Alfalaval ThinkTop V70 User manual

ThinkTop®
V50 and V70
Lit. Code 200000549-1-EN-GB
Manual No. 100000340
Instruction Manual
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Published by
Alfa Laval Kolding A/S
Albuen 31
DK-6000 Kolding, Denmark
[phone]
The original instructions are in English
© Alfa Laval Corporate AB 2019-05
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 or authorized by 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.
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Contents
1 EC Declaration of Conformity.......................................................................... 5
2 About ThinkTop..........................................................................................................7
2.1 About this manual......................................................................................................7
3 Installation..................................................................................................................... 9
3.1 Mechanical installation............................................................................................ 10
3.2 Pneumatic installation..............................................................................................11
3.3 Electrical installation, Digital-IO 24V........................................................................12
3.4 Electrical installation, AS-interface.......................................................................... 14
3.5 Electrical installation, IO-link....................................................................................15
3.6 Seat lift sensor installation.......................................................................................16
4 Setup...............................................................................................................................19
4.1 Auto Setup...............................................................................................................19
4.2 Flex Setup............................................................................................................... 20
4.3 Live Setup................................................................................................................22
4.4 Options.................................................................................................................... 23
5 Troubleshooting.......................................................................................................25
5.1 Calculating the error code....................................................................................... 25
5.2 Error descriptions.................................................................................................... 26
5.3 Interpreting the error code patterns.........................................................................28
5.4 Tips and Tricks........................................................................................................ 29
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1 EC Declaration of Conformity
Revision of Declaration of Conformity 2019–05–01
The Designation Company
Alfa Laval Kolding A/S
Compagny Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No
hereby declare that
Top Unit for Valve Control and Indication
Designation
ThinkTop V50, ThinkTop V70
Type
From serial number 0 to 10.000.000
is in conformity with the following directive with amendments:
- 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
Pump, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2019–05–01
Place Date Signature
200000549-1-EN-GB 5
EN
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200000549-1-EN-GB6
1 EC Declaration of ConformityEN
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2 About ThinkTop
ThinkTop is a valve-top control unit that provides surveillance and control of valves during the fluid
handling process. The control unit has been developed with user friendliness and robustness in mind.
ThinkTop comes with a valve control sensor board for connection to any PLC system. There are three
types of communication interfaces available:
Digital I/O 24 VDC, AS-Interface v3.0, AS-I v2.11 and IO-link.
When the ThinkTop receives a signal from the PLC system to open the valve, a built-in solenoid valve
shifts the connected valve into position. The position is detected through a sensor target attached to
the valve stem through a touch-free sensor system. The position is then evaluated and if valid, the
corresponding feedback is returned to the automation system via the communication interface.
V50 and V70 series
ThinkTop comes in two series: V50 and V70. The V50 series is the compact option with a feature set
tailored to valves that require only one solenoid valve such as butterfly and single seat valves. The
V70 series is the more flexible option that can be configured to meet the needs of the most
demanding valve applications such as Mixproof valves.
2.1 About this manual
In this manual, you will find detailed descriptions of how to install and setup the different ThinkTop
variants as well as detailed information about fault finding and maintenance. We recommend that you
familiarize yourself with the content of the manual before you begin installation.
2066-0001
ENTER
SETUP
AUTO
FLEX
SEAT VALVE
ROTARY VALVE
ERROR
1
2
4
8
16
200000549-1-EN-GB 7
EN
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200000549-1-EN-GB8
2 About ThinkTopEN
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3 Installation
This chapter covers the installation of any ThinkTop variant within the V50 and V70 families on any
Alfa Laval rising stem valve.
Tools
To carry out the installation, you need the following tools:
Hex key Adjustable spanner or flat wrenches
2.5 mm 14, 19 mm
2066-0037
(additional 12, 15 and 17 for Seat lift sensor installation)
When using wire end ferrules for ease of electrical installation it is recommended to choose ferrules
with a barrel length of 10mm to ensure full engagement in the terminals.
200000549-1-EN-GB 9
EN
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3.1 Mechanical installation
Mechanical installation is a two-step process, where you mount the sensor target to the actuator stem
and the ThinkTop to the actuator top.
1Fit the yellow sensor target to the actuator
stem.
