Alfalaval ThinkTop Basic Digital 10 User manual

ESE00225EN1 2006-11
ThinkTop® Basic Digital 10 - 30 VDC PNP/NPN
Instruction Manual

Alfa Laval
Company Name
Bjarne Søndergaard
Declaration of Conformity
The designating company
Designation
is in conformity with the following directives with amendments:
- Low Voltage Directive 73/23/EEC
- EMC Directive 89/336/EEC
- ROHS Directive 2002/95/EC
hereby declare that
Denomination Type Year
Address
Phone No.
Name
Title
Company Signature
Manager, Product Centres,
Compact Heat Exchangers & Fluid Handling
Alfa Laval Kolding
Albuen 31, DK-6000 Kolding, Denmark
[phone]
Top Unit for Valve Control & Indication
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ThinkTop® Basic 2006

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The information contained herein is correct at the time of issue but may be subject to change without prior notice.
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Table of contents
1. Safety .................................................................................................... 6
1.1 Important information ....................................................................... 6
1.2 Warning signs ................................................................................... 6
1.3 Safety precautions ............................................................................ 6
2. General information................................................................................7
2.1 Digital in general ............................................................................... 7
3. Technical specifications ....................................................................... 8
3.1 ThinkTop® Basic, PLC 10-30 VDC interface ..................................... 8
4. Installation ........................................................................................... 11
4.1 Installation on air actuators ............................................................. 11
4.2 Installation on Series 700 valves ..................................................... 14
4.3 Air connections .............................................................................. 15
4.4 Electrical connection ...................................................................... 16
5. Setup diagram .................................................................................... 17
5.1 ThinkTop® Basic setup utilising IR keypad ...................................... 17
6. Maintenance ....................................................................................... 18
6.1 Dismantling of ThinkTop® Basic .................................................... 18
6.2 Assembly of ThinkTop® Basic ........................................................ 20
6.3 Dismantling and assembly of Series 700 Valves ............................. 22
7. Parts list .............................................................................................. 24
7.1 ThinkTop® Basic Digital 10-30 VDC PNP/NPN ............................... 24
7.2 ThinkTop® Basic Series 700 valves ................................................. 26

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1.1 Important information
1.2 Warning signs
1.3 Safety precautions
1. 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.
Always read the manual before using the top unit!
WARNING!
Indicates that special procedures must be followed to avoid severe personal injury.
CAUTION!
Indicates that special procedures must be followed to avoid damage to the ThinkTop® Basic.
NOTE!
Indicates important information to simplify or clarify practices.
Installation
- Always observe the technical specifications (see chapter 3).
- Never install the ThinkTop® Basic before valve or relay is in a safe position.
- If welding close to the ThinkTop® Basic: Always earth close to the welding area.
- Disconnect the ThinkTop® Basic.
- Always have the ThinkTop® Basic electrically connected by authorized personnel.
Maintenance
- Always read the technical specifications thoroughly (see chapter 3).
- Always fit the seals between valve and ThinkTop® Basic correctly.
- Never service the ThinkTop® Basic before valve or relay is in a safe position.
- Never service the ThinkTop® Basic with valve/actuator under pressure.
- Never clean the ThinkTop® Basic with high pressure cleaning equipment.
- Never use cleaning agents when cleaning the ThinkTop® Basic.
Check with cleaning agent supplier.
General warning:
Dangerous electrical voltage:
Caustic agents:

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The ThinkTop® Basic is designed to ensure optimum valve control in conjunction with Alfa Laval valves and it is compatible
with most PLC systems (Programmable Logic Controllers maker with PNP/NPN interface).
The ThinkTop® Basic can be equipped with 0-3 solenoid valves. The solenoids are electrically controlled by the Digital PLC
and when activated the compressed air is activating the air actuator. All solenoids have built-in throttle function on both air
inlet and outlet which means that it is possible to control the opening and closing time of the air actuator. The solenoids are
also equipped with a manual hold override.
Visual LED lights are constantly indicating the status of the unit: Valve positions, solenoid activated, setup and local fault
indication etc.
The ThinkTop® Basic is characterized by a simple and modular design. It is exchangeable and is prepared for upgrading.
2. General information 2.1 Digital in general

