SPXFLOW APV CU4plus AS-i Instruction Manual
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SPXFLOW APV CU4plus AS-i Instruction Manual

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I N S T R U C T I O N M A N U A L
APV CU4plus AS-interface
C O N T R O L U N I T
F O R M N O . : H 3 3 3 9 7 8
R E V I S I O N : U K - 3
R E A D A N D U N D E R S TA N D T H I S M A N U A L P R I O R TO O P E R AT I N G O R S E RV I C I N G T H I S P R O D U C T.

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Summary of Contents for SPXFLOW APV CU4plus AS-i

  • Page 1 I N S T R U C T I O N M A N U A L APV CU4plus AS-interface C O N T R O L U N I T F O R M N O . : H 3 3 3 9 7 8 R E V I S I O N : U K - 3 R E A D A N D U N D E R S TA N D T H I S M A N U A L P R I O R TO O P E R AT I N G O R S E RV I C I N G T H I S P R O D U C T.

  • Page 3: Table Of Contents

    APV_CU4plus_AS-interface_UK-3_062019.indd Content Page Abbreviations and Definitions Safety Instructions 2.1. Sentinels 2.2. Intended use 2.3. General regulations for careful handling 2.4. Welding instructions 2.5. Persons 2.6. Warranty 2.7. Important safety instructions for AS-interface networks General Terms 3.1. Purpose of use 3.2. Design of CU4plus AS-interface 3.3.

  • Page 4: Abbreviations And Definitions

    APV_CU4plus_AS-interface_UK-3_062019.indd Abbreviations and Definitions Exhaust air American Wire Gauge Communauté Européenne Control Unit Digital Input Digital Output Electromagnetic Compatibility European Union Ground/mass potential International Protection Luminous diode Pneumatic Air Connection NOT element NEMA National Electrical Manufacturers Association Supply Air Connection PELV Protected Extra-Low Voltage Pulse-width modulation...

  • Page 5: Intended Use

    APV_CU4plus_AS-interface_UK-3_062019.indd Safety Instructions 2.2. Intended use The CU4plus AS-i control unit is only intended for use as described in chapter 3.1. Use beyond that described in chapter 3.1. do not comply with the regulations and SPX FLOW shall not be responsible for any damage resulting from this non-observance.

  • Page 6: Welding Instructions

    APV_CU4plus_AS-interface_UK-3_062019.indd Safety Instructions 2.4. Welding instructions It is generally recommended to avoid welding work in process installation in which control units are installed and connected. If welding is nonetheless required, earthing of the electrical devices in the welding area is a necessity. 2.5.

  • Page 7: Important Safety Instructions For As-Interface Networks

    APV_CU4plus_AS-interface_UK-3_062019.indd Safety Instructions 2.7. Important safety instructions for AS-interface networks Aside from complying with the Installation Guidelines according to AS-i Specification, observe the following instructions! 2.7.1 Earthing The PE connection of the AS-i power supply (protective earth) must (if existent) be grounded. The symmetry point of the AS-i network (GND, ground, shield) must be connected with the plant ground).
  • Page 8 APV_CU4plus_AS-interface_UK-3_062019.indd Safety Instructions Extension with repeater to max. 500 m (central positioning) 100m 100m 100m 100m 100m Master R Repeater Power Supply Slave AS-i power cables must be separated from the energy cables and must be as short as possible. External proximity switches must be connected to the slave as close as possible.
  • Page 9 APV_CU4plus_AS-interface_UK-3_062019.indd Safety Instructions 2.7.5. Increase in interference resistance The connection „Schirm“ (shield) at the AS-i power supply unit must be connected directly and with good RF characteristics with the potential equalization of the machine or plant. This is not a grounding measure for safety reasons, but a functional grounding so that the AS-i line can be operated symmetrically against the earth.

