Instruction Manual

ThinkTop® Digital, AS-Interface and DeviceNet

Patented Sensor System

Registered Design
Registered Trademark

ESE02952-EN3 2022-10
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. Declarations of Conformity ................................................................. 4

2. Safety .......................................................................................... 6
2.1. Important information ............................................................................. 6
2.2. Warning signs ..................................................................................... 6
2.3. Safety precautions ................................................................................ 6

3. General information ......................................................................... 7

3.1. ThinkTop at a glance ............................................................................. 7
3.2. Recycling information ............................................................................. 7

4. Technical specifications ..................................................................... 8

4.1. ThinkTop common specifications ............................................................... 8
4.2. ThinkTop Digital ................................................................................... 10
4.3. ThinkTop, AS-Interface ........................................................................... 11
4.4. ThinkTop DeviceNet .............................................................................. 13

5. Installation .................................................................................... 16
5.1. Installation on air actuators ...................................................................... 16
5.2. Installation on Series 700 valves ................................................................ 19
5.3. Air connections ................................................................................... 21
5.4. Electrical connection, internal - Digital 24 VDC ................................................ 22
5.5. Example of using common power supply ...................................................... 22
5.6. Electrical connection, internal - AS-Interface ................................................... 23
5.7. Electrical connection, internal - DeviceNet ..................................................... 24

6. Setup diagram ................................................................................ 25

6.1. ThinkTop setup- utilising local 'I' and 'II' keys .................................................. 25
6.2. ThinkTop setup- utilising IR keypad ............................................................. 28
6.3. ThinkTop quick setup guide ..................................................................... 30

7. Fault finding .................................................................................. 32

7.1. Fault finding and LEDs ........................................................................... 32

8. Maintenance .................................................................................. 34
8.1. Dismantling ThinkTop ............................................................................. 34
8.2. Assembly of ThinkTop ............................................................................ 35
8.3. Dismantling and assembling Series 700 valves ................................................ 37

9. Parts list ....................................................................................... 39

9.1. Diagrams for ThinkTop ........................................................................... 39
9.2. ThinkTop ........................................................................................... 40
9.3. Diagrams for ThinkTop: Series 700 ............................................................. 43
9.4. ThinkTop: Series 700 ............................................................................. 44

3
1 Declarations of Conformity

EU Declaration of Conformity

The Designated Company

Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00
Company name, address and phone number

Hereby declare that

Top Unit for Valve Control and Indication

Designation

ThinkTop® Basic Digital 10 - 30 VDC

Type

is in conformity with the following directives with amendments:

- EMC Directive 2014/30/EU
- RoHS Directive 2011/65/EU and amendments

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

Global Product Quality Manager Lars Kruse Andersen

Title Name

Kolding, Denmark 2022–10–01

Place Date (YYYY-MM-DD) Signature

This Declaration of Conformity replaces Declaration of Conformity dated 2017-03-01

4
 1 Declarations of Conformity

UK Declaration of Conformity

The Designated Company

Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00
Company name, address and phone number

Hereby declare that

Top Unit for Valve Control and Indication

Designation

ThinkTop® Basic Digital 10 - 30 VDC

Type

is in conformity with the following directives with amendments:

- The Electromagnetic Compatibility Regulations 2016
- The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012

Signed on behalf of: Alfa Laval Kolding A/S

Global Product Quality Manager Lars Kruse Andersen

Title Name

Kolding, Denmark 2022–10–01

Place Date (YYYY-MM-DD) Signature

DoC Revison_01_102022

5
2 Safety
This manual highlights 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 in order to avoid severe personal injury or damage to the top unit are avoided.

2.1 Important information

beforee using the top unit!
Always read the manual befor

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.

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 carefully

Never install the ThinkTop before the valve or relay are in a safe position
If welding close to the ThinkTop: Always perform earthing close to the welding area
Disconnect the ThinkTop.

Always ensure the ThinkTop electrically connected by authorised personnel

Maintenance:

Always read the technical data carefully

Always fit the seals between the valve and ThinkTop correctly
Never service the ThinkTop before the valve or relay are in a safe position
Never service the ThinkTop when the valve/actuator under pressure
Never clean the ThinkTop using high pressure cleaning equipment
Never use cleaning agents that will erode the exterior of the ThinkTop. Check with your cleaning agent supplier

6
 3 General information

3.1 ThinkTop at a glance

The ThinkTop is designed to ensure optimum and reliable valve control in conjunction with Alfa Laval valves and is compatible
with most PLC systems (Programmable Logic Controllers).

The ThinkTop can be equipped with 0-3 solenoid valves. The solenoids are electrically controlled by the PLC system and, when
activated, the compressed air is activating the air actuator. Depending on the type of control unit, the primary solenoid valve can
be provided with a built-in throttle function on both the air inlet and outlet, which means that it is possible to control the opening
and closing time of the air actuator. The solenoids are also equipped with a manual hold override.

