Instruction Manual

ThinkTop AS-Interface v.2.1 (31 nodes) & v.3.0 (62 nodes) 29.5 - 31.6 VDC

TD 800-242_1

Patented Sensor System Registered Design Registered Trademark

ESE00356-EN10
Original manual

2011-07

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 ....................................................................... 2. Safety .................................................................................................... 2.1. Important information ............................................................................. 2.2. Warning signs ..................................................................................... 2.3. Safety precautions ................................................................................ 3. General information ................................................................................... 3.1. AS-Interface in general ........................................................................... 4. Technical specifications .............................................................................. 4.1. ThinkTop, AS-Interface ........................................................................... 5. Installation .............................................................................................. 5.1. Installation on air actuators ...................................................................... 5.2. Installation on Series 700 valves ................................................................ 5.3. Air connections ................................................................................... 5.4. Electrical connection, internal ................................................................... 6. Setup diagram ......................................................................................... 6.1. ThinkTop setup utilising IR keypad .............................................................. 6.2. ThinkTop setup utilising local I and II keys ................................................... 6.3. ThinkTop quick setup guide ..................................................................... 7. Fault finding ............................................................................................ 7.1. Fault finding and LEDs ........................................................................... 8. Maintenance ........................................................................................... 8.1. Dismantling of ThinkTop .......................................................................... 8.2. Assembly of ThinkTop ............................................................................ 8.3. Dismantling and assembly of Series 700 valves ............................................... 9. Parts list and Service Kits ........................................................................... 9.1. Drawings for ThinkTop AS-Interface ............................................................ 9.2. ThinkTop AS-Interface ............................................................................ 9.3. Drawings for ThinkTop AS-Interface for Series 700 ........................................... 9.4. ThinkTop AS-Interface for Series 700 ...........................................................

4 5 5 5 6 7 7 8 8 14 14 17 18 19 20 20 22 24 26 26 28 28 30 32 33 33 34 37 38

1 EC Declaration of Conformity

The designating company Alfa Laval

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+45 79 32 22 00
Phone No.

hereby declare that Top Unit for Valve Control & Indication
Denomination

ThinkTop AS-Interface
Type Year

is in conformity with the following directives with amendments: - Low Voltage Directive (LVD) 2006/95/EF - EMC Directive 2004/108/EF - ROHS Directive 2002/95/EEC

Manager, Product Centres, Compact Heat Exchangers & Fluid Handling

Title

Bjarne Sndergaard
Name

Alfa Laval Kolding Company

Signature

Designation

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:

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: Always earth close to the welding area. Disconnect the ThinkTop. Always have the ThinkTop electrically connected by authorized 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 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.

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.

4 Technical specifications

4.1

ThinkTop, AS-Interface

No Touch sensor system

1 2 3 4 6 7 8 5

9 11

10

12 13
TD 800-267

14

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. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Terminals ASI + ASI Bus Connection Internal connections Solenoid signals (DC) Solenoid common External seat-lift (PNP) Supply sensors External connections

15

16 17

18 19

20

Type: Alfa Laval No Touch System. For wire connections: See 5.4 Electrical connection, internal. 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass valve type / keep present valve type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRC/ARC and Series 700 valves, only when self adjustment is enabled - Not recommended. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LKB (LKLA-T). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unique Mixproof, SMP-SC Spillage-Free, and SRC-PV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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)). Type 0: Type 1: Type 2: Type 3: Type 4: 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.

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 (4 - 10 mm). Direct external/sensor cable gland entry PG7 (3 - 6.5 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: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 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.

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 DI 1 DI 2 DI 3 DO 0 DO 1 DO 2 DO 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback # 1 De-Energised Position (closed position) # 2 Energised Position (open position) # 3-4 SeatLift 1 or 2 position # 5 Status

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 3

10

4 Technical specifications

ThinkTop Visual Indications

LED B

LED Indications LED B O LED D LED C LED E LED F LED A Open valve (Yellow) IR-Receiver Setup/Internal fault (Red) Seat-lift 1/2 (Yellow) Solenoid valves (Green) Maintenance (Orange) Closed valve (Yellow)

