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APV_CU4plus_AS-interface_UK-3_062019.indd

Control Unit

CU4plus AS-interface

Instruction Manual UK-3

APV

1. Abbreviations and Definitions

Exhaust air

AWG

American Wire Gauge

Communauté Européenne

Control Unit

Digital Input

Digital Output

EMV

Electromagnetic Compatibility

European Union

GND

Ground/mass potential

International Protection

LED

Luminous diode

Pneumatic Air Connection NOT element

NEMA

National Electrical Manufacturers Association

Supply Air Connection

PELV

Protected Extra-Low Voltage

PWM

Pulse-width modulation

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

Содержание APV CU4plus AS-i

Страница 1: ...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...

Страница 2: ......

Страница 3: ...ng actuator e g butterfly 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 Functi...

Страница 4: ...ed 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 t...

Страница 5: ...al 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...

Страница 6: ...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 instruction manual Work at the el...

Страница 7: ...rotection modules is recommended 2 7 2 Network design and voltage supply Use only AS i certified power supplies Output voltage 26 5 to 31 6 VDC AS i power supplies deliver up to 8A The voltage drop be...

Страница 8: ...tworks 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...

Страница 9: ...n 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 machine...

Страница 10: ...on 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...

Страница 11: ...d 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 ele...

Страница 12: ...ide 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 Chapte...

Страница 13: ...CU41Nplus 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...

Страница 14: ...filter 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 integr...

Страница 15: ...ve 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...

Страница 16: ...ntrol Unit CU4plus AS interface Instruction Manual UK 3 APV 16 4 Mechanics and Pneumatics 4 4 Functional description block diagrams 4 4 1 CU41plus AS interface internal position measuring system Valve...

Страница 17: ...nterface_UK 3_062019 indd UK Control Unit CU4plus AS interface Instruction Manual UK 3 APV 17 4 Mechanics and Pneumatics 4 4 Functional description block diagrams 4 4 2 CU41Nplus AS interface internal...

Страница 18: ...3 APV_CU4plus_AS interface_UK 3_062019 indd UK Control Unit CU4plus AS interface Instruction Manual UK 3 APV 18 4 Mechanics and Pneumatics 4 4 Functional description block diagrams 4 4 3 CU43plus AS...

Страница 19: ...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 dia...

Страница 20: ...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 magn...

Страница 21: ...seat lift cylinder lower valve seat 4 Mechanics and Pneumatics 4 4 Functional description block diagrams 4 4 6 CU43plus D4 V1 for DA4 double seat mix proof valves M1 magnet lower shaft M2 magnet upper...

Страница 22: ...cording to specification V3 0 vibration oscillation EN60068 2 6 safety of machinery DIN EN ISO 13849 1 Air hose 6 mm OD Pressure range 6 8 bar Compressed air quality quality class acc to DIN ISO 8573...

Страница 23: ...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 t...

Страница 24: ...U4plus AS interface Instruction Manual UK 3 APV 24 5 Adapter Adapter for different process valves 5 1 Valves with turning actuator e g butterfly valve 5 2 Single seat valve 5 3 Double seat mix proof v...

Страница 25: ...a slave for the fieldbus system AS Interface according to specification V3 0 The profile is S 7 A E 3 outputs and 2 4 inputs The CU4plus AS i is designed for the extended address range With these devi...

Страница 26: ...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 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...

Страница 27: ...eparate auxiliary energy PELV 24VDC for EMERGENCY STOP function only 7 5 VDC voltage supply for proximity switches 8 Sensor 3 signal sensor 3 evaluation of logic table for appropriate valve type 9 GND...

Страница 28: ...ification V3 0 Supply of solenoid valves pwm signal from electronic module Short circuit protection yes Excess voltage protection 100 mA Induction protection yes Status indication of outputs LED on bo...

Страница 29: ...5 25 VDC switching distance acc to SPX FLOW specification External sensors inductive proximity switch SPX FLOW UB 4 75 5 25 VDC switching distance acc to SPX FLOW specification 6 5 LED indications The...

Страница 30: ...f sensor voltage supply red permanent light AS i communication failure no data interchange with master master in stop mode slave cannot read master commands master in protect mode and slave not in pro...

Страница 31: ...t valve butterfly valve with internal feedback detection internal linear sensor 1 mm 3 mm 5 mm NC NO possible optional 1 2 3 Mix proof seat valve with external feedback detection external proximity sw...

Страница 32: ...closed 1 0 DI1 open 0 1 DI2 not occupied 1 1 DI3 not occupied 1 1 AS i Communication Output Data ODI solenoid 1 Main solenoid 2 solenoid 3 DO0 1 0 0 DO1 0 1 0 DO2 0 0 1 DO3 not occupied not occupied...

