Alfalaval ThinkTop Basic User manual

TD 804-001
Registered Design
Registered Trademark
ESE00810-EN3 2014-12
Original manual
Instruction Manual
ThinkTop®Basic Intrinsically Safe

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 5
3. General information ................................................................................... 6
3.1. ThinkTop Basic Intrinsically Safe in general .................................................... 6
4. Technical specifications .............................................................................. 7
5. Installation .............................................................................................. 8
5.1. Installation on air actuators ...................................................................... 8
5.2. Air connections ................................................................................... 10
5.3. Electrical connection, internal ................................................................... 11
6. Maintenance ........................................................................................... 12
6.1. Dismantling of ThinkTop Basic Intrinsically Safe ............................................... 12
6.2. Assembly of ThinkTop Basic Intrinsically Safe ................................................. 13
7. Parts list and service kits ............................................................................ 15
7.1. Drawings for ThinkTop Basic Intrinsically Safe ................................................. 15
7.2. ThinkTop Basic Intrinsically Safe ................................................................ 16
3

1 EC Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Top Unit for Valve Control and Indication
Designation
ThinkTop® Basic Intrinsically Safe
Type
is in conformity with the following directive with amendments:
- Low Voltage Directive (LVD) 2006/95/EC
- EMC Directive 2004/108/EC
- RoHS2 Directive 2011/65/EU
- Directive 94/9/EC for Equipment intended for use in Potentially Explosive Atmospheres (ATEX).
- Think Top Basic Intrinsically Safe is suitable for use in hazardous area zone 1 and zone 21 Marking: Ex II 2D/G EEx ia IIC T6
The following harmonised Standards and Regulations have been applied:
- EN 1127-1:1997 Explosive Atmospheres – Basic concept & methodology
- EN 12100-1/2: Basic terminology and methodology - Technical principles
- EN 13463-1: Non-electrical equipment - Basic method and requirements
- EN 13463-5: Non-electrical equipment - Protection by constructional safety
- EN 14121-1: Safety of machinery - Risk assessment, principles
The assembly must be installed strictly in accordance with the installation instruction supplied by the manufacturer.
Think Top Basic Intrinsically Safe is suitable for use in hazardous area zone 1 and zone 21
Marking: Ex II 2D/G EEx ia IIC T6
The Notified Body NB.0044 will retain this Declaration of Conformity TÛV-Nord technical file no.: TÜV 08 ATEX 8000365231
The person authorised to compile the technical file is the signer of this document
QHSE Manager, Quality, Health and safety & Environment Annie Dahl
Title Name
Kolding 2009-04-01
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs. All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury or damage to the top unit are avoided.
2.1 Important information
Always read the manual before using the top unit!
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the ThinkTop®.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Caustic agents:
2.3 Safety precautions
Installation:
Always read the technical data thoroughly
Never install the ThinkTop Basic Intrinsically Safe before valve or relay is in a safe position
If welding close to the ThinkTop Basic Intrinsically Safe: Always earth close to the welding area
Disconnect the ThinkTop Basic Intrinsically Safe
Always have the ThinkTop Basic Intrinsically Safe electrically connected by authorized personnel
The ThinkTop Basic Intrinsically Safe must be installed in an inherently safe circuit, according to the corresponding regulations.
Maintenance:
Always read the technical data thoroughly)
Always fit the seals between valve and ThinkTop Basic Intrinsically Safe correctly
Never install the ThinkTop Basic Intrinsically Safe before valve or relay is in a safe position
Never service the ThinkTop Basic Intrinsically Safe with valve/actuator under pressure
Never clean the ThinkTop Basic Intrinsically Safe with high pressure cleaning equipment
Never use cleaning agents when cleaning the ThinkTop Basic Intrinsically Safe. Check with cleaning agent supplier.
5