Visual LED lights constantly indicate the distinct status of the control unit: such as valve positions, solenoid valve energised,
setup and local fault indication etc.

The ThinkTop is characterised by its high durability, well-proven features and modular design. It is exchangeable and is ready to
fit Alfa Laval Sanitary actuators from the past and present.

3.2 Recycling information

• Unpacking
- Packing material consists of wood, plastics, cardboard boxes
- 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

• Maintenance
- All metal parts should be sent for material recycling
- Worn or defective electronic parts should be sent to a licensed handler for material recycling
- All non-metal wear parts must be handled in compliance with local regulations

• Scrapping
- End-of-life, the equipment shall be recycled according to relevant, local regulations. In addition to the equipment itself, any
hazardous residue from the process liquid must be taken into account and handled in the necessary way. When in doubt, or
in the absence of local regulations, please contact the local Alfa Laval sales company

7
4 Technical specifications

4.1 ThinkTop common specifications

Sensor System
Unique “No Touch” sensor system with no mechanical sensor adjustments. A magnet (indication pin) is mounted on the valve
stem and the translatory change in the magnetic field vectors are detected by the sensor board with a measuring accuracy
of ± 0.1mm.

Electrical connection:
Direct main cable gland entry (hard wired) PG11 (ø4 - ø10 mm).

Option: external sensor cable gland entry PG7 (ø3 - ø6.5 mm).

Option for AS-i version: Main connection as M12 plug, 2 wire.

The terminal row of the sensor unit is equipped with screw terminals for both internal and external cables and wires. The
terminals are suitable for wires up to 0.75 mm2 (AWG 19).
Exter nal sensors
The external sensors are used for seat-lift supervision when seat-lift can not be internally detected. The sensors obtain 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).

Note! If using an external sensor, the sensor must be active/activated when performing a setup routine of the control head.
Supply voltage. . . . . . . . . . . . . . . . . . . . . . . Must match the selected type of ThinkTop.
Supply current: . . . . . . . . . . . . . . . . . . . . . . Max. 15 mA per sensor.
Type of sensor: . . . . . . . . . . . . . . . . . . . . . . VDC, only 3-wire sensor PNP.
Sensor cable length: . . . . . . . . . . . . . . . . Max. 3 m.

Suitable external sensors, brackets and cable glands for setting up upper seat-lift defection on mixproof valves are available as
accessories in the catalogue.
ThinkTop
ThinkT op V isual Indications LED Indications

LED B “Open valve” (Yellow)

O IR-Receiver
LED D “Setup/Internal fault” (Red)
LED C “Seat-lift 1/2” (Yellow)
LED E “Solenoid valves” (Green)
LED F “Maintenance” (Orange)
LED A “Closed valve” (Yellow)

Status signal
The status signal is used for four purposes:
- To indicate that setup is in progress + (LED D).
- To indicate an error condition + (LED D). (Flashing LED = software error), (steady LED = hardware error).
- To indicate maintenance due to the self adjustment programme + (LED F).
- To indicate that the time for maintenance has been reached + (LED F).

8
 4 Technical specifications

Technical specifications
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 5 µ 5-5 mg/m3
Max. flow 180 l/min
Max. oil content 1 mg/m3
Max. water content 0.88 g/m3 -20 oC compressed air
Throughput ø2.5 mm
Air restriction (throttle function) air inlet/outlet. Yes. (solenoid valve 1 only)
Manual hold override. Yes
Throttle, air in/out 1A, 1B 0-100%
External air tube connection ø6 mm or 1/4” (specify when ordering)
Silencer/filter Connection possible via ø6 mm
(Filter recommended in tropical regions)
Materials
Plastic parts Nylon PA12.
Metal parts Stainless steel and Brass.
Seals Nitrile (NBR).
Gore vent. membrane PBT plastic.

Micro
Micr o envir
environment
onment demand specifications

Temperatur e
Working: -20°C to +85°C IEC 68-2-1/2
Storage: -40°C to +85°C IEC 68-2-1/2
Temperature change: -25°C to +70°C IEC 68-2-14
V ibration 10-55 Hz, 0.7 mm IEC 68-2-6
55-500 Hz, 10g
3 x 30 min, 1 octave/min
Drop
Dr op test IEC 68-2-32
Humidity
Constant humidity: +40°C, 21 days, 93% R.H. IEC 68-2-3
Cyclic humidity: +25°C/+55°C
12 cycles IEC 68-2-30
(working) 93% R.H.
Protection
Pr otection class IP66 and IP67 IEC 529
threshold
Input thr eshold
Voltage/current: Type 1 input requirements EN 61131-2
Directive
EMC Dir ective 2014/30/EU
Approval
UL Appr oval 8-30 VDC, Class 2 input,
45 mA max. output UL 508-E203255

9
4 Technical specifications

4.2 ThinkTop Digital

Power Supply
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 load.

The unit is reverse polarity and short circuit protected.

