Alfalaval ThinkTop Digital 8-30 VDC PNP/NPN Manual de usuario

Instruction Manual

ThinkTop®Digital 8 - 30 VDC PNP/NPN

TD 800-242_1

Patented Sensor System

Registered Design

Registered Trademark

ESE00353-EN11 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. Digital in general .................................................................................. 7

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

4.1. ThinkTop, PLC 8-30 VDC interface ............................................................. 8

5. Installation .............................................................................................. 12

5.1. Installation on air actuators ...................................................................... 12

5.2. Installation on Series 700 valves ................................................................ 15

5.3. Air connections ................................................................................... 16

5.4. Electrical connection, internal ................................................................... 17

5.5. Example of connecting power supplies ........................................................ 18

6. Setup diagram ......................................................................................... 19

6.1. ThinkTop setup utilising IR keypad .............................................................. 19

6.2. ThinkTop setup utilising local ’I’ and ’II’ keys ................................................... 21

6.3. ThinkTop quick setup guide ..................................................................... 23

7. Fault finding ............................................................................................ 26

7.1. Fault finding and LEDs ........................................................................... 26

8. Maintenance ........................................................................................... 28

8.1. Dismantling of ThinkTop .......................................................................... 28

8.2. Assembly of ThinkTop ............................................................................ 30

8.3. Dismantling and assembly of Series 700 valves ............................................... 32

9. Parts list and Service Kits ........................................................................... 33

9.1. Drawings for ThinkTop Digital VDC .............................................................. 33

9.2. ThinkTop Digital VDC ............................................................................. 34

9.3. Drawings for ThinkTop VDC for Series 700 .................................................... 37

9.4. ThinkTop VDC for Series 700 .................................................................... 38

1 EC Declaration of Conformity

The designating company

Alfa Laval

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+4579322200

Phone No.

hereby declare that

Top Unit for Valve Control & Indication ThinkTop Digital VDC

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/EC

Manager, Product Centres, Compact

Heat Exchangers & Fluid Handling

Bjarne Søndergaard

Title 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 severe 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:

2Safety

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 Digital in general

The ThinkTop is designed to ensure optimum valve control in conjunction with Alfa Laval valves and it is compatible with most

PLC systems (Programmable Logic Controllers maker with PNP/NPN interface).

The ThinkTop can be equipped with 0-3 solenoid valves. The solenoids are electrically controlled by the Digital PLC and

when activated the compressed air is activating the air actuator. All solenoids have built-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, PLC 8-30 VDC interface

“No Touch” sensor system

345

11 10

17 22

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. Terminals

12. Feedback signals

13. Solenoid signals

14. Supply voltage

15. Solenoid common

16. PLC Cable

17. Internal connections

18. Solenoid signals

19. Solenoid common

20. External seat-lift (PNP)

21. Supply sensors

22. External connections

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 4 feedback signals + 1 status signal = 5 digital PNP/NPN feedback signals. Selection of PNP

or NPN is done by a jumper. Two of the feedback signals can be 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.

Type 0: ...............................Bypass valve type / keep present valve type.

Type 1: ...............................SRC/ARCandSeries 700 valves, only when self adjustment is enabled - Not recommended.

Type 2: ...............................LKB (LKLA-T).

Type 3: ...............................Unique Mixproof, SMP-SC Spillage-Free, and SRC-PV.

Type 4: ...............................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)).

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 (ø4 - ø10 mm).

Direct external/sensor cable gland entry PG7 (ø3 - ø6.5 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, must meet the requirements of EN 61131-2

The ThinkTop is designed to be a part of the PLC’s Input/Output (I/O) system. It should be supplied from the same protected

power supply as the other I/O devices. The I/O power supply should not be used for other kinds of loads.

The unit is reverse polarity and short circuit protected.

Supply voltage: ......................8 - 30 VDC.

Supply voltage nominal: .............24 VDC (+20%, -15%) - pr. EN 61131-2.

Max ripple: ...........................5% of nominal supply voltage.

Supply voltage absolute max.: ......30 VDC.

Supply voltage absolute min.: ......8 VDC.

Supply current*): ....................Max. 45 mA (for sensor unit alone)

(excluding current to the solenoids, external sensor and the PLC input current).

*) The initial current during power-on is higher. The actual shape of the current pulse depends on the power supply used. Typical

values are 150 mA RMS during 13 ms (regulated PS) to 360 mA RMS during 8 ms (unregulated PS).

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

Output signals from the sensor unit to the connected PLC.

Nominal voltage: ....................Must match the selected type of ThinkTop.

Load current: ........................Typically 50 mA, max. 100 mA .

Voltage drop: ........................Typically 3 V at 50 mA.

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. ......................Must match the selected type of ThinkTop.

Supply current: ......................Max. 15 mA per sensor.

Type of sensor: ......................DC, Only 3-wire sensor PNP.

Sensor cable length: ................Max. 3 m.

Polarity

PNP (sourcing) or NPN (sinking) function is selected with a jumper in term. 12 and 13. Jumper present = PNP. If changing to

NPN remove the jumper and make a power recycle. A power recycle is always required when changing this function.

ThinkTop Visual Indications LED Indications

LED B “Open valve” (Yellow)

OIR-Receiver

LED D “Setup/Internal fault” (Red)

LED C “Seat-lift 1/2” (Yellow)

LED E “Solenoid valves” (Green)

LED F “Maintenance” (Orange)

LED B

LED D

LED C

LED E

LED F

LED A LED A “Closed valve” (Yellow)

Feedback signals

Signal: “Closed Valve” Terminal 1 (Feedback #1)

Signal: “Open Valve” Terminal 2 (Feedback #2)

Signal: “Seat-lift 1” Terminal 3 (Feedback #3)

Signal: “Seat-lift 2” Terminal 4 (Feedback #4)

Signal: “Status” Terminal 5 (Feedback #5)

For wire connections: See 5.4 Electrical connection, internal

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)

The status signal is used for four purposes:

- To indicate that setup is in progress + (LED D).

-Toindicat

e an error condition + (LED D). (Flashing LED = software error), (steady LED = hardware error).

- To indicate maintenance due to the self adjustment programme + (LED F).

- To indicate that the time for maintenance has been reached + (LED F).

Technical specifications solenoid valves

Solenoid valve signals

Three output signals (with one common, terminal 11) from the terminal row are used for activation of the solenoids. Depending

on the PLC used, the common could be either positive (connected with terminal 9) or negative for DC voltage. The signals are

galvanically isolated from the sensor circuits.

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.

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