Instruction Manual

ThinkTop® Basic AS-Interface v.3.0 (62 nodes) 29.5 - 31.6 VDC

TD 800-242_1

Patented Sensor System

Registered Design
Registered Trademark

ESE01516-EN2 2011-01
Original manual
 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 ................................................................................ 6

3. General information ................................................................................... 7

3.1. ThinkTop Basic AS-Interface in general ......................................................... 7

4. Technical specifications .............................................................................. 8

4.1. ThinkTop Basic AS-Interface ..................................................................... 8

5. Installation .............................................................................................. 12
5.1. Installation on air actuators ...................................................................... 12
5.2. Air connections ................................................................................... 15
5.3. Electrical connection, internal ................................................................... 16

6. Setup diagram ......................................................................................... 17

6.1. ThinkTop Basic AS-Interface setup ............................................................. 17

7. Maintenance ........................................................................................... 18
7.1. Dismantling of ThinkTop .......................................................................... 18
7.2. Assembly of ThinkTop ............................................................................ 20

8. Parts list and Service Kits ........................................................................... 23

8.1. Drawings for ThinkTop Basic AS-Interface ..................................................... 23
8.2. ThinkTop Basic AS-Interface ..................................................................... 24

3
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 ThinkTop Basic AS-Interface
Denomination 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 Bjarne Søndergaard

Heat Exchangers & Fluid Handling
Title Name

Alfa Laval Kolding

Company Signature

Designation

4
 2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs. All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury or damage to the top unit are avoided.

2.1 Important information

Always read the manual before using the top unit!

WARNING
Indicates that special procedures must be followed to avoid severe personal injury.

CAUTION
Indicates that special procedures must be followed to avoid damage to the ThinkTop Basic AS-Interface.

NOTE
Indicates important information to simplify or clarify procedures.

2.2 Warning signs

General warning:

Dangerous electrical voltage:

Caustic agents:

5
2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs. All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury or damage to the top unit are avoided.

2.3 Safety precautions

Installation

Always read the technical data thoroughly.

Never install the ThinkTop Basic AS-Interface before valve or relay is in a safe position.

If welding close to the ThinkTop Basic AS-Interface: Always earth close to the welding area.

Disconnect the ThinkTop Basic AS-Interface.

Always have the ThinkTop Basic AS-Interface electrically connected by authorized personnel.

Maintenance

Always read the technical data thoroughly.

Always fit the seals between valve and ThinkTop Basic AS-Interface correctly.

Never install the ThinkTop Basic AS-Interface before valve or relay is in a safe position.

Never service the ThinkTop Basic AS-Interface with valve/actuator under pressure.

Never clean the ThinkTop Basic AS-Interface with high pressure cleaning equipment.

Never use cleaning agents when cleaning the ThinkTop Basic AS-Interface. Check with cleaning
agent supplier.

6
 3 General information

3.1 ThinkTop Basic AS-Interface in general

The ThinkTop Basic AS-Interface is designed to ensure valve control in conjunction with Alfa Laval sanitary valves and it is
compatible with all major PLC systems (Programmable Logic Controller).

The ThinkTop Basic AS-Interface can be equipped with 0-3 solenoid valves. The solenoids are electrically controlled via the
AS-Interface and when activated the compressed air is activating the air actuator. All solenoid valves have build-in manual hold
override function which means that it is possible to manually open and close the actuator and seat lifts.

Visual LED lights are constantly indicating the status of the unit: Valve positions, solenoid energized, setup and local fault
indication etc.

The ThinkTop Basic AS-Interface is characterized by a simple and modular design.

7
4 Technical specifications

4.1 ThinkTop Basic AS-Interface

“No Touch” sensor system

1 1. Sensor board 11. Terminals

2 2. PLC, feedback 12. ASI +
3 4
5
6 3. Sensor unit 13. ASI -
4. PLC interface board 14. Bus Connection
7 8 5. N/A 15. Internal connections
6. N/A 16. Solenoid signals (DC)
7. Serial link 17. Solenoid common
9 12
10 14 8. LEDs 18. N/A
11 13
9. +5 V 19. N/A
10. Terminals 20. N/A
TD 800-267

16 18
15 17 19 20

Type: Alfa Laval “No Touch” System. For wire connections: See 5.3 Electrical connection, internal“.

