenoid valve (3) controlled

colour: blue, 1 blink

solenoid valve 2nd and 3rd (2) + (3) controlled

Internal luminous displays

Luminous

diode

1st solenoid valve (1) controlled

Luminous

diode

2nd solenoid valve (2) controlled

Luminous

diode

3rd solenoid valve (3) controlled

6.6. LED indicators

6. Electronic module

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7. Feedback unit

7.1. General terms

For the internal registration of the valve position indication, the feedback unit with 2 Hall effect sensors is applied. It is used when single seat and butterfly valves are installed. The control of these sensors is effected by magnets assembled on the valve shaft rod. The Hall effect sensors are installed on a movable threaded rod. By means of this assembly, the sensors can be adjusted via a large range, in accordance with the valve stroke.

7.2. Sensors

Hall effect sensors, APV type H 320385 UB 4,75-5,25 VDC operating distance according to APV specification

7.3. Adjustment of valve position feedback

By turning of the adjustment screws on which the Hall effect sensors are installed, the sensors can be moved into the respectively required position to detect the valve position. The o-rings on the adjusting srews prevent unintended ccidental displacement of these positions. After the installation of the control unit, check the correct adjustment of the position of the Hall sensor.

7.4. Use of external sensors

Instead of the internal Hall effect sensors, also 2 external proximity switches can be connected to the CU4 DC, e.g. for the valve position indication at double seat valves.

Proximity switch APV Type H208844 UB 4,75-5,25 VDC Operating distance according to APV specification

Hall effect sensor

adjustment screws

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8.1. Turning actuator, e.g. for butterfly valves

Caution!

The permanent magnet is made of fragile material and must be protected against mechanical load . – Risk of fracture! The magnetic fields can damage or delete data carrier or influence electronic and mechanic components.

Assembly of the Control Unit on the valve

1. Assembly of the adapter on the turning actuator.

Fasten with 3 screws. See to the right positioning of the o-rings on the lower side of the adapter and in the groove of the air transfer stud.

2. Install operating cam with shaft rod prolongation. Secure with Loctite semi-solid and fasten it.

3. Place the control unit via the operating cam onto the adapter. Observe alignment.

4. Attach the clamp rings and fasten them with the screws.

8. CU Assembly and Start-up

operating cam with permanent magnet

CU cover

CU base with electronic module, sensor tower and solenoid valves

clamp ring

fastening screws

adapter

turning actuator

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8.1.1. Pneumatic connection

Supply air: CAUTION

Shut off the compressed air supply before connecting the air hose!

See that the air hose is professionally cut to length. Use a hose cutter for this purpose.

Pneumatic air for valve actuator:

For the assembly of the control unit on the turning actuator with integrated air transfer, air hosing between the control unit and the actuator is not necessary.

Exhaust air:

As a standard, the exhaust air connection is equipped with a silencer. If required, the silencer can be removed and the exhaust air can be hosed separately when it must be led off to the exterior, for example.

8.1.2. Electric connection

CAUTION

Electric connections shall only be carried out by qualified personnel.

See to a professional execution and installation of the AS-interface network. Observe the Safety Instructions specified in chapter 2.

8. CU Assembly and Start-up

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lever

solenoid valve

8.1.3. Start-up

After proper assembly and installation of the control unit, start-up can be undertaken as described below:

1. Switch on the air supply.

2. Switch on the voltage supply.

3. Check the solenoid valves by turning the handle on the

upper side of the valve by 90°.

4. Check the valve position indicator and adjust feedbacks for

open and closed valve position as described below.

For valves in normally closed (air-to-raise, spring-to-lower) /normally open (air-to-lower, spring-to-raise) design with turning actuator, the following allocation applies:

Closed valve position feedback – sensor 1 controlled

For the adjustment, Hall sensor 1 with non-controlled (controlled) solenoid valve 1 is moved into the required position by turning the adjustment screw 1

. The LED Valve Closed lights up.

