Alfalaval ThinkTop v.3.0 User manual

TD 800-242_1
Patented Sensor System
Registered Design
Registered Trademark
ESE00356-EN12 2013-07
Original manual
Instruction Manual
ThinkTop®AS-Interface v.2.1 (31 nodes) & v.3.0 (62 nodes) 29.5 - 31.6 VDC

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. CE Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. General information ................................................................................... 7
3.1. AS-Interface in general ........................................................................... 7
4. Technical specifications .............................................................................. 8
4.1. ThinkTop, AS-Interface ........................................................................... 8
5. Installation .............................................................................................. 14
5.1. Installation on air actuators ...................................................................... 14
5.2. Installation on Series 700 valves ................................................................ 17
5.3. Air connections ................................................................................... 18
5.4. Electrical connection, internal ................................................................... 19
6. Setup diagram ......................................................................................... 20
6.1. ThinkTop®setup utilising IR keypad ............................................................ 20
6.2. ThinkTop®setup utilising local ’I’ and ’II’ keys ................................................. 22
6.3. ThinkTop®Quick setup guide ................................................................... 24
7. Troubleshooting ....................................................................................... 26
7.1. Troubleshooting and LEDs ....................................................................... 26
8. Maintenance ........................................................................................... 28
8.1. Dismantling the ThinkTop®....................................................................... 28
8.2. Assembling the ThinkTop®....................................................................... 30
8.3. Dismantling and assembly of Series 700 valves ............................................... 32
9. Parts list and Service Kits ........................................................................... 33
9.1. Drawings for ThinkTop AS-Interface ............................................................ 33
9.2. ThinkTop AS-Interface ............................................................................ 34
9.3. Drawings for ThinkTop AS-Interface for Series 700 ........................................... 37
9.4. ThinkTop AS-Interface for series 700 ........................................................... 38
3

1 CE Declaration of Conformity
The designating company
Alfa Laval
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Top Unit for Valve Control & Indication ThinkTop AS-Interface 29/12-09
Denomination Type Year
is in conformity with the following directives with amendments:
-LowVoltage Directive (LVD) 2006/95/EF
- EMC Directive 2004/108/EF
- ROHS Directive 2002/95/EEC
Manager, Product Centres, Compact
Heat Exchangers & Fluid Handling
Bjarne Søndergaard
Title Name
Alfa Laval Kolding
Company Signature
Designation
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®.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Dangerous electrical voltage:
Caustic agents:
5

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.
2.3 Safety precautions
Installation
Always
read the technical data thoroughly.
Never
install the ThinkTop®before valve or relay is in a safe position.
If welding close to the ThinkTop®:A
Always
earth close to the welding area.
Disconnect the ThinkTop®.
Always
have the ThinkTop®electrically connected by authorised personnel.
Maintenance
Always
read the technical data thoroughly.
Always
fit the seals between valve and ThinkTop®correctly.
Never
service the ThinkTop®before valve or relay is in a safe position.
Never
service the ThinkTop®with a 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.
6

3 General information
3.1 AS-Interface in general
The ThinkTop is designed to ensure optimum valve control in conjunction with Alfa Laval sanitary valves and it is compatible
with all major PLC systems (Programmable Logic Controller with AS-interface).
The ThinkTop can be equipped with 0-3 solenoid valves. The solenoids are electrically controlled by the AS-Interface and
when activated the compressed air is activating the air actuator. All solenoids have build-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 energized, setup and local fault
indication etc.
The ThinkTop is characterized by a simple and modular design. It is exchangeable and is prepared for upgrading.
7

