Instruction Manual: Thinktop Basic As-Interface V.3.0 (62 Nodes) 29.5 - 31.6 VDC
Instruction Manual: Thinktop Basic As-Interface V.3.0 (62 Nodes) 29.5 - 31.6 VDC
TD 800-242_1
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
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
5. Installation .............................................................................................. 12
5.1. Installation on air actuators ...................................................................... 12
5.2. Air connections ................................................................................... 15
5.3. Electrical connection, internal ................................................................... 16
7. Maintenance ........................................................................................... 18
7.1. Dismantling of ThinkTop .......................................................................... 18
7.2. Assembly of ThinkTop ............................................................................ 20
3
1 EC Declaration of Conformity
+45 79 32 22 00
Phone No.
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.
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.
General warning:
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.
Installation
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.
Always have the ThinkTop Basic AS-Interface electrically connected by authorized personnel.
Maintenance
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
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.
7
4 Technical specifications
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
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).
No. of slaves:
AS-Interface specification 3.0 for max. 62 ThinkTop Basic AS-Interface units on a single master/gateway
DO 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not connected
DO 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 1
DO 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 2
DO 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 3
9
4 Technical specifications
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
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
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
Step 1
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
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
16
6 Setup diagram
Return to step 1
Quick set-up:
Push: “I”, enter setup and wait until red LED flashes.
Push: “I”, restart set-up.
17
7 Maintenance
Study the instructions carefully.
Handle scrap correctly.
Always keep spare X-rings in stock.
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.
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
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
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
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.