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To monitor and control an efficient flow system, ABS offers a full range of accurate valve automation solutions from Alfa Laval. Alfa Laval’s automation systems provide reliable status feedback at all times, and are easy to both set-up and operate.

Add automation and visibility to your actuated valves with controls and indication from ABS!

 

Alfa Laval Valves: Sampling Valves, Shutter Valves, Ball Valves, Regulating Valves, Seat Valves, Mixproof Valves, Diaphragm Valves, Check Valves, Butterfly Valves

DescriptionFeaturesHow It WorksModelsDocumentation

Indication Units

Alfa Laval’s laterally mounted indication units are a simple option for providing valve position indication for Alfa Laval LKB/LKLA, SRC, ARC and ARC-SB air operated valves. These indication units are installed laterally between the air operated actuator and the valve.

All switches are EMC approved according to the following standards:

  • EN 50081-1, Generic emission standard, commercial and light industry
  • EN 50082-2, Generic immunity standard, industrial environment
  • PR EN 60947-5-2, Product family standard, proximity switches
  • KA 2791.30 section 5.5 EMC, Tetra Pak Corporate standard

Models:

  • Micro Switch
  • Inductive Proximity Switch
  • Hall Proximity Switch

 

Related Industries:

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

Safe, reliable and economical Valve Position Indicators

Alfa Laval indication units are cost-effective digital devices with up to two feedback signals that are mounted directly on the valve yoke, which provide feedback on the valve’s open/closed position. These valve position indicators (Side indicater and brackets) may be used on any Alfa Laval valve, but are especially competitive solutions for Alfa Laval SRC/ARC Single seat valves,and mixproof valves (brackets), and butterfly valves.

Four types of valve indications

Alfa Laval offers these standard valve position indicators for hygienic industries:

Micro-switch

This lightweight, electromechanical device offers precision operation and long service life. Hermetically sealed within a corrosion-resistant housing, the micro-switch provides high durability and may be directly manipulated, which means only limited operational safety can be provided compared to newer, more advanced technologies.

Inductive proximity sensor

Based on principles of electromagnetic conductivity and metallic detection, this non-contact electronic sensor is inherently resistant to dust, humidity and oil in industrial environments. This increases operational safety and reliability.

Hall proximity sensor

Based on principles of electromagnetic conductivity and magnetic detection, this non-contact electronic sensor provides safe and accurate detection of valve position compared to conventional proximity sensors. It provides enhanced reliability and longer service life for valve position sensing in any operating environment.

Namur sensor

This inductive proximity sensor, complete with bracket for butterfly valves, requires minimal energy to operate. It is an ATEX-certified device designed for intrinsically safe applications and may be used in hazardous and potentially explosive environments.

Individual brackets and inductive sensors

Alfa Laval offers an extensive portfolio of brackets and inductive sensors for use with any Alfa Laval valve that requires special support or an alternate sensing interface.

Operating principles

Micro-switch

Mechanically activated by a roller leaf, this electromechanical device requires physical contact to engage and sends an electrical signal to indicate valve positions as an on/off digital signal. The Micro-switch is distinguished from other sensor principles because the electrical circuit can operate at higher voltages that exceed 24VDC, or work with AC alternating voltages.

Inductive proximity sensor

This non-contact proximity sensor consists of an oscillator, which creates high-frequency electromagnetic fields that radiate from the sensing face. Each time a conductive metal (damping target) approaches the sensor, it reduces the electromagnetic field, thus changing the voltage of the oscillator. A trigger circuit converts this analog signal into an on/off digital signal and amplifies the output to 24VDC.

Hall proximity sensor

This non-contact proximity sensor consists of a Hall transistor, convert this Hall sensing into an on/off digital signal and amplifies  the output to 24VDC . The sensor indicates the valve position by using a magnetic field (North Pole) to measure the distance from the relative position of the  indication pin on the valve stem.

Namur sensor

NAMUR is most associated with two wire DC proximity sensors. Such sensors must be wired to isolator barriers or intrinsically safe devices in order to be used in hazardous environments. The NAMUR proximity sensor’s operation is similar to that of a variable resistor. As a metal target approaches the face of the NAMUR sensor, a change in impedance in the sensor occurs and, therefore, the current draw of the sensor is reduced. This triggers the galvanic isolator’s amplifier, which activates the isolator’s switch and thereby into an on/off digital output signal to the PLC system.