4 Technical specifications
4.1 ThinkTop, 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 unit
2. PLC, feedback
3. Sensor board
4. PLC interface board
5. IR Remote control
6. IR Rx
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. External seat-lift (PNP)
19. Supply sensors
20. External connections
Type: Alfa Laval “No Touch” System. For wire connections: See 5.4 Electrical connection, internal“.
F
Features
- Tolerance programmes.
- Self adjustment programme (SRC/ARC valves only).
- Built-in maintenance monitor.
- Setup by internal push buttons or remote control (IR Keypad).
- Setup and local fault supervision.
- Setup saved at power shutdown.
- Visual LED Indicator lights.
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 board. 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 3 feedback signals + 1 status signal = 4 feedback signals. (One of the feedback signals can
be used for two external sensors if necessary).
The status signal is used for detection of the following conditions:
- A set-up is in progress.
- Internal error.
- Maintenance is required (based on time and/or the self adjustment programme).
Tolerance programme
Individual programme according to valve types.
Type 0: ...............................Bypass valve type / keep present valve type.
Type 1: ...............................SRC/ARC and Series 700 valves, only when self adjustment is enabled - Not recommended.
Type 2: ...............................LKB (LKLA-T).
Type 3: ...............................Unique Mixproof, SMP-SC Spillage-Free, and SRC-PV.
Type 4: ...............................SMP-SC, SMP-TO, SMP-BC, SMP-BCA, SBV, SRC, ARC, Unique SSV,
Unique SSV Aseptic, Unique-TO and Series 700 valves.
Type 5: ...............................All Parameters Set To Default (also valid for MH valve and SMP-EC
(seat-lift indication not possible for SMP-EC)).
Preset and reset values: Tolerance programme No./Type 5 (± 5mm) and all functions are disabled.
Note!
Important to select the right tolerance programme in order to ensure optimum controlled closeness of valves.
8

4 Technical specifications
Self Adjustment (SRC/ARC valves only)
The self adjustment feature is an exceptional aspect of the ThinkTop design. A programme can be activated to allow an
adjustment of the tolerance band if the seals in the valve are being compressed or are worn. When the tolerance band of the
unit has been adjusted 0.3 mm, an alert warning will appear in the form of a status signal and a flashing maintenance LED.
After 0.5 mm adjustment an alarm warning appears: Loss of feedback signal, status signal and steady maintenance light
indicating a replacement of the seal.
Built-in Maintenance Monitor
The unit can be preset to indicate when the time for maintenance of the valve has been reached. A status signal and flashing
maintenance LED can be programmed to return after 3, 6, 9 or 12 months or more.
Technical specifications
Sensor system
Sensor accuracy: ....................± 0.1 mm.
Distance to indication pin: ..........5 ± 3 mm.
Stroke length: .......................0.1 - 80 mm.
Electrical connection:
Direct main cable gland entry (hard wired) PG11 (ø4 - ø10 mm).
Direct external/sensor cable gland entry PG7 (ø3 - ø6.5 mm) option, external sensor.
Terminals
The terminal row of the sensor unit is equipped with screw terminals for both internal as well as external cables and wires. The
terminals are suitable for wires up to 0.75 mm2(AWG 19).
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
Normal current consumption sensor
board: ................................45 mA (excluding current for the solenoids and the external sensor).
Max. current consumption sensor
board: ................................165 mA (If external devices e.g. solenoids and switches are connected to the sensor
board, a higher current consumption than 120 mA may occur and this will damage the
sensor boards).
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).
Feedback signals
Signals transmitted through the AS-Interface BUS to the AS-Interface master PLC.
9

4 Technical specifications
External sensors
The external sensors are used for seat-lift supervision when seat-lift can not be internally detected. The sensors get their supply
voltage from the terminal row. The output signals from the sensors are connected to two inputs on the terminal row on the
internal sensor unit. If the actual setup is set for internal seat-lift, the corresponding external signal is not used, otherwise the
external signal logically controls the corresponding feedback to the PLC (Programmable Logic Controller).
Note!
If using external sensor, the sensor must be active/activated when performing a setup routine of the control head.
Supply voltage: .....................As specified for the AS-Interface (typical 30VDC)
Supply current: ......................Max. 15 mA per sensor.
Type of sensor: ......................VDC, only 3-wire sensor, PNP.
Cable length: ........................Max. 3 m.
Slave profile v.2.1
Default slave address: 0
IO code: 7 (4 bit bi-directional)
ID code: F (slave without profile)
ID1 code: F
ID2 code: F
Slave profile = S-7.F.F.F
No. of slaves:
AS-Interface specification 2.1 for max. 31 ThinkTop units on a single master/gateway
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 = S-7.A.7.7
No. of slaves:
AS-Interface specification 3.0 for max. 62 ThinkTop units on a single master/gateway
AS-Interface bits assignment:
For the AS-Interface version with 31 and 62 nodes, the following bit assignment will be used:
DI 0 ..................................Feedback # 1 De-Energised Position (closed position)
DI 1 ..................................Feedback # 2 Energised Position (open position)
DI 2 ..................................Feedback # 3-4 SeatLift 1 or 2 position
DI 3 ..................................Feedback # 5 Status
DO 0 .................................Not connected
DO 1 .................................Solenoid valve 1
DO 2 .................................Solenoid valve 2
DO 3 .................................Solenoid valve 3
10

