.

ky Leave Surveillance to the Top

ky ThinkTop® Digital 8-30 VDC PNP/NPN

Application
The 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 PNP/NPN
interface). It is for use in food, dairy and brewery installations and in
biopharmaceutical applications and can be used indoors as well as
outdoors.

Working Principle
The ThinkTop® is a control head including position indication and
solenoid valves. It is used to control and supervise sanitary pneumatic
valves. 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 configure 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 may
not be necessary to remove the cover of the top unit.

Sensor System
The ThinkTop® features a “No Touch” sensor system without any
mechanical sensor adjustments. A magnet is mounted on the valve
ThinkTop®
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 ± 0.004”
(0.1
. mm). Note that the distance to the magnet can be 0.2” (5 mm) Standard Design
± 0.12” (3 mm). The ThinkTop® has a simple, modular and robust design which
ensures a quick and easy assembly/disassembly. It consists of a base
Feedback Signals containing a sensor unit with LEDs, an activator stem, terminals for
The sensor system can be used for 4 feedback signals + 1 status internal electrical connection, solenoid valves and a shell. See also Fig.
signal = 5 digital PNP/NPN feedback signals. Selection of PNP or 2 "Basic Design". It is prepared for upgrading and components are
NPN is done by a jumper. 2 of the feedback signals can be external interchangeable. The design is hygienic and easy to clean.
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
program).

The LEDs are constantly indicating the status of the unit: valve position,
solenoid activated, setup and local fault indication, maintenance and
seat-lift.
Features
Tolerance Programmes
Individual tolerance programs 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 ± 0.2” (5 mm).

Self Adjustment (SSV/SSV Aseptic valves only)

The self adjustment feature is an exceptional aspect of the ThinkTop® design. A program 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 0.012” (0.3 mm), an alert warning will
appear in the form of a status signal and a flashing maintenance LED. After a 0.2” (5 mm) adjustment, an alarm warning signals the following: loss of
feedback, status signal, a steady maintenance light, and indicates the minimum seal remaining before replacement is required.

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 6. Reinforced.
Steel parts: . . . . . . . . . . . . . . . . . . . Stainless steel AISI 304 and 316.
Seals: . . . . . . . . . . . . . . . . . . . . . . Nitrile (NBR). EPDM rubber for SMP-EC activator stem.

Technical Data
Sensor System:
Sensor accuracy: . . . . . . . . . . . . . . . ± 0.004” (0.1 mm)
Distance to magnet: . . . . . . . . . . . . . 0.2” ± 0.12” (5 ± 3 mm)
Stroke length: . . . . . . . . . . . . . . . . . 0.004”- 3.15” (0.1 - 80 mm)

Electrical connection
Direct cable gland entry (hard wired) PG11 0.15” - 0.39” (4 - 10 mm)
diameter.
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 0.75mm2 (19 AWG).

Power Supply - DC
The unit is reverse polarity and short circuit protected.

The power supply must meet the requirements of EN 61131-2.

Supply voltage: . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . .8 - 30 VDC

Supply voltage nominal: .......... ... . . . . . . . . . . . . . . . . . . . .24 VDC (+20%, -15%) - pr. EN 61131-2
Max. ripple 5% of nominal supply voltage .. . . . . . . . . . . . . . . . . . . . .
Supply voltage absolute max: ...... ... . . . . . . . . . . . . . . . . . . . .30 VDC
Supply voltage absolute min.: . . . . . . . ... . . . . . . . . . . . . . . . . . . . .8 VDC
Supply current: . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . .Max. 45 mA (for sensor unit alone)
(Excluding current to the solenoids, external proximity switches and the
PLC input current.)

Feedback Signals
Output signals from the sensor unit to the connected digital interface (PLC).

Nominal voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must match the selected type of ThinkTop®.

Load current: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Max. 100 mA
Voltage drop: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Max. 2 V at max. load current.

External Sensors
The external sensors are used for seat-lift supervision (upper seat-lift) when seat-lift cannot be internally detected. The sensors get their supply
voltage from the top unit. They connect directly to the terminal strip on the sensor unit. If the actual setup is set for internal seat-lift (lower 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: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Must match the selected type of ThinkTop®.

Supply current: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Max. 15 mA per sensor.
Type of sensor, DC: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Only 3-wire sensor PNP.