LED D LED C LED E LED F LED A

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 To To To indicate that the set-up is ongoing (LED D) indicate an error condition (LED D) (flashing = software error), (steady = hardware error) indicate that the time for maintenance has been reached (LED F) 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 Air supply Filtered air, max. particles or dirt Max. flow Max. oil content Max. water content Throughput Air restriction (throttle function) air inlet/outlet. Manual hold override. External air tube connection Silencer/filter Nominal voltage Nominal power 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. Must match the selected type of ThinkTop. Output voltage Load current Max. 100 mA per solenoid. Max. current from any number of energized output stages is 200 mA. Voltage drop Max. 3 V at 50 mA. 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 Steel parts Seals Gore vent. membrane Nylon PA12. Stainless steel AISI 304 and 316. Nitrile (NBR), EPDM rubber for SMP-EC activator stem. PBT plastic. 3/2 or 5/2 valve (only possible with one 5/2 valve). 300-900 kPa (3-9 bar). 5 5-5 mg/m3. 180 l/min. 1 mg/m3. 0.88 g/m3 -20 oC compressed air. 2.5 mm. Yes. Yes. 6 mm or 1/4 (specify when ordering). Connection possible via 6 mm or 1/4". (Filter recommended in tropical regions). 24 VDC. 1.0 W.

12

4 Technical specifications

Micro environment demand specifications Temperature Working: Storage: Temperature change: Vibration

-20C to +85C -40C to +85C -25C to +70C 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

Drop test Humidity Constant humidity: Cyclic humidity: (working) Protection class Input treshold Voltage/current: EMC Directive AS-Interface UL Approval

IEC 68-2-32 +40C, 21 days, 93% R.H. +25C/+55C 12 cycles 93% R.H. IP66 and IP67 Type 1 input requirements 2004/108/EF Version 2.1*) Version 3.0 **) 8-30 VAC/VDC, Class 2 input, 45 mA max. output IEC 68-2-3 IEC 68-2-30 IEC 529 EN 61131-2 EN 61000-6-3, EN 61000-6-2 EN50295

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 authorized personnel. Step 2 1. Fit the air fittings on actuator if not mounted. 2. Fit the activator stem (magnet) and tighten carefully with a spanner. SRC/ARC only

Step 3 1. Place the ThinkTop on top of the actuator. 2. Make sure X-ring is mounted.

85

Step 4 1. Ensure that the unit is correctly mounted by pressing down on top of the ThinkTop. 2. Tighten the two Allen screws carefully (1.50 Nm). 3. Turn the actuator to have LEDs in a front view.

14

5 Installation

Step 5 Fit the 6 mm (1/4) air tubes to ThinkTop. (see drawing Air connections page 18).

Step 6 Fit the air tubes to the actuator (see drawing Air connections page 18).

TD 800-131

Step 7 Untighten the four screws and pull off cover of ThinkTop.

TD 800-247

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

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

Installation on air actuators:

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.

TD 800-250

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. 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 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
A B

C K D

1 E

2 3 I G
TD 800-252

A. B. C. D. E. F. G. H. I. J. K.

Air restriction (throttle function) air inlet/outlet Air out 1A Air exhaust Air out 1B (5/2 port solenoid valve only) Solenoid 3/2 or 5/2 3/2 Solenoid valves only Air restriction (throttle function) air inlet/outlet Air in Air out 3 Air out 2 Manual hold override

18

5 Installation

5.4

Electrical connection, internal

A B Bus Connection Internal connections to solenoid 1-3 ***) C PWM Jumper**) D Incoming signals from external sensors ****) E 6 7 8 9 10 11 20 21 22 23 ASI + ASI N/C N/C N/C N/C Earth Solenoid common brown Solenoid 1, blue Solenoid 2, blue Solenoid 3, blue 1 2 3 4 5 12 13 24 25 26 27 Supply to external sensors *) N/C N/C N/C N/C N/C PWM Jumper **) PWM Jumper **) Seat-lift 1 upper *) Seat-lift 2 lower *) Supply + *) 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 +/- 5mm Step 3-8, disabled Active during set-up: Flashing in step 1 Steady in all other steps Steady showing hardware fault, indication pin out of range Flashing showing software fault

D LED:

Or during operations, error condition:

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 Remote distance 0-300 mm to ThinkTop

