apv cu4 direct connect - spx flow · cu43-m-dc / cu43-d4 design for double seat mixproof valves...

APV CU4 Direct ConnectCONTROL UNIT

FORM NO.: H323871 REVISION: UK-7 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.

INSTRUCTION MANUAL

APV_CU4 DC_UK-7_052018.indd

UK

Control Unit CU4 Direct ConnectInstruction Manual: UK-7

APV

3

Content Page

IT IS ESSENTIAL TO READ THIS INSTRUCTION MANUAL BEFORE USE OF THE CONTROL UNIT!

1. AbbreviationsandDefinitions 42. SafetyInstructions 42.1. Sentinels2.2. Intended Use2.3. General Regulations for Careful Handling2.4. Welding instructions2.5. Persons2.6. Warranty3. General Terms 73.1. Purpose of use3.2. Design of CU4 Direct Connect3.3. Function of the individual components 4. MechanicsandPneumatics 104.1. Air connection for valves with turning actuators4.2. Air connections for seat valves and double seat mix proof valves4.3. Pressure relief valve 4.4 Functional description - block diagrams4.5. Technical Data / Standards4.6. Solenoid valves4.7. Throttling function4.8. NOT element5. Adapter 195.1. Valveswithturningactuator,e.g.butterflyvalves5.2. Single seat valves5.3. Double seat mix proof valves DE3, DA3+5.4. Double seat mix proof valves D4, D4 SL, DA46. Electronicmodule 206.1 Function / Block diagram6.2. Functional description of connections6.3. Technical data for electronic module 6.4. Connections6.5. LED indication6.6. Wiring examples7. Feedback unit 267.1. General terms7.2. Sensors7.3. Adjustment of valve position feedback7.4. Use of external sensor8. CU Assembly and Startup 278.1. Valveswithturningactuator,e.g.butterflyvalves8.2. Single seat valves8.3. Double seat mix proof valves DE3, DA3+8.4. Double seat mix proof valves D4, D4 SL, DA49. Accessories and Tools 3910. Service 4010.1. Disassembly11. TroubleShooting 4112. Spare Parts Lists

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Control Unit CU4 Direct Connect

Instruction Manual: UK-7

1. AbbreviationsandDefinitions

A ExhaustairAWG American Wire GaugeCE Communauté EuropéenneCU Control UnitDI Digital InputDO Digital OutputEMV Electromagnetic CompatibilityEU European UnionGND Ground/mass potentialIP International ProtectionLED Luminous diodeN Pneumatic Air Connection NOT elementNEMA National Electrical Manufacturers AssociationP Supply Air ConnectionPWM Pulse-widthmodulationY Pneumatic Air Connection

2. Safety Instructions

2.1. Sentinels

Meaning:

Danger! Direct danger which can lead to severe bodily 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.

Thesespecialsafetyinstructionspointdirectlytotherespectivehandlinginstructions.Theyareaccentuatedbythecorrespondingsymbol.Carefullyreadtheinstructionstowhichthesentinelsrefer.Continuehandlingthecontrolunitonlyafterhavingreadtheseinstructions.

DANGERDANGER

!

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2.2. Intended UseThe CU4 control unit is only intended for use as described in chapter 3.1. Use beyond that described in chapter 3.1. does not comply with the regulations and SPX FLOW shall not be responsible for any damage resulting from this non-observance. The operator bears the full risk. Prerequisites for proper andsafe operation of the control unit are the appropriate transport and storing as well as the professional assembly. Intended use also means the observance of operating, service and maintenance conditions.

2.3. General Regulations for Careful HandlingTo ensure a faultless function of the unit and a long service life, the information given in this instruction manual as well as the operatingconditionsandpermissibledataspecifiedinthedata 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 electric 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 electric or pneumatic supply, ensureadefinedandcontrolledre-startoftheprocess!

- If these instructions are not observed, SPX FLOW will not accept any liability. Warranties on units, devices and accessories will expire!

