Alfalaval ThinkTop Basic User manual

2050-0029
Patented Sensor System
Registered Design
Registered Trademark
ESE02952-EN1 2016-10
Original manual
Instruction Manual
ThinkTop®Digital, AS-Interface and DeviceNet
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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 at a glance ............................................................................. 6
3.2. Recycling information ............................................................................. 6
4. Technical specifications .............................................................................. 7
4.1. ThinkTop common specifications ............................................................... 7
4.2. ThinkTop Digital ................................................................................... 9
4.3. ThinkTop, AS-Interface ........................................................................... 10
4.4. ThinkTop DeviceNet .............................................................................. 12
5. Installation .............................................................................................. 15
5.1. Installation on air actuators ...................................................................... 15
5.2. Installation on Series 700 valves ................................................................ 17
5.3. Air connections ................................................................................... 19
5.4. Electrical connection, internal - Digital 24 VDC ................................................ 20
5.5. Example of using common power supply ...................................................... 20
5.6. Electrical connection, internal - AS-Interface ................................................... 21
5.7. Electrical connection, internal - DeviceNet ..................................................... 22
6. Setup diagram ......................................................................................... 23
6.1. ThinkTop setup- utilising local ’I’ and ’II’ keys .................................................. 23
6.2. ThinkTop setup- utilising IR keypad ............................................................. 26
6.3. ThinkTop quick setup guide ..................................................................... 28
7. Fault finding ............................................................................................ 30
7.1. Fault finding and LEDs ........................................................................... 30
8. Maintenance ........................................................................................... 32
8.1. Dismantling ThinkTop ............................................................................. 32
8.2. Assembly of ThinkTop ............................................................................ 33
8.3. Dismantling and assembling Series 700 valves ................................................ 35
9. Parts list ................................................................................................ 37
9.1. Diagrams for ThinkTop ........................................................................... 37
9.2. ThinkTop ........................................................................................... 38
9.3. Diagrams for ThinkTop: Series 700 ............................................................. 41
9.4. ThinkTop: Series 700 ............................................................................. 42
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1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
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® Digital 24 VDC
ThinkTop® AS-Interface
ThinkTop® DeviceNet TM
Type
is in conformity with the following directive with amendments:
- EMC Directive 2014/30/EU
- RoHS2 Directive 2011/65/EU
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 2013-12-03
Place Date Signature
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2 Safety
This manual highlights unsafe practices and other important information are emphasised in this manual.
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 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:
2.3 Safety precautions
Installation:
Always read the technical data carefully !
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 electrically connected by authorised personnel
Maintenance:
Always read the technical data carefully !
Always fit the seals between the valve and ThinkTop correctly
Never service the ThinkTop before the valve or relay are in a safe position
Never service the ThinkTop when the valve/actuator under pressure
Never clean the ThinkTop using high pressure cleaning equipment
Never use cleaning agents that will erode the exterior of the ThinkTop. Check with your cleaning agent supplier
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3 General information
3.1 ThinkTop at a glance
The ThinkTop is designed to ensure optimum and reliable valve control in conjunction with Alfa Laval valves and is compatible
with most PLC systems (Programmable Logic Controllers).
The ThinkTop can be equipped with 0-3 solenoid valves. The solenoids are electrically controlled by the PLC system and, when
activated, the compressed air is activating the air actuator. Depending on the type of control unit, the primary solenoid valve can
be provided with a built-in throttle function on both the 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 constantly indicate the distinct status of the control unit: such as valve positions, solenoid valve energised,
setup and local fault indication etc.
The ThinkTop is characterised by its high durability, well-proven features and modular design. It is exchangeable and is ready to
fit Alfa Laval Sanitary actuators from the past and present.
3.2 Recycling information
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes
- Wood and cardboard boxes can be reused, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
• Maintenance
- 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 compliance with local regulations
• Scrapping
- End-of-life, the 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
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4 Technical specifications
4.1 ThinkTop common specifications
Sensor System
Unique “No Touch” sensor system with no mechanical sensor adjustments. A magnet (indication pin) is mounted on the valve
stem and the translatory change in the magnetic field vectors are detected by the sensor board with a measuring accuracy
of ± 0.1mm.
Electrical connection:
Direct main cable gland entry (hard wired) PG11 (ø4 - ø10 mm).
Option: external sensor cable gland entry PG7 (ø3 - ø6.5 mm).
Option for AS-i version: Main connection as M12 plug, 2 wire.
The terminal row of the sensor unit is equipped with screw terminals for both internal and external cables and wires. The
terminals are suitable for wires up to 0.75 mm2(AWG 19).
