Jaw System Overview

Course Introduction 3
TBA/19
Jaw System 4
020V
Final Folder Unit 5
Advanced Sterile System 6
Maintenance Filling System 7
Design Control System 8

Training Document
ASSU 9
This Training Document is intended for Training
purpose only, and must not be used for any
other purpose.
PMI 10
The Training Document is not replacing any Supply System 11
instructions or procedures (e.g. OM, MM, TeM,
IM, SPC) intended for specific equipment, and
must not be used as such. Head Space by Gas Injection 12
Note! For safe and proper procedures, refer
to the equipment specific documentation.
PLMS – TPOP 13
Name:
................................................................................................................ Electrical 14
................................................................................................................
Technical Training Centre Lund, Sweden

'

Information regarding
Safety Regulations at the
Technical Training Centre in Lund
This list summarizes a number of items which may concern you, as a
participant in this training course. Read the list, and if anything re-
mains less than clear, or if you have any questions, feel free to contact
your instructor.
1. Study and follow the sections on Safety in the course literature, for
instance the OM, MM and EM.
2. You are entitled to ask persons who have no business to be near the
machine, to stay at distance, for safety reasons.
3. Never touch any other machines than those used in your own training
course.
4. There may be cables which are still electrically live, although they
have been disconnected from their terminals.
5. In some machines, safety switches may be bridged or disconnected,
for training reasons.
6. Find out exactly where the emergency stop switches for the machine
as well as the conveyor are located.
7. When starting a machine, the person doing the starting must make
absolutely sure that this does not expose anyone else to danger.
8. Certain chemicals, used in your training course, may be hazardous to
your health and constitute a danger of fire or explosion. Make sure
you know how such chemicals are marked and how to handle them.
9. It is strictly prohibited to wear rings, watch, or necktie when working
with the machine. This prohibition also applies to loose-fitting
clothes or anything else that might get caught in the machinery.
10. A first aid kit and stretcher are kept in the machine hall.
11. Study the information on what to do in case of fire and which escape
routes to follow. A diagram of escape and evacuation routes is posted
in every classroom.
12. If you observe or discover anything that might jeopardize safety,
immediately tell your instructor.
Technical Training Centre 1/9701 TM-00001

.
@ D

Drive system
Overview
Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 2/0301 OH 1104
Final folder
Drive

Drive
Jaw system

Drive unit
Electrical clutch
Disengaged
Rotating
Stationary
Shim
Engaged

Drive unit
Electrical clutch,
cranking Disengaged
Rotating
Stationary
Shim
Engaged

Drive unit
Crank mechanism
Disengaged position
Engaged position

Main motor
Speed control
Start
Speed A−valve opens Design OK
7500
6000
Time
8 pkgs
Normal stop/Short stop

Speed
7500
Time
Emergency stop/Safety stop

Speed
7500
Time

)
J#

Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components of the jaw system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Movements in the jaw system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transferring the movements from the drive unit... . . . . . . . . . . . . . . . . . . 5
...to the jaw system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Forming of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Jaw cooperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Jaw gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Catches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Closing the jaw gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transversal sealing and cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Volume adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Volume flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Volume cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bulge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Underfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Support rollers and Tube folding device . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Support rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tube folding device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Folding flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Folding flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Folding flap positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Settings in the jaw system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lower turning position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Volume cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Jaw alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Yoke symmetry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Volume flap alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tube support rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Jaw gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Non parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Jaw over jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Folding flap mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Catch lifter cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Catch clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disconnection link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Sterile system
TBA/19 020V
This description of the sterile system of a TBA/19 machine includes the

following topics:
• A brief explanation of the concept “Aseptic food processing”.
TBA • An overview of the sterile system in a TBA machine.
Tetra Brik Aseptic
• Descriptions of the components in the sterile system.
• An overview of the aseptic production cycle.
• Description of the function of the sterile system in a TBA/19 machine.
Aseptic food processing
The sterile system

3
Sterilized
packaging
material
4
Sterile
surrounding
1 2
Commercially Aseptic 5
sterile food transfer
Aseptic packages
Aseptic food processing
Sterile Before arriving at the filling machine, the product is treated so that it is free
Free from micro-organisms. from all micro-organisms able of multiplying, which means that it is
commercially sterile. 1
Commercially sterile
Free from micro-organisms The piping is sterilised before conveying any product, which means that the
able of multiplying. transfer to the filling machine takes place under aseptic conditions. 2
Aseptic The packaging material is sterilised by the sterile system of the machine. 3
Prevents reinfection
The sterile system also creates a sterile surrounding 4 in which aseptic
packages are produced. 5
Technical Training Centre 1/0303 Training Document. For training purpose only. 3
Sterile system overview
Air
Peroxide
Aseptic chamber Product
Water
Packaging material
Peroxide bath
Compressor Peroxide tank

Tight tube
Air superheater
Sterile system overview
Before production can take place, the packaging material must be sterilised
and a sterile surrounding must be created in the aseptic chamber. This is the
task of the sterile system.
The aseptic chamber is sterilised by a small amount of peroxide, sprayed into
the aseptic chamber during start.
To maintain the sterile surrounding in the aseptic chamber, micro-
organisms must be prevented from entering during production. This is done by
creating an overpressure with heat-sterilised air in the aseptic chamber.
The packaging material is sterilised by warm peroxide in the peroxide bath,
before entering the aseptic chamber.
4 Training Document. For training purpose only. Technical Training Centre 1/0303
Evaporated peroxide The peroxide is The aseptic environment
is sprayed into an condensed and then is kept with an overpressure
enclosed area. dried with hot sterile air. of cooled sterile air.
Aseptic machine sterilisation
Creating and maintaining Sterilisation is part of the start procedure, and is performed in several steps.
a sterile surrounding First the sterile air system has to be isolated from the surrounding environ-
in the aseptic chamber ment. This is done by forming the packaging material into a tube and seal it.
Then a sterile surrounding in the aseptic chamber is created by spraying
peroxide into the heated air in the sterile air system. The peroxide will
evaporate in the hot air.
When the peroxide vapour reaches the aseptic chamber, it will condense on the
cold surfaces.
The peroxide will be dried up by means of heat-sterilised air, circulating
through the aseptic chamber.
During production, the sterile system will create an overpressure with heat-
sterilised air in the aseptic chamber. Thus the sterile surrounding is
maintained.
Components in the sterile system
35 33
18
20
32
11 19
14
10
17 34
27
1 1 21
9 12
13 15 26
16 25
5
7 24 29
31
2
3 23
8 6 28
22 30
4 1
1. Water ring compressor 11. Air inlet valve 19. Bending roller 30. Peroxide tank
2. Scrubber 12. Product valve, 20. Driven bending roller 31. Peroxide pump
3. Constant flow valve (A-valve) 21. Suction valve 32. Spray tank
4. Water separator 13. Sterile air valve, 22. Chamber pressure valve 33. Spray tank level sensor
5. Venting valve (B-valve) 23. Water circulation pump 34. Spraying peroxide valve
6. Heat exchanger 14. Steam barrier valve, 24. Water bath heater 35. Air valve, spraying
7. Heat exchanger valve (C-valve) 25. Water bath
8. Air superheater 15. LS-element 26. Peroxide bath
9. Peroxide evaporator 16. LS short stop-element 27. Membrane valve
10. Presterilisation 17. Filling pipe 28. Peroxide container
temperature sensor 18. Air knife 29. Filling peroxide pump
Sterile system TBA/19, Denominations
Water
Air
Scrubber
Scrubber The purpose of the scrubber is to remove the peroxide from the air exhausted
by suction from the peroxide bath and the aseptic chamber.
This is done by cooling the warm air with water. The peroxide, which is in
state of vapour, will then condense and mix with the water. For maximum
cooling effect, a nozzle will sprinkle the water finely into a mesh, which will
increase the contact area between the water and the air.
The scrubber will also remove paper dust from the air coming from the aseptic
chamber. The paper dust will stick to the water and follow it further to the
water separator.
Rubber ring Constant
flow rate
of water
Water with
fluctuating
pressure
Water at low Constant

pressure flow rate
Water at high
pressure Constant
flow rate
Constant flow valve
There is a constant flow valve fitted just before the scrubber. Its purpose is to Constant flow valve
see to that the water flow coming to the scrubber is constant no matter what
the incoming water pressure is.
The working part of the valve is a thick rubber ring.
When the incoming water pressure is low, the opening of the ring will remain
unaffected. But, when the incoming water pressure is high, the ring will be
deformed and its opening will become narrower. Thus the water flow rate after
the ring will be the same, no matter what the water pressure is.
Water ring compressor
Water ring compressor The purpose of the water ring compressor is to pump the air around in the
sterile air system.
When the compressor is running, a ring of water rotates against the inside of
the compressor housing.
The rotor is fitted assymmetrically in the lower part of the compressor
housing. When the rotor chambers are in the lower position they will be almost
filled with water, whereas in the upper position they will be almost empty.
This alternately filling and emptying, causes the pumping action. One could
say that the water works as pump pistons.
Some water will follow the air out of the compressor and continue to the water
separator, and new water is continously fed from the scrubber.
Water
Air
Water separator
The purpose of the water separator is to remove the water from the air that Water separator
comes from the water ring compressor.
The separator is so designed that a whirl will arise when the air enters it. The
air is forced uppwards, through a filter, where the water will gather into bigger
drops and fall down.
On the bottom of the separator there is a float which will open and let the water
out when the level is rising, and then close again when the level is sinking. The
water that remains on the bottom of the separator works as a waterseal,
preventing air leakage during operation.
‘
1 4
3 Heat exchanger
Heat exchanger The purpose of the heat exchanger is to cool as well as to warm up the air.
The cold air coming to the air superheater 1 is used to cool the air coming
from the air superheater 3 , so that it doesn´t heat up the packaging material
nor the aseptic chamber 4 .
In its turn, the cold air is warmed up by the hot air before entering the air
superheater 2 , which reduces energy consumption.
Insulating material
Air
Preheated air
Preheated air
Hot air
Hot air
Air
Insulating material
Air superheater
2 $$ $

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( + )
Spray nozzle
Peroxide
Peroxide evaporator
Compressed air
Hot air

2 $$ $') #$ #$ $')
$) ) $') ) ( $! 44 )
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$ 3 $ ) #$ $ ) $')
'
Suction valve
Suction valve, position during Production Suction valve, position during Normal stop and Short stop
2 $$ ## ' ')

$') #$ $') + ) $ +
2 ## ( $ %( $) $
$ 2 $') #$ (
$(( 5 $ ( $ )
$ $') #$ + ') $') +*
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" ## ) 6 7
$ )( $)* 6
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A
Aseptic product valve

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*
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(
AP valve, Position during production
2
$ 7 $
( $$ )(
AP valve, Position during sterilisation
2
$ ) $ 38 ## )
+ + ( ) $)
$$( 3 $
AP valve, Steam barrier
2 38 ## + $ 7 )) +# *

'$ $ )( (<
AP valve, Position during final cleaning
The aseptic production cycle
The aseptic production cycle describes what phases the Tetra Brik Aseptic
filling machine goes through. The sterile system is in operation only during a
part of the cycle.
Preparation of filling machine
Sterilsation of filling machine

No production planned time
Production
Weekly care
Daily care
External cleaning
CIP
The sterile system in
operation
Aseptic production cycle
The function of the sterile system
This section describes how the sterile system works. Below you can see which
machine modes, and sequences, are described:
Preheating I
Start Preheating II
Tight tube
Spray Preheating III
Sterilisation
sequence Filling spray tank
Spraying
Pause
Drying
Signal exchange
Production
Top filling during production
Normal stop
Short stop Stops
Security stop
Emergency stop
End of production
Venting
Venting; Ready for door opening
Starting the filling machine

