| ThinkTop® DeviceNetTM 11-25 VDC |
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ThinkTop® |
Application
The ThinkTop® is designed to ensure optimum valve control
in conjunction with Alfa Laval sanitary valves and it is compatible with
most PLC systems (Programmable Logic Controllers) with DeviceNet. 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 (class 4)
The sensor system can be used for 4 feedback signals + 1
status signal = 5 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).
- - A conflict in 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.
DEVICENET IS A TRADEMARK OF THE OPEN DEVICENET VENDOR
ASSOCIATION, INC. (ODVA)
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 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
minimum of seal left requiring 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.
Special features (class 100)
| - Time TOTAL |
- Time CLOSED |
| - Time OPEN |
- Time to maintenance |
| - Last Stroke Time |
- Last Stroke Length |
| - Coil Count #1 |
- CLOSED count |
| - Coil Count #2 |
- OPEN count |
| - Coil Count #3 |
- Time of last maintenance |
Other Features
Another very important fact is that the setup is kept
until programmed, even during failure in the power supply.
The accurate sensor system enables indication of seat-lift
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 |
DeviceNet interface
The baud rates: 125k, 250K and 500K.
Polling and change of state I/O slave messaging.
Poll: 7 or 2 bytes (optional)*
COS: 2 bytes, 7 bytes is not supported.
| * |
2 bytes = Inputs/outputs and alarms
(class 4) |
| |
7 bytes = Inputs/outputs, alarms and
class 4+100 attributes |
| |
Changing from 7 bytes to 2 bytes: Remove
jumper (#12 and #13). A power recycle is necessary when changing byte
sizes. |
Node address
Range: 0 – 63
Default slave address: 63
Power supply
The power supply to the complete unit is taken from the
DeviceNet network.
| Supply voltage: |
11 – 25 VDC, as specified for the DeviceNet |
| Supply current: |
Max. 45 mA (for sensor unit alone) (excluding current to the
solenoids and the external proximity switches). |
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
Input signals (produced by the sensor unit) transmitted
over the DeviceNet - class 4.
|
DeviceNet FEATURES |
| Device Type |
Generic |
Master/scanner |
N |
|
Explicit peer to peer messaging |
N |
I/O Slave messaging |
|
| I/O peer to peer messaging |
N |
• Bit strobe |
N |
|
Configuration consistency value |
N |
• Polling |
Y |
| Faulted node recovery |
N |
• Cyclic |
N |
|
Baud rates |
125K, 250K, 500K |
• Change of state
(COS) |
Y |
| Configuration method |
EDS |
|
|
External sensors
The external switches are used for seatlift supervision
when seatlift can not be internally detected. They get their supply
voltage from the sensor unit. They connect directly to the terminal strip
on the sensor unit. If the actual setup is for internal seatlift, the
corresponding external signal is not used. Otherwise the external signal
logically controls the corresponding feedback to the bus interface unit.
| Supply voltage: |
Must match the network power. |
| Supply current: |
Max. 15 mA per sensor. |
| Type of sensor: |
3-wire PNP-type. |
| Cable length: |
max. 3 m. |
Solenoid valves:
Up to 3 solenoid valves in each unit.
| 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 |
ø2.5 mm. |
Air restriction (throttle function) air inlet/outlet.
Manual hold override.
| External air tube connection |
ø6 mm or 1/4". |
| Silencer/filter*) |
Connection possible via ø6 mm or 1/4”. |
*) Filter recommended in tropical regions.
Solenoid drive:
| Solenoid valve |
8 VDC |
| O/P Voltage |
9 VDC +/- 5% |
| Power consumption |
0.75W Max. |
| Current consumption (per solenoid) |
30mA Max. |
| PWM Pull-in pulse length |
150ms Max. |
| PWM duty cycle |
40% +/- 10% |
| PWM frequency |
2 kHz +/- 10% |
PWM = Pulse width modulated
Technical specifications aux. outputs
Three aux. outputs can be used for external devices. The
drivers are always NPN outputs and PWM mode is not possible. The number of
aux. outputs for activation of external devices can be 0-3. Clarification:
All 3 outputs can be activated at the same time but if solenoid 1 is in
use, aux. 1 can not be used! If solenoid 1 and 2 are in use, aux. 1 and 2
can not be used! If solenoid 1, 2 and 3 are in use, no aux. can be used! A
mix of solenoid and aux. outputs is possible.