Options

Sensors with and without fixed cable and side indicators with M12, 5-pin plug connectors, including the plug counterpart, are available for connection to AC/DC power supply.

Alfa Laval ball valve with ergonomic handle for smooth control and reliable operation in fluid systems.

 

Sanitary Ball valve with handle and bracket for inductive proximity switches

Accurate Valve Sensing Models

Micro Switch

A micro switch can be compared with a standard light switch, but in a very small size and light weight, also called a sub-miniature switch. It is activated mechanically by a roller leaf. The standard function is normally open (NO) or normally closed (NC) and is always a digital signal (on/off).

The features of an environment-proof, sealed sub-miniature switch are:

  • Small size
  • Light weight
  • Ample electrical capacity
  • Precision operation
  • Long life

The micro switch used in indication units is enclosed within a corrosion-resistant aluminum housing to seal the switch contact and terminals against contamination.

Inductive Proximity Switch

This type of switch is a non-contact, electronic switch. It consists of an oscillator, which creates high frequency electromagnetic fields that radiate from the sensing face of the switch. Every approaching conductive metal (damping target) causes a reduction of the electromagnetic field. The result is a voltage change of the oscillator. This analogue signal is converted by a trigger circuit into an on/off signal and the output is amplified.

Hall Proximity Switch

Hall proximity switches are also non-contact, electronic switching elements. The sensor registers a magnetic field (north pole) and consists of a Hall element (a type of a transistor) matching part, an amplifier, and an output part. The output signal is always digital and on/off. The switching frequency is higher than the normal inductive switch or the micro switch. The Hall proximity switch is ideal for modern computer processing. NPN and PNP are two types of transistors; the difference is the composition of positive or negative semiconductive materials.

Alfa Laval Indication Units for LKBLKLA – Inductive – Product Leaflet.pdf2 
Alfa Laval Indication Units for LKBLKLA – Micro switch – Product Leaflet – ESE01257.pdf 
LKB-LKLA ø85 (Micro Switch Unit) – Installation Instruction.pdf 
Mounting Instructions – Indication unit LKLA ø133, PNP, 9611-99-5747_AL.pdf2 
Mounting Instructions – Indication unit LKLA ø133, PNP, 9611-99-5748_STD.pdf 
Mounting Instructions – Indication unit LKLA ø85, PNP, 9611-99-5749_AL.pdf 
Mounting Instructions – Indication unit LKLA ø85, PNP, 9611-99-5750_STD.pdf 
Mounting Instructions – Indication unit LKLA ø85, NPN, 9611-99-5751_AL 

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DescriptionFeaturesHow It WorksDetailsDocumentation

IndiTop Valve Position Indicator

The IndiTop® is a simple indication unit used in conjunction with all kinds of pneumatic processing valves. It is used to provide indication of the valve’s position by means of an electronic signal. Mounted on top of the valve, the IndiTop senses the valve’s position and sends feedback signals to the PLC to indicate whether the valve is open, closed, or outside of those two set positions.

IndiTop is a great choice when feedback is all you need. Its simple, enclosed design provides reliable feedback with minimal maintenance and installation requirements.

Related Industries:

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

Accurate Alfa Laval Set-and-forget sensor system

For straightforward real-time monitoring, the IndiTop provides accurate visual indication of valve position and status as well as power-supply status through the use of light-emitting diodes. Its universal fit makes it a natural choice for valve indication of any Alfa Laval air-actuated sanitary valve.

With its streamlined, low-maintenance design, IndiTop is ideal for use in new and existing plants. IndiTop does not use any solenoid valves, but relies on the use of basic  indication signals. Compatibility with all major PLC system having a digital PNP/NPN interface.

Valve cluster illustration caption: Combining the use of automated ThinkTop control heads and IndiTop valve position indicators provides a smart solution for cost-effective control of your plant.

Effective valve indicator

Reliable valve indication based on proven ThinkTop design contribute to process safety:

  • No-touch, set-and-forget sensor system.Detects both the condition and position of the valve stem with an accuracy of ± 1 mm. Set-up parameters are stored but, for greater flexibility and ease of operation, can easily be re-programmed.
  • Pre-set tolerance band. No manual adjustment of feedback sensors is required. Valve tolerance bands with preconfigured default setting of ±5mm ensure operational reliability on any Alfa Laval sanitary valve.
  • Two PNP/NPN feedback signals offer basic functionality to indicate energized and de-energized main valve positions. The PNP/NPN interface are selected by connecting one appointed wire to either the plus or minus terminal.

