Alfalaval ThinkTop D30 User manual

2064-0000_1
Patented Sensor System
Registered Design
Registered Trademark
ESE02248-EN4 2017-03
Original manual
Instruction Manual
ThinkTop®D30

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. Concept ........................................................................................... 6
3.2. Working principle ................................................................................. 6
3.3. Recycling information ............................................................................. 6
4. Installation .............................................................................................. 7
4.1. Product dimensions .............................................................................. 7
4.2. Compatible actuators ............................................................................ 7
4.3. Installation instructions ........................................................................... 8
4.4. Operating LED feedback ......................................................................... 10
5. Troubleshooting ....................................................................................... 11
6. Technical data ......................................................................................... 12
7. Parts list ................................................................................................ 14
7.1. Parts list ............................................................................................ 14
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2013-12-03
The Designated Company
Alfa Laval KoldingA/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® D30
Type
is in conformity with the following directive with amendments:
- Low Voltage Directive (LVD) 2014/35/EU
- EMC Directive 2014/30/EU
- RoHS2 Directive 2011/65/EU
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2017-03-01
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs. All warnings in the manual are summarised on this page.
Pay special attention to the instructions below so that serious personal injury or damage to the top unit are avoided.
2.1 Important information
Always read the manual before using the ThinkTop!
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 D30.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Dangerous electrical voltage:
Caustic agents:
2.3 Safety precautions
Installation:
Always read the technical data thoroughly !
Never install the ThinkTop D30 before the valve or relay is in a safe position
If welding close to the ThinkTop D30: Always earth close to the welding area
Disconnect the ThinkTop D30
Always have the ThinkTop D30 electrically connected by authorised personnel
Maintenance:
Always read the technical data thoroughly !
Always fit the seals between the valve and ThinkTop D30 correctly
Never install the ThinkTop D30 before valve or relay is in a safe position
Never service the ThinkTop D30 with the valve/actuator under pressure
Never clean the ThinkTop D30 with high pressure cleaning equipment
Never touch the moving parts if the actuator is supplied with compressed air
Never use cleaning agents that will attack the exterior of the ThinkTop D30. Check with your cleaning agent supplier
Never clean using Alcohol, Acetone, Chloroform, Methanol, Ammonium chloride and Ammonium Hydroxide etc.
5

3 General information
3.1 Concept
The ThinkTop D30 is designed to ensure valve control in a basic market, using Alfa Laval air operated actuators such as
butterfly, single and double-seat valves. it is compatible with all major PLC systems (Programmable Logic Controller) with a
digital PNP interface.
It is for use in food, dairy and brewery installations. ThinkTop D30 is a complementary, alternative solution to the existing
range of control units.
ThinkTop D30 is the first of its kind on the market that focuses on new methods to simplify all aspects of using a basic control
unit to minimise and optimise installations instead of using external solenoid valves
3.2 Working principle
The ThinkTop D30 is an easy-to-use plug ‘n play control unit with integrated intelligence which monitors the status of the operating
air pressure, identifying air leakage or failing air pressure. The integrated solenoid valve allows control of the processing valve.
Mounted on top of the valve, the unit receives signals from a PLC system to control the solenoid valve and it returns the
supervised air pressure signals for valve energised or de-energised feedback to the PLC system. The ThinkTop D30 has a 360
degree visual valve status indicator, which can be seen at a distance and at any angle.
3.3 Recycling information
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be reused, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
- Metal straps should be sent for material recycling
•Scrapping
- At the end of use, the equipment should be recycled according to relevant, local regulations. In addition to the actual
equipment, any hazardous residues from the process liquid must be considered and disposed of in a proper manner. When
in doubt, or in the absence of local regulations, please contact your local Alfa Laval representative.
6

4 Installation
4.1 Product dimensions
75 mm
Ø 105 mm
2064-0001_1
4.2 Compatible actuators
SBV Yes
Koltek Yes
LKLA-T Yes
LKLA No
ARC Yes
SRC Yes
SRC long stroke No
i-SSV Yes
Unique SSV Yes
Unique SSV long stroke No
SSV DN80 (76.1 mm) High pressure No
SSV DN100 (101.6 mm) High pressure No
SMP valves Yes
Unique Mixproof No
Air/air actuators No
7

