Alfalaval ThinkTop D30 User manual

PatentedSensorSystem
RegisteredDesign
RegisteredTrademark
ESE02248-EN62022-10
Originalmanual
InstrutionManual
ThinkTop®D30

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Safetypreautions................................................................................6
3.Generalinformation.........................................................................7
3.1.Conept...........................................................................................7
3.2.Workingpriniple.................................................................................7
3.3.Reylinginformation.............................................................................7
4.Installation....................................................................................8
4.1.Produtdimensions..............................................................................8
4.2.Compatibleatuators............................................................................8
4.3.Installationinstrutions...........................................................................9
4.4.OperatingLEDfeedbak.........................................................................11
5.Troubleshooting.............................................................................12
6.Technicaldata................................................................................13
7.Partslist.......................................................................................14
7.1.Partslist............................................................................................14
3

1DeclarationsofConformity
EU EU
EUDelaration Delaration Delarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydelarethat
TopUnitforValveControlandIndiation
Designation
ThinkTop®D30
Type
isinonformitywiththefollowingdiretiveswithamendments:
-EMCDiretive2014/30/EU
-RoHSDiretive2011/65/EUandamendments
Thepersonauthorisedtoompilethetehnialfileisthesignerofthisdoument.
GlobalProdutQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaeDate(YYYY-MM-DD)Signature
ThisDelarationofConformityreplaesDelarationofConformitydated2017-03-01
4

1DeclarationsofConformity
UK UK
UKDelaration Delaration Delarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydelarethat
TopUnitforValveControlandIndiation
Designation
ThinkTop®D30
Type
isinonformitywiththefollowingdiretiveswithamendments:
-TheEletromagnetiCompatibilityRegulations2016
-TheRestritionoftheUseofCertainHazardousSubstanesinEletrialandEletroniEquipmentRegulations2012
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProdutQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaeDate(YYYY-MM-DD)Signature
DoCRevison_01_102022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasisedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseriouspersonalinjuryordamagetothetopunitareavoided.
2.1Importantinformation
Always Always
Alwaysr r read ead eadthe the themanual manual manualbefor befor before e eusing using usingthe the theThinkT ThinkT ThinkTop! op! op!
W W
WARNING ARNING ARNING
Indiatesthatspeialproeduresmustbefollowedtoavoidseriouspersonalinjury.
CAUTION CAUTION
CAUTION
IndiatesthatspeialproeduresmustbefollowedtoavoiddamagetotheThinkTopD30.
NOTE NOTE
NOTE
Indiatesimportantinformationtosimplifyorlarifyproedures.
2.2Warningsigns
Generalwarning:
Dangerouseletrialvoltage:
Caustiagents:
2.3Safetyprecautions
Installation: Installation:
Installation:
Always Always
Alwaysreadthetehnialdatathoroughly
Never Never
NeverinstalltheThinkTopD30beforethevalveorrelayisinasafeposition
IfweldinglosetotheThinkTopD30:Always Always
Alwaysearthlosetotheweldingarea
DisonnettheThinkTopD30
Always Always
AlwayshavetheThinkTopD30eletriallyonnetedbyauthorisedpersonnel
Maintenane: Maintenane:
Maintenane:
Always Always
Alwaysreadthetehnialdatathoroughly
Always Always
AlwaysfitthesealsbetweenthevalveandThinkTopD30orretly
Never Never
NeverinstalltheThinkTopD30beforevalveorrelayisinasafeposition
Never Never
NeverservietheThinkTopD30withthevalve/atuatorunderpressure
Never Never
NeverleantheThinkTopD30withhighpressureleaningequipment
Never Never
Nevertouhthemovingpartsiftheatuatorissuppliedwithompressedair
Never Never
NeveruseleaningagentsthatwillattaktheexterioroftheThinkTopD30.Chekwithyourleaningagentsupplier
Never Never
NeverleanusingAlohol,Aetone,Chloroform,Methanol,AmmoniumhlorideandAmmoniumHydroxideet.
6

