Alfalaval ThinkTop D30 User manual

2064-0000_1

Patented Sensor System

Registered Design

Registered Trademark

ESE02248-EN4 2017-03

Original manual

Instruction Manual

ThinkTop®D30

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. Concept ........................................................................................... 6

3.2. Working principle ................................................................................. 6

3.3. Recycling information ............................................................................. 6

4. Installation .............................................................................................. 7

4.1. Product dimensions .............................................................................. 7

4.2. Compatible actuators ............................................................................ 7

4.3. Installation instructions ........................................................................... 8

4.4. Operating LED feedback ......................................................................... 10

5. Troubleshooting ....................................................................................... 11

6. Technical data ......................................................................................... 12

7. Parts list ................................................................................................ 14

7.1. Parts list ............................................................................................ 14

1 EC Declaration of Conformity

Revision of Declaration of Conformity 2013-12-03

The Designated Company

Alfa Laval KoldingA/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® D30

Type

is in conformity with the following directive with amendments:

- Low Voltage Directive (LVD) 2014/35/EU

- EMC Directive 2014/30/EU

- RoHS2 Directive 2011/65/EU

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

Global Product Quality Manager

Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen

Title Name

Kolding 2017-03-01

Place Date Signature

2 Safety

Unsafe practices and other important information are emphasised in this manual.

Warnings are emphasised by means of special signs. All warnings in the manual are summarised on this page.

Pay special attention to the instructions below so that serious personal injury or damage to the top unit are avoided.

2.1 Important information

Always read the manual before using the ThinkTop!

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 D30.

NOTE

Indicates important information to simplify or clarify procedures.

2.2 Warning signs

General warning:

Dangerous electrical voltage:

Caustic agents:

2.3 Safety precautions

Installation:

Always read the technical data thoroughly !

Never install the ThinkTop D30 before the valve or relay is in a safe position

If welding close to the ThinkTop D30: Always earth close to the welding area

Disconnect the ThinkTop D30

Always have the ThinkTop D30 electrically connected by authorised personnel

Maintenance:

Always read the technical data thoroughly !

Always fit the seals between the valve and ThinkTop D30 correctly

Never install the ThinkTop D30 before valve or relay is in a safe position

Never service the ThinkTop D30 with the valve/actuator under pressure

Never clean the ThinkTop D30 with high pressure cleaning equipment

Never touch the moving parts if the actuator is supplied with compressed air

Never use cleaning agents that will attack the exterior of the ThinkTop D30. Check with your cleaning agent supplier

Never clean using Alcohol, Acetone, Chloroform, Methanol, Ammonium chloride and Ammonium Hydroxide etc.

3 General information

3.1 Concept

The ThinkTop D30 is designed to ensure valve control in a basic market, using Alfa Laval air operated actuators such as

butterfly, single and double-seat valves. it is compatible with all major PLC systems (Programmable Logic Controller) with a

digital PNP interface.

It is for use in food, dairy and brewery installations. ThinkTop D30 is a complementary, alternative solution to the existing

range of control units.

ThinkTop D30 is the first of its kind on the market that focuses on new methods to simplify all aspects of using a basic control

unit to minimise and optimise installations instead of using external solenoid valves

3.2 Working principle

The ThinkTop D30 is an easy-to-use plug ‘n play control unit with integrated intelligence which monitors the status of the operating

air pressure, identifying air leakage or failing air pressure. The integrated solenoid valve allows control of the processing valve.

Mounted on top of the valve, the unit receives signals from a PLC system to control the solenoid valve and it returns the

supervised air pressure signals for valve energised or de-energised feedback to the PLC system. The ThinkTop D30 has a 360

degree visual valve status indicator, which can be seen at a distance and at any angle.

3.3 Recycling information

• Unpacking

- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps

- Wood and cardboard boxes can be reused, recycled or used for energy recovery

- Plastics should be recycled or burnt at a licensed waste incineration plant

- Metal straps should be sent for material recycling

•Scrapping

- At the end of use, the equipment should be recycled according to relevant, local regulations. In addition to the actual

equipment, any hazardous residues from the process liquid must be considered and disposed of in a proper manner. When

in doubt, or in the absence of local regulations, please contact your local Alfa Laval representative.

4 Installation

4.1 Product dimensions

75 mm

Ø 105 mm

2064-0001_1

4.2 Compatible actuators

SBV Yes

Koltek Yes

LKLA-T Yes

LKLA No

ARC Yes

SRC Yes

SRC long stroke No

i-SSV Yes

Unique SSV Yes

Unique SSV long stroke No

SSV DN80 (76.1 mm) High pressure No

SSV DN100 (101.6 mm) High pressure No

SMP valves Yes

Unique Mixproof No

Air/air actuators No

4 Installation

4.3 Installation instructions

Step 1

Place the ThinkTop D30 on top of the actuator.

Ensure that the unit is correctly mounted by pressing down on

top of the ThinkTop D30.

Cross-tighten the two allen screws carefully (1.50 Nm).

When mounting the ThinkTop D30 on a horizontal mounted

actuator make sure that the exhaust port is not pointing upwards.

The exhaust port is marked with "EX.".

2064-0002

Step 2

Connect the air supply to the air-in port (A).

Connect the air-out port (B) to the actuator.

NOTE!

Option in case of a ¼” air supply hose system.

Connect the air supply hose via an ø6 / ¼” angle adaptor.

The angle adaptor is sold separately:

Article number: 9611-99-5679, ø6 / ¼” angle adaptor.

The angle adaptor is also available as ø6 / ø6:

Article number: 9611-99-5678, ø6 / ø6 angle adaptor.

2064-0003

Step 3

Remove the top cover by turning the top cover anti-clockwise.

When the mark on the top cover (C) is aligned with the open

padlock symbol (D), the top cover can be lifted off.

2064-0004

4 Installation

Step 4

Install the cable in the cable gland.

NOTE

Cable connection

Cable gland: PG7 (cable dia. ø4.0 - ø6.8 mm)

Recommended conductor

cross section: 0.5 mm2(AWG 20).

If the cable gland comes loose from the control head during

installation, it must be secured with a tightening torque of 1.50 Nm.

To fulfil the UL requirements in UL61010, the unit must be supplied

by an isolating source that complies with the requirements for class

2 power units (UL1310) or class 2 and 3 transformers (UL1585).

2064-0005_1

Electrical connection Digital Interface

Sensor board

Terminal strip

GND -

Connection of power supply 24 VDC +

PLC output signal Trigger solenoid T

Alarm A

De-energised D

PLC input signals Energised E

Step 5

Put the top cover back on by pushing it down when the mark on

the top cover (E) and the open padlock (F) are aligned.

Then turn it clockwise towards the closed padlock (G) to secure

the top cover.

2064-0007

4 Installation

4.4 Operating LED feedback

Actuator status LED feedback

De-energised Green

Energised Yellow

Alarm (Air pressure) Red flashing

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