Instruction Manual

Instruction Manual
ThinkTop Basic Digital and AS-Interface
2050-0029
Patented Sensor System
Registered Design
Registered Trademark
ESE02954-EN1
Original manual
2016-10
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 ....................................................................................................
2.1. Important information .............................................................................
2.2. Warning signs .....................................................................................
2.3. Safety precautions ................................................................................
5
5
5
5
3. General information ...................................................................................
3.1. ThinkTop Basic in general ........................................................................
3.2. Recycling information .............................................................................
6
6
6
4. Technical specifications ..............................................................................
4.1. ThinkTop Basic common specifications ........................................................
4.2. ThinkTop Basic Digital ............................................................................
4.3. ThinkTop Basic AS-Interface .....................................................................
7
7
9
10
5. Installation ..............................................................................................
5.1. Installation on air actuators ......................................................................
5.2. Installation on Series 700 Valves ................................................................
5.3. Air connections ...................................................................................
5.4. Electrical connection, internal - Digital ..........................................................
5.5. Electrical connection, internal - AS-Interface ...................................................
11
11
13
15
16
17
6. Setup diagram .........................................................................................
6.1. ThinkTop Basic setup ............................................................................
18
18
7. Maintenance ...........................................................................................
7.1. Dismantling the ThinkTop® .......................................................................
7.2. Assembling the ThinkTop® .......................................................................
7.3. Dismantling and assembling Series 700 Valves ................................................
19
19
21
23
8. Part list ..................................................................................................
8.1. Diagrams for ThinkTop Basic ....................................................................
8.2. ThinkTop Basic ....................................................................................
8.3. Diagrams for ThinkTop Basic for Series 700 ...................................................
8.4. ThinkTop Basic for Series 700 Valves ...........................................................
25
25
26
28
30
3
1 EC Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
+45 79 32 22 00
Phone No.
hereby declare that
Top Unit for Valve Control and Indication
Designation
ThinkTop® Basic Digital 10 - 30 VDC
ThinkTop® Basic AS-Interface
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
4
Global Product Quality Manager
Pump, Valves, Fittings and Tank Equipment
Lars Kruse Andersen
Title
Name
Kolding
2013-12-03
Place
Date
Signature
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:
Dangerous electrical voltage:
Caustic agents:
2.3
Safety precautions
Installation:
Always read the technical data carefully (See chapter 6 Setup diagram)
Never install the ThinkTop Basic before the valve or relay are in a safe position
If welding close to the ThinkTop Basic: Always perfom earthing close to the welding area
Disconnect the ThinkTop Basic
!
Always ensure the ThinkTop Basic electrically connected by authorised personnel
Maintenance:
Always read the technical data carefully (See chapter 6 Setup diagram)
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
3.1
ThinkTop Basic in general
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 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 regulations
• Scrapping
-
6
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
4 Technical specifications
4.1
ThinkTop Basic 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 magnetic field is detected by 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.
Electrical connection
Direct main cable gland entry (hard wired) PG11 (ø4 - ø10 mm).
Option for AS-i version: Main connection as M12 plug, 2 wire.
Terminals
The terminal row of the sensor board is equipped with screw terminals for both internal and external wires. The terminals are
suitable for wires up to 0.75 mm2 (AWG 19).
ThinkTop Basic Visual Indications
LED A
LED Indications
LED A
-
“Energised” (Yellow)
LED B
-
“Setup/Fault” (Red)
LED C
LED C
-
“Solenoid” (Yellow)
LED D
LED D
“De-Energised" (Green)
LED B
-
TD 800-030_1
7
4 Technical specifications
Technical specifications
0 to 3 solenoid valves in each unit.
Type
Air supply
Filtered air, max. particles or dirt
Max. flow
Max. oil content
Max. water content
Throughput
Air restriction (throttle function)
Manual hold override.
