Alfa Laval ThinkTop Basic Digital 10, Instruction Manual

Page 1: ...ESE00225EN1 2006 11 ThinkTop Basic Digital 10 30 VDC PNP NPN Instruction Manual ...

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Page 3: ...nts Low Voltage Directive 73 23 EEC EMC Directive 89 336 EEC ROHS Directive 2002 95 EC hereby declare that Denomination Type Year Address Phone No Name Title Company Signature Manager Product Centres Compact Heat Exchangers Fluid Handling Alfa Laval Kolding Albuen 31 DK 6000 Kolding Denmark 45 79 32 22 00 Top Unit for Valve Control Indication 3 ThinkTop Basic 2006 ...

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Page 5: ... ThinkTop Basic PLC 10 30 VDC interface 8 4 Installation 11 4 1 Installation on air actuators 11 4 2 Installation on Series 700 valves 14 4 3 Air connections 15 4 4 Electrical connection 16 5 Setup diagram 17 5 1 ThinkTop Basic setup utilising IR keypad 17 6 Maintenance 18 6 1 Dismantling of ThinkTop Basic 18 6 2 Assembly of ThinkTop Basic 20 6 3 Dismantling and assembly of Series 700 Valves 22 7 ...

Page 6: ...fy or clarify practices Installation Always observe the technical specifications see chapter 3 Never install the ThinkTop Basic before valve or relay is in a safe position If welding close to the ThinkTop Basic Always earth close to the welding area Disconnect the ThinkTop Basic Always have the ThinkTop Basic electrically connected by authorized personnel Maintenance Always read the technical speci...

Page 7: ... 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 activated setup and local fault indication et...

Page 8: ...ed for external sensors if necessary Output signals from the sensor unit to the connected digital interface PLC Nominal voltage Same as connected to the ThinkTop Basic Load current 50 mA typical 100 mA max Voltage drop Typical 3 V 50 mA Power supply DC The ThinkTop Basic is designed to be part of the PLC s Input Output I O system It should be supplied from the same protected power supply as the ot...

Page 9: ...terminals 9 and 10 Jumper present PNP standard If changing to NPN remove the jumper and make a power recycle A power recycle is always required when changing this function Typical power consumption ThinkTop Basic Test conditions One ThinkTop Basic connected and 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 Supp...

Page 10: ...17 VAC rms 1 min EN 61131 2 EMC Directive 89 336 EEC EN 61000 6 3 EN 61000 6 2 UL CSA 10 30 VDC AC Class 2 input 45 mA max output UL 508 E203255 Solenoid Valves 0 to 3 solenoid valves in each unit possible Type 3 2 or 5 2 port only possible with one 5 2 port Air supply 300 900 kPa 3 9 bar Filtered air max particles or dirt 0 01 mm Max flow 180 l min Max oil content 1 0 ppm Max water content 0 0075 ...

Page 11: ...ttings on actuator if not mounted 2 Fit the activator stem magnet and tighten carefully with a spanner Step 3 1 Place the ThinkTop Basic on top of the actuator 2 Make sure X ring is mounted Step 4 1 Ensure that the unit is correctly mounted by pressing down on top of the ThinkTop Basic 2 Tighten the two Allen screws carefully 3 Turn the actuator to have LEDs in a front view NOTE After a relevant p...

Page 12: ... later in this chapter Step 6 Fit the air tubes to the actuator see drawing Air connections later in this chapter Step 7 Untighten the four screws and pull off cover of ThinkTop Basic Step 8 1 Install cable if not present through the cable gland 2 Connect the ThinkTop Basic electrically see section 4 4 Electrical connection internal ...

Page 13: ...ke sure the cable gland is completely tightened Step 10 Set up the ThinkTop Basic see chapter 5 NOTE The unit can be set up with the cover installed by using the IR keypad To energize the valve use a separate air tube or be in radio contact with the control room ...

Page 14: ... counter nut and indicator magnet on actuator rod Engage approx thread Tighten counter nut and indicator with two wrenches Step 3 1 Place the two O rings in the grooves in the bottom of the adapter Then place the adapter on the actuator top The small O ring must be positioned over the air hole on the actuator 2 Fasten the adapter with the four 5 16 Allen screws Step 4 Mount the base on the adapter...

Page 15: ...15 4 Installation 4 3 Air connections Air out 1A Air exhaust Air out 1B 5 2 port solenoid valve only Air in Air out 3 Air out 2 Manual hold override Solenoid valve 1 2 3 ...

Page 16: ...se De energized PLC input Energized PLC input Activation of solenoid 1 PLC output Activation of solenoid 2 PLC output Activation of solenoid 3 PLC output Supply voltage sensor 10 30 VDC Supply voltage sensor 0 0 V Common supply solenoids PNP NPN jumper PNP NPN jumper Solenoid common internal connection Solenoid 1 internal connection Solenoid 2 internal connection Solenoid 3 internal connection Ele...

Page 17: ...y yellow flashing if energized position disabled yellow steady if energized position enabled Set De energized Position II Store Position I Bypass II Disable function Hold for 5 sec Actuator in De energized Position Step 2 Set Energized Position II Store Position I Bypass II Disable function Hold for 5 sec Step 3 Actuator in Energized Position Accept Settings I Restart set up sequence II Save Exit I...

Page 18: ...te Turn banjo connection Step 3 1 Untighten screws 2 Remove solenoid valves up to three and replace them with new ones Step 4 1 To dismantle the adapter the lower part of the ThinkTop Basic 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 X ring 16 Study the instructions carefully Handle scrap correctly Alw...

Page 19: ...tenance 6 1 Dismantling of ThinkTop Basic Step 5 To remove the sensor unit untighten screw and pull out the sensor unit Study the instructions carefully Handle scrap correctly Always keep spare X rings in stock ...

Page 20: ...he groove The X ring is not square The highest h part must be placed as fig Note Turn banjo connection Step 3 1 Replace solenoid valves up to three with new ones 2 Tighten screws 0 2 Nm Step 4 1 Replace X ring 9 2 Replace cover of ThinkTop Basic and tighten the three screws 0 6 Nm CAUTION Do NOT twist the X ring in the groove The X ring is not square The highest h part must be placed as fig Study th...