Features
- Easy and simple set-up, using locally pushbottons.
- No manual sensor adjustments at all.
- No sensor "movements" due to vibrations.
- Modular and hygienic design with exchangeabilities.
- Clear LED’s for visual status indication.
- Setup saved at power shutdown.

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 unit. 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 2 feedback signals.

Electrical connection
Direct main cable gland entry (hard wired) PG11 (ø4 - ø10 mm).

Terminals
The terminal row of the sensor board is equipped with screw terminals for both internal as well as external wires. The terminals
are suitable for wires up to 0.75 mm2 (AWG 19).

8
 4 Technical specifications

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

Typical power consumption ThinkTop Basic AS-Interface

Test conditions = One ThinkTop Basic AS-Interface connected with 1 feedback active (on) and:

No solenoids on Supply voltage 24 VDC 30 mA

1 solenoid active Supply voltage 24 VDC 75 mA
2 solenoids active Supply voltage 24 VDC 120 mA
3 solenoids active Supply voltage 24 VDC 165 mA

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).

Technical specifications sensor system

Sensor accuracy: . . . . . . . . . . . . . . . . . . . ± 0.1 mm.
Tolerance band: . . . . . . . . . . . . . . . . . . . . . ± 5 mm.
Distance to indication pin: . . . . . . . . . . 5 ± 3 mm.
Stroke length: . . . . . . . . . . . . . . . . . . . . . . . 0.1 - 80 mm.
Electrical connection: . . . . . . . . . . . . . . . Direct cable gland entry
PG11 (ø4 - ø10 mm).

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback # 1 De-Energized Position (closed position)
DI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback # 2 Energized Position (open position)
DI 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback # 3 Not connected
DI 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback # 4 Status

DO 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not connected
DO 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 1
DO 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 2
DO 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 3

Status signal (Feedback # 4) input bit 3

The status signal is used for two purposes:
- To indicate that the setup is ongoing (LED B).
- To indicate an error condition (LED B). (Flashing LED = software error), (steady LED = hardware error).

9
4 Technical specifications

ThinkTop Basic AS-Interface Visual Indications LED Indications

LED A
LED A “Energized” (Yellow)
- -
LED B
LED B “Setup/Fault” (Red)
- -
LED C LED C “Solenoid” (Yellow)
- -
LED D LED D “De-Energized" (Green)
TD 800-030_1

Technical specifications solenoid valves

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.

Technical specifications
0 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 5 μ 5-5 mg/m3
Max. flow 180 l/min
Max. oil content 1 mg/m3
Max. water content 0.88 g/m3 -20 oC compressed air
Throughput ø2.5 mm
Manual hold override. Yes
External air tube connection ø6 mm or 1/4” (specify when ordering)
Silencer/filter Connection possible via ø6 mm or 1/4".
(Filter recommended in tropical regions)
Internal connections (solenoids)
The power consumption of the solenoids is being reduced via PWM (Pulse Width Modulation). The PWM can be disabled by
removing the jumper (terminal 3, 4)
Nominal voltage 24 VDC
Nominal power 1.0 W
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 Nylon PA6
Steel parts Stainless steel AISI 304
Seals Nitrile (NBR)
Gore vent. membrane PBT plastic

10
 4 Technical specifications

Micro environment demand specifications

Temperature
Working: -20°C to +85°C IEC 68-2-1/2
Storage: -40°C to +85°C IEC 68-2-1/2
Temperature change: -25°C to +70°C IEC 68-2-14
Vibration 10-55 Hz, 0.7 mm IEC 68-2-6
55-500 Hz, 10g
3 x 30 min, 1 octave/min
Drop test IEC 68-2-32
Humidity
Constant humidity: +40°C, 21 days, 93% R.H. IEC 60068-2-78
Cyclic humidity: +25°C/+55°C
12 cycles
(working) 93% R.H.
Protection class IP66 and IP67 IEC 60529
Input treshold
Voltage/current: Type 1 input requirements EN 61131-2
EMC Directive 2004/108/EF EN 61000-6-3, EN 61000-6-2
AS-Interface Version 3.0*) EN50295
UL/CSA 10-30 VDC, Class 2 input,
45 mA max. output UL 508-E203255
*) Max. 62 ThinkTop Basic AS-Interface units on a single master/gateway.

