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Summary of Contents for Alfa Laval ThinkTop Basic Intrinsically Safe
- Page 1 Alfa Laval ThinkTop® Basic Intrinsically Safe Sensing and control 2055-0004 Instruction Manual Lit. Code 200007585-2-EN-GB BRITISH ENGLISH...
- Page 2 © Alfa Laval AB 2024-04 This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval AB (publ) or any of its affiliates (jointly “Alfa Laval”). No part of this document may be copied, re-produced or transmitted in any form or by any means, or for any purpose, without Alfa Laval’s prior express written permission. Information and services provided in this document are made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose.
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Page 3: Table Of Contents
Warning Signs in Text....................9 Requirements of Personnel..................10 Recycling Information....................11 3 Introduction .........................13 4 General information ....................15 ThinkTop Basic Intrinsically Safe at a glance............15 5 Installation ........................17 Installation on air actuators..................17 Air connections......................20 Electrical connection, internal..................21 6 Maintenance ...................... - Page 4 This page is intentionally left blank.
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Page 5: Declaration Of Conformity
1 Declaration of Conformity 1.1 EU Declaration of Conformity The designated company Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00 Company name, address and phone number Hereby declare that Top Unit for Valve Control and Indication Designation ®... -
Page 6: Declaration Of Conformity
1 Declaration of Conformity 1.2 UK Declaration of Conformity The designated company Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00 Company name, address and phone number Hereby declare that Top Unit for Valve Control and Indication Designation ®... -
Page 7: Safety
Instruction Manual without prior notice or any obligation. The English version of the Instruction Manual is the original manual. Alfa Laval cannot be held responsible for incorrect translations. In case of doubt, the English version applies. -
Page 8: Safety Signs
2.2 Safety Precautions All warnings in the manual are summarised on this page. Pay special attention to the instructions below so that severe personal injury and/or damage to the supplied Alfa Laval product is avoided. Installation Always read the technical data thoroughly... -
Page 9: Warning Signs In Text
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate damage to the supplied Alfa Laval product. NOTE Indicates important information to simplify or clarify procedures. 200007585-2-EN-GB... -
Page 10: Requirements Of Personnel
Trainees can perform tasks under the supervision of an experienced employee. People in general The public shall not have access to the supplied Alfa Laval product. In some cases, specially skilled personnel may need to be hired (i.e. electricians, welders). In some cases the personnel has to be certified according to local regulations with experience of similar types of work. -
Page 11: Recycling Information
Metal straps should be sent for material recycling Maintenance During maintenance, oil (if used) and wear parts in the supplied Alfa Laval product should be replaced. • Oil and all non-metal wear parts must be disposed of in accordance with local regulations •... - Page 12 This page is intentionally left blank.
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Page 13: Introduction
3 Introduction ® The Alfa Laval ThinkTop Basic Intrinsically Safe is a modular, explosion- safe automated valve control unit that offers cost-effective operation and standard functionality for automated sensing and control of hygienic valves. It provides real-time information about valve operating status 24/7 while boosting productivity. - Page 14 This page is intentionally left blank.
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Page 15: General Information
4 General information 4.1 ThinkTop Basic Intrinsically Safe at a glance The ThinkTop Basic Intrinsically Safe is designed to ensure optimum valve control in conjunction with Alfa Laval valves. The ThinkTop Basic Intrinsically Safe can be equipped with 0-2 solenoid valves. The solenoids are electrically controlled by the Digital PLC and, when activated, the compressed air is activating the air actuator. - Page 16 This page is intentionally left blank.
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Page 17: Installation
5 Installation 5.1 Installation on air actuators Always read the technical data carefully. Always ensure the ThinkTop is electrically connected by authorised personnel. Never install the ThinkTop in the presence of a potentially explosive atmosphere. a) Fit the air fittings on actuator if not mounted. - Page 18 The Allen screws are part of the ground 2050-0017 connection. Ensure that they are properly fastened. Install the air tubes with reference to the Air connections diagram on page 10. 2050-0018 Untighten the four screws and pull off the cover of ThinkTop Basic Intrinsically Safe. 2050-0043 200007585-2-EN-GB...
