Alfalaval ThinkTop Basic User manual

2050-0029
Registered Design
Registered Trademark
ESE00810-EN5 2016-06
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 at a glance .................................................. 6
3.2. Recycling information ............................................................................. 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 ................................................. 14
7. Parts list and service kits ............................................................................ 16
7.1. Diagrams for ThinkTop Basic Intrinsically Safe ................................................. 16
7.2. ThinkTop Basic Intrinsically Safe ................................................................ 18
3

1 EC Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S hereby declare that
Company Name
Albuen 31, DK-6000 Kolding, Denmark Top Unit for Valve Control and Indication
Address Designation
[phone] ThinkTop® Basic Intrinsically Safe
Phone No. Type
is in conformity with the following directive with amendments:
- EMC Directive 2014/30/EU
- RoHS2 Directive 2011/65/EU
IftheThinkTopisATEXmarkeditisinconformitywith:
- Equipment Explosive Atmospheres (ATEX) Directive 2014/34/EC,
EN 1127-1:2011 Explosive atmospheres – Explosion prevention and protection
Part 1: Basic concepts and methodology
EN 13463-1:2009 Non-electrical equipment for use in potentially explosive atmospheres
Part 1: Basic method and requirements
EN 13463-5:2011 Non-electrical equipment intended for use in potentially explosive atmospheres
Part 5: Protection by constructional safety ‘c’
EN ISO 12100:2011 Saftey of machinery - General principles for design - Risk assessment and risk reduction
DS/ISO/TR 14121-2:2012 Safety of machinery - Risk assessment
Part 2: Practical guidance and examples of methods
EN 60079-11:2012 Explosive atmospheres
Part 11: Equipment protection by intrinsic safety ‘i’ (“ia” eller “ib”)
Intrinsically Safety
The electrical energy available in circuits and equipment, is limtited to a level too low to ignite the most easily ignitable mixtures
in a hazardous area. Instrinsically safe barriers, as Zener, are installed in the circuit to limit current and voltage in the hazardous
areas to avoid sparks or hot spots under fault conditions.
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
Global Product Quality Manager
Pump, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2016-05-01
Place Date Signature
4

2 Safety
This manual highlights unsafe practices and other important information.
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 in order to avoid severe personal injury or damage to the top unit.
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 before the valve or relay are in a safe position
If welding close to the ThinkTop: Always perform earthing close to the welding area
Disconnect the ThinkTop
Always ensure the ThinkTop is electrically connected by authorised personnel
The ThinkTop must be installed in an inherently safe circuit, according to the corresponding regulations.
Maintenance:
Always read the technical data carefully. !
Always fit the seals between the valve and ThinkTop correctly
Never install the ThinkTop before the valve or relay are in a safe position
Never service the ThinkTop with the valve/actuator under pressure
Never clean the ThinkTop with high pressure cleaning equipment
Never use cleaning agents when cleaning the ThinkTop. Check with cleaning agent supplier.
5

3 General information
This manual highlights unsafe practices and other important information.
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 in order to avoid severe personal injury or damage to the top unit.
3.1 ThinkTop Basic Intrinsically Safe at a glance
The ThinkTop Basic Intrinsically Safe is designed to ensure optimum valve control in conjunction with Alfa Laval valves.
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!
The end user is responsible for performing the explosion risk assessment and classifying the group and the corresponding zone
(dust or gas) in accordance with the Directive 1999/92/EC.
The following table shows 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 equipment group
II 2 G/D or II 3 G/D if removing the blue plastic cover on bottom of 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 equipment-group
II2G/DorII3G/D
Note! Contact customer support to obtain the "ATEX Product Statement 2009" with listed valves inside/outside the scope of ATEX Directive
94/9/EC
3.2 Recycling information
• Unpacking
- Packing material consists of wood, plastics and cardboard boxes
- Wood and cardboard boxes can be reused, recycled or used for energy recovery
- Plastics should be recycled or incinerated at a licensed waste incineration plant
•Main
tenance
- All metal parts should be sent for material recycling
- Worn or defective electronic parts should be sent to a licensed handler for material recycling
- All non-metal wear parts must be handled in accordance with local regulations
• Scrapping
- End-of-life equipment shall be recycled according to relevant, local regulations. In addition to the equipment itself, any
hazardous residue from the process liquid must be taken into account and handled in the necessary way. When in doubt, or
in the absence of local regulations, please contact the local Alfa Laval sales company
6

4 Technical specifications
This manual highlights unsafe practices and other important information.
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 in order to avoid severe personal injury or damage to the top unit.
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 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
Air restriction (throttle function) No
Manual hold override Yes
External air tube connection ø6 mm or 1/4". (specify when ordering)
Silencer/filter Connection possible via ø6 mm
(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 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
Metal parts Stainless steel and bras
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 <1GΩ(ohm) EN 60079-0
Type of ex protection Ex II 2G/D EEx ia IIC T6 ATEX directive 94/9/EC
7

5 Installation
This manual highlights unsafe practices and other important information.
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 in order to avoid severe personal injury or damage to the top unit.
5.1 Installation on air actuators
Step 1
Always read the technical data carefully.
Always ensure the ThinkTop is electrically connected by authorised personnel.
Step 2
1. Fit the air fittings on actuator if not mounted.
2. Fit the activator on the stem and tighten carefully with a
spanner.
2050-0015
Step 3
1. Place the ThinkTop Basic Intrinsically Safe on top of the
actuator.
2. Make sure X-ring is mounted.
2050-0016
8

