Im 81657 0104

IM
Installation Manual
TBA/19 Tetra Brik Aseptic 020V
2.281657014fr.fm
Tetra Pak
Doc. No. IM-81657-0104
This document is valid for:
Series No/ Machine No Sign.
648160-2000
TBA/19 Tetra Brik Aseptic 020V
Options included:
Automatic Splicing Unit ASU19
648116-0100
Temperature Control Steam Barrier

-
PullTab Unit PT19

648121-0200
Headspace by Gas Injection HI19

2545082-0100
2.281657014fr.fm
Valid from Series No.: 21204/00001
Issue 2003-09
Doc. No. IM-81657-0104
Tetra Pak Carton Ambient S.p.A.

Table of contents
Introduction
Equipment information . . . . . . . . . . . . . . . . . . . . . . . . . 2
Document information . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety precautions
Hazard information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mandatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Warning signs on the machine . . . . . . . . . . . . . . . 12
Personnel requirements. . . . . . . . . . . . . . . . . . . . . . . . 17
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General safety precautions . . . . . . . . . . . . . . . . . . . . . 19

Hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Machine safety devices . . . . . . . . . . . . . . . . . . . . . . . . 22

Emergency stop buttons . . . . . . . . . . . . . . . . . . . . 22
Doors, covers and guards . . . . . . . . . . . . . . . . . . . 25
Cooling system
(electrical cabinet - service unit) . . . . . . . . . . . . . . 28
Chemical products . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Personal protective equipment . . . . . . . . . . . . . . . 29
General emergency procedures . . . . . . . . . . . . . . . 29
Hydrogen peroxide . . . . . . . . . . . . . . . . . . . . . . . . 30
Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Equipment for lifting and moving loads . . . . . . . . . . . 33
Tetra Pak Doc. No. IM-81657-0104 I

Table of contents
3 Drawings and Technical Data

3.1 Installation drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2 Basic machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3 Mass (weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.4 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.5 Emissions and thermal load . . . . . . . . . . . . . . . . . . . . 55
3.6 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.7 Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.8 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.9 Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.10 Outfeed conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.281657011TOC.fm
4 Crate handling
4.1 Crate data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.1.1 Main crate (filling machine) . . . . . . . . . . . . . . . . . 68
4.1.2 ASU crate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1.3 PT unit crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2 Lifting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.3 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3.1 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3.2 Using an overhead gantry or mobile crane . . . . . . 72
4.3.3 Using a fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.4 Moving and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.4.1 Moving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.4.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
II Doc. No. IM-81657-0104 Tetra Pak

Table of contents
5 Installation
5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.1.1 General requirements . . . . . . . . . . . . . . . . . . . . . . 79
5.2 Opening the crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

5.2.1 Land transport crate. . . . . . . . . . . . . . . . . . . . . . . . 81
5.2.2 Air transport crate . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3 Unpacking the main crate . . . . . . . . . . . . . . . . . . . . . . 84

5.3.1 Separate components. . . . . . . . . . . . . . . . . . . . . . . 84
5.3.2 Removing the machine body with an
overhead gantry or mobile crane. . . . . . . . . . . . . . 85
5.3.3 Removing the machine body with a fork lift . . . . 87
5.3.4 Removing tie rods and eyebolts . . . . . . . . . . . . . . 89
5.3.5 Removing transport beams . . . . . . . . . . . . . . . . . . 90
5.4 Unpacking the PT unit crate . . . . . . . . . . . . . . . . . . . . 91

2.281657011TOC.fm
5.5 Unpacking the ASU crate. . . . . . . . . . . . . . . . . . . . . . . 93
5.6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.7 Disposal or return of packing . . . . . . . . . . . . . . . . . . . 96
5.8 Transporter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.9 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.10 Approximate levelling . . . . . . . . . . . . . . . . . . . . . . . . 100
5.11 Main installation operations . . . . . . . . . . . . . . . . . . . 102

