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Alfa Laval ThinkTop Digital Automation Valve.

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ThinkTop® Digital 8-30 VDC PNP/NPN

 
Application
ThinkTop DigitalThe 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.

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 4 feedback signals + 1 status signal = 5 digital PNP/NPN feedback signals. Selection of PNP or NPN is done by a jumper. 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.

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 (SSV/SSV 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 cable gland entry (hard wired) PG11 (¸4 - ¸10 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 ThinkTop® is designed to be a part of the PLC's Input/Output (I/O) system. It should be supplied from the same protected power supply as the other I/O devices. The I/O power supply should not be used for other kinds of loads. 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 absolutemax: . . . . . .30 VDC
Supply voltage absolutemin.: . . . . . . .8 VDC
Supply current*): . . . . . . . . . . . . . . .Max. 45mA (for sensor unit alone)
(Excluding current to the solenoids, external proximity switches and the PLC input current.)

*) The initial current during power-on is higher. The actual shape of the current pulse depends on the power supply used. Typical values are 150mA RMS during 13 ms (regulated PS) to 360 mA RMS during 8 ms (unregulated PS).

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

Nominal voltage: . . . . . . . . . . . . . . .Must match the selected type of ThinkTop®.
Load current: . . . . . . . . . . . . . . . . . .50mA typical, 100mAmax.
Voltage drop: . . . . . . . . . . . . . . . . . .Typical 3 V at 50 mA

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: . . . . . . . . . . . . . . . .Must match the selected type of ThinkTop®.
Supply current: . . . . . . . . . . . . . . . .Max. 15mA per sensor.
Type of sensor: . . . . . . . . . . . . . . . .DC, only 3-wire sensor PNP.
Cable length: . . . . . . . . . . . . . . . . . .Max. 3 m.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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.
Manual hold override.

External air tube connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .¸6 mm or 1/4".
Silencer/filter *) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connection possible via ¸6 mm or 1/4"ť.
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 VDC
Nominal power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 W.
**) Filter recommended in tropical regions.

Micro environment demand specifications:
Enviroment Demand
 
Electrical connection, internal
A. Digital interface command signals
B. Internal connections to solenoid 1-3 **)
C. Feedback signals to digital interface
D. Incoming signals from external sensors
E. Supply to external sensors
F. Digital interface command signals

6. Solenoid 1
Electrical Connection7. Solenoid 2
8. Solenoid 3
9. Supply +
10. Supply -
11. Solenoid com.
Earth
20. Solenoid common blue
21. Solenoid 1, brown
22. Solenoid 2, brown
23. Solenoid 3, brown
1. Closed valve
2. Open valve
3. Seat-lift 1
4. Seat-lift 2
5. Status
12. NPN/PNP Jumper
13. NPN/PNP 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 = PNP. If changing the function a power recycle is necesssary. 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:
Img 1Img 2
A) Jumper (if positive activation of solenoids)
 
Two power supplies, one for sensor system and one for the solenoid valves:
Img 3
Img 4
C) If positive activation of solenoids
D) If negative activation of solenoids
 
 ThinkTop Design
1. Sensor unit
2. Light guide
3. O-ring
4. Base
5. Adapter
6. Shell
7. Terminals
8. Activator stem
9. Cable gland
10. Special X-ring
11. Air fitting
12. Solenoid valve (3/2 or 5/2)
13. Safety valve
14. Solenoid valve (3/2)
Fig. 1. Basic design, ThinkTop®.

Fig. 2. Dimensions.
*Note! This is the basic design. The clearance should be approximately:
¸225 x 250 mm (SSV NC, SMP-SC/-BC/-TO, Unique, Koltek MH, SBV, AMP)
¸225 x 320 (SSV NO)
¸225 x 300 (LKB/LKLA-T)

Options
- Solenoids 24 VAC, 110 VAC.
- 5mPVCcontrolcable12x0.5mm2, (AWG 20).

Note! Cable not UL approved.

Accessories
Dimension- IRkeypad.
- External indication bracket for SMP-SC.
- External indication bracket for Unique.

Note! For further information: See also IM 70824.

Note! The ThinkTop® has Patented Sensor System, Registered Design and Registered Trademark.

Ordering
Please state the following when ordering:

- Digital 8-30 VDC PNP/NPN.
- 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 SSV-LS Stop valve size 63.5 - 101.6 mm/DN 65 - 100: Special indication pin 9612-6370-01

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