5 Installation
This manual highlights unsafe practices and other important information.
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 in order to avoid severe personal injury or damage to the top unit.
Step 4
1. Ensure that the unit is correctly mounted by pressing down on
top of the ThinkTop Basic Intrinsically Safe.
2. Cross-tighten the two Allen screws carefully in the two
opposite directions.
3. Turn the actuator so that LEDs are at front
2050-0017
Step 5
Install the air tubes with reference to the Air connections diagram
on page 10.
2050-0018
Step 6
Untighten the four screws and pull off the cover of
ThinkTop Basic Intrinsically Safe.
2050-0043
9

5 Installation
This manual highlights unsafe practices and other important information.
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 in order to avoid severe personal injury or damage to the top unit.
Step 7
1. Install cable (if not present) through the cable gland.
2. Connect the electrics of the ThinkTop Basic Intrinsically Safe
(see page11 “Electrical connection, internal”).
2050-0044
Step 8
Make sure the cable gland is fully tightened.
2050-0045
Step 9
Positioning of the inductive proximity switches
1. The two screws (26) holding the sensor frame shall be tightend
slightly to enable the frame to be moved back and forth.
2. Align the marking on the left proximity switch with the indication
pin by turning the left set screw.
3. Energise the valve
4. Align the right proximity switch with the indication pin 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 energise the valve, use the Manual hold override on the
Solenoid valve.
2050-0025
26
*
5.2 Air connections
B
A
1
3
C
E
D
F
G
2050-0026
A. Air out 1A
B. Air exhaust
C. Solenoid 3/2
D. Solenoid 3/2
E. Air in
F. Air out 3
G. Manual hold override
10

5 Installation
This manual highlights unsafe practices and other important information.
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 in order to avoid severe personal injury or damage to the top unit.
5.3 Electrical connection, internal
Electrical connection
Safe area Hazardous area - Zone 1
The ThinkTop Basic Intrinsically Safe must always be
installed in an intrinsically safe circuit.
Sensor
The two inductive NAMUR sensors must be connected 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=0mH
Ci=0nF
The electrical installation of ThinkTop Basic Intrinsically Safe
must be done according to standard EN 60079-14.
TD 804-038
TD 800-273
3
2
1
4
5
6
7
Electrical connections, internal
1. Sensor 1 [de-energised] (blue) 8 VDC (-)
2. Sensor 1 [de-energised] (brown) (+)
3. Sensor 2 [energised] (blue) 8 VDC (-)
4. Sensor 2 [energisd] (brown) (+)
5. Common; solenoids (black) 12 VDC (-)
6. Input; solenoid #1 (red) (+)
7. Input; solenoid #3 (red) (+)
11

6 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings in to hand.
6.1 Dismantling of ThinkTop Basic Intrinsically Safe
Step 1
1. Untighten the two Allen screws and remove the
ThinkTop from the actuator
2. Remove X-ring and replace it
2050-0030
19
Step 2
1. Untighten the four screws
2. Remove cover of ThinkTop
3. Remove X-ring (grey)
2050-0046
Step 3
1. Untighten screws
2. Remove solenoid valves (up to two) and replace them with
new ones
2050-0047
12

6 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings in to hand.
Step 4
1. To dismantle the adapter (the lower part of the ThinkTop
bracket from base (the middle part), unscrew the three screws
2. Turn the lower part clockwise slightly and pull
3. Replace adapter if necessary
4. Remove the black X-ring
2050-0048
Note:
Turn banjo connection!
Step 5
To remove the sensor frame, unscrew the three screws and pull
out the frame.
2050-0038
13

6 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings in to hand.
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).
2050-0039
Step 2
1. Replace the black X-ring.
2. Assemble base with adapter by turning adapter slightly
anticlockwise and tighten the four screws (2 Nm).
CAUTION!
DoNOTtwisttheX-ringinthegroove!
The X-ring is not square.
The highest (h) part must be positioned as shown
h
2050-0036
2050-0033
Note:
Turn banjo
connection!
Step 3
1. Replace solenoid valves (up to two) with new ones.
2. Tighten screws (0.2 Nm).
2050-0041
14

6 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings in to hand.
Step 4
1. Replace the grey X-ring.
2. Replace cover of ThinkTop Basic Intrinsically Safe and tighten
the four screws (0.6 Nm).
2050-0042
Step 5
1. Replace the black X-ring.
2. Mount ThinkTop Basic Intrinsically Safe on actuator.
2050-0016
15

7 Parts list and service kits
The diagrams illustrate ThinkTop Basic Intrinsically Safe.
The items refer to the parts lists in the following sections
7.1 Diagrams for ThinkTop Basic Intrinsically Safe
2053-0000
300 mm (12”)
ø137 mm (5½”)
225 mm (9”)
172 mm (7”)
TD 804-034
5
9
8
16
15
17
19
1
20
18
TD 804-035
1
3
10
6
14
13
12
11
6
26
7
4
16

.
17

7 Parts list and service kits
The diagrams illustrate ThinkTop Basic Intrinsically Safe.
The items refer to the parts lists in the following sections
7.2 ThinkTop Basic Intrinsically Safe
TD 804-047
6
6
26
18

7 Parts list and service kits
The diagrams illustrate 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 2-3 Air fitting elbow
11 1 Blow-off valve
12 1Thread plug, PG7
13 1Cable gland, PG11
14 1 Gore vent
15 1 Adapter complete
16 1 Special X-ring, black
17 1 O-ring
18 2 Allen screw
19 1Special X-ring
20 1Indication pin
26 2 Screw
27 1Threaded plate (accessories for
the Think Top)
19

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.