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3.1 “No Touch” sensor system
Type: Alfa Laval “No Touch” System
For wire connections: See section 4.5 “Electrical connection, internal”.
Features
• Easy and simple set-up, using locally pushbuttons
• No manual sensor adjustments at all
• No sensor “movements” due to vibrations
• Modular and hygienic design with exchangeabilities
• Clear LED’s for visual status indication
• Set-up parameters saved in case of power failure
Sensor system
Unique “No Touch” sensor system without any mechanical sensor adjustments. A magnet is mounted on the valve stem and
the magnetic field (axial) is detected by sensor chips inside the sensor unit. The measuring angle from each chip is used to
locate the current position of the valve stem with an accuracy of ± 0.1mm. Note that the distance to the magnet can be 5
mm ± 3 mm.
Feedback signals
The sensor system can be used for 2 digital PNP/NPN feedback signals. Selection of PNP or NPN is done by a jumper.
Two of the feedback signals can be used for external sensors if necessary.
Output signals from the sensor unit to the connected digital interface (PLC).
Nominal voltage: Same as connected to the ThinkTop® Basic.
Load current: 50 mA typical, 100 mA max.
Voltage drop: Typical 3 V 50 mA.
Power supply - DC:
The ThinkTop® Basic is designed to be part of the PLC’s Input/Output (I/O) system. It should be supplied from the same
protected power supply as the other I/O devises. The I/O power supply should not be used for other kinds of loads.
The unit is reverse polarity and short circuit protected. The power supply must meet the requirements of EN 61131-2.
Supply voltage: 10 - 30 VDC.
Supply voltage nominal: 24 VDC (+20%, -15%) - pr. EN 61131-2.
Max ripple: 5% of nominal supply voltage.
Supply voltage absolute max.: 30 VDC.
Supply voltage absolute min.: 10 VDC.
Supply current*): Max. 45 mA (for sensor unit alone, excluding solenoids)
*) The initial current during power-on is higher. The actual shape of the current pulse depends on the power supply used.
Typical values are 150 mA RMS during 13 ms (regulated PS) to 330 mA RMS during 8 ms (unregulated PS).
3. Technical specifications3.1 ThinkTop® Basic, PLC 10-30 VDC interface
PLC,
DC feedback

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3. Technical specifications 3.1 ThinkTop® Basic, PLC 8-30 VDC interface
The fulfilling of the UL requirements in UL 508 requires that the unit is supplied by an isolating source complying with the
requirements for class 2 power units (UL 1310) or class 2 and 3 transformers (UL 1585).
Sensor detection system:
Sensor accuracy: +/- 0,1 mm.
Tolerance band: +/- 5 mm.
Distance to magnet: 5 +/- 3 mm.
Stroke length: 0.1 - 80 mm.
PNP/NPN polarity
PNP (sourcing) or NPN (sinking) function is selected by a jumper in terminals 9 and 10. Jumper present = PNP (standard).
If changing to NPN remove the jumper and make a power recycle. A power recycle is always required when changing this
function.
Typical power consumption ThinkTop® Basic:
Test conditions = One ThinkTop® Basic connected and 1 feedback active (on) and:
No solenoids on Supply voltage 24 VDC 30 mA
1 solenoid active Supply voltage 24 VDC 75 mA
2 solenoids active Supply voltage 24 VDC 120 mA
3 solenoids active Supply voltage 24 VDC 165 mA
Note! “Power-on” current is higher - See power supply - DC.
ThinkTop® Basic visual indications LED indications
LED A A = “Energized” (Yellow)
B = “Set-up/fault” (red)
LED B C = “Solenoids” (Yellow)
D = “De-energized” (Green)
LED C
LED D

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3. Technical specifications 3.1 ThinkTop® Basic, PLC 8-30 VDC interface
Micro environment demand specifications
Temperature
Working: -20°C to +85°C IEC 68-2-1/2
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: +25°C/+55°C
12 cycles
(working) 93% R.H.
Protection class IP66 and IP67 EN 60529
Input treshold
Voltage/current: Type 1 input requirements EN 61131-2
Solenoid signals
Isolation voltage (1000 + 2 x 117) VAC rms/1 min EN 61131-2
EMC Directive 89/336/EEC EN 61000-6-3, EN 61000-6-2
UL/CSA 10-30 VDC/AC, Class 2 input,
45 mA max. output UL 508-E203255
Solenoid Valves:
0 to 3 solenoid valves in each unit possible.
Type: 3/2 or 5/2 port (only possible with one 5/2 port).
Air supply: 300-900 kPa (3-9 bar).
Filtered air, max. particles or dirt: 0.01 mm.
Max. flow: 180 l/min.
Max. oil content: 1.0 ppm.
Max. water content: 0.0075 kg/kg air.
Throughput: ø2.5 mm.
Manual hold override: Yes.
External air tube connection: øø 6 mm or ¼” (select when ordering).
Nominal voltage: 24 VDC.
Nominal power: 1.0 W.
Silencer/filter **): Connection possible via ø 6 mm or ¼”.
Materials
Plastic parts: Nylon PA 6, reinforced.
Steel parts: Stainless steel AISI 304 and 316.
Air fitting: Special coated brass (FDA approved).
Seals: Nitrile (NBR).
**) Filter recommended in tropical regions.