External sensors
The external sensors are used for seat-lift supervision when seat-lift can not be internally detected. The sensors obtain 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 an external sensor, the sensor must be active/activated when performing a setup routine of the control head.
Supply voltage. ......................Must match the selected type of ThinkTop.
Supply current: ......................Max. 15 mA per sensor.
Type of sensor: ......................VDC, only 3-wire sensor PNP.
Sensor cable length: ................Max. 3 m.
Suitable external sensors, brackets and cable glands for setting up upper seat-lift defection on mixproof valves are available as
accessories in the catalogue.
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)
Status signal
The status signal is used for four purposes:
- To indicate that setup is in progress + (LED D).
- To indicate an error condition + (LED D). (Flashing LED = software error), (steady LED = hardware error).
- To indicate maintenance due to the self adjustment programme + (LED F).
- To indicate that the time for maintenance has been reached + (LED F).
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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 content 1mg/m
3
Max. water content 0.88 g/m3-20 oC compressed air
Throughput ø2.5 mm
Air restriction (throttle function) air inlet/outlet. Yes. (solenoid valve 1 only)
Manual hold override. Yes
Throttle, air in/out 1A, 1B 0-100%
External air tube connection ø6 mm or 1/4” (specify when ordering)
Silencer/filter Connection possible via ø6 mm
(Filter recommended in tropical regions)
Materials
Plastic parts Nylon PA12.
Metal parts Stainless steel and Brass.
Seals Nitrile (NBR).
Gore vent. membrane PBT plastic.
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 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 threshold
Voltage/current: Type 1 input requirements EN 61131-2
EMC Directive 2014/30/EU
UL Approval 8-30 VDC, Class 2 input,
45 mA max. output UL 508-E203255
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4 Technical specifications
4.2 ThinkTop Digital
Power Supply
The ThinkTop is designed to be a 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 devices. The I/O power supply should not be used for other kinds of load.
The unit is reverse polarity and short circuit protected.
Supply voltage nominal: .............24 ± 10% VDC
Supply voltage absolute max.: ......30 VDC.
Supply voltage absolute min.: ......8 VDC.
Supply current*): ....................Max. 45 mA (for sensor unit alone)
(excluding current to the solenoids, external sensor and the PLC input current).
*) 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 360 mA RMS during 8 ms (unregulated PS).
Fulfillment of the UL requirements in UL508 requires the unit to be supplied by an isolating source that complies with the
requirements for class 2 power units (UL1310) or class 2 and 3 transformers (UL1585).
Feedback signals
The sensor system can be used for 4 feedback signals + 1 status signal = 5 digital PNP/NPN feedback signals.
Output signals from the sensor unit to the connected PLC.
Nominal voltage: ....................Must match the selected type of ThinkTop.
Load current: ........................Typically 50 mA, max. 100 mA .
Voltage drop: ........................Typically 3 V at 50 mA.
PNP/NPN Polarity
PNP (sourcing) or NPN (sinking) function is selected with a jumper in term. 12 and 13. Jumper present = PNP. If changing to
NPN, remove the jumber and make a power recycle. A power recycle is always required when changing this function.
Solenoid valve signals
Three output signals (with one common, terminal 11) from the terminal row are used for activation of the solenoids. Positive
(connected with terminal 9) or negative.
Technical specifications
Norminal voltage
Nominal power
24 VDC
1.0 W.
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4 Technical specifications
4.3 ThinkTop, AS-Interface
Feedback signals
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, which this will damage
the sensor boards).
Feedback signals
Signals transmitted through the AS-Interface BUS to the AS-Interface master PLC.
The sensor system can be used for 3 feedback signals + 1 status signal = 4 feedback signals.
Slave profile options: (specify when ordering)
Slave profile v.2.1
Default slave address: 0
IO code: 7 (4 bit bi-directional)
IO 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)
IO 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.
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4 Technical specifications
AS-Interface bits assignment:
For the AS-Interface version with 31 and 62 nodes, the following bit assignment will be used:
DI 0 ..................................De-Energised position (closed position)
DI 1 ..................................Energised position (open position)
DI 2 ..................................SeatLift 1 and 2 position (sum SeatLift signal)
DI 3 ..................................Status
DO 0 .................................Not connected
DO 1 .................................Solenoid valve 1
DO 2 .................................Solenoid valve 2
DO 3 .................................Solenoid valve 3
Solenoid valve signals
Signals transmitted through the AS-Interface BUS to the AS-Interface master PLC.