External air tube connection
Nominal voltage
Nominal power
Silencer/filter
3/2 or 5/2 valve (only possible with one 5/2 valve)
300-900 kPa (3-9 bar)
5 µ 5-5 mg/m3
180 l/min
1 mg/m3
0.88 g/m3 -20 oC compressed air
ø2.5 mm
No
Yes
ø6 mm or 1/4” (specify when ordering)
24 VDC
1.0 W
Connection possible via ø6 mm
(Filter recommended in tropical regions)
Materials
Plastic parts
Metal parts
Seals
Gore vent. membrane
Nylon PA6, reinforced
Stainless steel and brass
Nitrile (NBR)
PBT plastic
Micro environment demand specifications
Temperature
Working:
Storage:
Temperature change:
Vibration
Drop test
Humidity
Constant humidity:
Cyclic humidity:
(working)
Protection class
Input threshold
Voltage/current:
EMC Directive
UL/CSA
8
-20°C to +85°C
-40°C to +85°C
-25°C to +70°C
10-55 Hz, 0.7 mm
55-500 Hz, 10g
3 x 30 min, 1 octave/min
IEC
IEC
IEC
IEC
68-2-1/2
68-2-1/2
68-2-14
68-2-6
IEC 68-2-32
+40°C, 21 days, 93% R.H.
+25°C/+55°C
12 cycles
93% R.H.
IP66 and IP67
Type 1 input requirements
2014/30/EU
10-30 VDC, Class 2 input,
45 mA max. output
IEC 60068-2-78
IEC 60529
EN 61131-2
UL 508-E203255
4 Technical specifications
4.2
ThinkTop Basic Digital
Power Supply
The ThinkTop Basic is designed to be 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 devises. The I/O power supply should not be used for other kinds of load. The unit is reverse
polarity and short circuit protected. The power supply must meet the requirements of EN 61131-2.
Supply voltage nominal: . . . . . . . . . . . . . 24 ± 10% VDC
Supply voltage absolute max.: . . . . . . 30 VDC
Supply voltage absolute min.: . . . . . . 10 VDC
Typical power consumption: ThinkTop Basic
Test conditions = One ThinkTop Basic connected with 1 feedback active (on) and:
No solenoids on
1 solenoid active
2 solenoids active
3 solenoids active
Supply voltage
Supply voltage
Supply voltage
Supply voltage
24 VDC
24 VDC
24 VDC
24 VDC
30 mA
75 mA
120 mA
165 mA
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 2 digital PNP/NPN feedback signals. Selection of PNP or NPN is performed by a jumper.
Output signals from the sensor unit to the connected digital interface (PLC).
Nominal voltage: . . . . . . . . . . . . . . . . . . . . Same as connected to the ThinkTop Basic.
Load current: . . . . . . . . . . . . . . . . . . . . . . . . 50 mA typical, 100 mA max.
Voltage drop: . . . . . . . . . . . . . . . . . . . . . . . . Typical 3 V 50 mA.
PNP/NPN polarity
PNP (sourcing) or NPN (sinking) function is selected by a jumper in terminals 9 and 10. Jumper present = PNP (standard). If
changing to NPN, remove the jumper and make a power recycle. A power recycle is always required when changing this function.
9
4 Technical specifications
4.3
ThinkTop Basic AS-Interface
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
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
DI 1
DI 2
DI 3
DO 0
DO 1
DO 2
DO 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . De-Energised position (closed position)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Energised position (open position)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not connected
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not connected
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 3
Status signal input bit 3
The status signal is used for two purposes:
-
10
To indicate that the setup is ongoing (LED B).
To indicate an error condition (LED B). (Flashing LED = software error), (steady LED = hardware error).
5 Installation
5.1
Installation on air actuators
Step 1
Always read the technical data carefully.
Always ensure the ThinkTop Basic electrically connected by authorised personnel.
Step 2
1. Fit the air fittings on actuator if not mounted.
2. Fit the indication pin and tighten carefully
with a spanner.
2050-0015
Step 3
1. Place the ThinkTop Basic 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 Basic.
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
11
5 Installation
Step 5
Install the air tubes with reference to the Air connections diagram
on page 15.
2050-0018
Step 6
Untighten the four screws and pull off the cover of ThinkTop Basic.
2050-0019
Step 7a - Cable gland version
1. Install cable (if not present) through the cable gland.
2. Connect the electrics of the ThinkTop Basic
(see 5.4 Electrical connection, internal - Digital).
NOTE!
Make sure the cable gland is fully tightened.
2050-0020
Step 7b - M12 plug version
1. Install M12 socket cable.
NOTE!