3 General information
3.1 ThinkTop Basic Intrinsically Safe in general
The ThinkTop Basic Intrinsically Safe is designed to ensure optimum valve control in conjunction with Alfa Laval valves and it is
compatible with most PLC systems.
The ThinkTop Basic Intrinsically Safe can be equipped with 0-2 solenoid valves. The solenoids are electrically controlled by
the Digital PLC and when activated the compressed air is activating the air actuator. The solenoids are also equipped with a
manual hold override.
The ThinkTop Basic Intrinsically Safe does not support Unique SSV Long Stroke and SRC-LS valves.
Important!
It will be the responsibility of the end user to perform the explosion risk assessment and to classify the group and the
corresponding zone (dust or gas) in accordance with the Directive 1999/92/EC.
The following table list show the ATEX evaluated Alfa Laval sanitary valves as ThinkTop Basic Intrinsically Safe can be installed on
and in accordance with Atex Directive 94/9/EC.
Valve / actuator type ATEX evaluation notes
Unique SSV ATEX II 2 G D c T4
Unique Mixproof
Non electric equipment with no own ignition source which can be used within the
equipment-group II 2 G/D or II 3 G/D if removing the blue plastic cover on bottom of the
Mixproof valve
SRC
SMP-SC
SMP-TO
SMP-BC
LKLA-T
Koltek MH
SBV
Non electric equipment with no own ignition source which can be used within the
equipment-group II 2 G/D or II 3 G/D
Note! Contact customer support to get the "ATEX Product Statement 2009" with listed valves inside/outside the scope of ATEX Directive 94/9/EC
6

4 Technical specifications
Solenoid valves
0 to 2 solenoid valves in each unit possible.
Type 3/2 port.
Air supply 0.15 - 0.7 MPa (1.5-7 bar).
Filtered air, max. particles or dirt 5mm5-5mg/m
3.
Max. flow 180 l/min.
Max. oil content 1mg/m
3.
Max. water content 0.88 g/m3-20 oC compressed air.
Throughput ø2.5 mm.
Manual hold override Yes.
External air tube connection ø6 mm or 1/4".
Silencer/filter Connection possible via ø6 mm or 1/4".
(Filter recommended in tropical regions).
Nominal voltage 12 VDC.
Nominal power 0.52 W.
Allowable voltage fluctuation ±10% of rated voltage
Certificate of conformity KEMA 08 ATEX 0093 X
Inductive sensor
Switching element function NAMUR NC
Nominal voltage: Uo 8 V
Measuring plate not detected 3 mA
Measuring plate detected 1 mA
Indication of the switching state: LED, yellow
EMC in accordance with IEC / EN 60947-5-2:2004; NE 21
Standards DIN EN 60947-5-6 (NAMUR)
Certificate of conformity PTB 00 ATEX 2032 X
Materials
Plastic parts Nylon PA6, reinforced, stainless steel fibres.
Steel parts Stainless steel AISI 304 and 316.
Air fitting Special coated brass (FDA approved).
Seals Nitrile (NBR).
Gore vent. membrane PBT plastic.
Micro environment demand specifications
Temperature
Working: -10°C to +45°C EN 50020
Storage: -40°C to +85°C IEC 68-2-1/2
Temperature change: -25°C to +70°C IEC 68-2-14
Vibration 10-55 Hz, 0.7 mm IEC 68-2-6
55-500 Hz, 10g
3 x 30 min, 1 octave/min
Drop test IEC 68-2-32
Humidity
Constant humidity: +40°C, 21 days, 93% R.H. IEC 60068-2-78
Cyclic humidity: +15°C/+45°C EN 60068-2-30
12 cycles
(working) 93% R.H.
Protection class IP66 and IP67 EN 60529
Surface resistance <1G• EN 60079-0
Type of Ex protection Ex II 2G/D EEx ia IIC T6 ATEX directive 94/9/EC
7

