Course Introduction 1. Machine Introduction 2. Sterile System 3. Peroxide System 4. Drive System 5. Jaw System 6. Filling System 8.

Course Introduction 1
TBA/19 Machine Introduction 2
Training Document Sterile System 3

This Training Document is intended for
Training purpose only, and must not be
used for any other purpose.
The Training Document is not replacing
any instructions or procedures (e.g. OM,
Peroxide System 4
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such.
Note!
For safe and proper procedures, refer to Drive System 5
the equipment specific documentation.
Jaw System 6
Name:
................................................................................................................ Tube Forming and Paper Tracking 7

................................................................................................................
Filling System 8
Final Folder 9
Design Control System 10
Package Integrity 11
Cleaning 12
Supply System 13
14
Technical Training Centre
Lund, Sweden
WB-40-01
Issue 2/0101
15
1
Course
Introduction

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

Information to Course Participants at
the Technical Training Centre in Lund
Welcome to Technical Training Centre!
Here is some information which might be helpful to you as a course
participant. If you need additional information or help, feel free to ask
your instructor.
Start of course Normally, the first day of your course begins at 08.30. Your instructor will
meet and welcome you in the coffee room.
Daily time schedule
Classes 08.00 - 09.30
Breakfast 09.30 - 10.00
Classes 10.00 - 12.00
Lunch 12.00 - 13.00
Classes 13.00 - 16.00
Your instructor will tell you if there are any changes in the schedule.
Breakfast Breakfast is free of charge and served in the restaurant, where a special area
has been reserved for Technical Training Centre course participants. Breakfast
consists of coffee or tea and bread rolls. If you want anything in additional, for
instance from the serving counters of the restaurant or cafeteria, you have to
pay for it yourself. Your instructor will help you with the procedure.
Lunch Lunch is served in the restaurant. You can choose among several dishes; men-
us are posted at the restaurant entrance and in the coffee room.
If you are a customer course participant, your instructor will give you a cash
card. For participants other than customers, cash cards are for sale in the caf-
eteria. Your instructor will help you with the procedure.
Coffee room You are invited to use the coffee room and the vending machine during all
breaks in classes.
Smoking The entire Tetra Pak plant, outdoors as well as indoors, is a no smoking area.
Smoking is allowed though in the smoking-room adjoining the machine hall.
Telephones If you need to call long-distance within Sweden or abroad, please use the
phone in the telephone room. There are also telephones in the coffee room and
in the spare parts store, adjoining the machine hall. These phones are for local
or internal calls only. When using the phones, please be brief, as there may be
others who wish to make calls. Furthermore, there is a pay-phone outside the
assembly-hall.
Computers There are three computers for the use of course participants. Two computers
in the machine hall, on which ORBIS (the Tetra Pak Intranet) is available, and
one in the coffee room, on which Internet and the World Wide Web is availa-
ble.
Technical Training Centre 2/9903 TM-00010 1

ID card On your first day you will recieve an ID card. This card must be returned at
the Tetra Pak Main reception at the end of the course. Anyone not handing the
card back will be charged SEK 400.
Safety regulations At the start of the course, your instructor will go through the Safety Regula-
tions (TM-00001). These regulations must be strictly observed. In case you are
uncertain about anything in the regulations, you must clarify it with your in-
structor.
Course evaluation You are requested to write down your comments on the course on the Course
Evaluation form. At the end of the course your instructor will collect all the
forms.
Working clothes It is necessary to wear safety shoes in the Technical Training Centre, while
working at the machines. If you didn’t bring your own, safety shoes are for
sale in the Tetra Shop. Your instructor will take you there. For your use during
the course, you may borrow a set of coveralls.
Each participant is given a locker in the changing-room. The instructor will
hand you the locker key. You may then select a set of coveralls from the cov-
eralls cabinet in the changing-room. Your instructor will help you if needed.
You may exchange your coveralls for clean ones every Monday morning. Ask
your instructor if you need to change at any other time. Used and soiled cov-
eralls are to be placed in the laundry basket in the changing-room.
At the end of the course you have to empty and lock your locker and return the
key to the instructor. If you wish to retain your locker for a subsequent training
course, tell your instructor.
Valuables You are responsible for your own valuables.
Money exchange To change currency or cash traveller’s cheques, please go to the cashier’s of-
fice, which is open 09.00 - 16.00.
Hotels In the coffee room, there is a list of the various hotels, with addresses, phone
numbers, etc. If you want to change hotel during the course period, please con-
tact the course co-ordinator at Technical Training Centre.
Transport Certain hotels provide free of charge transport to and from Tetra Pak. Ask the
hotel receptionist about this. If you wish to use this service, you must tell the
receptionist the day before.
Travel arrangements Go to the Resespecialisterna travel agency for reservations, reservation chang-
es, or confirmation of reservations. The travel agency is located at the plant
and open 07.30 - 17.30 (fridays - 17.00).
Visa Course participants from certain countries require visas in case they wish to
visit another scandinavian country, for example Denmark. The Resespecial-
isterna travel agency deals with all visa applications and related matters. A
Letter of Guarantee, which is required to apply for a visa, can be obtained from
the course co-ordinator at Technical Training Centre.
Medical care For medical care, unless it is an emergency situation, go to Citykliniken, lo-
cated in the centre of Lund. Information concerning this clinic is posted on the
notice board in the coffee room.
Leisure time In the coffee room you will find information about the city of Lund and the
surrounding region as well as on available facilities and activities.

Sport Centre Bookings for the Tetra Pak Sport Centre are free of charge and can be made at
the Main Guard, located next to the Main Reception. If you visit the Sport
Centre, you must enter and leave via the Main Guard.
Gifts and souvenirs Gifts, souvenirs, articles of clothing, etc. are on sale in the Tetra Shop, which
is open 09.00 - 15.00.
Tetra Pak 1 Main Reception

Part of the plant at 2 Main Guard
Ruben Rausings gata
Lund
3 Technical Training Centre
4 Restaurant
5 Cashier´s office
6 Resespecialisterna Travel agency
7 Sport Centre
8 Tetra Shop
1 2
315
305
4 306
313 310
3 101
8 5 309 311
6
N
106 7
107
111

2
Machine
Introduction

Brik Aseptic
Tetra
Tetra Brik Aseptic, TBA/19

k
Tetra Pa
Technical Training Centre Machine type Issue
Lund, Sweden TBA/19 2/9706 OH 492
TBA/19
TBA/19
Tetra Brik Aseptic packaging machine
Tetra Brik Aseptic Tetra Br

ik Aseptic
Tetra Pak
TBA/19 filling machine packages liquid food in TBA portion Steam

packages Supply pressure, (overpressure)
kPa (bar) [psi] 170 (1.7) [25]
Printed design in register is achieved by means of a bar code, Max pressure fluctuation, kPa
which is printed on the packaging material. As standard, the (bar) [psi] ±30 (±0.3) [±4.5]
machine is equipped with Automatic Splicing Unit 19 for the Temperature, °C (°F) 130±4 (266±7.2)
longitudinal strip and also with an external cleaning system for Consumption, kg/h (Ibs/h) 2.4 (5.3)
the jaw system and the final folder, i.e. those units by which Water Quality: Drinking water
the packages are formed, sealed and shaped.
Hydrogen peroxide, H202
Type 35% aseptic grade
Consumption, l/h 0.7-1.2
Development step
010V Product
Capacity Supply pressure, kPa (bar) [psi] 50-350 (0.5-3.5)
[7.2-50.7]
Packages per hour 7500/6000 (-0% + 4%) Maximum pressure fluctuation,
to be specified when kPa (bar) [psi] 100 (1) [14.3]
ordering pH 2.5-8.0
Package volumes, cm3 (ml) See table Viscosity, max calculated pressure
Headspace will give drop (CPD), kPa (bar) [psi] 150 (1.5) [22]
intermediate volumes Filling temperature °C (°F) 5-50 (41-122)
Electric power External cleaning equipment

Type, frequency Hz, voltage V 3N~, 50/60, 400/230 Supply pressure, kPa (bar) [psi] 300-450 (3-4.5)
[43.5-65]
Other voltages require adaption Hot water consumption, litres
transformer. per cleaning cycle 300
Recommended main fuse to obtain Hot water temperature, °C (°F) 60-70 (140-158)
selectivity, A 100 Special detergent consumption,
Consumption during preheating, kW 9-29 litres per cleaning cycle 0.8
Consumption during sterilization, kw 12-18 Detergent pH 8-12
Consumption during production, kW 22
Consumption during cleaning, kW 5 Cleaning in place (CIP)
Thermal Load, Kw 15.4 Max. inlet pressure, kPa (bar) [psi] 350 (3.5) [50.7]
Min. flow, l/h 8000
Compressed air
Lubrication
Supply pressure, kPa (bar) [psi] 600-700 (6-7)
[87-102] Consumption, l/h 0.01
Consumption, Nl/min (cu tr/min) 400±100 (14.0±3.5)
Max particles, µm 20 Weight
Max particles, mg/m3 25 Approx. weight, kg (Ibs) 5600 (12400)
Dew point °C (°F) 2 (35.6)
Oil content, mg/m3 0.01 Ambient temperature
Min. ambient temp., °C (°F) 5 (41)
Cooling water Max. ambient temp., °C (°F) 50 (122)
Supply pressure, kPa (bar) [psi] 300-450 (3-4.5) Recommended ambient temp., °C (°F) 15 to 30 (59 to 86)
[43.5-65]
Max. inlet temperature, °C (°F) 20 (68) Noise
Consumption, l/min (imp. galls/min) 10 (2.2) Sound pressure level, (Lpa), dB(A) ≤80
pH 5.0-8.0 (acc. to ISO 11204)
Of the total consumption, approx.
5 litres per minute (1.1 imp. galls/min) Installation drawing Nos.
can be recirculated 577753-1, 577753-2
TBA/19
TBA/19
Optional Equipment Temperature Controlled Steam Barrier TCSB19
Controls and reduces the steam barrier temperature, avoid-
PullTab PT19 ing overheating and cleaning difficulties due to burnt pro-
PullTab version for TBA/19 filling machine released for all the duct residues.
existing volumes. Offset Splicing Table 19
Headspace by Gas Injection HI19 Splicing table for packaging material with outer lacquer.
Headspace by Gas Injection allows up to approximately Multi-installation 19
10% headspace by means of either sterile gas air or inert Platforms and railing for mutli machine installations.
gas (N2), available for all the existing volumes.
SCU/4
Volume Conversion VC19
Separate Cleaning Unit for cleaning of product pipes and
Volume Conversion 19 OE/OK to change volume, available
valves.
for: TBA 125 S / TBA 100 B
TBA 200 B / TBA 250 B
TBA 200 M / TBA 250 S
TBA 200 S / TBA 160 S
Accessories
TBA 250 B / TBA 200 B
- Tool cabinet
TBA 250 S / TBA 200 M
- Leak finding equipment to check overpressure and
TBA 250 B / TBA 284 B - TBA 300 S
underpressure in the aseptic chamber and bath
TBA 250 B / TBA 330 S
- Peroxide container
Automatic Splicing Unit ASU19 - Filling station for peroxide containers
Double reel Automatic Splicing Unit for packaging material, - Trolley to transport the peroxide containers
available for all the existing volumes. - Manometer for product pressure
- Oil pump for refilling of oil
High Viscous Aseptic HVA19 - Code insert sets, various types for ink dating unit
High Viscous Aseptic 19 allows the filling of homogeneous
high viscous products under aseptic conditions.
Standard version of TBA/19 (not equipped with options)