  • Page 10: General Terms

    APV_CU4plus_AS-interface_UK-3_062019.indd General Terms 3.1. Purpose of use fig. 3.2. The control unit CU4plus AS-i has been developed for the control of process valves in food processing industry as well as related industries. The CU4plus AS-i control unit operates as interface between process control and process valve and controls the electric and pneumatic signals.

  • Page 11: Function Of The Individual Components

    APV_CU4plus_AS-interface_UK-3_062019.indd 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.
  • Page 12 APV_CU4plus_AS-interface_UK-3_062019.indd 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.

  • Page 13: Mechanics And Pneumatics

    APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics Air connections for turning actuator 4.1. 4.1.1. Function CU41plus-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 AIR IN AIR IN Air connections seat valves and double seat mix proof valves...
  • Page 14 APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics 4.2.1. Function CU41plus-D4-V1 design for D4 double seat mix proof valves without seat lift function air supply with integrated particle filter control air connection for main actuator exhaust air, with exhaust silencer CU43plus-D4-V1 design for D4 SL, DA4 double seat mixproof valves with seat lift function air supply with integrated particle filter control air connection for main actuator...

  • Page 15: Pressure Relief Valve

    APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics 4.3. Pressure relief valve The base of the control unit is equipped with a pressure relief valve which prevents an inadmissible pressure build-up in the inner control unit. If required, the pressure relief valve vents into the clearance between the base and the adapter of the control unit.
  • Page 16 APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics 4.4. Functional description - block diagrams 4.4.1. CU41plus AS-interface (internal position measuring system) Valve types: SW4, MS4, SV1, SVS1F AS-i Bus + AS-i Bus + AS-i Bus - AS-i Bus - LED 6 PELV E + PELV E- LED 5 5 VDC...
  • Page 17 APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics 4.4. Functional description - block diagrams 4.4.2. CU41Nplus AS-interface (internal position measuring system) Valve type: SD4 AS-i Bus + AS-i Bus + AS-i Bus - AS-i Bus - LED 6 PELV E + PELV E- LED 5 5 VDC Sensor 3 LED 9...
  • Page 18 APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics 4.4. Functional description - block diagrams 4.4.3. CU43plus AS-interface for DA3+SLD double seat valve (internal position measuring system and 2 external proximity switches) AS-i Bus + AS-i Bus + view X AS-i Bus - AS-i Bus - LED 6 PELV E + PELV E-...

  • Page 19: Functional Description - Block Diagrams

    APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics 4.4. Functional description - block diagrams 4.4.4. CU41plus-D4-V1 for D4 double seat mix proof valves AS-i Bus + AS-i Bus + AS-i Bus - AS-i Bus - LED 6 PELV E + PELV E- LED 5 5 VDC sensor 3 Sensor 3...
  • Page 20 APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics 4.4. Functional description - block diagrams 4.4.5. CU43plus-D4-V1 for D4 SL / PMO double seat mix proof valves AS-i Bus + AS-i Bus + AS-i Bus - AS-i Bus - Operating directions of valve targets LED 6 PELV E + main stroke down...
  • Page 21 APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics 4.4. Functional description - block diagrams 4.4.6. CU43plus-D4-V1 for DA4 double seat mix proof valves AS-i Bus + AS-i Bus + AS-i Bus - AS-i Bus - LED 6 Operating directions of valve targets PELV E + main stroke down M1 + M2...

  • Page 22: Technical Data / Standards

    APV_CU4plus_AS-interface_UK-3_062019.indd Mechanics and Pneumatics 4.5. Technical data / Standards Material: PA6.6/PA12 Ambient temperature: -20 to +70 °C, -4 to +158 °F EMC 2014/30/EU (89/336/EEC) Standards and environmental audits: protective class IP 67 EN 60529/ complies with NEMA 6 EMV interference resistance EN 61000-6-2 EMV emitted interference EN61000-6-4 AS-interface certification according to...

  • Page 23: Solenoid Valves

    APV_CU4plus_AS-interface_UK-3_062019.indd 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 connector. control: PWM signal handle: rotary switch at valve 4.7.