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2.4. WeldinginstructionsIt is generally recommended to avoid welding work in process installations in which control units are installed and connected. If welding is nonetheless required, earthing of the electric devices in the welding area is a necessity.

2.5. Persons - Installation and maintenance work may only be carried out by

qualifiedpersonnelandbymeansofappropriatetools. - Thequalifiedpersonnelmustgetaspecialtrainingwithregardto

possible risks and must know and observe the safety instructions indicated in the instruction manual.

- Work at the electrical installation may only be carried out by personnel skilled in electrics!

2.6. WarrantyThis 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 compliancewiththespecifiedconditionsofapplication.

Note! This warranty only applies to the Control Unit. No liability will be accepted for consequential damage of any kind arising from failure or malfunction of the device.

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fig. 3.2.1

fig. 3.2.

5.

2.

3.

1.

6.

4.3.

2.

cable guide

3. General Terms

3.1. Purpose of useThe CU4 Direct Connect Control Unit is designed for the control of process valves used in the food 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 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 for potential-free contacts. The corresponding light signals in the control unit provide for an external indiciation of the valve positions.

3.2. DesignofCU4DirectConnect(fig.3.2.)

The CU4 Direct Connect 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 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 the control, evaluation of feedback signals and control of solenoid valves as well as the valve position indication through LED.

5. Clamp ring to fasten the CU4 on the adapter.

6. Cover with LED optics.

The cable/s by means of which the solenoid valves are connected with the electronic module must be guided through the cable guide at the rear side of the electronic module. (fig.3.2.1)

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3. General Terms

3.3. Functionoftheindividualcomponents

The installation of the control unit is undertaken by special adapters which are available for the different valve types, see chapter5. Adapter. The snap connectors for supply air and pneumatic air to the individual cylinders of the valves are located at the outside of the control unit. In case of 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 exchangeableairfilter.Observanceoftherequiredcompressedair quality is imperative. Please also see chapter4.5.

The number of the solenoid valves installed in the CU4 dependsonthevalveactuatorstobecontrolled.Singleseatandbutterfly 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 has 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 areavailable,e.g.DirectConnect,AS-interface,Profibusand DeviceNet. The CU4 Direct Connect module described herein provides for the direct parallel wiring of the control.

A feedback unit is required to detect the valve position. The CU4 Direct Connect is equipped with 2 adjustable Hall effect sensors. These are activated by a valve control rod installed on the operating cam. In this way, the open and closed valve position can be detected.The 2 Hall effect sensors are continuously adjustable over anadditional range. Thus, feedback messages for different valveswith different stroke lengths can be adjusted properly. Alternatively, external proximity switches can be connected insteadof the integrated Hall effect sensors when the valve positionindication is undertaken direct at the process valve.

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3. General Terms

3.3. Functionoftheindividualcomponents

The luminous diodes are arranged at the front side of the electronic module. Their signals are visibly indicated to the outside by an optical window in the cover of the control unit. Beside the open and closed valve position, the existence of the operating voltage aswell as different diagnostic information are indicated. Chapter6.5.“LED indication” contains more details.

The complete control unit has been designed on the buildingblock 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.

Note! Wiring must also be changed.

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4.2.1. Function

CU41-S-DC/CU41-M-DC/CU41-D4 design for seat valves and double seat mix proof valves withoutseatlift P airsupplywithintegratedparticlefilter Y1 control air connection for main actuator A1 exhaust air, with exhaust silencer

CU41N-S-DC designforseatvalveswithNOTelement P airsupplywithintegratedparticlefilter Y1 control 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-DC/CU43-D4 designfordoubleseatmixproofvalveswithseatlift P airsupplywithintegratedparticlefilter Y1 control 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-DC designforvalvewithturningactuator,e.g.butterflyvalves

P airsupplywithintegratedparticlefilter Y1 bore to transfer control air to turning actuator A1 exhaust air, with exhaust silencer

4. MechanicsandPneumatics

4.1. Airconnectionforvalveswithturningactuators

4.2. Airconnectionsforseatvalvesanddoubleseatmixproofvalves

A1

A1 A2

Y1

Y1 Y2(N) Y3

PAIR IN

PAIR IN

S3

S2

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DANGER


4.3. Pressurereliefvalve

The base of the control unit is equipped with a pressure relief valve which prevents an inadmissible pressure build-up in theinner control unit. If required, the pressure relief vents into the clearance betweenthe base and the adapter of the control unit.