Technical specifications
Nominal voltage 24 VDC
Nominal power 1.0 W
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4 Technical specifications
4.4 ThinkTop DeviceNet
DeviceNet features and functionality
Network size Up to 63 nodes
Network length Selectable end-to-end network distance varies with speed
Baud Rate
125 Kbps
250 Kbps
500 Kbps
Distance
500 m (1,640 ft)
250 m (820 ft)
100 m (328 ft)
Data packets 0-8 bytes
Bus topology Linear (trunk line/drop line); power and signal on the same network cable
Bus addressing Peer-to-peer with multi-cast (one-to-many); multi-master and master/slave special case; polled
or change-of-state (exception-based)
System features Removal and replacement of devices from the network under power
The basic trunk-line/drop-line topology provides separate twisted-pair buses for both signal and power distribution. A thick or thin cable can be
used for either trunk lines or drop lines. End-to-end network distance varies with data rate and cable size
Data rates 125 Kbps 250 Kbps 500 Kbps
Thick trunk length 500 m (1,640 ft) 250 m (820 ft) 100 m (328 ft)
Thick trunk length 100 m (328 ft) 100 m (328 ft) 100 m (328 ft)
Maximum drop length 6m(20ft) 6m(20ft) 6m(20ft)
Cumulative drop length 156 m (512 ft) 78 m (256 ft) 39 m (128 ft)
The end-to-end network distance varies with data rate and cable thickness.
DeviceNet requires a terminating resistor to be installed at each end of the trunk:
-121 ohm
-1% metal film
-1/4 watt
Terminating resistors should not be installed at the end of a drop line, only at the two ends of the trunk-line.
For further information please refer to the DeviceNet Standard.
DeviceNet Features
Device type Generic Master/scanner N
Explicit peer-to-peer messaging NI/O Slave messaging
I/O peer-to-peer messaging N•BitstrobeN
Configuration consistency value N• Polling Y
Faulted node recovery N• Cyclic N
Baud rates 125K, 250K, 500K •Changeofstate(COS) N
Configuration method EDS
The end-to-end network distance varies with data rate and cable thickness.
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4 Technical specifications
DeviceNet interface
Baud rates: 125K, 250K and 500K.
Polling I/O slave messaging.
Poll: 1bytes.
1 bytes = Input/outputs and alarms (class 4).
Node address
Range: 0-63.
Default slave address: 63.
Power supply
The power supply to the complete unit is taken from the DeviceNet.
Supply voltage: .....................11-25 V DC, as specified for the DeviceNet.
Supply current: ......................Max. 45 mA (for sensor unit alone)
(excluding current to the solenoids and the external proximity switches).
ThinkTop DeviceNet features
Feedback signals
Input signals (produced by the sensor unit) transmitted over the DeviceNet - class 4.
Five feedback signals: closed valve, open valve, seatlift 1, seatlift 2 and status.
The status signal is used for five purposes:
- Toindicatethatasetupisinprogress(LEDD).
- To indicate an error condition (LED D), (flashing = software error), (steady = hardware error).
- To indicate that maintenance is required (LED F).
- To indicate whether there is a conflict in the self adjustment programme (LED F).
- To indicate whether any communication exists between ThinkTop®and PLC (LED D, steady).
Solenoid signals
Output signals received from the DeviceNet.
Three bits to control the solenoid drives located in the sensor unit.
ThinkTop EDS file
The EDS file can be downloaded from www.alfalaval.com by searching "ThinkTop" at the top of the main landing page. On the
ThinkTop landing page, choose Documentation in the menu and find the EDS package. Alternatively, both the EDS file and
further information on DeviceNet can found at www.odva.org
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4 Technical specifications
ThinkTop DeviceNet attribute list
Path Raw data
Name Attributes R/W/CS data
type
len. LSB
Release DNET 4.6 Class Inst dec. hex. “poll”
Valve value
Valve command
4
4
1
3
3
3
-
-
-
-
R
R/W
Byte
Byte
1
1
-
-
ThinkTop DeviceNet attribute list
Name Eng. Units Conv. Bit maps/data
mult. divisor units byte 1 byte 2 byte 3 byte 4
Release DNET 4.6
Valve value
Valve command
-
-
-
-
-
-PLC_image
Solenoids
-
-
-
-
-
-
ThinkTop DeviceNet bit mappings
PLC_Image
Valve valuexxx
Maint. SL2 SL1 OPEN CLOSED
Solenoid 1, 2 & 3
(Valve command) xxxx
Coil #3 Coil #2 Coil #1 x
ThinkTop DeviceNet Poll command structures
Poll request message format
bit
byte 765432
10
0xx x x
Coil #3
de-energise
Coil #2
de-energise
Coil #1
de-energise x
Poll response message format
bit
byte 76543210
0Travel in
Progress
Timer
Expired xMAINT.