Dimensions in mm (ft in)
* Multi installations 2000 (6’7”)
Dimensions of packages and packaging material

PACKAGE PACKAGING MATERIAL Tetra Pak Marketing Services AB. Code 8247 en. Date 11.98 AD:Ikos Printed in Italy
TBA Volumes Dimensions, mm Approx. qty packages Appr. weight

cm3 (ml) a b c per Jumbo reel of reel (kg)
100 B 69.3 32 47 30000 145

125 S 86 32 47 29000 145
160 S 93.5 38 47 23500 185
180 B 75.5 41 63 5000* 38
a 200 B 83 41 62 23500 185
200 M 106 38 53 15000 149
200 S 119.3 38 47 19000 170
250 B 106.3 41 62 20000 190
250 S 131 38 53 18000 170
b c 284 B 119.7 41 63 18000 190
300 S 119.7 41 63 18000 190
330 S 136.3 41 62 14000 190
TPA Volumes
330 Sq 124.6 48.5/58.8 49.5/59.8 11000 120
S = Slim packages B = Base packages * Standard reel only. For the other packages standard reel on request.
M = Mid packages Sq = Square packages
Business Unit Tetra Brik We reserve the right to introduce design modifications without
prior notice. Tetra Pak and Tetra Brik Aseptic are trademarks
belonging to the Tetra Pak Group.
Measurements for TBA/19
Technical Training Centre 1/9910
Volumes F-pan. S-pan Height Repeated Web LS Tube Theor. Under-

Width Depht lenght Width Theor. diam. Crease filling
volume
ml mm mm mm mm mm mm mm ml %
100 B 47 32 69.3 113.33 162 4 50.29 104.2 4.0%
TM-00134
125 S 47 32 86 130.00 162 4 50.29 129.3 3.4%

160 S 47 38 93.5 147.50 174 4 54.11 167.0 4.2%
180 B 63 41 75.5 132.50 214 6 66.21 195.0 7.7%
Training Document. For training purpose only.
200 B 62 41 83 140.00 214 8 65.57 211.0 5.2

200 M 53 38 106 160.00 188 6 57.93 213.5 6.3%
200 S 47 38 119.3 173.33 174 4 54.11 213.1 6.1
250 B 62 41 106.3 163.33 214 8 65.57 270.2 7.5%
250 S 53 38 131 185.00 188 6 57.93 263.8 5.2%
284 B 63 41 119.7 176.67 214 6 66.21 309.2 8.1%
300 S 63 41 119.7 176.67 214 6 66.21 309.2 3.0%
330 S 62 41 136.3 193.33 212 6 65.57 346.5 4.8%
1
TBA/19
Lifting unit
Lifting tool
Transport plate
Lifting eyebolt
Transporter
No lifting area
Transporter
Technical Training Centre 1/9910 TM-00132 Training Document. For training purpose only. 1
TBA/19
Cold water
Cirk. cold water inlet
Cirk cold water outlet
Hot water
Air
TBA/19
TBA/19
3
Sterile System

Evaporated peroxide is
sprayed into an enclosed area.
The peroxide is condenced

and then dried with hot sterile air.
The aseptic is kept with

an overpressure of cooled sterile air.
Lund, Sweden
Aseptic food processing

Machine type
Sterilized
packaging
material
Sterile
surrounding
Issue
1/9501
Commercially Aseptic
sterile food transfer
OH 525
Aseptic packages
Sterile system overview
Lund, Sweden
Air
Peroxide
Aseptic chamber Product
Water
Machine type
TBA/8, 9, 19, 21
Packaging material
Issue
1/9610
Peroxide bath
OH 613
Compressor Peroxide tank

Tight tube
Air superheater
Sterile system TBA/19 010V
57 19
51
50
49
20 21
Lund, Sweden
47 37 Valve,
draining
9 48 peroxide bath
14 38 Safety cap
39 Peroxide
55 11 pump
46
22 40 Filter
41 Pump
10
56 59 23 42 Peroxide container
10
43 Peroxide tank
12 44 Diluting tank
45 Chamber pressure valve
1 1
8
46 Filter
47 Valve, filling spray tank
Machine type
58
48 Valve, spraying peroxide
49 Spray tank
60 50 Air valve, spraying
24
28
51 Sterile air filter
61 2
13 52 Level sensor
TBA/19 010V
53 Pressure switch
2
25 54 Air superheater temperature
5 55 Presterilization temperature
29 56 Steam temperature
15 57 Air knife temperature
26 58 Level sensor, water bath
59 Level sensor, peroxide bath
27
60 LS temperature, production
32
61 LS temperature, tube sealing
62 Water bath temperature
62
53 30
63 Peroxide bath temperature
31
64 Level floater
Issue
63
4/9507
7 37
4 36
33 41
17
40 42
34 38
39
18
16
OH 490:1
45
35
52
2
1
6
54 43 64
3
19 Air knife
20 Driven bending roller
7 Heat exchanger valve 13 Sterile air valve (B) 21 Calender roller
44
8 Peroxide evaporator 14 Steam filter 22 Filling pipe
9 Air inlet valve 15 Regulating valve 23 Membrane valve 26 Peroxide 29 LS, short stop elem. 33 Circulation pump
1 Compressor 4 WEAC valve 10 Steam trap 16 Sealing water valve 24 Suction valve bath 30 Level detector 34 Safety valve
2 Water separator 5 Air superheater 11 Steam barrier valve (C) 17 Constant flow valve 25 Valve, top filling 27 Water bath 31 Floater 35 Pressure expansion tank
3 Float unit 6 Heat exchanger 12 Product valve (A) 18 Scrubber or circulation 28 LS element 32 Water bath heater 36 Valve, filling/draining peroxide bath
Scrubber
Water
Air

Lund, Sweden TBA/8, TBA/19 1/9501 OH 493
Principle of constant flow valve
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

Lund, Sweden 1/9904 OH 819
Water separator
Water
Air

Insulating material
Pre−heated air
Hot air
Air
Air superheater

Lund, Sweden TBA/19 TBA/21 TBA/22 3/9508 OH 107
Sterile system
Peroxide evaporator
Peroxide
Compressed air
Hot air

Suction valve
Preheating l
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:2
Preheating ll
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:3
Tube sealing
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:4
Preheating lll
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:5
Spraying
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:6
Pause
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:7
Drying
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Closes after
19 minutes
Issue
4/9507
OH 490:8
Production
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:9
Normal stop
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:10
Short stop
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:11
WEAC
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:12
WEAC ready for door opening

Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Machine type
1 1
Steam
Product
Water
TBA/19 010V
Peroxide
2
Compressed air
2
Issue
4/9507
OH 490:13
Lund, Sweden
37 Valve,
draining
peroxide bath
38 Safety cap
39 Peroxide
pump
40 Filter
41 Pump
42 Peroxide container
43 Peroxide tank
44 Diluting tank
45 Chamber pressure valve
1 1
46 Filter
47 Valve, filling spray tank
Machine type
48 Valve, spraying peroxide

49 Spray tank
50 Air valve, spraying
51 Sterile air filter
2
52 Level sensor
TBA/19 010V
53 Pressure switch
2 54 Air superheater temperature
55 Presterilization temperature
56 Steam temperature
57 Air knife temperature
58 Level sensor, water bath
59 Level sensor, peroxide bath
60 LS temperature, production
61 LS temperature, tube sealing
62 Water bath temperature
63 Peroxide bath temperature
64 Level floater
Issue
4/9507
OH 490:14
19 Air knife
20 Driven bending roller
7 Heat exchanger valve 13 Sterile air valve (B) 21 Calender roller
8 Peroxide evaporator 14 Steam filter 22 Filling pipe
9 Air inlet valve 15 Regulating valve 23 Membrane valve 26 Peroxide 29 LS, short stop elem. 33 Circulation pump
1 Compressor 4 WEAC valve 10 Steam trap 16 Sealing water valve 24 Suction valve bath 30 Level detector 34 Safety valve
2 Water separator 5 Air superheater 11 Steam barrier valve (C) 17 Constant flow valve 25 Valve, top filling 27 Water bath 31 Floater 35 Pressure expansion tank
3 Float unit 6 Heat exchanger 12 Product valve (A) 18 Scrubber or circulation 28 LS element 32 Water bath heater 36 Valve, filling/draining peroxide bath
Ladder diagram
Symbol Name Criteria Function

Lund, Sweden TBA/9 140V, TBA/19 010V 3/9503 OH 476: 1
Ladder diagram
Symbol Name Criteria Function

Lund, Sweden TBA/9 140V, TBA/19 010V 3/9503 OH 476: 2
4
Peroxide System

Peroxide
system
TBA/19 010V
Refilling
peroxide tank
during
Preheating l
Water
Peroxide
Compressed air

Lund, Sweden TBA/19 010V 4/9507 OH 515:1
Peroxide
system
TBA/19 010V
Circulation
of peroxide
Water
Peroxide
Compressed air
Hot air

Lund, Sweden TBA/19 010V 4/9507 OH 515: 2
Peroxide
system
TBA/19 010V
Filling
spray tank
Water
Peroxide
Compressed air
Hot air

Peroxide
system
TBA/19 010V
Spraying
Water
Peroxide
Compressed air
Hot air

Peroxide
system
TBA/19 010V
Filling
peroxide bath
Water
Peroxide
Compressed air
Pre−heated air
alt. cooled air

Peroxide
system
TBA/19 010V
Refilling
peroxide tank
during
Production
Water
Peroxide
Compressed air
Pre−heated air
alt. cooled air

Peroxide
system
TBA/19 010V
Top filling and

circulation
during
Production
Water
Peroxide
Compressed air
Pre−heated air
alt. cooled air

Peroxide
system
TBA/19 010V
Draining
peroxide bath
Water
Peroxide
Compressed air
Pre−heated air
alt. cooled air

Peroxide handling TBA/19 010V
Emptying
diluting tank
Emptying
peroxide tank
Peroxide
Water

Peroxide handling TBA/19 010V
Filling new
peroxide
Diluting peroxide
during
compressor run
Peroxide
Water

Peroxide filling station
Peroxide
Compressed air
Vacuum

Lund, Sweden Tetra Brik Aseptic 1/9609 OH 594
5
Drive System

Drive system
Lund, Sweden TBA/19 TB/19 2/9810 OH 544
Drive

Lund, Sweden TBA/19 TB/19 2/9810 OH 545
Drive unit
Electrical clutch
Disengaged
rotating
stationary
Engaged

Lund, Sweden TB/9, TBA/9, TB/19, TBA/19 3/9811 OH 60
Drive unit

Drive unit
Crank mechanism
Engaged position
Disengaged position

6
Jaw System

Basic jaw setting system
SET LOWER JAW GAP
TURNING POSITION FINE SETTING
4.7-1 4.7-4
CHECK STROKE
4.7-6 CHECK SET
NON-PARALLELITY NON-PARALLELITY
WRONG SET STROKE 4.7-5 4.7-5
4.7-8
CHECK JAW OVER JAW SET JAW OVER

JAW GAP 4.7-16 JAW
SET VOLUME CURVE BASIC SETTING 4.7-17
WRONG
PIECE 4.7-4
4.7-9 CHECK GAP BETWEEN SET JAW GAP
VOLUME FLAP AND RH SIDE
CUTTING JAW < 0.7 mm 4.7-4
SET JAW ALIGNMENT
4.7-11
SET DESIGN CORR.

