Alfalaval ThinkTop DeviceNet 11 VDC User manual

Instruction Manual

ThinkTop®DeviceNet TM 11-25VDC

TD800100_3

The Top is identified by 4 fastening screws

ESE00355-EN92011-04

Original manual

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 ................................................................................ 6

3. General information ................................................................................... 7

3.1. DeviceNetTM in generel ........................................................................... 7

4. Technical specifications .............................................................................. 9

4.1. ThinkTop ® DeviceNet TM features .............................................................. 9

5. Installation .............................................................................................. 18

5.1. Installation on air actuators ...................................................................... 18

5.2. Installation on Series 700 valves ................................................................ 21

5.3. Air connections ................................................................................... 22

5.4. Electrical connection, internal ................................................................... 23

6. Setup diagram ......................................................................................... 24

6.1. ThinkTop setup utilising IR keypad .............................................................. 24

6.2. ThinkTop setup utilising local ’I’ and ’II’ keys ........................ ........................... 26

6.3. ThinkTop quick setup guide ..................................................................... 28

7. Fault finding ............................................................................................ 30

7.1. Fault finding and LEDs ........................................................................... 30

8. Maintenance ........................................................................................... 32

8.1. Dismantling of ThinkTop .......................................................................... 32

8.2. Assembly of ThinkTop ............................................................................ 34

8.3. Dismantling and assembly of Series 700 valves ............................................... 36

9. Part list and Service Kits ............................................................................. 37

9.1. Drawings for ThinkTop DeviceNet 11-25 VDC ................................................. 37

9.2. ThinkTop DeviceNet 11-25 VDC ................................................................ 38

9.3. Drawings for ThinkTop Series 700 Valves ...................................................... 40

9.4. ThinkTop Series 700 Valves ...................................................................... 41

1 EC Declaration of Conformity

The designating company

Alfa Laval

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+4579322200

Phone No.

hereby declare that

Top Unit for Valve Control & Indication ThinkTop®DeviceNetTM

Denomination Type Year

is in conformity with the following directives with amendments:

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

- EMC Directive 2004/108/EF

- ROHS Directive 2002/95/EEC

Manager, Product Centres,

Compact Heat Exchangers & Fluid Handling

Bjarne Søndergaard

Title Name

Alfa Laval Kolding

Company Signature

Designation

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:

Dangerous electrical voltage:

Caustic agents:

2Safety

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.

Never

install the ThinkTop before valve or relay is in a safe position.

If welding close to the ThinkTop: A

Always

earth close to the welding area.

Disconnect the ThinkTop.

Always

have the ThinkTop electrically connected by authorized personnel.

Maintenance

Always

read the technical data thoroughly.

Always

fit the seals between valve and ThinkTop correctly.

Never

service the ThinkTop before valve or relay is in a safe position.

Never

service the ThinkTop with valve/actuator under pressure.

Never

clean the ThinkTop with high pressure cleaning equipment.

Never

use cleaning agents when cleaning the ThinkTop. Check with cleaning agent supplier.

3 General information

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.

3.1 DeviceNetTM in generel

DeviceNetTM is a low-cost communication link to connect industrial devices (such as limit switches, photoelectrical sensors, valve

manifolds, motor starters, process sensors, bar cod readers, variable frequency drives, panel display and operator interfaces) to

a network and eliminate expensive handwiring. The direct connectivity provides improved communication between devices as

well as important device-level diagnostics not easily accessible or available through hardwires I/O interfaces. DeviceNetTM is a

simple networking solution that reduces costs as well as time to wire and install industrial automation devices, while providing

interchangeabillity of similar components from multiple vendors.

DeviceNetTM is an open network standard.

