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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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. Safety Instructions
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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Instruction Manual: UK-7
2. Safety Instructions
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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Instruction Manual: UK-7
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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Instruction Manual: UK-7
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. MechanicsandPneumatics
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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Instruction Manual: UK-7
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. MechanicsandPneumatics
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.
A / Exhaust airP / Air supply
Solenoid valve
NOT-element
Pressure reducing valve(locked to 5bar)
Self-lockconnector
Throttle valves
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
2
3456
9
10
1112
131415
78
4. MechanicsandPneumatics
4.4.2. CU41NDirectConnect
Functional description - block diagram
Sensor 2“Valve open”
Sensor 1“Valve closed”
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Control Unit CU4 Direct Connect
Instruction Manual: UK-7
The picture shows a standard NC (spring to closed) valve.
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 3“Valve closed”
2
3
4
5
A / Exhaust airP / Air supply
Solenoid valve
Throttle valves
6
9
101112131415
78
4. MechanicsandPneumatics
4.4.3. CU41-D4DirectConnectforD4doubleseatmixproofvalve
Functional description - block diagram
M1 - magnet upper shaft
M2 - magnet lower shaftM1
M2
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The picture shows a standard NC (spring to closed) valve.
Exhaust air
Exhaust air
IN air
Sensor 2“Valve open”
Sensor 1“Valve closed”
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
Functional description - block diagram
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Control Unit CU4 Direct Connect
Instruction Manual: UK-7
The picture shows a standard NC (spring to closed) valve.
Exhaust air
Exhaust air
IN air
Sensor 2“Valve open”
Sensor 3“Valve closed”
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. MechanicsandPneumatics
4.4.5. CU43-D4DirectConnectforDA4/D4SLdoubleseatmixproofvalves
Functional description - block diagram
M1
M2
M1 - magnet upper shaft
M2 - magnet lower shaft
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4. MechanicsandPneumatics
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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Instruction Manual: UK-7
throttling screws
4. MechanicsandPneumatics
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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Control Unit CU4 Direct Connect
Instruction Manual: UK-7
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. Electronic module
6.2. Functional description of connections
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6. Electronic module
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. Electronic module
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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Instruction Manual: UK-7
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. Electronic module
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. Electronic module
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
27
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APV UK
Control Unit CU4 Direct ConnectInstruction Manual: UK-7
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
28
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct Connect
Instruction Manual: UK-7
8. CU Assembly and Startup
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.
!
29
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct ConnectInstruction Manual: UK-7
8. CU Assembly and Startup
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
30
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct Connect
Instruction Manual: UK-7
8. CU Assembly and Startup
8.2. Single seat valves
CAUTION!The permanent magnet is made of fragile material and must beprotected against mechanical load . – Risk of fracture!Themagneticfieldscandamageordeletedatacarrierorinfluenceelectronicandmechaniccomponents.
AssemblyoftheControlUnitonthevalve
1. Assembly of the adapter on the single seat valve. Fasten with 4 screws.
2. Secure operating cam with Loctite semi-solid and fasten it.
3. Place the control unit via the operating cam onto the adapter. Observe alignment.
4. Attach the clamp rings and fasten them with the screws.
!
CU cover
CU base with elect-ronic module, sensor tower and solenoid valves
clamp ring
fastening screws
adapter
actuator
operating cam withpermanent magnet
31
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct ConnectInstruction Manual: UK-7
8. CU Assembly and Startup
8.2.1. 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: 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.
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.
!
32
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct Connect
Instruction Manual: UK-7
8. CU Assembly and Startup
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
2. Switch on the voltage supply.
3. Check the solenoid valves by turning the handle on the upper side of the valve by 90°.
4. Check the valve position indicator and adjust feedbacks for open and closed valve position as described below.
For single seat valves in normally closed (normally open)the following allocation applies:
Closed valve position feedback – sensor 1 controlled
For the adjustment, Hall sensor 1 with non-controlled (controlled)solenoid valve 1 is moved into the required position by turning theadjustment 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 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
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APV UK
Control Unit CU4 Direct ConnectInstruction Manual: UK-7
8. CU Assembly and Startup
8.3. DoubleseatmixproofvalvesDE3,DA3+
AssemblyoftheControlUnitonthevalve
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.
