1222265 - ThinkTop Basic

Doc No. 1222265-0101Tetra Pak

Maintenance & Spare Parts

ThinkTop Basic(Alfa Laval)

PLC 10-30 VDC interface / AS-Interface v3.0, 29.5-31.6 VDC

Tetra Pak Processing Systems AB

ThinkTop BasicPLC 10-30 VDC interface / AS-Interface v3.0, 29.5-31.6 VDCThis document refers to components specified in Technical Manual,on Maintenance & Spare Parts CD/DVD or on Tetra Pak Intranet.

Doc No. 1222265-0101

Version 05 Issue 2010-10

Table of contents

iDoc No. 1222265-0101Tetra Pak

Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2LED indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Change Top unit and Spare parts. . . . . . . . . . . . . . . . . . . . . . . 7

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Function Description

1Doc No. 1222265-0101Tetra Pak

Function DescriptionGeneralThinkTop Basic PLC 10-30 VDC interfaceThe ThinkTop Basic is designed to ensure optimum valve control inconjunction with Alfa Laval valves and it is compatible with most PLCsystems (Programmable Logic Controllers maker with PNP/NPN interface).The ThinkTop Basic can be equipped with 0-3 solenoid valves. Thesolenoids are electrically controlled by the Digital PLC and when activatedthe compressed air is activating the air actuator. All solenoids have built-inthrottle function on both air inlet and outlet which means that it is possible tocontrol the opening and closing time of the air actuator. The solenoids arealso equipped with a manual hold override.

Visual LED lights are constantly indicating the status of the unit: Valvepositions, solenoid activated, setup and local fault indication etc.

ThinkTop Basic AS-InterfaceThe ThinkTop Basic AS-Interface is designed to ensure valve control inconjunction with sanitary valves and it is compatible with all major PLCsystems (Programmable Logic Controller).The ThinkTop Basic AS-Interface can be equipped with 0-3 solenoid valves.The solenoids are electrically controlled via the AS-Interface and whenactivated the compressed air is activating the air actuator. All solenoid valveshave build-in manual hold override function which means that it is possibleto manually open and close the actuator and seat lifts.

Visual LED lights are constantly indicating the status of the unit: Valvepositions, solenoid energized, setup and local fault indication etc.

Sensor SystemUnique No Touch sensor system without any mechanical sensoradjustments. A magnet (indication pin) is mounted on the valve stem and themagnetic field (axial) is detected by sensor chips inside the sensor unit. Themeasuring angle from each chip is used to locate the current position of thevalve stem with an accuracy of 0.1mm. Note that the distance to theindication pin can be 5 mm 3 mm.

Maintenance

Tetra Pak2 Doc No. 1222265-0101

MaintenanceRisk of injury!Always fit the seals between valve and ThinkTop Basic correctly.

Never install the ThinkTop Basic before valve or relay is in a safeposition.

Never service the ThinkTop Basic with valve/actuator under pressure.

Never clean the ThinkTop Basic with high pressure cleaningequipment.

Caution! Never use cleaning agents when cleaning the ThinkTop Basic.

Set-upTime-outA 60 second time-out is started as soon as any button(s) are released. If nobutton is pressed during the time-out period, go to normal condition(cancel & exit).Red LEDActive during set-up: Flashing in step 1. Steady in all other steps.Or during operations, error condition: Steady showing hardware fault, pin out of range. Flashing showing software fault.

DANGER!

Maintenance


(Cont'd)

Step 1 Step 2 Step 3

Accept SettingsI Restart set-upsequenceII Save & ExitII* Cancel & Exit,no changesaccepted* Hold for 5 sec.

Set De-energizedPositionII Store Position-----------------------I BypassII* Disable function* Hold for 5 sec.

Set EnergizedPositionII Store Position-----------------------I BypassII* Disable function* Hold for 5 sec.

red flashing Actuator inDe-energized

Position

Actuator inEnergizedPosition

red steadygreen flashing

if de-energizedposition disabled

green steadyif de-energized

position enabled

red steadyyellow flashing

if de-energizedposition disabled

yellow steadyif de-energized

position enabled

Maintenance


(Cont'd)Quick set-upa) Push: I, enter set-up and wait until red LED flashes.b) Push: I, restart set-up.

Actuator in De-energized positiona) Push: II, store position.Actuator in energized positiona) Push: II, store position.b) Push: II, when red LED is flashing (save & exit).c) Set-up done.