11
5 Installation

5.1 Installation on air actuators

Step 1

Always read the technical data thoroughly.

Always have the ThinkTop Basic AS-Interface electrically

connected by authorized personnel.

Never install the ThinkTop Basic AS-Interface before valve or relay

is in a safe position.

Step 2
1. Fit the air fittings on actuator if not mounted.
2. Fit the indication pin and tighten carefully SRC only
with a spanner.

Step 3
1. Place the ThinkTop Basic AS-Interface 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 Basic AS-Interface.
2. Tighten the two Allen screws carefully (1.50 Nm).
3. Turn the actuator to have LEDs in a front view.

12
 5 Installation

Step 5
Fit the ø6 mm (1/4”) air tubes to ThinkTop Basic AS-Interface .
(see drawing “Air connections” page 15).

Step 6
Fit the air tubes to the actuator
(see drawing “Air connections” page 15).

TD 800-131

Step 7
Untighten the four screws and pull off cover of ThinkTop Basic
AS-Interface.

TD 800-158

Step 8
1. Install cable (if not present) through the cable gland.
2. Connect the ThinkTop Basic AS-Interface electrically
(see page 5.3 Electrical connection, internal).

TD 800-157

13
5 Installation

Step 9
Make sure the cable gland is completely tightened.

TD 800-159

Step 10
Set up the ThinkTop Basic AS-Interface (see chapter 6 Setup
diagram).

NOTE!
The unit can be set up by internal push bottons on sensor board.
To energize the valve, use manual hold override on the solenoids
valve or be in radio contact with the control room.

14
 5 Installation

5.2 Air connections

I B

D
H

TD 800-184_1
G

A. Air out 1A
B. Air exhaust
C. Air out 1B (5/2 port solenoid valve only)
D. Solenoid 3/2 or 5/2
E. Solenoid valve (3/2) only
F. Air in
G. Air out 3
H. Air out 2
I. Manual hold override

15
5 Installation

5.3 Electrical connection, internal

Electrical connections, internal

1. ASI +
2. ASI -
3. PWM jumper
4. PWM jumper
5. Solenoid common, internal connection (Brown)
6. Solenoid # 1, internal connection (Blue)
7. Solenoid # 2, internal connection (Blue)
8. Solenoid # 3, internal connection (Blue)
TD 805-003

Note! Remember to isolate wires that are not in use.

16
 6 Setup diagram

6.1 ThinkTop Basic AS-Interface setup

ThinkTop Basic Digital and AS-Interface

A printable “one page” version of ThinkTop Basic setup diagram is available on the Alfa Laval website and can easily be found
be typing the document name “ThinkTop Basic setup diagram” in the searh field.

Time- A 60 second time-out is started as soon as any

out: button(s) are released. If no button is pressed
during the time-out period, go to normal
condition (cancel & exit).
Red Active during set-up
LED: - Flashing in step 1 “red” steady “
“red” steady
- Steady in all other steps green” flashing if
“yellow” flashing if energized
de-energized position
or during operations, error condition: position disabled “yellow”
disabled “green” steady
- Steady showing hardware fault, steady if energized position
if de-energized position
indication pin out of range enabled
enabled
- Flashing showing software fault

Actuator in De-energized Actuator in Energized

“red” flashing
Position Position

Step 1 Step 2 Step 3

Accept Settings Set De-energized Position Set Energized Position

Next step Next Next
Restart set-up
“I” step “II” Store Position step “II” Store Position
sequence
Enter
set-up “II” Save & Exit “I” Bypass “I” Bypass
“1”
Cancel & Exit, no
“II”* “II”* Disable function “II”* Disable function
changes accepted

* Hold for 5 sec. * Hold for 5 sec. * Hold for 5 sec.