The pressure relief valve must not be mechanically blockedunder any circumstances.

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The picture shows a standard NC (spring to closed) valve.If a NO (spring to open) valve is used,the sensor wiring can be different.

1Power

Power

DO Valve closed

DO Valve open

DO Common

DI Main ValveNot usedNot usedDI Common

5V DC

Sensor 1

Gnd

5V DC

Sensor 2

Gnd

Sensor 2“Valve open”

Sensor 1“Valve closed”

23

4

5

A / Exhaust airP / Air supply

Solenoid valve

Throttle valves

6

9

101112131415

78


4.4 Functionaldescription-blockdiagrams

4.4.1. CU41DirectConnect

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The picture shows a standard NC (spring to closed) valve.If a NO (spring to open) valve is used,the sensor wiring can be different.


Solenoid valve

NOT-element

Pressure reducing valve(locked to 5bar)

Self-lockconnector

Throttle valves

1Power

Power

DO Valve closed

DO Valve open

DO Common


5V DC

Sensor 1

Gnd

5V DC

Sensor 2

Gnd

2

3456

9

10

1112

131415

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4.4.2. CU41NDirectConnect

Functional description - block diagram



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The picture shows a standard NC (spring to closed) valve.

1Power

Power

DO Valve closed

DO Valve open

DO Common


5V DC

Sensor 1

Gnd

5V DC

Sensor 2

Gnd



2

3

4

5


Solenoid valve

Throttle valves

6

9

101112131415

78


4.4.3. CU41-D4DirectConnectforD4doubleseatmixproofvalve


M1 - magnet upper shaft

M2 - magnet lower shaftM1

M2

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Exhaust air

Exhaust air

IN air



1PowerPowerDO Valve closedDO Valve openDO CommonDI Main ValveDI upper Seat liftDI lower Seat liftDI Common

5V DCSensor 1Gnd5V DCSensor 2Gnd

23456

9

101112

sol. 1

sol. 2

sol. 3

131415

78

mai

n cy

linde

ran

d in

tegr

ated

sea

t lift

cy

linde

rup

per v

alve

sea

t

seat

lift

cylin

der

low

er v

alve

sea

t4. MechanicsandPneumatics

4.4.4. CU43DirectConnectforDE3,DA3+doubleseatmixproofvalve


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Exhaust air

Exhaust air

IN air



1PowerPowerDO Valve closedDO Valve openDO CommonDI Main ValveDI upper Seat liftDI lower Seat liftDI Common

5V DCSensor 1Gnd5V DCSensor 2Gnd

23456

9

101112

sol. 1

sol. 2

sol. 3

131415

78

mai

n cy

linde

ran

d in

tegr

ated

sea

t lift

cy

linde

rup

per v

alve

sea

t

seat

lift

cylin

der

low

er v

alve

sea

t


4.4.5. CU43-D4DirectConnectforDA4/D4SLdoubleseatmixproofvalves


M1

M2

M1 - magnet upper shaft

M2 - magnet lower shaft

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4.5. TechnicalData/Standards

Material: PA6.6

Ambient temperature: -20°C to +70°C

EU: EMC 2014/30/EU (89/336/EEC)

Standards and environmental audits: protection class IP 67 EN 60529 / complies with NEMA 6 EMC interference resistance EN 61000-6-2 EMC emitted interference EN 61000-6-4

vibration/oscillation EN 60068-2-6 safety of machinery

DIN EN ISO 13849-1

Airhose: 6 mm / ¼“ 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 m³ 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 higher altitudes, consider additional measures to reduce the pressure dew point accordingly.

content of oil: quality class 1, max. 0,01 mg/m³

TheoilappliedmustbecompatiblewithPolyurethane elastomer materials.