Supply voltage nominal: . . . . . . . . . . . . . 24 ± 10% VDC
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 sensor 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 150 mA RMS during 13 ms (regulated PS) to 360 mA RMS during 8 ms (unregulated PS).

Fulfillment of the UL requirements in UL508 requires the unit to be supplied by an isolating source that complies with the
requirements for class 2 power units (UL1310) or class 2 and 3 transformers (UL1585).

Feedback signals
The sensor system can be used for 4 feedback signals + 1 status signal = 5 digital PNP/NPN feedback signals.

Output signals from the sensor unit to the connected PLC.

Nominal voltage: . . . . . . . . . . . . . . . . . . . . Must match the selected type of ThinkTop.
Load current: . . . . . . . . . . . . . . . . . . . . . . . . Typically 50 mA, max. 100 mA .
Voltage drop: . . . . . . . . . . . . . . . . . . . . . . . . Typically 3 V at 50 mA.

PNP/NPN Polarity

PNP (sourcing) or NPN (sinking) function is selected with a jumper in term. 12 and 13. Jumper present = PNP. If changing to
NPN, remove the jumber and make a power recycle. A power recycle is always required when changing this function.

Solenoid valve signals

Three output signals (with one common, terminal 11) from the terminal row are used for activation of the solenoids. Positive
(connected with terminal 9) or negative.

Technical specifications
Norminal voltage 24 VDC
Nominal power 1.0 W.

10
 4 Technical specifications

4.3 ThinkTop, AS-Interface

Feedback signals

Power Supply
The power supply to the complete unit is taken from the AS-Interface loop. The unit is reverse polarity protected.
Supply voltage: . . . . . . . . . . . . . . . . . . . . . . 29.5 - 31.6 VDC

Normal current consumption sensor

board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 mA (excluding current for the solenoids and the external sensor).

Max. current consumption sensor

board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 mA (if external devices e.g. solenoids and switches are connected to the sensor
board, a higher current consumption than 120 mA may occur, which this will damage
the sensor boards).

Feedback signals

Signals transmitted through the AS-Interface BUS to the AS-Interface master PLC.

The sensor system can be used for 3 feedback signals + 1 status signal = 4 feedback signals.

Slave profile options: (specify when ordering)

profile
Slave pr ofile v.2.1
address:
Default slave addr ess: 0

IO code: 7 (4 bit bi-directional)

IO code: F (slave without profile)
ID1 code: F
ID2 code: F
Slave profile = S-7.F.F.F

No. of slaves:
AS-Interface specification 2.1 for max. 31 ThinkTop units on a single master/gateway

profile
Slave pr ofile v.3.0
address:
Default slave addr ess: 0

IO code: 7 (4 bit bi-directional)

IO code: A
ID1 code: 7
ID2 code: 7
Slave profile = S-7.A.7.7

No. of slaves:
AS-Interface specification 3.0 for max. 62 ThinkTop units on a single master/gateway.

11
4 Technical specifications

AS--Interface bits assignment:

AS
For the AS-Interface version with 31 and 62 nodes, the following bit assignment will be used:
DI 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . De-Energised position (closed position)
DI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Energised position (open position)
DI 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SeatLift 1 and 2 position (sum SeatLift signal)
DI 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status

DO 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not connected
DO 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 1
DO 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 2
DO 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid valve 3

Solenoid valve signals

Signals transmitted through the AS-Interface BUS to the AS-Interface master PLC.

Technical specifications
Nominal voltage 24 VDC
Nominal power 1.0 W

12
 4 Technical specifications

4.4 ThinkTop DeviceNet

DeviceNet featur es and functionality

Network size Up to 63 nodes

Network length Selectable end-to-end network distance varies with speed
Baud Rate Distance
125 Kbps 500 m (1,640 ft)
250 Kbps 250 m (820 ft)
500 Kbps 100 m (328 ft)
Data packets 0-8 bytes
Bus topology Linear (trunk line/drop line); power and signal on the same network cable
Peer-to-peer with multi-cast (one-to-many); multi-master and master/slave special case; polled
Bus addressing
or change-of-state (exception-based)
System features Removal and replacement of devices from the network under power
The basic trunk-line/drop-line topology provides separate twisted-pair buses for both signal and power distribution. A thick or thin cable can be
used for either trunk lines or drop lines. End-to-end network distance varies with data rate and cable size

Data rates 125 Kbps 250 Kbps 500 Kbps

Thick trunk length 500 m (1,640 ft) 250 m (820 ft) 100 m (328 ft)
Thick trunk length 100 m (328 ft) 100 m (328 ft) 100 m (328 ft)
Maximum drop length 6 m (20 ft) 6 m (20 ft) 6 m (20 ft)
Cumulative drop length 156 m (512 ft) 78 m (256 ft) 39 m (128 ft)
The end-to-end network distance varies with data rate and cable thickness.