SET YOKE SYMMETRY MECHANISM
4.7-12 4.7-18
CHECK FOLDING FLAP FOLDING FLAPS

CHECK JAW MECHANISM PARALLEL
VERTICAL POSITION 4.7-13 4.1-1
4.7-13
SET VOLUME FLAP FIT VOLUME FLAPS

ALIGNMENT
4.7-14
SET CATCH PIVOT SPRING
SET TUBE SUPPORT 4.3-3
ROLLERS
4.7-15
BLEED PRESSURE AND
CUTTING JAW
REMOVE VOLUME 4-3
FLAPS AND SPRING
ON RH & LH CUTTING
SET CATCH LIFTER CAM
JAWS
4.7-19
CHECK CATCH
CLEARANCE
4.3-4
CHECK CATCHES
4.3-4
SET DISCONNECTION
LINK
3.6-2
Lower turning position
Stroke
Volume curve piece
Jaw alignment
Jaw symmetry
Jaw gap
Jaw above jaw
Jaw movement and functions
Jaws moves apart

Cutting
Volume flaps
Folding flaps
Sealing pulse Cooling
Jaw pressure
Jaw gap measurement
Jaws catch tube
Lund, Sweden TB,TBA 2/0002 OH 892
7
Tube Forming and
Paper Tracking

Paper magazine
Lund, Sweden TBA/19 010V 1/9411 OH 514
TBA/19
Strip Applicator
Technical Training Centre 1/9904 TM-00086.fm Training Document. For training purpose only. 1
Forming of the tube
1
2
1
2
4
5

8
Filling System

Leakage
detector
I/P Transducer
Y107
Product
Compressed air
Principle of
filling system
Lund, Sweden TBA/19 010V 2/9502 OH 498
Regulating
Lund, Sweden
valve

Machine type
Issue
Product
5/0004
Compressed air
Non−conductive part
of the regulator
Conductive layer
in the diaphragm
OH 497
Non−conductive layer
in the diaphragm
Non−conductive coating
Lund, Sweden
Level Regulated Filling

Machine type
TBA/19
L 11 L 10
Alarm overfill
17 18 1 3 Floater bottom position
19
Level regulator Level detector
421071 9
Production 10 24 V
11
5
Issue
0 − 10 V
1/9911
Cleaning 15 6
Sterilazation 16
I/P Transducer
7
OH 898
0 − 20 mA
8
25
C
A
AP−Valve
440630−020V
(Aseptic Product Valve)

TETRA
PAK Lund, Sweden 1/9208 OH 453:1
9
Final Folder

Final folder
Station chain
Compressed air
Final folder
Drop chute
Lund, Sweden TB/9, TBA/9, TB/19, TBA/19 3/9812 OH 152:1
Final folder
Pull down device
Hydraulic oil not under pressure
Hydraulic oil under pressure

Final folder
Flap sealing
Hot air
element
Air
Final folder
Pressure unit
Hydraulic oil not under pressure
Hydraulic oil under pressure

and sidefeeder
Outfeeder
Overload protection
Outfeeder
10
Design Control
System

TBA/19
DSC19, Design Control System
TMCC
TM-00087.fm
Read
Photocells
∝ Read
Angle Encoder
Calculation
(PID)
Output to
Bending Roller
and Folding flap
Communication
with PLC
and terminal
Parameter
settings
1
TMCC
Design control system
1
+ 24 VDC
2
TMCC
DC common
3
Design adjustment pot.(MUPP)
FAULT
7
Speed Sensor Bending Roller POWER
9 6
Bit 0 S 1 Bar code detected Bending roller speed control
S 2 Design OK
10 S3
S 4 Correction Cylinder ON
11 S 5 Left Cylinder ON
S 6 Right Cylinder ON
S7
12 S8
Encoder 26
13 Air valve. Right
345
14 27
EF 2
67 A
01
89
BCD Air valve. Left

15
28
16 Air valve. Correction
Bit 7
30
17 Request volume values
RCM photocell 4 bars
18 31
RCM photocell 3 bars RCM pulse
21
Design enable 32
22 Design OK
Volume enable
23
Volume clock
24
Volume data

Register code reading
26 bits
10
01
11010001111011010001111000
11010001111011010001111000

Compressed air high
Compressed air low
Full paper feed
Pre correction
Correction
Design correction
Lund, Sweden TB/9, TBA/9, TB/19, TBA/19 4/9910 OH 166:1
Tube regulation
by web tension
High web tension

(low product pressure)
Low web tension
(high product pressure)

Lund, Sweden TB/TBA 1/9904 OH 818
135 RPM
DCS/19 Design correction principle
135 RPM
110
135 RPM
110
Output
100
Lund, Sweden Design correction TBA/19 2/9911 OH 571
DC - Motor Drive Control
12
Fuse 3.15 AF
13
42 N
1
14 43 P
Power
44
15 45
F
46 2
16 A
47
Flashing Trip
11 overload
IxR
Ext Speed
3
10
Acc Ramp
7 Internal Speed 4
1
2
6
8
3 5
9
1. POWER indicator.
2. TRIP, indicates an overload on the output. Flashing at current limit.
Fixed light, when switched off due to overload.
3. EXT SPEED, indicates that external speed is selected.
4. INTERNAL SPEED 1, indicates that internal speed 1 is selected.
5. INTERNAL SPEED 2, indicates that internal speed 2 is selected.
6. INTERNA SPEED LED 1 + 2, indicates that internal speed 3 is selected.
7. Potentiometer for setting internal speed 1.
10. ACC. RAMP, potentiometer for setting acceleration ramp.
11. I x R compensation. Adjustment for different motor powers. Too high
settings will result in unstable motion.
12. PROTECTIVE EARTH
13. NEUTRAL
14. PHASE
15. FIELD
16. ARMATURE
Technical Training Centre 1/9910 TM-00131 Training Document. For training purpose only.
Report from TMCC
DesignError (mm) : OutSignal (0-255) :BendrollRevs (rpm): CylPos Descriptions.
47.41 : 0 : 85 : -- : NotEnabled
58.70 : 0 : 85 : -- : NotEnabled
70.31 : 0 : 85 : -- : NotEnabled
79.88 : 0 : 85 : -- : NotEnabled Precorrection speed for bending
roler.
89.00 : 0 : 85 : -- : NotEnabled
-82.24 : 0 : 85 : -- : NotEnabled
-64.79 : 0 : 85 : -- : NotEnabled
-52.79 : 0 : 85 : -- : NotEnabled
-42.78 : 0 : 85 : -- Design enable
-34.57 : 0 : 85 : --
-25.93 : 0 : 85 : --
-18.30 : 0 : 85 : --
-10.91 : 0 : 85 : --
Precorrection
-3.50 : 2 : 100 : --
-0.91 : 83 : 124 : -- Left and right side correction
0.44 : 118 : 134 : --
0.83 : 140 : 121 : L- Left side full paper feed,
0.47 : 139 : 120 : L- right side correction.
1.22 : 160 : 126 : L-
0.08 : 139 : 120 : L-
0.04 : 121 : 115 : L-
0.02 : 121 : 115 : L-
PHOTOCELL MISS Register code mark missed by
0.24 : 123 : 116 : L- photocell
-0.64 : 116 : 114 : L-
Left and right side full
1.56 : 238 : 130 : LR
paper feed
-0.00 : 118 : 114 : L-
-0.28 : 121 : 115 : R Right side full paper feed,
-0.19 : 108 : 111 : L- left side correction.
-0.56 : 108 : 111 : L-
0.03 : 116 : 114 : L-
Start 1
DesignError: OutSignal 0-255: BendRollRevs: CylPos mm: (L)
69.85 : 0: 85: -- : NotEnabled
79.37 : 0: 85: -- : NotEnabled
88.66 : 0: 85: -- : NotEnabled
-83.66 : 0: 85: -- : NotEnabled
-65.70 : 0: 85: -- : NotEnabled
-52.93 : 0: 85: -- : NotEnabled
-43.38 : 0: 85: --
-34.78 : 0: 85: --
-26.85 : 0: 85: --
-18.50 : 0: 85: --
-11.28 : 0: 85: --
-3.84 : 0: 85: --
3.59 : 254 :134 : L-
4.72 : 254 :134 : LR
3.67 : 254 :134 : LR
3.77 : 254 :134 : LR
2.89 : 254 :134 : LR
2.30 : 254 :134 : LR
1.56 : 238 :130 : LR
0.67 : 135 :119 : L-
0.71 : 142 :121 : L-
0.26 : 129 :117 : L-
0.23 : 122 :115 : L-
0.27 : 116 :114 : L-
0.21 : 120 :115 : L-
-0.15 : 117: 114 : L-
0.04 : 119 : 114 : L-
-0.43 : 114 : 113 : L-
Production
DesignError (mm) : OutSignal (0-255) : BendRollRevs (rpm) : CylPos
-0.08 : 127 : 117 : L-
-0.68 : 117 : 114 : L-
-0.26 : 116 : 114 : L-
-0.55 : 115 : 113 : L-
-0.57 : 107 : 111 : L-
-0.53 : 107 : 111 : L-
-0.49 : 108 : 111 : L-
-0.51 : 107 : 111 : L-
-0.50 : 106 : 111 : L-
-0.61 : 102 : 109 : L-
-0.25 : 109 : 111 : L-
-0.53 : 108 : 111 : L-
-0.43 : 104 : 110 : L-
-0.63 : 99 : 128 : L-
-0.08 : 110 : 132 : --
0.04 : 114 : 133 : --
0.20 : 116 : 133 : --
0.27 : 118 : 134 : --
0.41 : 122 : 115 : L-
0.13 : 119 : 114 : L-
0.25 : 119 : 114 : L-
-0.45 : 113 : 113 : L-
-0.15 : 112 : 112 : L-
-0.41 : 110 : 112 : L-
-0.34 : 107 : 111 : L-
-0.84 : 93 : 127 : L-
-0.48 : 90 : 126 : --
-0.31 : 108 : 131 : --
0.27 : 113 : 132 : --
0.58 : 122 : 115 : L-
0.01 : 115 : 113 : L-
0.35 : 116 : 114 : L-
-0.21 : 111 : 112 : L-
0.07 : 113 : 113 : L-
0.12 : 113 : 113 : L-
0.15 : 114 : 113 : L-
Status Report
DesignError (mm) : OutSignal (0-255) : BendRollRevs (rpm) : CylPos
-0.38 : 111 : 112 : -R
0.29 : 117 : 114 : -R
-0.23 : 112 : 112 : -R
0.52 : 118 : 114 : -R
--- D C S 1 9 Status ---