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throttling screws


4.6. Solenoidvalves

In the base of the control unit max. 3 solenoid valves are installed.The 3/2-way solenoid valves are connected with the electronicmodule by moulded cables and plug connectors.

control: effected by pwm-signalhandle: rotary switch at valve

4.7. Throttlingfunction

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 firstsolenoid 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. NOTelement

Through the installation of the logic NOT element, the closing force of the valve actuator can be increased by additional compressed air. The NOT element conveys the compressed air via an external reducing valve (max. 5 bar) to the spring side of the valve actuator.

Thepressurereducingvalveisfixedto5bar.

Note! The air connection of the NOT element is equipped with an integrated non-return valve. The air hose must be slided into the air connection until it stops - in order to open the non-return valve.

The NOT element is also used for air/air actuators.

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5. Adapter

Adapter for different process valves

5.1. Valveswithturningactuator,e.g.butterflyvalves

5.2. Single seat valves

5.3. DoubleseatmixproofvalvesDE3,DA3+

5.4. DoubleseatmixproofvalvesD4,D4SL,DA4

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Power

Power

1

1

2

3

14

6

4

3

2

13

12

11

10

9

5

DO Valve Closed

DO Common

DO Valve Open

DI Common

Sensor 1

5 VDC

GND

5 VDC

Sensor 2

15 GND

7

8

DI Main valve

DI Lower Seat Lift

DI Upper Seat Lift

CU 43Direct Connect

brown

brown

black

black

red

red

black

black

white

white

blue

blue

hallsensor

hallsensor

N15-K11K-AN5X

N15-K11K-AN5X

6. Electronic module

6.1 Function / Block diagramThe electronic module CU4 Direct Connect operates as interface between superordinated control (PLC) and is connected direct by parallel wiring, i.e. every individual signal is on a separate line. The large input voltage range from 15 to 48VDC provides for versatile connections. All operating ranges within the electronic module such as the control of the solenoid valves, position feedback and LED indication are separated galvanically and can, thus, be operated with different voltages. Control of the solenoid valves is effected in energy-saving manner via pwm-signals.

Power

Power

1

1

2

3

14

6

4

3

2

13

12

11

10

9

5

DO Valve Closed

DO Common

DO Valve Open

DI Common

Sensor 1

5 VDC

GND

5 VDC

Sensor 2

15 GND

7

8

DI Main valve

DI Lower Seat Lift

DI Upper Seat Lift

red

red

black

black

white

white

hallsensor

hallsensor

CU 43 - D4Direct Connect

S3

S2

Electronic module with sensors for allSPX FLOW APV valves

Electronic module with sensors for SPX FLOW APV / WCB D4 valves

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Terminal Designation Functional description for all valve types

Functional descriptionforD4,D4SLandDA4valvetypes

1 Power Operating voltage Operating voltage

2 Power Operating voltage Operating voltage

3 DO Closed Valve Digital potential-free output for closed valve position

Digital potential-free output for closed valve position

4 DO Open Valve Digital potential-free output for open valve position

Digital potential-free output for open valve position

5 DO Common Common potential for digital output to valve position indication

Common potential for digital output to valve position indication

6 DI Main Valve Digital input to control 1st solenoid valve (valve open)

Digital input to control 1st solenoid valve (valve open)

7 DI Upper Seat LiftDigital input to control 2nd solenoid valve (seat lifting of upper valve seat)

Digital input to control 2nd solenoid valve (seat lifting of upper valve seat)

8 DI Lower Seat LiftDigital input to control 3rd solenoid valve (seat lifting of lower valve seat)

Digital input to control 3rd solenoid valve (seat lifting of lower valve seat)

9 DI Common Common potential for digital inputs to control valve

Common potential for digital inputs to control valve

10 5 VDC Voltage supply for valve sensor Voltage supply for valve sensor

11 Sensor 1 Sensor signal 1 (closed valve position)

Connection Hall sensor 3(closed valve position)