DeviceNet requires a terminating resistor to be installed at each end of the trunk:

- 121 ohm
- 1% metal film
- 1/4 watt

Terminating resistors should not be installed at the end of a drop line, only at the two ends of the trunk-line.

For further information please refer to the DeviceNet Standard.

DeviceNet Featur es

Device type Generic Master/scanner N

Explicit peer-to-peer messaging N I/O Slave messaging
I/O peer-to-peer messaging N • Bit strobe N
Configuration consistency value N • Polling Y
Faulted node recovery N • Cyclic N
Baud rates 125K, 250K, 500K • Change of state (COS) N
Configuration method EDS
The end-to-end network distance varies with data rate and cable thickness.

13
4 Technical specifications

DeviceNet interface
Baud rates: 125K, 250K and 500K.
Polling I/O slave messaging.

Poll: 1 bytes.
1 bytes = Input/outputs and alarms (class 4).
address
Node addr ess
Range: 0-63.
Default slave address: 63.

Power supply
The power supply to the complete unit is taken from the DeviceNet.
Supply voltage: . . . . . . . . . . . . . . . . . . . . . 11-25 V DC, as specified for the DeviceNet.
Supply current: . . . . . . . . . . . . . . . . . . . . . . Max. 45 mA (for sensor unit alone)
(excluding current to the solenoids and the external proximity switches).

ThinkTop
ThinkT op DeviceNet featur es

Feedback signals
Input signals (produced by the sensor unit) transmitted over the DeviceNet - class 4.
Five feedback signals: closed valve, open valve, seatlift 1, seatlift 2 and status.

The status signal is used for five purposes:

- To indicate that a setup is in progress (LED D).
- To indicate an error condition (LED D), (flashing = software error), (steady = hardware error).
- To indicate that maintenance is required (LED F).
- To indicate whether there is a conflict in the self adjustment programme (LED F).
- To indicate whether any communication exists between ThinkTop® and PLC (LED D, steady).

Solenoid signals
Output signals received from the DeviceNet.
Three bits to control the solenoid drives located in the sensor unit.

ThinkTop
ThinkT op EDS file
The EDS file can be downloaded from www.alfalaval.com by searching "ThinkTop" at the top of the main landing page. On the
ThinkTop landing page, choose Documentation in the menu and find the EDS package. Alternatively, both the EDS file and
further information on DeviceNet can found at www.odva.org

14
 4 Technical specifications

ThinkTop
ThinkT op DeviceNet attribute list

Path Raw data

Name Attributes R/W/CS data len. LSB
type
Release DNET 4.6 Class Inst dec. hex. “poll”
Valve value 4 1 3 - - R Byte 1 -
Valve command 4 3 3 - - R/W Byte 1 -

ThinkTop
ThinkT op DeviceNet attribute list

Name Conv..
Eng. Units Conv Bit maps/data
mult. divisor units byte 1 byte 2 byte 3 byte 4
Release DNET 4.6
Valve value - - - PLC_image - - -
Valve command - - - Solenoids - - -

ThinkTop
ThinkT op DeviceNet bit mappings

PLC_Image
x x x Maint. SL2 SL1 OPEN CLOSED
Valve value
Solenoid 1, 2 & 3
x x x x Coil #3 Coil #2 Coil #1 x
(Valve
(V alve command)

ThinkTop
ThinkT op DeviceNet Poll command structur es

Poll request message format

bit
byte 7 6 5 4 3 2 1 0
Coil #3 Coil #2 Coil #1
0 x x x x x
de-energise de-energise de-energise

Poll response message format

bit
byte 7 6 5 4 3 2 1 0
Travel in Timer MAINT. Seat #2 Seat #1 OPEN CLOSED
0 x
Progress Expired ERROR Status Status Status Status

Typical power consumption

Test conditions: One ThinkTop DeviceNet connected to the network with 1 input (on) and:

No solenoids on supply voltage 25 VDC 20 mA

1 solenoid active (PWM) supply voltage 25 VDC 28 mA
2 solenoid active (PWM) supply voltage 25 VDC 36 mA
3 solenoid active (PWM) supply voltage 25 VDC 44 mA

No solenoids on supply voltage 11 VDC 34 mA

1 solenoid active (PWM) supply voltage 11 VDC 58 mA
2 solenoid active (PWM) supply voltage 11 VDC 82 mA
3 solenoid active (PWM) supply voltage 11 VDC 106 mA

15
5 Installation

5.1 Installation on air actuators

Step 1

Always read the technical data carefully.

Always ensure the ThinkTop is electrically connected by authorised personnel.

Step 2
1. Fit the air fittings on the actuator if not mounted.
2. Fit the activator stem (magnet) and tighten carcarefully
efully
with a spanner.

Step 3
1. Place the ThinkTop on top of the actuator.
2. Make sure X-ring is mounted.