DesignError mean (mm) : 0.05
Output mean (0-255) : 108
Machine Speed, (p/h) : 7659
Repeat Length (mm) : 185.00
Production Angle const (dec.degr) : 2
Production Angle +pot (dec.degr) : 0.32
Precorr Bend. Roller Speed (rpm) : 85
MaxDesignOK (mm) : 1.50
MaxRevs, MinRevs (V) : 7.84, 5.80
Pot Voltage (V) : 7.45
-0.09 : 118 : 114 : -R

0.28 : 121 : 115 : -R
-0.71 : 112 : 112 : -R
-0.09 : 112 : 112 : -R
-0.57 : 110 : 112 : -R
58017
Functional Description 1(15)
F. Bassissi
Tetra Pak DCS19, Design Control System, TB/A/19 1997-11-21
Modena, Italy 47835 - 0200 ECN 71221
1. Table of Content
1. TABLE OF CONTENT ................................... 1 10. ENCODER FUNCTION AND GRAY CODES ...... 8
2. ABBREVIATIONS ......................................... 1 11. DESIGN ADJUSTMENT POTENTIOMETER ...... 9
3. INTRODUCTION .......................................... 1 12. OUTPUT SIGNALS ..................................... 9
4. DESIGN CONTROL SYSTEM OVERVIEW ......... 2 13. TERMINAL (PC) COMMUNICATION ............. 10
5. TMCC CONNECTIONS ................................ 3 14. VOLUME PARAMETER TRANSFER .............. 11
6. BASIC PROGRAM FUNCTIONS ...................... 5 15. BENDING ROLLER REVS SETTING ............. 12
7. OTHER PROGRAM FUNCTIONS .................... 6 16. DIAGNOSTIC OUTPUT .............................. 13
8. TMCC FRONT PANEL SWITCH .................... 7 17. PROGRAM DOWNLOAD ............................ 13
9. TMCC FRONT PANEL LEDS ....................... 8 18. APPENDICES .......................................... 14
2. Abbreviations
DCS8 Design Control System for TB/A/8 filling machines
DCU Design Correction Unit (68 457-010V)
EEPROM Electrically Erasable/Programmable Read-Only Memory
LED Light Emitting Diode
MultiStep MultiStep Design Correction Unit (67 382-010V)
MUPP Multi-purpose Potentiometer (558 389-010V)
PC Personal Computer
PID Proportional, Integral and Derivative control algorithm
PLC Programmable Logic Controller, (like TPMC or GE-Fanuc)
TMCC Tetra Pak Multi-Purpose Compact Controller (558 230-010V)
3. Introduction
The DCS19 program is intended for the TB/A/19 filling machines, and the program runs on the TMCC,
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 bending roller motor speed and the folding flap position.
Package specific parameters are sent from the PLC. (This program was previously called DCS9 intended
for the TB/A/9 machines).
This program is one version in the family of design control programs running on the TMCC. The other
versions are used on the TBA/3, TB/A/8 and TBA/21 filling machines. The basic function of these
programs are the same, the main difference is the output routines. The TB/A/19 uses a three step air
cylinder system to control the folding flaps and a bending roller for the fine adjustment.
Some similar systems, DCU and MultiStep, have previously been used on the filling machines TB/A/8,
and some features of these designs are also used in the TMCC design control systems.
This Functional Description is intended for users of the DCS19 "function", i.e. electrical designers, test
engineers, service engineers and alike. Its purpose is to give a full understanding of the behaviour of the
DCS19 program together with the TMCC as a system. (The internal structures of the DCS19 program will
not be discussed. For electronic system development purposes a special report covering these areas will
be available.)
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
4. Design Control System Overview

The design control system can be illustrated as below, where TMCC is the central part in the system, and
all other parts in the system are connected to the TMCC. Inside the TMCC symbol is a simple
representation of the functional blocks of the software:
Photocells TMCC
Read
Photocells
α Angle Encoder
Read
Angle Encoder
Potentiometer
Calculation
(PID) Bending Roller Motor
Output to
Bending Roller
and Folding Flaps Folding Flap Air Cylinder
PLC Terminal, (PC)

Communication
with PLC
and Terminal
Parameter Bending Roller Sensor

Settings
The connections and the functions are explained in the following pages. The DCS19 program flow is
further explained in the "Basic Program Functions" chapter.
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
5. TMCC connections
The TMCC is a general purpose hardware and its inputs and outputs are fully controlled by the software,
in this case the DCS19 program. The connections below have been chosen for the DCS19 function (a
pin connection diagram is available in the appendices):
1
TMCC
+24V
2 Power Supply
Ground
26
Air Valve, Right
9 27
Angle Encoder, bit0 HighOut1-3 Air Valve, Left
10 28
Air Valve, Correction
11
12 6
AnalogOut1 Bending Roller Out Signal
13 LowIn0-7
14 31
Register Mark Photocell Pulse
15 HighOut6-7 32
Design OK
16
Angle Encoder, bit7
5
17
AnalogOut0 Diagnostic Analogue Output
Register Mark Photocell, (4bar)
18 HighIn0-1
Register Mark Photocell, (3bar)
3
Design Adjustment Pot (MUPP) AnalogIn0
20
DCS19 Enabled HighIn3
7
Bending Roller Sensor FastIn0
22 30
Volume Enable HighOut5 Volume Acknowledge
23
Volume Clock HighIn5-7
24
Volume Data
19
HighIn/LowOut2 Not Used
21
HighIn/LowOut4 Not Used
4 25
Not Used AnalogIn1 HighOut0 Not Used
8 29
Not Used FastIn1 HighOut4 Not Used
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, (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).
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
Register Mark Photocell, (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).
Design Adjustment Pot (MUPP)

Analog (0-10V) input from the Design Adjustment Potentiometer (in this case, the Multi-
purpose Potentiometer, MUPP). 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.
DCS19 Enabled
24V input from the PLC. When this signal is:
• LOW (0V) - the DCS19 sets the precorrection mode.
• HIGH (24V) - the DCS19 runs in the regulating mode if possible.
(Refer to next chapters for explanation of the precorrection and regulating modes).
Bending Roller Sensor

24V input from an inductive sensor mounted on the bending roller motor. This sensor is
used for setting the maximum and minimum speed of the motor.
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 Bending Roller Prestep Speed values to the DCS19
program. Refer to the chapter below describing this transmission protocol.
Air Valve, Right

Air Valve, Left
Air Valve, Correction
These three 24V outputs from the TMCC controls the pressurised air valves that are
connected to the air cylinders controlling the folding flaps. The combinations below are valid:
Air Valves Air cylinder position

Right Left Correction Right Side Left Side
0V 0V 0V Precorrection Precorrection
0V 0V 24V Correction Correction
0V 24V 24V Correction Full paper feed
24V 0V 24V Full paper feed Correction
24V 24V 24V Full paper feed Full paper feed
Bending Roller Signal

Analog (0-10V) output signal connected to the motor controller card for the bending roller
motor. The exact working range for this signal is determined during the setting of the
maximum and minimum bending roller speed (refer to that chapter), but is approx. from
6V to 9V.
Register Mark Photocell Pulse

24V output to the PLC. This is a 40 ms long pulse sent when the DCS19 program has
decoded a register mark. The pulse is delayed with the sum of:
• a constant delay corresponding to 32.7 mm tube movement,
• a variable delay depending of the Design Adjustment Pot (± 5 mm).
(This delay corresponds to the MultiStep function).
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
Design OK
24V output to the PLC. This signal is HIGH (24V) as long as:
• the design error of a package is less than ±1.5 mm, OR
• the mean design error of the two latest packages are less than ±1.5 mm.
(These conditions corresponds to the MultiStep function).
Diagnostic Analog Output

An analogue (0-10V) output that sets one of the following signals after each package:
SW1 position Function

8 Design error of current package.
9 Mean design error of the two latest packages.
A Filtered design error ("90% old + 10% new"-algorithm).
B Output signal to bending roller and folding flaps.
C Filtered output signal
D Design Adjustment Pot signal
Refer to the appropriate chapter below for a complete description of this function.
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 DCS19 program. They should be left
unconnected.
6. Basic Program Functions

The DCS19 program for the TMCC 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
parameters that need to be changed (e.g. volume parameters) are controlled from the PLC.
Program flow:
At start-up or reset (the TMCC may be reset manually by setting the SW1 switch on the front panel in
position "0" for a few seconds, and then back to its previous position) the DCS19 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:
• 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.
• When the register mark has been detected the DCS19 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.
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
• When the register mark has been detected the DCS19 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 Potentiometer position (±5 mm).
• 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 Potentiometer setting (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.
• 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.
• 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 bending roller
and a digital setting of the air valves for the air cylinder controlling the folding flaps. The conversion is
illustrated in the chapter "Output Signals".
• From the calculated design error the DCS19 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 ±1.5 mm is the Default value. It is possible to change by terminal (refer to
Chapter 13 for more details).
• The DCS19 program then start again to search for a new register mark.
Besides this main program flow the DCS19 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.
7. Other Program Functions

Besides the basic program functions described above the DCS19 program performs some other functions
and decisions:
Precorrection vs. Regulating mode:

