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Alfa Laval ThinkTop ASI Automation Valve.

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Leave Surveillance to the Top

ThinkTop® AS-Interface 29.5 - 31.6 VDC

Application
TTopThe ThinkTop® is designed to ensure optimum valve control in conjunction with Alfa Laval sanitary valves and it is compatible with all major PLC systems (Programmable Logic Controller with AS-interface). It is for use in food, dairy and brewery installations and in biopharmaceutical applications.
 
Working Principle
The ThinkTop® is a control head including indication units and solenoid valves to control all kinds of processing valves. It is used to control and supervise pneumatic valves and it is mounted on top of the valve. It receives signals from a PLC to control the valve and it sends feedback signals to the PLC to indicate when the valve is in a certain position.
To adapt the sensor unit to the specific valve and to the application, the user sets up the ThinkTop® either by the local keys or by using the key pad (which is ordered separately). When using the key pad it is not necessary to dismantle the top unit.
 
Sensor System
Unique "No Touch" sensor system without any mechanical sensor adjustments. A magnet is mounted on the valve stem and the magnetic field (axial) is detected by sensor chips inside the sensor unit. 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 magnet can be 5 mm ± 3 mm.
 
Feedback Signals
The sensor system can be used for 3 feedback signals + 1 status signal = 4 feedback signals. 2 of the feedback signals can be external sensors if necessary.

The status signal is used for detection of the following:

- Set-up is in progress.
- Internal error.
- Maintenance is required (based on time and/or the self adjustment programme).
The LEDs are constantly indicating the status of the unit: Valve position, solenoid activated, setup and local fault indication, maintenance and seat-lift.
 
Standard Design
The ThinkTop® has a simple, modular and robust design which ensures a quick and easy assembly/disassembly. It consists of a base containing a sensor unit with LEDs, an activator stem, terminals for internal electrical connection, solenoid valves and a shell. See also Fig. 2 "Basic Design". It is prepared for upgrading and is exchangeable. The design is hygienic and easy to clean.
 
AS-INTERFACE IS A TRADEMARK OF THE ACTUATOR SENSOR INTERNATIONAL ASSOCIATION (AS-I).
 
Features
Tolerance Programmes
Individual tolerance programmes for all Alfa Laval sanitary valve types are part of the ThinkTop® concept ensuring correct feedback to the PLC for open and closed valve position. If the function is disabled the tolerance band will be ± 5 mm.
 
Self Adjustment (SRC/ARC Aseptic 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 that a replacement of the seal is necessary.
 
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.
 
Other Features
Another very important fact is that the setup is kept until programmed otherwise even during failure in the power supply.
 
The accurate sensor system enables indication of seatlift to be integrated in the top unit.
 
Materials
Plastic parts: Nylon PA 12.
Steel parts: Stainless steel 1.4301 (304) and 1.4404 (316).
Seals: Nitrile (NBR).
 
Technical Data
Sensor System:
Sensor accuracy: ± 0,1 mm
Distance to magnet: 5 ± 3 mm
Stroke length: 0.1 - 80 mm
 
Electrical connection
Direct main cable gland entry (hard wired) PG11 (4 - 10 mm).
Direct external/sensor cable gland entry PG7 (3 - 6.5 mm).
 
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).
 
Power Supply - DC
The power supply to the complete unit is taken from the AS-Interface.
The unit is reverse polarity protected.
 
Supply voltage: 29.5 - 31.6 VDC
Normal current consumption sensor board: 45 mA (excluding current for the solenoids and the external proximity switches).
Max. current consumption sensor board: 120 mA (If external devices e.g. solenoids and switches are connected to the sensor board, a higher current consumption than 120 mA may occur and this will damage the sensor boards).
 
The fulfilling of the UL requirements in UL508 requires that the unit is supplied by an isolating source complying with the requirements for class 2 power units (UL1310) or class 2 and 3 transformers (UL1585).
 
Feedback Signals
Signals transmitted over the AS-Interface BUS to the AS-Interface master PLC.
 
External Sensors
The external sensors are used for seat-lift supervision when seat-lift cannot 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).
 
Supply voltage: As specified for the AS-Interface (typical 24 VDC)
Supply current: Max. 15 mA per sensor.
Type of sensor: VDC, only 3-wire sensor PNP.
Cable length: Max. 3 m.
 
Default slave address: 0
IO code: 7 (4 bit bi-directional)
ID code: F (slave without profile)
ID1 code: F
ID2 code: F
Slave profile = S-7.F.F
 
No. of nodes:
Max. 31 ThinkTops® on a single master/gateway
 
ASi-bus bit assignment
For the AS-Interface version, the following bit assignment will be used:
 
Input bit 0 Feedback #1 Closed position:
Output bit 0 Not connected
Input bit 1 Feedback #2 Open position:
Output bit 1 Solenoid valve 1
Input bit 2 Feedback #3-4 Seat 1 or 2 position:
Output bit 2 Solenoid valve 2
Input bit 3 Feedback #5 Status:
Output bit 3 Solenoid valve 3
 
Solenoid valves:
Up to 3 solenoid valves in each unit.
 
Air restriction (throttle function) air inlet/outlet.
Manual hold override.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3/2 or 5/2 valve (only possible with one 5/2 valve).
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 kg/kg air.
Throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .¸2.5 mm.
Air restriction (throttle function) air inlet/outlet . . . . . . . . . . . . . . . . . . . .Yes.
Manual hold override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes.
External air tube connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .¸6 mm or 1/4".
Silencer/filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connection possible via ¸6 mm or 1/4"ť. (Filter recommended in tropical regions).
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 VDC.
Nominal power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 W.