Sturdy and durable

With its hardy hygienic design, IndiTop ensures the effects of physical impact, pollution, frost, UV radiation and temperatures up to 80°C while supporting continuous production.

Completely watertight and IP66/IP67-compliant, IndiTop prevents water condensation and the penetration of dust, water and other particles into the unit. The unit can 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.

Construction

IndiTop consists of a valve indication housing, proven no-touch, set-and-forget sensor system with light-emitting diodes (LEDs) and valve control sensor board for connection to the PLC (Programming Logic Controller) system.

Operating principle

The sensor system calculates the angle between the axial magnetic field produced by an indication pin mounted on the valve stem. This provides indication with an accuracy of ± 1mm of the position of the valve at any given time through the use of microchip sensors.

The IndiTop unit transmits status and condition to any PLC system using one of two DC/AC or PNP/NPN digital feedback signals. LEDs display the current main valve position and on/off power status at all times.

Options

Three versions based on fixed cable lengths are available for connection: 5 m, 10 m or 0.5 m with an M12, 5-pin stainless steel plug connector including the plug counterpart.

Ease of installation

Installation is straightforward; no special expertise, adapters or tools are required. IndiTop fits onto all Alfa Laval sanitary actuators equipped with mushrooms. Simply press a five-button startup sequence to initiate foolproof manual setup. Or facilitate setup using the optional remote control wire function in combination with the PLC system. No dismantling is required.

Applications

Compatible with all major PLC (programmable logic controller) compatible valve control sensors digital input cards, the IndiTop is ideal for use in food, dairy, and brewery installations as well as biopharmaceutical applications.

Working Principle

Alfa Laval Set-and-forget sensor system utilizes a magnet (supplied with the unit), which is threaded onto the valve stem. The magnet’s target sensor is integrated into the IndiTop unit. This unique no-touch system eliminates the need for mechanical adjustments, as no mechanical switches are used.

The unit is mounted while its target is threaded onto the valve actuator “mushrooms” with two Allen screws on the valve stem. Once set up—either by the quick and easy 5-push setup or remotely from the PLC—the unit will be able to send feedback about the valve position through a fixed cable. This process establishes the “open” and “closed” positions of the valve with an accuracy of ± 0.04 inches.

Key Features

  • Works with both DC and AC supply voltage (8-30V DC/AC)
  • Two PNP/NPN digital DC/AC feedback signals
  • Quick and easy 5-push setup through push-buttons
  • Remote setup from the PLC
  • Keeps the setup during power outages
  • Visual indication through LEDs
  • 16 foot fixed cable
  • No mechanical adjustments
  • ± 0.2 inch tolerance for saved positions

Feedback Signals

IndiTop is capable of providing two PNP/NPN digital feedback signals in both DC and AC. Selection of PNP or NPN is done by wiring. Visual indication through LEDs constantly display the current valve position and power (ON/OFF).

Materials

Plastic Parts Nylon PA 6 and POM
Rubber Parts SEBS
Metal Parts Stainless steel DIN 914 A2 brass

Technical Data

Sensor Accuracy ± 0.04 inch
Distance to Magnet 0.2 ± 0.12 inch
Stroke Length 0.24 – 3.17 inch
Power Supply Voltage 8 – 30 VDC/AC
Power Supply Current* Max 45 mA
Electrical Interface 5m 0.2 inch ø fixed PVC cable with (6) 26 AWG conductors
Protection Class IP66/67

 

*The initial current during power-on is higher. The actual shape of the current pulse depends on the power supply used. Typical values are 150 mA 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).

Alfa Laval IndiTop Product Leaflet ESE00182EN.pdf 
IndiTop Declaration of Conformity ESE02248EN.pdf  
IndiTop Installation Instructions ESE00163EN.pdf

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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.