Страница 33: ...I2 upper seat lifting 0 1 0 1 DI3 lower seat lifting 1 1 0 0 The appropriate AS i signal for valve position will be generated within the CU by logic combination of the 4 sensor signals The appropriate...

Страница 34: ...r signal S1 sensor signal S2 sensor signal S3 sensor signal S4 DI0 closed 1 0 not used 0 1 mm 1 mm DI1 open 0 0 not used 1 1 mm 1 mm DI2 DI3 AS i output data solenoid 1 Main solenoid 1 upper seat lift...

Страница 35: ...DI0 closed 1 0 1 0 1 mm 1 mm DI1 open 0 0 0 1 1 mm 1 mm DI2 upper seat lift 0 1 1 0 1 mm 1 mm DI3 lower seat lift 1 0 0 0 1 mm 1 mm AS i output data solenoid 1 Main solenoid 2 upper seat lift solenoid...

Страница 36: ...2 upper seat lift 0 1 0 0 1 mm 1 mm DI3 lower seat lift 1 0 1 0 1 mm 1 mm AS i output data solenoid 1 Main solenoid 2 upper seat lift solenoid 3 lower seat lift DO0 1 0 0 DO1 0 1 0 DO2 0 0 1 6 Electro...

Страница 37: ...EPROM error S2 Automatic unique duplicate address detection S1 Periphery fault S0 Address not permanently stored AS i diagnosis inputs 0 Air pressure availed 1 Teach in successfully completed 6 8 Serv...

Страница 38: ...e generated via the teach in function and permanently saved in the electronic 7 2 Tolerance band of the valve position measuring system The tolerance band of the valve position measuring system descri...

Страница 39: ...dule The key must be pressed permanently for 3 seconds After the start of the Teach In the LED 9 lights up and the valve travels into the corresponding final positions and back into the basic position...

Страница 40: ...inal valve stroke is not restricted e g through chunky products in the valve Selected switching logic complies with the installed process valve adjustment is realized via CU4plus Toolbox software deli...

Страница 41: ...y 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...

Страница 42: ...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 Attention Electric connections shall only...

Страница 43: ...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 switching cam with Lo...

Страница 44: ...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 2 2 Ele...

Страница 45: ...embly 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 Attac...

Страница 46: ...r 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 ex...

Страница 47: ...f the control unit startup can be undertaken as described below 1 Switch on the air supply 2 Switch on the voltage supply 3 Adjust AS i address at the CU4plus AS i 4 Adjust corresponding logic profile...

Страница 48: ...ew 2 Assemble the adapter with the 4 screws on the double seat valve 3 Assemble the operating cam M1 with guide rod extension on the guide rod 4 Place the control unit onto the adapter Observe alignme...

Страница 49: ...nnect 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 stand...

Страница 50: ...actuator of the corresponding double seat valves Observance of the instruction manual for double seat valves is essential 8 4 4 Startup After proper assembly and installation of the control unit star...

Страница 51: ...4 perifault blink together with LED 5 6 9 blink 8 adjust hall sensors S3 Toolbox tower spindle 1 S4 Toolbox tower spindle 2 8a sensor S3 tower spindle 1 not used 8b adjust S4 tower spindle 2 manually...

Страница 52: ...all sensor is OFF turn tower spindle 1 2 times counter clockwise LED should still be ON manually activate solenoid 3 lower seat lift LED at hall sensor OFF manually deactivate solenoid 3 lower seat li...

Страница 53: ...s ON turn tower spindle 1 further clockwise until LED just is OFF turn tower spindle 1 2 times counter clockwise LED should still be ON manually de activate solenoid 3 valve to return into closed posi...

Страница 54: ...g upper seat lifting DO2 upper seat 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 c...

Страница 55: ...bly 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 disasse...

Страница 56: ...ke 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 termina...

Страница 57: ...eling to the electronic module LED indication is missing Check AS i bus communication Check cabeling to the electronic module Control Unit CU41 installed on Butterfly valves Movement of valve flap is...

Страница 58: ...nt with manual 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...

Страница 59: ...arts for the different control unit designs and adapters are included in the attached spare parts drawings with corresponding lists CU4plus AS interface RN 01 044 6 CU4 Adapter RN 01 044 3 1 When you...

Страница 60: ......

Страница 61: ...9 Weitergabe sowie Vervielf ltigung dieser Unterlage Verwertung und Mitteilung ihres Inhalts nicht gestattet soweit nicht schriftlich zugestanden Versto verpflichtet zum Schadensersatz und kann strafr...