The start of the filling machine is performed by the control system of the ma-
chine, with assistance from the operator.
The start is performed in several steps, beginning with Preheating I and ending
with Production. Before stepping up the machine, it must be provided with
• cooling water
• compressed air and
• power supply.
Below is described what happens in each step.
Sterile system TBA/19 020V
Preheating l
Air
Air
Hot air
Hot air
Pre−heated air
1 1 alt. cooled air
Pre heated air
Steam
alt.Product
cooled air
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Preheating I
Preheating I In this mode the water bath is to be warmed up and the peroxide tank to be
filled up.
When the machine is stepped up to Preheating I, the heating of the water in the
water bath starts and the circulation pump starts circulating the water.
The peroxide tank is filled with peroxide from the peroxide container. The
filling peroxide pump will stop when the correct level is reached, and the ma-
chine can be stepped up to Preheating II.
Preheating ll
Air
Air
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Preheating II
In this mode the LS-element is to be heated, as well as the piping between the Preheating II
air superheater and the air inlet valve.
The peroxide starts circulating to be warmed up in the peroxide bath.
When the machine is stepped up to Preheating II, the water ring compressor
will start. Once the pressure is correct, the compressor will continue running LS
Longitudinal seal
by itself. As soon as the compressor has started, the LS-element will be acti-
vated as well.
The compressor circulates the air in the sterile air system. The heat exchanger
will be bypassed and the cold air will continue directly to the air superheater,
where it is heated, and then further on to the aseptic chamber and the LS-
nozzle. This way the LS-nozzle will reach its correct temperature faster.
When the LS-nozzle has reached the correct temperature, the machine is ready
to create a tight tube.
Tube sealing
Air
Air
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Tube sealing
Tube sealing In this mode the packaging material, which is formed into a tube, is sealed.
This will isolate the aseptic chamber from the surrounding environment.
The machine will feed the packaging material and LS-strip will be applied by
the strip applicator. To make sure that the whole length of packaging material
is fitted with strip, the feeding will continue until the packaging material from
the strip applicator has reached the jaw system.
The machine will also check that there is neither strip splices nor packaging
material splices inside the aseptic chamber. Should that be the case, Tube seal-
ing will proceed until any splice has left the aseptic chamber.
The machine will finish Tube sealing by performing a transversal sealing on
the last package in the machine; and the tube is sealed.
Now, sterilisation can take place. The machine will automatically change to
last package in
Preheating III.
the machine
transversal seal
Packaging material tube
Preheating lll
AirAir
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Preheating III
In this mode the piping between the air superheater and the air inlet valve is to Preheating III
be sterilised.
The air inlet valve changes position to prevent the air from passing through the
aseptic chamber, to prevent unwanted heating. Instead it will be led back to the
scrubber.
As no air is let into the aseptic chamber, the suction valve changes position and
air is exhausted via the peroxide bath instead. On the bath is fitted a membrane
valve, letting in air.
The pressure chamber valve too, will change position to increase the amount
of air let in.
When pre-sterilisation air temperature is reached at the air inlet valve, the
spray sequence can be started.
The spray sequence
The spray sequence is a sequence of four modes:
• Filling spray tank
• Spraying
• Pause
• Drying
Filling spray tank
Air
Air
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Filling spray tank
In this mode the spray tank is to be filled up with peroxide. Filling spray tank
When the machine is not in production, the peroxide is kept in the peroxide
tank. From there it is pumped to the spray tank. In the spray tank are fitted two
level sensors. The short one indicates when the correct level is reached. level
sensors
The peroxide surplus will be led back to the peroxide tank.
If the spray container level is correct within a certain time limit, the machine
will automatically change to Spraying.
Spray tank
Spraying
Air
Air
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Spraying
Spraying In this mode the aseptic chamber is sprayed with peroxide.

The spraying peroxide valve opens at the same time as the air valve opens for
the compressed air. The compressed air is led into the spray tank and will press
the peroxide through a pipe to the spray nozzle on the peroxide evaporator.
From the air valve, there is also a pipe leading compressed air directly to the
spray nozzle.
The compressed air and the peroxide is forced through the spray nozzle and
into the peroxide evaporator.The peroxide will evaporate in the hot air, coming
from the air superheater. It will follow the air flow, via the air knife into the
aseptic chamber, and through the B-valve via the filling pipe, the LS-element
and the LS short stop-element into the aseptic chamber.
To make the peroxide vapour reach also the part of the bending roller covered
by packaging material, the roller rotates during spraying.
To make sure that the peroxide vapour reaches the peroxide bath, and to pre-
vent that the peroxide vapour is exhausted out of the aseptic chamber immedi-
ately, the suction valve is in position to allow exhaustion from the peroxide
bath.
Pause
AirAir
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt.Product
cooled air
Steam
Water
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Pause
In this mode the peroxide vapour will condense on the cold surfaces in the Pause
aseptic chamber.
To make this possible, the air inlet valve will change position to by-pass the
aseptic chamber and lead the air directly to the compressor.
The heat exchanger valve changes position to let the cold air flow via the heat
exchanger to cool the heated air from the air superheater.
During Pause the bending roller continues to rotate.
The machine will automatically change to drying.
Drying
Air
Air
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Drying
Drying In this mode the peroxide in the aseptic chamber will be dried up.
The air inlet valve will change position and let the warm air circulate via the
aseptic chamber. The peroxide will evaporate and follow the air flow, out of
the aseptic chamber.
The bending roller rotates during the end of this mode, to allow the peroxide
on all of its surface to dry up.
The B-valve will close at the end of this mode, to stabilise the air flow to the
LS-element, and to increase the air flow through the jet diverter pipe, making
drying-up more efficient.
Now, the filling machine is sterilised and ready to produce packages.
A signal is sent from the filling machine to the processing equipment. 1 Signal exchange with the
If the processing equipment is ready for production and there is product in the processing equipment
product pipe, a signal is sent from the processing equipment to the filling ma- 1
chine. 2
During this signal exchange, nothing changes in the sterile system of the filling Processing Filling
machine. equipment machine
2
Product
Signal exchange
Production
Air
Air
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Production
Production Before production can start, the jaw system and the final folder are synchro-
nised, the peroxide bath is filled with peroxide and the LS short stop-element
is activated for a short while before the counter roller and the LS-element are
activated.
Then the drive motor will feed the packaging material that has been standing
still in the peroxide bath and the aseptic chamber.
When the correct filling position is found, the A-valve opens and the packag-
ing material tube is filled with product.
When the design correction system has located the correct position of the
packaging material, the packages will drop into the final folder unit, and pro-
duction has started.
Top filling during production
Air
Air
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Top filling the peroxide bath
Some of the warm peroxide will evaporate and be exhausted from the peroxide Top filling the peroxide
bath. To compensate for this loss, and to renew the peroxide in the bath, more bath
peroxide will be added at regular intervals.
The amount of peroxide being pumped from the peroxide tank to the bath is
bigger than the amount lost. The peroxide surplus will flow back to the perox-
ide tank. This is called top filling.
At top filling the temperature and concentration of the peroxide is levelled out
between the bath and the tank.
Stopping the filling machine
The filling machine can be stopped in several ways:
• Normal stop is used when the length of the stop is estimated to no
more than 40 minutes.
• Short stop and Security stop is used when the length of the stop is
estimated to no more then 5 minutes. Should the length of the stop
exceed 5 minutes, the machine will automatically change to Normal
stop.
• End of production is used when production is finished.
• Emergency stop is used in case of danger to person or machine.
The machine, and the sterile system, will respond differently depending on
which way the machine is stopped.
The machine can also be stopped by its control system, for example; in case of
an alarm.
Normal stop
Air
Air
Hot air
Hot air air

Pre−heated
alt. cooled air
1 1
Pre heated air

Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Normal stop
Normal stop is used when the time of the stop is estimated to 5-40 minutes. Normal stop
The A-valve is closed to stop the inflow of product but the machine will
continue in order to empty the tube of product.
When the machine has stopped, the peroxide bath will be emptied and the
suction valve will change position.
When the stop has lasted for 20 minutes, the machine must be inched as the
packaging material might have been affected by peroxide vapour from the
peroxide bath, and the heat in the aseptic chamber.
After a Normal stop, the machine is still sterile and production can be restarted
if the maximum time of 40 minutes has not been exceeded.
Short stop/Security stop
Air
AirHot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt.Product
cooled air
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Short stop/Security stop
Short stop Short stop is used when the time of the stop is estimated to no more than 5 min-
utes.
The A-valve is closed to stop the inflow of product to the machine and
production is interrupted. This means that product remains in the filling pipe
and the packaging material tube.
The machine will remain in design and the jaw system will stop in short stop
position.
When the jaw system has stopped, the peroxide bath will be emptied and the
After a Short stop, the machine is still sterile and production can be restarted
if the maximum time of 5 minutes has not been exceeded.
If the stop has lasted for more than 5 minutes, the machine will automatically
change to Normal stop, and the machine must be inched to empty the packag-
ing material tube of product.
Security stop Security stop will be the result of a number of alarms from the final folder unit.
The machine will take the same action as in Short stop, and remain in design,
but; the jaw system will stop immediately.
If the stop has lasted for more than 5 minutes, the machine will automatically
change to Normal stop, and the machine must be inched to empty the packag-
ing material tube of product.
The emergency stop button is to be used only in case of danger to a person or Emergency stop
the machine.
All mechanical movements will stop immediately and the machine will step
down to zero.
After an Emergency stop the machine is not sterile any more. Before starting
production again, it must be cleaned and sterilised.
Emergency stop button
End of production
Air
Air
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt. cooled air
Product
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, End of production
End of production End of production stop is used when production is finished.

The A-valve is closed to stop the inflow of product but the machine will
continue in order to empty the tube of product.
The C-valve will change position and steam will be blown into the filling pipe
to empty it from product.
When the jaw system has stopped, the peroxide bath will be emptied and the
After 2 minutes the machine will change to Venting. During these 2 minutes
production can be restarted.
After Venting has started, the machine is not sterile any more. Before starting
Venting
Air
Air
Hot air
Hot air
Pre−heated air
1 1 alt. cooled air
Pre heated air
Steam
alt.Product
cooled air
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Venting
In this mode the aseptic chamber is cooled and the air is cleaned from peroxide Venting
vapour. This will improve the environment for the operator.
All elements are turned off but the compressor will continue circulating the air.
The air is cleaned and cooled in the scrubber, and will in its turn cool the
aseptic chamber.
Venting will normally be in progress for 5 minutes. If, for some reason, the
spray sequence is interrupted after peroxide has been sprayed into the peroxide
evaporator, venting will be in progress for 15 minutes.
After Venting has started, the machine is not sterile any more. Before starting
The machine will automatically change to Venting; Ready for door opening.
Venting Ready for door opening
Air
Air
Hot air
Hot air air
Pre−heated
1 1 alt. cooled air
Pre heated air
Steam
alt.Product
cooled air
Water
Steam
Peroxide
Product
Compressed air
Water
Peroxide
Compressed air
Sterile system TBA/19, Venting, ready for door opening
Venting; In this mode an underpressure is created in the aseptic chamber, and air will
Ready for door opening be sucked in to instead of escape out of the aseptic chamber when the door is
opened. This will improve the environment for the operator.
The venting valve will close and no air will pass the aseptic chamber, but the
compressor will continue exhausting air from the aseptic chamber. This will
create the underpressure in the aseptic chamber.
F
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S terilisation 9
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P roduction 10
C leaning 11 Normal or P refilling starts P roduction
12 C leaning
P refilling
S terilisation
Force download 13
High level alarm Level higher than 83%
C ommunication enable 14 Level higher than 66%

Level higher than 50%
C ommunication clock 15
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C ommunication data 16 R S 232 R S 485
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27 Filling OK
28 Transmission OK
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Start sequence
Motor starts
Run X packages
(according to timer)
Look for filling position
A-valve opens
First start use default value

Filling OK within set time
Minimum
5.5 s
Design error -10 to 0 mm
MDCS into regulating mode
Design error < ± 1.5 mm A-valve closes
Yes No
50 pkgs not in design

Production 1:st time
(from A-valve open)
2:nd time
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MDCS19
1. Table of contents 12. DESIGN ADJUSTMENT SIGNAL 13

1. TABLE OF CONTENTS 1 13. OUTPUT SIGNAL 13
2. ABBREVIATIONS 1 14. TERMINAL (PC) COMMUNICATION 13
3. INTRODUCTION 1 15. VOLUME PARAMETER TRANSFER 16
4. DESIGN CONTROL SYSTEM OVERVIEW 2 16. PARAMETER BIT REGISTER 16
5. TMCC2 CONNECTIONS 3 17. I/P TRANSDUCER SETTING 17
6. BASIC PROGRAM FUNCTIONS 6 18. SETTING CRITERIA 18
7. OTHER PROGRAM FUNCTIONS 7 19. FLAP CYLINDERS CALIBRATION 18
8. TMCC2 FRONT PANEL DISPLAY 8 20. PROGRAM DOWNLOAD 19
9. MENU STRUCTURE 10 21. GREY CODE TABLE 19
10. PHOTOCELLS MANAGEMENT 11
11. ENCODER FUNCTION AND GRAY CODES 11
2. Abbreviations
DCS22 Design Control System for TBA/22 filling machines

DCS21 Design Control System for TBA/21 filling machines
DCU Design Correction Unit (68 457-010V)
EEPROM Electrically Erasable/Programmable Read-Only Memory
LED Light Emitting Diode
MDCS19 Motorized Design Control System for TBA/19 filling machines
PC Personal Computer
PID Proportional, Integral and Derivative control algorithm
PLC Programmable Logic Controller, (like TPMC or GE-Fanuc)
TMCC2 Tetra Pak Multi-Purpose Compact Controller (559810-0101)
TPOP Tetra Pak Operator Panel
Flexbox Industrial Computer Interfacing the TPOP and logging the machine events
3. Introduction
The MDCS19 program is intended for the TBA/19 filling machines, and the program runs on the
TMCC2, Tetra Pak Multi-purpose Compact Controller, hardware. The program reads the register mark
photocells at the paper tube and the machine angle encoder. From these parameters the output is
calculated via a PID-algorithm. The output value sets the new I/P Transducer pressure and the folding
flap position. Package specific parameters are sent from the PLC.
The current software release is intended for photocells provided with remote control function and
integrates an advanced management of the photocells allowing a easy setting, a powerful failure
diagnostic and an improved reading capability.
This program is one version in the family of design control programs running on the TMCC2. The other
versions are used on the TBA/21and TBA/22 filling machines. The basic function of these programs are
the same, the main difference is the output routines. The TBA/19 uses a twenty-six step motorized
cylinder system to control the folding flaps and an I/P Transducer.
This Functional Description is intended for users of the MDCS19 "function", i.e. electrical designers, test
engineers, service engineers and alike. Its purpose is to give a full understanding of the behaviour of
the MDCS19 program together with the TMCC2 as a system.
Tetra Pak Carton Ambient S.p.A. Functional Description

Issued by / Date: Approved by / Date:
ECM 121627
Fabio Bassissi / 20-December-2002 Fabio Bassissi / 20-December-2002
Identity Document type Version Page
4-2589439-0000 DSC 00 1 (20)

MDCS19
4. Design Control System Overview

The design control system can be illustrated as below, where TMCC2 is the central part in the system,
and all other parts in the system are connected to the TMCC2. Inside the TMCC2 symbol is a simple
representation of the functional blocks of the software:
Photocells TMCC2
Read
Photocells
I/P Transducer
D Angle Encoder
Read
Angle Encoder
TPOP
Calculation
(PID)
Output to Fold. Flap Motorized Cylinder

Flexbox I/P Transducer
And Folding Flap
PLC
Communication Terminal, (PC)
with PLC
and Terminal
Parameter
Settings
The connections and the functions are explained in the following pages. The MDCS19 program flow is
further explained in the "Basic Program Functions" chapter.