IR Keypad: Symbols
X

Push key on IR keypad with the same number Simple representation of LED indication:

Yellow IR-Reciver Red Yellow Green Orange Yellow

B D C E F A

Steady LED

Flashing LED

General commands in each step (except step 1):

0

Next step / skip step

(In step 3-6 the program automatically moves to the next step when a position is stored) (In step 2 this resets the unit and set the step 2-8 to default) (The command is accepted when all unit LEDs flash briefly) It is recommended to reset the unit before performing a setup Always check for correct signals after the setup

Clear / disable step

20

6 Setup diagram

Step 1 B D Next C step E F A

Enter Setup
1 Save and Exit

2 Exit no change accepted

Step 2 Setup valve type B Default +/- 5mm D Next C step E 1 F A

SRC/ARC Series 700 (Only used when self adjustment feature is required)

LKB (LKLA-T)

Unique Mixproof, SRC-PV spillage-free SMP-SC

SMP-SC SMP-BC SMP-TO SMP-BCA SBV Unique SSV. SRC/ARC Series 700

Reset unit

Step 3 Set closed position Default B D Next C step E F A Activate the valve to the close position (De-energized)

Position stored. Cleat position

auto

Step 4 Set open position Default B

Position stored Activate the valve to the open position (Energized) Clear position

Next D step C E F

auto

Step 5 Set upper seat lift. Default B

Position stored Activate the valve to upper seat lift. When using an external sensor the sensor must be active when 1 is pushed Clear position

Next D step C E F A

auto

Step 6 Set lower seat lift. Default B Next Activate the valve to lower seat lift. When step D C using an external sensor the sensor must be E F active when 1 is pushed A

Position stored. Clear position

5
auto

Step 7 Set self adjust (Recommended: Disabled) B Default Associated Next Disabled with step D closed/ open C position E 1 2 F A Step 8 Setup maintenance B Default Disabled Next D step C E 1 F A

Associated with closed position

Associated with open position

Disable function

90 days

180 days

270 days

360 days Disable function

21

6 Setup diagram

6.2

ThinkTop setup utilising local I and II keys

General Default is: Step 2, tolerance is +/- 5mm Step 3-8, disabled A 60 sec. timeout is started as soon as any button(s) are released On timeout the setup is exited with no changes saved

Timeout:

Flashing LED means no value set. Steady LED means value set as shown Active during set-up: Flashing in step 1 [D] LED: Steady in all other steps Or during operations, error condition: Steady showing hardware fault, indication pin out of range Flashing showing software fault

General commands in each step (except step 1):

5s

Next step / skip step

(In step 3-6 the program automatically moves to the next step when a position is stored) (In step 2 this resets the unit to default) (The command is accepted when all unlit LEDs flash briefly)

5s

Clear / disable step

It is recommended to reset the unit before performing a setup

Symbols
5s

Push local key I Push local key II Hold key II for 5 sec

5s

5s

Simple representation of LED indication:

Yellow IR-Reciver Red Yellow Green Orange Yellow B D C E F A

Steady LED

Flashing LED

22

6 Setup diagram

Step 1 B D Next C step E F A

Enter Setup
5s 5s

Save and Exit Exit no change accepted

Step 2 Setup valve type B Default +/- 5mm D Next C step E F A Next step Step 3 Set closed position Default B D Next C step E F A

SRC/ARC Series 700 (Only used when self adjustment feature is required)

LKB (LKLA-T)

Unique Mixproof, SRC-PV spillage-free SMP-SC

SMP-SC SMP-BC SMP-TO SMP-BCA SBV Unique SSV SRC/ARC Series 700

Position stored

Activate the valve to the closed position (De-energized) auto

Step 4 Set open position Default B Next D step C E F Activate the valve to the open position (Energized)

Position stored

auto

Step 5 Set upper seat lift Default B Next D step C E F A Activate the valve to upper seat lift. When using an external sensor the sensor must be active when II is pushed

Position stored

auto

Step 6 Set lower seat lift Default B D Next C step E F A Activate the valve to lower seat lift. When using an external sensor the sensor must be active when II is pushed