ThinkTop AS Interface

AS-Interface
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

Instruction Manual ThinkTop Basic Digital 10 – 30 VDC PNP-NPN –

EN Instruction Manual – ThinkTop® Digital 8 – 30 VDC PNP NPN –

EN Instruction Manual – ThinkTop® DeviceNet TM 11-25 VDC –

EN Instruction Manual – ThinkTop® AS-Interface v.2.1 (31 nodes) v.3.0 (62 nodes) 29.5 – 31.6 VDC – EN

Setup – ThinkTop setup utilising IR keypad.pdf 
Setup – ThinkTop setup utilising local I and II keys.pdf 
ThinkTop Digital, AS-Interface and DeviceNet – Instruction Manual – ESE02952EN.pdf 
DescriptionFeaturesHow It WorksLiterature

ThinkTop® Basic

ThinkTop Basic offers simplicity of operation, standard functionality and reliable, cost-effective operation for general applications in the dairy, food and beverage, and biopharm industries.

Related Industries:

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

The Standard Valve Control

ThinkTop Basic combines Alfa Laval quality with standard functionality for automated sensing and control of sanitary valves. Like the premium ThinkTop unit, ThinkTop Basic offers a durable watertight design, a proven and inherently safe design and low total cost of ownership. Simplicity of operation, however, is the main focus for ThinkTop Basic so this valve sensing and control head is optimized with fewer options and fewer digital connections. ThinkTop Basic is available in Digital, AS-Interface and ATEX versions.

Tough and effective Hygienic Valve Sensing

The reliable and automated design of the ThinkTop Basic contributes 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.
  • Pre-set tolerance band. No manual adjustment of the feedback sensors is required. Valve tolerance bands with a preconfigured default setting of ±5mm for the set-up parameters ensure operational reliability on any Alfa Laval sanitary air-operated valve.
  • Two PNP/NPN feedback signals controlled by a jumper on the sensor board offer basic indication functionality for energized and de-energized main valve positions.

Sturdy and durable

Engineered for operation in virtually any environment, ThinkTop Basic 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 while supporting continuous production.

Completely watertight and IP66/IP67-compliant, ThinkTop Basic 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.

ATEX-certified valve control

For use in potentially explosive environments, there’s ThinkTop Basic Intrinsically Safe (IS) equipped with ATEX-compliant solenoid valves and feedback sensors. Durable, accurate and easy to install, ThinkTop Basic IS complies with the ATEX equipment Directive 94/9/EC, Group II, Categories 2 Gas and dust.

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 Basic 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 Basic 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

The sensor system accurately detects valve stem movement, the position of the valve 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 energize or de-energize the air-operated valve. It then transmits feedback signals indicating the main valve position and condition back to the PLC system.

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

Each control head fits any Alfa Laval sanitary valve and has a valve tolerance band with a default tolerance. This boosts eliminates the need to re-adjust the sensors, boosts productivity and effectively prevents operating errors.

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

Integrated communications

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

• Digital interfaces
• AS-Interface (with 62 nodes)

Ease of installation

ThinkTop Basic fits onto all Alfa Laval sanitary actuators equipped with mushrooms. Installation is straightforward; no special expertise, adapters or tools are required. Simply press a five-button startup sequence to initiate foolproof manual setup.

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DescriptionFeaturesHow It Works

ThinkTop D30 Valve Control Unit

Compact and intelligent, ThinkTop® D30 is an easy-to-install integrated control unit for hygienic applications. It is a cost-effective alternative for use where space is limited and operational simplicity and reliability is important.

Related Industries:

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

 

Compact, easy-to-install valve control

Installation and commissioning is quick and easy due to few termination points. With its compact 75mm-high, 105mm-in-diameter profile, the ThinkTop D30 Compact valve control unit easily fits into most installations, and its 60mm stroke length fits most actuators. This cuts both the time and costs associated with valve control for hygienic installations as well as installation using bracket, inductive sensors and external solenoid valves.

Simply position the unit directly on top of the valve actuator, connect the air and then connect the cable to the PLC system. No special expertise, adapters or tools is required. The pre-set tolerance band eliminates the need to adjust the feedback position at regular intervals.

Reliable and hygienic valve control

The ThinkTop D30 withstands the effects of physical impact, vibration, water hammer, thermal variation and pressure shock. Because it is watertight and IP66- and IP67-compliant, the ThinkTop D30 prevents 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 affecting the preconfigured settings. This contributes to maximum hygiene and effectively eliminates problems associated with corrosion and external contamination.

The control head can therefore be hosed down with water or cleaning fluid without affecting the preconfigured settings. This contributes to maximum hygiene and effectively eliminates problems associated with corrosion and external contamination.