ECM 121627
4-2589439-0000 DSC 00 2 (20)

MDCS19
5. TMCC2 connections
The TMCC2 is a general purpose hardware and its inputs and outputs are fully controlled by the
software, in this case the MDCS19 program. The connections below have been chosen for the MDCS19
function (a pin connection diagram is available in the appendices):
1 TMCC2
+24V
2 Power Supply 25
Ground MDCS Right Step Pulse
26
MDCS Left Step Pulse
9 27
Angle Encoder, bit0 HighOut 0-5 MDCS Direction
10 28
29
MDCS Alarm
11
30
Not Used
12
Volume Acknowledge
13 LowIn0-7
14
15
16
Angle Encoder, bit7
7
Register Mark Photocell Q, (3bar) FastIn0-1
8
Register Mark Photocell Q, (4bar) AnalogOut1 6 I/P transducer Out Signal
17 31
Register Mark Photocell ET, (3bar) Register Mark Photocell Pulse
HighIn0-1 HighOut6-7
Register Mark Photocell ET, (4bar) 18 32 Design OK
AnalogOut0 5 Diagnostic Analogue Output

MDCS Right Sensor Home 19
MDCS Left Sensor Home 20 HighIn2-3
AnalogIn0 3 Design Adjustment Signal
MDCS Enabled 21
22
Volume Enable HighIn4-7
23
Volume Clock
24
Volume Data
4
Not Used AnalogIn1
The functions of these signals are as follows (some functions are further explained in the
following chapters):
+24V +24 Volt power supply. From the Electrical Cabinet +24V supply.
Ground Ground power supply. From the Electrical Cabinet ground connection.
Angle Encoder, bit0 - bit7

24V inputs from the machine angle encoder that has 8 bits and counts from 0 to 255
(decimal). bit7 is the Most Significant Bit (MSB) and bit0 is the LSB.
Register Mark Photocell Q, (4bars)

24V input from the register mark photocell positioned beside the paper tube above the jaw
system. The (4bars) indicates that this photocell reads the 4 bars part of the register mark
(also called clock).

ECM 121627
4-2589439-0000 DSC 00 3 (20)

MDCS19
Register Mark Photocell Q, (3bars)

24V input from the register mark photocell positioned beside the paper tube above the jaw
system. The (3bars) indicates that this photocell reads the 3 bars part of the register mark
(also called data).
Register Mark Photocell ET, (4bars)

24V output to program the register mark photocell positioned beside the paper tube above
the jaw system. The (4bars) indicates that this photocell reads the 4 bars part of the
register mark (also called clock).
Register Mark Photocell ET, (3bars)

24V output to program the register mark photocell positioned beside the paper tube above
the jaw system. The (3bars) indicates that this photocell reads the 3 bars part of the
register mark (also called data).
Design Adjustment Analog Input

Analog (0-10V) input which is connected to the PLC analog output. A voltage close to 0V
means that the paper tube position (compared with the jaws) will be higher than with a
voltage close to 10V (in other words: an increasing voltage on this input will move the
paper tube downwards in the jaw system).
The total tube adjustment range is ± 5 mm.
MDCS19 Enabled
24V input from the PLC. When this signal is:
x LOW (0V) - the MDCS19 sets the precorrection mode.
x HIGH (24V) - the MDCS19 runs in the regulating mode if possible.
(Refer to next chapters for explanation of the precorrection and regulating modes).
Volume Enable
Volume Clock
Volume Data
These 24V input signals are controlled from the PLC. They are used for transmitting the
Repeat Length, Production Angle and I/P Transducer constant pressure values to the
MDCS19 program. Refer to the chapter below describing this transmission protocol.
I/P Transducer Signal

Analog (0-10V) output signal connected to the I/P Transducer. This signal is converted into
an air pressure from 0 to 3 bar, which is applied to the pendulum dancing roller. In this way
the MDCS program can control the paper web tension for a better design correction
performance and for a better package forming.
The working range for this signal is determined during the setting of the maximum and
minimum pressure (refer to that chapter).
MDCS Right sensor home

24V input from the right sensor home. The sensor has to be put as a reference of the
home position, where the motorized cylinder is in completely backward position.
MDCS Left sensor home

24V input from the left sensor home. The sensor has to be put as a reference of the
home position, where the motorized cylinder is in completely backward position.
MDCS Right step pulse

24V output from the TMCC2. This signal is connected to the stepper motor drive and on
every transition moves the motor by one step.

ECM 121627
4-2589439-0000 DSC 00 4 (20)

MDCS19
MDCS Left step pulse

24V output from the TMCC2. This signal is connected to the stepper motor drive and on
every transition moves the motor by one step.
MDCS direction
24V output from the TMCC2. This signal is connected to the stepper motor drives and
determines the direction of both the motorized cylinders (Right or Left side).
MDCS alarm
24V output to the PLC. This signal is LOW (0V) as long as:
x the sensor is broken in status ON RH or LH cylinder;
x the sensor is broken in status OFF RH or LH cylinder.
The signal is ON when home position is done.
Register Mark Photocell Pulse

24V output to the PLC. This is a 40 ms long pulse sent when the MDCS19 program has
decoded a register mark. The pulse is delayed with the sum of:
x a constant delay corresponding to 32.7 mm tube movement,
x a variable delay depending of the Design Adjustment (± 5 mm).
Design OK
24V output to the PLC. This signal is HIGH (24V) as long as:
x the design error of a package is less than ±1.5 mm, OR
x the mean design error of the two latest packages are less than ±1.5 mm.
Diagnostic Analog Output

An analogue (0-10V) output that sets one of the following signals after each package:
x Design error of current package ( ).
x Mean design error of the lastest two packages ( ).
x Filtered design error ("90% old + 10% new"-algorithm). ( )
x Output signal to I/P Transducer and motor.cylinder folding flaps. ( )
x Filtered output signal. ( )
x Design Adjustment signal. ( )
0…10V on this output equals to -5…+5 mm.

0…10V on this output equals to 0 to 255 range to output signal.
The selection of the parameter to be monitored, is done through the MDCS19 menu
structure.
Refer to the "Menu Structure chapter" to know which commands have to be used to select
the desired parameter which have to be sent to the diagnostic output.
NOTE: that all the values (incl Design Adjustment) change only when the filling machine
is running (the values change for every package).
Volume Acknowledge
This is a 24V output to the PLC. Refer to the chapter below describing the transmission
protocol for volume parameters.
Not Used
These inputs and outputs are not used in the MDCS19 program. They should be left
unconnected.

ECM 121627
4-2589439-0000 DSC 00 5 (20)

MDCS19
6. Basic Program Functions

The MDCS19 program for the TMCC2 is written in the C-language and it is not possible to modify this
without the proper knowledge and development tools (this must be done in a technical development
facility). The compiler use is “FFMC-16 family softune workbench V33L22”.
The parameters that need to be changed (e.g. volume parameters) are controlled from the PLC.
Program flow:
At start-up or reset (the TMCC2 may be reset manually by pressing the DOWN and ENTER pushbuttons,
on the front panel, for a few seconds) the MDCS19 program initiates all its internal variables and reads
the volume parameters sent from the PLC. After this first step the program enters an eternal loop, i.e. it
repeats the program over and over again. This loop has the following basic functions:
x Wait for a valid photocell reading of the register mark. This routine decodes the edges of the
register mark (and of the other part of the design as well) and for every edge (black to white, white
to black) it stores the photocell values in a shift register. The shift register is a 26-bit single register
(compared to the first MultiStep routine that used two separate shift registers with 6 and 7 bits
respectively, which in some cases could cause a false decoding). This shift register is compared
with a special pattern that corresponds to a correct register mark. If they are equal a register mark
has been detected and the program can proceed with its calculations.
x When the register mark has been detected the MDCS19 program reads the machine angle encoder.
To get an acceptable accuracy of the machine angle an interpolation is done by comparing the
remaining time of the current angle (i.e. until the angle encoder changes to a new value) with the time
for a complete angle. This gives a decimal number (for example, 72.95) telling where the register
mark is in relation to the machine jaw system.
x When the register mark has been detected the MDCS19 program also sends the Register Mark
Photocell Pulse signal to the PLC. This signal is delayed a certain time from the actual register mark
detection. The delay time depends of the current machine speed and corresponds to a distance on
the paper tube. This distance is independent of volume settings. The delay is a constant 32.7 mm in
addition to a variable delay depending on the Design Adjustment position (±5 mm).
x The calculated register mark angle is now compared to the preferred design angle, i.e. the
production angle set from the PLC offset by the Design Adjustment value (for example, 74 - 1.25 =
72.75). The comparison gives the angle error and together with the repeat length it is possible to
calculate the design error in millimetres for the current package (the example: 72.95 - 72.75 = 0.20;
0,20 * 245(repeat length) / 128(no of angle degrees per package) = 0.38 mm design error). The
design error is positive if the register mark (the design) is too "high" in relation to the jaw system, and
vice versa.
x The design error is used as an input to the PID control algorithm. Actually, it is the mean design error
of the two latest packages that are used, this giving a more smooth running system in case of
different mechanical adjustments of the left and right side of the machine. The algorithm uses a
quadratic P-part, which means that it has a faster response for larger design errors. Otherwise, it is a
standard PID with integral and output range limitations. The P, I and D factors have been tested on
filling machines to give a well working design control in both normal production and start/stop
sequences.
x When the PID algorithm has calculated a new output value, ranging from 0 (precorrection), 1
(minimal paper pull) to 255 (maximal paper pull), this is converted into an analogue signal for the I/P
Transducer and a digital setting of the driver for the motorized cylinder controlling the folding flaps.
The conversion is illustrated in the chapter "Output Signal".

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MDCS19
x From the calculated design error the MDCS19 program also decides whether it should accept the
package or not. If the package is accepted the DesignOK signal to the PLC is set. The decision is
based upon the following rules:
Design Error Package Accepted

Design error of last package is less than ±1.5 mm YES
Mean design error of last two packages is less than ±1.5 mm YES
Otherwise NO
Note: The window of r1.5 mm is the Default value. It is possible to change by terminal or menu
structure (refer to chapter 9 for more details).
x The MDCS19 program then start again to search for a new register mark.
Besides this main program flow the MDCS19 program also checks if anything is sent from a terminal
through the RS-232 serial interface. If so, it returns the appropriate answers to the terminal, refer to the
"Terminal communication" chapter.
The MDCS19 program manages the display and the pushbuttons according to a built in menu structure.
Refer to the "Menu structure chapter" for more details.
7. Other Program Functions

Besides the basic program functions described above the MDCS19 program performs some other
functions and decisions:
Precorrection vs. Regulating mode:

x The motorized cylinders and, consequently, the folding flaps can be set in twenty-six different
positions, one precorrection and twenty-six regulating positions.
x The precorrection mode is used when the paper tube is far out of design, to move it as fast as
possible to the correct position. The precorrection position lets the paper tube "move upwards" in
relation to the jaws, approx. 10 to 20 mm each jaw stroke (depends on volume and filling on/off).
x A normal production start always begins in the precorrection mode. A number of packages are
thrown away before the PLC starts its search for the filling position, i.e. when the Register Mark
Photocell Pulse is found in this position the filling is turned on. The filling position is chosen so that
when the paper tube is fully filled then the design control system has also found the correct design
position.
x The Filling Position is updated by the PLC to get the design time as close as possible to the filling
time. This function has to be selected in the Bit Parameter Register and is useful for reducing the
packages waste at start. The calculation of the filling position is done in this way: the 1st BC detected
closer to the design position is indicated to the PLC through the output Design OK in order to
calculate the time to get in design from start. Then the PLC compares the design time with the filling
time. If the design time is the same as the filling time within a window of r1s the filling position is not
updated. If it is greater, the filling position is increased of 5 degrees (moved closer to the design
position), if it is lower, the filling position is reduced of 5 degrees. The filling position is also not
updated if the filling time is off the setpoint filling time of r1s.
x The MDCS19 program continuously calculates the design error, also during precorrection mode.
When, in this mode, the design error becomes less than a certain value (-10mm ÷ 0mm) the
MDCS19 program prepares to switch into regulating mode. I.e. tries to find the correct motorized
cylinder position, one of the twenty-six possible positions and I/P transducer, to minimise the design
error.
x When in regulating mode the MDCS19 program tries to keep as low design error as possible. When:

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MDCS19
x the design error is less than ±1.5 mm, or

x the mean design error of the two latest packages is less than ±1.5 mm,
then the Design OK signal (and front panel LED) is turned on. The filling machine is "in
production".
x When the MDCS19 program runs in the regulating mode it continues in this mode until:
x more that three consecutive packages have a design error greater than ±20 mm,
x more than four Register Marks should have passed the photocells, i.e. they are missed,
x the PLC resets the MDCS19 Enable signal.
When one, or more, of these condition is true the MDCS19 program switches to precorrection mode.
x When the filling machine is in short stop the design control system remains in regulating mode.
When started again the MDCS19 program tries to keep the design control as good as possible, just
like in normal production mode.
x Every time the filling machine is in stop, the I/P transducer pressure is set to 0,5 bar to maintain the
packaging material tensioned.
Volume Parameters:
x Normally the volume parameters are sent from the PLC, refer to the "Volume Parameter Transfer"
chapter.
8. TMCC2 Front Panel Display

The TMCC2 card is equipped with an alphanumeric display and three pushbuttons, placed on the
front panel. The following picture shows their position:
TMCC2
559810 Display / Led
"UP" Pushbutton S1
S2
S3
"DOWN" Pushbutton S4
S5
S6
"ENTER" Pushbutton S7
S8
The display can be used to send text messages or each character can be used as an Led to signal
program alarms and status.
When the program is in an idle status the display shows the program name and number. When the
program became active the each character is used as a Led with the following meaning:

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MDCS19
LED Function
S1 MDCS Register mark decoded
S2 Design OK
S3 RH / LH motor step pulse.
S4 RH / LH motor direction ON=CW / OFF=CCW.
S5 Cylinder Position 19-25.
Note: if LEDs S5 and S6 are ON means that the sensor is broken in status ON. If LEDs S7 and S8
are ON means that the sensor is broken in status OFF.
At any time by pressing any pushbutton it is possible to enable a menu structure composed by
different levels and sub-menus. By using the "UP" and "DOWN" pushbuttons it is possible to navigate
through the menu items of a certain level and by pressing the "ENTER" pushbutton it is possible to
change the menu level or to execute a function associated to a menu item. The program functionality
is not influenced by accessing to the menu structure; if the menu allows to change some program
parameters then the program behavior can be influenced. Refer to the "Menu structure chapter" to
have more details about the menu structure and the functions that it is possible to activate through it.

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MDCS19
9. Menu structure
The MDCS menu structure is shown by means of the following table:
Menu Level
1 2 3 4 Description
MONITOR Select what data to view on the display
DES ERR Displays the Design Error
MEAN DER Displays the Mean Design Error
OUTPUT Displays the Output to the I/P (0-255)
BACK Back to Level 1
Select what data to send to the analog
DIAG OUT
output on Pin 6 of the TMCC2
DES ERR Outputs the Design Error of every pack.
MEAN2 DE Outputs the Mean Design Error of the
last 2 pack.
MEAN DER Outputs a filter of the Mean Design Error
OUTPUT Outputs the output value to I/P
MEAN OUT Outputs the mean output value to I/P
DES ADJ Outputs the Design Adjustment Value
PHOT. Photocells menu
CONF? Y Photocells configuration menu
GREEN Sets the photocells spot color to green
BLUE Sets the photocells spot color to blue
RED Sets the photocells spot color to red
CALIB. Manual calibration menu
USE CAL. Use previous manual calibration
RUN CAL. Start manual calibration
BACK Exit from manual calibration menu
BACK Exit from photocell configuration menu
CONF? N Exit from photocells configuration menu
MAX D OK Max allowed design error menu
DOK=±X.X Set the max allowed design error ( )
PRESSURE Set the pressure I/P transducer WTC
MIN PRES Minimum pressure menu
MIN= X.X Set the minimum pressure (0-10 V)
MAX PRES Maximum pressure menu
MAX= X.X Set the maximum pressure (0-10 V)
BACK Exit from menu structure
See chapter “besic program function”.

For more details about the photocells setting refer to the "Photocells management chapter".
For more details about the I/P tranducer setting refer to the " I/P Tranducer Setting chapter".
NOTE: the values XX=XX in the table can be changed by using the UP and DOWN pushbuttons and
the storage is performed after pressing the ENTER pushbutton.

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MDCS19
10. Photocells Management

Photocells features
x Remote setting from the TMCC2 card (see Photocell setting)
x Manual Teach-In function enabled from TMCC2 card (see Photocell setting)
x Increased lifetime obtained switching off the light spot after 20 minutes of machine stop; the light
spots are switched on again at machine start.
x Advanced diagnostic connecting a terminal to the TMCC2 serial port.
It is possible to know the total number of register marks decoded or missed, the parameters used by
the photocells, the status of the photocells, the number of hours that every light spot LED has been
working.
Photocells setting:
The photocells can be set by using the menu structure of the MDCS19 program.
When register mark decoding errors occur the first thing to check is the photocells alignment and
distance.
Then it is possible to change the spot color of the photocell, keeping the Dynamic Threshold = 20 and
the Teach Button disabled, in order to optimize the contrast between the register mark color and the
white. The following table gives the suggested light spot color, related to the register mark color to obtain
the best detecting performances:
Register mark Photocell spot color.

color
Black GREEN, RED, BLUE
Blue GREEN, RED
Light Blue / Cyan RED
Green RED, BLUE
Yellow BLUE
Red GREEN, BLUE
Magenta GREEN
It is also possible to perform the setting of the photocells through a manual teaching procedure. This
procedure must be used only if the basic settings (GREEN, RED, BLUE) do not solve register mark
decoding problems and a finer adjustment is required:
1. Stop the machine.
2. Go to menu item "RUN CAL." and press the enter pushbutton. This command enables the teach
button of the photocells.
3. Position the packaging material at 12mm from the first photocell in order to have the light spot on
the white background.
4. Push the teach button on the rear of the first photocell.
5. Move the packaging material so that the light spot scans through the register code.
6. Release the teach button.
7. Perform the steps 3-6 for the second photocell.
8. Go to menu item "USE CAL." and press the enter pushbutton. This command sends the taught
values to the photocells.
9. Run the machine.
11. Encoder Function and Gray Codes

The angle encoder is connected to the machine main shaft and outputs 128 degrees (values) for each
package. The encoder is 256 degrees version, which means that one package range from 0 to 127
degrees and the following from 128 to 255 degrees and then back to 0 again.
The value sent to the TMCC2 is Gray-coded, which means that only one of the eight signals (bits)
changes for each change in degree (this prevents erroneous angle values on the signal lines.) This also

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MDCS19
means that the MDCS19 program must convert the value into a "normal" representation before it can be
used in calculations. A conversion table is given in the “grey code table” chapter.

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MDCS19
12. Design Adjustment Signal

The TPOP is used to move (fine-adjust) the design position in relation to the jaw system. The TPOP is
connected via Flexbox to an analog output of the PLC. The MDCS19 program converts the voltage level
into an angle offset that is then added to the constant production angle set by the PLC. The adjustment
range ±500 on TPOP corresponds to a movement of ±5 mm on the design position, this range being the
same for all volumes.
Negative settings will move the design downward in relation to the jaw system, and vice versa.
13. Output Signal

The PID algorithm calculates a new output value for every package. The calculated output value ranges
from 0 to 255. This value is converted into an analogue signal for the I/P Transducer and twenty-six
digital signals to the driver controlling the folding flap motorized cylinders. The I/P Transducer signal
overlaps the motorized cylinder positions (hysteresis) as below:
25
Max.
(2.5 bar)
13
Cylinder I/P transducer
position pressure (bar)
Min.
0 (0.5 bar)
0 1 10 128 255
1 Output value
Output value = 0 sets the precorrection position of the motorized cylinders and sets the maximum
pressure on the I/P Transducer.
14. Terminal (PC) communication

A terminal, or a PC with a terminal program, is not necessary during normal production, but may be used
for test and service purposes. Through the serial interface it is possible to see the design error, output
values and other MDCS19 status values.
The communication is a standard RS-232 serial interface. Use a cable suitable for the TMCC2 and the
PC (terminal). Necessary pin connections are:

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MDCS19
PC 9-pin TMCC2 9-pin

female male
2 3
3 2
5 5
If you are using a PC, a terminal program like HyperTerminal, windows 3.11 terminal etc. may be used.
Configure the program for:
x Baudrate: 9600
x Parity: None
x Bits: 8
x Stopbits: 1
x Flow Control: None
The commands and parameters, if any, to the MDCS19 program is entered on the keyboard, and the
command is executed when the RETURN key is entered. The functions described below are available:
Annn Angle nnn. The Production Angle (=machine angle) may be set with this command. nnn is
the new angle value, ranging from 0 to 255 decimal degrees. Normally the Production
Angle is set from the PLC, but this command overrides the PLC setting. It may be used in
test purpose to find the correct nominal Production Angler, which will later be set from the
PLC. Note that the Design Adjustment setting is added to this value.
For example: A72 sets the Production Angle to 72 degrees (110 octal).
CAL Execute the calibration sequence of the motorized cylinder.
Dddd D-constant: Sets the D parameter in the PID controller algorithm, in 1/100 units. The
original value will be restored after a TMCC2 reset.
E Displays the current Encoder value, first the hexadecimal Gray code, then converted to
octal.
Fooo Force ooo. This command forces the outputs, I/P Transducer pressure and Motorized
Cylinder position, to a certain value which is (ooo-1). F0 resets the forcing:
F0 Reset (disable) output force.
F1 Force to Precorrection output.
F2 Force to output = 1.
...
F255 Force to output = 254.
(This means that output=255 is not possible but since it is a small step in the upper region
of the output range this has no practical meaning.)
NOTE! This function is only available when the machine is running.
H Help Menu: displays the commands available.
Iiii I-constant: Sets the I parameter in the PID controller algorithm, in 1/100 units. The original
value will be restored after a TMCC2 reset.
L Show the LED function.

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MDCS19
Mnn Change the Design OK window and the value is stored into the EEPROM, so kept even
after a shut down or a reset. The value is expressed in 1/10 of mm. (i.e. 20 means r 2.0
mm).
Pppp P-constant: Sets the P parameter in the PID controller algorithm, in 1/100 units. The original
value will be restored after a TMCC2 reset.
Rn Reporting ON/OFF. This command enables and disables the automatic reporting of the
design error and output value for every package.
R0 Disable reporting.
R1 Enable reporting.
Note! When the monitoring is finished, remember to set R0, in order to avoid delays
in the scanning time.
S Status: This command displays a list of parameters that may be of interest for test and
service purposes:
DesignError mean (mm) : A filtered* value.

Output mean (0-255) : A filtered* value.
Machine Speed, (p/h) : In packages per hours.
Repeat Length (mm) : The Repeat Length set from PLC.
Production Angle const (dec.degr.) : The Production Angle set from the
PLC.
Production Angle +pot (dec.degr.) : The Production Angle + the Design
Adjustment Pot offset.
WTC constant pressure (bar*0.1) : The pressure set from the PLC.
MaxDesignOK (mm) : The max allowed design error.
MaxPressure, MinPressure (bar*0.1): The maximum and minimum pressure
set by the TMCC2 front panel buttons.
Design Adjustment (V) : A value 0 -10 Volt depending on the
Design Adjustment position.
Filling Position Calculation: ON.
Pc=, Ic=, Dc=: The constants for the PID controller
algorithm.
Photocell Status: Show if there is a failure of the
photocells.
* = Filter algorithm: 90%(old values) + 10%(new values)
Y Displays a detailed status of the photocells for test and service purposes:
Commands OK: Total number of commands executed by the

photcells
Commands failed: Total number of commands failed by the photcells
Barcode decoded: Total number of barcodes decoded by the TMCC2
Barcode errors: Total number of barcodes missed by the TMCC2
Dynamic Threshold: Photocell threshold
Light Spot: Color of the light spot used by the photocells
Output: Logic of the photocell outputs (Light/Dark switching)
Photoswitch Working Hours: Number of hours that every LED of the photocell has
been working
Photocell Software ver. / S.N.: Software version of the photocell firmware and serial
number

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MDCS19
15. Volume Parameter Transfer

The Repeat Length, the Production Angle, the I/P Transducer Constant Pressure and the Parameter
Bit Register may be sent from the PLC to the MDCS19 program. This sending uses four digital +24V
signals and the protocol is as follows:
From PLC:
VolumeEnable
VolumeClock
VolumeData
From TMCC2:
VolumeAcknowledge
8. Repeat the message until

1. Set VolumeEnable 5. Output last bit
VolumeAcknowledge is set
2. Output bit 1 6. Toggle VolumeClock
3. Toggle VolumeClock 7. Reset VolumeEnable
4. Shift out all data bits
x The bit time must be at least 5 ms.

x The output bits are shifted with the least significant bit (LSB) first:
<LSB>Repeat Length<MSB><LSB>Production Angle<MSB><LSB>WTCConstantPressure<MSB>

<LSB>Bit Parameters<MSB>
x The Repeat Length is in 1/10 of mm, i.e. a repeat length of 245 mm is sent as 2450.
x The Production Angle is in integer degrees, i.e. an angle of 123 is sent as 123. (Octal or decimal
degrees notation is irrelevant since the number is sent in bit format which is the same for both
alternatives).
x The WTC Constant Pressure is sent as the value air pressure / minute (bar).
x The 16 Bit Parameters register is used to select specified functions in the program.
Other features:
x The signal VolumeAcknowledge in the protocol is useful when, for example, the PLC starts up earlier
than the TMCC2 or if the TMCC2 is replaced or reset during power on. In these cases the
VolumeAcknowledge is reset to low and the PLC should start to send the message again.
x The MDCS19 program must receive at least two complete messages that are exactly the same
before it sets the VolumeAcknowledge signal.
16. Parameter Bit Register

A 16 bit parameter register is used by the PLC to select particular functions in the TMCC2 Program.
The LSB bit is used to select the Filling Position Calculation. See figure:
MSB LSB
Bit Parameters 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1
Filling Sector
Calculation ON
With this function the TMCC2 card sends to the PLC the 1st BC in design within an error of r 8mm during
precorrection. This lets the PLC to calculate the time to get the 1st BC in design after start so to adjust
the filling position in order to have the design time as close as possible to the filling time.