**) Filter recommended in tropical regions.

*) Max. 31 ThinkTops® on a single master/gateway.

Micro environment demand specifications:
Temperature
Working: -20°C to +85°C IEC 68-2-1/2
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. IEC68-2-3
Cyclic humidity: +25°C/+55°C
12 cycles IEC 68-2-30
(working) 93% R.H.
Protection class IP67 IEC 529
Input treshold
Voltage/current: Type 1 input requirements EN 61131-2
EMC Directive 89/336/EEC EN 50081-1, EN 50082-2
AS-Interface Version 2.11*) EN50295
UL Approval 8-30 VAC/VDC, class 2 input,
45 mA max. output UL508 - E203255
 
AS-Interface Standard Specification Overview (EN50295)
Medium
Unshielded two-wire cable for data and energy (30 VDC/typical up to 8A for the bus).
 
Length of bus cable
100 m max. (300 m with repeaters).
 
Number of slaves
31 max. (each slave has its own address).
 
Number of participants
Up to 4 sensors and 4 actuators per slave (max. 124, bidirectional = max. 248 binary participants).
 
Addresses
Each slave has a unique address. The address is set by the master or by a "handheld" programmer.
 
Messages
The master transmits to each single address in turn with immediate response from each slave.
 
Bit-rate
4 bits (net) per slave and message.
 
Cycle time with 31 slaves
5 ms.
 
Error detection
Incorrect messages are reliably identified and repeated.
 
Device-interface
4 configurable data ports (as inputs or bidirectional) plus 4 parameter outputs and 2 control outputs (strobe).
 
Process data in the master
Cyclic poling of all participants.
Cyclic transmission of data to the host or to the slaves respectively.
 
Master services
Initiation of the network.
Identification of participants.
A cyclic setting of parameter values to the slaves.
Diagnosis of bus and AS-Interface slaves.
Error messages to the host.
Setting of addresses in replaced slaves.
 
Signal Coding
AS-Interface uses a master code in which a negative sin2 pulse represents a falling edge and a positive sin2 pulse represents a rising edge. This neutralizes RFI effects and allows unscreened two-wire cable to carry both power and data reliably.
 
Electrical connection, internal


- Bus connection
- Internal connections to solenoid 1-3 **)
- Jumper connections **)
- Incoming signals from external sensors
- Supply to external sensors

  • - 6. ASI P Brown (+)
  • - 7. ASI N Blue (-)
  • - 8. N/C
  • - 9. N/C
  • - 10. N/C
  • - 11. N/C
  • - Earth
  • - 20. Solenoid common brown
  • - 21. Solenoid 1, blue
  • - 22. Solenoid 2, blue
  • - 23. Solenoid 3, blue
  • - 1. N/C
  • - 2. N/C
  • - 3. N/C
  • - 4. N/C
  • - 5. N/C
  • - 12. PWM Jumper
  • - 13. PWM Jumper
  • - 24. Seat-lift 1 "upper" *)
  • - 25. Seat-lift 2 "lower" *)
  • - 26. Supply + *)
  • - 27. Supply - *)


*) Note! Terminals 24, 25, 26 and 27 can be used for external seat-lift sensors as well as for any digital input. Always use an external PNP sensor. 2 external signals can be connected, they are associated with feedback signal 3 (seatlift 1) and 4 (seatlift 2). External sensor must always be a 8-30 VDC PNP 3 wire sensor. Connect (-) common on terminal 27, and (+) common on terminal 26. The signals from the external sensors are associated as follows: sensor signal on terminal 24 (seatlift 1) associated with feedback 3 (seatlift 1), and sensor signal on terminal 25 (seatlift 2) associated with feedback 4 (seatlift 2).
**) Note! Jumper present = PWM mode (pulse width modulated "on"ť solenoid valve).
***) Note! Internal connections: Terminals for connection for the solenoids mounted internally in the control head. The number of solenoids actually mounted in the control head could be 0 - 3. The signals are taken directly from the terminal row.
****) Note! If using external sensor, the sensor must be activated when performing a configuration of the sensor board.

  • - Sensor unit
  • - Light guide
  • - O-ring
  • - Base
  • - Adapter
  • - Shell
  • - Terminals
  • - Activator stem
  • - Cable gland
  • - Special X-ring
  • - Air fitting
  • - Solenoid valve (3/2 or 5/2)
  • - Solenoid valve (3/2)


Fig. 1. Basic design, ThinkTop®.
*Note! This is the basic design. The clearance should be approximately:
¸225 x 250 mm (SRC NC, SMP-SC/-BC/-TO, Unique, Koltek MH, SBV, AMP)
¸225 x 320 (SRC NO)
¸225 x 300 (LKB/LKLA-T)

Fig. 2. Dimensions
Options
- 2m cable (2 x 0.5 mm2) with ASI flat cable connector (Hirschmann).

Accessories
- IR keypad.
- External indication bracket for SMP-SC.
- External indication bracket for Unique.
Ordering
Please state the following when ordering:
 
- AS-Interface 29.5 - 31.6 VDC.
- Number of solenoids (0-3).
- Type of valve (3/2, 5/2).
- Air connection ¸6mm or 1/4"
- Please state if for series 700 valves.
- For ThinkTop® when used on SRC-LS Stop valve size 63.5 - 101.6 mm/DN 65 - 100: Special indication pin must be used; 9612-6370-01
- For ThinkTop® when used on Unique SSV-LS valves: special indication pin must be used; 9613-1581-01.
 
Note! For further information: See also ESE000356.
Note! The ThinkTop® has Patented Sensor System, Registered Design and Registered Trademark.
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