Instruction Manual - Alfa Laval

1 ThinkTopV50 and V70 Lit. Code200000549-5-EN-GBManual ManualPublished byAlfa Laval Kolding A/SAlbuen 31DK-6000 Kolding, Denmark+45 79 32 22 00 The original instructions are in English Alfa Laval Corporate AB 2020-10 This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced ortransmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB s prior express written permission. Information and services provided in this document aremade 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. All rightsare EC Declaration of 52 About About this Mechanical Pneumatic Electrical installation, Digital-IO Electrical installation, Electrical installation, Option - Upper seat-lift Option Valve speed Option Valve closing speed Auto Flex Live Calculating the error Error Interpreting the error code Tips and 321EC Declaration of ConformityRevision of Declaration of Conformity 2019 05 01 The Designation CompanyAlfa Laval Kolding A/SCompagny NameAlbuen 31, DK-6000 Kolding, DenmarkAddress+45 79 32 22 00 Phone Nohereby declare thatTop Unit for Valve Control and IndicationDesignationThinkTop V50, ThinkTop V70 TypeFrom serial number 0 to in conformity with the following directive with amendments.

2 - EMC Directive 2014/30/EU- RoHS2 Directive 2011/65/EUThe person authorised to compile the technical file is the signer of this documentGlobal Product Quality ManagerPump, valves , Fittings and Tank EquipmentLars Kruse AndersenTitleNameKolding2019 05 01 PlaceDateSignature200000549-5-EN-GB5EN20 0000549-5-EN-GB61EC Declaration of ConformityEN2 About ThinkTopThinkTop is a valve-top control unit that provides surveillance and control of valves during the fluidhandling process. The control unit has been developed with user friendliness and robustness in comes with a valve control sensor board for connection to any PLC system. There are threetypes of communication interfaces available:Digital I/O 24 VDC, AS-Interface , AS-I and the ThinkTop receives a signal from the PLC system to open the valve, a built-in solenoid valveshifts the connected valve into position. The position is detected through a sensor target attached tothe valve stem through a touch-free sensor system.

3 The position is then evaluated and if valid, thecorresponding feedback is returned to the automation system via the communication and V70 seriesThinkTop comes in two series: V50 and V70. The V50 series is the compact option with a feature settailored to valves that require only one solenoid valve such as butterfly and single seat valves . TheV70 series is the more flexible option that can be configured to meet the needs of the mostdemanding valve applications such as Mixproof this manualIn this Manual , you will find detailed descriptions of how to install and setup the different ThinkTopvariants as well as detailed information about fault finding and maintenance. We recommend that youfamiliarize yourself with the content of the Manual before you begin VALVEROTARY VALVEERROR1248162066-0137T AA1812 DIO 24 VDC9615-3945-01200000549-5-EN-GB7EN20000 0549-5-EN-GB82 About ThinkTopEN3 InstallationThis chapter covers the installation of any ThinkTop variant within the V50 and V70 families on anyAlfa Laval rising stem carry out the installation, you need the following tools.

4 Hex keyAdjustable spanner or flat mm14, 19 mm2066-0037(additional 12, 15 and 17 for Seat lift sensor installation)When using wire end ferrules for ease of electrical installation it is recommended to choose ferruleswith a barrel length of 10mm to ensure full engagement in the installationMechanical installation is a two-step process, where you mount the sensor target to the actuator stemand the ThinkTop to the actuator the yellow sensor target to the the sensor target by hand or use a 22mm spanner ( Nm)2066-00382 Mount the ThinkTop centred and flat againstthe actuator the ThinkTop flat and steady against theactuator a mm hex key to lightly tighten one ofthe two set the second set screw ( Nm).Tighten the first set screw ( Nm).2066-0040 NOTEW hile you can perform the mechanical installation of a seat lift sensor at this time, theelectrical installation must be completed before you can test the seat lift sensor.

5 Forinformation on how to install and test the seat lift sensor, see Install the seat lift sensor Option - Upper seat-lift surveillance on page installationBefore you begin the pneumatic installation, cut the hoses to the preferred the air hoses between the airconnectors on the ThinkTop and the air portson the double seat valves , ensure that the hosesrun parallel to each other and do not way, the hoses will be the air the supply air hose to the Air inconnector and turn on the supply 2 Verify that the air exhaust plug pointsdownwards as indicated by the arrow to avoidwater ingress in the pneumatic system. Youcan rotate the exhaust plug until it points inthe right the valve is placed horizontally so that themushrooms are also horizontal, it is notpossible to make the exhaust plug outlet pointdownwards. Instead, you can replace it with adownwards facing colour and air connectionsOn the ThinkTop, the marking, numbering and colour coding of air hoses, air fittings, visual feedback,and electrical feedback follow the same pattern.