Open valve position feedback – sensor 2 controlled

For the adjustment of Hall sensor 2, at first, the (non-controlled) solenoid valve 1 is controlled. This can optionally be made manually or electrically. The open valve position and the corresponding feedback can be adjusted. This is undertaken by turning the adjustment screw 2 until the required position is reached and the LED Valve Ope

n lights up.

Observe the switching hysteresis of the Hall effect sensors! Therefore, adjust the switch-point of the sensors with overlap in order to permit small variations and, thus, to prevent failures!

8. CU Assembly and Start-up

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8. CU Assembly and Start-up

8.2. Single seat valves

CAUTION

Assembly of the Control Unit on the valve

1. Assembly of the adapter on the single seat valve.

Fasten with 4 screws.

2. Secure operating cam with Loctite semi-solid and fasten it.

3. Place the control unit via the operating cam onto the adapter.

Observe alignment.

4. Attach the clamp rings and fasten them with the screws.

CU cover

clamp ring

fastening screws

adapter

actuator

CU base with electronic module, sensor tower and solenoid valves

operating cam with permanent magnet

Page 30

Control Unit

CU4 AS-interface

Operating Manual: UK-0

Control Unit CU4 AS-interface UK-0 / 31.05.2010

8.2.1. Pneumatic connection

Supply air: CAUTION

Shut off the compressed air supply before connecting the air hose!

See that the air hose is professionally cut to length. Use a hose cutter for this purpose.

Pneumatic air for valve actuator:

Connect the pneumatic air connection Y1 with the valve actuator.

- For the CU41N (with logic NOT element), the pneumatic air connection N must be connected with the spring side of the actuator. See to the spring side of the actuator during the assembly of the pressure-reducing valve.

Exhaust air:

8.2.2. Electric connection

CAUTION

Electric connections shall only be carried out by qualified personnel.

See to a professional execution and installation of the AS-interface network. Observe the Safety Instructions specified in chapter 2.

8. CU Assembly and Start-up

Page 31

Control Unit CU4 AS-interface UK-0 / 31.05.2010

Control Unit CU4 AS-interface Operating Manual: UK-0

lever

solenoid valve

8.2.3. Start-up

After proper assembly and installation of the control unit, start-up can be undertaken as described below:

1. Switch on the air supply.

2. Switch on the voltage supply.

3. Check the solenoid valves by turning the handle on the upper side

of the valve by 90°.

4. Check the valve position indicator and adjust feedbacks for

open and closed valve position as described below.

For single seat valves in normally closed (normally open) the following allocation applies:

Closed valve position feedback – sensor 1 controlled

For the adjustment, Hall sensor 1 with non-controlled (controlled) solenoid valve 1 is moved into the required position by turning the adjustment screw 1. The LED Valve Closed

lights up.

Open valve position feedback – sensor 2 controlled

For the adjustment of Hall sensor 2, at first, the (non-controlled) solenoid valve 1 is controlled

. This can optionally be made manually or electrically. The open valve position and the corresponding feedback can be adjusted. This is undertaken by turning the adjustment screw 2 until the required position is reached and the LED Valve Open

lights up.

Observe the switching hysteresis of the Hall effect sensors! Therefore, adjust the switch-point of the sensors with overlap in order to permit small variations and, thus, to prevent failures!

8. CU Assembly and Start-up

Page 32

Control Unit

CU4 AS-interface

Operating Manual: UK-0

Control Unit CU4 AS-interface UK-0 / 31.05.2010

8.3. Double seat valves

Assembly of the Control Unit on the valve

1. Assembly of the adapter on the double seat valve.

Fasten with 4 screws.

2. Align air connections of the control unit to the valve actuator.

3. Place the control unit onto the adapter.

Observe alignment!