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MDCS19
17. I/P Transducer Setting

The I/P Transducer pressure is set manually with TMCC2 push button, refer to the menu structure and
the following sequence are used (for more detailed instruction see MM book):
A) Basic Setting on TMCC2 card:

The Analog output signal (0-10V) connected to the I/P Transducer must be first set on the TMCC2
card as follows:
1. The connector must be removed on I/P transducer to not damage the manometer.
2. Connect the voltmeter between Pin No 2 and 6 on the back plane of the TMCC2 card.
3. Select “MIN PRES”, check the reading is 0 volts, if not adjust using Pushbotton “UP or DOWN”.
4. Select “MAX PRES”, check the reading is 10 volts, if not adjust using Pushbotton “UP or DOWN”.
5. Reconnect the connector.
B) Basic setting on I/P transducer:

1. Open the rubber cover placed over the setting window as shown in the picture.
2. Set the Gain trimmer (G) fully anti clock wise in order to reduce the gain of the I/P at the minimum
level.
3. Select “MIN PRES” and check the output pressure of the I/P. Turn the Zero trimmer (Z) in order to
have zero bar at the I/P output.
4. Select “MAX PRES” and check the output pressure of the I/P. Turn the Span trimmer (S) in order to
have 3.0 bar at the I/P output.
5. Go back to point 3 and repeat the point 4 until the setting is satisfactory.
Z S G
Setting
Connector
C) Final Setting of I/P transducer:
1. Set the I/P Transducer minimum pressure (basic setting 0.5 bar) with “MIN PRES” using
Pushbotton “UP or DOWN” and check the pressure on the manometer.
2. When correct minimum pressure has been reached, set the I/P Transducer maximum pressure
(basic setting 2.5 bar) with “MAX PRES” using Pushbotton “UP or DOWN” and check the pressure
on the manometer.
3. Repeat item 1 and 2 until the pressure is correct.
4. Exit the menu on the TMCC2 see chapter “Menu Structure”.

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MDCS19
18. Setting Criteria

The TMCC2 by menu structure can modify the working pressure range for the I/P transducer. For more
detailed instruction please see MM book.
It is necessary to check the package forming during start-up and production in order to decide if it is
worth to decrease the maximum pressure. When using low stiffness to packaging material, it is
recommended to reduce pressure to preserve integrity.
It is also possible, as an alternative function set the WTC to a constant pressure from the PLC (for
example, value 10=1bar), which means the pressure will be fixed. When design OK is enable, the
pressure, in precorrection condition is set according the maximum value.
The motorized cylinder will work with twenty-six positions on both conditions.
19. Flap Cylinders Calibration

The flap cylinders calibration procedure is enabled by using a PC command (refer chapter Terminal
PC communication) see the tables below.
PC command Function
C Calibration: full distance
H Home position
M Maximum forward movement in correction mode.
V View acceleration motor profile
E Exit
Note: View acceleration motor profile is only for internal use. If you press the «V» key, press it
repeatedly until the main menu is displayed.
Calibration Procedure:
1. Connect the cable between the PC and the TMCC2 front panel connector and start the
communication.
2. To enable the calibration of the Right Cylinder manually move the machine to 120°-220°
3. Type the command CAL to enter the menu calibration and the currently enabled cylinder will move
to its home position, then the full distance.
4. Press the «H» key to enter the home position. The cylinder will move to find the sensor.
5. Press the «C» key to enter the calibration full distance. The cylinder will move its full distance
42mm.
6. Go back to point 3 and repeat the point 4 and 5 until the setting is satisfactory. The operator can
adjust the sensor position and the cylinder by following the MM instructions.
Note: the cylinder must not touch the mechanical stops on the forward or backward movements.
7. From point 5 press the «M» key to enter the maximum forward movement. The cylinder will move
10mm (correction mode).
8. Press the «E» to exit from calibration.
9. To enable the calibration of the Left Cylinder manually move the machine to 301°-40° and repeat
the point from 4 to 7.
10. When both cylinders are calibrated repeat the point 8.

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MDCS19
20. Program Download

The MDCS19 program should be downloaded to the TMCC2 with status in Power ON. The download is
done from a PC with at least one diskette station and one serial RS-232 interface. Refer to the "Terminal
(PC) Communication" chapter for a description of the communication parameters.
Download procedure:
1. Connect the cable between the PC and the TMCC2 RS232 connector.
2. Start the HyperTerminal program on the PC.
3. If there is an application running type STOP<enter> or keep DOWN and ENTER pushbutton
pressed for few seconds to stop it.
4. Insert the program diskette marked "2589440-0001” into the PC diskette station.
5. Type the command E FLASH<enter> to erase the TMCC2 flash memory.
6. When the erasing operation is completed type D<enter> to prepare the application download.
7. Select the menu Transfer and the menu item Send Text File.
8. Select the file 2589440.1001 on the diskette marked "2589440-0001.
9. The downloading starts and the progress of the download is shown with dots on the terminal
screen.
10.When the new program is downloaded without errors type RUN<enter> or ENTER pushbutton
pressed two time to start the application program.
11. Check the I/P transducer setting (refer to that chapter).

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MDCS19
21. Grey Code Table

Gray O D Me Gray O D Me Gray O D Me Gray O D Me
-------- 0 0 0.0 -¤¤----- 1 6 90,0 ¤¤------ 2 1 180, ¤-¤----- 3 1 270,
-------¤ 1 1 1,4 -¤¤----¤ 1 6 91,4 ¤¤-----¤ 2 1 181, ¤-¤----¤ 3 1 271,
------¤¤ 2 2 2,8 -¤¤---¤¤ 1 6 92,8 ¤¤----¤¤ 2 1 182, ¤-¤---¤¤ 3 1 272,
------¤- 3 3 4,2 -¤¤---¤- 1 6 94,2 ¤¤----¤- 2 1 184, ¤-¤---¤- 3 1 274,
-----¤¤- 4 4 5,6 -¤¤--¤¤- 1 6 95,6 ¤¤---¤¤- 2 1 185, ¤-¤--¤¤- 3 1 275,
-----¤¤¤ 5 5 7,0 -¤¤-- 1 6 97,0 ¤¤--- 2 1 187, ¤-¤-- 3 1 277,
-----¤-¤ 6 6 8,4 -¤¤--¤-¤ 1 7 98,4 ¤¤---¤-¤ 2 1 188, ¤-¤--¤-¤ 3 1 278,
-----¤-- 7 7 9,8 -¤¤--¤-- 1 7 99,8 ¤¤---¤-- 2 1 189, ¤-¤--¤-- 3 1 279,
----¤¤-- 1 8 11,3 -¤¤-¤¤-- 1 7 101, ¤¤--¤¤-- 2 1 191, ¤-¤-¤¤-- 3 2 281,
----¤¤-¤ 1 9 12,7 -¤¤-¤¤- 1 7 102, ¤¤--¤¤- 2 1 192, ¤-¤-¤¤- 3 2 282,
----¤¤¤¤ 1 1 14,1 -¤¤- 1 7 104, ¤¤-- 2 1 194, ¤-¤- 3 2 284,
----¤¤¤- 1 1 15,5 -¤¤- 1 7 105, ¤¤-- 2 1 195, ¤-¤- 3 2 285,
----¤-¤- 1 1 16,9 -¤¤-¤-¤- 1 7 106, ¤¤--¤-¤- 2 1 196, ¤-¤-¤-¤- 3 2 286,
----¤-¤¤ 1 1 18,3 -¤¤-¤- 1 7 108, ¤¤--¤- 2 1 198, ¤-¤-¤- 3 2 288,
----¤--¤ 1 1 19,7 -¤¤-¤--¤ 1 7 109, ¤¤--¤--¤ 2 1 199, ¤-¤-¤--¤ 3 2 289,
----¤--- 1 1 21,1 -¤¤-¤--- 1 7 111, ¤¤--¤--- 2 1 201, ¤-¤-¤--- 3 2 291,
---¤¤--- 2 1 22,5 -¤¤¤¤--- 1 8 112, ¤¤-¤¤--- 2 1 202, ¤-¤¤¤--- 3 2 292,
---¤¤--¤ 2 1 23,9 -¤¤¤¤-- 1 8 113, ¤¤-¤¤-- 2 1 203, ¤-¤¤¤-- 3 2 293,
---¤¤-¤¤ 2 1 25,3 -¤¤¤¤- 1 8 115, ¤¤-¤¤- 2 1 205, ¤-¤¤¤- 3 2 295,
---¤¤-¤- 2 1 26,7 -¤¤¤¤- 1 8 116, ¤¤-¤¤- 2 1 206, ¤-¤¤¤- 3 2 296,
---¤¤¤¤- 2 2 28,1 -¤¤¤ 1 8 118, ¤¤-¤ 2 1 208, ¤-¤¤ 3 2 298,
---¤ 2 2 29,5 -¤¤¤ 1 8 119, ¤¤-¤ 2 1 209, ¤-¤¤ 3 2 299,
---¤¤¤-¤ 2 2 30,9 -¤¤¤¤¤- 1 8 120, ¤¤-¤¤¤- 2 1 210, ¤-¤¤¤¤- 3 2 300,
---¤¤¤-- 2 2 32,3 -¤¤¤¤¤- 1 8 122, ¤¤-¤¤¤- 2 1 212, ¤-¤¤¤¤- 3 2 302,
---¤-¤-- 3 2 33,8 -¤¤¤-¤-- 1 8 123, ¤¤-¤-¤-- 2 1 213, ¤-¤¤-¤-- 3 2 303,
---¤-¤-¤ 3 2 35,2 -¤¤¤-¤- 1 8 125, ¤¤-¤-¤- 2 1 215, ¤-¤¤-¤- 3 2 305,
---¤-¤¤¤ 3 2 36,6 -¤¤¤- 1 9 126, ¤¤-¤- 2 1 216, ¤-¤¤- 3 2 306,
---¤-¤¤- 3 2 38,0 -¤¤¤- 1 9 128, ¤¤-¤- 2 1 218, ¤-¤¤- 3 2 308,
---¤--¤- 3 2 39,4 -¤¤¤--¤- 1 9 129, ¤¤-¤--¤- 2 1 219, ¤-¤¤--¤- 3 2 309,
---¤--¤¤ 3 2 40,8 -¤¤¤-- 1 9 130, ¤¤-¤-- 2 1 220, ¤-¤¤-- 3 2 310,
---¤---¤ 3 3 42,2 -¤¤¤---¤ 1 9 132, ¤¤-¤---¤ 2 1 222, ¤-¤¤---¤ 3 2 312,
---¤---- 3 3 43,6 -¤¤¤---- 1 9 133, ¤¤-¤---- 2 1 223, ¤-¤¤---- 3 2 313,
--¤¤---- 4 3 45,0 -¤-¤---- 1 9 135, ¤¤¤¤---- 2 1 225, ¤--¤---- 3 2 315,
--¤¤---¤ 4 3 46,4 -¤-¤---¤ 1 9 136, ¤¤¤¤--- 2 1 226, ¤--¤---¤ 3 2 316,
--¤¤--¤¤ 4 3 47,8 -¤-¤--¤¤ 1 9 137, ¤¤¤¤-- 2 1 227, ¤--¤--¤¤ 3 2 317,
--¤¤--¤- 4 3 49,2 -¤-¤--¤- 1 9 139, ¤¤¤¤-- 2 1 229, ¤--¤--¤- 3 2 319,
--¤¤-¤¤- 4 3 50,6 -¤-¤-¤¤- 1 1 140, ¤¤¤¤- 2 1 230, ¤--¤-¤¤- 3 2 320,
--¤¤- 4 3 52,0 -¤-¤- 1 1 142, ¤¤¤¤- 2 1 232, ¤--¤- 3 2 322,
--¤¤-¤-¤ 4 3 53,4 -¤-¤-¤-¤ 1 1 143, ¤¤¤¤-¤- 2 1 233, ¤--¤-¤-¤ 3 2 323,
--¤¤-¤-- 4 3 54,8 -¤-¤-¤-- 1 1 144, ¤¤¤¤-¤- 2 1 234, ¤--¤-¤-- 3 2 324,
--¤¤¤¤-- 5 4 56,3 -¤-¤¤¤-- 1 1 146, ¤¤¤¤ 2 1 236, ¤--¤¤¤-- 3 2 326,
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--¤¤ 5 4 60,5 -¤-¤ 1 1 150, ¤¤¤¤ 2 1 240, ¤--¤ 3 2 330,
--¤¤¤-¤- 5 4 61,9 -¤-¤¤-¤- 1 1 151, ¤¤¤¤¤- 2 1 241, ¤--¤¤-¤- 3 2 331,
--¤¤¤- 5 4 63,3 -¤-¤¤- 1 1 153, ¤¤¤¤¤- 2 1 243, ¤--¤¤- 3 2 333,
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--¤¤¤--- 5 4 66,1 -¤-¤¤--- 1 1 156, ¤¤¤¤¤-- 2 1 246, ¤--¤¤--- 3 2 336,
--¤-¤--- 6 4 67,5 -¤--¤--- 1 1 157, ¤¤¤-¤--- 2 1 247, ¤---¤--- 3 2 337,
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--¤- 6 5 74,5 -¤-- 1 1 164, ¤¤¤- 2 1 254, ¤--- 3 2 344,
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--¤-¤¤-- 6 5 77,3 -¤--¤¤-- 1 1 167, ¤¤¤-¤¤- 2 1 257, ¤---¤¤-- 3 2 347,
--¤--¤-- 7 5 78,8 -¤---¤-- 1 1 168, ¤¤¤--¤-- 2 1 258, ¤----¤-- 3 2 348,
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--¤----- 7 6 88,6 -¤------ 1 1 178, ¤¤¤----- 2 1 268, ¤------- 3 2 358,