4 Installation
4.3 Installation instructions
Step 1
Place the ThinkTop D30 on top of the actuator.
Ensure that the unit is correctly mounted by pressing down on
top of the ThinkTop D30.
Cross-tighten the two allen screws carefully (1.50 Nm).
When mounting the ThinkTop D30 on a horizontal mounted
actuator make sure that the exhaust port is not pointing upwards.
The exhaust port is marked with "EX.".
2064-0002
Step 2
Connect the air supply to the air-in port (A).
Connect the air-out port (B) to the actuator.
NOTE!
Option in case of a ¼” air supply hose system.
Connect the air supply hose via an ø6 / ¼” angle adaptor.
The angle adaptor is sold separately:
Article number: 9611-99-5679, ø6 / ¼” angle adaptor.
The angle adaptor is also available as ø6 / ø6:
Article number: 9611-99-5678, ø6 / ø6 angle adaptor.
A
B
2064-0003
Step 3
Remove the top cover by turning the top cover anti-clockwise.
When the mark on the top cover (C) is aligned with the open
padlock symbol (D), the top cover can be lifted off.
2064-0004
C
D
8

4 Installation
Step 4
Install the cable in the cable gland.
NOTE
Cable connection
Cable gland: PG7 (cable dia. ø4.0 - ø6.8 mm)
Recommended conductor
cross section: 0.5 mm2(AWG 20).
If the cable gland comes loose from the control head during
installation, it must be secured with a tightening torque of 1.50 Nm.
To fulfil the UL requirements in UL61010, the unit must be supplied
by an isolating source that complies with the requirements for class
2 power units (UL1310) or class 2 and 3 transformers (UL1585).
2064-0005_1
Electrical connection Digital Interface
Sensor board
Terminal strip
GND -
Connection of power supply 24 VDC +
PLC output signal Trigger solenoid T
Alarm A
De-energised D
PLC input signals Energised E
Step 5
Put the top cover back on by pushing it down when the mark on
the top cover (E) and the open padlock (F) are aligned.
Then turn it clockwise towards the closed padlock (G) to secure
the top cover.
2064-0007
E
F
G
9

4 Installation
4.4 Operating LED feedback
Actuator status LED feedback
De-energised Green
Energised Yellow
Alarm (Air pressure) Red flashing
10

5 Troubleshooting
Error scenarios
Condition Possible cause Solution
Red LED flashing. Insufficient air pressure in the actuator. Check the air supply and the air connections on the unit.
11

6 Technical data
Technical data
General
Operating pressure 400 - 700 kPa ( 4-7 bar)
Supply air quality Class 3 ISO 8573-1
Push-in fittings ø6 mm tube
Ambient temperature (operating) -10°C to +50°C
Storage temperature (non operating) -15°C to +60°C
Protection class IP66 and IP67 IEC 60529
Approvals
UL listed UL 61010
CSA listed
Rated: 24V, 39mA
Class 2 input
Environment type 1 C22.2 No. 61010
Communication
Interface Digital - PNP EN61131-2
Supply voltage 24 VDC ± 10%
Current consumption - solenoid active 39 mA
Current consumption - solenoid inactive 28 mA
Short circuit and brownout protection Yes EN61131-2
Solenoid valve
Type of solenoid 3/2 NC
Number of solenoids 1
Manual override Yes (Non-locking)
Actuation flow (at 6 bar) 160 l/min
Exhaust flow (at 6 bar) 140 l/min
Physical data
Materials
Body Black nylon PA 6 (reinforced)
Light guide Transparent polyamide
Seals Nitrile (NBR)
Cable connection
Cable gland PG7 (cable range ø4.0 - ø6.8 mm)
Recommended conductor cross section 0.5 mm2(AWG20)
Terminal block connection data
Conductor cross section min. 0.5 mm2(AWG20)
Conductor cross section max. 1.5 mm2(AWG16)
12

.
13

7 Parts list
7.1 Parts list
11
13
14
12.1
12.1
11
2
A
2064-0008_1
14

7 Parts list
Parts list
Pos. Qty Denomination
ATop incl. prism and O-rings
21O-ring
11 2 Allen screw
12.1 1Air fitting
13 1Cable gland PG7
14 1 X-ring
15

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.