ERROR
Seat #2
Status
Seat #1
Status
OPEN
Status
CLOSED
Status
Typical power consumption
Test conditions: One ThinkTop DeviceNet connected to the network with 1 input (on) and:
No solenoids on supply voltage 25 VDC 20 mA
1 solenoid active (PWM) supply voltage 25 VDC 28 mA
2 solenoid active (PWM) supply voltage 25 VDC 36 mA
3 solenoid active (PWM) supply voltage 25 VDC 44 mA
No solenoids on supply voltage 11 VDC 34 mA
1 solenoid active (PWM) supply voltage 11 VDC 58 mA
2 solenoid active (PWM) supply voltage 11 VDC 82 mA
3 solenoid active (PWM) supply voltage 11 VDC 106 mA
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5 Installation
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 the actuator if not mounted.
2. Fit the activator stem (magnet) and tighten carefully
with a spanner.
2050-0015
Step 3
1. Place the ThinkTop on top of the actuator.
2. Make sure X-ring is mounted.
2050-0016
Step 4
1. Ensure that the unit is correctly mounted by pressing down
on top of the ThinkTop.
2. Cross tighten the two Allen screws carefully in the two opposite
directions.
3. Turn the actuator so that the LEDs are at the front
2050-0017
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5 Installation
Step 5
Install the air tubes with reference to the Air connections diagram
on page 19
2050-0018
Step 6
Untighten the four screws and pull off the ThinkTop cover.
2050-0019
Step 7a -C
able gland version
1. Install cable (if not present) through the cable gland.
2. Connect the electrics of the ThinkTop
(see 5.4 Electrical connection, internal - Digital 24 VDC).
NOTE!
Make sure the cable gland is fully tightened.
2050-0020
Step 7b -M12plugversion
1. Install M12 socket cable.
NOTE!
M12 plug Electrical connection:
1
1
3
3
BN
BU
2050-0056
Step 8
Set up the ThinkTop (see chapter 6 Setup diagram).
NOTE!
The unit can be set up by the internal push buttons on the sersor board. To energise the valve, use manual hold override on the
solenoids valve or ensure you are in radio contact with the control room.
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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:
2050-0023
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.
2050-0049
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.
2050-0035
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5 Installation
Step 4
Mount the base on the adapter in the necessary position (can be
rotated 120° in both directions). Note that one of the screw towers
on the adapter has a guide recess (see * on diagram).
2050-0037
*
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5 Installation
5.3 Air connections
A
F
E
D
C
B
K
J
H
G
2050-0022
3
2
1
AAirout1A
B Air exhaust
C Solenoid 3/2 or 5/2
D Air out 1B (5/2 port solenoid valve only)
E Solenoid valves only 3/2
F Air in
GAirout3
HAirout2
J Manual hold override
K Air restriction (throttle function) air inlet/outlet
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5 Installation
5.4 Electrical connection, internal - Digital 24 VDC
6Solenoid 1 1Closed valve
7Solenoid 2 2Open valve
8Solenoid 3 3Seat-lift 1
9Supply + 4Seat-lift 2
10 Supply - 5Status
11 Solenoid com 12 NPN/PNP Jumper **)
Earth Earth 13 NPN/PNP Jumper **)
20 Solenoid common grey 24 Seat-lift 1 “upper” *)
21 Solenoid 1, grey 25 Seat-lift 2 “lower” *)
22 Solenoid 2, grey 26 Supply + *)
6
23
22
21
20
11
10
9
8
7
1
27
26
25
24
12
5
4
3
2
13
P2
P1
2050-0013
23 Solenoid 3, grey 27 Supply - *)
Table 1. Note!
*) If using external sensor, the sensor must be active/activated when performing a set-up routine of the control head.
Terminals 24, 25, 26 and 27 can be used for external seat lift sensorsaswellasforanydigitalinput.Alwaysuseanexternal
PNP sensor. Two external signals can be connected; these 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 = PNP. If changing the function a power recycle is necessary. The selection NPN/PNP is done by
the jumper.
***) 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.
Note! Remember to isolate wires that are not in use.
5.5 Example of using common power supply
Install a jumper between terminal 10 + 11 to extend the sensor board supply to the solenoid valves.
TD 800-206
A: Jumper
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