Alfalaval ThinkTop Basic User manual

TD 804-001

Registered Design

Registered Trademark

ESE00810-EN3 2014-12

Original manual

Instruction Manual

ThinkTop®Basic Intrinsically Safe

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 ................................................................................ 5

3. General information ................................................................................... 6

3.1. ThinkTop Basic Intrinsically Safe in general .................................................... 6

4. Technical specifications .............................................................................. 7

5. Installation .............................................................................................. 8

5.1. Installation on air actuators ...................................................................... 8

5.2. Air connections ................................................................................... 10

5.3. Electrical connection, internal ................................................................... 11

6. Maintenance ........................................................................................... 12

6.1. Dismantling of ThinkTop Basic Intrinsically Safe ............................................... 12

6.2. Assembly of ThinkTop Basic Intrinsically Safe ................................................. 13

7. Parts list and service kits ............................................................................ 15

7.1. Drawings for ThinkTop Basic Intrinsically Safe ................................................. 15

7.2. ThinkTop Basic Intrinsically Safe ................................................................ 16

1 EC Declaration of Conformity

The Designated Company

Alfa Laval Kolding A/S

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+4579322200

Phone No.

hereby declare that

Top Unit for Valve Control and Indication

Designation

ThinkTop® Basic Intrinsically Safe

Type

is in conformity with the following directive with amendments:

- Low Voltage Directive (LVD) 2006/95/EC

- EMC Directive 2004/108/EC

- RoHS2 Directive 2011/65/EU

- Directive 94/9/EC for Equipment intended for use in Potentially Explosive Atmospheres (ATEX).

- Think Top Basic Intrinsically Safe is suitable for use in hazardous area zone 1 and zone 21 Marking: Ex II 2D/G EEx ia IIC T6

The following harmonised Standards and Regulations have been applied:

- EN 1127-1:1997 Explosive Atmospheres – Basic concept & methodology

- EN 12100-1/2: Basic terminology and methodology - Technical principles

- EN 13463-1: Non-electrical equipment - Basic method and requirements

- EN 13463-5: Non-electrical equipment - Protection by constructional safety

- EN 14121-1: Safety of machinery - Risk assessment, principles

The assembly must be installed strictly in accordance with the installation instruction supplied by the manufacturer.

Think Top Basic Intrinsically Safe is suitable for use in hazardous area zone 1 and zone 21

Marking: Ex II 2D/G EEx ia IIC T6

The Notified Body NB.0044 will retain this Declaration of Conformity TÛV-Nord technical file no.: TÜV 08 ATEX 8000365231

The person authorised to compile the technical file is the signer of this document

QHSE Manager, Quality, Health and safety & Environment Annie Dahl

Title Name

Kolding 2009-04-01

Place Date Signature

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 serious 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:

Caustic agents:

2.3 Safety precautions

Installation:

Always read the technical data thoroughly

Never install the ThinkTop Basic Intrinsically Safe before valve or relay is in a safe position

If welding close to the ThinkTop Basic Intrinsically Safe: Always earth close to the welding area

Disconnect the ThinkTop Basic Intrinsically Safe

Always have the ThinkTop Basic Intrinsically Safe electrically connected by authorized personnel

The ThinkTop Basic Intrinsically Safe must be installed in an inherently safe circuit, according to the corresponding regulations.

Maintenance:

Always read the technical data thoroughly)

Always fit the seals between valve and ThinkTop Basic Intrinsically Safe correctly

Never install the ThinkTop Basic Intrinsically Safe before valve or relay is in a safe position

Never service the ThinkTop Basic Intrinsically Safe with valve/actuator under pressure

Never clean the ThinkTop Basic Intrinsically Safe with high pressure cleaning equipment

Never use cleaning agents when cleaning the ThinkTop Basic Intrinsically Safe. Check with cleaning agent supplier.

3 General information

3.1 ThinkTop Basic Intrinsically Safe in general

The ThinkTop Basic Intrinsically Safe is designed to ensure optimum valve control in conjunction with Alfa Laval valves and it is

compatible with most PLC systems.

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. The solenoids are also equipped with a

manual hold override.

The ThinkTop Basic Intrinsically Safe does not support Unique SSV Long Stroke and SRC-LS valves.

Important!

It will be the responsibility of the end user to perform the explosion risk assessment and to classify the group and the

corresponding zone (dust or gas) in accordance with the Directive 1999/92/EC.

The following table list show the ATEX evaluated Alfa Laval sanitary valves as ThinkTop Basic Intrinsically Safe can be installed on

and in accordance with Atex Directive 94/9/EC.