5 Installation
5.1 Installation on air actuators
Step 1
Always read the technical data thoroughly.
Always have the ThinkTop Basic Intrinsically Safe electrically connected by authorised personnel.
Step 2
1. Fit the air fittings on actuator if not mounted.
2. Fit the activator stem and tighten carefully with a spanner (A).
Note:
The threaded plate (B) is only used for the SRC and SMP valve
types.
(A)
(B)
TD 800-011_2
Step 3
1. Place the ThinkTop Basic Intrinsically Safe on top of the
actuator.
2. Make sure X-ring is mounted.
TD 804-026
Step 4
1. Ensure that the unit is correctly mounted by pressing down on
top of the ThinkTop Basic Intrinsically Safe.
2. Tighten the two Allen screws carefully (1.50 Nm).
TD 804-004
8

5 Installation
Step 5
Fit the ø6 mm (1/4”) air tubes to ThinkTop Basic Intrinsically Safe.
(see drawing “Air connections” page 10).
TD 804-005
Step 6
Fit the air tubes to the actuator
(see drawing “Air connections” page 10).
TD 804-006
Step 7
Untighten the four screws and pull off cover of
ThinkTop Basic Intrinsically Safe.
TD 804-027
Step 8
1. Install cable (if not present) through the cable gland.
2. Connect the ThinkTop Basic Intrinsically Safe electrically
(see page11 “Electrical connection, internal”).
TD 804-028
9

5 Installation
Step 9
Make sure the cable gland is completely tightened.
TD 804-009
Step 10
Positioning of the inductive proximity switches.
1. The two screws (26) holding the sensor frame shall be slightly
tightened, enabling the frame to be moved back and forth.
2. Align the marking on the left proximity switch with the indication
pin (20) by turning the left set screw.
3. Energize the valve.
4. Align the right proximity switch with the indication pin (20) by
turning the right set screw.
5. The proximity switches must be close to the indication pin, but
not touch. Shear the frame for correction.
6. Tighten the two screws holding the sensor frame (1 Nm).
NOTE!
To energize the valve, use a separate air tube or be in radio
contact with the control room.
7. Mount the cover of ThinkTop Basic Intrinsically Safe and tighten
(0.6 Nm) the four screws.
TD 804-030
26
*
5.2 Air connections
TD 804-031
1
3
A
B
C
D
E
F
GA. Manual hold override
B. Air out 1A
C. Air exhaust
D. Solenoid 3/2
E. Solenoid 3/2
F. Air in
G. Air out 3
10

5 Installation
5.3 Electrical connection, internal
Electrical Connection
Safe Area Hazardous Area - Zone 1
The ThinkTop Basic Intrinsically Safe must always be
installedinanintrinsicsafecircuit.
Sensor
ThetwoinductiveNAMURsensorsmustbeconnected
to a certified intrinsically safe circuit (e.g. Zener barrier)
for apparatus group IIC with the following maximum
values:
Ui=15V
Ii=50mA
Pi=1W
Li= 100µH
Ci=100nF
Solenoid valve
The intrinsic safe solenoid valves must also be
connected to a certified intrinsically safe circuit (e.g.
Zener barrier) for apparatus group IIC with the following
maximum values:
Ui=28V
Ii=225mA
Pi=1W
Li=0µH
Ci=0nF
The electrical installation of ThinkTop Basic Intrinsically
Safe must be done according to the standard EN
60079-14.
TD 804-023_1
TD 804-023_2
TD 800-273
3
2
1
4
5
6
7
Electrical connections, internal
1. Sensor 1 [De-energized] (blue) 8 VDC
2. Sensor 1 [De-energized] (brown)
3. Sensor 2 [Energized] (blue) 8 VDC
4. Sensor 2 [Energized] (brown)
5. Common; solenoids (black) 12 VDC
6. Input; solenoid #1 (red)
7. Input; solenoid #3 (red)
11