ECM 121627
4-2589439-0000 DSC 00 20 (20)

0
/D

Strip Magazine
Splice sequence
Step 3a

Lund, Sweden ASU 1/0105 OH 1041:4
Strip Magazine
Splice sequence
Step 3b

Strip Magazine
Splice sequence
Step 3c

'*
/D,

Packaging Material
Infeed

''

Valve panel TBA/19
Lund, Sweden
Technical Training Centre
Y184 Y107 A2
Machine type
B2
X032 X034
TBA/19 020V
Y100/2
Y1/1 Y27/1
Y102/3 Y26/2
Y037/5 Y24/3
Y105/4 Y21/4
A1 Z3 Z5 Y32
Y20/5
Y86/7 Y129/6
Issue
Y25/8 Y177/7
Y23/9
1/0303
Y19/10
Y9/1 Z1 A4 Y31
Y7/2
Y8/4
Y17/3
Y6/6
Y5/5 Y103/3
Y3/8
Y2/7 Y030/4
X033 X035
Y51
Y39 B7
OH 1342
A3 Y29
Air diagram TBA/19

Hydraulic diagram TBA/19

Pressure regulation
Reduction valve
Cutting pressure
Jaw pressure
Over flow valve
To tank
From pump

Lund, Sweden TBA/21 1/9609 OH 597
Water diagram TBA/19

Lubrication diagram TBA/19

Central lubrication system
Lubrication oil
Compressed air
PLC

Lund, Sweden 1/9905 OH 820
Central lubrication pump
and dosing valve
Rest position
Lubrication oil
Compressed air

Lund, Sweden 1/9905 OH 821:1
and dosing valve
Pressure stroke
Lubrication oil
Compressed air

and dosing valve
Discharge pressure
Lubrication oil
Compressed air

Lubrication cycles
Lund, Sweden
Single lubrication pulse

15 min
10 s 10 s
Machine type
TBA/19
Long lubrication cycle
Issue
10 s 30 s 10 s 30 s 10 s 30 s 10 s 30 s 10 s
1/0011
Lubrication
OH 1022
Check for no oil pressure
Check for oil pressure
12
Head Space By
Gas Injection

Headspace
by injection
TBA/19 020V
Training Document
This Training Document is intended for
Training purposes only, and must not be
used for any other purpose.
The Training Document does not replace
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such.
Note!
For safe and proper procedures, refer to
the equipment specific documentation.

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preheating 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preheating 2 and tight tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preheating 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Filling spray tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Spraying and pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Short stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Normal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Introduction
The purpose of Headspace by Injection (HI) is to give the package a certain
amount of empty space. HI allows up to 10% headspace. The headspace is
created by injection of gas, nitrogen or air, depending on the product being
filled.
The main purposes of headspace is to:
• be able to shake the package before opening it
• increase the pourability of the package
• allow different volumes to be packed in the same machine
• to pack by weight instead of volume
The main part of the HI unit is the control cabinet, where valves and main
filters are located. In the heat exchanger after the air superheater, the gas is
heated and becomes sterile. The sterile gas is cooled to approximately 30 °C
and then injected into the product via the HI nozzle in the product pipe. The
product is filled into the packaging material tube. The gas will then create the
headspace in the package.
The filling machine can also be run without headspace. The OM describes how
to proceed in both cases.
Control cabinet
Sterile gas
Heat exchanger
N2
HI nozzle
Product pipe
Injection gas
Packaging material tube
Package with headspace
Overview
Headspace 19
by injection 18 Sensor HI
ON/OFF
17
16
15 10 8
11
12 20
13
9
14
Non return 4 3
6 1
valves 5 2
1. Air/Nitrogen valve
2. Filtering section
3. Pressure switch
4. I/P transducer
5. Flow meter
6. HI ON/OFF
7. HI spray tank drain/spray valve
8. HI spray tank filling valve
9. HI spray tank emptying valve
10.HI spray tank
11.HI spray tank, high level probe
12.HI spray tank, low level probe
13.HI filling gas sterilization section
14.Air superheater, temperature probe
15.Stainless steel filter
16.CIP connection
17.HI circuit temperature probe
18.Injection ON/OFF valve
19.HI injection nozzle
20.Injection stop valve
Function
Preheating 1
Air Preheated/cooled air Water Product Nitrogen

Hot air Compressed air Steam Peroxide Cleaning liquid
The HI-unit is automatically activated when the pipe with the HI-nozzle is
installed. A sensor monitors that the pipe is in place. The operator has to select
the nozzle that is used on the TPOP. During the beginning of Preheating 1 the
Air/Nitrogen valve allows compressed air to pressurize the pipe up to the
Injection ON/OFF valve, which is closed. During the delay the flow meter
monitors the flow of air which should be zero, i.e. no flow.
After the delay the Injection ON/OFF valve opens to allow air flow through
the circuit.
Preheating 2
and tight tube

In Preheating 2 and tight tube the valves in the control cabinet are in the same
positions as during Preheating 1, in order to allow more time for drying. The
I/P transducer opens to allow a 4.5 litre/minute flow. The air superheater is
switched on and the compressed air is heated. This will accelerate the drying.
Preheating 3

In Preheating 3 the compressed air flow is directed trough the spray tank in the
control cabinet. The ON/OFF valve is closed and the spray tank filling, the
spray tank drain/spray, and the spray tank emptying valves, allow the com-
pressed air to flow through the spray tank.
Filling
spray tank

The spray sequence in the HI unit follows the spray sequence for the filling
machine. The temperature in the pipe to the HI injection nozzle is monitored,
and the spray sequence does not start if the temperature is higher than 60 °C.
If the temperature is higher than 60 °C an alarm is triggered and the start of the
spray sequence is delayed until the temperature has decreased to 60 °C. In
addition, the spray tank must be empty before the filling of the container starts,
and the container will have to be filled during a certain period of time. The
high level probe monitors the level in the spray tank. If the spray tank is not
filled within the pre-set time, an alarm is triggered and the machine will step
down to Preheating 3.
Spraying
and pause

There is no lower time limit for the spraying since a very small amount of
peroxide is being used. The low level probe in the spray tank monitors the
upper time limit for the spraying. If the level probe detects remaining peroxide
in the spray tank when the spray time has expired, an alarm is triggered and
the machine will step to Venting.
In order to check that the peroxide has passed trough the HI unit, the temperature
at the injection point is monitored by a thermocouple. The temperature must
exceed 60 °C during the pause after the spraying. When the peroxide passes the
air superheater it will be heated. The temperature in the pipe to the HI injection
nozzle will increase when the peroxide passes, since peroxide as a liquid con-
tains more heating energy than air. If the temperature does not exceed 60 °C,
an alarm will be triggered and the machine will step to Venting.
When the spray sequence is completed the machine will step to Drying.
Drying

During the 20 minutes of Drying the airflow in the HI unit is directed in the
same way as during Production. This will dry off peroxide residues.
Production

During the first start, the nitrogen is switched on and remains on until the end
of the production cycle.
The injection stop valve opens at the same time as the A-valve. Nitrogen is
injected into the product pipe in order to provide the product with an even flow
of nitrogen. The nitrogen creates bubbles which will raise to the top of the
package after a while. The package has now got a headspace.
The size of the headspace in the package can be adjusted by controlling the
flow of nitrogen. Different products may need different flow and pressure in
order to get the same headspace size. Different nozzles, with various hole
diameters, may also be used in order to get correct headspace. There is a nozzle
with four holes to be used during special conditions.
Short stop

During a Short stop the filling machine is at a stand still with product in the
filling pipe and the packaging material tube. The injection stop valve closes in
order to stop the nitrogen from flowing into the product pipe. The flow meter
monitors that no gas flows.
During the Short stop the nitrogen that has been injected into the product raises
and disappear from the product, out into the superstructure. When the machine is
restarted the first packages will be fully filled and must be ejected. All packages
from the Longitudinal Seal nozzle and downwards will be ejected.
Normal stop

At a Normal stop the packaging material tube is emptied from product and the
machine steps down to Ready for motor start. Restarting from a Normal stop is
equal to a Normal start, except for the Air/Nitrogen valve that feeds nitrogen.
Cleaning

When the filling machine is being prepared for cleaning the HI unit also has to
be prepared for cleaning. The parts of the HI unit that have to be cleaned are
the HI injection nozzle and the end part of the pipe in front of the HI injection
nozzle. The HI injection nozzle will have to be cleaned manually with a brush
and the end part of the pipe will be cleaned by the CIP flow that cleans the rest
of the machine. When the CIP flow passes the outlet of the CIP pipe from the
HI unit, an under-pressure is created in the HI CIP pipe because of the venturi
principle. This will increase the flow in the HI CIP pipe.
When preparing the machine for production it is important that the pipes,
connected in the CIP flow, are properly drained.
13
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100±240 VAC
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INPUT
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50/60HZ 100VA
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+
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OUTPUT
0.8A MAX.
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PLC
Line Supervision
Com 3
Com 4
Serial Communication
Com 1 (Data distribution)
LPT 1
Hardware lock for InTouch.

VGA
Mouse USB Keyboard
Display
Mini- Mini- 25-pin

DIN DIN condensed
LPT COM 1
25-pin female 9-pin male
LVDS
25-pin female
Reset Termination SB
switch
4-pin
COM 3 COM 4
9-pin female 9-pin female
PWR

Ext. Keyboard Ext. Display
Mouse
Clips-III
PS/2 connector

PS/2 connector
VGA
COM2
Keyboard
LPT1 InTouch
Runtime
(male)
Lock
25-pin D-sub
COM1
Serial Communication
(male)
9-pin D-sub
RCL PCB
AccuTouch
Display Backlight Power

LVDS
LCD Data
HCL PCB Power
Data Signal
Display Backlight
Data Inverter
LVDS Controller
10 m COM2 Touch Signal TFT-LCD Display 8.4"
Touch

COM2
HD
Keyboard

26-pin D-sub
Keyboard
PS/2 connector
2 Ch. Isolated COM4 Line Supervision

LED 12V
LED 5V
LED 3,3V
RS4xx PCB (Distribution equipement)
(female)
9-p D-sub
Panel
COM3
GE Fanuc
(female)
PLC communication
9-p D-sub
Flexbox

&

PC
Telephone modem
Remote access
(Tetra Pak)
Serial
communication

'-

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+
Telephone line
Filling machine
Dairy office
Electrical cabinet
PLMS Master PC
Telephone
modem
Westermo
Westermo receive modem
Send Modem

'-

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Plant office PC
PLMSREC
Serial communications
Filling machine TPOP
RS232/422 PLMSSEND
COM1
PLMSSEND COM2
Ethernet COM3
Log db 1
Log Log Log Log
db 1 db 2 db 3 db 4
PLMSSEND
Phone modem
Log db 2
Phone modem
Log db 3
Filling machine TPOP "Other" office PC
PLMSREC
Log db 4 Log Log Log Log

db 1 db 2 db 3 db 4
= Direction data file flow
Log db n = A database of PLMS log data (BIN) files for machine No n

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Minimum configuration: only one machine connected.
PC desktop Modem USR Telephone line

Windows NT Standard Com 1:
4.0 Wks hardware Westermo Westermo Filling
PLMS Receive Com 2: machine # 1
MA-12 MA-12
PLMS Send
Westermo Westermo Filling

Com 3:
MA-12 MA-12 machine # 2
Moxa
C104H Westermo Westermo Filling
Com 4: MA-12 machine # 3
4 serial MA-12
port Westermo Westermo Filling
hardware Com 5: MA-12 MA-12 machine # 4
Westermo Westermo Filling

Com 6: machine # 5
MA-12 MA-12
Add this equipment to connect from two to five machines
= Serial communication kit
= 25 pin female to 9 pin male adapter

'-

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Modems connected,
no data transfer.
Modems connected,
data transfer active.
Modems disconnected.