Return to step 1

Quick set-up:
Push: “I”, enter setup and wait until red LED flashes.
Push: “I”, restart set-up.

Actuator in De-energized position

Push: “II”, store position

Actuator in energized position

Push: “II”, store position
Push: “II”, when red LED is flashing (save & exit)
Set-up done.

17
7 Maintenance
Study the instructions carefully.
Handle scrap correctly.
Always keep spare X-rings in stock.

7.1 Dismantling of ThinkTop

Step 1
1. Remove the ThinkTop Basic AS-Interface 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 Basic AS-Interface.
3. Remove the grey X-ring (9).

TD 805-006

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

TD 800-235

Step 4
1. To dismantle the adapter (the lower part of the ThinkTop Basic
AS-Interface) 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 800-230

18
 7 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 805-004

19
7 Maintenance
Study the instructions carefully.
Handle scrap correctly.
Always keep spare X-rings in stock.

7.2 Assembly of ThinkTop

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

TD 805-005

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 Note:
must be placed as fig. Turn banjo
connection!

TD 800-233

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

TD 800-234

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

TD 805-007

20
 7 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 Basic AS-Interface on actuator.

85

21
.

22
 8 Parts list and Service Kits
The drawings show ThinkTop Basic AS-Interface v.3.0 (62 nodes) 29.5 - 31.6 VDC.
The items refer to the parts lists in the following sections

8.1 Drawings for ThinkTop Basic AS-Interface

5
1
AS-Interface (+)

AS-Interface (-)

PWM Jumper/Diagnostic

PWM Jumper/Diagnostic

Solenoid common

20
Solenoid 1

Solenoid 2

Solenoid 3

9
H

171.6 mm

16

15
TD 805-002
17
19
TD 800-149

ø137 mm

Note! This is the basic design.

Valve Type W H

Unique SSV NC 225 250

SMP-SC/-BC/-TO 225 250
Unique Mixproof 225 250 6b
MH 225 250
SBV 225 250
Unique SSV NO 225 320
LKLA-T 225 300

6a
TD 800-171

23
8 Parts list and Service Kits
The drawings show ThinkTop Basic AS-Interface v.3.0 (62 nodes) 29.5 - 31.6 VDC.
The items refer to the parts lists in the following sections

8.2 ThinkTop Basic AS-Interface

6b
6a

TD 805-001

24
 8 Parts list and Service Kits
The drawings show ThinkTop Basic AS-Interface v.3.0 (62 nodes) 29.5 - 31.6 VDC.
The items refer to the parts lists in the following sections

Parts list
Pos. Qty Denomination
1 1 Shell complete
3 1 Screw
4 1 Washer
5 1 Sensor board AS-Interface
6a 1-3 Solenoid valves (3/2),
6b 1 Solenoid valves (3/2 or 5/2),
7 3 PT screw
8 1 Base
9 1 Special X-ring, grey
10 1 Air fitting
11 1 Blow-off valve
12 1 Thread plug, PG7 ø3-ø6.5 mm
13 1 Cable gland, PG11 ø4-ø10 mm
14 1 Gore vent High airflow
15 1 Adapter complete (Pos. 17,18,19
included)
16 1 Special X-ring, black
17 1 O-ring
18 2 Allen screw
19 1 Special X-ring
20 1 Indication

Service kits
a Sensor board AS-Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9613-4754-01
a Solenoid valve 3/2, 24 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-4635
a Solenoid valve 5/2, 24 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3327
a Indication pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-5623-01
a Special indication pin, SRC-LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-6370-01
a Special indication pin, Unique SSV-LS: only stop valves size
63.5 - 101.6 mm/DN65-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9613-1581-01
a Special indication pin, Unique SSV High Pressure Valve size
76.1 - 101.6 mm/DN80-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9613-1581-01
a Air fitting, Ø6 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3405
a Air fitting, 1/4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-3433
a Gore vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-99-4722
a X-ring, pos. 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9613-4564-01
a X-ring, pos. 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-9994-01
a X-ring, pos. 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9612-5696-01

TD 900-565

25
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 direct.

© 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.