• The air cylinders and, consequently, the folding flaps can be set in five different positions, one
precorrection and four regulating positions. Two of the regulating positions are equal from the design
control's point of view, which practically means that there are three different regulating position:
1. Both sides: CORRECTION
2. Left: FULL PAPER FEED, Right: CORRECTION, or
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
Left: CORRECTION, Right: FULL PAPER FEED

3. Both sides: FULL PAPER FEED
• 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).
• 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 sector, i.e. when the Register Mark Photocell
Pulse is found in this sector the filling is turned on. The filling sector is chosen so that when the paper
tube is fully filled then the design control system has also found the correct design position.
• The DCS19 program continuously calculates the design error, also during precorrection mode. When,
in this mode, the design error becomes less than a certain value (which depends on the precorrection
step length) the DCS19 program prepares to switch into regulating mode, i.e. it tries to find the
correct air cylinder position, one of the three possible positions.
• When in regulating mode the DCS19 program tries to keep as low design error as possible. When:
• the design error is less than ±1.5 mm, or
• 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".
• When the DCS19 program runs in the regulating mode it continues in this mode until:
• more that three consecutive packages have a design error greater than ±20 mm,
• more than four Register Marks should have passed the photocells, i.e. they are missed,
• the PLC resets the DCS19 Enable signal.
When one, or more, of these condition is true the DCS19 program switches to precorrection mode.
• When the filling machine is in short stop the design control system remains in regulating mode.
When started again the DCS19 program tries to keep the design control as good as possible, just like
in normal production mode. Though, in order to have a better forming during the acceleration
sequence the DCS19 porgram sets the maximum bending roller speed for the first two packages after
short stop.
Volume Parameters:
• Normally the volume parameters are sent from the PLC, refer to the "Volume Parameter Transfer"
chapter.
• However, for test purposes and in special cases, it is possible to set a default Repeat Length and
Production Angle with the SW2 switch on the TMCC side (the TMCC must be pulled out of the rack
system). The Production Angle is always set to 0 (dec), this may be changed with the "A" command
from a terminal. The Repeat Length may be set to one of:
SW2 Pos. 1 2 3 4 5 6 7 8 9 A
Repeat Length, mm 115 130 140 160 173 190 207 226 245 268
• If SW2 is set to anything else than those values above, a message "No volume set" will be displayed
on the terminal at a TMCC start-up or reset.
8. TMCC Front Panel Switch

The front panel switch SW1 is used both for setting the bending roller revs and for selecting one of the
available formats for the diagnostic output. This chapter contains the basic principle for setting the switch,
the functions above are fully described in their respective chapters.
SW1 Function
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
0 Programming mode: in this position it is possible to download the DCS19 program. Refer
to the "Program Download" chapter.
1 to 7 Bending Roller Revs Setting: These positions are used to set the Bending Roller Revs.
Refer to the "Bending Roller Revs Setting" chapter.
8 to D Diagnostic output mode: These positions select one of the available formats for the
diagnostic output. Refer to the "Diagnostic Output" chapter.
E Not used.
F Automatic Bending Roller Revs Setting: In this position the Bending Roller Revs are set
automatically. Refer to the "Bending Roller Revs Setting" chapter.
NOTE: In normal production mode the SW1 should be set to position 8.
9. TMCC Front Panel LEDs

The TMCC front panel LEDs have the following meaning in normal production mode:
LED Function
FAULT Not used in this program
POWER Should be turned on (Green). Indicates that the power supply to the TMCC is correct.
S1 Flashes when a Register Mark is detected, the flash being approx. 40 ms.
S2 Turns ON when the design is OK, i.e. "in production".
S3 Not used
S4 ON = Correction Air Cylinder On.
S5 ON = Left Side Air Cylinder On
S6 ON = Right Side Air Cylinder On.
S7 Not used
S8 Not used
When the LEDs are flashing simultaneously this indicates a malfunction in the program. It is possible to
find out the type of error by noticing which LED is not flashing:
LED not flashing Meaning

S1 Error in EEPROM writing. This error indicates that there may be a hardware
problem when trying to store the bending roller revs manually or
automatically.
S2 No Bending Roller Sensor pulses. This indicates either:
• that the bending roller is not rotating, or
• a faulty or badly adjusted sensor, or
• a bad connection between sensor and TMCC.
Besides these meanings the LEDs are used for special functions in the Bending Roller Revs Setting,
refer to that chapter.
10. 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 TMCC 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
means that the DCS19 program must convert the value into a "normal" representation before it can be
used in calculations. A conversion table is given in the appendices.
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
11. Design Adjustment Potentiometer

The Design Adjustment Potentiometer is used to move (fine-adjust) the design position in relation to the
jaw system. This device is a MUPP (Multi-purpose Potentiometer), which outputs a 0-10V analogue
signal depending of the position of the potentiometer knob. The signal is sent to the TMCC and the
DCS19 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 corresponds to a movement of ±5 mm on the
design position, this range being the same for all volumes.
The potentiometer is turned clockwise to move the design downwards in relation to the jaw system, and
vice versa:
12. Output Signals

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 bending roller and three digital
signals to the air valves controlling the folding flap air cylinders. The bending roller signal overlaps the
air cylinder positions (hysteresis) as below:
Cylinder
position
Bending Roller Revs (rpm)
Corr Left Right
100 135
ON OFF OFF
ON ON OFF 110 135
ON OFF ON
110 135
ON ON ON
1 102 120 169 188 255 Output Value
Output value = 0 sets the precorrection position of the air cylinders (= all OFF) and sets the Prestep
Speed on the bending roller (set from the PLC).
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
13. 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 DCS19 status values.
The communication is a standard RS-232 serial interface. Use a cable suitable for the TMCC and the PC
(terminal). Necessary pin connections are:
PC 9-pin TMCC 9-pin

female male
2 3
3 2
5 5
If you are using a PC, any terminal program may be used, like "TIT" or "Windows Terminal". Configure the
program for:
• Baudrate: 9600
• Parity: None
• Bits: 8
• Stopbits: 1
• Flow Control: None
The commands and parameters, if any, to the DCS19 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 Pot setting is added to this value.
For example: A72 sets the Production Angle to 72 degrees (110 octal).
E Displays the current Encoder value, first the hexadecimal Gray code, then converted to
octal.
Fooo Force ooo. This command forces the outputs, Bending Roller speed and Air 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.
Mnnn 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 ± 2.0
mm).
Rn Reporting ON/OFF. This command enables and disables the automatic reporting of the
design error and output value for every package.
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
R0 Disable reporting.
R1 Enable reporting.
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.
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.
Precorr Bend. Roller Speed (rpm) : The speed set from the PLC.
MaxDesignOK (mm) : The max allowed design error.
MaxRevs, MinRevs (V) : The voltages set on the bending roller
output for maximum and minimum speed.
Pot Voltage (V) : A value 0 -10 Volt depending on the
Design Adj. Pot position.
* = Filter algorithm: 90%(old values) + 10%(new values)
14. Volume Parameter Transfer

The Repeat Length, Production Angle and Bending Roller Prestep Speed may be sent from the PLC to the
DCS19 program. This sending uses four digital +24V signals and the protocol is as follows:
From PLC:
VolumeEnable
VolumeClock
VolumeData
From TMCC:
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
• The bit time must be at least 5 ms.

• The output bits are shifted with the least significant bit (LSB) first:
<LSB>Repeat Length<MSB><LSB>Production Angle<MSB><LSB>BendRollerPrestepSpeed<MSB>
• The Repeat Length is in 1/10 of mm, i.e. a repeat length of 245 mm is sent as 2450.
• 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.)
• The BendRollerPrestepSpeed is sent as the number of revs / minute (rpm).
Other features:
• The signal VolumeAcknowledge in the protocol is useful when, for example, the PLC starts up earlier
than the TMCC, or if the TMCC 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.
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
• The DCS19 program must receive at least two complete message that are exactly the same before is
sets the VolumeAcknowledge signal.
15. Bending Roller Revs Setting

The Bending Roller Revs may be set manually or automatically.
To start with the automatically this setting needs a sensor at the bending roller motor shaft. This sensor
must transmit one pulse per revolution of the shaft. The length of the pulse is not important, only the
raising edge is used for rev calculation. The automatic setting is initiated when the SW1 switch on the
TMCC front panel is set to position "F".
NOTE that the bending roller motor must be running (enabled) during the automatic setting. This
may be accomplished by setting the appropriate bit in the PLC. If the motor is not running an
error is indicated by flashing LEDs on the front panel.
The DCS19 program then outputs a first voltage setting to the motor controller and after a few seconds it
determines the bending roller speed. If then the speed is too low the DCS19 program tries a higher
voltage setting, and vice versa. This trying continues until the correct MaxRevs value has been found,
and this takes approx. 15 sec. Then the MinRevs value is set in the same way. When both values are
found they are stored in the EEPROM.
The progress of the automatic revs setting is indicated by the LEDs flashing for every "try" voltage set by
the DCS19 program. The final EEPROM storing is indicated with a long flash (approx. 1 sec.) After this
flash the setting procedure is terminated and the SW1 switch may be set to the production position "8".
The manual setting of the bending roller speed may be done in two different ways, either via the PLC
(described in the previous chapter) or by the use of the SW1 front panel switch:
• When set from the PLC some of the SW1 positions described below may be used to set the minimum
and maximum bending roller speed (pos. 1 and 4).
• When setting the bending roller speed with the SW1 the following positions are used:
SW1 pos. Function

1 Output minimum bending roller speed.
2 Decrease the minimum speed.
3 Increase the minimum speed.
4 Output the maximum bending roller speed.
5 Decrease the maximum speed.
6 Increase the maximum speed.
7 Store the values in the EEPROM.
8 Normal production position
Manual Setting Procedure:

1. Set the enable signal to the bending roller motor to start the motor.
2. Set SW1 to "1" and the motor will start to revolve with its current minimum speed.
3. Read the bending roller speed with a tachometer.
4. If the speed is too high, set the SW1 to "2". The speed will now decrease with approx. 1 rpm / sec.
5. Otherwise, if the speed is too low, set SW1 to "3", and the speed increases.
6. When correct minimum speed has been reached, set SW1 to "4". The motor now runs with its
current maximum speed.
7. Read the bending roller speed with a tachometer.
8. If the speed is too high, set the SW1 to "5". The speed will now decrease with approx. 1 rpm / sec.
9. Otherwise, if the speed is too low, set SW1 to "6", and the speed increases.
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
10. When correct maximum speed has been reached, set SW1 to "7", and wait for at least one flashing
of the front panel LEDs. This shows that the set values have been stored in EEPROM.
11. Set the SW1 to production position "8" and reset the forced enable signal to the motor.
16. Diagnostic Output