Valve / actuator type ATEX evaluation notes

Unique SSV ATEX II 2 G D c T4

Unique Mixproof

Non electric equipment with no own ignition source which can be used within the

equipment-group II 2 G/D or II 3 G/D if removing the blue plastic cover on bottom of the

Mixproof valve

SRC

SMP-SC

SMP-TO

SMP-BC

LKLA-T

Koltek MH

SBV

Non electric equipment with no own ignition source which can be used within the

equipment-group II 2 G/D or II 3 G/D

Note! Contact customer support to get the "ATEX Product Statement 2009" with listed valves inside/outside the scope of ATEX Directive 94/9/EC

4 Technical specifications

Solenoid valves

0 to 2 solenoid valves in each unit possible.

Type 3/2 port.

Air supply 0.15 - 0.7 MPa (1.5-7 bar).

Filtered air, max. particles or dirt 5mm5-5mg/m

Max. flow 180 l/min.

Max. oil content 1mg/m

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".

Silencer/filter Connection possible via ø6 mm or 1/4".

(Filter recommended in tropical regions).

Nominal voltage 12 VDC.

Nominal power 0.52 W.

Allowable voltage fluctuation ±10% of rated voltage

Certificate of conformity KEMA 08 ATEX 0093 X

Inductive sensor

Switching element function NAMUR NC

Nominal voltage: Uo 8 V

Measuring plate not detected 3 mA

Measuring plate detected 1 mA

Indication of the switching state: LED, yellow

EMC in accordance with IEC / EN 60947-5-2:2004; NE 21

Standards DIN EN 60947-5-6 (NAMUR)

Certificate of conformity PTB 00 ATEX 2032 X

Materials

Plastic parts Nylon PA6, reinforced, stainless steel fibres.

Steel parts Stainless steel AISI 304 and 316.

Air fitting Special coated brass (FDA approved).

Seals Nitrile (NBR).

Gore vent. membrane PBT plastic.

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 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: +15°C/+45°C EN 60068-2-30

12 cycles

(working) 93% R.H.

Protection class IP66 and IP67 EN 60529

Surface resistance <1G• EN 60079-0

Type of Ex protection Ex II 2G/D EEx ia IIC T6 ATEX directive 94/9/EC

5 Installation

5.1 Installation on air actuators

Step 1

Always read the technical data thoroughly.

Always have the ThinkTop Basic Intrinsically Safe electrically connected by authorised personnel.

Step 2

1. Fit the air fittings on actuator if not mounted.

2. Fit the activator stem and tighten carefully with a spanner (A).

Note:

The threaded plate (B) is only used for the SRC and SMP valve

types.

(A)

(B)

TD 800-011_2

Step 3

1. Place the ThinkTop Basic Intrinsically Safe on top of the

actuator.

2. Make sure X-ring is mounted.

TD 804-026

Step 4

1. Ensure that the unit is correctly mounted by pressing down on

top of the ThinkTop Basic Intrinsically Safe.

2. Tighten the two Allen screws carefully (1.50 Nm).

TD 804-004

5 Installation

Step 5

Fit the ø6 mm (1/4”) air tubes to ThinkTop Basic Intrinsically Safe.

(see drawing “Air connections” page 10).

TD 804-005

Step 6

Fit the air tubes to the actuator

(see drawing “Air connections” page 10).

TD 804-006

Step 7

Untighten the four screws and pull off cover of

ThinkTop Basic Intrinsically Safe.

TD 804-027

Step 8

1. Install cable (if not present) through the cable gland.

2. Connect the ThinkTop Basic Intrinsically Safe electrically

(see page11 “Electrical connection, internal”).

TD 804-028

5 Installation

Step 9

Make sure the cable gland is completely tightened.

TD 804-009

Step 10

Positioning of the inductive proximity switches.

1. The two screws (26) holding the sensor frame shall be slightly

tightened, enabling the frame to be moved back and forth.

2. Align the marking on the left proximity switch with the indication

pin (20) by turning the left set screw.

3. Energize the valve.

4. Align the right proximity switch with the indication pin (20) by

turning the right set screw.

5. The proximity switches must be close to the indication pin, but

not touch. Shear the frame for correction.

6. Tighten the two screws holding the sensor frame (1 Nm).

NOTE!

To energize the valve, use a separate air tube or be in radio

contact with the control room.

7. Mount the cover of ThinkTop Basic Intrinsically Safe and tighten

(0.6 Nm) the four screws.

TD 804-030

5.2 Air connections

TD 804-031

GA. Manual hold override

B. Air out 1A

C. Air exhaust

D. Solenoid 3/2

E. Solenoid 3/2

F. Air in

G. Air out 3

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