DeviceNetTM features and functionality

Network size Up to 63 nodes

Network length Selectable end-to-end network distance varies with speed

Baud Rate

125 Kbps

250 Kbps

500 Kbps

Distance

500 (1,640 ft)

250 (820 ft)

100 (328 ft)

Data Packets 0-8 bytes

Bus Topology Linear (trunk line/drop line); power and signal on the same network cable

Bus Addressing Peer-to-Peer with Multi-Cast (one-to-many); Multi-Master and Master/Slave special case; polled

or change-of-state (exception-based)

System Features Removal and replacement of devices from the network under power

The basic trunk line/drop line topology provides separate twisted pair busses for both signal and power distribution. Thick or

thin cable can be used for either trunk lines or drop lines. End-to-end network distance varies with data rate and cable size.

Data Rates 125 Kbps 250 Kbps 500 Kbps

Thick Trunk Length 500 m (1,640 ft) 250 m (820 ft) 100 m (328 ft)

Thick Trunk Length 100 m (328 ft) 100 m (328 ft) 100 m (328 ft)

Maximum Drop Length 6m(20ft) 6m(20ft) 6m(20ft)

Cumulative Drop Length 156 m (512 ft) 78 m (256 ft) 39 m (128 ft)

The end-to-end network distance varies with data rate and cable thickness.

DeviceNetTM requires a terminating resistor to be installed at each end of the trunk:

-121 Ohm

-1% metal film

-1/4 Watt

Terminating resistors should not be installed at the end of a drop line, only at the two ends of the trunk line.

For further information please see the DeviceNetTM Standard.

3 General information

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.

DeviceNetTM Features

Device Type Generic Master/scanner N

Explicit peer to peer messaging N I/O Slave messaging

I/O peer to peer messaging N•BitstrobeN

Configuration consistency value N • Polling Y

Faulted node recovery N•Cyclic N

Baud rates 125K, 250K, 500K 125K, 250K, 500K Y

Configuration method EDS

The end-to-end network distance varies with data rate and cable thickness.

Special DeviceNetTM functions

Class 100 Attributes

• Setup commands • Time to maintenance •Opencount

•Configurator •Laststroketraveltime •Closedcount

•Alarmsetup • Last stroke travel length (mm) • Time of last maintenance

•TimeTotal • Current position [mm] (0 - 80 mm)

• Time Closed • Activation’s solenoid no. 1

•TimeOpen • Activation’s solenoid no. 2

• Activation’s solenoid no. 3

See also section 3.1.4 ThinkTop DeviceNetTMAttribute List

DeviceNetTM interface

Baud rates: 125k, 250K and 500k.

Polling and change of state (COS) I/O slave messaging.

Poll:

7 or 2 bytes (optional).

2 bytes = Input/outputs and alarms (class 4).

7 bytes = Input/outputs alarms and class 100/attributes.

7 bytes is standard.

Changing from 7 bytes to 2 bytes: remove jumper (#12 and #13). A power recycle is necessary when changing

byte sizes.

COS:

2bytes,7by

tesisnotsupported.

Node address

Range: 0 – 63.

Default slave address: 63.

Power Supply

The power supply to the complete unit is taken from the DeviceNet.

Supply voltage: 11 – 25 V DC, as specified for the DeviceNet.

Supply current: Max. 45 mA (for sensor unit alone)

(excluding current to the solenoids and the external proximity switches).

Electrical connection: Direct cable gland entry (hard wired).

PG11 (ø4 - ø10 mm).

PG7 (ø3 - ø6.5 mm) option, external sensor.

4 Technical specifications

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.

4.1 ThinkTop ® DeviceNet TM features

“No Touch” sensor system

345

11 10 12

15 20

TD 800-267

1. Sensor unit

2. PLC, feedback

3. Sensor board

4. PLC interface board

5. IR Remote control

6. IR Rx

7. Serial link

8. LEDs

9. +5 V

10. Terminals

11. Terminals

12. ASI +

13. ASI -

14. Bus Connection

15. Internal connections

16. Solenoid signals (DC)

17. Solenoid common

18. External seat-lift (PNP)

19. Supply sensors

20. 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.

- Setup by internal push buttons or remote control (IR Keypad).

- Setup and local fault supervision.

- Setup saved at power shutdown.

- Visual LED Indicator lights.