To facilitate diagnosis of the design control system the analogue output on TMCC pin 5 may be connected
to a paper recorder or an oscilloscope. The following output signals are available on this pin:
SW1 pos. Function Output format

8 "Normal" position, outputs the calculated design 0 to 10 V =>
error of every package. -5 to +5 mm design error
9 Outputs the average (mean) design error of the two 0 to 10 V =>
last packages. -5 to +5 mm design error
A Outputs a filtered* average of the design error. 0 to 10 V =>
-5 to +5 mm design error
B Outputs the calculated output signal to the Bending 0 to 10 V =>
Roller and Air Cylinder. The output range of 0 to 0 to 255 range of output signal
255 is the value calculated accord. to the chapter
"Output Signals"
C Outputs a filtered* average of the output signal. 0 to 10 V =>
0 to 255 range of output signal
D Outputs the Design Adjustment Potentiometer 0 to 10 V =>
setting -5 to +5 mm adjustment range
* = Filter algorithm: 90%(old values) + 10%(new value)
NOTE that all the values (incl Design Adjustment Potentiometer) change only when the filling machine is
running (the values change for every package).
17. Program Download

The DCS19 program should be downloaded to the TMCC during machine production, but it may be
necessary to do a new download if the TMCC has been replaced or if a new release of the DCS19
program is available. 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 TMCC front panel connector.
2. Set the SW1 front panel switch to position "0"
3. Insert the program diskette marked "47 835 - 0201" into the PC diskette station.
4. Start the download program TMCC.EXE by entering the command: A:TMCC<enter>
5. When the program menu appears enter the communication port in use, normally "1".
6. Now a directory listing will appear. Select the A: drive by pressing the <HOME> key.
7. A list of the files on diskette A: will appear. Select the file D47835.201 by using the arrow keys.
(First the right arrow to select the file window).
8. When the file is selected press the function key <F2>, and the automatic download starts.
9. The progress of the download may be monitored in the lower part of the screen.
10. When the new program is downloaded without errors press the function key <F10> to exit the
TMCC.EXE download program.
11. Set the TMCC front panel switch SW1 to production position "8" and the download procedure is
finished.
12. If a label (with the program number and LED functions) is supplied together with the diskette this
label should be affixed to the TMCC front panel, aligned with the LEDs.
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
18. Appendices
Gray Code Table
Gray Oct Dec Mech Gray Oct Dec Mech Gray Oct Dec Mech Gray Oct Dec Mech
---- ---- 0 0 0.0 -¤¤- ---- 100 64 90,0 ¤¤-- ---- 200 128 180,0 ¤-¤- ---- 300 192 270,0
---- ---¤ 1 1 1,4 -¤¤- ---¤ 101 65 91,4 ¤¤-- ---¤ 201 129 181,4 ¤-¤- ---¤ 301 193 271,4
---- --¤¤ 2 2 2,8 -¤¤- --¤¤ 102 66 92,8 ¤¤-- --¤¤ 202 130 182,8 ¤-¤- --¤¤ 302 194 272,8
---- --¤- 3 3 4,2 -¤¤- --¤- 103 67 94,2 ¤¤-- --¤- 203 131 184,2 ¤-¤- --¤- 303 195 274,2
---- -¤¤- 4 4 5,6 -¤¤- -¤¤- 104 68 95,6 ¤¤-- -¤¤- 204 132 185,6 ¤-¤- -¤¤- 304 196 275,6
---- -¤¤¤ 5 5 7,0 -¤¤- -¤¤¤ 105 69 97,0 ¤¤-- -¤¤¤ 205 133 187,0 ¤-¤- -¤¤¤ 305 197 277,0
---- -¤-¤ 6 6 8,4 -¤¤- -¤-¤ 106 70 98,4 ¤¤-- -¤-¤ 206 134 188,4 ¤-¤- -¤-¤ 306 198 278,4
---- -¤-- 7 7 9,8 -¤¤- -¤-- 107 71 99,8 ¤¤-- -¤-- 207 135 189,8 ¤-¤- -¤-- 307 199 279,8
---- ¤¤-- 10 8 11,3 -¤¤- ¤¤-- 110 72 101,3 ¤¤-- ¤¤-- 210 136 191,3 ¤-¤- ¤¤-- 310 200 281,3
---- ¤¤-¤ 11 9 12,7 -¤¤- ¤¤-¤ 111 73 102,7 ¤¤-- ¤¤-¤ 211 137 192,7 ¤-¤- ¤¤-¤ 311 201 282,7
---- ¤¤¤¤ 12 10 14,1 -¤¤- ¤¤¤¤ 112 74 104,1 ¤¤-- ¤¤¤¤ 212 138 194,1 ¤-¤- ¤¤¤¤ 312 202 284,1
---- ¤¤¤- 13 11 15,5 -¤¤- ¤¤¤- 113 75 105,5 ¤¤-- ¤¤¤- 213 139 195,5 ¤-¤- ¤¤¤- 313 203 285,5
---- ¤-¤- 14 12 16,9 -¤¤- ¤-¤- 114 76 106,9 ¤¤-- ¤-¤- 214 140 196,9 ¤-¤- ¤-¤- 314 204 286,9
---- ¤-¤¤ 15 13 18,3 -¤¤- ¤-¤¤ 115 77 108,3 ¤¤-- ¤-¤¤ 215 141 198,3 ¤-¤- ¤-¤¤ 315 205 288,3
---- ¤--¤ 16 14 19,7 -¤¤- ¤--¤ 116 78 109,7 ¤¤-- ¤--¤ 216 142 199,7 ¤-¤- ¤--¤ 316 206 289,7
---- ¤--- 17 15 21,1 -¤¤- ¤--- 117 79 111,1 ¤¤-- ¤--- 217 143 201,1 ¤-¤- ¤--- 317 207 291,1
---¤ ¤--- 20 16 22,5 -¤¤¤ ¤--- 120 80 112,5 ¤¤-¤ ¤--- 220 144 202,5 ¤-¤¤ ¤--- 320 208 292,5
---¤ ¤--¤ 21 17 23,9 -¤¤¤ ¤--¤ 121 81 113,9 ¤¤-¤ ¤--¤ 221 145 203,9 ¤-¤¤ ¤--¤ 321 209 293,9
---¤ ¤-¤¤ 22 18 25,3 -¤¤¤ ¤-¤¤ 122 82 115,3 ¤¤-¤ ¤-¤¤ 222 146 205,3 ¤-¤¤ ¤-¤¤ 322 210 295,3
---¤ ¤-¤- 23 19 26,7 -¤¤¤ ¤-¤- 123 83 116,7 ¤¤-¤ ¤-¤- 223 147 206,7 ¤-¤¤ ¤-¤- 323 211 296,7
---¤ ¤¤¤- 24 20 28,1 -¤¤¤ ¤¤¤- 124 84 118,1 ¤¤-¤ ¤¤¤- 224 148 208,1 ¤-¤¤ ¤¤¤- 324 212 298,1
---¤ ¤¤¤¤ 25 21 29,5 -¤¤¤ ¤¤¤¤ 125 85 119,5 ¤¤-¤ ¤¤¤¤ 225 149 209,5 ¤-¤¤ ¤¤¤¤ 325 213 299,5
---¤ ¤¤-¤ 26 22 30,9 -¤¤¤ ¤¤-¤ 126 86 120,9 ¤¤-¤ ¤¤-¤ 226 150 210,9 ¤-¤¤ ¤¤-¤ 326 214 300,9
---¤ ¤¤-- 27 23 32,3 -¤¤¤ ¤¤-- 127 87 122,3 ¤¤-¤ ¤¤-- 227 151 212,3 ¤-¤¤ ¤¤-- 327 215 302,3
---¤ -¤-- 30 24 33,8 -¤¤¤ -¤-- 130 88 123,8 ¤¤-¤ -¤-- 230 152 213,8 ¤-¤¤ -¤-- 330 216 303,8
---¤ -¤-¤ 31 25 35,2 -¤¤¤ -¤-¤ 131 89 125,2 ¤¤-¤ -¤-¤ 231 153 215,2 ¤-¤¤ -¤-¤ 331 217 305,2
---¤ -¤¤¤ 32 26 36,6 -¤¤¤ -¤¤¤ 132 90 126,6 ¤¤-¤ -¤¤¤ 232 154 216,6 ¤-¤¤ -¤¤¤ 332 218 306,6
---¤ -¤¤- 33 27 38,0 -¤¤¤ -¤¤- 133 91 128,0 ¤¤-¤ -¤¤- 233 155 218,0 ¤-¤¤ -¤¤- 333 219 308,0
---¤ --¤- 34 28 39,4 -¤¤¤ --¤- 134 92 129,4 ¤¤-¤ --¤- 234 156 219,4 ¤-¤¤ --¤- 334 220 309,4
---¤ --¤¤ 35 29 40,8 -¤¤¤ --¤¤ 135 93 130,8 ¤¤-¤ --¤¤ 235 157 220,8 ¤-¤¤ --¤¤ 335 221 310,8
---¤ ---¤ 36 30 42,2 -¤¤¤ ---¤ 136 94 132,2 ¤¤-¤ ---¤ 236 158 222,2 ¤-¤¤ ---¤ 336 222 312,2
---¤ ---- 37 31 43,6 -¤¤¤ ---- 137 95 133,6 ¤¤-¤ ---- 237 159 223,6 ¤-¤¤ ---- 337 223 313,6
--¤¤ ---- 40 32 45,0 -¤-¤ ---- 140 96 135,0 ¤¤¤¤ ---- 240 160 225,0 ¤--¤ ---- 340 224 315,0
--¤¤ ---¤ 41 33 46,4 -¤-¤ ---¤ 141 97 136,4 ¤¤¤¤ ---¤ 241 161 226,4 ¤--¤ ---¤ 341 225 316,4
--¤¤ --¤¤ 42 34 47,8 -¤-¤ --¤¤ 142 98 137,8 ¤¤¤¤ --¤¤ 242 162 227,8 ¤--¤ --¤¤ 342 226 317,8
--¤¤ --¤- 43 35 49,2 -¤-¤ --¤- 143 99 139,2 ¤¤¤¤ --¤- 243 163 229,2 ¤--¤ --¤- 343 227 319,2
--¤¤ -¤¤- 44 36 50,6 -¤-¤ -¤¤- 144 100 140,6 ¤¤¤¤ -¤¤- 244 164 230,6 ¤--¤ -¤¤- 344 228 320,6
--¤¤ -¤¤¤ 45 37 52,0 -¤-¤ -¤¤¤ 145 101 142,0 ¤¤¤¤ -¤¤¤ 245 165 232,0 ¤--¤ -¤¤¤ 345 229 322,0
--¤¤ -¤-¤ 46 38 53,4 -¤-¤ -¤-¤ 146 102 143,4 ¤¤¤¤ -¤-¤ 246 166 233,4 ¤--¤ -¤-¤ 346 230 323,4
--¤¤ -¤-- 47 39 54,8 -¤-¤ -¤-- 147 103 144,8 ¤¤¤¤ -¤-- 247 167 234,8 ¤--¤ -¤-- 347 231 324,8
--¤¤ ¤¤-- 50 40 56,3 -¤-¤ ¤¤-- 150 104 146,3 ¤¤¤¤ ¤¤-- 250 168 236,3 ¤--¤ ¤¤-- 350 232 326,3
--¤¤ ¤¤-¤ 51 41 57,7 -¤-¤ ¤¤-¤ 151 105 147,7 ¤¤¤¤ ¤¤-¤ 251 169 237,7 ¤--¤ ¤¤-¤ 351 233 327,7
--¤¤ ¤¤¤¤ 52 42 59,1 -¤-¤ ¤¤¤¤ 152 106 149,1 ¤¤¤¤ ¤¤¤¤ 252 170 239,1 ¤--¤ ¤¤¤¤ 352 234 329,1
--¤¤ ¤¤¤- 53 43 60,5 -¤-¤ ¤¤¤- 153 107 150,5 ¤¤¤¤ ¤¤¤- 253 171 240,5 ¤--¤ ¤¤¤- 353 235 330,5
--¤¤ ¤-¤- 54 44 61,9 -¤-¤ ¤-¤- 154 108 151,9 ¤¤¤¤ ¤-¤- 254 172 241,9 ¤--¤ ¤-¤- 354 236 331,9
--¤¤ ¤-¤¤ 55 45 63,3 -¤-¤ ¤-¤¤ 155 109 153,3 ¤¤¤¤ ¤-¤¤ 255 173 243,3 ¤--¤ ¤-¤¤ 355 237 333,3
--¤¤ ¤--¤ 56 46 64,7 -¤-¤ ¤--¤ 156 110 154,7 ¤¤¤¤ ¤--¤ 256 174 244,7 ¤--¤ ¤--¤ 356 238 334,7
--¤¤ ¤--- 57 47 66,1 -¤-¤ ¤--- 157 111 156,1 ¤¤¤¤ ¤--- 257 175 246,1 ¤--¤ ¤--- 357 239 336,1
--¤- ¤--- 60 48 67,5 -¤-- ¤--- 160 112 157,5 ¤¤¤- ¤--- 260 176 247,5 ¤--- ¤--- 360 240 337,5
--¤- ¤--¤ 61 49 68,9 -¤-- ¤--¤ 161 113 158,9 ¤¤¤- ¤--¤ 261 177 248,9 ¤--- ¤--¤ 361 241 338,9
--¤- ¤-¤¤ 62 50 70,3 -¤-- ¤-¤¤ 162 114 160,3 ¤¤¤- ¤-¤¤ 262 178 250,3 ¤--- ¤-¤¤ 362 242 340,3
--¤- ¤-¤- 63 51 71,7 -¤-- ¤-¤- 163 115 161,7 ¤¤¤- ¤-¤- 263 179 251,7 ¤--- ¤-¤- 363 243 341,7
--¤- ¤¤¤- 64 52 73,1 -¤-- ¤¤¤- 164 116 163,1 ¤¤¤- ¤¤¤- 264 180 253,1 ¤--- ¤¤¤- 364 244 343,1
--¤- ¤¤¤¤ 65 53 74,5 -¤-- ¤¤¤¤ 165 117 164,5 ¤¤¤- ¤¤¤¤ 265 181 254,5 ¤--- ¤¤¤¤ 365 245 344,5
--¤- ¤¤-¤ 66 54 75,9 -¤-- ¤¤-¤ 166 118 165,9 ¤¤¤- ¤¤-¤ 266 182 255,9 ¤--- ¤¤-¤ 366 246 345,9
--¤- ¤¤-- 67 55 77,3 -¤-- ¤¤-- 167 119 167,3 ¤¤¤- ¤¤-- 267 183 257,3 ¤--- ¤¤-- 367 247 347,3
--¤- -¤-- 70 56 78,8 -¤-- -¤-- 170 120 168,8 ¤¤¤- -¤-- 270 184 258,8 ¤--- -¤-- 370 248 348,8
--¤- -¤-¤ 71 57 80,2 -¤-- -¤-¤ 171 121 170,2 ¤¤¤- -¤-¤ 271 185 260,2 ¤--- -¤-¤ 371 249 350,2
--¤- -¤¤¤ 72 58 81,6 -¤-- -¤¤¤ 172 122 171,6 ¤¤¤- -¤¤¤ 272 186 261,6 ¤--- -¤¤¤ 372 250 351,6
--¤- -¤¤- 73 59 83,0 -¤-- -¤¤- 173 123 173,0 ¤¤¤- -¤¤- 273 187 263,0 ¤--- -¤¤- 373 251 353,0
--¤- --¤- 74 60 84,4 -¤-- --¤- 174 124 174,4 ¤¤¤- --¤- 274 188 264,4 ¤--- --¤- 374 252 354,4
--¤- --¤¤ 75 61 85,8 -¤-- --¤¤ 175 125 175,8 ¤¤¤- --¤¤ 275 189 265,8 ¤--- --¤¤ 375 253 355,8
--¤- ---¤ 76 62 87,2 -¤-- ---¤ 176 126 177,2 ¤¤¤- ---¤ 276 190 267,2 ¤--- ---¤ 376 254 357,2
--¤- ---- 77 63 88,6 -¤-- ---- 177 127 178,6 ¤¤¤- ---- 277 191 268,6 ¤--- ---- 377 255 358,6
Connection Diagram
58017
F. Bassissi
Modena, Italy 47835 - 0200 ECN 71221
LowIn0 9
+24V
1 +24V TMCC 10
AngleEncoder0 (LSB)
2 LowIn1 AngleEncoder1
Ground 0V 11
LowIn2 AngleEncoder2
LowIn3 12
AngleEncoder3
LowIn4 13
AngleEncoder4
DesignAdjustmentPot LowIn5 14
3 AnalogIn0 AngleEncoder5
LowIn6 15
4 AnalogIn1 AngleEncoder6
LowIn7 16
AngleEncoder7 (MSB)
5 AnalogOut0
DiagnosticOutput HighIn/LowOut0 17
6 AnalogOut1 RegisterMarkPhotocell, 4bar (clock)
BendingRollerSignal HighIn/LowOut1 18
RegisterMarkPhotocell, 3bar (data)
HighIn/LowOut2 19
7 FastIn0
BendingRollerSensor HighIn/LowOut3 20
8 FastIn1 DCS19Enabled
HighIn/LowOut4 21
HighIn/LowOut5 22
VolumeEnable
HighIn/LowOut6 23
VolumeClock
RS-232/CAN HighIn/LowOut7 24
VolumeData
FP3 Transmit
FP2 Receive HighOut0 25
FP4 StatusOut HighOut1 26
AirValveRight
FP6 StatusIn HighOut2 27
AirValveLeft
FP5 Ground HighOut3 28
AirValveCorrection
FP7 +10V HighOut4 29
FP1 CANhigh HighOut5 30
VolumeAcknowledge
FP9 CANlow HighOut6 31
PhotocellPulse
FP8 NoConnect HighOut7 32
DesignOK
+24V
MUPP
Ground
11
Package Integrity