  • Page 24: Adapter

    APV_CU4plus_AS-interface_UK-3_062019.indd 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 valve DE3, DA3+ 5.4. Double seat mix proof valves D4, D4 SL, DA4 Control Unit CU4plus AS-interface Instruction Manual UK-3...

  • Page 25: Electronic Module

    APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.1. Function/block diagram The CU4plus AS-i control unit is 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 devices in the extended address range up to 62 slaves (formerly known as 2.1) can be connected with one AS-Interface cable.

  • Page 26: Function/Block Diagram

    APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.1. Function/block diagram 6.1.2. CU41plus-D4-V1 CU43plus-D4-V1 AS-i Bus + AS-i Bus + AS-i Bus - AS-i Bus - LED 6 PELV E + PELV E- LED 5 hall 1 hall 5 VDC (left) sensor Sensor 3 LED 9 LED 3/4 LED 8 LED 7...

  • Page 27: Functional Description Of Connections

    APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.2. Functional description of connections Terminal Designation Functional Description AS-i + connection AS-i network AS-i - connection AS-i network bridge Z+ / PELV E+ (in case of energy supply for solenoid valves via AS-i bus) bridge Z- / PELV E - (in case of energy supply for solenoid valves via AS-i bus) PELV E+ separate auxiliary energy PELV 24VDC + (for EMERGENCY STOP function, only) PELV E-...

  • Page 28: Technical Data / As-Interface

    APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.3. Technical data / AS-interface AS-interface-profile: S-7.A.*.E Extended address mode: is supported Serial communication mode: Inverse-polarity protection: exists Indication "Power": LED 3 (green) Indication "Fault": LED 4 (red) AS-interface voltage range: 26.5…31.6 V External voltage supply PELV 24 VDC max.

  • Page 29: Connections

    APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.4. Connections Sensors for valve position detection: Internal sensors: internal linear sensor SPX FLOW type switching distance acc. to SPX FLOW specification Internal hall sensors: "magnetic hall sensor" SPX FLOW UB 4.75 - 5.25 VDC switching distance acc. to SPX FLOW specification External sensors: inductive proximity switch...
  • Page 30 APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.5.1. LED indication / Indicator lights solenoid valve 2 / solenoid valve 2 controlled blue, 1 blink upper seat * lifted upper seat lift LED 1 solenoid valve 3 / solenoid valve 3 controlled blue, 2 blinks lower seat * lifted lower seat lift LED 2...

  • Page 31: Adjustement Of Valve Profiles

    APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.6. Adjustement of valve profiles The adjustment of valve profiles is carried out with the Service Software CU4plus Toolbox (see CU4plus Toolbox manual). For the different process valves different logic profiles exist. These differ in view of the detection of the feedback and the logic profile of the valve. Valve profile: Valve position Valve basic position Invert Number of Valve profile Tolerance band measuring system NO/NC valve position indication solenoids Mix proof valve internal linear sensor and 2...

  • Page 32: As-I Communication / Data Signals

    APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.7. AS-i communication / Data signals 6.7.1. Single seat valves with internal feedback detection NC - normally closed Application: single seat / butterfly valve with internal feedback detection (SW4, SD4, MS4, SVS, SV etc.) AS-i Communication valve state sensor 1 sensor 2 Input Data / IDI...
  • Page 33 APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.7. AS-i communication / Data signals 6.7.2. Mix proof valve with seat lift detection (DA3+ SLD) NC - normally closed Application: Double seat mix proof valve with seat lift detection (SLD) AS-i Communication valve state sensor 4 sensor 3 sensor 2 sensor 1...
  • Page 34 APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.7. AS-i communication / Data signals 6.7.3. Mix proof valve D4 operating main stroke downwards main stroke valve operating direction: downwards lower shaft signal S3 internal hall sensors valve target signal S4 upper shaft signal S2 linear sensor valve target signal S1 linear sensor...
  • Page 35 APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.7. AS-i communication / Data signals 6.7.4. Mix proof valve D4 SL / PMO operating main stroke downwards upper seat lift upwards lower seat lift downwards main stroke valve operating direction: downwards lower shaft signal S3 internal hall sensors valve target signal S4 upper shaft...
  • Page 36 APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.7. AS-i communication / Data signals operating main stroke downwards 6.7.5. Mix proof valve DA4 upper seat lift upwards lower seat lift upwards main stroke valve operating direction: downwards lower shaft signal S3 internal hall sensors valve target signal S4 upper shaft signal S2...

