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SPX FLOW APV CU41-D4 Instruction Manual Download Page 13

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

APV_CU4 AS-i_UK-5_072018.indd

UK

Control Unit

CU4 AS-interface

Instruction manual: UK - rev. 5

APV

13

Summary of Contents for APV CU41-D4

Page 1: ...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 ...

Page 2: ......

Page 3: ...id valves 4 7 Throttling function 4 8 NOT element 5 Adapter 19 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 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 Feed...

Page 4: ...r 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 ...

Page 5: ... as well as the operating conditions and permissible data specified 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...

Page 6: ... 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 dam...

Page 7: ...tion 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 solenoi...

Page 8: ...alves are provided with a safe lever 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 ...

Page 9: ... 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 direc...

Page 10: ...le seat mix proof valves without seat lift P ir supply with integrated particle filter 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 ...

Page 11: ... 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 ...

Page 12: ...ND 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 ...

Page 13: ... 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 APV_CU4 AS i_UK 5_072018 indd UK Control Unit CU4 AS interface Instruction manual UK rev 5 APV 13 ...

Page 14: ... 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 APV_CU4 AS i_UK 5_072018 indd UK Control Unit CU4 AS interface Instruction manual UK rev 5 APV 14 ...

Page 15: ...aust 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 APV_CU4 AS i_UK 5_072018 indd UK Control Unit CU4 AS interface Instruction manual UK rev 5 APV 15 ...

Page 16: ...nterface 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 APV_CU4 AS i_UK 5_072018 indd UK Control Unit CU4 AS interface Instruction manua...

Page 17: ...ation EN60068 2 6 Safety of machinery DIN EN ISO 13849 1 Air connection 6 mm 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 m 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 hig...

Page 18: ...y 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 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 elem...

Page 19: ...interface Instruction manual UK rev 5 APV 19 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 ...

Page 20: ... diagram The Control Unit 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 CU4 is designed for the extended address ...

Page 21: ...lve open and valve closed will flash in this case 6 2 Functional description of connections Terminal Designation Functional description for all valve types Funtional description for D4 D4 SL and DA4 valve types 1 AS i AS i network connection AS i network connection 2 AS i AS i network connection AS i network connection 3 5 VDC voltage supply for valve sensor voltage supply for valve sensor 4 Senso...

Page 22: ... current DO1 0 upper seat lifting optional Low no electric current output 1 High current DO2 0 lower seat lifting optional Low no electric current output 1 High current DO3 free output Feedback bridge Data bit normal 10 11 12 reverse 10 11 12 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 pos...

Page 23: ...es PWM signal from electronic module Short circuit protection yes Excess voltage protection 100 mA Induction protection ja 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 S 7 A E only Simultaneously LED3 flashes acc...

Page 24: ...nections Sensors to detect the valve positions Internal sensors Hall effect sensors APV valves H320385 APV WCB D4 valves H337014 UB 4 75 5 25 VDC operating distance according to SPX FLOW specification External sensors Inductive proximity switches H208844 UB 4 75 5 25 VDC operating distance according to SPX FLOW specification ...

Page 25: ...lour red green AS i status peripheral failure e g shortcircuit excess voltage cable break profile S 7 A E only colour red permanent light Communication failure Solenoid Main colour blue permanent light 1st solenoid valve 1 controlled Solenoid Main upper seat lower seat colour blue 1 blink 2nd solenoid valve 2 controlled colour blue 2 blinks 3rd solenoid valve 3 controlled colour blue 1 blink solen...

Page 26: ...Hall effect sensors APV valves H320385 Hall effect sesonrs APV WCB D4 valves H337014 UB 4 75 5 25 VDC operating distance according to SPX FLOW 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 adjus...

Page 27: ...ted 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 ...

Page 28: ...ntrol 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 connec...

Page 29: ...cation 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...

Page 30: ...anent 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 single seat valve Fasten with 4 screws 2 Secure operating cam with Loctite semi solid and fasten it 3 Place the control...

Page 31: ...gic 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 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...

Page 32: ...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 elect...

Page 33: ...linder 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 external proximity switches feedback ...

Page 34: ... 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 Obse...

Page 35: ...lves by turning the lever 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 pro...

Page 36: ...the operating cam M1 with guide rod extension on the guide rod 4 Place the control unit onto the adapter Observe alignment 5 Attach the clamp rings and fasten them with the 2 screws 6 Align air connections of the control unit to the valve actuator CU cover CU41 CU43 screws clamp ring actuator adapter operating cam with magnet M1 operating cam with magnet M2 APV_CU4 AS i_UK 5_072018 indd UK Control...