LED indications

ThinkTop Basic visual indications

A Energized YellowB Set-up/fault RedC Solenoids YellowD De-energized Green

Maintenance


Electrical connectionThinkTop Basic PLC 10-30 VDC interface

*) Jumper present = PNP. If changing the function a power recycle isnecessary. The selection NPN/PNP is done by the jumper.

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

(Cont'd)

De-energized (PLC input)

Energized (PLC input)

Activation of solenoid # 1 (PLC output)



Supply voltage sensor (+) 10-30 VDC

Supply voltage sensor (0) 0 V

Common supply solenoids

PNP/NPN jumper*)

PNP/NPN jumper*)

Solenoid common, internal connection

Solenoid # 1, internal connection



Maintenance


(Cont'd)ThinkTop Basic AS-Interface

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

ASI +

ASI -

PWM jumper

PWM jumper

Solenoid common, internal connection

Solenoid # 1, internal connec-



Maintenance


Change Top unit and Spare partsRisk of injury!Shut off the power supply before changing the unit.Never service the top unit before the valve is in a safe position.Never service the top unit with valve/actuator under pressure.Always have the top unit electrically connected by authorizedpersonnel.Never clean the top unit with high-pressure cleaning equipment.Never use cleaning agents when cleaning the top unit.

Disassemblea) Remove the ThinkTop Basic (1) from the actuator.b) Pull out X-ring (2) and replace it.c) Loosen the four screws (3).d) Pull off the cover (4).e) Remove X-ring (5) and replace it.

(Cont'd)

WARNING!

1 ThinkTop Basic2 X-ring3 Screws4 Cover5 X-ring

Maintenance


(Cont'd)f) Loosen the screws (6).g) Remove solenoid valves (7) (up to three) and replace them with new

ones.

h) Loosen the three screws (8) to dismantle the adapter (9) from the base(10).

i) Turn the adapter (9) a little clockwise and pull.j) Replace adapter if necessary.k) Remove the X-ring (11) and replace with a new one.l) Loosen the screw (12) and remove the sensor unit (13).

6 Screws7 Solenoid valves8 Screws9 Adapter

10 Base11 X-ring12 Screw13 Sensor unit

Maintenance


Assemblya) Place the sensor unit (1) in the base (2) and tighten the screw (3) to a

torque of 1 Nm. Make sure that the wires are connected the same way asbefore.

b) Replace the X-ring (6) with a new one.c) Assemble the base (2) with adapter (4) by turning the adapter slightly

anticlockwise and tighten the three screws (5) to a torque of 1.9 Nm.

(Cont'd)

1 Sensor unit2 Base3 Screw4 Adapter5 Screws6 X-ring

CAUTION!Do NOT twist the X-ring inthe groove!The X-ring is not square;The highest (h) part must beplaced as in the figure.

Maintenance


(Cont'd)d) Replace solenoid valves (7) with new ones. Tighten screws (8) to a

torque of 0.2 Nm.e) Replace X-ring (9).f) Replace cover (10) of the ThinkTop Basic and tighten the four screws to

a torque of 0.6 Nm.g) Replace X-ring (11)h) Mount ThinkTopBasic on actuator.

7 Solenoid valve8 Screws9 X-ring

10 Cover11 X-ring

Maintenance


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Spare parts


Spare parts

Spare parts


Spare partsArticle No.

Description Pos. Qty

6-9611-99-3458 Screw 3 16-9611-99-3459 Washer 4 16-9613-41-9201 Sensor unit Digital 10-30 VDC PNP/NPN 5 16-9613-47-5401 Sensor unit AS-Interface V3.0 29.5-31.6VDC 16-9613-44-3403 Sensor system AS-Interface cpl v.3.0 (62 node) 16-9611-99-4635 Solenoid valve 3/2, 24 VDC 6 1-36-9611-99-3327 Solenoid valve 5/2, 24 VDC 16-9613-45-6401 X-ring, Special 9 16-9611-99-3405 Air fitting 6 mm 10 16-9611-99-3433 Air fitting 1/4" 16-9612-56-3603 Blow-off valve 11 16-9611-99-3407 Thread plug, PG7 12 16-9611-99-3517 Cable gland, PG11 4-10 mm 13 16-9611-99-4722 Gore vent High airflow 14 16-9612-99-9401 X-ring, Special 16 16-9611-99-3350 O-ring 17 16-9612-56-9601 X-ring, Special 19 1

1222265 - ThinkTop Basic

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