Construction

The ThinkTop D30 is a basic valve control unit that consists of a proven no-touch sensor system with 360-degree LED visual status indicator, an integrated 3/2-way solenoid valve for spring-loaded actuator, and valve control sensor board for connection to any PLC (Programming Logic Controller) system.

Operating principle

Installed directly onto the top of the valve actuator, the ThinkTop D30 Compact valve control unit is an easy-to-use valve control unit with integrated intelligence to monitor the status of the operating air pressure, identifying air loss or leakage. The integrated solenoid valve enables control of the processing valve.

The ThinkTop D30 receives signals from a PLC system to control the solenoid valve and transmits air pressure signals to the PLC system indicating whether the valve actuator is energized and de-energized or if an air pressure alarm occurs. ThinkTop D30 has a 360-degree visual status indicator, which can be seen at a distance and at any angle.

Integrated communications made easy

The ThinkTop D30 provides communications with any PLC system using two feedback signals, one air surveillance signal and one solenoid valve signal with any of the 24 VDC digital interfaces available.

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IntroductionFeaturesHow It WorksDocumentation

The ThinkTop V20 valve indication unit by Alfa Laval provides real-time valve status monitoring for efficient process control, enhancing productivity.ThinkTop V20

The Alfa Laval ThinkTop V20 is an intelligent valve control unit that optimizes the performance and efficiency of fluid handling systems in industries that demand high hygienic standards. With cutting-edge technology and a focus on reliability, the V20 is engineered for precise automation in sectors such as food and beverage, dairy, and pharmaceuticals. This versatile control unit ensures accurate valve operation, reduces downtime, and simplifies valve monitoring, making it an indispensable tool for enhancing process efficiency and reducing operational costs in complex industrial systems.

 

 

  • 360° LED Indicator: One of the standout features of the ThinkTop V20 is the 360° LED visual status indicator. This gives operators a clear view of the valve’s status from any angle, even in difficult-to-reach or busy environments. It enhances operational efficiency by allowing personnel to quickly assess the operational state of the valve at a glance, reducing the risk of overlooking important information.
  • Integrated Position Sensors: The V20 integrates high-precision position sensors that provide real-time feedback on the valve’s status. This feedback ensures optimal valve control and minimizes operational errors, helping ensure process stability in industries where accuracy is crucial, such as in pharmaceuticals or dairy.
  • IP66/67 Protection: Built to endure harsh environmental conditions, the ThinkTop V20 features IP66/67 ingress protection, making it resistant to both dust and water. This makes the unit ideal for installation in washdown zones or areas where high levels of hygiene and durability are required.
  • Plug-and-Play Installation: The V20 is designed for quick and simple installation. The plug-and-play setup means minimal downtime during commissioning, ensuring that you can integrate it into your existing system without complications.
  • Low Power Consumption: Designed with energy efficiency in mind, the ThinkTop V20 operates with minimal power consumption. This contributes to operational cost savings and aligns with sustainability goals, making it an excellent choice for companies looking to optimize both performance and energy use.
  • Advanced Diagnostics and Maintenance Alerts: The ThinkTop V20 includes built-in diagnostic capabilities that provide valuable insights into the performance of the valve control system. These diagnostics allow operators to perform preventive maintenance, reducing unplanned downtime and minimizing maintenance costs. With real-time alerts for valve performance anomalies, it ensures issues are addressed promptly.

The ThinkTop V20 functions as the nerve center for controlling valve operations in automated systems. It integrates seamlessly into fluid handling systems, with its position sensors continuously monitoring valve position and sending feedback to the control system. The system adapts in real-time, ensuring valves are always positioned optimally for the current process requirements.
The 360° LED indicator continuously displays the valve’s status, with color-coded lights providing immediate visual feedback. The unit’s advanced diagnostic tools monitor system health and identify issues such as valve misalignment, wear, or other operational inefficiencies. When maintenance is required, the V20 alerts operators, ensuring that issues are addressed before they escalate, ultimately reducing downtime.
The ThinkTop V20 operates in a variety of conditions, from low-temperature environments to areas exposed to frequent cleaning cycles. Its plug-and-play installation ensures easy setup without complex integration, allowing for faster commissioning of automated systems.

Why Choose ThinkTop V20?

The Alfa Laval ThinkTop V20 brings multiple advantages to modern fluid handling systems. With its combination of advanced diagnostics, precise control, and high durability, the V20 reduces operational errors and enhances system performance. Its hygienic design, coupled with energy-efficient operation, ensures that it meets the stringent requirements of industries where cleanliness, reliability, and efficiency are paramount. Whether used for cleaning-in-place (CIP) applications or for direct valve control, the V20 is engineered to meet the demands of the most challenging environments.