Step 4
pressing
1. Ensure that the unit is correctly mounted by pr essing down
on top of the ThinkTop.
2. Cross tighten the two Allen screws carefully in the two opposite
directions.
3. Turn the actuator so that the LEDs are at the front

16
 5 Installation

Step 5
Install the air tubes with reference to the Air connections diagram
on page 21

Step 6
Untighten the four screws and pull off the ThinkTop cover.

Step 7a - Cable gland version

1. Install cable (if not present) through the cable gland.
2. Connect the electrics of the ThinkTop
(see 5.4 Electrical connection, internal - Digital 24 VDC).

NOTE!
Make sure the cable gland is fully tightened.

Step 7b - M12 plug version

1. Install M12 socket cable.

NOTE!
M12 plug Electrical connection:

17
5 Installation

Step 8
Set up the ThinkTop (see chapter 6 Setup diagram).

NOTE!
The unit can be set up by the internal push buttons on the sersor board. To energise the valve, use manual hold override on the
solenoids valve or ensure you are in radio contact with the control room.

18
 5 Installation

5.2 Installation on Series 700 valves

Step 1 Installation on air actuators:

1. Remove the cover by loosening the four cover screws.
2. Separate the adapter from the base by loosening the three
recess screws on top of the base.

Step 2
1. Fit air fittings on actuator.
2. Position packing retainer in recess on actuator top.
3. Fit counter nut and indication pin (magnet) on actuator rod.
Engage approx. ¼ thread. Tighten counter nut and indicator
with two wrenches.

Step 3
1. Place the two O-rings in the grooves in the bottom of the
adapter. Then place the adapter on the actuator top. The small
O-ring must be positioned over the air hole on the actuator.
2. Fasten the adapter with the four 5/16” Allen screws.

19
5 Installation

Step 4
Mount the base on the adapter in the necessary position (can be
rotated 120° in both directions). Note that one of the screw towers
on the adapter has a guide recess (see * on diagram).

20
 5 Installation

5.3 Air connections

A Air out 1A
B Air exhaust
C Solenoid 3/2 or 5/2
D Air out 1B (5/2 port solenoid valve only)
E Solenoid valves only 3/2
F Air in
G Air out 3
H Air out 2
J Manual hold override
K Air restriction (throttle function) air inlet/outlet

21
5 Installation

5.4 Electrical connection, internal - Digital 24 VDC

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 **)
Eart- Earth 13 NPN/PNP Jumper **)
h
20 Solenoid common grey 24 Seat-lift 1 “upper” *)
21 Solenoid 1, grey 25 Seat-lift 2 “lower” *)
22 Solenoid 2, grey 26 Supply + *)
23 Solenoid 3, grey 27 Supply - *)

Table 1. Note!

*) If using external sensor, the sensor must be active/activated when performing a set-up routine of the control head.

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. Two external signals can be connected; these are associated with feedback signal 3 (seat-lift 1) and 4 (seat-lift
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 (seat-lift 1)
associated with feedback 3 (seat-lift 1) and sensor signal on terminal 25 (seat-lift 2) associated with feedback 4 (seat-lift 2).
**) Jumper present = PNP. If changing the function a power recycle is necessary. The selection NPN/PNP is done by
the jumper.
***) Internal connections: Terminals for connection for the solenoids mounted internally in the control head. The number of
solenoids actually mounted in the control head could be 0 - 3. The signals are taken directly from the terminal row.

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

5.5 Example of using common power supply

Install a jumper between terminal 10 + 11 to extend the sensor board supply to the solenoid valves.

A: Jumper

22
 5 Installation

5.6 Electrical connection, internal - AS-Interface

6 ASI + (BN, brown) 1 N/C

7 ASI - (BU, blue) 2 N/C
8 N/C 3 N/C
9 N/C 4 N/C
10 N/C 5 N/C
11 N/C 12 PWM Jumper **)
Eart- Earth 13 PWM Jumper **)
h
20 Solenoid common grey 24 Seat-lift 1 “upper” *)
21 Solenoid 1, grey 25 Seat-lift 2 “lower” *)
22 Solenoid 2, grey 26 Supply + *)
23 Solenoid 3, grey 27 Supply - *)

Table 2. Note!

*) If using external sensor, the sensor must be active/activated when performing a set-up routine of the control head.

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. Two external signals can be connected; these are associated with feedback signal 3 (seat lift 1) and 4 (seat lift
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 (seat lift 1)
associated with feedback 3 (seat lift 1) and sensor signal on terminal 25 (seat lift 2) associated with feedback 4 (seat lift 2).
**) Jumper present = PWM. Reducing power consumption of solenoid valves.
***) Internal connections: Terminals for connection for the solenoids mounted internally in the control head. The number of
solenoids actually mounted in the control head could be 0 - 3. The signals are taken directly from the terminal row.