| Output: |
NPN (sinking). |
| Output voltage: |
24 VDC ± 15%. Network power connection!
User must ensure 24 VDC on the network (at the top) when these outputs
are used. |
| Load current: |
Max 75 mA. As these outputs drive
constant current, using several nodes in this mode will reduce the
number of nodes supported by a typical 8A network supply. The user
must ensure that total network current consumption is less than the
supply rating. |
Typical power consumption
Test conditions: One ThinkTop® DeviceNet 11-25 VDC
connected to the network with 1 input (on) and:
| No solenoids on |
supply voltage 25 VDC 20 mA |
| 1 solenoid active (PWM) |
supply voltage 25 VDC 28 mA |
| 2 solenoids active (PWM) |
supply voltage 25 VDC 36 mA |
| 3 solenoids active (PWM) |
supply voltage 25 VDC 44 mA |
| No solenoids on |
supply voltage 11 VDC 34 mA |
| 1 solenoid active (PWM) |
supply voltage 11 VDC 58 mA |
| 2 solenoids active (PWM |
supply voltage 11 VDC 82 mA |
| 3 solenoids active (PWM) |
supply voltage 11 VDC 106 mA |
|
Note! |
If the Aux. Outputs are used instead of
the solenoids for activation of external devices, the consumption is
depending on the load current (see "Aux. Outputs"). |
Electrical connection, internal
- - Internal connections to solenoid 1-3
- - Bus connection
- - Jumper **)
- - Incoming signals from external sensors
- - Supply to external sensors
|
| |
|
- - 6. Aux. Common (+)
- - 7. Aux.1 (-)
- - 8. Aux. 2 (-)
- - 9. Aux. 3 (-)
- - 10. N/C
- - 11. N/C
- - Earth
- - 20. Solenoid common brown
- - 21. Solenoid 1, blue
- - 22. Solenoid 2, blue
- - 23. Solenoid 3, blue
|
- - 1. Power Bus V-(black)
- - 2. CAN_L (blue)
- - 3. Drain (bare)
- - 4. CAN_H (white)
- - 5. Power Bus V+ (red)
- - 12. Jumper
- - 13. 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 seatlift sensors as well as for any digital input. 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. |
| **) |
Note! |
| |
Jumper present = 7 I/O bytes (Rx size 7 and Tx size 7) - standard.
Changing from 7 bytes to 2 bytes: Remove jumper (#12 and #13). A power
recycle is necessary when changing byte sizes. |
| ***) |
Note! |
| |
Three aux. outputs can be used for external devices. The drivers are
always NPN outputs and PWM mode is not possible. The number of aux.
outputs for activation of external devices can be 0-3. Clarification:
All 3 outputs can be activated at the same time but if solenoid 1 is
in use, aux. 1 can not be used! If solenoid 1 and 2 are in use, aux. 1
and 2 can not be used! If solenoid 1, 2 and 3 are in use, no aux. can
be used! A mix of solenoid and aux. outputs is possible.
Output: NPN (sinking).
Output voltage: 24 VDC ± 15%. Network power connection! User must
ensure 24 VDC on the network (at the top) when these outputs are used.
Load current: Max 75 mA. As these outputs drive constant current,
using several nodes in this mode will reduce the number of nodes
supported by a typical 8A network supply. User must ensure that total
net work current consumption is less than the supply rating. |
 |
- - Sensor unit
- - Light guide
- - O-ring
- - Base
- - Adapter
- - Shell
- - Terminals
- - Actuator stem
- - Cable gland
- - Special X-ring
- - Air fitting
- - Solenoid valve (3/2 or 5/2)
- - Safety valve
- - Solenoid valve (3/2)
|
 |
| Fig. 1. Basic design, ThinkTop®. |
|
 |
*Note! This is the basic design.
The clearance should be approximately:
ø225 x 250 mm (SRC NC, SMP-SC/-BC/-TO, Unique, Koltek MH, SBV, AMP)
ø225 x 320 (SRC NO)
ø225 x 300 (LKB/LKLA-T) |
| Fig. 2. Dimensions. |
|
| 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 |
|
| (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 |
|
ODVA Approval |
DeviceNet v. 2.0 |
Conformance test version 14 |
|
UL Approval |
8-30 VAC/VDC, class 2 input, |
|
| |
45 mA max. output |
UL508-E203255 |
Accessories
- - IR keypad.
- - External indication bracket for SMP-SC .
- - External indication bracket for Unique.
Note!
For further information: See also IM 70826.
Note!
The ThinkTop® has Patented Sensor System,
Registered Design and Registered Trademark.
Ordering
Please state the following when ordering:
- - DeviceNet.
- - Number of solenoids (0-3).
- - Type of solenoids (3/2, 5/2).
- - Air connection ø6 mm or 1/4"
- - Please state if series 700 valves.
- - For ThinkTop when used on SRC-LS Stop valve size 63.5 - 101.6 mm/DN
65 - 100: Special indication pin 9612-6370-01
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