12 GND Mass potential for sensor supply Mass potential for sensor supply

13 5 VDC Voltage supply for valve sensor Voltage supply for valve sensor

14 Sensor 2 Sensor signal 2 (open valve position)

Connection Hall sensor 2(open valve position)

15 GND Mass potential for sensor supply Mass potential for sensor supply


6.2. Functional description of connections

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6.3. Technicaldataforelectronicmodule

CU4DirectConnect Operating voltage: 15 – 24VDC

Supply of solenoid valve: pwm-signal from electronic module Dig.input(DI): 15 – 48VDC Imax. 1mA/24VDC

Dig.output(DO): Umax. 48VDC Imax. 150mA RI 5,6Ohm / 100mA

Voltage supply of sensors: 5VDC (+/-5%) Power consumption Minimum about 20mA, at 24VDC (Power ON, 2 LED, no solenoid valve) Typically about 35mA, at 24VDC (Power ON, 2 LED, 1 solenoid valve) Maximum about 55 mA, at 24VDC (Power ON, 3 LED, 2 solenoid valves)

Connecting terminals: conductor cross section 0,5-1,5 mm² (with conductor sleeve) complying with AWG 20-16

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6.4. Connections

Sensorstodetectthevalvepositions:

Internal sensors: Hall effect sensors (APV valves): H320385 (APV / WCB D4 valves): H337014 UB 4,75-5,25 VDC operating distance according to SPXFLOWspecification

External sensors: Inductive proximity switches: H208844 UB 4,75-5,25 VDC operating distance according to SPXFLOWspecification

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External luminous displays

Valve Open colour green, permanent light valve in open position

Valve Closed colour orange, permanent light valve in closed position

Power Diagnosecolour green, permanent light operating voltage at module - faultless

colour green, flashing failure solenoid valve (wire fracture)

Solenoid Main colour blue, permanent light main solenoid valve (1) controlled

Solenoid Main○upperseat○○lowerseat

colour blue, 1 blink solenoid valve (2) for upper seat lift controlled

colour blue, 2 blinks solenoid valve (3) for lower seat lift controlled

colour blue, permanent blink solenoid valves (2) + (3) for diagnosis, only

Internal luminous displays

Luminousdiode 1 1st solenoid valve (1) controlled

Luminousdiode 2 2nd solenoid valve (2) controlled

Luminousdiode 3 3rd solenoid valve (3) controlled

Valve Open

1

2

3

Valve Closed

Power DiagnoseSolenoid Main

Solenoid○upperseat○○lowerseat


6.5. LED indication

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Power

Power

Power

Power

Power

Power

Power

Power

DO Valve closed

DO Valve closed

DO Valve closed

DO Valve closed

DO Valve open

DO Valve open

DO Valve open

DO Valve open

DO Common

DO Common

DO Common

DO Common

DI Main Valve

DI Main Valve

DI Main Valve

DI Main Valve

DI upper seat lift

DI upper seat lift

DI upper seat lift

DI upper seat lift

DI lower seat lift

DI lower seat lift

DI lower seat lift

DI lower seat lift

DI Common

DI Common

DI Common

DI Common

15 - 48 VDC 1

1

1

1

3

3

3

3

5

5

5

5

8

8

8

8

2

2

2

2

4

4

4

4

7

7

7

7

6

6

6

6

9

9

9

9

Example 1

Example 2

Example 3

Example4

15 - 48 VDC

15 - 48 VDC

15 - 48 VDC

15 - 48 VDC

15 - 48 VDC

15 - 48 VDC

15 - 48 VDC

DC Gnd

DC Gnd

DC Gnd

Gnd

Gnd

15 - 48 VDC

DC Gnd

Gnd

5/7 cable requiredDC supplyDC valve signal2 feedback to SPScommon DC mass

5/7 cable requiredDC supplyDC valve signal2 feedback to SPScommon DC mass

7/9 cable requiredDC supplyDC valve signal2 feedback to SPSseparated DC mass, functional unitsgalvanically isolated

7/9 cable requiredDC supplyDC valve signal2 feedback to SPSseparated DC mass, functional unitsgalvanically isolated


6.6. Wiring examples

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7. Feedback unit

7.1. General termsFor the internal registration of the valve position indication,the feedback unit with 2 Hall effect sensors is applied. It is usedwhensingleseatandbutterflyvalvesareinstalled.The control of these sensors is effected by magnets assembledon the valve shaft rod. The Hall effect sensors are installed on amovable threaded rod. By means of this assembly, the sensorscan be adjusted via a large range, in accordance with the valvestroke.