4 Technical specifications
ThinkTop Visual Indications LED Indications
LED B “Open valve” (Yellow)
OIR-Receiver
LED D “Setup/Internal fault” (Red)
LED C “Seat-lift 1/2” (Yellow)
LED E “Solenoid valves” (Green)
LED F “Maintenance” (Orange)
LED B
LED D
LED C
LED E
LED F
LED A LED A “Closed valve” (Yellow)
Note:
If the programmer wishes to detect a physical closed valve position in an “Open Valve” sensor position, then there is no
longer any consistence between the sensor valve detection position and the visual indications of the ThinkTop.
Status signal (feedback # 5) Input bit 3:
The status signal is used for four purposes:
To indicate that the set-up is ongoing (LED D)
To indicate an error condition (LED D) (flashing = software error), (steady = hardware error)
To indicate that the time for maintenance has been reached (LED F)
To indicate if there is a conflict in the self adjustment programme (LED F)
Technical specifications solenoid valves
Solenoid valve signals
Signals transmitted through the AS-Interface BUS to the AS-Interface master PLC.
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. The signals are taken directly from the terminal row.
11

4 Technical specifications
Technical specifications
Up to 3 solenoid valves in each unit.
Type 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 5μ5-5mg/m
3.
Max. flow 180 l/min.
Max. oil content1mg/m
3.
Max. water content 0.88 g/m3-20 oCcompressedair.
Throughput ø2.5 mm.
Air restriction (throttle function) air inlet/outlet. Yes.
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).
Nominal voltage 24 VDC.
Nominal power 1.0 W.
Internal connections (solenoids)
The solenoid drivers can reduce the solenoid power by PWM after the activation time. The PWM function is enabled by a
jumper (12, 13). The number of solenoids actually mounted in the Control head could be 0 - 3.
Nominal voltage 24 VDC.
Nominal power 1.0 W.
Output voltage Must match the selected type of ThinkTop.
Load current Max. 100 mA per solenoid.
Max. current from any number of energized output stages
is 200 mA.
Voltage drop Max. 3 Vat50mA.
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 PA12.
Steel parts Stainless steel AISI 304 and 316.
Seals Nitrile (NBR), EPDM rubber for SMP-EC activator stem.
Gore vent. membrane PBT plastic.
12

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
10-55 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 68-2-3
Cyclic humidity: +25°C/+55°C
12 cycles IEC 68-2-30
(working) 93% R.H.
Protection class
IP66 and IP67 IEC 529
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 2.1*) EN50295
Version 3.0 **)
UL Approval
8-30 VAC/VDC, Class 2 input,
45 mA max. output UL 508-E203255
*) Max. 31 ThinkTop units on a single master/gateway. **) Max. 62 ThinkTop units on a single master/gateway.
13

5 Installation
5.1 Installation on air actuators
Step 1
Always
read the technical data thoroughly.
Always
have the ThinkTop®electrically connected by authorised
personnel.
Step 2
1. Fit the air fittings on actuator if not mounted.
2. Fit the activator stem (magnet) and tighten c
carefully
with a spanner.
SRC/ARC only
S
Step 3
1. Place the ThinkTop on top of the actuator.
2. Make sure X-ring is mounted.
85
S
Step 4
1. Ensure that the unit is correctly mounted by p
pressing
down
on top of the ThinkTop.
2. Tighten the two Allen screws c
carefully
(1.50 Nm).
3. Turn the actuator to have LEDs in a front view.
14

5 Installation
Step 5
Fit the ø6 mm (1/4”) air tubes to ThinkTop.
(see drawing “Air connections” page 18).
S
Step 6
Fit the air tubes to the actuator
(see drawing “Air connections” page 18).
TD 800-131
S
Step 7
Untighten the four screws and pull off cover of ThinkTop.
TD 800-247
S
Step 8
1. Install cable (if not present) through the cable gland.
2. Connect the ThinkTop electrically
(see page 5.4 Electrical connection, internal).
TD 800-248
15

5 Installation
Step 9
Make sure the cable gland is completely tightened.
TD 800-249
S
Step 10
Set up the ThinkTop (see chapter 6 Setup diagram).
NOTE!
The unit can be set up with the cover installed by using the IR
keypad. To energize the valve, use a separate air tube or be in
radio contact with the control room.
16