6 This pattern ensures that Auto Setup main valve function connects to the Out 1 air connector on the ThinkTop, which is keyed to thewhite/main upper seat-lift or auxiliary valve function connects to Out 2, which is keyed to the lower seat-push valve function connects to Out 3, which is keyed to the yellow/Lsp air connection numbers are printed on the cover of the control the valve Manual for information on the individual air ports on the the V70 with 5/2 solenoid valve, port Out 1 is normally closed (NC) and port Out 2 is normallyopen (NO). installation, Digital-IO 24V1a) Remove the top cover by turning itcounter clockwise and then lifting ) Connect the cable to the ThinkTop, andthen connect the wires to the terminalsaccording to the wiring ) Tighten the cable gland using a 19 mmwrench (3 Nm).Or tighten the M12 connector using a 14mm wrench ( Nm).d) Put the top cover back in ) Turn on the power installed correctly, the light guide eadcbWiring diagramsTerminals V50 Digital-IO 24V1 Power supply24V(brown) (M12, pin 1)2 Power supplyGND(blue) (M12, pin 3)3out (PLC in)Valve state(white) (M12, pin 2)4outValve de-energised (DE-EN)(black) (M12, pin 4)5outMain valve energised (EN)(grey) (M12, pin 5)6inSolenoid valve 1 for main valve (SV1)(pink) (M12, pin 6)200000549-5-EN-GB123 InstallationENTerminals V70 Digital-IO 24V1 Power supply24V(brown) (M12, pin 1)2 Power supplyGND(blue) (M12, pin 3)3outValve state(white) (M12, pin 2)4outValve de-energised (DE-EN)(black) (M12, pin 4)5outMain valve energised (EN)(grey) (M12, pin 5)6outUpper seat lift energised (USL)(pink) (M12, pin 6)7outLower seat push energised (LSP)(violet) (M12, pin 7)8inSolenoid valve 1 for main valve (SV1)(yellow) (M12, pin 8)9inSolenoid valve 2 for USL (SV2)

7 (green) (M12, pin 9)10inSolenoid valve 3 for LSP (SV3)(red) (M12, pin 10)1 Seat lift sensorSupply(brown)2 Seat lift sensorGND(blue)3 Seat lift sensorSignal(black) installation, AS-interface1a) Remove the top cover by turning itcounter clockwise and then lifting ) To allocate an address, use your preferredaddressing device. See the devicemanual for more ) Connect the cable to the ThinkTop, andthen connect the wires to the terminalsaccording to the wiring ) Tighten the cable gland using a 19 mmwrench (3 Nm).Or tighten the M12 connector using a 14mm wrench ( Nm).e) Put the top cover back in ) Turn on the power installed correctly, the light guide diagramsTerminals V50 AS-interface1AS-i supplyAS-i +(brown) (M12, pin 1)2AS-i supplyAS-i (blue) (M12, pin 3)Terminals V70 AS-interface1AS-i supplyAS-i +(brown) (M12, pin 1)2AS-i supplyAS-i (blue) (M12, pin 3)1 Seat lift sensorSupply(brown)2 Seat lift sensorGND(blue)3 Seat lift sensorSignal(black) installation, IO-link1a) Remove the top cover by turning itcounter clockwise and then lifting ) Fit the cable to the M12 connector andtighten it using a 14 mm wrench ( ).

8 C) Put the top cover back in ) Turn on the power installed correctly, the light guide Wiring diagramsTerminals V50 IO-Link1 Power supplyL+ 24V(brown) (M12, pin 1)2 Power supplyL- GND(blue) (M12, pin 3)3 SignalIO-Link(black) (M12, pin 4)Terminals V70 IO-Link1 Power supplyL+ 24V(brown) (M12, pin 1)2 Power supplyL- GND(blue) (M12, pin 3)3 SignalIO-Link(black) (M12, pin 4)1 Seat lift sensorSupply(brown)2 Seat lift sensorGND(blue)3 Seat lift sensorSignal(black) - Upper seat-lift surveillanceThis section is relevant for V70 variants where feedback for the upper seat lift function in a doubleseat valve application is parts referred to in this section are available as a seat lift sensor kit, art no. the valve at hand doesn t have the holes in the yoke an additional bracket kit is required. Thebracket kit has art no. 9613095503 and its own installation will need an adjustable spanner or flat wrenches in the following sizes for this installation: 12, 14,15 and 17 the blue plug in the ThinkTophousing with a 14 mm flat the seat lift sensor cable gland to theThinkTop housing with at 15 mm flat wrench( Nm).

9 Fit the sensor cable in the cable the wires to the seat lift sensorterminal according to the colour codes notednext to the the cable gland nut with at 15 mm flatwrench ( Nm).2066-00622 Fit the black bushing in the relevant hole inthe valve yoke.(The icons on the yoke refer to the shape ofthe valve plug.)(The bushing will be fastened together withthe sensor nut in step 7)2066-0050200000549-5-EN-GB163 InstallationEN3 Position the valve so that the mechanicaltarget is in front of the sensor by manuallycontrolling solenoid valve a nut approximately half way into thethread on the the sensor in the bushing, so the tip of thesensor is approximately 1 2 mm from themechanical target of the the sensor cable on the sensor with theelbow pointing the nut by hand on the sensoragainst the bushing for on the installation by energizing anddeenergizing the upper seat lift function andverify that the LED on the seat lift sensorchanges the sensor position if necessary.

10 Thegoal is to center the transition point betweenthe always ON limit and the always OFF the sensor nut with a 17 mm flatwrench ( Nm)Fasten the sensor cable with a 14 mm flatwrench ( Nm). NOTES ensor centering advice:a) Closed seat position - Screw in the sensor until the local sensor LED comes ) Open seat position - Unscrew the sensor while counting the rotations until ) Close the seat and screw the sensor approximately half the rotations back in andorient the cable plug Valve speed reductionThis section is relevant for valve applications where reduction of closing or opening speed is one-way air throttle valves referred to in this section are available as art. no. 9611996114 for 6hoses and art. no. 9611996115 for 1/4" hex key is needed to remove the air fitting on the ThinkTop and an 8 mm spanner for tightening thespecial fitting.(Hex key size: 4mm for the blue rim, 6, fitting and 5mm for the grey rim, 1/4", fitting)1 The one-way air throttle valve controls thevalve closing speed when mounted on theactuator (A), and controls the valve openingspeed when it is mounted on the ThinkTop(B).