7.2. SensorsHall effect sensors (APV valves): H320385Hall effect sesonrs (APV / WCB D4 valves): H337014UB 4,75-5,25 VDC operatingdistanceaccordingtoSPXFLOWspecification

7.3. Adjustment of valve position feedbackBy 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 accidental displacement of these positions. After the installation of the control unit, check the correct adjustment of the position of the Hall sensor.

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

Proximity switch: H208844UB 4,75-5,25 VDCOperatingdistanceaccordingtoSPXFLOWspecification

adjustment screws

Hall effect sensor

Hall effect sensors

adjustment screws

S2

S3

Feedback unit for SPX FLOW APV valves

Feedback unit for SPX FLOW APV / WCB D4 valves

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8. CU Assembly and Startup

8.1. Valveswithturningactuator,e.g.butterflyvalves

Caution!The permanent magnet is made of fragile material and must be protected against mechanical load . – Risk of fracture!Themagneticfieldscandamageordeletedatacarrierorinfluenceelectronicandmechaniccomponents.

AssemblyoftheControlUnitonthevalve

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.

!

CU cover

CU base with elect-ronic module, sensor tower and solenoid valves

clamp ring

fastening screws

O-ring

adapter

actuator

operating cam withpermanent magnet

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8.1.1. 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 for valve actuator: For the assembly of the control unit on the turning actuator withintegrated air transfer, air hosing between the control unit andthe actuator is not required. Exhaustair: As a standard, the exhaust air connection is equipped with asilencer. If required, the silencer can be removed and the exhaustair can be hosed separately when it must be led off to the exterior,for example.

8.1.2. Electric connection

Attention! Electricconnectionsshallonlybecarriedoutbyqualifiedpersonnel!

Make sure that the operating voltage is correct!

After determining the connecting variant according to chapter 6.6. Wiring Examples, select the corresponding cable.

Guide the cable through the cable gland and connect it accordingto the Wiring Diagram. Preferably use wire terminations!

Tighten the cable gland in order to ensure the correspondingprotective class.

!

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8.1.3 StartupAfter 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.

Forvalvesinnormallyclosed(air-to-raise,spring-to-lower)/normallyopen(air-to-lower,spring-to-raise)designwithturningactuator,thefollowingallocationapplies:

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

FortheadjustmentofHallsensor2,atfirst,the(non-controlled)solenoid valve 1 is controlled. This can optionally be mademanually or electrically. The open valve position and the corresponding feedback can be adjusted. This is undertakenby turning the adjustment screw 2 until the required position isreached and the LED Valve Open lights up.

ObservetheswitchinghysteresisoftheHalleffectsensors!Therefore,adjusttheswitch-pointofthesensorswithoverlapinordertopermitsmallvariationsand,thus,to prevent failures!

lever

solenoid valve

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8.2. Single seat valves

CAUTION!The permanent magnet is made of fragile material and must beprotected against mechanical load . – Risk of fracture!Themagneticfieldscandamageordeletedatacarrierorinfluenceelectronicandmechaniccomponents.


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.


!

CU cover

CU base with elect-ronic module, sensor tower and solenoid valves

clamp ring

fastening screws

adapter

actuator

operating cam withpermanent magnet

31


APV UK




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 for valve actuator: Connect the pneumatic air connection Y1 with the valve actuator.

- For the CU41N (withlogicNOTelement), the pneumatic air connection N must be connected with the spring side of the actuator.Take note of the spring side of the actuator during the assembly of the pressure-reducing valve.

