Alfalaval ThinkTop Basic User manual

TD 800-242_1
Patented Sensor System
Registered Design
Registered Trademark
ESE01516-EN3 2014-12
Original manual
Instruction Manual
ThinkTop®BasicAS-Interfacev.3.0(62nodes)29.5-31.6VDC

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 AS-Interface in general ......................................................... 6
4. Technical specifications .............................................................................. 7
4.1. ThinkTop Basic AS-Interface ..................................................................... 7
5. Installation .............................................................................................. 11
5.1. Installation on air actuators ...................................................................... 11
5.2. Air connections ................................................................................... 13
5.3. Electrical connection, internal ................................................................... 14
6. Setup diagram ......................................................................................... 15
6.1. ThinkTop Basic AS-Interface setup ............................................................. 15
7. Maintenance ........................................................................................... 16
7.1. Dismantling the ThinkTop®....................................................................... 16
7.2. Assembling the ThinkTop®....................................................................... 17
8. Parts list and service kits ............................................................................ 19
8.1. Drawings for ThinkTop Basic AS-Interface ..................................................... 19
8.2. ThinkTop Basic AS-Interface ..................................................................... 20
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 AS-Interface
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
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 2010-03-01
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 Basic AS-Interface.
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 (See chapter 6 Setup diagram)
Never install the ThinkTop Basic AS-Interface before valve or relay is in a safe position
If welding close to the ThinkTop Basic AS-Interface: Always earth close to the welding area
Disconnect the ThinkTop Basic AS-Interface.
Always have the ThinkTop Basic AS-Interface electrically connected by authorized personnel
Maintenance:
Always read the technical data thoroughly (See chapter 6 Setup diagram)
Always fit the seals between valve and ThinkTop Basic AS-Interface correctly
Never install the ThinkTop Basic AS-Interface before valve or relay is in a safe position
Never service the ThinkTop Basic AS-Interface with valve/actuator under pressure
Never clean the ThinkTop Basic AS-Interface with high pressure cleaning equipment
Never use cleaning agents when cleaning the ThinkTop Basic AS-Interface. Check with cleaning agent supplier.
5

3 General information
3.1 ThinkTop Basic AS-Interface in general
The ThinkTop Basic AS-Interface is designed to ensure valve control in conjunction with Alfa Laval sanitary valves and it is
compatible with all major PLC systems (Programmable Logic Controller).
The ThinkTop Basic AS-Interface can be equipped with 0-3 solenoid valves. The solenoids are electrically controlled via the
AS-Interface and when activated the compressed air is activating the air actuator. All solenoid valves have build-in manual hold
override function which means that it is possible to manually open and close the actuator and seat lifts.
Visual LED lights are constantly indicating the status of the unit: Valve positions, solenoid energized, setup and local fault
indication etc.
The ThinkTop Basic AS-Interface is characterized by a simple and modular design.
6

4 Technical specifications
4.1 ThinkTop Basic AS-Interface
“No Touch” sensor system
2
1
345
6
8
7
9
11 10 12
13
16
17
18
19
15 20
14
TD 800-267
TD 800-267
1. Sensor board
2. PLC, feedback
3. Sensor unit
4. PLC interface board
5. N/A
6. N/A
7. Serial link
8. LEDs
9. +5 V
10. Terminals
11. Terminals
12. ASI +
13. ASI -
14. Bus Connection
15. Internal connections
16. Solenoid signals (DC)
17. Solenoid common
18. N/A
19. N/A
20. N/A
Type: Alfa Laval “No Touch” System. For wire connections: See 5.3 Electrical connection, internal“.
Features
- Easy and simple set-up, using locally pushbottons.
- 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.
- Setup saved at power shutdown.
Sensor System
Unique “No Touch” sensor system without any mechanical sensor adjustments. A magnet (indication pin) 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
indication pin can be 5 mm ± 3 mm.
Feedback signals
The sensor system can be used for 2 feedback signals.
Electrical connection
Direct main cable gland entry (hard wired) PG11 (ø4 - ø10 mm).
Te r m i n a l s
The terminal row of the sensor board is equipped with screw terminals for both internal as well as external wires. The terminals
are suitable for wires up to 0.75 mm2(AWG 19).
7