Page 37: ...uator 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 4 2 Electric connection Attention Electric connections shall only be carried out by qualified personnel See to a professional executi...

Page 38: ...cribed below 1 Switch on the air supply 2 Switch on the voltage supply 3 Check the solenoid valves by turning the lever 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...

Page 39: ...at lifting lower seat lifting In order to prevent the activation of the wrong seat lift after CU replacement the following adaptions can be carried out Change in the control software or The interchange of the electrical connections of the pneumatic valves 2 and 3 at the electronic module of CU43 In this case the signals of CU43 as well as of CU33 can be controlled The air hoses leading to the actu...

Page 40: ...isassembly 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 jaw wrench torx wrench hexagon so...

Page 41: ...en 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 Ha...

Page 42: ...unication 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 Failure Remedy Control Unit CU41 installed on Butterfly valves Movement of valve flap is missing with actuated solenoid valve Check if the right control unit is installed Check label in type window of control unit CU41 T AS in...

Page 43: ...er at solenoid valve Check cabeling between electronic module and solenoid valve Check compressed air min 6 bar 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 the right control unit is installed Check label in type window of control unit CU43 M AS interfa...

Page 44: ...e 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 45: ...lz 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 SPX FLOW Germany ...

Page 46: ... 45 254 93 08 45 255 93 H320470 08 45 136 93 H324671 H324675 H324676 H324677 H324672 08 45 131 93 08 45 256 93 08 45 133 93 08 45 134 93 H324667 H324668 H324684 H324685 H324686 08 46 554 93 H324687 H324679 08 45 272 93 08 45 273 93 08 45 274 93 08 45 275 93 08 45 270 93 08 45 271 93 H319853 H319854 H319855 H319854 08 46 552 93 08 46 553 93 H324682 H324683 08 46 552 93 08 46 556 93 H319853 SPX FLOW...

Page 47: ...Blatt 3 Geprüft Ersatzteilliste spare parts list Name D Schulz Datum 07 18 CU4 AS interface 1 10 CU4 Towerabdeckung Zyl Schraube M4x100 13 1 item 11 9 pos 4 2 12 1 1 CU41 T CU41 S A2 NBR PA12 CU4 tower cover O Ring 3x2 Material 2 CU41N S description 12 Beschreibung Menge material 2 Ejot Delta PT Schraube WN5452 35x14 Ejot Delta PT screw WN5452 35x14 Hall Sensor Hall sensor O ring 3x2 2 CU4 e modul...

Page 48: ... 051 99 H312732 17 1 1 08 60 750 93 H312732 14 Ejot Delta PT Schraube WN5452 30x10 A2 65 17 110 13 Ejot Delta PT screw WN5452 30x10 4 x H320363 15 1 1 Blindstopfen G1 8 Ms vern 08 60 051 99 Plug G1 8 H320482 H320482 15 2 1 Blindstopfen G1 8 Ms vern 08 60 051 99 Plug G1 8 H320482 16 1 Verschraubung selbstabsperrend Ms vern 08 63 241 99 Connector self locking H320551 17 1 W Verschraubung G1 8 6x1 1 ...

Page 49: ...lve H320352 24 1 O Ring 120 32 x 2 62 NBR 58 06 583 83 O ring 120 32 x 2 62 H320402 25 1 Kabelverschraubung M20x1 5 Kabel ø5 9 PA Screwed cable gland M20x1 5 cable ø5 9 08 46 041 93 H320372 26 1 Kabelverschraubung M20x1 5 Kabel 2x ø5 PA Screwed cable gland M20x1 5 cable 2x ø5 28 1 Druckreduzierventil Ms vern Pressure reducing valve 27 2 Initiator Ni5 K11K AN 5X 5 Proximity switch Ni5 K11K AN 5X 5 ...

Page 50: ...D4 AS i extended 62 sla kpl 1 4 OD M12 08 45 392 93 08 45 393 39 CU4 D4 AS i standard 31 sla cpl 6x1 M12 H338898 H338899 CU4 D4 AS i Standard 31 sla kpl 6x1 M12 08 45 388 93 08 45 391 39 CU4 D4AS i standard 31 sla cpl 1 4 OD M12 H338902 H338903 CU4 D4AS i Standard 31 sla kpl 1 4 OD M12 08 45 394 08 45 395 39 CU4 base H319855 H319857 1 1 CU4 base PA6 6 GF30 08 46 552 93 08 46 556 93 2 0 1 CU4 e mod...