3Generalinformation
3.1Concept
TheThinkTopD30isdesignedtoensurevalveontrolinabasimarket,usingAlfaLavalairoperatedatuatorssuhas
butterfly,singleanddouble-seatvalves.itisompatiblewithallmajorPLCsystems(ProgrammableLogiController)witha
digitalPNPinterfae.
Itisforuseinfood,dairyandbreweryinstallations.ThinkTopD30isaomplementary,alternativesolutiontotheexisting
rangeofontrolunits.
ThinkTopD30isthefirstofitskindonthemarketthatfousesonnewmethodstosimplifyallaspetsofusingabasiontrol
unittominimiseandoptimiseinstallationsinsteadofusingexternalsolenoidvalves
3.2Workingprinciple
TheThinkTopD30isaneasy-to-useplug`nplayontrolunitwithintegratedintelligenewhihmonitorsthestatusoftheoperating
airpressure,identifyingairleakageorfailingairpressure.Theintegratedsolenoidvalveallowsontroloftheproessingvalve.
Mountedontopofthevalve,theunitreeivessignalsfromaPLCsystemtoontrolthesolenoidvalveanditreturnsthe
supervisedairpressuresignalsforvalveenergisedorde-energisedfeedbaktothePLCsystem.TheThinkTopD30hasa360
degreevisualvalvestatusindiator,whihanbeseenatadistaneandatanyangle.
3.3Recyclinginformation
• •
•Unpaking Unpaking Unpaking
-Pakingmaterialonsistsofwood,plastis,ardboardboxesandinsomeasesmetalstraps
-Woodandardboardboxesanbereused,reyledorusedforenergyreovery
-Plastisshouldbereyledorburntataliensedwasteininerationplant
-Metalstrapsshouldbesentformaterialreyling
• •
•Srapping Srapping Srapping
-Attheendofuse,theequipmentshouldbereyledaordingtorelevant,loalregulations.Inadditiontotheatual
equipment,anyhazardousresiduesfromtheproessliquidmustbeonsideredanddisposedofinapropermanner.When
indoubt,orintheabseneofloalregulations,pleaseontatyourloalAlfaLavalrepresentative.
7

4Installation
4.1Productdimensions
4.2Compatibleactuators
SBVYes
KoltekYes
LKLA-TYes
LKLANo
ARCYes
SRCYes
SRClongstrokeNo
i-SSVYes
UniqueSSVYes
UniqueSSVlongstrokeNo
UniqueSSVDN125-DN150No
SSVDN80(76.1mm)HighpressureNo
SSVDN100(101.6mm)HighpressureNo
SMPvalvesYes
UniqueMixproofNo
Air/airatuatorsNO
8

4Installation
4.3Installationinstructions
Step Step
Step1 1 1
PlaetheThinkTopD30ontopoftheatuator.
Ensurethattheunitisorretlymountedbypressingdownon
topoftheThinkTopD30.
Cross-tightenthetwoallensrewsarefully(1.50Nm).
WhenmountingtheThinkTopD30onahorizontalmounted
atuatormakesurethattheexhaustportisnotpointingupwards.
Theexhaustportismarkedwith"EX.".
Step Step
Step2 2 2
Connettheairsupplytotheair-inport(A).
Connettheair-outport(B)totheatuator.
NOTE! NOTE!
NOTE!
Optioninaseofa¼”airsupplyhosesystem.
Connettheairsupplyhoseviaanø6/¼”angleadaptor.
Theangleadaptorissoldseparately:
Artilenumber:9611-99-5679,ø6/¼”angleadaptor.
Theangleadaptorisalsoavailableasø6/ø6:
Artilenumber:9611-99-5678,ø6/ø6angleadaptor.
Step Step
Step3 3 3
Removethetopoverbyturningthetopoveranti-lokwise.
Whenthemarkonthetopover(C)isalignedwiththeopen
padloksymbol(D),thetopoveranbeliftedoff.
9