M12 plug Electrical connection:
1
3
1
BN
3
BU
2050-0056
Step 8
Set up the ThinkTop Basic (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.
12
5 Installation
5.2
Installation on Series 700 Valves
Step 1
1. Remove the cover by loosening the four cross recess 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 indicator (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
13
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
14
5 Installation
5.3
Air connections
A
B
I
C
D
1
2
H
3
G
A.
B.
C.
D.
E.
F.
G.
H.
I.
Air out 1A
Air exhaust
Solenoid 3/2 or 5/2
Air out 1B (5/2 port solenoid valve only)
Solenoid valve (3/2) only
Air in
Air out 3
Air out 2
Manual hold override
E
2050-0027
F
15
5 Installation
5.4
Electrical connection, internal - Digital
P1
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
De-energised (PLC input)
Energised (PLC input)
Activation of solenoid # 1 (PLC input)
Activation of solenoid # 2 (PLC input)
Activation of solenoid # 3 (PLC input)
Supply voltage sensor (+) 10-30 VDC
Supply voltage sensor (o) 0 VDC
Common supply solenoids
PNP/NPN jumper*)
PNP/NPN jumper*)
11
12
13
14
Solenoid
Solenoid
Solenoid
Solenoid
7
8
9
common, internal connection (Grey)
# 1, internal connection (Grey)
# 2, internal connection (Grey)
# 3, internal connection (Grey)
10
11
12
13
14
2053-0001
Note! Remember to isolate wires that are not in use.
*) Jumper present = PNP.
If changing the function, a power recycle is necessary.
The selection NPN/PNP is performed by the jumper.
16
5 Installation
5.5
Electrical connection, internal - AS-Interface
P1
1
2
3
4
5
1
2
3
4
5
6
7
8
ASI +
ASI PWM jumber
PWM jumber
Solenoid common, internal connection (Grey)
Solenoid # 1 nternal connection (Grey)
Solenoid # 2 internal connection (Grey)
Solenoid # 3 internal connection (Grey)
6
7
8
2054-0000
Note! Remember to isolate wires that are not in use.
17
6 Setup diagram
6.1
ThinkTop Basic setup
Timeout:
A 60-second time-out is started as soon as any
button/s isreleased. If no button is pressed
during the time-out period, go to normal
condition (cancel & exit).
Red
LED:
Active during setup
- Flashing in step 1
- Steady in all other steps
or during operations, error condition:
- Steady indicates hardware fault,
indication pin out of range
- Flashing indicates software fault
“red” flashing
Next step
Enter
setup
“1”
Step 1
Accept settings
Restart setup
“I”
sequence
“II” Save & exit
Cancel & exit, no
“II”*
changes accepted
* Hold for 5 sec.
Next
step
“red” steady “
green” flashing if
de-energised position
disabled “green” steady
if de-energised position
enabled
“red” steady
“yellow” flashing if energised
position disabled “yellow”
steady if energised position
enabled
Actuator in de-energised
position
Actuator in Energised
position
Step 2
Set de-energised position
Step 3
Set energised position
“II”
Store position
“I”
Bypass
“II”*
Disable function
* Hold for 5 sec.
Next
step
“II”
Store position
“I”
Bypass
“II”*
Disable function
* Hold for 5 sec.
Return to step 1
Quick setup:
Push: “I”, enter setup and wait until red LED flashes.
Push: “I”, restart setup.
Actuator in de-energised position
Push: “II”, store position
Actuator in energised position
Push: “II”, store position
Push: “II”, when red LED is flashing (save & exit)
Setup done.
Tolerance program
The ThinkTop Basic has a fixed tolerance program optimised for valve types such as LKB (LKLA-T) and MH Koltek.
18
7 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.
7.1
Dismantling the ThinkTop®
Step 1
1. Remove the ThinkTop Basic from the actuator.
2. Remove X-ring and replace it.
85
Step 2
1. Untighten the four screws.
2. Remove ThinkTop Basic cover.
3. Remove the grey X-ring.
TD 800-162_1
Step 3
1. Untighten screws.
2. Remove solenoid valves (up to three) and replace them with
new ones.
TD 800-235
19
7 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.
Step 4
1. To dismantle the adapter (the lower part of the ThinkTop Basic)
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.