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Main graph
Down time “system”
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Main graph
Event graph
Comparing two filling machines
Daily report
Reports
Summary report
Event driven report
Daily production report
Stop report
Waste report
14
Electrical

Level relay
Peroxide spray quantity
L 51 A1
L 50
A2
B1 B3 B2 18 16 15
L 11
To PLC
RM3 LA1
A1 A2
16
15
18 50k
26
25
Function 28 R−sector
10
1 5
(x0.1)
Time value s R−value (x10)

Sequence diagram
Spraying/Drying
Lund, Sweden
Spraying pos. 40
112s Spraying fulfilled, %M108

3s 11s
Filling spray tank, Y34

20s 51s 110s
Too fast emptying Too slow emptying
Machine type
Level spray tank
Level relay signal, %I42
TBA/19 010V
PLC, check level signal
Spraying (steam), Y4
Issue
50s
2/0401
Air inlet valve, Y19 Open Pause
109s 18 19 min
Bending roller motor, %Q83
20 min
Drying, %R551
OH 1144
17 min
B−valve, Y8 Open
Sequence diagram
Spraying pos. 40 Spray fault
11.1-20s
Lund, Sweden
Too fast emptying

51-110s
Too slow emptying
15 min
Machine type
To Ventilation
To Position 00
Ready for door opening
TBA/19 010V
Spraying pos. 40 Spray tank filling fault
11s
Issue
Position 30
2/0401
11.1s 90s
Evacuation of spraytank
Y4, Y35
91s
Evacuation finished
OH 1159
OK step up to pos. 40
Temperature regulating principle
PLC
0 230

This drawing must not without the consent of Tetra Pak
RELEASED be copied, transmitted or disclosed to any third party.
1 2 3 4 5 6 7 8 9 10
L7 L7
L8 L8
L9 L9
N N
1
-F021 -X009 2
1 1 1 1 1 1 1
-X009 5 -F104 2 -F100A+C -F101A+C
1,5 mm² BK 1,5 mm² L. BU
2 2 2 2 2 2 2
2,5 mm² L. BU 2,5 mm² BK 3 6 mm² BK 6 mm² BK
-K001
1 /100.07 1 3 5 1 3 5
-K005 4 -K015 -K016
/100.07 L10 L10 /100.07 /100.07
2 2 4 6 2 4 6
AN / /32.07
1 4 AR / /31.07 AT / /32.07
-K206
1 4 1 4 1 4 1 4 1 4
-K200 -K201 -K202 -K203 -K204
2 3 AP / /102.03
2 3 2 3 2 3 2 3 2 3
240
220
200
0
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1
12
9
6
0
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1
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94
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93
PE
37
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4
5
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2 E 1 2 E Z X Y E Z Z X X Y Y
E
1 E 2 1 U V W
U U V V W W
+M-R035 +M-R033 +M-R034 +M-R036 +M-R032

LONGITUDINAL STRIP SEALING SUPPLY STRIP PEROXIDE BATH, AIR SUPER HEATER
SEALING (L.S.) AND CUTTING CUTTING WATER
Designer Date Machine

@V=00@EN=(1) THE CONNECTION OF THE PRIMARYMUST BE ADAPT ALPO/AIR 08/31/2003 TBA/19 020V
ECM No Denomination Page Type
@V=00@EN=THE TENSION OF APPROPRIATE NET. 140649 CIRCUIT DIAGRAM ELEMENTS
Company Document No. Doc. type Version Page
Drawing remarks Tetra Pak Carton Ambient SpA 44954-0003 ELD AD 10

Solid state relay
4 1
Zero detection
Input Photo Trigger Power

And
circuit detector circuit circuit
+
3 2

Lund, Sweden TBA/21 TB/19 2/9812 OH 600
Thermocouple type K
Material: Nickel−Cromium v Nickel−Aluminium (NiCr − NiAl)

Voltage: DC 4mV / 100 C
Colour: Overall yellow
NiCr yellow positive
NiAl red negativ
Thermoelement
Temperatureregulator

1 2 3 4 5 6 7 8 9 10
L51
L11
L50
-A202
+C-A202 TEMP. REGULATOR LS
25 o 27
t
26 7
8
+M-W450 -W035 -W049
+M-X037 A -K101
YE -X004
1 21
+ 1 5 9
+M-B037A +M-B037A LS SEALED TUBE, TEMP.
RD 1
2 22
- 2
-W036
+M-X037 B 3 17 AN / /10.03
YE -K101
+ 3 AO / /10.03
+M-B037B 4 18 +M-B037B LS ELEMENT, TEMP.
RD 7 11
- 4 3
5 9
+M-W410
-K101
6 10
-W075 10 6
BB / /78.06 2
19 20 /101.07
23 24 BC / /78.06
-A203
+C-A203 TEMP. REGULATOR AIR
25 o 27 SUPERHEATER
t
26 7
8
+M-W409
+M-X039 C -W037 -W070 A
YE -X004
1 21
+ 5
+M-B039 C A +M-B039 AIR SUPERHEATER, TEMP.
RD
2 22
- 6
3 17 AT / /10.10
/59.05 / BD
4 18 AS / /10.08
/59.05 / BE
5 9
-K102
6 10
-W076 1 3
BF / /78.06 4
19 20 /101.07
N
24V
220V
23 24 BG / /79.06
L51
L11
L50

ALPO/AIR 08/31/2003 TBA/19 020V
140649 CIRCUIT DIAGRAM REGULATORS


Temperature controller
H − heating
(relay ON = yellow LED lit) C − without function
X − process value
W 2 lit with 2nd set point W − 1st set point
HCA − heating current error

LC1 − limit contact (current < limits = green LED lit)
(X within limits = green LED lit)
Selector key
Decrease value Increase value
N 16
27
15 Digital
230V
26 Mains Digital interface 14 Interface
115V 13
25
12
24 11
3 Alarm 1 Local (open) / remote L/R
23 10
1st set−point (open) 2nd set−point 9
W/W2
0/4...20mA
22 Continous output
2 Current converter 8
21 0/4 ... 20mA 9404 407 50001 7
Earth terminal 6
20 0 ... 10V
Voltage 5
4 Alarm 2 0/4 ... 20mV
19 Current 4
Pt 100 3
18 Heating (logic output) 0 2
1
0/>
_5V DC Typical 13 V DC
17
Thermocouple 1

Symbols temperature regulator
SP1 (W) Set Point 1
SP2 (W2) Set point 2
Pt 2 Acceleration Time between W --- SP2 (Minutes)
LCL 1 Limit Contact Low 1 (valid for SP1)
LCH 1 Limit Contact High1 (valid for SP1)
LCL 2 Limit Contact Low 2 (valid for SP2)
LCH 2 Limit Contact High 2 (valid for SP2)
HCA Heating Current Limit (0-30A)
LOC Operation Locking
SPL Set Point Low Limit
SPH Set Point High Limit
Pb 1 Proportional Band Heating (0.1 --- 999.9%)
ti Integral Time (0 --- 9999 sec)
td Derivative Time tv (0 --- 9999 sec)
tl Cycle Time Heating (0.4 --- 999.9 sec)
Technical Training Centre 1/9610 TM-00041.fmTraining Document. For training purpose only.
KS 40 temperature regulator -
setting sequence
LOCK
KS 40
A
KS 40 initial state
Operating level 1 Remove the regulator from the housing
Open LOCK
Fit back the regulator in the housing
Press >3 s
Parameter level 2 Press to step forward to LOC
Set LOC to 0
Press >5 s
Configuration level 3 Set Con1 to 0230
Set Con2 to 0000
Press once
Operating level 1 Press >3 s
Parameter level 2 Press to step through parameters
Set parameter value according to MM with and
Press once
Operating level 1 Press >3 s
Parameter level 2 Press to step forward to LOC
Set LOC to 4
Operating level 1 Remove the regulator from the housing
Close LOCK
Fit back the regulator in the housing
Temperature settings, principal
Temp °C
LOC
SPH
LCH 1
SP 1
LCL 1
LCH 2
SP 2
LCL 2
SPL
Maintenance/Behaviour in case of trouble
The controller needs no maintenance. The rules to be followed in case of
trouble are:
• Check mains (voltage, frequency and correct connections)
• Check, if all connections are correct
• Check the correct function of the sensors
• Check the two configuration woed for required function
• Check the adjusted parameters for required operation
If the controller still does not work properly after these checks, shut down the
controller and replace it.
Safety relay
A1 S13 S24 X2 41 13 23 33
JSBR 4 24VDC
Reset
/Test
In
B 1 1 1 1
To activate a safety relay, both On
supervision circuits must be closed In

Type: JSBR4
Out
simultaneously and the reset circuit
In 2 2 2 2
must be closed and opened again. A
Furthermore there must be no
A2 S14 S23 X3 42 14 24 34
connection between the two
supervision circuits.
A1 X2
S13
K2
S14
Protec-
tion Reset and supervision circuit
circuit
S24
K1
S23
A2 X3
13 23 33 41
K1 K1 K1
K1 K2
K2 K2 K2
14 24 34 42
Technical Training Centre 3/0306. TM-00003 Training Document. For training purpose only.
Safety relay
Lund, Sweden
24 VDC Emergency stop switch Alarm reset
Machine type
A1 S13 S24 X2 41 13 23 33 A1 S13 S24 X2 41 13 23 33 A1 S13 S24 X2 41 13 23 33
Reset Reset Reset
/Test /Test /Test
24VDC 24VDC 24VDC
Issue
In 1 1 1 1 In 1 1 1 1 In 1 1 1 1
B B B
On JOKAB SAFETY On JOKAB SAFETY On JOKAB SAFETY
TYPE: JSBR4 TYPE: JSBR4 TYPE: JSBR4
3/0306
In In In
Out Out Out

In 2 2 2 2 In 2 2 2 2 In 2 2 2 2
A A A
A2 S14 S23 X3 42 14 24 34 A2 S14 S23 X3 42 14 24 34 A2 S14 S23 X3 42 14 24 34
OH 868
(Cont'd)
24V DC Power 24V DC
2 Reset
M
1
Emergency stop
switches 3
1
2 Reset
M
Final Folder, Jaw Sys-
tem and Superstructure 1
door switches
3 1
EM3.081803012en.fm
2 Reset
5
Crease wheel/PMI
Enable
3
1 M
1 High-power relay (contactor)

2 Safety relay module
3 PLC output
4 PLC Input
5 Frequency converter
6 DMC
7 Delayed safety relay module
8 TMCC
(Cont'd)
3-4 Doc No. EM-81803-0104 Tetra Pak

(Cont'd)
PT valves
PT door switches
2
Reset 5
Enable
1
3 7 M
6
Enable
1
EM3.081803012en.fm
Strip Applicator door switches

M
2
3
Various outputs
Reset
4 ASU door switches 3

ASU valves
1 High-power relay (contactor)

2 Safety relay module
3 PLC output
4 PLC Input
5 Frequency converter
6 DMC
7 Delayed safety relay module
8 TMCC
Tetra Pak Doc No. EM-81803-0104 3-5

(Cont'd)
Safety relay module A 506 connection
Emergency stop
24 VDC, 0V Safety L21, L20 L21, L20

Supply controlled
L15, L10
Input output
K 030 Contactor to
ensure redundancy
Reset
K 030
K 006 Compressor
K 007 Hydraulic pump Safety
K 009 Peroxide pump chain
relay Y
K 026 Cabinet doors switches
K 113 Reset relay
K 001 Splicer control voltage
K 012 Peroxide bath water pump
K 009, M.M 010 Peroxide pump
K 016 Air super heater
K 007, M.M 005 Hydraulic pump
EM3.081803012en.fm
K 018 Preheating 3 final folder
S 011 K 006, M.M 007 Compressor
K 015 Peroxide bath element
S 005 M.Y 032 Compressor, water
K 005 Preheating 2 LS element
S 004 M.Y 001 Flap sealing, air set
K 024 LS Short stop S 900 M.Y 100 Flap sealing, air reset
K 030 Contactor to ensure S (External)
M.Y 102 Main air valve
redundancy S 002
S 001 K 004 Power IH - Unit TS
K 020 Heating element PT
S 006 K 001 Splicer control voltage
K 012 , M.M 017 Peroxide bath water pump
K 016 Air super heater
K 018 Preheating 3 final folder
K 015 Peroxide bath element
K 002 Detergent pump
K 005 Preheating 2 LS element
K 014 Power IH -
Unit strip applicator
K 024 LS Short stop
K 026, M016,
M 001 Cabinet cooler and fan
K 020 Heating element PT
K 031, M.M 008,
M.M 003 PT stepper motor
(Cont'd)

(Cont'd)
Final Folder, Superstructure and

Jaw System Stop Function
Safety L31, L30 L31, L30

L21, L20 Supply
controlled
output
K 003 Redundancy
L12, L10 Input
Contactor
K 003
Reset
K
K 003 Redundancy
K 008 Clean syst. circ. pump Safety
K 011 Main motor, power chain
relay
K 013 Start conveyor Y
K 019 Bending roller
K 113 Reset relay
EM3.081803012en.fm
M.Y 131 Press jaw right

M.B 011 K 029, M.M 029 Sterilisation roller
M.B 015
K 099 Press jaw enable
M.B 012
M.B 019 M.Y 132 Press jaw left
M.B 021A K 013, M.PLE 1 External conveyor
M.B 021B M.Y 027 Drop chute
M.B 021C M.Y 026 LS counter roll
M.B 010 M.Y 024 LS-element, movem.
M.Y 021 Air knife, squeezer roll
Positive through PLC,
0V directly M.Y 020 Short stop
M.Y 029 Air blow bottom flaps
M.Y 177 Tube folding device
G 004 Main motor ramp down
K 019, M.M 013 Bending roller
K 011, M.M 001 Main motor
G 004 Main motor low speed
G 004 Main motor high speed
K 008, M.M 004 Clean unit circ. pump
M.Y 103 Pressure device
M.Y 030 Shut-off final folder
G 003 Bending roller enable
G 004 Main motor start command
A 500 Sealing pulse TS
K 028, M.M 132,
M.M 133 MCDS motors