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

23
5 Installation

5.7 Electrical connection, internal - DeviceNet

Electrical connection

DeviceNet 63 node
Sensor board
Terminal strip
P2
P1 1 Power bus V- (Black)
N/C 6 2 CAN_L (Blue)
N/C 7 3 Drain (Bare) Bus cable
N/C 8 4 CAN_H (White)
Not Connected
N/C 9 5 Power bus V+ (Red)
N/C 10 12 N/C
Not connected
N/C 11 13 N/C
Earth Earth 24 Seat-lift 1 "upper" Incoming signals from external
Solenoid com.grey 20 25 Seat-lift 2 "lower" sensors *)
Internal connections Solenoid 1, grey 21 26 Supply +
Supply to external sensors *)
to solenoids 1-3 ***) Solenoid 2, grey 22 27 Supply -
Solenoid 3, grey 23

Table 3. Note!

*) If using external sensor, the sensor must be active/activated when performing a set-up routine of the control head.

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. Two external signals can be connected; these are associated with feedback signal 3 (seat-lift 1) and 4 (seat-lift
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 (seat-lift 1)
associated with feedback 3 (seat-lift 1) and sensor signal on terminal 25 (seat-lift 2) associated with feedback 4 (seat-lift 2).
***) Internal connections: Terminals for connection for the solenoids mounted internally in the control head. The number of
solenoids actually mounted in the control head could be 0 - 3. The signals are taken directly from the terminal row.

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

24
 6 Setup diagram

6.1 ThinkTop setup- utilising local 'I' and 'II' keys

General
Default is:
Step 2, tolerance is +/- 5 mm
Step 3-8, disabled
Timeout: A 60 sec. timeout is started as soon as any button(s) is released.
On timeout the setup is exited with no changes saved.
Flashing LED means no value set. Steady LED means value set as shown
[D] LED: Active during setup: Flashing in step 1
Steady in all other steps
Or during operations, error condition: Steady indicates hardware fault, indication pin out of range
Flashing indicates software fault
General commands in each step (except step 1):
Next step / skip step (In step 3-6 the program automatically moves to the next step
when a position is stored)
Clear / disable step (In step 2 this resets the unit to default)
(The command is accepted when all unlit LEDs flash briefly)

beforee performing a setup.

We recommend resetting the unit befor

Symbols
Push local key “I”

Push local key “II”

Hold key “II” for 5 sec

Simple representation of LED indication:

Yellow B
IR-Reciver
Red D Steady LED
Yellow C
Green E
Orange F
Yellow A Flashing LED

25
6 Setup diagram

26
 6 Setup diagram

programs
Tolerance pr ograms

Default No. 1 No. 2 No. 3 No. 4

(Used for self
adjustment)
MH Koltek ARC LKB Unique Mixproof Unique SSV

SMP-EC SRC (LKLA-T) SMP-SC Spillage free Unique Mixproof PMO

Unique SSV NO Series 700 SRC-PV Unique Mixproof Curd

shut off AMP Unique Mixproof CP3

Unique Mixproof LP

Unique Mixproof HT

Unique Mixproof VT

Unique Mixproof 3A

Unique 7000

ARC

SRC

SBV

Series 700

27
6 Setup diagram

6.2 ThinkTop setup- utilising IR keypad

General

Flashing LED means no value set. Steady LED means value set as shown.
Default: Step 2, factory-set tolerance band +/- 5 mm
Step 3-8, disabled
D LED: Active during setup: Flashing in step 1
Steady in all other steps
Or during operations, error condition: Steady indicates hardware fault, indication pin out of range
Flashing indicates software fault
Timeout: A 60 sec. timeout is started as soon as any button/s is released
On timeout the setup is exited with no changes saved
IR Keypad: Remote distance 0-300 mm to ThinkTop®
Symbols

Push key on IR keypad with the same number

Simple representation of LED indication:

Yellow B
IR-Reciver
Red D Steady LED
Yellow C
Green E
Orange F
Yellow A Flashing LED

General commands in each step (except step 1):

Next step / skip step (In step 3-6 the program automatically moves to the next step
when a position is stored)
Clear / disable step (In step 2 this resets the unit and sets the step 2-8 to default)
(The command is accepted when all unit LEDs flash briefly)

beforee performing a setup.

We recommend resetting the unit befor
correct
Always check for corr ect signals after the setup.