4. Attach the clamp rings and fasten them with the screws.

5. Assemble the external proximity switches at the actuator.

8. CU Assembly and Start-up

external

proximity switches

feedback 1 for

closed

valve position

feedback 2 for

open

valve position

CU cover

CU41/CU43

clamp ring

fastening screws

adapter

air actuator

seat lift cylinder

spring cylinder

Page 33

Control Unit CU4 AS-interface UK-0 / 31.05.2010

Control Unit CU4 AS-interface Operating Manual: UK-0

8. CU Assembly and Start-up

8.3.1. Pneumatic connection

Supply air:

CAUTION

Shut off the compressed air supply before connecting the air hose!

See that the air hose is professionally cut to length. Use a hose cutter for this purpose.

Pneumatic air to valve actuator:

Connect pneumatic air connection Y1 with the valve actuator. Main actuator

Connect pneumatic air connection Y2 with the valve actuator. (seat lifting - upper valve seat)

Connect pneumatic air connection Y3 with the valve actuator. (seat lifting – lower valve seat)

Exhaust air:

As a standard, the exhaust air connections A1 and A2 are equipped with a silencer. If required, the silencer can be removed and the exhaust air can be hosed separately when it must be led off to the exterior, for example.

8.3.2. Electric connection

CAUTION

Electric connections shall only be carried out by qualified personnel.

See to a professional execution and installation of the AS-interface network. Observe the Safety Instructions specified in chapter 2.

Page 34

Control Unit

CU4 AS-interface

Operating Manual: UK-0

Control Unit CU4 AS-interface UK-0 / 31.05.2010

8. CU Assembly and Start-up

lever

solenoid valve

8.3.3. Connection of external proximity switches

The electric connection of the proximity switches specified by APV is undertaken according to the terminal layout described in

chapter 6.1.

The mechanic assembly of the proximity switches is carried out at the actuator of the corresponding double seat valves. Observance of the operating manual for double seat valves is essential!

8.3.4. Start-up

After proper assembly and installation of the control unit, start-up can be undertaken as described below:

1. Switch on the air supply.

2. Switch on the voltage supply.

3. Check the solenoid valves by turning the handle on the upper

side of the valve by 90°.

4. Check the valve position indicator. The proximity switches are installed at the double seat valves with a mechanical stop. Adjustment is not required!

The following allocation applies for double seat valves:

Closed valve position feedback – sensor 1 controlled

Open valve position feedback – sensor 2 controlled

Check the proper fit of the proximity switches to provide for the accurate transfer of the signals for the corresponding valve position.

Page 35

Control Unit CU4 AS-interface UK-0 / 31.05.2010

Control Unit CU4 AS-interface Operating Manual: UK-0

Assembly/disassembly - adapter on valve actuator:

• hexagon socket wrench 6 mm

• screwdriver 4mm

Assembly/disassembly – CU on adapter:

• hexagon socket wrench 3 mm

Assembly/disassembly – electronic module:

• torx wrench TX20

• screwdriver 3.5 mm

Assembly/disassembly – feedback unit:

• torx wrench TX15

Assembly/disassembly – electronic modules:

• torx wrench TX20

Assembly/disassembly – air connections:

• jaw wrench M13

Assembly/disassembly – pressure relief valve:

• torx wrench TX10

Loctite semi-solid

hexagon socket wrench

torx wrench

jaw wrench

screwdriver

9. Accessories and Tools

Page 36

Control Unit

CU4 AS-interface

Operating Manual: UK-0

Control Unit CU4 AS-interface UK-0 / 31.05.2010

10. Disassembly

10.1. Dismantling

Before disassembly, verify the following items:

• The valve must be in safety position and must not be controlled!

• Shut off air supply!

• Cut off current to control unit, i.e. interrupt the supply voltage!

Solenoid valve (4, 5, 6)

+ Open the CU cover by turning in anticlockwise direction. + Release the plug connection at the electronic module for the

corresponding solenoid valve. + Release and remove the 2 screws (20) TX20. + Replace the solenoid valve. + Assembly in reverse order. See to a proper fit of the flat seal!

Electronic module (2)

Before releasing the cable connections make sure that all lines

are de-energised! + Open the CU cover by turning in anticlockwise direction. + Release the plug connection of the solenoid valves. + Release the cable from the terminal strip, all terminals 1-15. + Release and remove the 3 screws (20) TX20. + Replace the electronic module. + Assembly in reverse order.