6 Maintenance
Study the instructions carefully.
Handle scrap correctly.
Always keep spare X-rings in stock.
6.1 Dismantling of ThinkTop Basic Intrinsically Safe
Step 1
1. Untighten the two Allen screws and remove the
ThinkTop Basic Intrinsically Safe from the actuator.
2. Pull out X-ring (19) and replace it.
TD 804-026
Step 2
1. Untighten the four screws.
2. Pull off cover of ThinkTop Basic Intrinsically Safe.
3. Remove X-ring (9) (grey).
TD 804-032
Step 3
1. Untighten screws.
2. Remove solenoid valves (up to two) and replace them with
new ones.
TD 804-012
Step 4
1. To dismantle the adapter (the lower part of the ThinkTop Basic
Intrinsically Safe) from base (the middle part), unscrew the three
screws.
2. Turn the lower part a little clockwise and pull.
3. Replace adapter if necessary.
4. Remove the black X-ring.
TD 804-013
Note:
Turn banjo connection!
12

6 Maintenance
Study the instructions carefully.
Handle scrap correctly.
Always keep spare X-rings in stock.
Step 5
To remove the sensor frame unscrew the three screws and pull
out the frame.
TD 804-014
6.2 Assembly of ThinkTop Basic Intrinsically Safe
Step 1
Place sensor frame in base on top of the four washers, two under
each side, and tighten screws (torque: 1 Nm).
TD 804-015
Step 2
1. Replace the black X-ring.
2. Assemble base with adapter by turning adapter slightly
anticlockwise and tighten the four screws (1.9 Nm).
CAUTION!
DoNOTtwisttheX-ringinthegroove!
The X-ring is not square.
The highest (h) part must be placed as fig.
TD 804-016
Note: Turn banjo
connection!
Step 3
1. Replace solenoid valves (up to two) with new ones.
2. Tighten screws (0.2 Nm).
TD 804-017
13

6 Maintenance
Study the instructions carefully.
Handle scrap correctly.
Always keep spare X-rings in stock.
Step 4
1. Replace the grey X-ring.
2. Replace cover of ThinkTop Basic Intrinsically Safe and tighten
the four screws (0.6 Nm).
TD 804-033
Step 5
1. Replace the black X-ring.
2. Mount ThinkTop Basic Intrinsically Safe on actuator.
TD 804-026
14

7 Parts list and service kits
The drawings show ThinkTop Basic Intrinsically Safe.
The items refer to the parts lists in the following sections
7.1 Drawings for ThinkTop Basic Intrinsically Safe
TD 804-019_1
W
ø137 mm
171.6 mm
H
TD 804-034
5
9
8
16
15
17
19
1
20
18
Note! This is the basic design.
Valve Type HW
Unique SSV ATEX NC 225 250
SRC NC 225 250
SMP-SC/-BC/-TO 225 250
Unique Mixproof 225 250
Koltek MH 225 250
SBV 225 250
Unique SSV ATEX NO 225 320
SRC NO 225 320
LKLA-T 225 300
TD 804-035
1
3
10
6
14
13
12
11
6
26
7
4
15

7 Parts list and service kits
The drawings show ThinkTop Basic Intrinsically Safe.
The items refer to the parts lists in the following sections
7.2 ThinkTop Basic Intrinsically Safe
TD 804-036
6
6
26
16

7 Parts list and service kits
The drawings show ThinkTop Basic Intrinsically Safe.
The items refer to the parts lists in the following sections
Parts list
Pos. Qty Denomination
11
Shell, complete
42Washer
51
Frame cpl. with sensors
61-2
Solenoid valve (3/2)
74
PT screw
81Base
91Special X-ring, grey
10 1Air fitting elbow
11 1 Blow-off valve
12 1 Thread plug, PG7
13 1 Cable gland, PG11
14 1 Gore vent
15 1 Adapter complete
16 1Special X-ring, black
17 1 O-ring
18 2 Allen screw
19 1 Special X-ring
20 1 Indication pin
26 2 Screw
17

How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
© Alfa Laval Corporate AB
This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this
document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any
form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB
will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.