By incorporating the ThinkTop V20, companies can expect improved system uptime, easier maintenance routines, and increased overall productivity. Its user-friendly interface and advanced features make it an ideal choice for anyone looking to optimize valve automation in the most demanding applications.

 

Alfa Laval ThinkTop V20 Product Leaflet

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IntroductionFeaturesDocumentation

ThinkTop V55 – A sensing and control unit for diaphragm valves, offering smarter automation solutions in pharmaceutical and biotech industries.

ThinkTop V55

The Alfa Laval ThinkTop V55 revolutionizes the sensing and control of diaphragm valves due to its exceptional accuracy, efficiency, and user-friendliness. The pharmaceutical, food and beverage, and other industries hold it to high standards. Sensing and control unit diaphragm valves offer both excellent performance and are simple to use. It stands out due to its plug-and-play installation process and its real-time diagnostic capabilities. Power users of the pharmaceutical, biotech and beverage manufacturing industries need to get this update.

 

 

Diaphragm Valve Control Unit Features

  • Optimizes valve control for increased uptime.
  • Simplifies setup and replacement for efficient production.
  • Fits into tight spaces for maximum plant efficiency.
  • Provides real-time monitoring and control via digital, ASI, and Industry 4.0-based IO-Link platforms.
  • Self-diagnostic technology prevents unplanned downtime.
  • Employs innovative sensor technology for real-time valve monitoring.
  • The system accurately pinpoints the operational conditions and the location of the valves.
  • It employs advanced algorithms to provide feedback and expedite diagnosis.
  • The system carries out instructions to ensure precise valve functioning.
  • The system continuously provides feedback to enhance operating efficiency and ensure optimal uptime.

Alfa Laval ThinkTop V55 Product Catalogue

Alfa Laval ThinkTop V55 Automation Accessories 

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DescriptionFeaturesHow It WorksDocumentation

Unique Control for LKB Butterfly valves 

The Unique Control LKB automation unit with built-in actuator offers intelligent control for LKB butterfly valves used in all applications. This straightforward all-in-one actuator offers superior flow control, hygiene, durability and reliability.

Related Industries:

Agriculture Processing, Processed Foods, Home and Personal care

Intelligent reliability and control for butterfly valves

The Alfa Laval Unique Control LKB is an integrated valve control unit and actuator with an enhanced hygienic one-piece design. Tested to over a million strokes without service, Unique Control LKB is the most durable actuator available today. Its well-built design with tough composite casing withstands most harsh environments.

IP66/IP67-approved, the Unique Control LKB features superior technology, shape and material, which prevent condensation and the penetration of dust, water and other particles into the unit. This contributes to maximum hygiene and effectively eliminates problems associated with corrosion, external contamination and the effects of physical impact, including vibration, pressure shock, frost, heat, UV radiation and environments polluted with grease, oil and chemicals, without disrupting production.

In addition, the Unique Control LKB provides integrated automation with a clear 360° visible indication and an air surveillance system for reliable real-time monitoring of the operating air pressure. Instead of being controlled by a conventional mechanical spring like most butterfly valve actuators, an air spring controls the actuator of the Unique Control LKB. This, combined with the intelligent capabilities of the sensing and control unit, enables operation at a lower air pressure and delivers significant benefits in terms of durability, reliability and more system uptime.

Simplified setup for butterfly valve control

Push n’ Play self-configuration gets the Unique Control LKB up and running five times faster than conventional solutions. Simply press one button and the Unique Control, which is compatible with both digital and AS interfaces, configures and calibrates itself to ensure the best possible mode of operation. This convenient one-button process saves time and money.

One size actuator fits all LKB butterfly valves

For ultimate convenience, a single actuator is suitable for most valve solutions thanks to the high torque, which enables the unit to fit any valve size. In addition, it is easy to switch from normally open (NO) to normally closed (NC) and vice versa onsite. This one-size-fits-every-valve design makes engineering, ordering, installation, onsite configuration and stock keeping easy.

Easy upgrade for butterfly valve actuators

The Unique Control fits all manual and actuated butterfly valves in the Alfa Laval LKB range. Existing installations are easy to upgrade to Unique Control LKB; all that is required is a new bracket. Simply order the optional bracket kit for that particular LKB valve size in order to mount the Unique Control unit easily onto any of the 1” to 4” and DN25 – DN100 valves in the LKB valve range.

