Alfa Laval ThinkTop Digital 8-30 VDC PNP/NPN Instruction Manual
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Alfa Laval ThinkTop Digital 8-30 VDC PNP/NPN Instruction Manual

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Instruction Manual
®
ThinkTop
Digital 8 - 30 VDC PNP/NPN
Patented Sensor System
Registered Design
Registered Trademark
ESE00353-EN11
Original manual
2011-01
TD 800-242_1

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Summary of Contents for Alfa Laval ThinkTop Digital 8-30 VDC PNP/NPN

  • Page 1 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...

  • Page 3: Table Of Contents

    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.

  • Page 4: Ec Declaration Of Conformity

    - Low Voltage Directive (LVD) 2006/95/EF - EMC Directive 2004/108/EF - ROHS Directive 2002/95/EC Manager, Product Centres, Compact Bjarne Søndergaard Heat Exchangers & Fluid Handling Title Name Alfa Laval Kolding Company Signature Designation...

  • Page 5: Safety

    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...

  • Page 6: Safety Precautions

    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.

  • Page 7: General Information

    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.

  • Page 8: Technical Specifications

    20. External seat-lift (PNP) 10. Terminals 21. Supply sensors 11. Terminals 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.
  • Page 9 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.
  • Page 10 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.
  • Page 11 4 Technical specifications Technical specifications Up 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). 5 μ 5-5 mg/m Filtered air, max. particles or dirt Max.

  • Page 12: Installation

    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 SRC/ARC only 1. Fit the air fittings on actuator if not mounted. 2. Fit the activator stem (magnet) and tighten carefully with a spanner.
  • Page 13 5 Installation Step 5 Fit the ø6 mm (1/4”) air tubes to ThinkTop (see drawing “Air connections” page 16). Step 6 Fit the air tubes to the actuator (see drawing “Air connections” page 16). TD 800-131 Step 7 Untighten the four screws and pull off cover of ThinkTop. TD 800-247 Step 8 1.
  • Page 14 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.

  • Page 15: Installation On Series 700 Valves

    5 Installation 5.2 Installation on Series 700 valves Step 1 Installation on air actuators: 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.

  • Page 16: Air Connections

    5 Installation 5.3 Air connections TD 800-252 A. Air restriction (throttle function) air inlet/outlet B. Air out 1A C. Air exhaust D. Air out 1B (5/2 port solenoid valve only) E. Solenoid 3/2 or 5/2 F. 3/2 Solenoid valves only G.

  • Page 17: Electrical Connection, Internal

    5 Installation 5.4 Electrical connection, internal Digital interface command signals D Jumper connections **) Internal connections to E Incoming signals from external solenoid 1-3 ***) sensors ****) C Feedback signals to digital interface F Supply to external sensors *) 1 Closed valve Solenoid 1 Solenoid 2 2 Open valve...

  • Page 18: Example Of Connecting Power Supplies

    5 Installation 5.5 Example of connecting power supplies When using one power supply for sensor system and solenoid valves: Example of connecting power supplies TD 800-207 TD 800-206 A. Jumper if positive activation of solenoids B. Jumper if negative activation of solenoids When using two power supplies, one for sensor board and one for the solenoid valves: Sensor System: If positive activation of solenoids...

  • Page 19: Setup Diagram

    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 D LED: Active during set-up: Flashing in step 1 Steady in all other steps Or during operations, error condition:...
  • Page 20 6 Setup diagram Enter Setup Step 1 – Save and Exit Next C Exit no change accepted step E Step 2 – Setup valve type Default SRC/ARC Unique SMP-SC +/- 5mm Series 700 (LKLA-T) Mixproof, SMP-BC (Only used SRC-PV SMP-TO Next C when self spillage-free...

  • Page 21: Thinktop Setup Utilising Local 'I' And 'Ii' Keys

    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 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 Flashing LED means no value set.
  • Page 22 6 Setup diagram Enter Setup Step 1 – Save and Exit Exit no change accepted Next C step E Step 2 – Setup valve type Unique Default SRC/ARC SMP-SC +/- 5mm Series 700 (LKLA-T) Mixproof, SMP-BC (Only used SRC-PV SMP-TO Next C when self spillage-free...

  • Page 23: Thinktop Quick Setup Guide

    6 Setup diagram 6.3 ThinkTop quick setup guide Valve: Unique SSV, SRC/ARC type NC (selfadjustment disabled) Push: - and wait until red LED flashes Push: - hold for 5 sec (clear all stored parameters) Push: Push: (red + yellow LED) Push: (red + yellow + green LED) Push:...
  • Page 24 6 Setup diagram Setup done...
  • Page 25 6 Setup diagram Valve: LKB Valve (Butterfly) NO - and wait until red LED flashes Push: Push: Push: - hold for 5 sec (clear all stored parameters) Push: (red + yellow LED) Push: (red + yellow + green LED) Push: Activate - to approve valve closed (indication stem up) Push:...

  • Page 26: Fault Finding

    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 steady: Unit in set-up mode or internal hardware fault.
  • Page 27 7 Fault finding Yellow steady: Position B (open valve). Yellow B 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.

  • Page 28: Maintenance

    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. Step 2 1.
  • Page 29 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...

  • Page 30: Assembly Of Thinktop

    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.
  • Page 31 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.

  • Page 32: Dismantling And Assembly Of Series 700 Valves

    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 Step 1 Installation on air actuators: 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.

  • Page 33: Parts List And Service Kits

    9 Parts list and Service Kits The drawings show ThinkTop Digital 8-30 VDC PNP/NPN. The items refer to the parts lists in the following sections 9.1 Drawings for ThinkTop Digital VDC TD 800-263 TD 800-205 ø137 mm Note! This is the basic design.

  • Page 34: Thinktop Digital Vdc

    9 Parts list and Service Kits The drawings show ThinkTop Digital 8-30 VDC PNP/NPN. The items refer to the parts lists in the following sections 9.2 ThinkTop Digital VDC TD 800-265...
  • Page 35 9 Parts list and Service Kits The drawings show ThinkTop Digital 8-30 VDC PNP/NPN. The items refer to the parts lists in the following sections Parts list Pos. Denomination (Pos.9,12,13,14 included) Shell complete Screw Washer Sensor board Solenoid valve PT screw...

  • Page 37: Drawings For Thinktop Vdc For Series 700

    9 Parts list and Service Kits The drawings show ThinkTop Digital 8-30 VDC PNP/NPN Series 700 valves. The items refer to the parts lists in the following sections 9.3 Drawings for ThinkTop VDC for Series 700 TD 800-269 TD 800-205 ø137 mm...

  • Page 38: Thinktop Vdc For Series 700

    9 Parts list and Service Kits The drawings show ThinkTop Digital 8-30 VDC PNP/NPN Series 700 valves. The items refer to the parts lists in the following sections 9.4 ThinkTop VDC for Series 700 TD 800-268...
  • Page 39 9 Parts list and Service Kits The drawings show ThinkTop Digital 8-30 VDC PNP/NPN Series 700 valves. The items refer to the parts lists in the following sections Parts list Pos. Denomination (Pos.9,12,13,14 included) Shell complete Screw Washer Sensor board...
  • Page 40 © 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.

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