Sensor System

Unique “No Touch” sensor system without any mechanical sensor adjustments. A magnet (indication pin) is mounted on the

valve stem and the magnetic field (axial) is detected by sensor chips inside the sensor board. The measuring angle from each

chip is used to locate the current position of the valve stem with an accuracy of ± 0.1mm. Note that the distance to the

indication pin can be 5 mm ± 3 mm.

Feedback signals

Input signals (produced by the sensor unit) transmitted over the DeviceNetTM -class4.

Five feedback signals: Closed valve, open valve, seatlift 1, seatlift 2 and status.

The status signal is used for five purposes:

• To indicate that a setup is in progress (LED D).

• To indicate an error condition (LED D), (flashing = software error), (steady = hardware error).

• To indicate that maintenance is required (LED F).

• To indicate if there is a conflict in the self adjustment programme (LED F).

• To indicate if no communication exists between ThinkTop® and PLC (LED D, steady).

Tolerance programme

Individual programme according to valve types.

Type 0: ...............................Bypass valve type / keep present valve type.

Type 1: ...............................SRC/ARC and Series 700 valves, only when self adjustment is enabled - Not recommended.

Type 2: ...............................LKB (LKLA-T).

Type 3: ...............................Unique Mixproof, SMP-SC Spillage-Free, and SRC-PV.

Type 4: ...............................SMP-SC, SMP-TO, SMP-BC, SMP-BCA, SBV, SRC, ARC, Unique SSV,

Unique SSV Aseptic, Unique-TO and Series 700 valves.

Type 5: ...............................All Parameters Set To Default (also valid for MH valve and SMP-EC

(seat-lift indication not possible for SMP-EC)).

Preset and reset values: Tolerance programme No./Type 5 (± 5mm) and all functions are disabled.

Note!

Important to select the right tolerance programme in order to ensure optimum controlled closeness of valves.

4 Technical specifications

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.

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.

After 0.5 mm adjustment an alarm warning appears: Loss of feedback signal, status signal and steady maintenance light

indicating a replacement of the seal.

Built-in Maintenance Monitor

The unit can be preset to indicate when the time for maintenance of the valve has been reached. A status signal and flashing

maintenance LED can be programmed to return after 3, 6, 9 or 12 months or more.

Technical specifications

Sensor system

Sensor accuracy: ... .. ... .. . ... .. ... . ± 0.1 mm.

Distance to indication pin: ..........5 ± 3 mm.

Stroke length: .......................0.1 - 80 mm.

Electrical connection:

Direct main cable gland entry (hard wired) PG11 (ø4 - ø10 mm).

Direct external/sensor cable gland entry PG7 (ø3 - ø6.5 mm) option, external sensor.

Terminals

The terminal row of the sensor unit is equipped with screw terminals for both internal as well as external cables and wires. The

terminals are suitable for wires up to 0.75 mm2(AWG 19).

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. If the actual setup is set for internal seat-lift, the corresponding external signal is not used, otherwise the

external signal logically controls the corresponding feedback to the PLC (Programmable Logic Controller).

Note!

If using external sensor, the sensor must be active/activated when performing a setup routine of the control head.

Supply voltage: .....................As specified for the AS-Interface (typical 30VDC)

Supply current: ......................Max. 15 mA per sensor.

Type of sensor: ......................VDC, only 3-wire sensor, PNP.

Cable length: ........................Max. 3 m.

Alarm mask

Output signals received from the DeviceNetTM (consumed by the sensor unit).

Four-bit mask to disable the alarm functions for the states “closed”, “open”, “seatlift 1” and “seatlift 2” respectively.

See also section 3.1.4 “ThinkTop® DeviceNetTM Attribute List”.

ThinkTop Visual Indications LED Indications

LED B “Open valve” (Yellow)

OIR-Receiver

LED D “Setup/Internal fault” (Red)

LED C “Seat-lift 1/2” (Yellow)

LED E “Solenoid valves” (Green)

LED F “Maintenance” (Orange)

LED B

LED D

LED C

LED E

LED F

LED A LED A “Closed valve” (Yellow)

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