Packaging material,
TBA/m and TBA/j
Moisture
or water
Product
Light
Micro
organism
Oxygen
Flavour
Odours
Internal coating 2 Alifoil Paper board Printing

Internal coating 1 Lamination Paper board Outer coating

Lund, Sweden Tetra Brik Aseptic 1/9501 OH 526
Labels
1
98 11 23
3 9
5
6
7
10
The label contains the following information:

1. Date of production
2. Type of packaging material
3. Volume of package
4. Quantity of packages on the reel
5. Pallet packaging alternative (Code)
6. Production order number
7. Id-number
8. Web position number (Reel number)
9. Customer adress
10. Bar-code containing parts of above information
Technical Training Centre TM-00130 Training Document. For training purpose only.
Choice of packaging material
/aq lk
, /a
k
k
/ok
/ak
/m
/tk
/jk
/lk
/w
/w
Product TBA LS/strip
/j
Plain milk, Sweetened cond. milk R - - - - - - - - R* LHL or PPP
Flavoured milk - R - - - - - - - R* PPP
Drinks cont. fat 1) - R - - - - - - - - PPP
Formulated Tomato products 2) - - - - - - - - R R PPP or LSE

Not formulated Tomato products - R - - - - - - - - PPP
Fruit and Vegetable juices & drinks - R - - - - - - - R* PPP
Tea & Coffee - R - - - - - - - R* PPP or LSE

Wine and Alcohol drinks, < 20% - - - R - - - - - R* Wine
Alcohol drinks, > 20% - - - - R - - - - R Wine
Dressing - - - - - - - - R R PPP or LSE

Soups and Sauces - - - - - - - - R R PPP or LSE
Oil and Butter - - - - - - - R - R PPP
Vinegar products 3) - R - - - - - - - - PPP
Products for Hot-vending machines - - R - - - - - R R PPP
Special Dietetic Products (SPD) - - R - - - - - - R PPP
Water, flavoured - R - - - - - - - - PPP
Mineral water - - - - - R - - - - PPP
High quality Mineral water - - - - - - R - - - PPP
Scrambled and Liquid eggs - - - - - - - - R R PPP
Cake mix and Pancake mix R - - - - - - - R R PPP
Desserts - - - - - - - - R R PPP or LSE
R = Recommendable
1) e.g. Coconut, Soya bean
2) e.g. with additives oil, salt, vinegar etc.
3) max 1.0% acetic acid
* For Large Size Containers (LSC) 1500 ml, /lk packaging material only Sales Manual Carton Packaging Material G 001

Lund, Sweden 1/0007 OH 979:11
Longitudinal seal (LS) strips
Lund, Sweden
Machine type
LDPE LDPE LDPE LDPE
Primer Primer Primer
HDPE PET EVOH PET
Primer Primer Primer

LDPE
Issue
LDPE LDPE LDPE
1/9411
LHL−STRIPS PPP−STRIPS LSE−STRIPS WINE−STRIPS
7,5/0,1 7,5/0,075 7,5/0,075 7,5/0,075
62125 409813 115382 144536
code number code number code number code number
OH 512
Normally used for Used for most Used for products Must be used
UHT milk and water filling products sensitive to exposure when filling wine
of oxygen
Test ink
Ink solution with low surface tension easily penetrate capillary

leakage channels.
Test ink is availabel from TP and can be ordered on TP No 90298-261.
Components:
Isopropanol (solvent)
Erythrosine (powder)
Preparation:
1. Mix 1.5 g Erythosine with 1.000 ml Isopropanol.
2. Shake.
3. Leave overnight, protected against evaporation.
4. Filtrate.
Use a glass funnel and a filter for moderate filtration speed.
Technical Training Centre TM-00128 Training Document. For training purpose only.
12
Cleaning