4 Technical specifications
Power Supply
The power supply to the complete unit is taken from the AS-Interface loop. The unit is reverse polarity protected.
Supply voltage: ......................29.5 - 31.6 VDC
Typical power consumption ThinkTop Basic AS-Interface
Test conditions = One ThinkTop Basic AS-Interface connected with 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
The fulfilling of the UL requirements in UL508 requires that the unit is supplied by an isolating source complying with the
requirements for class 2 power units (UL1310) or class 2 and 3 transformers (UL1585).
Technical specifications sensor system
Sensor accuracy: ...................± 0.1 mm.
Tolerance band: .....................± 5 mm.
Distance to indication pin: ..........5 ± 3 mm.
Stroke length: .......................0.1 - 80 mm.
Electrical connection: ...............Direct cable gland entry
PG11(ø4-ø10mm).
Slave profile v.3.0
Default slave address: 0
IO code: 7 (4 bit bi-directional)
ID code: A
ID1 code: 7
ID2 code: 7
Slave profile = 7.A.7.7
No. of slaves:
AS-Interface specification 3.0 for max. 62 ThinkTop Basic AS-Interface units on a single master/gateway
AS-Interface bits assignment:
For the AS-Interface version with 62 nodes, the following bit assignment will be used:
DI 0 ..................................Feedback # 1 De-Energized Position (closed position)
DI 1 ..................................Feedback # 2 Energized Position (open position)
DI 2 ..................................Feedback # 3 Not connected
DI 3 ..................................Feedback # 4 Status
DO 0 .................................Not connected
DO 1 .................................Solenoid valve 1
DO 2 .................................Solenoid valve 2
DO 3 .................................Solenoid valve 3
Status signal (Feedback # 4) input bit 3
The status signal is used for two purposes:
- To indicate that the setup is ongoing (LED B).
- To indicate an error condition (LED B). (Flashing LED = software error), (steady LED = hardware error).
8

4 Technical specifications
ThinkTop Basic AS-Interface Visual Indications LED Indications
LED A “Energized” (Yellow)
--
LED B “Setup/Fault” (Red)
--
LED C “Solenoid” (Yellow)
--
TD 800-030_1
LED A
LED D
LED C
LED B
LED D “De-Energized" (Green)
Technical specifications solenoid valves
Internal connections
Terminals for wire connection of the solenoids mounted internally in the control head. The number of solenoids actually mounted
in the control head could be 0 - 3.
Technical specifications
0 to 3 solenoid valves in each unit.
Ty p e 3/2 or 5/2 valve (only possible with one 5/2 valve)
Air supply 300-900 kPa (3-9 bar)
Filtered air, max. particles or dirt 5 µ 5-5 mg/m3
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” (specify when ordering)
Silencer/filter Connection possible via ø6 mm or 1/4".
(Filter recommended in tropical regions)
Internal connections (solenoids)
The power consumption of the solenoids is being reduced via PWM (Pulse Width Modulation). The PWM can be disabled by
removing the jumper (terminal 3, 4)
Nominal voltage 24 VDC
Nominal power 1.0 W
Load current Max. 100 mA per solenoid
Max. current from any number of energized output stages
is 200 mA
Voltage drop Max. 3 V at 50 mA
Activation time 60 ± 10 ms (time with full power if PWM is enabled)
PWM duty cycle 40% (after activation time if PWM is enabled)
PWM frequency 2 - 5 kHz
Materials
Plastic parts Nylon PA6
Steel parts Stainless steel AISI 304
Seals Nitrile (NBR)
Gore vent. membrane PBT plastic
9

4 Technical specifications
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 10-55Hz,0.7mm 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 IEC 60529
Input treshold
Voltage/current: Type 1 input requirements EN 61131-2
EMC Directive 2004/108/EF EN 61000-6-3, EN 61000-6-2
AS-Interface Version 3.0*) EN50295
UL/CSA 10-30VDC,Class2input,
45 mA max. output UL 508-E203255
*) Max. 62 ThinkTop Basic AS-Interface units on a single master/gateway.
10

5 Installation
5.1 Installation on air actuators
Step 1
Always read the technical data thoroughly.
Always have the ThinkTop Basic AS-Interface electrically
connected by authorised personnel.
Never install the ThinkTop Basic AS-Interface before valve or relay
is in a safe position.
Step 2
1. Fit the air fittings on actuator if not mounted.
2. Fit the indication pin 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 AS-Interface on top of the actuator.
2. Make sure X-ring is mounted.
85
11

5 Installation
Step 4
1. Ensure that the unit is correctly mounted by pressing down on
top of the ThinkTop Basic AS-Interface.
2. Tighten the two Allen screws carefully (1.50 Nm).
3. Turn the actuator to have LEDs in a front view.
Step 5
Fit the ø6 mm (1/4”) air tubes to ThinkTop Basic AS-Interface .
(see drawing “Air connections” page 13).
Step 6
Fit the air tubes to the actuator
(see drawing “Air connections” page 13).
TD 800-131
Step 7
Untighten the four screws and pull off cover of ThinkTop Basic
AS-Interface.
TD 800-158
12

5 Installation
Step 8
1. Install cable (if not present) through the cable gland.
2. Connect the ThinkTop Basic AS-Interface electrically
(see page 5.3 Electrical connection, internal).
TD 800-157
Step 9
Make sure the cable gland is completely tightened.
TD 800-159
Step 10
Set up the ThinkTop Basic AS-Interface (see chapter 6 Setup diagram).
NOTE!
The unit can be set up by internal push bottons on sensor board. To energize the valve, use manual hold override on the
solenoids valve or be in radio contact with the control room.
5.2 Air connections
TD 800-184_2
A
B
C
D
E
F
G
H
I
A. Air out 1A
B. Air exhaust
C. Air out 1B (5/2 port solenoid valve only)
D. Solenoid 3/2 or 5/2
E. Solenoid valve (3/2) only
F. Ai r i n
G. Air out 3
H. Air out 2
I. Manual hold override
13