5.11.1 Platform, ladder, and handrail . . . . . . . . . . . . . . . 102
5.11.2 Drying chamber. . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.11.3 Hydrogen peroxide generator . . . . . . . . . . . . . . . 114
5.11.4 Large diameter pipes . . . . . . . . . . . . . . . . . . . . . . 115
5.11.5 Aseptic product valve (APV) and remaining
large pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.11.6 Small diameter pipes . . . . . . . . . . . . . . . . . . . . . . 129
5.11.7 Electrical connections . . . . . . . . . . . . . . . . . . . . . 137
5.12 Strip applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Tetra Pak Doc. No. IM-81657-0104 III

Table of contents
5.13 PullTab unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.14 Covers and guards. . . . . . . . . . . . . . . . . . . . . . . . . . . 152

5.14.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.14.2 Protective guards . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.15 Precision levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.16 Outfeed conveyor connections. . . . . . . . . . . . . . . . . 160
5.17 Utility, product, and drain connections . . . . . . . . . . 161
5.18 PLMS photocells . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.19 Line supervision - DE connection . . . . . . . . . . . . . . 170

5.19.1 Single DE unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.19.2 Multiple DE units. . . . . . . . . . . . . . . . . . . . . . . . . 171
5.20 External dating unit (Domino) . . . . . . . . . . . . . . . . . . 173
5.21 Final folder outfeed conveyor . . . . . . . . . . . . . . . . . . 174
2.281657011TOC.fm
5.22 ASU on filling machine . . . . . . . . . . . . . . . . . . . . . . . 175
5.22.1 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5.22.2 Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.23 Other operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.23.1 Levelling regulating valve . . . . . . . . . . . . . . . . . . 180
5.23.2 Fit accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5.23.3 Check transformers . . . . . . . . . . . . . . . . . . . . . . . 183
6 Final installation checks

6.1 Installation and connection checks . . . . . . . . . . . . . 186
6.2 Lubricant level checks. . . . . . . . . . . . . . . . . . . . . . . . 187
6.3 Valve checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6.4 Safety checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
IV Doc. No. IM-81657-0104 Tetra Pak

Table of contents
7 Preparation for commissioning

7.1 Presence and correctness checks . . . . . . . . . . . . . . 193
7.2 Product and utility value checks. . . . . . . . . . . . . . . . 195
7.3 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

7.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
7.3.2 Normal operating checks. . . . . . . . . . . . . . . . . . . 197
7.3.3 Changing PLC parameters . . . . . . . . . . . . . . . . . 199
7.4 Health and safety checks. . . . . . . . . . . . . . . . . . . . . . 201
7.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8 Disassembly and removal

8.1 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8.1.1 Draining methods . . . . . . . . . . . . . . . . . . . . . . . . 205
2.281657011TOC.fm
8.1.2 Draining preparations . . . . . . . . . . . . . . . . . . . . . 206

8.1.3 Draining procedure . . . . . . . . . . . . . . . . . . . . . . . 209
8.2 Moving and transporting the equipment . . . . . . . . . 221

8.2.1 Short moves and short term storage . . . . . . . . . . 221
8.2.2 Long moves and long term storage . . . . . . . . . . . 223
8.3 Return to the manufacturer . . . . . . . . . . . . . . . . . . . . 225
8.4 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Tetra Pak Doc. No. IM-81657-0104 V

Table of contents
This page intentionally left blank
2.281657011TOC.fm
VI Doc. No. IM-81657-0104 Tetra Pak

Introduction
To ensure maximum safety, always read the Safety precautions section
before doing any work on the equipment or making any adjustments.
2.281657013in.fm
Tetra Pak Doc. No. IM-81657-0104 1

Introduction
Equipment information
Intended use
This Tetra Pak equipment is designed to package liquid products.
Manufacturer
This Tetra Pak equipment has been manufactured by:
Via Delfini 1
41100 MODENA
Italy
Service
Contact the nearest Tetra Pak market company.
(Cont'd)
2.281657013in.fm
2 Doc. No. IM-81657-0104 Tetra Pak