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_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct Connect
Instruction Manual: UK-7
8. CU Assembly and Startup
8.3.1. 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. 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!
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.
!
35
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct ConnectInstruction Manual: UK-7
8. CU Assembly and Startup
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
1. Switch on the air supply
2. Switch on the voltage supply.
3. Check the solenoid valves by turning the handle on the upper side of the valve by 90°.
4. Check the valve position indicator. The proximity switches are installed at the double seat valves with a mechanical stop. Adjustment is not required!
Thefollowingallocationappliesfordoubleseatvalves:
Closed valve position feedback – sensor 1 controlled
Open valve position feedback – sensor 2 controlled
Checktheproperfitoftheproximityswitchestoprovidefortheaccuratetransferofthesignalsforthecorresponding valve position.
lever
solenoid valve
36
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct Connect
Instruction Manual: UK-7
8. CU Assembly and Startup
8.4. DoubleseatmixproofvalvesD4,D4SL,DA4
AssemblyoftheControlUnitonthevalve
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_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct ConnectInstruction Manual: UK-7
8. CU Assembly and Startup
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!
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.
1
2
3
!
38
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct Connect
Instruction Manual: UK-7
8. CU Assembly and Startup
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
1. Switch on the air supply
2. Switch on the voltage supply.
3. Check the solenoid valves by turning the handle on the upper side of the valve by 90°.
4. Check the valve position indicator. The proximity switches are installed at the double seat valves with a mechanical stop. Adjustment is not required!
Thefollowingallocationappliesfordoubleseatvalves:
Closed valve position feedback – sensor 3 controlled
Open valve position feedback – sensor 2 controlled
Checktheproperfitoftheproximityswitchestoprovidefortheaccuratetransferofthesignalsforthecorresponding valve position.
lever
solenoid valve
39
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct ConnectInstruction Manual: UK-7
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_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct Connect
Instruction Manual: UK-7
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_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct ConnectInstruction Manual: UK-7
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_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct Connect
Instruction Manual: UK-7
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 cabeling between electronic module and sole-noid valve.
Check compressed air (min. 6 bar).
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 cabeling between electronic module and sole-noid valve.
Check compressed air (min. 6 bar).
Check control air connection between the CU43 and the DA3 / DA4 / D4 SL actuator.
43
APV_CU4 DC_UK-7_052018.indd
APV UK
Control Unit CU4 Direct ConnectInstruction Manual: UK-7
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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---
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---
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211
117
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---
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08-6
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---
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---
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---
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117
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PA
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H20
8825
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0482
---
--
H32
0482
ref.-
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ref.-
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65-0
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08-4
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---
--
---
--
CU
41N
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---
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---
--
08-1
0-00
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H31
2732
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17.3
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---
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Menge
CU
43-M
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41N
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ref.-
no.
mat
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lW
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r.W
S-N
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---
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11/0
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1 1S
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21
---
--
---
--
08-6
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9/93
---
--
H20
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---
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---
--
---
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0371
---
--
---
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---
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---
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---
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* g
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Dat
um:
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CU
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rüft:
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CU
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---
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9952
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H33
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---
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---
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---
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H20
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2732
Ers
atzt
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ste:
spa
re p
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list
Dat
um:
05.0
4.18
CU
4 D
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Nam
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PX
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APV CU4 Direct Connect CONTROL UNIT
SPX FLOW SPX FLOW
Design Center Production
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SPX FLOW reserves the right to incorporate the latest design and material changes without notice or obligation.
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ISSUED 05/2018 - Translation of Original Manual
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