28
6 Setup diagram

29
6 Setup diagram

6.3 ThinkTop quick setup guide

Valve: Unique SSV

SSV,, SRC/ARC type NC (self -adjustment disabled)
Push: I - and wait until red LED flashes
Push: I
Hold: II 5s - hold for 5 sec (clear all stored parameters)
Push: II (red + yellow LED)
Push: II (red + yellow + green LED)
Push: II (red + yellow + green + orange LED)
Push: II (red + yellow + green + orange + yellow LED)
Push: I
Push: II - to approve valve down (closed)
Activate Valve opens
Push: II - to approve (open)
Deactivate Valve returns to closed
Push: I (no upper seat-lift)
Push: I (no lower seat-lift)
Push: I (no self-adjustment)
Push: I (no maintenance)
Push: II Red LED flashes (save & exit by push)
Setup complete

Valve: SRC/ARC type NO (self -adjustment enabled)

Push: I - and wait until red LED flashes
Push: I
Hold: II 5s - hold for 5 sec (clear all stored parameters)
Push: II (red + yellow LED)
Push: I
Activate Valve closes
Push: II - to approve valve closed
Deactivate Valve opens
Push: II - to approve valve is open
Push: I (no upper seat-lift)
Push: I (no lower seat-lift)
Push: II = self-adjustment
Push: I
Push: I (no maintenance)
Push: II Red LED flashes (save & exit by push)

Setup complete

Valve: LKB Valve (Butterfly) NC

Push: I - and wait until red LED flashes
Push: I
Hold: II 5s - hold for 5 sec
Push: II (red + yellow LED)
Push: II (red + yellow + green LED)
Push: I
Push: II - to approve valve closed (indication- stem up)
Activate LKB valve - open position (indication- stem down)
Push: II - to approve valve is open
Deactivate Valve returns to closed
Push: I (no upper seat-lift)
Push: I (no lower seat-lift)
Push: I (no self-adjustment)
Push: I (no maintenance)
Push: II Red LED flashes (save & exit by push)
Setup complete

30
 6 Setup diagram

Valve: LKB Valve (Butterfly) NO

Push: I - and wait until red LED flashes
Push: I
Hold: II 5s - hold for 5 sec (clear all stored parameters)
Push: II (red + yellow LED)
Push: II (red + yellow + green LED)
Push: I
Activate - to close valve
Push: II - to approve valve closed
Deactivate LKB valve - open position
Push: II - to approve valve open
Push: I (no upper seat-lift)
Push: I (no lower seat-lift)
Push: I (no self-adjustment)
Push: I (no maintenance)
Push: Red LED flashes (save & exit by push)
II
Setup complete
mixproof
Valve: Unique mixpr oof Valve (with lower seat
seat--lift, but without exter nal sensor for upper seat detection)
Push: I - and wait until red LED flashes
Push: I
Hold: II 5s - hold for 5 sec (clear all stored parameters)
Push: II (red + yellow LED)
Push: II (red + yellow + green LED)
Push: II (red + yellow + green + orange LED)
Push: I
Push: II - to approve valve closed
Activate Valve opens
Push: II - to approve valve is open
Deactivate Valve returns to closed
Push: I (no upper seat-lift)
Activate Lower seat-lift active
Push: II - to approve
Deactivate Valve returns to closed
Push: I (no self-adjustment)
Push: I (no maintenance)
Push: II Red LED flashes (save & exit by push)

Setup complete

31
7 Fault finding

7.1 Fault finding and LEDs

The information below explains the meaning of the LEDs' indications for fault finding in connection with the operation of
the ThinkTop.

Red flashing: Unit in setup mode or internal software fault. If internal software fault is present,
re-programme unit.

Red Red steady: Unit in setup mode or internal hardware fault. If internal hardware fault is present, check
magnet is in range and check correct wiring.

Yellow B 1 Orange flashing: Time for maintenance has experied. The unit has been self-adjusted into a maintenance
. alert condition. Valve maintenance is strongly recommended. After maintenance: Disabling
of maintenance/self-adjustment function is required before setting new position, however,
it is strongly recommended to perform an entirely new setup after valve maintenance.
2 Orange steady, The unit has been self-adjusted into a maintenance alarm condition and the feedback is
. yellow flashing lost (a minimum of seal left). Valve maintenance is required. After maintenance: Disabling
(A and/or B): of the self-adjustment function is required before setting new position, however, it is
strongly recommended to perform an entirely new setup after valve maintenance.
Orange NOTE! The maintenance indicator lights up and an open or closed light flashes..... = Note
the following:
Yellow A - Self-adjustment program is only valid for SRC/ARC valves; do not use the program for
other valve types.
- Use tolerance/valve type 1.
- In conjunction with valve type change-over; 21, 22, 31 and 32, the open position
must be defined as the upper sensor position (when the indication pin is in the highest
position).
- A loose top, indication pin or sensor system can also generate the alert/alarm condition.
- Removing a ThinkTop with self-adjust activated, will immediately generate an alarm
condition! If the ThinkTop has to be removed - not because of a valve maintenance
issue - but for another reason and you wish to store the data already adjusted, disable
the self-adjust function before removing the ThinkTop and enable it again once the
ThinkTop is back on the actuator.
- After valve maintenance it is necessary to disable the self-adjustment function before
setting a new position, however, it is strongly recommended to perform an entirely new
setup (disable all functions in step 2 valve type - and perfom an entirely new setup).

Yellow A Yellow steady: Position A (closed valve).

32
 7 Fault finding

Yellow B Yellow steady: Position B (open valve).

Yellow steady: Position C (Seat lift 1-2 or external sensors).

