Alfa Laval ThinkTop Control and Indication Unit

DescriptionFeaturesHow It WorksDetailsDocumentation

ThinkTop Control and Indication Unit

For reliable, automated system control, look to the new ThinkTop^® control and indication unit from Alfa Laval. ThinkTop offers the most advanced, automated control of valves in the industry. Whether you are modifying an existing plant or planning a new installation, ThinkTop is just right for your process. ThinkTop’s registered design features a modularity and flexibility like no other control unit Alfa Laval has ever offered.

The ThinkTop control and indication unit is so versatile, it can be used on any air-operated, sanitary valve from Alfa Laval, including single-seat, butterfly and mixproof valves.

Related Industries:

Processed Foods, High-Acid Foods, Dairy, Beverages, Brewery, Home & Personal Care, Pharmaceutical, Biotech, Chemical

The premium valve control unit

ThinkTop is an automated, valve-top pneumatic valve sensing and control unit that provides exceptional surveillance and control of the fluid handling process. Cost-effective and flexible, ThinkTop offers a single sensor solution for Alfa Laval butterfly, single-seat and mixproof valves.

Proven safe and effective

The inherently safe, automated design of the ThinkTop reduces human error and increases production efficiencies – no matter how tough the operating environment. These features contribute to process safety:

No-touch, set-and-forget sensor system with up to three solenoid valves. Detects both the condition and position of the valve stem with an accuracy of ± 0.1 mm. Set-up parameters are stored but, for greater flexibility and ease of operation, can easily be re-programmed. Because the microchip sensors are moulded directly into the control head, they are less sensitive to the effects of temperature, vibration and pressure shock.
Individual pre-set tolerance bands. No manual adjustment of feedback sensors is required; individual preset valve tolerance bands eliminate self-adjustment and ensure optimum operational reliability on any Alfa Laval sanitary air-operated valve. This helps prevent contamination and production failure as well as contributes to increased productivity, longer valve service life and more uptime.
Five feedback signals increase the versatility of the valve sensing and control system and enable comprehensive valve record management data. ThinkTop features four feedback signals: for open position, for closed position, and for up to two integrated seat lifts or two external signals as well as one status signal for a total of five digital PNP/NPN feedback signals.

500 000 valve control units

Engineered for operation in virtually any environment, ThinkTop features a robust, durable and reliable valve sensing and control assembly. Its hygienic design withstands the effects of physical impact, pollution, frost, UV radiation and temperatures up to 85°C. Over the past decade, more than 500,000 units have provided continuous operation in processing plants around the world.

Completely watertight and IP66/IP67-compliant, ThinkTop features the superior GORE™ protective venting technology, which prevents water condensation and the penetration of dust, water and other particles into the control head. The control head can therefore be hosed down with water or cleaning fluid without putting important settings at risk. This contributes to maximum hygiene and effectively eliminates problems associated with corrosion and external contamination.

Retrofitting boosts performance

Upgrading older valve automation systems with advanced valve sensing and control technology can significantly lower investment, boost plant performance and cut operating costs. In many cases, the air-operated valve remains the same; only the replacement of the control head interfaces is required. Should upgrading require control head replacement, ThinkTop offers fast return on investment and long-term savings on operating and maintenance costs.

Caption: Upgrading increases reliability while lowering operating costs.

Construction

The ThinkTop sensing and control unit is a uniform modular control head that consists of a proven no-touch, set-and-forget sensor system with light-emitting diodes (LEDs), solenoid valves and valve control sensor board for connection to any PLC (Programming Logic Controller) system.

Operating principle

Inside the ThinkTop control head, the sensor system accurately detects valve stem movement, the valve position at any given time, with an accuracy of ± 0.1mm through the use of microchip sensors. To locate the current valve position, sensor chips inside the sensor board calculate the angle between the axial magnetic field produced by an indication pin mounted on the valve stem.

The sensor system receives signals from the PLC system to open or close the valve and transmits feedback signals on the main valve or seat lift position and condition back to the PLC system.

Up to three solenoid valves convert the sensor signals from electrical current into mechanical energy to open or close the air-operated valve, using the physical stimulus of an indication pin mounted on the valve stem.

Manual hold override enables valve operation during commissioning or maintenance without requiring assistance from plant operators and plant automation. Air throttling of the inlet/outlet makes it possible to slow the opening or closing of the valve thereby preventing pressure shocks and water hammer.

Possibility to customize each control head with an individual tolerance band to detect any deviation in the opening/closing of the valve and seat lift. This boosts productivity and effectively prevents operating errors.

LEDs conveniently display main valve, seat lift position, solenoid activation, setup and local fault indication and maintenance on the control head.