Page 51: ...valve 3 sol 7 0 CU4 Sensortower PA12 CU4 sensor tower 8 1 O Ring 45 6 x 2 4 NBR O ring 45 6 x 2 4 58 06 218 83 H320401 9 4 Ejot Delta PT Schraube WN5452 35x14 A2 Ejot Delta PT screw WN5452 35x14 10 0 Hall Sensor 11 2 O Ring 3x2 NBR 58 06 043 83 O ring 3x2 H208644 12 0 Zyl Schraube M4x100 A2 50 Cyl screw M4x100 13 0 CU4 Towerabdeckung PA12 CU4 tower cover on request on request on request on request...

Page 52: ...ctor G1 8 1 4 OD Elbow connector G1 8 6x1 H208825 H208825 Elbow connector G1 8 1 4 OD H312732 H312732 17 1 1 W Verschraubung G1 8 6x1 1 4301 PA 17 2 1 W Verschraubung G1 8 6x1 1 4301 PA Elbow connector G1 8 6x1 W Verschraubung G1 8 1 4 OD 1 4301 PA Elbow connector G1 8 1 4 OD 08 60 811 93 H312732 17 3 1 W Verschraubung G1 8 6x1 1 4301 PA Elbow connector G1 8 6x1 W Verschraubung G1 8 1 4 OD 1 4301 ...

Page 53: ...verschraubung M20x1 5 Kabel ø5 9 PA Screwed cable gland M20x1 5 cable ø5 9 26 0 Kabelverschraubung M20x1 5 Kabel 2x ø5 PA Screwed cable gland M20x1 5 cable 2x ø5 27 0 Initiator Ni5 K11K AN 5X 5 Proximity switch Ni5 K11K AN 5X 5 08 46 933 93 28 1 Druckreduzierventil Ms vern Pressure reducing valve 29 1 D4 Sensortower Kmpl Grilamid TR55 08 46 933 93 D4 sensor tower cmpl H338146 H338146 30 1 Zylinder...

Page 54: ......

Page 55: ...FLOW Germany C Keil RN 01 044 3 Name Trytko Datum 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 ...

Page 56: ... 1 8 10 quantity Beschreibung description RN 01 044 3 Zylinderschraube M4x40 Cyl screw M4x40 1 3 1 ref no H79012 H315760 Schulz Geprüft CU4 T WS Nr Trytko C Keil Geprüft Spliethoff 11 14 Name Spliethoff 11 10 Peters Trytko Schulz Datum pos Menge Spliethoff Datum 03 13 Ersatzteilliste spare parts list CU4 Adapter 01 09 03 09 Peters 11 08 Name Peters 05 18 Trytko 08 46 571 93 H319875 H319876 08 46 5...

Page 57: ...ytko 3 von 5 Datum 03 13 Geprüft Spliethoff 11 14 05 18 Datum C Keil Blatt RN 01 044 3 Geprüft Schulz Spliethoff Spliethoff 01 09 03 09 Peters 11 08 11 10 Peters Ersatzteilliste spare parts list V seal V Dichtung NBR Peters Trytko Schulz Name pos 20 0 PA6 6 Zyl Schraube M5x35 CU4 switch rod SPX FLOW Germany Zylinderschraube M8x25 Cyl screw M8x25 D4 Zugstangen Adapter für CU4 D4 guide rod adapter f...

Page 58: ...pter T PA6 6 GF30 CU4 adapter M 1 1 0 CU4 Adapter M PA6 6 GF30 CU4 adapter cpl H337098 ref no CU4 Adapter kpl 08 46 646 93 WS Nr WS Nr WS Nr WS Nr ref no ref no ref no ref no ref no ref no item description material WS Nr WS Nr WS Nr pos Menge quantity Beschreibung Material CU4 D4 5 Name Trytko Trytko C Keil RN 01 044 3 Geprüft Schulz SPX FLOW Germany Datum 03 13 11 14 05 18 Blatt 4 von Name Peters...

Page 59: ...thoff SPX FLOW Germany Datum 03 13 11 14 05 18 Blatt 5 CU4 Adapter Name Peters Peters Trytko Schulz Geprüft Spliethoff Spliethoff Peters Ersatzteilliste spare parts list Datum 11 08 01 09 03 09 11 10 Zylinderschraube M8x25 Cyl screw M8x25 D4 Zugstangen Adapter für CU4 D4 guide rod adapter for CU4 D4 Magnet Hall sensor kpl D4 magnet Hall sensor cpl Weitergabe sowie Vervielfältigung dieser Unterlage...

Page 60: ... right to incorporate the latest design and material changes without notice or obligation Design features materials of construction and dimensional data as described in this manual are provided for your information only and should not be relied upon unless confirmed in writing Please contact your local sales representative for product availability in your region For more information visit www spxf...

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