Cleaning
what product component is
removed by
what solution
WA
TE
ID
Salt
AC
and R
mineral Sugar
Protein Fat
ALK ALI

Intermediate cleaning
Lund, Sweden
TBA/19
Machine type
TBA/19
Issue
2/9804
Hot air
OH 533:1
Pre−heated air
alt. cooled air
Steam
Product
Cleaning liquid
Final cleaning
TBA/19
Cleaning liquid
Cleaning liquid
Steam
Lund, Sweden TBA/19 2/9804 OH 533:2
Cleaning in Place
Final
Cleaning steps To restore Ph in the return pipe rinsing
Rinsing
To force out the Acid cold water
Acid
To dissolve mineral deposits cleaning
TM-00135
Final
rinsing To restore Ph in the return pipe
Rinsing
cold water To force out the Alkali
Alkali
cleaning Cleaning with Alkali
Rinsing
warm water Rinsing the pipes and melting any fat built-ups
Rinsing
cold water To force out product, remaning in the product pipe
Daily cleaning
Weekly cleaning ( or when required)

1
13
Supply Systems

Valve panel TBA/19
Lund, Sweden
U21 T21
Y1 Y27
U4 T4
Y102 Y26 A1 Z3 Z5 Y32
U12 T12
Y24
Y21 U1 T1
Machine type
Y20 U31 T31

Z1 A4 Y31
Y86 U5
Y25
TBA/19 010V
1 2
Y23
B7
Y19
U18 U62
Y17
Y9 Y105 Y51 A3 Y29

Z31.1
Y8 Y106
B2 Y39
T2
F2 A2
Issue
Y7 Y14
O102
3/9512
Z31.2
Y6 Y13
U107
Y5 Y12 Z4
U2
Y3
OH 501
Y2
Z2
PP17
B6
SUCTION VALVE PRESSURE FEED
F23:1 C23:1 C23:2 F23:2
Air diagram STEAM BARRIER (C)
S9
A2 Z2 T2 F2
TUBE DRAINING FILLING, DRAINING LUBRICATION AIR
FLUSHING WATER PANEL PEROXIDE BATH PEROXIDE BATH CENTRAL PUMP
F7
Y39 STEAM U2
F9 P17
B2
Lund, Sweden
F5 F6 HEAT EXCHANGER VACCUM VALVE
STERILE PRODUCT (A)
AIR (B) B6
AIR BLOWING AIR BLOWING F8 FLAP SEALING
C25 F25 C86
WASTE PACKAGES DROP CHUTE AIR INLET AIR
S8
F19 O19
DRAINING

CLEANING TRAY S91 MAIN AIR
VALVE
O102
F2
WATER Y2 Y3 Y5 Y6 Y7 Y8 Y9 Y17 Y19 Y23 Y25 Y86 Y102 Y1
Machine type
OUTFEEDER
FINAL FOLDER
TBA/19
AIR KNIFE
Z31:1 T31 T1 T12 T4 T21

C21:1
Z31:2 LS−ELEMENT LS−COUNTER
MOVEMENT ROLLER
PHOTOCELL
DESIGN
U31 U1 U12 U4 U21
CORRECTION LS−SHORT STOP
ELEMENT MOVEMENT SQUEEZER ROLLER C24:1 C26
Z4
AUTO CORRECTION
LEFT RIGHT C20:1 C21:2
AIR BLOWING SPRAYTANK AIR
COOLING LS−STRIP
Issue
C12:1 C12:2
BOTTOM FLAPS DROP CHUTE
FINAL FOLDER
C13 C14 C106 C105
PRE CORRECTION Y4
C27
1/9911
O4
PEROXIDE BATH
STRIP MAGAZINE
SPLICING DEVICE
Y12 Y13 Y14 Y106 Y105 Y129 Y20 Y21 Y24 Y26 Y27
OH 888
Y107
Y51
REGULATING VALVE
U107 AIR JET AIR INJECTION PULL TAB ASU

PISTOL COOLING WATER
Water diagram
SUPERSTRUCTURE SERVICE UNIT SUPERSTRUCTURE
Bath Separator
Steam
Lund, Sweden
Heating System (Peroxide)
Tube flusher
M17
M GUARD

Dilution tank (B50)
R36
Steam
Scrubber M (M7) trap
Compressor Drain
MACHINE BODY
Z1 B4 B5 Y2
Machine type
J6
VALVE PANEL
Y51 J5 PNEUMATIC
GUARD
Cirk. cold PANEL Spray gun
water inlet B7
Y39
A4
(3.8L/MIN)
TBA/19
Y32
A1 M5 FINAL FOLDER
Z3 Z5 Air injection
Cold water
LIME SEPARATOR
Y31
A3
Hot water
Y29
JAW SYSTEM Station chain
sprinkler
Cirk. cold
water outlet
TS−
L R Sealing Z40
Issue
sealing
unit
Cleaning
M4 system
SERVICE UNIT (K50) M circulation
1/9911
pump
M6 FM2 FM3
Cooler
M Y33 hydraulic PNEUMATIC
system PANEL
Y2
A2 Cleaning
Detergent tray
F2 draining
pump
OH 889
Function of hydraulic system

Lund, Sweden TB/9, TBA/), TBA/19 3/9911 OH 258
Pressure regulation
Reduction valve
Cutting pressure
Jaw pressure
Over flow valve
To tank
From pump

Lubricating diagram
1 5 37 39 41 43 42 44 38 40 6 2
Lund, Sweden
9 10
POS Distributor
BL8 BL7 LUBRICATION POINT C−GROUP
L R Size
11 12
JAW SYSTEM

BL17
3 7 8 4 1 2 Pivot pin Yoke 10
3 4 Pivot pin Yoke 10
9 10 Guide Yoke 10
BL6 BL5 11 12 Guide Yoke 10
13 14 Housing Cutting saw 30
15 16 Roller Yoke 10
17 18 Block Yoke 10
19 20 Arm Yoke 10
21 22 Roller Yoke 10
Machine type
23 24 Bearing Guides 10
25 26 Link upper Guides 10
27 28 Link lower Guides 10
13 15 17 19 21 22 20 18 16 14 29 30 Link upper Guides 10
31 32 Link lower Guides 10
BL14 BL12 33 34 Housing Pressure jaw 30
35 36 Roller catch Pressure jaw 10
TBA/19
37 38 Roller volume flap Volume flap 30
BL13 JAW SYSTEM LEFT MACHINE BODY JAW SYSTEM RIGHT BL11 39 40 Roller volume flap Volume flap 30
MACHINE BODY
23 24 41 42 Brushing guide Machine body 30
BL18 43 44 Brushing guide Machine body 30
45 46 Brushing guide Machine body 30
47 48 Brushing guide Machine body 30
33 34 DRIVE UNIT
35 36 49 50 Bracket Arm 10
51 52 Roller Arm 30
25 27 29 31 32 30 28 26 53 54 Pulley Arm 10
55 56 Link upper Arm 10
57 58 Link lower Arm 10
59 60 Pulley Arm 10
BL9 85 87 BL4 61 62 Bracket Link 10
FINAL FOLDER 63 64 Roller Link 30
Issue
65 66 Belt holder Link 10
BL10 86 67 68 Link upper Link 10
45 47 79 80 48 46 100 98 96 95 97 99 69 70 Link lower Link 10
1/9911
94 92 90 89 91 93 75 76 Bracket Arm 10
TANK 77 78 Bracket Arm 10
79 80 Bearing Worm gear 10
BL20 FINAL FOLDER
82 84 81 83 BL1 SERVICE UNIT PP 17 81 82 Station chain Bracket 50
83 84 Station chain Bracket 50
85 Sprocket Covering panel 50
86 Pusher shaft Outfeeder 50
51 53 55 57 59 60 58 56 54 52 87 Sprocket Outfeeder 50
89 90 Pressure device Pressure device 50
SERVICE UNIT
95 96 Impulse transmitter Pipe work 10
OH 890
BL3 BL2 97 98 Impulse transmitter Pipe work 10
99 100 Impulse transmitter Pipe work 10
63 65 67 69 75 61 49 77 78 50 62 76 70 68 66 64
DRIVE UNIT LEFT DRIVE UNIT RIGHT
Central lubrication system
Lubrication oil
Compressed air
PLC

Central lubrication pump
and dosing valve
Rest position
Lubrication oil
Compressed air

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

Course Introduction 1. Machine Introduction 2. Sterile System 3. Peroxide System 4. Drive System 5. Jaw System 6. Filling System 8.

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Course Introduction 1. Machine Introduction 2. Sterile System 3. Peroxide System 4. Drive System 5. Jaw System 6. Filling System 8.

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Course Introduction 1

TBA/19 Machine Introduction 2

Training Document Sterile System 3

................................................................................................................ Tube Forming and Paper Tracking 7

Design Control System 10

Technical Training Centre

Technical Training Centre 1/9701 TM-00001

Technical Training Centre 2/9903 TM-00010 1

Valuables You are responsible for your own valuables.

Technical Training Centre 2/9903 TM-00010 2

Tetra Pak 1 Main Reception

Technical Training Centre 2/9903 TM-00010 3

Technical Training Centre

Tetra Brik Aseptic, TBA/19

Tetra Brik Aseptic Tetra Br

TBA/19 filling machine packages liquid food in TBA portion Steam

Electric power External cleaning equipment

Standard version of TBA/19 (not equipped with options)

Dimensions of packages and packaging material

TBA Volumes Dimensions, mm Approx. qty packages Appr. weight

100 B 69.3 32 47 30000 145

Volumes F-pan. S-pan Height Repeated Web LS Tube Theor. Under-

125 S 47 32 86 130.00 162 4 50.29 129.3 3.4%

200 B 62 41 83 140.00 214 8 65.57 211.0 5.2

Cirk. cold water inlet

Cirk cold water outlet

Technical Training Centre

The peroxide is condenced

The aseptic is kept with

Aseptic food processing

Compressor Peroxide tank

Technical Training Centre Machine type Issue

Rubber ring Constant

Water at low Constant

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

WEAC ready for door opening

48 Valve, spraying peroxide

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre

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

Top filling and

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

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

CHECK JAW OVER JAW SET JAW OVER

SET DESIGN CORR.

CHECK FOLDING FLAP FOLDING FLAPS