Position stored

auto

Step 7 Set self adjust (Recommended: Disabled) B Default Associated Disabled with Next D closed/ step C open position E F A Next step Step 8 Setup maintenance B Default Disabled Next D step C E F A Next step

Associated with closed position

Associated with open position

90 days

180 days

270 days

360 days

+90 days (Up to max. 18 years)

23

6 Setup diagram

6.3

ThinkTop quick setup guide

Valve: Unique SSV, SRC/ARC type NC (selfadjustment disabled) - and wait until red LED flashes Push: I Push: I - hold for 5 sec (clear all stored parameters) Push: II Push: (red + yellow LED) II Push: (red + yellow + green LED) II Push: (red + yellow + green + orange LED) II Push: (red + yellow + green + orange + yellow LED) II Push: I - to approve valve down (closed) Push: II Valve opens Activate - to approve (open) Push: II Push: (no upper seat-lift) I Push: (no lower seat-lift) I Push: (no self adjustment) I Push: (no maintenance) I Push: Red LED flashes (save & exit by push) II

Setup done Valve: SRC/ARC type NO (selfadjustment enabled) - and wait until red LED flashes Push: I Push: I - hold for 5 sec (clear all stored parameters) Push: II Push: (red + yellow LED) II Push: I Activate Valve closes - to approve valve closed Push: II Push: Deactivate Valve opens - to approve valve is open Push: II Push: (no upper seat-lift) I Push: (no lower seat-lift) I = self adjustment Push: II Push: I Push: (no maintenance) I Push: Red LED flashes (save & exit by push) II

Setup done Valve: LKB Valve (Butterfly) NC - and wait until red LED flashes Push: I Push: I - hold for 5 sec Push: II Push: (red + yellow LED) II Push: (red + yellow + green LED) II I - to approve valve closed (indication stem up) Push: II Push: LKB valve- open position (indication-stem down) Activate - to approve valve is open Push: II Push: (no upper seat-lift) I Push: (no lower seat-lift) I Push: (no self adjustment) I Push: (no maintenance) I Push: Red LED flashes (save & exit by push) II Setup done

24

6 Setup diagram

Valve: LKB Valve (Butterfly) NO Push: Push: Push: Push: Push: Push: Push: Push: Push: Push: Push: Push: Push: Push: I I II II II I Activate II Deactivate II I I I I II Setup done Valve: Unique mixproof Valve (with lower seat-lift) - and wait until red LED flashes Push: I Push: I - hold for 5 sec (clear all stored parameters) Push: II Push: (red + yellow LED) II Push: (red + yellow + green LED) II Push: (red + yellow + green + orange LED) II I - to approve valve closed Push: II Valve opens Activate - to approve valve is open Push: II Push: (no upper seat-lift) I Push: Activate Lower seat-lift active - to approve Push: II Push: (no self adjustment) I Push: (no maintenance) I Push: Red LED flashes (save & exit by push) II - and wait until red LED flashes - hold for 5 sec (clear all stored parameters) (red + yellow LED) (red + yellow + green LED) - to approve valve closed (indication stem up) - to approve valve closed LKB valve-open position (indication-stem up) - to approve valve is open (no upper seat-lift) (no lower seat-lift) (no self adjustment) (no maintenance) Red LED flashes (save & exit by push)

Setup done

25

7 Fault finding

7.1

Fault finding and LEDs

Below is stated the meaning of the LEDs indications for fault finding in connection with the operation of the ThinkTop.

Red flashing:

Unit in set-up mode or internal software fault. If internal software fault, re-programme unit.

Red

Red steady:

Unit in set-up mode or internal hardware fault. If internal hardware fault, check if magnet is in range and check correct wiring.

