Instruction Manual

ThinkTop® D30

2064-0000_1

Patented Sensor System

Registered Design
Registered Trademark

ESE02248-EN5 2017-07
Original manual
 Table of contents

The information herein is correct at the time of issue but may be subject to change without prior notice

1. EC Declaration of Conformity ....................................................................... 4

2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 5

3. General information ................................................................................... 6

3.1. Concept ........................................................................................... 6
3.2. Working principle ................................................................................. 6
3.3. Recycling information ............................................................................. 6

4. Installation .............................................................................................. 7
4.1. Product dimensions .............................................................................. 7
4.2. Compatible actuators ............................................................................ 7
4.3. Installation instructions ........................................................................... 8
4.4. Operating LED feedback ......................................................................... 10

5. Troubleshooting ....................................................................................... 11

6. Technical data ......................................................................................... 12

7. Parts list ................................................................................................ 14

7.1. Parts list ............................................................................................ 14

3
1 EC Declaration of Conformity

Revision of Declaration of Conformity 2013-12-03

The Designated Company

Alfa Laval Kolding A/S

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+45 79 32 22 00
Phone No.

hereby declare that

Top Unit for Valve Control and Indication
Designation

ThinkTop® D30
Type

is in conformity with the following directive with amendments:

- Low Voltage Directive (LVD) 2014/35/EU

- EMC Directive 2014/30/EU
- RoHS2 Directive 2011/65/EU

The person authorised to compile the technical file is the signer of this document

Global Product Quality Manager

Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name

Kolding 2017-03-01
Place Date Signature

4
 2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs. All warnings in the manual are summarised on this page.
Pay special attention to the instructions below so that serious personal injury or damage to the top unit are avoided.

2.1 Important information

Always read the manual before using the ThinkTop!

WARNING
Indicates that special procedures must be followed to avoid serious personal injury.

CAUTION
Indicates that special procedures must be followed to avoid damage to the ThinkTop D30.

NOTE
Indicates important information to simplify or clarify procedures.

2.2 Warning signs

General warning:

Dangerous electrical voltage:

Caustic agents:

2.3 Safety precautions

Installation:

Always read the technical data thoroughly !

Never install the ThinkTop D30 before the valve or relay is in a safe position
If welding close to the ThinkTop D30: Always earth close to the welding area
Disconnect the ThinkTop D30

Always have the ThinkTop D30 electrically connected by authorised personnel

Maintenance:

Always read the technical data thoroughly !

Always fit the seals between the valve and ThinkTop D30 correctly
Never install the ThinkTop D30 before valve or relay is in a safe position
Never service the ThinkTop D30 with the valve/actuator under pressure
Never clean the ThinkTop D30 with high pressure cleaning equipment
Never touch the moving parts if the actuator is supplied with compressed air
Never use cleaning agents that will attack the exterior of the ThinkTop D30. Check with your cleaning agent supplier

Never clean using Alcohol, Acetone, Chloroform, Methanol, Ammonium chloride and Ammonium Hydroxide etc.

5
3 General information

3.1 Concept

The ThinkTop D30 is designed to ensure valve control in a basic market, using Alfa Laval air operated actuators such as
butterfly, single and double-seat valves. it is compatible with all major PLC systems (Programmable Logic Controller) with a
digital PNP interface.

It is for use in food, dairy and brewery installations. ThinkTop D30 is a complementary, alternative solution to the existing
range of control units.

ThinkTop D30 is the first of its kind on the market that focuses on new methods to simplify all aspects of using a basic control
unit to minimise and optimise installations instead of using external solenoid valves

3.2 Working principle

The ThinkTop D30 is an easy-to-use plug ‘n play control unit with integrated intelligence which monitors the status of the operating
air pressure, identifying air leakage or failing air pressure. The integrated solenoid valve allows control of the processing valve.

Mounted on top of the valve, the unit receives signals from a PLC system to control the solenoid valve and it returns the
supervised air pressure signals for valve energised or de-energised feedback to the PLC system. The ThinkTop D30 has a 360
degree visual valve status indicator, which can be seen at a distance and at any angle.

3.3 Recycling information

• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be reused, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
- Metal straps should be sent for material recycling

• Scrapping
- At the end of use, the equipment should be recycled according to relevant, local regulations. In addition to the actual
equipment, any hazardous residues from the process liquid must be considered and disposed of in a proper manner. When
in doubt, or in the absence of local regulations, please contact your local Alfa Laval representative.