(Cont'd)
Paper magazine safety

stop module

L20, L21 Supply
controlled
output
L11, L10 Input
Reset
K
K 017 Paper magazine inverters Safety

K 112 Auxiliary relay alarm reset chain
K 113 Auxiliary relay alarm reset relay
K 017, M.M 021,
EM3.081803012en.fm
M.M 022 Paper magazine
M.B 108
G 001 Enable paper magazine
(Cont'd)

(Cont'd)
SA Valves Safety Stop Function
Safety
L20, L21 Supply
controlled
L21 → PLC Input output
Reset
Safety
chain
relay Y
EM3.081803012en.fm
M.Y 105 LS Strip splice

M.B 113A M.Y 037 Shut-off strip applicator
M.B 113B
(Cont'd)

(Cont'd)
ASU Safety Stop Module

L20, L21 Supply controlled
output
L15, L10 Input
Reset
K
K 112 Auxiliary relay alarm reset

Safety
chain
relay Y
M.Y 150 ASU venting valve

M.Y 151 Side feeder L-R
EM3.081803012en.fm
M.B 141 M.Y 152 Side feeder R-L
M.B 142 M.Y 155 Pressure rail
M.B 143 M.Y 154 Cutting
M.B 144
M.Y 153 Web tension
K 022 ASU TPO bar power
(Cont'd)

(Cont'd)
PT safety module

L20, L21 Supply
controlled
output
L14, L10 Input
Reset
K
K 032 PT power inverters Safety

K 113 Auxiliary relay alarm reset chain
K 021 Power to DMC relay
Y
A520 PT delayed safety stop
module
EM3.081803012en.fm
K 032,
M.M 014 PT infeed
M.B 042 A 520 PT delayed safety stop module
MY 053 Shut off valve
MY 044 Punch
MY 045 Patch pre-sealer
MY 046 Patch final sealer
MY 047 Tab sealer
MY 048 Cap blowing
(Cont'd)

(Cont'd)
PT delayed safety stop module
Safety
L20, L21 Supply
controlled
L21 → PLC Input output
EM3.081803012en.fm
K 021, M.M 002 DMC
G 006 Enable PT infeed motor
A 002 Enable DMC motor

1 2 3 4 5 6 7 8 9 10
L21
L20
L20
-A504 +C-A504 SA SAFETY STOP MODULE
A1 A2
41 42
/99.02 / FD 13 14 FE / /99.03 SHUT-OFF STRIP APPLICATION
/98.02 / FA 23 24 FB / /98.03 LS STRIP SPLICE
33 34 GI / /123.06
X2
S23
X1
S13
C
/72.06 / BZ S14
+M-W615 +M-W802
+M-W802 +M-W803 +M-W803 +M-W615
-X018 +M-X031 11 12 +M-X031 +M-X031 11 12 +M-X031 -X018 A
+M-B113A SPLICE UNIT, RIGHT DOOR
6 4 21 22 5 8 21 22 9 7
S24 +M-B113B SPLICE UNIT, LEFT DOOR
5 3 6 7 10 8
+M-B113A +M-B113B
PE PE
0V
0V
24V
L21
L20
L20

ALPO/AIR 08/31/2003 TBA/19 020V
140649 CIRCUIT DIAGRAM SA VALVE SAFETY STOP FUCTION


1 2 3 4 5 6 7 8 9 10
L21
L10
L15
L20
ASU
-A505
A1 A2 +C-A505 ASU SAFETY

STOP MODULE
L70
L71
41 42
13 14
23 24
33 34
L70
L71
-K112
/74.06 / IC
X2
5 9
1 /102.07
S13
X3
S23
/123.06 / ID
+M-W759
+M-X060 -X015
S14 +M.B141 SIDE LEFT
+M-B141 +M-B142 +M-B143 +M-B144 19 6
+M-X060 +M-X060 +M-X060 +M-X060 ASU DOOR
/66.02 / AJ 11 12 11 12 11 12 11 12
+M.B142 SIDE RIGHT
/66.02 / IE 9 21 22 11 13 21 22 15 17 21 22 21 22
ASU DOOR
10 12 14 16 18
+M-X060 +M-W762 +M-W762 +M.B143 RIGHT DOOR ASU
+M-W763 +M-W763 +M-W764 +M-W766 +M-W765 S24
20 7
0V
0V
+M.B144 LEFT DOOR ASU
24V
24V
L20
L21
L10
L15
ALPO/AIR 08/31/2003 TBA/19 020V
140649 CIRCUIT DIAGRAM (ASU) VALVE SAFETY STOP FUCTION


1 2 3 4 5 6 7 8 9 10
L15
L10
L21
L20
L15
L10
-A506 +C-A506 SAFETY EMERGENGY
A1 A2 STOP MODULE
41 42
13 14
23 24
33 34 CC / /74.06
-K001 -K005 -K006 -K007 -K009 -K012

-K113
21 22 22 21 21 22 22 21 21 22 22 21
9 5 /100.07 /100.07 /98.07 /98.07 /98.07 /100.07 -X003
1
/102.07 78
PT X2 A
-K015 -K016 -K018 -K024 -K030 -K026 -K020 -V010
21 22 22 21 21 22 22 21 21 22 21 22 21 22 K
/100.07 /100.07 /100.07 /99.07 .08 /99.07
77
S13 -K251
.07
.07
1 5 2 6 POWER FAILURE STOP

+M-W018 13 14
-S001 -S002 9 10
-X002 -X002 -X002 -X002 22 21 22 21 -X004 +P-X901
GO / /58.02 /58.02 / GM
31 GP / /58.02 /58.02 / GN 32 212 209 12 11 12 11 151 113
29 30 211 210 152 114 +M-S001 EMERGENCY STOP
X3
+M-S002 EMERGENCY STOP
+M-S004 EMERGENCY STOP
+M-W615 +M-W605 +M-W605 +M-W615 +M-W434 +M-W434 +M-W018 74
A +M-S005 EMERGENCY STOP
-X018 +M-X031 12 11 +M-X031 -X018 -X004 12 11 -X004 -X004 +P-X901 12 11
-V007 +M-S006 EMERGENCY STOP ASU
18 28 22 21 25 15 58 22 21 55 153 115 22 21 +M-S011 EMERGENCY STOP
S23 K
17 27 26 16 57 56 154 116 +P-S900 EMERGENCY STOP
PE 73
+M-S005 +M-S004 +P-S900
-K030
CONTACTOR TO ENSURE
.05
A2 A1
/5.08
/5.08
/5.08
-K251
1 3 5 21 REDUNDANCY
ASU S14
ASU 10 6
+M-W760 2 4 6 22
+M-W800 +M-W760 2
+M-W800 .08
-X016 +M-S011 +M-S006 -X016
21 22 21 22
11 12 11 12 -K251
5 72 73 6
S24
4 71 74 7 9 5
+M-X060 +M-X060 1
0V
.08
24V
0V
0V
24V
24V
+M-W780 +M-W780
PMI
L15
L10
L21
L20
L15
L10

ALPO/AIR 08/31/2003 TBA/19 020V
140649 CIRCUIT DIAGRAM EMERGENCY STOP FUCTION


1 2 3 4 5 6 7 8 9 10
L21
L10
L11
L12
L31
L30
L20
-A507 +C-A507 SAFETY STOP MODULE
A1 A2
41 42
13 14
23 24
33 34 CD / /74.06
-K113 -K019 -K013 -K011 -K008 -K003

21 22 22 21 21 22 22 21 21 22
X2
6 10 /97.07 /82.08 /97.07 /97.07 .07
.05
-K003
/5.09
/5.09
/5.09
/11.08
2 /102.07 1 3 5 13 21
A1 A2
2 4 6 14 22
CONTACTOR TO ENSURE REDUNDANCY
S13
-X003
76
A
-V008
X3
K
75
S23
/98.02 / EZ S14
/92.06 / EL S24
0V
0V
0V
24V
24V
24V
24V
L21
L10
L11
L12
L31
L30
L20

ALPO/AIR 08/31/2003 TBA/19 020V
140649 CIRCUIT DIAGRAM FF,SS AND JAW SYS.STOP FUCTION


1 2 3 4 5 6 7 8 9 10
L10
L14
L21
L81
L80
L20
PT -A509 +C-A509 PT SAFETY
A1 A2 STOP MODULE
-V012
K A
.04
/16.07
41 42 -K032 /51.08
1 13 21
+C-K032 PT MOTOR POWER
/110.03 / IW A1 A2 2 14 22
13 14
23 24
33 34
-K113 -K021 -K032

/65.05 / OB 21 22 21 22
X2
8 12 /65.07 .06
4 /102.07
S13
X3
S23
/118.06 / NA C
S14
+M-W525 +M-W526 +M-W526 +M-W525

-X025 +M-X025 21 22 +M-X025 -X025 A
3 3 31 32 6 6
S24 +M-B042 PT LEFT SIDE DOOR
4 4 5 5
+M-B042
0V
0V
24V
0V
24V
24V
L10
L14
L21
L81
L80
L20

ALPO/AIR 08/31/2003 TBA/19 020V
140649 CIRCUIT DIAGRAM PT SAFETY STOP FUCTION (PT)


1 2 3 4 5 6 7 8 9 10
L10
L81
L80
L21
L80
PT -A520
+C-A520 PT SAFETY
A1 A2 STOP MODULE
DELAYED
S14
S24
/64.03 / OB X1
X2 -V013
K A
-K021
/17.02
/17.02
/17.02
/64.04
1 3 5 21 POWER TO DMC
/110.03 / MS A1 A2
13 14
2 4 6 22
23 24
/110.03 / OD 33 34 MQ / /18.04 PT HW ENABLE
/110.03 / MZ 43 44 LQ / /16.06
INFEED PT MOTOR ENABLE
51 52
0V
0V
0V
24V
24V
L10
L81
L80
L21
L80

ALPO/AIR 08/31/2003 TBA/19 020V
140649 CIRCUIT DIAGRAM PT SAFETY STOP FUCTION (PT)


1 2 3 4 5 6 7 8 9 10
L11
L21
L20
L10
L20
-A512
+C-A512 PACKAGING MATERIAL INFEED
A1 A2 SAFETY STOP MODULE
L41
L40
41 42
13 14
23 24
L41
33 34 CE / /74.06
L40
ASU
-K113 -K017
B
A 21 22
X2
7 11 /115.07
3 /102.07
-K112
C
7 11
S13
ASU 3 /102.07
X3
S23
C
/92.06 / GQ S14
/61.02 / AJ
PMI
+M-W759 +M-W788 +M-W788 +M-X060 +M-W790 +M-W759
+M-W790 A
-X015 +M-X060 21 22 +M-X060 21 22 +M-X060 -X015
+M-B108 DATING UNIT DOOR GUARD
1 1 11 12 3 5 11 12 7 4
S24
2 2 4 6 8 3 PMI
+M-B108 +M-B115
+M.B115 PMI RIGHT DOOR GUARD
0V
0V
0V
24V
24V
/61.02 / IE
+M-W801 ASU
L11
L21
L20
L10
L20

ALPO/AIR 08/31/2003 TBA/19 020V
140649 CIRCUIT DIAGRAM PMI/ASU SAFETY STOP FUCTION


Overvoltage Protection
12 14 11
L/N L/N L/N L/N
PU 4 C-R PU 4 C-R PU 4 C-R PU 4 C-R PU 4 C-R
UH : 230 V~ UH : 230 V~ UH : 230 V~ UH : 230 V~

UH : 230 V~ Umax : 275 V~ / Umax : 275 V~ / Umax : 275 V~ / Umax : 275 V~ /
IN : 6 A 350 V- 350 V. 350 V- 350 V-
802 152 802 152 802 152 802 152 802 152

Jaw System Overview

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Jaw System Overview

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Course Introduction 3

Maintenance Filling System 7

Design Control System 8

Technical Training Centre Lund, Sweden

Technical Training Centre 1/9701 TM-00001

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Normal stop/Short stop

Emergency stop/Safety stop

Technical Training Centre Machine type Issue

TBA/19 020V $

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This description of the sterile system of a TBA/19 machine includes the

Aseptic food processing

The sterile system

Compressor Peroxide tank

Sterile system overview

Aseptic machine sterilisation

Water at low Constant

Constant flow valve

2 $$    $   

Aseptic product valve

   

AP valve, Position during production

AP valve, Position during sterilisation

AP valve, Steam barrier

2 38 ##   +  $ 7 ))  +#  *

AP valve, Position during final cleaning

Preparation of filling machine

Sterilsation of filling machine

Aseptic production cycle

Starting the filling machine

Sterile system TBA/19, Preheating I

Sterile system TBA/19, Preheating II

Sterile system TBA/19, Tube sealing

Packaging material tube

Sterile system TBA/19, Preheating III

Filling spray tank

Sterile system TBA/19, Filling spray tank

Sterile system TBA/19, Spraying

Spraying In this mode the aseptic chamber is sprayed with peroxide.

Sterile system TBA/19, Pause

Sterile system TBA/19, Drying

Sterile system TBA/19, Production

Top filling during production

Sterile system TBA/19, Top filling the peroxide bath

Hot air air

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