Tighten the sensor target by hand or by using
a 2.5 mm hex key (1...2 Nm)
2066-0038
2Mount the ThinkTop centred and flat against
the actuator top.
Hold the ThinkTop flat and steady against the
actuator top.
Use a 2.5 mm hex key to lightly tighten one of
the two set screws.
Tighten the second set screw (1...1.5 Nm).
Tighten the first set screw (1...1.5 Nm).
2066-0040
NOTE
While you can perform the mechanical installation of a seat lift sensor at this time, the
electrical installation must be completed before you can test the seat lift sensor. For
information on how to install and test the seat lift sensor, see Install the seat lift sensor
Seat lift sensor installation on page 16.
200000549-1-EN-GB10
3 InstallationEN
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3.2 Pneumatic installation
Before you begin the pneumatic installation, cut the hoses to the preferred length.
1Connect the air hoses between the air
connectors on the ThinkTop and the air ports
on the valve.
For double seat valves, ensure that the hoses
run parallel to each other and do not overlap.
This way, the hoses will be connected
correctly.
Connect the air supply.
Connect the supply air hose to the Air in
connector and turn on the supply air.
2066-0043
ü
2Verify that the air exhaust plug points
downwards as indicated by the arrow to avoid
water ingress in the pneumatic system. You
can rotate the exhaust plug until it points in
the right direction.
If the valve is placed horizontally so that the
mushrooms are also horizontal, it is not
possible to make the exhaust plug outlet point
downwards. Instead, you can replace it with a
downwards facing fitting.
2066-0019
Indication colour and air connections
On the ThinkTop, the marking, numbering and colour coding of air hoses, air fittings, visual feedback,
and electrical feedback follow the same pattern. This pattern ensures that Auto Setup functions
properly.
The main valve function connects to the Out 1 air connector on the ThinkTop, which is keyed to the
white/main feedback.
The upper seat-lift or auxiliary valve function connects to Out 2, which is keyed to the blue/Usl
feedback.
The lower seat-push valve function connects to Out 3, which is keyed to the yellow/Lsp feedback.
The air connection numbers are printed on the cover of the control unit.
See the valve manual for information on the individual air ports on the valve.
On the V70 with 5/2 pilot valve, port Out 1 is normally closed (NC) and port Out 2 is normally open
(NO).
200000549-1-EN-GB 11
Installation 3 EN
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3.3 Electrical installation, Digital-IO 24V
1
a) Remove the top cover by turning it
counter clockwise and then lifting it
upwards.
b) Connect the cable to the ThinkTop, and
then connect the wires to the terminals
according to the wiring diagram.
c) Tighten the cable gland using a 19 mm
wrench (3 Nm).
Or tighten the M12 connector using a 14
mm wrench (0.6...1.5 Nm).
d) Put the top cover back in place.
e) Turn on the power supply.
If installed correctly, the light guide flashes
green.
2066-0048
e
a
d
c
b
Wiring diagrams
Terminals V50 Digital-IO 24V
1Power supply 24V (brown)
2Power supply GND (blue)
3out (PLC in) Status OK (white)
4out Valve de-energised (DE-EN) (black)
5out Main valve energised (EN) (grey)
6in Solenoid valve 1 for main valve (SV1) (pink)
200000549-1-EN-GB12
3 InstallationEN
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Terminals V70 Digital-IO 24V
1Power supply 24V (brown)
2Power supply GND (blue)
3out Status OK (white)
4out Valve de-energised (DE-EN) (black)
5out Main valve energised (EN) (grey)
6out Upper seat lift energised (USL) (pink)
7out Lower seat push energised (LSP)
8in Solenoid valve 1 for main valve (SV1)
9in Solenoid valve 2 for USL (SV2)
10 in Solenoid valve 3 for LSP (SV3)
1Seat lift sensor Supply (brown)
2Seat lift sensor GND (blue)
3Seat lift sensor Signal (black)
M12 plug option wiring overview (8-pin A-coded plug)
Factory wiring overview for each solenoid valve configuration
1
4
8
6
2
7
5
3
2066-0049
Control board
1x3/2 2x3/2 3x3/2 1x5/2
Terminal reference
1 24V Brown (pin 1) Brown (pin 1) Brown (pin 1) Brown (pin 1)
2 GND Blue (pin 3) Blue (pin 3) Blue (pin 3) Blue (pin 3)
3 out: Status White (pin 2) White (pin 2) White (pin 2) White (pin 2)
4 out: DE-EN Black (pin 4) Black (pin 4) Black (pin 4) Black (pin 4)
5 out: EN, Main valve Grey (pin 5) Grey (pin 5) Grey (pin 5) Grey (pin 5)
6 out: USL, Upper seat Pink (pin 6) - - Pink (pin 6)
7 out: LSP
, Lower seat Violet (pin 7) Violet (pin 7) - Violet (pin 7)
8 in: SV1, Main valve Orange (pin 8) Orange (pin 8) Orange (pin 8) Orange (pin 8)
9 in: SV2, Upper seat - Pink (pin 6) Pink (pin 6) -
10 in: SV3, Lower seat - - Violet (pin 7) -
200000549-1-EN-GB 13
Installation 3 EN
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3.4 Electrical installation, AS-interface
1
a) Remove the top cover by turning it
counter clockwise and then lifting it
upwards.