Polarity
PNP (sourcing) or NPN (sinking) function is selected with a jumper in terminals 12 and 13. Jumper present = PNP. If changing to NPN remove the
jumper and make a power recycle. A power recycle is always required when changing this function.
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 . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . .43.5 - 130.5 PSI (3-9 bar).
Filtered air, max. particles or dirt .. . . . . . . . . . . . . . . . . . . . . . . . . . .0.0004” (0.01 mm).
Max. oil content ......... ... . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 ppm.
Max. water content . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . .0.0165 lb/lb air
Throughput ............ ... . . . . . . . . . . . . . . . . . . . . . . . . . .0.98” (2.5 mm) diameter

Air restriction (throttle function) air inlet/outlet.

Manual hold override.

External air tube connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1/4” or 6 mm diameter.

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 VDC
Nominal power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 W.

Environment/Approvals

Temperature
Working: -4° F to 185° F (-20° C to +85° C) IEC 68-2-1/2
Storage: -40° F to 185° F (-40° C to +85° C) IEC 68-2-1/2
Temperature change: -13° F to 212° F (-25° C to +100° C) IEC 68-2-14
Vibration 10-55 Hz, 0.03” (0.7 mm) IEC 68-2-6
55-500 Hz, 10g
3*30 min, 1 octave/minute
Drop test IEC 68-2-32
Humidity
Constant humidity: 104° F (+40° C), 21 days, 93% RH IEC68-2-3
Cyclic humidity: 77° F/131° F (+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
Solenoid signals
Isolation voltage (1000 + 2*117) VAC rms/1minute EN 61131-2
EMC Directive 89/336/EEC EN 50081-1, EN 50082-2
KA 2791.30 Tetra Pak Corporate Standard
UL approval ThinkTop sensor unit UL E203255
Project # 99NK20566
Electrical connection, internal
A. Digital interface command
signals
B. Internal connections to
solenoid 1-3
C. Feedback signals to digital
interface
D. Jumper connections **)
E. Incoming signals from
external sensors
F. Support to external sensors

6. Solenoid 1 1. Closed valve

7. Solenoid 2 2. Open valve
8. Solenoid 3 3. Seat-lift 1
9. Supply + 4. Seat-lift 2
10. Supply - 5. Status
11. Solenoid com. 12. NPN/PNP Jumper
Earth 13. NPN/PNP Jumper
20. Solenoid com. 24. Seat-lift 1 “upper” *)
21. Solenoid 1 25. Seat-lift 2 “lower” *)
22. Solenoid 2 26. Supply + *)
23. Solenoid 3 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 = PNP. If changing the function a power recycle is necessary. The selection NPN/PNP is done by the jumper.

Note! Remember to isolate wires that are not in use. .

Example of connecting power supplies

One power supply for sensor system and solenoid valves:

A) Jumper (if positive activation of solenoids) B)Jumper (if negative activation of solenoids)

Two power supplies, one for sensor system and one for the solenoid valves:

Sensor system

Solenoid valves

C) If positive activation of solenoids

D) If negative activation of solenoids
 *Note!This is the basic design. The clearance should be
approximately:
7.1” dia. x 9.8” (ø180 x 250 mm) (SSV NC, SMP-SC/-BC/- TO,
Unique, Koltek MH, SBV, AMP)
7.1” dia. x 12.6” (ø180 x 320 mm) (SSV NO)
Fig. 2. Basic design, ThinkTop®. 7.1” dia. x 11.8” (ø180 x 300 mm) (LKB/LKLA-T)

Options
- Solenoids 24 VAC, 110 VAC.
1. Sensor unit
- 5 m PVC control cable 12 x 0.5 mm2, (24 AWG).
2. Light guide
3. O-ring
Accessories
4. Base
- IR keypad.
5. Adapter
- External indication bracket for SMP-SC.
6. Shell
7. Terminals Note! The ThinkTop® has Patented Sensor System,
8. Activator stem Registered Design and Registered Trademark.
9. Cable gland
10. Special X-ring
..
11. Air fitting
12. Solenoid valve (3/2 or 5/2) Ordering
13. Safety valve Please state the following when ordering:
14. Solenoid valve (3/2)
- Digital 8-30 V DC PNP/NPN.
- Number of solenoids (0-3).
Note!1.) The ThinkTop® for the SMP-EC valve has a longer activator
- Type of valve (3/2, 5/2).
stem which is going through the shell (see Ordering Leaflet). - Air connection ø6mm or 1/4""
2.) The ThinkTop® for the SRC-LS requires a special magnet. - Please state if for series 700 valves.
Contact Alfa Laval. - For ThinkTop when used on SSV-LS Stop valve size 2.5" - 4" / DN
65 - 100: Special indication pin 9612-6370-01.
.

ESE00297ENUS 0705 The information contained herein is correct at the time of issue,
but may be subject to change without prior notice.

How to contact Alfa Laval

Contact details for all countries
are continually updated on our website.
Please visit www.alfalaval.com to
access the information direct.