Feedback unit

Before releasing the cable connections make sure that all lines

are de-energised!

+ Open the cover.

+ Release the cable for the Hall effect sensors from the terminal

strip, terminals 3-8.

+ Release the clamp ring and lift the CU4 from the adapter.

+ Remove the 4 screws (9) TX15 at the lower side of the

CU base (1). + Take out the feedback unit to the bottom.

Hall effect sensors

The Hall effect sensors can only be replaced at the dismantled

feedback unit. + Remove the 3 screws (14) TX10. + Remove the tower lid (13). + Remove the o-rings (11). + Dismantle the sensors by turning of the adjusting screw (12).

To simplify adjustment of feedbacks: + Mark the position of the sensor on the adjusting screw! + Assembly in reverse order. + Check the correct position of the Hall effect sensors and their

functions as described in chapter 8 CU assembly and start-up.

Hall effect sensors

Page 37

Control Unit CU4 AS-interface UK-0 / 31.05.2010

Control Unit CU4 AS-interface Operating Manual: UK-0

11. Trouble Shooting

Failure Remedy

Valve position is not indicated.

Re-adjust Hall sensors.

Check fastening of magnetic operating cam.

Check cabeling of the Hall sensors to the electronic module.

Feedback via proximity switches is missing

Check positioning of proximity switches.

Check operating voltage.

Check cabeling to the electronic module.

LED indication is missing

Check operating voltage.

Check cabeling to the electronic module.

LEDs 'valve open' and 'valve closed' are flashing

No bridge between the terminals 10, 11 and 12. Install the corresponding bridge.

Control Unit CU41 installed on Butterfly valves

Movement of valve flap is missing with actuated solenoid valve.

Check if right control unit is installed.

Check label in type window of control unit: CU41-T-AS-interface (1 EMV/solenoid valve)

Check valve movement with manual at solenoid valve.

Check cabeling between electronic module and solenoid valve.

Check compressed air (min. 6 bar).

Bore for transfer of control air to turning actuator must be open.

Air leakage at lower side of adapter.

Check o-rings of adapter.

Page 38

Control Unit

CU4 AS-interface

Operating Manual: UK-0

Control Unit CU4 AS-interface UK-0 / 31.05.2010

Failure Remedy

Control Unit CU41 installed on Single seat and Double seat valves

Valve position movement is missing with actuated solenoid valve.

Check if right control unit is installed.

Check label in type window of control unit: CU41-S-AS-interface (1 EMV/solenoid valve)

Check valve movement with manual at solenoid valve.

Check cabeling between electronic module and solenoid valve.

Check compressed air (min. 6bar).

Check control air connection between the CU41 and the valve actuator.

Control Unit CU43 installed on Double seat valves

Valve position movement is missing with actuated solenoid valve.

Check if right control unit is installed.

Check label in type window of control unit: CU43-M-AS-interface (3 EMV/solenoid valves)

Check valve movement with manual at solenoid valve.

Check cabeling between electronic module and solenoid valve.

Check compressed air (min. 6bar).

Check control air connection between the CU43 and the DA3 valve actuator.

11. Trouble Shooting

12. Spare Parts Lists

The reference numbers of spare parts for the different

control unit designs and adapters are included in the

attached spare parts drawings with corresponding lists.

CU4 AS-interface RN 01.044.5

CU4 adapter RN 01.044.3

When you place an order for spare parts, please indicate the

following data:

- number of parts required

- reference number

- parts designation

Data are subject to change.

Page 39

Page 40

Your local contact:

APV, An SPX Brand Zechenstraße 49 D-59425 Unna Phone: +49(0) 23 03 / 108-0 Fax: +49(0) 23 03 / 108-210

For more information about our worldwide locations, approvals, certifications, and local representatives, please visit www.spxft.com.