Exhaustair: 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.

8.2.2. Electric connection

Attention!Electric connections shall only be carried out by qualifiedpersonnel.


After determining the connecting variant according to chapter 6.6 Wiring Examples, select the corresponding cable.

Guide the cable through the cable gland and connect it accordingto the Wiring Diagram. Preferably use wire terminations!Tighten the cable gland in order to ensure the correspondingprotective class.

!

32


APV UK




8.2.3. StartupAfter proper assembly and installation of the control unit, start-upcan be undertaken as described below:

1. Switch on the air supply



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:


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


FortheadjustmentofHallsensor2,atfirst,the(non-controlled)solenoid valve 1 is controlled. This can optionally be mademanually or electrically. The open valve position and thecorresponding feedback can be adjusted. This is undertakenby turning the adjustment screw 2 until the required position isreached and the LED Valve Open lights up.

ObservetheswitchinghysteresisoftheHalleffectsensors!Therefore,adjusttheswitch-pointofthesensorswithoverlapinordertopermitsmallvariationsand,thus,to prevent failures!

lever

solenoid valve

33


APV UK



8.3. DoubleseatmixproofvalvesDE3,DA3+


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!


5. Assemble the external proximity switches at the actuator.

CU cover

CU41/CU43

externalproximity switches

feedback 2 foropen

valve position

feedback 1 forclosed

valve position

clamp ring

fastening screws

adapter

spring cylinder

air actuator

seat lift actuator

34


APV UK





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. Main actuator

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

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

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

8.3.2 Electric connection

Attention!Electricconnectionsshallonlybecarriedoutbyqualifiedpersonnel!


After determining the connecting variant according to chapter 6.6.Wiring Examples, select the corresponding cable.

Guide the cable through the cable gland and connect it accordingto the Wiring Diagram. Preferably use wire terminations! Tighten the cable gland in order to ensure the correspondingprotective class.

!

35


APV UK



8.3.3 ConnectionofexternalproximityswitchesTheelectricconnectionoftheproximityswitchesspecifiedbySPX FLOW is undertaken according to the terminal layout described in chapter 6.1.The mechanic assembly of the proximity switches is carried outat the actuator of the corresponding double seat valves.Observance of the instruction manual for double seat valves is essential!

8.3.4 StartupAfter proper assembly and installation of the control unit, start-upcan be undertaken as described below




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

Thefollowingallocationappliesfordoubleseatvalves:



Checktheproperfitoftheproximityswitchestoprovidefortheaccuratetransferofthesignalsforthecorresponding valve position.

lever

solenoid valve

36


APV UK




8.4. DoubleseatmixproofvalvesD4,D4SL,DA4


1. Assemble the magnet M2 on the upper shaft under the stop screw.

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 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

37


APV UK



8.4.1 Pneumaticconnection

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. Main actuator

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

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

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

8.4.2 Electricconnection

Attention!Electricconnectionsshallonlybecarriedoutbyqualifiedpersonnel!


After determining the connecting variant according to chapter 6.6.Wiring Examples, select the corresponding cable.

Guide the cable through the cable gland and connect it accordingto the Wiring Diagram. Preferably use wire terminations! Tighten the cable gland in order to ensure the correspondingprotective class.

1

2

3

!

38


APV UK




8.4.3 ConnectionofexternalproximityswitchesTheelectricconnectionoftheproximityswitchesspecifiedbySPX FLOW is undertaken according to the terminal layout described in chapter 6.1.The mechanic assembly of the proximity switches is carried outat the actuator of the corresponding double seat valves.Observance of the instruction manual for double seat valves is essential!