  • Page 37: Service And Maintenance Software Cu4Plus Toolbox

    APV_CU4plus_AS-interface_UK-3_062019.indd Electronic Module 6.7. AS-i communication / Data signals 6.7.6. AS-i parameter data / status / diagnosis AS-i parameter data (inverted) inputs outputs not occupied not occupied Teach mode not occupied Aux. Voltage not occupied Service requ. not occupied AS-i status inputs EEPROM error...

  • Page 38: Valve Position Indication

    APV_CU4plus_AS-interface_UK-3_062019.indd Valve Position Indication 7.1. Continuously measuring valve position measuring system For the internal detection of the valve position indication, a contact- free operating linear sensor is used which is actuated via the magnetic switching cam installed at the valve rod. The nominal measuring range of the measuring system amounts to 0 - 72 mm, relative repetitive accuracy < 0.1 mm.

  • Page 39: Adjustment Of Valve Position Indication / Teach-In

    APV_CU4plus_AS-interface_UK-3_062019.indd Valve Position Indication 7.3. Adjustment of valve position indication / Teach-in The continuously measuring valve position measuring system is tought via a reference valve movement. The respective positions for the closed and open valve position as well as for further valve positions, e.g. seat lifting, are travelled to and the corresponding position of the sensor system is permanently stored in the memory of the electronic module.

  • Page 40: Use Of External Sensors

    APV_CU4plus_AS-interface_UK-3_062019.indd Valve Position Indication 7.3.1. To be observed before teach-in: Corresponding switching cam is mounted to the valve guide rod. Note! Caution! The switching cam is not identical with the standard CU switching cam! CU4plus AS-i control unit is not duly installed on the valve. ist ordnungsgemäß...

  • Page 41: Cu Assembly And Startup

    APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.1. Valves with turning actuator, e.g. for butterfly valve CU cover CU base with electronic module, sensor tower and solenoid valves clamp ring fastening screws o-ring switching cam with adapter permanent magnet actuator Caution! The permanent magnet is made of fragile material and must be protected against mechanical load .
  • Page 42 APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 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.

  • Page 43: Single Seat Valve

    APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.2. Single seat valve CU cover CU base with electronic module, sensor tower and solenoid valves clamp ring fastening screws switching cam with permanent magnet adapter actuator Caution! The permanent magnet is made of fragile material and must be protected against mechanical load .
  • Page 44 APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 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.

  • Page 45: Double Seat Valve Da3+ With Activated Seat Lift Detection (Sld)

    APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.3. Double seat valve DA3+ with activated Seat Lift Detection (SLD) CU cover sensor 1 (TeachSignal) CU43plus sensor 2 (TeachSignal) clamp ring fastening screws magnetic switching cam guide rod extension CU adapter seat lift cylinder sensor 3 main actuator sensor 4...
  • Page 46 APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 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.
  • Page 47 APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.3.4. Startup After proper assembly and installation of 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.