b) To allocate an address, use your preferred
addressing device. See the device
manual for more information.
c) Connect the cable to the ThinkTop, and
then connect the wires to the terminals
according to the wiring diagram.
d) Tighten the cable gland using a 19 mm
wrench (1…3 Nm).
Or tighten the M12 connector using a 14
mm wrench (0.6...1.5 Nm).
e) Put the top cover back in place.
f) Turn on the power supply.
If installed correctly, the light guide flashes
green.
2066-0052
fa
e
d
c
Wiring diagrams
Terminals V50 AS-interface
1AS-i supply AS-i + (brown)
2AS-i supply AS-i – (blue)
Terminals V70 AS-interface
1AS-i supply AS-i + (brown)
2AS-i supply AS-i – (blue)
1Seat lift sensor Supply (brown)
2Seat lift sensor GND (blue)
3Seat lift sensor Signal (black and white)
M12 option (4-pin A-coded plug):
2066-0053
1
4
2
3
AS-i +
AS-i -
1
3
BN
BU
200000549-1-EN-GB14
3 InstallationEN
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3.5 Electrical installation, IO-link
1a) Remove the top cover by turning it
counter clockwise and then lifting it
upwards.
b) Fit the cable to the M12 connector and
tighten it using a 14 mm wrench (0.6...1.5
Nm).
c) Put the top cover back in place.
d) Turn on the power supply.
If installed correctly, the light guide flashes
green.
2066-0079
Wiring diagrams
Terminals V50 IO-Link
1Power supply L+ 24V (brown)
2Power supply L- GND (blue)
3Signal IO-Link (black)
Terminals V70 IO-Link
1Power supply L+ 24V (brown)
2Power supply L- GND (blue)
3Signal IO-Link (black)
1Seat lift sensor Supply (brown)
2Seat lift sensor GND (blue)
3Seat lift sensor Signal (black)
M12 option (4-pin A-coded plug):
BN
BK OUT1
BU
L+
L -
2066-0055
1
4
2
3
1
3
4
2
200000549-1-EN-GB 15
Installation 3 EN
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3.6 Seat lift sensor installation
This section is relevant for V70 variants where feedback for the upper seat lift function in a double
seat valve application is required. The parts referred to in this section are available as a seat lift
sensor kit. You will need an adjustable spanner or flat wrenches in the following sizes for this
installation: 12, 14, 15 and 17 mm.
1Remove the blue plug in the ThinkTop
housing with a 14 mm flat wrench.
Fasten the seat lift sensor cable gland to the
ThinkTop housing with at 15 mm flat wrench
(1.5 Nm).
Fit the sensor cable in the cable gland.
Connect the wires to the seat lift sensor
terminal according to the colour codes noted
next to the terminals.
Fasten the cable gland nut with at 15 mm flat
wrench (1.5 Nm).
2066-0062
2Fit the black bushing in the relevant hole in
the valve yoke.
(The icons on the yoke refer to the shape of
the valve plug.)
(The bushing will be fastened together with
the sensor nut in step 7)
2066-0050
200000549-1-EN-GB16
3 InstallationEN
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3Position the valve so that the mechanical
target is in front of the sensor by manually
controlling solenoid valve two.