4Installation
Step Step
Step4 4 4
Installtheableintheablegland.
NOTE NOTE
NOTE
Cable Cable
Cableonnetion onnetion onnetion
Cablegland:PG7(abledia.ø4.0-ø6.8mm)
Reommendedondutor
rosssetion:0.5mm2(AWG20).
Iftheableglandomesloosefromtheontrolheadduring
installation,itmustbeseuredwithatighteningtorqueof1.50Nm.
TofulfiltheULrequirementsinUL61010,theunitmustbesupplied
byanisolatingsourethatomplieswiththerequirementsforlass
2powerunits(UL1310)orlass2and3transformers(UL1585).
Eletrial Eletrial
Eletrialonnetion onnetion onnetionDigitalInterfae
Sensorboard
Terminalstrip
GND-
Connetionofpowersupply24VDC+
PLCoutputsignalTriggersolenoidT
AlarmA
De-energisedD
PLCinputsignalsEnergisedE
Step Step
Step5 5 5
Putthetopoverbakonbypushingitdownwhenthemarkon
thetopover(E)andtheopenpadlok(F)arealigned.
Thenturnitlokwisetowardsthelosedpadlok(G)toseure
thetopover.
10

4Installation
4.4OperatingLEDfeedback
Atuator Atuator
Atuatorstatus status statusLED LED LEDfeedbak feedbak feedbak
De-energisedGreen
EnergisedYellow
Alarm(Airpressure)Redflashing
11

5Troubleshooting
Err Err
Error or orsenarios senarios senarios
Condition Condition
ConditionPossible Possible
Possibleause ause auseSolution Solution
Solution
RedLEDflashing.Insuffiientairpressureintheatuator.Chektheairsupplyandtheaironnetionsontheunit.
12

6Technicaldata
T T
Tehnial ehnial ehnialdata data data
General General
General
Operatingpressure400-700kPa(4-7bar)
SupplyairqualityClass3ISO8573-1
Push-infittingsø6mmtube
Ambienttemperature(operating)-10°Cto+50°C
Storagetemperature(nonoperating)-15°Cto+60°C
ProtetionlassIP66andIP67IEC60529
Appr Appr
Approvals ovals ovals
ULlistedUL61010
CSAlisted
Rated:24V,39mA
Class2input
Environmenttype1C22.2No.61010
Communiation Communiation
Communiation
InterfaeDigital-PNPEN61131-2
Supplyvoltage24VDC±10%
Currentonsumption-solenoidative39mA
Currentonsumption-solenoidinative28mA
ShortiruitandbrownoutprotetionYesEN61131-2
Solenoid Solenoid
Solenoidvalve valve valve
Typeofsolenoid3/2NC
Numberofsolenoids1
ManualoverrideYes(Non-loking)
Atuationflow(at6bar)160l/min
Exhaustflow(at6bar)140l/min
Physial Physial
Physialdata data data
Materials Materials
Materials
BodyBlaknylonPA6(reinfored)
LightguideTransparentpolyamide
SealsNitrile(NBR)
Cable Cable
Cableonnetion onnetion onnetion
CableglandPG7(ablerangeø4.0-ø6.8mm)
Reommendedondutorrosssetion0.5mm2(AWG20)
T T
Terminal erminal erminalblok blok blokonnetion onnetion onnetiondata data data
Condutorrosssetionmin.0.5mm2(AWG20)
Condutorrosssetionmax.1.5mm2(AWG16)
13

7Partslist
7.1Partslist
14

7Partslist
Parts Parts
Partslist list list
Pos.QtyDenomination
ATopinl.prismandO-rings
21O-ring
112Allensrew
12.11Airfitting
131CableglandPG7
141X-ring
15

How How
Howto to toontat ontat ontatAlfa Alfa AlfaLaval Laval Laval
Contatdetailsforallountriesare
ontinuallyupdatedonourwebsite.
Pleasevisitwww.alfalaval.omtoaesstheinformationdiretly.
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