The information contained in this document, including any specifications and other product details, are subject to change without notice. While we have taken care to ensure the information is accurate at the time of going to press, we assume no responsibility for errors or omissions nor for any damages resulting from the use of the information contained herein.

Page 41

Blatt 1 von 4

APV Rosista GmbH, D-59425 Unna Germany

RN 01.044.5

D.Schulz

CU4 AS - Interface

Datum: Name: Geprüft:

Ersatzteilliste: spare parts list

05/10

Weitergabe sowie Vervielfältigung dieser Unterlage, Verwertung und Mitteilung

ihres Inhalts nicht gestattet, soweit nicht schriftlich zugestanden. Verstoß

verpflichtet zum Schadensersatz und kann strafrechtliche Folgen haben

(Paragraph 18 UWG, Paragraph 106 UrhG). Eigentum und alle Rechte, auch

für Patenterteilung und Gebrauchsmustereintragung, vorbehalten. APV Rosista GmbH.

Page 42

Page 43

-----

08-46-581/9308-46-581/93

H320385 ----- H320385

-----

08-46-580/93

H319952

08-46-564/93

H319857

H320389

08-46-596/93

H320385

58-06-218/83

H320401

H324761

CU4 AS-i extended 62 slaves kpl. (6x1)

CU4 AS-i extended 62 slaves cpl. (6x1)

08-45-132/93 08-45-133/93 08-45-134/93

08-46-556/93

H320472

08-45-116/93

H320473

Ersatzteilliste: spare parts list

CU4 AS - Interface

Geprüft:

Material

Datum:

Name:

Geprüft:

pos.

Menge

quantity

Beschreibung

APV Rosista GmbH, D-59425 Unna Germany

RN 01.044.5

Blatt

2 von 4

Datum:

05/10

Name:

D.Schulz

item description

1 1

2 1

Ejot Delta PT screw WN5452 35x14

10 2

9 4

Ejot Delta PT Schraube WN5452 35x14

Hall-Sensor

Hall-sensor

65-17-122/13

H320364

8 1

O-Ring 45,6 x 2,4

NBR

O-ring 45,6 x 2,4

7 1

CU4 Sensortower

PA12

CU4 Sensortower

6 1

Magnetventilblock 3 EMV

PPS

solinoid valve 3 EMV

5 1

Magnetventilblock 1 EMV + NOT-Element

PPS

solinoid valve 1 EMV + NOT-element

4 1

Magnetventilblock 1 EMV

soninoid valve 1EMV

2.1

CU4 E-Modul Asi Standard

CU4 E-Modul Asi standard

3 1

CU4 Haube kpl.

PA12 GF30

CU4 cap cpl.

CU4 AS-i Standard 31 slaves kpl. (1/4"OD)

CU4 AS-i Standard 31 slaves kpl. (6x1)

CU4 AS-i standard 31 slaves cpl. (6x1)

CU4 AS-i standard 31 slaves cpl. (1/4"OD)

CU4 AS-i extended 62 slaves cpl. (1/4"OD)

CU4 E-Modul Asi extended 62 slaves

CU4 Base

PA6.6 GF30

CU4 Base

CU4 AS-i extended 62 slaves kpl. (1/4"OD)

PPS

H319868

08-46-579/93

H319951

-----

material

CU41-S CU41-T

08-46-559/93

WS-Nr.

ref.-no.

WS-Nr.

ref.-no.

WS-Nr.

ref.-no.

H320471

08-45-115/93

08-45-135/93

CU41N-T CU43-M CU43-S

WS-Nr.

ref.-no.

WS-Nr.

ref.-no.

CU41-M

WS-Nr.

ref.-no.

WS-Nr.

ref.-no.