Fit a nut approximately half way into the
thread on the sensor.
Fit the sensor in the bushing, so the tip of the
sensor is approximately 1 mm from the
mechanical target of the valve.
2066-0051
4Fit the sensor cable on the sensor with the
elbow pointing downwards.
Tighten the nut by hand on the sensor
against the bushing for stability.
5Turn on power.
6Test the installation by energizing and
deenergizing the upper seat lift function and
verify that the LED on the seat lift sensor
changes state.
Adjust the sensor position if necessary. The
goal is to center the transition point between
the always ON limit and the always OFF limit.
7Fasten the sensor nut with a 17 mm flat
wrench (1...2 Nm)
Fasten the sensor cable with a 14 mm flat
wrench (0.6...1.5 Nm).
NOTE
If the valve at hand doesn´t have the holes in the yoke an additional bracket kit is
required. The bracket kit has art no. 9613095503 and it comes with its own installation
instruction.
200000549-1-EN-GB 17
Installation 3 EN
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200000549-1-EN-GB18
3 InstallationEN
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4 Setup
When the ThinkTop has been installed correctly and is powered up for the first time, it flashes green.
You can then begin the setup process.
Auto Setup works well for most applications, and we therefore recommend that you run Auto Setup
before trying any of the other setup options.
4.1 Auto Setup
Auto Setup activates all available pilot valves and automatically completes the setup.
Perform Auto Setup
1Remove the top cover by turning it counter
clockwise and then lifting it upwards.
2Press the SELECT button and then the
ENTER button to initiate the Auto Setup
functionality.
When Auto Setup has completed
successfully, the following happens:
• The light guide lights steady green.
• The control unit is now in operation mode,
and the following features are activated:
• Solenoid valve interlock
• Surveillance mode
• Logical signal adaption
SELECT ENTER
SETUP
AUTO
FLEX
SEAT VALVE
ROTARY VALVE
ERROR
1
2
4
8
16
2066-0057
SELECT ENTER
SETUP
AUTO
FLEX
SEAT VALVE
ROTARYVALVE
ERROR
1
2
4
8
16
3Put the top cover back in place.
4Run an IO test to verify that the system
returns the correct feedback.
Auto setup issues
- If Auto Setup returns an error, read the troubleshooting section for more information.
- If the IO test does not work as expected after completing Auto Setup, consider using Flex Setup.
Canceling Auto Setup
Press the SELECT button, to cancel Auto Setup.
200000549-1-EN-GB 19
EN
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4.2 Flex Setup
Flex Setup allows the setup of any rising stem valve and is a flexible alternative to Auto Setup.
However, Flex Setup is not able to check for common installation mistakes. Flex Setup facilitates the
detection and linking of valve functions and the related positions or sensor states to the outputs.
Because it relies on additional operator input, the operator must be familiar with the content of the
user manual.
Use Flex Setup in the following situations:
• When using a valve assembly that would prompt a fault during Auto Setup.
• When using external solenoid valves that the ThinkTop does not have direct control of.
• When adapting the ThinkTop to the closed / open valve position feedback paradigm.
• When setting up the specific valve type: SSV NO, shut off, maintainable. This valve type requires
the rotary valve option. The valve would otherwise be detected as a seat valve by Auto Setup,
which could lead to feedback issues on the main energized position.
The Flex Setup process varies depending on the ThinkTop and valve variants. The following
describes a standard process:
• The process consists of a series of steps where each position of the valve is stored.
• Each step is keyed to specific visual feedback.
• A step must be skipped if a valve function does not provide a change in the sensor system relative
to any of the other positions. To skip a step, press SELECT.
• The V50 has two setup steps and the V70 has four setup steps.
• All steps are generic and the labels that are used that relate to the Unique Mixproof valve are only
placeholders.
• All steps are linked to a change of state of the seat lift sensor if no change of the main sensor
system is detected.
• There is a 5 minute timeout in each setup. On timeout, the setup is cancelled, and no changes are
saved.
The valve can be manually controlled conveniently via the solenoid valves.
You can operate the solenoid valves manually by turning the white manual override screw feature
counter-clockwise.
2066-0014
200000549-1-EN-GB20
4 SetupEN
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