Valve control and automation range

The Unique Control LKB offers intelligent automation and control of Alfa Laval LKB butterfly valves and complements our broad range of valve control and automation solutions.

Operating principle

The Unique Control LKB uses an air spring, which enables the unit to be operated at a significantly lower air pressure compared to control units using a conventional mechanical spring. This reduces wear thereby eliminating the need for maintenance.

When air enters the Unique Control LKB, the built-in solenoid valve diverts the flow either above or below the piston. The helix inside the piston transfers the vertical movement into a rotation ensuring smooth valve operation. The design enables the Unique Control LKB to operate at an air pressure of only 3 bar.

Integrated air surveillance system

A built-in pressure sensor monitors the air supply. In the event of a critical drop in air pressure, the actuator sends a warning signal, but continues to operate. In the event that the supply of air is cut off, the actuator also sends a warning signal, maintains its position and continues to operate after resolving the problem.

Switching from NC to NO

Changing the normally closed contact to normally open position is easy. Simply open the top cover, loosen the screws, lift up and rotate the top 180°, then re-assemble it.

Options

Communication interface: AS-interface v.2.1, 31 nodes; AS-interface v.3.0, 62 nodes; and digital interface.

Bracket kit: 1″ to 4″ and DN 25 – DN 100:

Bracket sizes: DN25-50, DN65, DN80 and DN100

PD Sheet – Unique Control LKB – EN

Instruction Manual – Unique Control for Butterfly Valves – EN

DescriptionDetails

TRI-CLOVER® GREEN TOP CONTROL AND INDICATION UNIT

ABS provides the Tri-Clover® Green Top control and indication housing unit from Alfa Laval for use with LKB butterfly valves or Tri-Clover 700 series valves. This robust module utilizes a combination of switches and/or solenoids to provide the valve control and position indication suited to your application.

The control module is designed for quick assembly and disassembly, and its durable construction means it can stand up to even the most punishing environments. The Green Top can accommodate normally open or normally closed valves, and it is compatible with either long-stroke or short-stroke actuators. It also meets the NEMA 4 rating against leakage.

Related Industries:

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

WORKING PRINCIPLE

The top is fitted on the valve actuator in place of the visual position indicator. An extension attached to the actuator piston moves up and down with the valve movement. This movement is then detected by the position sensors, and a digital signal is sent back to the PLC control system. When used, a pneumatic solenoid allows for valve control via an electronic signal.

STANDARD DESIGN

It can be mounted at either end of the actuator to accommodate normally open (NO) or normally closed (NC) valves, with no internal modifications to the actuator assembly needed. It is also compatible with either long-stroke or short-stroke actuators.

Constructed from durable, glass-reinforced Nylon 12, the control housing is manufactured to stand up to the most punishing environments. It meets the NEMA 4 rating against leakage. Specially molded gaskets guard against leakage and breakdown, so the housing can be installed in any position.

Additional application versatility can be achieved by specifying a solenoid in the control housing. This transforms the valve into a solenoid-operated air valve with integral flow control. The module will then provide valve position feedback through your choice of mechanical switches or proximity switches.

ENCLOSURE RATING

NEMA Type 4 enclosures are intended for indoor or outdoor use to protect the enclosed equipment against splashing water, water seepage, falling or hose-directed water, and severe external condensation.

OPTIONS

TECHNICAL DATA
Mechanical Switch Proximity Sensor*
Description SPDT
3 amps/125 or 250VAC**
½ amp, 125VDC
¼ amp, 250VDC		 2 wire, normally open
20-140VAC, 50-60 Hz
10-140VDC 200mA (max load current)
.8mA (leakage current)
Pressure Range 0 – 120 psig*** 0 – 120 psig***
Fluids Air or inert gas Air or inert gas
Lubrication Not required Not required
AC 110/60 5.4 watts 5.4 watts
AC 24/60 7.4 watts 7.4 watts
DC 24 4.2 watts 4.2 watts
Coil General purpose class A, continuous duty General purpose class A, continuous duty

*Other sensor types available, contact CSI for details.
** 3 amps/125Vac max due to 20 gauge wiring.
*** Supply pressure to any valve/actuator should not exceed 80 psig.