6
 4 Installation

4.1 Product dimensions

75 mm

2064-0001_1

Ø 105 mm

4.2 Compatible actuators

SBV Yes
Koltek Yes
LKLA-T Yes
LKLA No
ARC Yes
SRC Yes
SRC long stroke No
i-SSV Yes
Unique SSV Yes
Unique SSV long stroke No
Unique SSV DN125 - DN150 No
SSV DN80 (76.1 mm) High pressure No
SSV DN100 (101.6 mm) High pressure No
SMP valves Yes
Unique Mixproof No
Air/air actuators NO

7
4 Installation

4.3 Installation instructions

Step 1
Place the ThinkTop D30 on top of the actuator.
Ensure that the unit is correctly mounted by pressing down on
top of the ThinkTop D30.
Cross-tighten the two allen screws carefully (1.50 Nm).

When mounting the ThinkTop D30 on a horizontal mounted

actuator make sure that the exhaust port is not pointing upwards.
The exhaust port is marked with "EX.".

2064-0002

Step 2
Connect the air supply to the air-in port (A). A
Connect the air-out port (B) to the actuator.

NOTE!
Option in case of a ¼” air supply hose system.
Connect the air supply hose via an ø6 / ¼” angle adaptor.

The angle adaptor is sold separately:

Article number: 9611-99-5679, ø6 / ¼” angle adaptor.
The angle adaptor is also available as ø6 / ø6: B
Article number: 9611-99-5678, ø6 / ø6 angle adaptor.
2064-0003

Step 3
Remove the top cover by turning the top cover anti-clockwise. C
D
When the mark on the top cover (C) is aligned with the open
padlock symbol (D), the top cover can be lifted off.

2064-0004

8
 4 Installation

Step 4
Install the cable in the cable gland.

NOTE
Cable connection
Cable gland: PG7 (cable dia. ø4.0 - ø6.8 mm)
Recommended conductor
cross section: 0.5 mm2 (AWG 20).

2064-0005_1

If the cable gland comes loose from the control head during
installation, it must be secured with a tightening torque of 1.50 Nm.

To fulfil the UL requirements in UL61010, the unit must be supplied

by an isolating source that complies with the requirements for class
2 power units (UL1310) or class 2 and 3 transformers (UL1585).

Electrical connection
Digital Interface
Sensor board
Terminal strip

GND -
Connection of power supply 24 VDC +
PLC output signal Trigger solenoid T
Alarm A
PLC input signals De-energised D
Energised E

Step 5
Put the top cover back on by pushing it down when the mark on
the top cover (E) and the open padlock (F) are aligned. E
Then turn it clockwise towards the closed padlock (G) to secure
the top cover.
F
G

2064-0007

9
4 Installation

4.4 Operating LED feedback

Actuator status LED feedback

De-energised Green
Energised Yellow
Alarm (Air pressure) Red flashing

10
 5 Troubleshooting

Error scenarios

Condition Possible cause Solution

Red LED flashing. Insufficient air pressure in the actuator. Check the air supply and the air connections on the unit.

11
6 Technical data

Technical data

General
Operating pressure 400 - 700 kPa ( 4-7 bar)
Supply air quality Class 3 ISO 8573-1
Push-in fittings ø6 mm tube
Ambient temperature (operating) -10°C to +50°C
Storage temperature (non operating) -15°C to +60°C
Protection class IP66 and IP67 IEC 60529
Approvals

UL listed Rated: 24V, 39mA UL 61010

Class 2 input
CSA listed Environment type 1 C22.2 No. 61010

Communication
Interface Digital - PNP EN61131-2
Supply voltage 24 VDC ± 10%
Current consumption - solenoid active 39 mA
Current consumption - solenoid inactive 28 mA
Short circuit and brownout protection Yes EN61131-2
Solenoid valve
Type of solenoid 3/2 NC
Number of solenoids 1
Manual override Yes (Non-locking)
Actuation flow (at 6 bar) 160 l/min
Exhaust flow (at 6 bar) 140 l/min
Physical data
Materials
Body Black nylon PA 6 (reinforced)
Light guide Transparent polyamide
Seals Nitrile (NBR)
Cable connection
Cable gland PG7 (cable range ø4.0 - ø6.8 mm)
Recommended conductor cross section 0.5 mm2 (AWG20)
Terminal block connection data
Conductor cross section min. 0.5 mm2 (AWG20)
Conductor cross section max. 1.5 mm2 (AWG16)

12
.

13
7 Parts list

7.1 Parts list

13

11
12.1

11

12.1

14
2064-0008_1

14
 7 Parts list

Parts list
Pos. Qty Denomination
A Top incl. prism and O-rings
2 1 O-ring
11 2 Allen screw
12.1 1 Air fitting
13 1 Cable gland PG7
14 1 X-ring

15
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 directly.

© Alfa Laval Corporate AB

This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this
document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any
form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB
will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.