Note: Turn banjo
connection!
TD 800-230
Step 5
To remove the sensor unit, untighten the screw and pull out
the sensor unit.
TD 800-231
20
7 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.
7.2
Assembling the ThinkTop®
Step 1
Place sensor unit in base and tighten screw (torque: 1 Nm).
TD 800-232
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).
Note:
Turn banjo
connection!
h
CAUTION!
Do NOT twist the X-ring in the groove!
The X-ring is not square; The highest (h) part
must be placed as fig.
TD 800-079
TD 800-233
Step 3
1. Replace solenoid valves (up to three) with new ones.
2. Tighten screws (0.2 Nm).
TD 800-234
21
7 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.
Step 4
1. Replace the grey X-ring.
2. Replace ThinkTop Basic cover and tighten
the four screws (0.6 Nm).
TD 805-007
Step 5
1. Replace the black X-ring.
2. Mount ThinkTop Basic on actuator.
85
22
7 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.
7.3
Dismantling and assembling Series 700 Valves
Step 1
1. Remove the cover by loosening the four cross recess screws.
2. Separate the adapter from the base by loosening the three
recess screws on top of the base.
Installation on air
actuators:
TD 800-160
Step 2
1. Fit air fittings on actuator.
2. Position packing retainer in recess on actuator top.
3. Fit counter nut and indicator (magnet) on actuator rod.
Engage approx. 1/4 thread. Tighten counter nut and indicator
with two wrenches.
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.
Step 4
- Remove X-rings (9) (grey) and (16) (black).
- Replace with new ones.
- 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).
CAUTION!
Do NOT twist the X-ring (16) in the groove! The X-ring is not
square; the highest (h) part must be positioned as shown.
9
16
TD 800-237
23
.
24
8 Part list
The items refer to the parts lists in the following sections
Diagrams for ThinkTop Basic
225 mm (9”)
5
1
172 mm (7”)
20
300 mm (12”)
8.1
9
8
16
TD 800-277
15
17
19
2053-0000
ø137 mm (5½”)
6b
1
2
3
6a
TD 800-171
25
8 Part list
The items refer to the parts lists in the following sections
8.2
ThinkTop Basic
6b
6a
TD 800-172
26
8 Part list
The items refer to the parts lists in the following sections
Parts list
Pos.
Qty
Denomination
1
3
4
5
6a
6b
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
27
1
1
1
1
1-2
1
3
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
Shell complete
Screw
Washer
Sensor board
Solenoid valve (3/2)
Solenoid valve (3/2 or 5/2)
PT screw
Base
Special X-ring, grey
Air fitting elbow
Blow-off valve
Thread plug
Cable gland (or optimal M12 plug)
Gore vent
Adapter complete
Special X-ring, black
O-ring
Allen screw
Special X-ring
Indication pin
5 m flying PVC cable
Threaded plate only for SRC/ARC
valves (accessory for the Think
Top)
27
8 Part list
The items refer to the parts lists in the following sections
8.3
Diagrams for ThinkTop Basic for Series 700
225 mm (9”)
5
1
172 mm (7”)
300 mm (12”)
22
23
9
8
16
15
17
19
TD 800-239
2053-0000
ø137 mm (5½”)
6b
1
2
3
6a
TD 800-171
28
.
29
8 Part list
The items refer to the parts lists in the following sections
8.4
ThinkTop Basic for Series 700 Valves
1
3
16
4
5
17
18
6b
6a
15
11
7
19
9
21
10
20
11
14
22
8
12
13
23
2053
30
-0002
8 Part list
The items refer to the parts lists in the following sections
Parts list
Pos.
Qty
Denomination
1
3
4
5
6a
6b
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
1
1
1
1-2
1
3
1
1
2-5
2
1
1
1
1
1
1
4
1
1
1
1
1
Shell complete
Screw
Washer
Sensor board
Solenoid valve (3/2)
Solenoid valve (3/2 or 5/2)
PT screw
Base
Special X-ring, grey
Air fitting
Blow-off valve
Thread plug
Cable gland
Gore vent
Adapter complete
Special X-ring, black
O-ring
Screw
Retainer
O-ring
O-ring
Indicator pin
Nut
31
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.