Doc No.

1222265-0101
Tetra 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 Basic
PLC 10-30 VDC interface / AS-Interface v3.0, 29.5-31.6 VDC
This 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
i Doc No. 1222265-0101 Tetra Pak
Function Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LED indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Change Top unit and Spare parts. . . . . . . . . . . . . . . . . . . . . . . 7
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Function Description
1 Doc No. 1222265-0101 Tetra Pak
Function Description
General
ThinkTop Basic PLC 10-30 VDC interface
The ThinkTop Basic is designed to ensure optimum valve control in
conjunction with Alfa Laval valves and it is compatible with most PLC
systems (Programmable Logic Controllers maker with PNP/NPN interface).
The ThinkTop Basic can be equipped with 0-3 solenoid valves. The
solenoids are electrically controlled by the Digital PLC and when activated
the compressed air is activating the air actuator. All solenoids have built-in
throttle function on both 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 are constantly indicating the status of the unit: Valve
positions, solenoid activated, setup and local fault indication etc.
ThinkTop Basic AS-Interface
The ThinkTop Basic AS-Interface is designed to ensure valve control in
conjunction with sanitary valves and it is compatible with all major PLC
systems (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 when
activated the compressed air is activating the air actuator. All solenoid valves
have build-in manual hold override function which means that it is possible
to manually open and close the actuator and seat lifts.
Visual LED lights are constantly indicating the status of the unit: Valve
positions, solenoid energized, setup and local fault indication etc.
Sensor System
Unique No Touch sensor system without any mechanical sensor
adjustments. A magnet (indication pin) is mounted on the valve stem and the
magnetic field (axial) is detected by sensor chips inside the sensor unit. The
measuring angle from each chip is used to locate the current position of the
valve stem with an accuracy of 0.1mm. Note that the distance to the
indication pin can be 5 mm 3 mm.
Maintenance
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2 Doc No. 1222265-0101
Maintenance
Risk of injury!
Always fit the seals between valve and ThinkTop Basic correctly.
Never install the ThinkTop Basic before valve or relay is in a safe
position.
Never service the ThinkTop Basic with valve/actuator under pressure.
Never clean the ThinkTop Basic with high pressure cleaning
equipment.
Caution! Never use cleaning agents when cleaning the ThinkTop Basic.
Set-up
Time-out
A 60 second time-out is started as soon as any button(s) are released. If no
button is pressed during the time-out period, go to normal condition
(cancel & exit).
Red LED
Active 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
3 Doc No. 1222265-0101 Tetra Pak
(Cont'd)



Step 1 Step 2 Step 3
Accept Settings
I Restart set-up
sequence
II Save & Exit
II* Cancel & Exit,
no changes
accepted
* Hold for 5 sec.
Set De-energized
Position
II Store Position
-----------------------
I Bypass
II* Disable function
* Hold for 5 sec.
Set Energized
Position
II Store Position
-----------------------
I Bypass
II* Disable function
* Hold for 5 sec.
red flashing Actuator in
De-energized
Position
Actuator in
Energized
Position
red steady
green flashing
if de-energized
position disabled
green steady
if de-energized
position enabled
red steady
yellow flashing
if de-energized
position disabled
yellow steady
if de-energized
position enabled
Maintenance
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4 Doc No. 1222265-0101
(Cont'd)
Quick set-up
a) Push: I, enter set-up and wait until red LED flashes.
b) Push: I, restart set-up.
Actuator in De-energized position
a) Push: II, store position.
Actuator in energized position
a) 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 Yellow
B Set-up/fault Red
C Solenoids Yellow
D De-energized Green







Maintenance
5 Doc No. 1222265-0101 Tetra Pak
Electrical connection
ThinkTop Basic PLC 10-30 VDC interface
*) Jumper present = PNP. If changing the function a power recycle is
necessary. 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)
Activation of solenoid # 2 (PLC output)
Activation of solenoid # 3 (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
Solenoid # 2, internal connection
Solenoid # 3, internal connection
Maintenance
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6 Doc No. 1222265-0101
(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-
Solenoid # 2, internal connec-
Solenoid # 3, internal connec-
Maintenance
7 Doc No. 1222265-0101 Tetra Pak
Change Top unit and Spare parts
Risk 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 authorized
personnel.
Never clean the top unit with high-pressure cleaning equipment.
Never use cleaning agents when cleaning the top unit.
Disassemble
a) 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 Basic
2 X-ring
3 Screws
4 Cover
5 X-ring
Maintenance
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8 Doc No. 1222265-0101
(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 Screws
7 Solenoid valves
8 Screws
9 Adapter
10 Base
11 X-ring
12 Screw
13 Sensor unit
Maintenance
9 Doc No. 1222265-0101 Tetra Pak
Assembly
a) 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 as
before.
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 unit
2 Base
3 Screw
4 Adapter
5 Screws
6 X-ring
CAUTION!
Do NOT twist the X-ring in
the groove!
The X-ring is not square;
The highest (h) part must be
placed as in the figure.
Maintenance
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10 Doc No. 1222265-0101
(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 valve
8 Screws
9 X-ring
10 Cover
11 X-ring
Maintenance
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Spare parts
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Spare parts
Spare parts
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Spare parts
Article No.
Description Pos. Qty
6-9611-99-3458 Screw 3 1
6-9611-99-3459 Washer 4 1
6-9613-41-9201 Sensor unit Digital 10-30 VDC PNP/NPN 5 1
6-9613-47-5401 Sensor unit AS-Interface V3.0 29.5-31.6VDC 1
6-9613-44-3403 Sensor system AS-Interface cpl v.3.0 (62 node) 1
6-9611-99-4635 Solenoid valve 3/2, 24 VDC 6 1-3
6-9611-99-3327 Solenoid valve 5/2, 24 VDC 1
6-9613-45-6401 X-ring, Special 9 1
6-9611-99-3405 Air fitting 6 mm 10 1
6-9611-99-3433 Air fitting 1/4" 1
6-9612-56-3603 Blow-off valve 11 1
6-9611-99-3407 Thread plug, PG7 12 1
6-9611-99-3517 Cable gland, PG11 4-10 mm 13 1
6-9611-99-4722 Gore vent High airflow 14 1
6-9612-99-9401 X-ring, Special 16 1
6-9611-99-3350 O-ring 17 1
6-9612-56-9601 X-ring, Special 19 1