Integrated communications

Three types of interfaces can connect ThinkTop to any PLC system and may be used in any combination:

Digital interfaces
AS-Interface (with 31 nodes or 62 nodes)
DeviceNet interface (with 63 nodes)

Ease of installation

ThinkTop fits onto all Alfa Laval sanitary actuators equipped with mushrooms. Installation is straightforward; no special expertise, adapters or tools are required. To initiate manual setup, simply press the push-button startup sequence. Or set up without dismantling the control head using the optional IR keypad for remote control.

AS-Interface

ThinkTop Control and Indication Unit Applications

The ThinkTop is a control and indication unit used in conjunction with multiple kinds of processing valves. It is used mainly to control and monitor pneumatic valves. Mounted on top of the valve, it receives signals from a PLC to control the valve and sends feedback signals to the PLC to indicate when the valve is in a certain position. The ThinkTop is used to control a pneumatic valve and/or to report the position of the valve remotely through an electronic signal.

ThinkTop is available with a digital signal, AS-Interface, or DeviceNet network protocol compatibility.

WORKING PRINCIPLE

Alfa Laval’s ThinkTop utilizes a magnet mounted on the valve stem and a sensor unit to detect the valve position. The sensor unit contains sensor chips that detect the axial magnetic field of the magnet with an accuracy of ± 0.004 inches. This magnetic system means that the ThinkTop can provide accurate position feedback without any mechanical switches, and without any mechanical adjustments. Valve control is provided by means of optional 1, 2, or 3 pneumatic solenoids installed within the unit.

The ThinkTop unit is set up through a simple process that utilizes a few switches within the unit.

FEEDBACK SIGNALS

The sensor system can be used for four feedback signals and one status signal, for a total of five digital PNP/NPN feedback signals. The selection of PNP or NPN is done by a jumper. Two of the feedback signals can be external sensors if necessary. The status signal is used for detection of the following:

Set-up in progress
Internal error
Required maintenance (based on time and/or the self adjustment program)

The LED lights constantly indicate the status of the unit:

Valve position
Solenoid activated
Setup and local fault indication
Maintenance and seat lift

SET & FORGET

In the past, a control unit had difficulty in maintaining set parameters entered by the user. With ThinkTop, you set it just the one time, and then forget about it. Using a combination of a state-of-the-art, patented sensor system and pre-set tolerance bands, the ThinkTop self-adjusts, eliminating the need for adjustment over time.

SIMPLE INTEGRATION

Most control tops in the industry only offer open and closed signals, while the ThinkTop goes one step further. In addition to open and closed signals, ThinkTop offers two additional internal signals, external signals, or one of each. The accuracy of the sensor system allows ThinkTop to detect the seat-lift motion of a mixproof valve.

MAINTENANCE NOTIFICATION

ThinkTop allows you to set a specific time frame, using 90-day intervals, to indicate when normal valve maintenance is required. When this period of time has expired, ThinkTop will send a signal to the control computer and an orange LED light will light up.

Based on the valve’s movement along the previously set tolerance band, ThinkTop can also detect if any elastomers have worn out before scheduled maintenance. Over time, the valve may move outside the tolerance band into an “alert” band, which is often caused by seal wear. While the system retains its feedback signal and continues to operate, you will be notified that maintenance is necessary. Again, an orange LED light will light up, and a signal will be sent to the control system.

This maintenance notification eliminates valve seal leakage and unnecessary shutdown. Knowing the condition of your valve before it is too late will ultimately improve its overall performance.

FITS ALL VALVES

The ThinkTop control and indication unit can be used on any air-operated, sanitary valve from Alfa Laval, including single-seat, butterfly, and mixproof valves. This means you do not have to worry about attaching ThinkTop to a specific Alfa Laval valve, thus virtually eliminating any room for error. Since one ThinkTop fits all valves, any surplus valve purchased can be used for your other valve applications.

FEATURES

Self-adjusts when installed
Can be set-up without dismantling or readjusting
Fits all air-operated, sanitary valves from Alfa Laval
Includes a wide range of interface modules
Integrated indication of seat-lift
Offers the ability to integrate external signals in the top
Includes maintenance indication integrated in the top
Saves set parameters until reprogrammed, even during power failure

MATERIALS

Plastic Parts	Nylon PA 6, reinforced
Steel Parts	304, 316
Seals	Nitrile (NBR), EPDM rubber for SMP-EC activator stem

TECHNICAL DATA

Sensor Accuracy	± 0.004 inch
Distance to Magnet	0.2 ± 0.12 inch
Stroke Length	0.004 – 3.15 inch
Electrical Connection	Direct cable gland entry (hard wired) PG11 0.15 – 0.39 inch diameter
Power Supply Voltage	8 – 30 VDC
Power Supply Current	Max 45 mA (excluding current to the solenoids, external proximity switches, and the PLC input current)
Protection Class	IP67