CU4plus - Valve Control Units
Industries : Dairy
CU4plus valve control unit offers seamless automation with ASi-3 and ASi-5 bus systems, Direct Connect and IO-Link capabilities, ensuring efficient, reliable control of hygienic sanitary valves, enhancing connectivity and improving overall system performance for various fluid management applications.
FEATURES
The CU4plus valve control unit is designed to enhance the operation, safety, and reliability of APV® and Waukesha Cherry-Burrell® air-operated sanitary valves. Ideal for industries such as dairy, beverage, processed food, healthcare, and pharmaceuticals, the CU4plus integrates advanced APV control technology, offering precise control and seamless monitoring for improved process accuracy and efficiency.
Key Features Include:
- Highly Accurate Valve Stem Measurement: The contact-free valve stem measuring system ensures precise positioning, improving process accuracy and reducing operational errors.
- Teach-In Function: Simplifies the feedback adjustment process, making setup fast and efficient.
- Clear LED Indicators: Ultra-bright LEDs provide clear, immediate feedback on valve position, power status, and solenoid activation, aiding in smooth operations.
- Manual Overrides and Adjustable: Solenoids include manual override functionality, with an adjustment screw to easily control actuator air flow.
- Retrofitting Capability: Easily adaptable to existing valves, allowing for seamless upgrades without the need for major system overhauls.
- Toolbox Software: Offers advanced monitoring, control, and diagnostic tools to help maintain optimal valve performance.
The CU4plus is available in 24VDC Direct Connect and supports modern communication protocols including IO-Link, ASi-3 and the latest ASi-5 technology, enhancing flexibility and scalability.
CU4plus ASi-5
The CU4plus ASi-5 is a next-generation valve control solution built on the advanced ASi-5 standard, offering enhanced connectivity, flexibility, and performance for APV and Waukesha Cherry-Burrell sanitary valves. With faster installation, improved control, and streamlined daily operations, it is ideal for modern automated systems.
Key Benefits:
- Increased Productivity: Controls up to 96 devices on a single network, handling 36% more devices than ASi-3.
- Fast Response: Delivers process control four times faster than ASi-3, improving efficiency and performance.
- Quick Maintenance Response: air pressure and valve parameter monitoring alarm indicates service needs in real-time in the PLC, enabling improved operating efficiency.
- Comprehensive Data: Transfers up to 32 bytes of process data per control unit, ensuring detailed monitoring.
- Automated Configuration: Stores and reloads configurations for fast system recovery during valve service.
- Enhanced Sustainability: Reduces cleaning-in-place (CIP) leakage by up to 80% through advanced seat-lift pulsation technology.
- Reduced CAPEX / OPEX: Reduced installation costs, maintenance and downtime compared with other protocols.
With IoT (Internet of Things) integration and real-time diagnostics, CU4plus ASi-5 offers smarter operations, faster processes and efficient maintenance.
CU4plus IO-Link Control Unit
The CU4plus IO-Link Control Unit is compatible with all APV valve ranges and can be easily retrofitted into existing systems with an IO-Link master. This Industry 4.0-ready protocol connects sensors and actuators to automation systems, streamlining data transfer to and from hygienic valves.
The CU4plus IO-Link enhances preventative maintenance by providing real-time data and early warnings of potential issues. The built-in pressure sensor helps monitor air pressure for valve actuation. Seamless integration into existing systems means no need for full-line upgrades, optimizing performance, uptime and protocol interoperability.
Key Benefits:
- Ease of Installation: IO-Link enables quick integration across multiple protocols.
- Improved Uptime: Real-time data monitoring updates valve limits and triggers maintenance based on hours, cycles or air pressure.
- Reduced Downtime: Automated configuration storage in the IO-Link master ensures fast, error-free system restoration during replacements.
- Enhanced CIP & Sustainability: on-off pulse seat lifting reduces cleaning-in-place (CIP) time, fluid waste, and disposal costs.
With its interoperable flexibility, real-time diagnostics, and unique air pressure monitoring, the CU4plus IO-Link Control Unit ensures optimized maintenance, network reliability and enhanced sustainability.
IO-Link Device Description (IODD) file available here.
The CU4plus valve control unit is engineered to deliver exceptional valve management and monitoring, making it a versatile and efficient component in modern process control systems. It operates by controlling and monitoring the opening and closing of sanitary valves through advanced sensors and real-time data analysis, ensuring precise and reliable valve actuation.
At its core, the CU4plus utilizes a contact-free valve stem sensor, which provides highly accurate, real-time feedback on the valve's position. This sensor eliminates wear and tear associated with contact-based systems, increasing both the accuracy and longevity of the valve control unit. The unit’s Teach-In function allows operators to easily adjust and set the valve’s feedback, enabling quick calibration during installation or system changes.
The CU4plus integrates with multiple communication protocols, including ASi-5 and IO-Link, which provide enhanced connectivity and real-time data monitoring. In systems using ASi-5, for example, the CU4plus can manage up to 96 devices on a single network, significantly improving control efficiency. The IO-Link protocol, meanwhile, allows for seamless data exchange between sensors and actuators, ensuring real-time diagnostics and early detection of potential issues such as air pressure drops, preventing downtime and improving maintenance scheduling.
The CU4plus also supports automated configuration and diagnostics, storing configuration and firmware data that can be easily reloaded during system replacements or service minimizing downtime and simplifying maintenance tasks. Whether upgrading an existing system or installing a new one, the CU4plus offers exceptional operational efficiency and process control.