Yellow C

Green Green steady: Solenoid valves energised.

Note! LED lights have different functions during setup.

33
8 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.

8.1 Dismantling ThinkTop

Step 1
1. Untighten the two Allen screws and remove the ThinkTop from
the actuator
2. Pull out X-ring (19) and replace it

Step 2
1. Untighten the four screws
2. Remove ThinkTop cover
3. Remove X-ring (9) (grey)

Step 3
1. Untighten screws
2. Remove solenoid valves (up to three) and replace them with
new ones

Step 4
1. To dismantle the adapter (the lower part of the ThinkTop) from
base (the middle part), unscrew the three screws
2. Turn the lower part clockwise slightly and pull
3. Replace adapter if necessary Note:
4. Remove the black X-ring
Turn banjo connection!

34
 8 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.

Step 5
To remove the sensor unit, untighten screw and pull out
the sensor unit.

8.2 Assembly of ThinkTop

Step 1
Place sensor unit in base and tighten screw (torque: 1 Nm).

Step 2
1. Replace the black X-ring.
2. Assemble base with adapter by turning adapter slightly
anticlockwise and tighten the four screws (1.9 Nm).

CAUTION!
Do NOT twist the X-ring in the groove! Note:
The X-ring is not square. The highest (h) part Turn banjo
must be positioned as shown. connection!

35
8 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.

Step 3
1. Replace solenoid valves (up to three) with new ones.
2. Tighten screws (0.2 Nm).

Step 4
1. Replace the grey X-ring.
2. Replace cover of ThinkTop and tighten
the four screws (0.6 Nm).

Step 5
1. Replace the black X-ring.
2. Mount ThinkTop on actuator.

36
 8 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.

8.3 Dismantling and assembling Series 700 valves

Step 1
1. Remove the cover by loosening the four cover screws.
2. Separate the adapter from the base by loosening the three
recess screws on top of the base.

Step 2
1. Fit air fittings on actuator.
2. Position packing retainer in recess on actuator top.
3. Fit counter nut and indicator (magnet) on actuator rod. Engage
approx. ¼” thread. Tighten counter nut and indicator with two
wrenches.

Step 3
1. Place the two O-rings in the grooves in the bottom of the
adapter. Then place the adapter on the actuator top. The small
O-ring must be positioned over the air hole on the actuator.
2. Fasten the adapter with the four 5/16” Allen screws.

37
8 Maintenance
Read the instructions carefully.
Handle scrap correctly.
Always have spare X-rings to hand.

Step 4
1. Mount the base on the adapter in the necessary position (can
be rotated 120° in both directions). Note that one of the screw
towers on the adapter has a guide recess (see * on drawing).
2. Remove X-rings (9) (grey) and (16) (black).
3. Replace with new ones.

CAUTION! Do NOT twist the X-ring in the groove! The X-ring is

not square; The highest (h) part must be positioned as shown

38
 9 Parts list
The items refer to the parts lists in the following sections

9.1 Diagrams for ThinkTop

39
9 Parts list
The items refer to the parts lists in the following sections

9.2 ThinkTop

40
 9 Parts list
The items refer to the parts lists in the following sections

Parts list
Pos. Qty Denomination
1 1 Shell complete
3 1 Screw
4 1 Washer
5 1 Sensor board
6a 1-2 Solenoid valve (3/2)
6b 1 Solenoid valve (3/2 or 5/2)
7 3 PT screw
8 1 Base
9 1 Special X-ring, grey
10 2-5 Air fittings
11 1 Blow-off valve
12 1 Thread plug, PG7
13 1 Cable gland, PG11 (or optional
M12 plug)
14 1 Gore vent
15 1 Adapter complete
16 1 Special X-ring, black
17 1 O-ring
18 2 Allen screw
19 1 Special X-ring
20 1 Indication pin
27 1 Threaded plate (accessory for the
Think Top)

41
.

42
 9 Parts list
The items refer to the parts lists in the following sections

9.3 Diagrams for ThinkTop: Series 700

43
9 Parts list
The items refer to the parts lists in the following sections

9.4 ThinkTop: Series 700

44
 9 Parts list
The items refer to the parts lists in the following sections

Parts list
Pos. Qty Denomination
1 1 Shell complete
3 1 Screw
4 1 Washer
5 1 Sensor board
6a 1-2 Solenoid valve (3/2)
6b 1 Solenoid valve (3/2 or 5(2)
7 3 PT screw
8 1 Base
9 1 Speciel X-ring, grey
10 2-5 Air fittings
11 2 Blow-off valve
12 1 Thread plug, PG7
13 1 Cable gland, PG11
14 1 Gore vent
15 1 Apapter complete
16 1 Special X-ring, black
17 1 O-ring
18 4 Screw
19 1 Retainer
20 1 O-ring
21 1 O-ring
22 1 Indicator pin
23 1 Nut

45
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

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