5 Installation
5.2 Installation on Series 700 valves
Step 1
1. Remove the cover by loosening the four cover screws.
2. Separate the adapter from the base by loosening the three
recess screws on top of the base.
Installation on air actuators:
TD 800-250
S
Step 2
1. Fit air fittings on actuator.
2. Position packing retainer in recess on actuator top.
3. Fit counter nut and indication pin (magnet) on actuator rod.
Engage approx. ¼” thread. Tighten counter nut and indicator
with two wrenches.
S
Step 3
1. Place the two O-rings in the grooves in the bottom of the
adapter. Then place the adapter on the actuator top. The small
O-ring must be positioned over the air hole on the actuator.
2. Fasten the adapter with the four 5/16” Allen screws.
S
Step 4
Mount the base on the adapter in the position needed (can be
rotated 120° in both directions). Note that one of the screw towers
on the adapter has a guide recess (see * on drawing).
TD 800-251
17

5 Installation
5.3 Air connections
1
2
3
TD 800-252
A
B
C
D
E
F
G
H
I
J
K
A. Air restriction (throttle function) air inlet/outlet
B. Air out 1A
C. Air exhaust
D. Air out 1B (5/2 port solenoid valve only)
E. Solenoid 3/2 or 5/2
F. 3/2 Solenoid valves only
G. Air restriction (throttle function) air inlet/outlet
H. Air in
I. Air out 3
J. Air out 2
K. Manual hold override
18

5 Installation
5.4 Electrical connection, internal
ABus Connection C PWM Jumper*
**)
B Internal connections to
solenoid 1-3 *
***)
DIncoming signals from external sensors *
****)
ESupply to external sensors *
*)
6ASI + 1N/C
7ASI - 2N/C
8N/C 3N/C
9N/C 4N/C
10 N/C 5N/C
11 N/C 12 PWM Jumper **)
Earth 13 PWM Jumper **)
20 Solenoid common brown 24 Seat-lift 1 “upper” *
*)
21 Solenoid 1, blue 25 Seat-lift 2 “lower” *
*)
22 Solenoid 2, blue 26 Supply + *
*)
23 Solenoid 3, blue 27 Supply - *
*)
Table 1. Note!
*) Terminals 24, 25, 26 and 27 can be used for external seat lift sensors as well as for any digital input. Always use an external
PNP sensor. Two external signals can be connected, they are associated with feedback signal 3 (seat lift 1) and 4 (seat lift
2). External sensor must always be a 8-30 VDC PNP 3 wire sensor. Connect (-) common on terminal 27, and (+) common
on terminal 26. The signals from the external sensors are associated as follows: sensor signal on terminal 24 (seat lift 1)
associated with feedback 3 (seat lift 1), and sensor signal on terminal 25 (seat lift 2) associated with feedback 4 (seat lift 2).
**) Jumper present = PWM. See section 3.1.3 “Technical specifications solenoid valves”.
***) Internal connections: Terminals for connection for the solenoids mounted internally in the control head. The number of
solenoids actually mounted in the control head could be 0 - 3. The signals are taken directly from the terminal row.
****) If using external sensor, the sensor must be active/activated when performing a set-up routine of the control head.
19

6 Setup diagram
6.1 ThinkTop®setup utilising IR keypad
General
Flashing LED means no value set. Steady LED means value set as shown.
Default: Step 2, factory-set tolerance band +/- 5 mm
Step 3-8, disabled
D LED: Active during set-up: Flashing in step 1
Steady in all other steps
Or during operations, error condition: Steady showing hardware fault, indication pin out of range
Flashing showing software fault
Timeout: A 60 sec. timeout is started as soon as any button(s) are released
On timeout the setup is exited with no changes saved
IR Keypad:Remote distance 0-300 mm to ThinkTop®
Symbols
XPush key on IR keypad with the same number
Simple representation of LED indication:
Yellow B
IR-Reciver
Red DSteady LED
Yellow C
Green E
Orange F
Yellow AFlashing LED
G
General commands in each step
(except step 1):
0Next step / skip step (In step 3-6 the program automatically moves to the next step
when a position is stored)
5Clear / disable step (In step 2 this resets the unit and sets the step 2-8 to default)
(The command is accepted when all unit LED’s flash briefly)
I
It is recommended to reset the unit before
performing a setup.
Always check for correct signals after the setup.
20