- Page 19 Installation 5 Always ensure that power is disconnected before starting the electrical installation. a) Install cable (if not present) through the cable gland. b) Connect the electrics of the ThinkTop Basic Intrinsically Safe (see Electrical connection, internal on page 21). 2050-0044 Make sure the cable gland is fully tightened to 3Nm.
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Page 20: Air Connections
5 Installation 5.2 Air connections A. Air out 1A B. Air exhaust C. Solenoid 3/2 D. Solenoid 3/2 E. Air in F. Air out 3 G. Manual hold override 2050-0026 200007585-2-EN-GB... -
Page 21: Electrical Connection, Internal
5.3 Electrical connection, internal Electrical connection Safe area Hazardous area The ThinkTop Basic Intrinsically Safe must always be installed in an intrinsically safe circuit. Sensor The two inductive NAMUR sensors must be con- nected to a certified intrinsically safe circuit (e.g. - Page 22 This page is intentionally left blank.
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Page 23: Maintenance
6 Maintenance 6.1 Dismantling of ThinkTop Basic Intrinsically Safe a) Untighten the two Allen screws and remove the ThinkTop from the actuator. b) Remove X-ring and replace it. 2050-0030 Never dismantle the ThinkTop in the presence of a potentially explosive atmosphere. - Page 24 6 Maintenance a) Untighten screws. b) Remove solenoid valves (up to two) and replace them with new ones. 2050-0047 Always ensure that power is disconnected before untightening electrical connections. a) To dismantle the adapter (the lower part of the ThinkTop bracket from base (the middle part), unscrew the three screws.
- Page 25 Maintenance 6 To remove the sensor frame, unscrew the three screws and pull out the frame. 2050-0038 200007585-2-EN-GB...
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Page 26: Assembly Of Thinktop Basic Intrinsically Safe
6 Maintenance 6.2 Assembly of ThinkTop Basic Intrinsically Safe Place sensor frame in base on top of the four washers, two under each side, and tighten screws (torque: 1 Nm). 2050-0039 a) Replace the black X-ring. b) Assemble base with adapter by turning adapter slightly anticlockwise and tighten the four screws (2 Nm). - Page 27 Tighten screws (0.2 Nm). 2050-0041 a) Replace the grey X-ring. b) Replace cover of ThinkTop Basic Intrinsically Safe and tighten the four screws (0.6 Nm). 2050-0042 a) Replace the black X-ring. b) Mount ThinkTop Basic Intrinsically Safe on actuator. 2050-0016 200007585-2-EN-GB...
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Page 28: Diagrams For Thinktop Basic Intrinsically Safe
6 Maintenance 6.3 Diagrams for ThinkTop Basic Intrinsically Safe 225 mm (9”) TD 804-034 2053-0000 ø137 mm (5½”) TD 804-035 200007585-2-EN-GB... -
Page 29: Technical Specifications
7 Technical specifications Solenoid valves Number of solenoid valves 0, 1 or 2 Type 3/2 port Air supply 0.15 - 0.7 MPa (1.5-7 bar) Filtered air, max. particles or dirt 5 µ 5-5 mg/m3 Max. flow 180 l/min Max. oil content 1mg/m3 Max. - Page 30 7 Technical specifications Micro environment demand specifications Temperature Working: - 10°C to +45°C EN 50020 Storage: - 40°C to +85°C IEC 68-2-1/2 Temperature change: - 25°C to +70°C EC 68-2-14 10-55 Hz, 0.7 mm 55-500 Hz, 10g Vibration IEC 68-2-6 3 x 30 min, 1 octave/min Drop test Humidity...
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Page 31: Spare Parts
Alfa Laval representative for availability. You can find our spare part catalogue at https://hygienicfluidhandling-catalogue.alfalaval.com. Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on use of Alfa Laval genuine spare parts. 8.1 Ordering Spare Parts When ordering spare parts, please always state: 1.
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