Yellow B

1. Orange flashing:

Time for maintenance has run out. The unit has been self-adjusted into a maintenance alert condition. Valve maintenance is strongly recommended. After maintenance: Disabling of maintenance/self-adjustment function is required before setting new position, however, it is strongly recommended to make a complete new set-up after valve maintenance. The unit has been self-adjusted into a maintenance alarm condition and the feedback is lost (a minimum of seal left). Valve maintenance is required. After maintenance: Disabling of the self-adjustment function is required before setting new position, however, it is strongly recommended to make a complete new set-up after valve maintenance. The maintenance indicator lighting up, and an open or closed light flashing..... = Note the following: - Self-adjustment programme is only valid for SRC/ARC valves, do not use the programme for other valve types. - Use tolerance/valve type 1. - In conjunction with valve type change-over; 21, 22, 31 and 32, the open position must be defined as the upper sensor position (when the indication pin is in the highest position). - A loose top, indication pin or sensor system can also generate the alert/alarm condition. - Removing a ThinkTop with self-adjust activated, will immediately generate an alarm condition! If the ThinkTop has to be removed, not because of a valve maintenance issue, but for some other reasons, and you want to store the already adjusted data - disable the self-adjust function before removing the ThinkTop and enable it again once the ThinkTop is back on the actuator. - After valve maintenance a disabling of the self-adjustment function is required before setting a new position, however, it is strongly recommended to make a complete new set-up (disable all functions in step 2 valve type - and make a complete new set-up).

2. Orange steady, yellow flashing (A and/or B): Orange Yellow A NOTE!

Yellow A

Yellow steady:

Position A (closed valve).

26

7 Fault finding

Yellow B

Yellow steady:

Position B (open valve).

Yellow steady:

Position C (Seat lift 1-2 or external sensors).

Yellow C

Green

Green steady:

Solenoid valves energized.

Note! During set-up LED lights have different functions.

27

8 Maintenance
Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock.

8.1

Dismantling of ThinkTop

Step 1 1. Untighten the two Allen screws and remove the ThinkTop from the actuator. 2. Pull out X-ring (19) and replace it.

85

Step 2 1. Untighten the four screws. 2. Pull off cover of ThinkTop. 3. Remove X-ring (9) (grey).

TD 800-253

Step 3 1. Untighten screws. 2. Remove solenoid valves (up to three) and replace them with new ones.

TD 800-254

Step 4 1. To dismantle the adapter (the lower part of the ThinkTop) from base (the middle part), unscrew the three screws. 2. Turn the lower part a little clockwise and pull. 3. Replace adapter if necessary. 4. Remove the black X-ring. Note: Turn banjo connection!

TD 800-255

28

8 Maintenance
Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock.

Step 5 To remove the sensor unit untighten screw and pull out the sensor unit.

TD 800-256

29

8 Maintenance
Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock.

8.2

Assembly of ThinkTop

Step 1 Place sensor unit in base and tighten screw (torque: 1 Nm).

TD 800-257

Step 2 1. Replace the black X-ring. 2. Assemble base with adapter by turning adapter slightly anticlockwise and tighten the four screws (1.9 Nm). 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.

Note: Turn banjo connection!

TD 800-258

Step 3 1. Replace solenoid valves (up to three) with new ones. 2. Tighten screws (0.2 Nm).

TD 800-259

Step 4 1. Replace the grey X-ring. 2. Replace cover of ThinkTop and tighten the four screws (0.6 Nm).

TD 800-260

30

8 Maintenance
Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock.

Step 5 1. Replace the black X-ring. 2. Mount ThinkTop on actuator.

85

31

8 Maintenance
Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock.

8.3

Dismantling and assembly of Series 700 valves

Installation on air actuators:

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.

TD 800-250

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. 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 1. 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). 2. Remove x-rings (9) (grey) and (16) (black). 3. Replace with new ones. 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 800-251

32

9 Parts list and Service Kits

The drawings show ThinkTop AS-Interface v.2.1 (31 nodes) & v.3.0 (62 nodes) 29.5 - 31.6 VDC. The items refer to the parts lists in the following sections

9.1

Drawings for ThinkTop AS-Interface

171.6 mm

TD 800-263

18

TD 800-149

137 mm

Note! This is the basic design. Valve Type H Unique SSV NC SMP-SC/-BC/-TO Unique Mixproof MH SBV Unique SSV NO LKLA-T 225 225 225 225 225 225 225

W 250 250 250 250 250 320 300

6b

2 3
6a
TD 800-171

33

9 Parts list and Service Kits

The drawings show ThinkTop AS-Interface v.2.1 (31 nodes) & v.3.0 (62 nodes) 29.5 - 31.6 VDC. The items refer to the parts lists in the following sections