8.4.4 StartupAfter proper assembly and installation of the control unit, start-upcan be undertaken as described below




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

Thefollowingallocationappliesfordoubleseatvalves:



Checktheproperfitoftheproximityswitchestoprovidefortheaccuratetransferofthesignalsforthecorresponding valve position.

lever

solenoid valve

39


APV UK


9. 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 – air connections:• jaw wrench M13

Assembly/disassembly – pressure relief valve:• torx wrench TX10 Loctite semi-solid

jaw wrench torx wrench

hexagon socket wrenchscrewdriver

40


APV UK



10. Service

10.1. DisassemblyBefore disassembly, verify the following items:

• Thevalvemustbeinsafetypositionandmustnotbecontrolled!• Shutoffairsupply!• Cutoffcurrenttocontrolunit,i.e.interruptthesupplyvoltage

Solenoidvalve(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. Seetoaproperfitoftheflatseal!

Electronicmodule(2)Before releasing the cable connections make sure that all lines are switched off!

+ 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 1-8.+ Release and remove the 3 screws (20) TX20.+ Replace the electronic module.+ Assembly in reverse order.

Feedback unitBefore releasing the cable connections make sure that all linesare switched off!

+ 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 sensorsThe 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-ring (11)+ Dismantle the sensors by turning 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 chapter8 „CU assembly and start-up“.

adjusting screws

Hall effect sensor

Hall effect sensors

adjustingscrews

Feedback unit for SPX FLOW APV valves

Feedback unit for SPX FLOW APV / WCB D4 valves

41


APV UK


11. TroubleShooting

General Failures 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.

Failure Remedy

ControlUnitCU41installedonButterflyvalves

Movement of valve flap is missingwith actuated solenoid valve.

Check if right control unit is installed.Check label in type window of control unit: CU41-T-DirectConnect(1EMV/solenoidvalve)

Check valve movement with manual at solenoid valve.

Check cabeling between electronic module and sole-noid 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.

42


APV UK



11. TroubleShooting

Failure Remedy

ControlUnitCU41installedonSingleseatandDoubleseatvalves

Valve position movement is missingwith actuated solenoid valve.

Check if right control unit is installed.Check label in type window of control unit: CU41-S-DirectConnect(1EMV/solenoidvalve)CU41-M-DirectConnectCU41-D4-DirectConnect

Check valve movement with manual lever at solenoid valve.



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

ControlUnitCU43installedonDoubleseatvalves

Valve position movement is missingwith actuated solenoid valve.

Check if right control unit is installed.Check label in type window of control unit: CU43-M-DirectConnect(3EMV/solenoidvalves)CU43-D4-DirectConnect

Check valve movement with manual lever at solenoid valve.



Check control air connection between the CU43 and the DA3 / DA4 / D4 SL actuator.

43


APV UK


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.

CU4DirectConnect RN01.044.4CU4Adapter RN01.044.3

When you place an order for spare parts, please indicate thefollowing data:

- number of parts required - reference number - parts designation

Data are subject to change.

Datum:

Name:

Geprüft:

Ersatzteilliste: spare parts list

06/10

D.Schulz

D.Schulz

07/08

Peters

SPX FLOWGermany

CU4 Direct Connect

Peters

02/10

Peters

D.Schulz

11/0808/08

Peters

04/18

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---

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---

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WS

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Dat

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9874

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08-4

8-63

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8096

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7150

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9874

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58-0

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H32

0505

CU

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ax

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no.

08-4

8-61

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H32

1988

08-4

6-56

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H31

9873

08-4

8-60

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H32

0475

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H31

9875

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08-4

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1987

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08-4

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0476

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08-4

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H32

0474

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APV CU4 Direct Connect CONTROL UNIT

SPX FLOW SPX FLOW

Design Center Production

Gottlieb-Daimler-Straße 13 Stefana Rolbieskiego 2

D-59439 Holzwickede, Germany PL- Bydgoszcz 85-862, Poland

P: (+49) (0) 2301-9186-0 P: (+48) 52 566 76 00

F: (+49) (0) 2301-9186-300 F: (+48) 52 525 99 09

SPX FLOW reserves the 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.spxflow.com.

ISSUED 05/2018 - Translation of Original Manual

COPYRIGHT ©2018 SPX FLOW, Inc.

apv cu4 direct connect - spx flow · cu43-m-dc / cu43-d4 design for double seat mixproof valves...

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