5 Installation
5.3 Electrical connection, internal
TD 805-003
Electrical connections, internal
1. ASI +
2. ASI -
3. PWM jumper
4. PWM jumper
5. Solenoid common, internal connection (Brown)
6. Solenoid # 1, internal connection (Blue)
7. Solenoid # 2, internal connection (Blue)
8. Solenoid # 3, internal connection (Blue)
Note! Remember to isolate wires that are not in use.
14

6 Setup diagram
6.1 ThinkTop Basic AS-Interface setup
ThinkTop Basic Digital and AS-Interface
A printable “one page” version of ThinkTop Basic setup diagram is available on the Alfa Laval website and can easily be found
be typing the document name “ThinkTop Basic setup diagram” in the searh field.
Time-
out:
A 60 second time-out is started as soon as any
button(s) are released. If no button is pressed
during the time-out period, go to normal
condition (cancel & exit).
Red
LED:
Active during set-up
-Flashinginstep1
- Steady in all other steps
or during operations, error condition:
- Steady showing hardware fault,
indication pin out of range
- Flashing showing software fault
“red” steady “
green” flashing if
de-energized position
disabled “green” steady
if de-energized position
enabled
“red” steady
“yellow” flashing if energized
position disabled “yellow”
steady if energized position
enabled
“red” flashing Actuator in De-energized
Position
Actuator in Energized
Position
Step 1 Step 2 Step 3
Accept Settings Set De-energized Position Set Energized Position
Next step
“I” Restart set-up
sequence
Next
step “II” Store Position
Next
step “II” Store Position
“II” Save & Exit “I” Bypass “I” Bypass
“II”* Cancel & Exit, no
changes accepted “II”* Disable function “II”* Disable function
Enter
set-up
“1”
* Hold for 5 sec. * Hold for 5 sec. * Hold for 5 sec.
Return to step 1
Quick set-up:
Push: “I”, enter setup and wait until red LED flashes.
Push: “I”, restart set-up.
Actuator in De-energized position
Push: “II”, store position
Actuator in energized position
Push: “II”, store position
Push: “II”, when red LED is flashing (save & exit)
Set-up done.
15

7 Maintenance
Study the instructions carefully.
Handle scrap correctly.
Always keep spare X-rings in stock.
7.1 Dismantling the ThinkTop®
Step 1
1. Remove the ThinkTop Basic AS-Interface from the actuator.
2. Pull out X-ring (19) and replace it.
85
Step 2
1. Untighten the four screws.
2. Pull off cover of ThinkTop Basic AS-Interface.
3. Remove the grey X-ring (9).
TD 805-006
Step 3
1. Untighten screws.
2. Remove solenoid valves (up to three) and replace them with
new ones.
TD 800-235
Step 4
1. To dismantle the adapter (the lower part of the ThinkTop Basic
AS-Interface) 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 800-230
Note: Turn banjo
connection!
16

7 Maintenance
Study the instructions carefully.
Handle scrap correctly.
Always keep spare X-rings in stock.
Step 5
To remove the sensor unit untighten screw and pull out
the sensor unit.
TD 805-004
7.2 Assembling the ThinkTop®
Step 1
Place sensor unit in base and tighten screw (torque: 1 Nm).
TD 805-005
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 800-233
Note:
Turn banjo
connection!
17

7 Maintenance
Study the instructions carefully.
Handle scrap correctly.
Always keep spare X-rings in stock.
Step 3
1. Replace solenoid valves (up to three) with new ones.
2. Tighten screws (0.2 Nm).
TD 800-234
Step 4
1. Replace the grey X-ring.
2. Replace cover of ThinkTop Basic AS-Interface and tighten
the four screws (0.6 Nm).
TD 805-007
Step 5
1. Replace the black X-ring.
2. Mount ThinkTop Basic AS-Interface on actuator.
85
18

8 Parts list and service kits
The drawings show ThinkTop Basic AS-Interface v.3.0 (62 nodes) 29.5 - 31.6 VDC.
The items refer to the parts lists in the following sections
8.1 Drawings for ThinkTop Basic AS-Interface
TD 800-149
ø137 mm
H
W
171.6 mm
TD 805-002
5
9
8
16
15
17
19
1
20
AS-Interface (+)
PWMJumper/Diagnostic
AS-Interface (-)
Solenoid common
PWMJumper/Diagnostic
Solenoid 1
Solenoid 2
Solenoid 3
Note! This is the basic design.
Valve Type WH
Unique SSV NC 225 250
SMP-SC/-BC/-TO 225 250
Unique Mixproof 225 250
MH 225 250
SBV 225 250
Unique SSV NO 225 320
LKLA-T 225 300
6b
6a
TD 800-171
1
2
3
19

8 Parts list and service kits
The drawings show ThinkTop Basic AS-Interface v.3.0 (62 nodes) 29.5 - 31.6 VDC.
The items refer to the parts lists in the following sections
8.2 ThinkTop Basic AS-Interface
TD 805-001
6b
6a
20