Страница 62: ...extended CU41Nplus S AS i extended Name ref no ref no ref no Gepr ft WS Nr WS Nr WS Nr Material material Datum Name WS Nr Schulz CU41Nplus T AS i extended WS Nr ref no H333127 08 46 553 93 item PA 6...

Страница 63: ...m Name Trytko Gepr ft Schulz C Keil Datum 04 01 16 WS Nr WS Nr WS Nr Blatt 3 von 10 16 05 19 CU41plus M AS i extended CU41Nplus S AS i extended CU41Nplus T AS i extended pos Menge quantity Beschreibun...

Страница 64: ...CU41Nplus S AS i extended Scheibe DIN9021 A 3 2 67 01 001 12 Washer H320404 CU41plus S AS i extended CU41plus T AS i extended 25 1 NBR 70 Shore A O Ring OR 120 32 x 2 62 O ring 24 1 CU4 berstr mventi...

Страница 65: ...ded material CU43plus AS i extended kpl 6x1 CU43plus AS i extended cpl 6x1 WS Nr item description 08 46 556 93 H319857 08 46 915 93 H333117 Name ref no ref no CU4 cap cpl with solenoid LED 4 Magnetven...

Страница 66: ...connector G1 8 1 4 OD W Verschraubung G1 8 6x1 Elbow connector G1 8 6x1 W Verschraubung G1 8 1 4 OD Plug G1 8 with o ring Blindstopfen G1 8 mit O Ring Plug G1 8 with o ring W Verschraubung G1 8 6x1 El...

Страница 67: ...NE SD M20x1 5 H324895 08 46 040 93 1 Kabelverschraubung M20x1 5 Kabel 5 9 PA schwarz Screwed cable gland M20x1 5 Kabel 5 9 H320372 08 46 041 93 29 1 Kabelverschraubung M20x1 5 Kabel 2x5 PA schwarz Er...

Страница 68: ...338819 H338820 CU4plus D4 AS i ext V1 08 45 555 93 08 45 556 93 item description material WS Nr WS Nr WS Nr WS Nr WS Nr WS Nr ref no ref no ref no ref no ref no ref no pos Menge quantity Beschreibung...

Страница 69: ...ref no ref no pos Menge quantity Beschreibung Material CU41 Plus D4 AS i ext V1 CU43 Plus D4 AS i ext V1 Control Unit CU4 plus AS i extended Name Name RN 01 044 6 Gepr ft SPX FLOW Germany Datum Blatt...

Страница 70: ...rz 08 46 041 93 Plug V NE SD M20x1 5 27 1 Blindstopfen V NE SD M20x1 5 PA schwarz RAL 9005 item description material WS Nr WS Nr WS Nr WS Nr WS Nr WS Nr ref no ref no ref no ref no ref no ref no pos M...

Страница 71: ...ermany C Keil Weitergabe sowie Vervielf ltigung dieser Unterlage Verwertung und Mitteilung ihres Inhalts nicht gestattet soweit nicht schriftlich zugestanden Versto verpflichtet zum Schadensersatz und...

Страница 72: ...Ring O ring Cyl Screw DIN EN ISO 4762 M4x40 Zylinderschraube Cyl Screw Zylinderschraube DIN EN ISO 4762 SPX FLOW Germany 20 05 19 Trytko C Keil Datum Datum 26 01 16 Name Trytko Schulz Gepr ft Schulz E...

Страница 73: ...al pos Zylinderschraube 15 3 Zylinderschraube DIN EN ISO 4762 M5x16 NBR Cyl Screw 17 4 16 DIN EN ISO 7092 9x5 48 item Menge quantity Beschreibung 1 4 Washer description V sealing CU4 Schaltstange CU4...

Страница 74: ...schale kpl 3 2 Zylinderschraube DIN EN ISO 4762 M4x40 A2 70 Cyl Screw 2 2 Grivory GH 5H1 5 1 Zytel HTN 08 46 767 93 08 60 900 93 H333099 H320479 4 1 NBR H333136 7 1 PA6 08 46 920 93 6 4 A2 70 9 1 PA6...

Страница 75: ...6 18 4 Zylinderschraube M8x25 A2 70 65 05 122 13 Cyl screw M8x25 H79014 17 4 A2 70 20 1 08 46 924 93 D4 Magnet CU4plus V1 kpl D4 magnet CU4plus V1 cpl D4 Zugstangen Adapter f r CU4 D4 guide rod adapt...

Страница 76: ...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 sh...

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