CU41N-S

-----

----- -----

-----

----- 08-46-581/93

08-45-110/93

H320467

08-45-111/93

H320468

08-45-112/93

H320469

08-45-113/93

H320470

08-45-114/93

08-45-136/93

H324666 H324667 H324668 H324669 H324670 H324671 H324672

08-45-131/9308-45-130/93

08-45-250/93 08-45-251/93 08-45-252/93 08-45-253/93 08-45-254/93 08-45-255/93 08-45-256/93

H324673 H324674 H324675 H324676 H324677 H324678 H324679

08-45-270/93 08-45-271/93 08-45-272/93 08-45-273/93 08-45-274/93 08-45-275/93 08-45-276/93

H324682 H324683 H324684 H324685 H324686 H324687 H324688

08-46-552/93

H319853

08-46-552/93 08-46-553/9308-46-553/93

H319854

08-46-554/93

H319855 H319853 H319854

08-46-595/93

H320388

08-46-578/93

H319950

-----

08-46-598/93

H324760

H319860

08-46-599/93

Weitergabe sowie Vervielfältigung dieser Unterlage, Verwertung und Mitteilung

ihres Inhalts nicht gestattet, soweit nicht schriftlich zugestanden. Verstoß

verpflichtet zum Schadensersatz und kann strafrechtliche Folgen haben

(Paragraph 18 UWG, Paragraph 106 UrhG). Eigentum und alle Rechte, auch

für Patenterteilung und Gebrauchsmustereintragung, vorbehalten. APV Rosista GmbH.

Page 44

Page 45

08-60-750/93

H208825

08-60-811/93

CU4 air filter

08-60-750/93

H208825

08-60-811/93 -----

-----

H208825

-----

08-60-811/93

H312732 H312732

08-60-750/93

H208825

08-60-811/93

-----

08-60-051/99

-----

H320482

08-60-051/99

-----

08-63-241/99

08-60-750/93

08-60-051/99

-----

H208644

65-03-290/13 ----- 65-03-290/13 ----- 65-03-290/13

----- 58-06-043/83

-----

08-46-565/93 ----- 08-46-565/93

H319869 ----- H319869

H320482

H320361

H320551

58-06-043/83 ----- 58-06-043/83

H319869 -----

H320482

-----

CU4 Luftfilter

W-Verschraubung G1/8" 1/4"OD

Elbow connector G1/8" 1/4" OD

4 x H320363

05/10

Datum:

RN 01.044.5

Geprüft:

CU4 AS - Interface

Ersatzteilliste: spare parts list

APV Rosista GmbH, D-59425 Unna Germany

Blatt

3 von 4

Datum:

1.4301 / PA

W-Verschraubung G1/8" 1/4"OD

Elbow connector G1/8" 1/4" OD

W-Verschraubung G1/8" 6x1

1.4301 / PA

-----

H312732

17.3 1

W-Verschraubung G1/8" 6x1

Elbow connector G1/8" 6x1

1.4301 / PA

16 1

item

15.1

Elbow connector G1/8" 6x1

12 2

PA12

Ms / vern.

1.4301 / PA

Ms / vern.

15.2 1

pos.

Material

quantity

Beschreibung

Menge

material

A2-50

cyl. Screw M4x100

description

17.2 1

connector self locked

W-Verschraubung G1/8" 6x1

Elbow connector G1/8" 1/4" OD

W-Verschraubung G1/8" 1/4"OD

Elbow connector G1/8" 1/4" OD

Name:

D.Schulz

CU41-T

65-17-110/13

CU41-S

H320361

08-46-565/93

H312732

-----

Name:

Geprüft:

plug G1/8"

Ms / vern.

plug G1/8"

H208644

----- H320361

-----

Verschraubung selbstabsperrend

O-Ring 3x2

NBR

O-ring 3x2

CU4 Towerabdeckung

CU4 towercower

Ejot Delta PT Schraube WN5452 30x10

Ejot Delta PT screw WN5452 30x10

Blindstopfen G1/8"

Zyl.-Schraube M4x100

----- H208644 -----

WS-Nr.

ref.-no.

WS-Nr.

ref.-no.

WS-Nr.

ref.-no.

H208825

08-60-811/93

H312732

18 1 PE-porös

08-10-005/93

H320223

-----

CU41-M CU41N-S CU41N-T CU43-M CU43-S

08-60-811/93

17.1 1