  • Page 48: Double Seat Mix Proof Valves D4, D4 Sl, Da4

    APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.4. Double seat mix proof valves D4, D4 SL, DA4 CU cover linear sensor CU41/CU43 sensor 3 sensor 4 hall 1 hall 2 operating cam with magnet M1 screws clamp ring adapter operating cam with magnet M2 actuator Assembly of the control unit on the valve 1.
  • Page 49 APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.4.1 Pneumatic connection Supply air: Caution! Shut off the compressed air supply before connecting the air hose! Make sure 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.
  • Page 50 APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.4.3 Connection of external proximity switches The electric connection of the proximity switches specified by lever SPX FLOW is undertaken according to the terminal layout described in chapter 6. The mechanic assembly of the proximity switches is carried out at the actuator of the corresponding double seat valves. Observance of the instruction manual for double seat valves is essential! 8.4.4...
  • Page 51 APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.4.5.1. Pre-setting of CU4plus AS-i on D4 mix proof valve Step Description assembly of adapter assembly of CU4plus connect air hoses with CU and D4 valve actuator - Air out 1 / main actuator - Air out 2 / upper seat lift actuator - Air out 3 / lower seat lift actuator CU4plus AS-i power ON switch compressed control air supply ON...
  • Page 52 APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.4.5.2. Pre-setting of CU4plus AS-i on D4 SL / PMO mix proof valve Step Description assembly of adapter assembly of CU4plus connect air hoses with CU and D4 valve actuator - Air out 1 / main actuator - Air out 2 / upper seat lift actuator - Air out 3 / lower seat lift actuator CU4plus AS-i power ON...
  • Page 53 APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.4.5.3. Pre-setting of CU4plus AS-i on DA4 mix proof valve Step Description assembly of adapter assembly of CU4plus connect air hoses with CU and D4 valve actuator - Air out 1 / main actuator - Air out 2 / upper seat lift actuator - Air out 3 / lower seat lift actuator CU4plus AS-i power ON switch compressed control air supply ON...

  • Page 54: Replacement Of Cu3 Versions

    APV_CU4plus_AS-interface_UK-3_062019.indd CU Assembly and Startup 8.5. Replacement of CU3 versions Replacement of a standard CU3 AS-i All CU41 variants can substitute a CU3 control unit without changing the signal routing. When replacing the CU3, the larger dimensions of the CU4 control unit must, however, be considered. If a CU43 is to replace a CU33 control unit, the change of the seat lifting signals must be observed.

  • Page 55: Accessories And Tools

    APV_CU4plus_AS-interface_UK-3_062019.indd Accessories and Tools Assembly/disassembly - adapter on valve actuator: • hexagon socket wrench 6 mm • screwdriver 4 mm 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 –...

  • Page 56: 10. Service

    APV_CU4plus_AS-interface_UK-3_062019.indd 10. Service 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.

  • Page 57: Trouble Shooting

    APV_CU4plus_AS-interface_UK-3_062019.indd Trouble Shooting Failure Remedy Valve position is not indicated. Carry out teach-in. Check fastening of magnetic switching cam. Check adjusted logic profile and process valve. Feedback via proximity Check positioning of proximity switches is missing. switches. Check AS-i bus communication. Check cabeling to the electronic module.
  • Page 58 APV_CU4plus_AS-interface_UK-3_062019.indd Trouble Shooting Failure Remedy Control Unit CU41 installed on Single seat, Double seal and Double seat valves Valve position movement is Check if right control unit is missing with actuated solenoid installed. Check label in type valve. window of control unit: CU41plus-S AS-i CU41Nplus-S AS-i CU41plus-M AS-i...

  • Page 59: 12. Spare Parts Lists

    APV_CU4plus_AS-interface_UK-3_062019.indd 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. CU4plus AS-interface RN 01.044.6 CU4 Adapter RN 01.044.3-1 When you place an order for spare parts, please indicate the following data: number of parts required ID number...
  • Page 61 Datum: 04.01.16 16.05.19 Name: Trytko C.Keil Geprüft: Schulz Ersatzteilliste: spare parts list SPX FLOW Germany Blatt Control Unit CU4plus AS-i extended RN 01.044.6...
  • Page 76 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.spxflow.com. ISSUED 06/2019 - Original Manual...

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