9.2

ThinkTop AS-Interface

6b

6a

TD 800-270

34

9 Parts list and Service Kits

The drawings show ThinkTop AS-Interface v.2.1 (31 nodes) & v.3.0 (62 nodes) 29.5 - 31.6 VDC. The items refer to the parts lists in the following sections

Parts list
Pos. 1 3 4 5 6a 6b 7 8 9 10 11 12 13 14 15 16 17 18 19 20 23 Qty 1 1 1 1 1-2 1 3 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Denomination (Pos.9,12,13,14 included) 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, PG7 3-6.5 mm Cable gland, PG11 4-10 mm Gore vent High airflow Adapter complete Special X-ring, black O-ring Allen screw Special X-ring Indication pin 2 m ASI drop cable (2 x 0.5 mm2) with flat cable connector

Service kits
a a a a a a a a a a a a a a a Solenoid valve 3/2, 24 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3324 Solenoid valve 5/2, 24 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3327 Indication pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-5623-01 Special indication pin, SRC-LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-6370-01 . . . . . . . . . . . . . . . . . . . . . . . . 9613-1581-01 Special indication pin, Unique SSV-LS Air fitting, 6 mm Gore vent

Special indication pin, Unique SSV High Pressure . . . . . . . . . . . . . 9613-1581-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3405 Air fitting, 1/4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3433 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-4722 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9613-4564-01 X-ring, pos. 9

X-ring, pos. 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-9994-01 X-ring, pos. 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-5696-01 Sensor board AS-Interface 29.5-31.6 VDC (Period -0902 . . . . . 9612-5627-03 Sensor board AS-Interface v.2.1 (31 nodes) (Period 0902- ) Sensor board AS-Interface v.3.0 (62 nodes) (Period 0902- ) . . 9613-4434-02 . . 9613-4434-03

TD 900-389/3

35

36

9 Parts list and Service Kits

The drawings show ThinkTop AS-Interface v.2.1 (31 nodes) & v.3.0 (62 nodes) 29.5 - 31.6 VDC Series 700 valves. The items refer to the parts lists in the following sections

9.3

Drawings for ThinkTop AS-Interface for Series 700

171.6 mm

TD 800-269

TD 800-205

137 mm

Note! This is the basic design. Valve Type H W Unique SSV NC SMP-SC/-BC/-TO Unique Mixproof MH SBV Unique SSV NO LKLA-T 225 225 225 225 225 225 225 250 250 250 250 250 320 300

6b

6a

TD 800-262

37

9 Parts list and Service Kits

The drawings show ThinkTop AS-Interface v.2.1 (31 nodes) & v.3.0 (62 nodes) 29.5 - 31.6 VDC Series 700 valves. The items refer to the parts lists in the following sections

9.4

ThinkTop AS-Interface for Series 700

6b

6a

266

38

9 Parts list and Service Kits

The drawings show ThinkTop AS-Interface v.2.1 (31 nodes) & v.3.0 (62 nodes) 29.5 - 31.6 VDC Series 700 valves. The items refer to the parts lists in the following sections

Parts list
Pos. 1 3 4 5 6a 6b 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 Qty 1 1 1 1 1-2 1 3 1 1 1 2 1 1 1 1 1 1 4 1 1 1 1 1 1 Denomination (Pos.9,12,13,14 included) 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, PG7 3-6.5 mm Cable gland, PG11 4-10 mm Gore vent High airflow Adapter complete Special X-ring, black O-ring Screw Retainer O-ring O-ring Indicator pin Nut 2 m ASI drop cable (2 x 0.5 mm2) with flat cable connector

Service kits
a a a a a a a a a a Solenoid valve 3/2, 24 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3324 Solenoid valve 5/2, 24 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3327 Indication pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-6357-02 Air fitting, 1/4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3433 Gore vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-4722 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9613-4564-01 X-ring, pos. 9

X-ring, pos. 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-9994-01 Sensor board AS-Interface 29.5-31.6 VDC (Period -0902 . . . . . 9612-5627-03 Sensor board AS-Interface v.2.1 (31 nodes) (Period 0902- ) Sensor board AS-Interface v.3.0 (62 nodes) (Period 0902- ) . . 9613-4434-02 . . 9613-4434-03

TD 900-393/3

39

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