Introduction
(Cont'd)
Identification
The figure below shows an example of the equipment data plate. The plate
carries data needed when contacting Tetra Pak concerning this specific
equipment.
CE marking
This equipment complies with the basic health and safety regulations of the
European Economic Area (EEA).
Machine without ASU
1 2
Machine type 3
Drawing Spec.
Machine No.
Manufacturer
4
5
Year of manufacture
6
8 7
2.281657013in.fm
1 Machine type
2 Volume
3 Drawing specifications
4 Machine serial number
5 Manufacturer
6 (Designed by)
Machine with ASU 7 CE mark
8 Year of manufacture

Introduction
Document information
Purpose of Installation Manual (IM)
The purpose of this Installation Manual is to provide service technicians with
information on how to safely install this Tetra Pak equipment.
It is important to:
• keep the manual for the life of the equipment
• pass the manual on to any subsequent holder or user of the equipment.
Design modifications
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Tetra Pak
production plant.
Number of pages
This document contains a total of 228 pages.
Copyright  2003
All rights reserved. No parts of this document may be reproduced or copied
in any form or by any means without the written permission of Tetra Pak
Carton Ambient S.p.A.
2.281657013in.fm
Technical publications
The technical publications for this equipment are:
• Electrical Manual (EM)
• Installation Manual (IM)
• Maintenance Manual (MM)
• Operation Manual (OM)
• Spare Parts Catalogue (SPC)
Additional copies can be ordered from TP Global Technical Support AB,

Lund, Sweden, or the nearest Market Company.
When ordering technical publications, always quote the document number
that can be found in the machine specification document.

Introduction
Other documents
The following documents are attached to the main crate:
• Packing List
• Declaration of EC conformity
• Installation Manual (this manual)
The following documents are located on the equipment itself, behind the rear
LH door of the service unit:
• Machine Specification Document
• Final Inspection Report
• Machine Deviation Report (if relevant)
• Start-up Machine Quality Report (including Transport Damage Report)
• Feedback from MC form
• System drawings
2.281657013in.fm

Introduction
Glossary
AP Aseptic Product MM Maintenance Manual
ASU Automatic Splicing Unit OM Operation Manual
ASSU Automatic Strip Splicing Unit PC Personal Computer
AW Acidified Water (optional) PLC Programmable Logic Controller
CAP Counter Air Pressure PLMS Packaging Line Monitoring System
CPU Central Processing Unit PMI Packing Material In-feed
CS Control System PT Pull Tab (optional)
DCSM Design Control System Multistep RH Right Hand
DE Distribution Equipment SA Strip Applicator
DMC Digital Motion Controller SP Spare Part
EM Electrical Manual SPC Spare Part Catalogue
EN Norme Européenne (European standard) SS Short Stop
FCMM Frequency Controlled Main Motor SSS Strip Splice Sensor
FCS Filling Control System TCSB Temperature Controlled Steam Barrier
HD Hard Disk TFD Tube Folding Device
HI Headspace by Injection TMCC2 TetraPak Multipourpose Controller
HF High Frequency TP Tetra Pak
IM Installation Manual TPIH Tetra Pak Induction Heating
2.281657013in.fm
LED Light Emitting Diode TPMS Tetra Pak Maintenance System
LH Left Hand TPOP Tetra Pak Operator Panel
LS Longitudinal Sealing TS Transversal Sealing
MC Motion Controller WTC Web Tension Control (Pendulum)
MDCS Motorized Design Control System

Safety precautions
To ensure maximum safety, always read this document carefully before
doing any work on the equipment or making any adjustments.
2.2c 81657013sp.fm

Safety precautions
Hazard information
General
Failure to observe information marked “DANGER!” puts your life in
danger.
DANGER!
Failure to observe information marked “WARNING!” can result in

personal injury or serious damage to or destruction of
equipment.
WARNING!
Caution! Failure to observe information marked “Caution!” can result in

damage to equipment.
2.2c 81657013sp.fm

Safety precautions
Mandatory signs
Wear eye protection Wear hearing protection
Wear head protection Wear protective gloves

2.2c 81657013sp.fm
D I SI N F E C
Disinfect hands or gloves

Safety precautions
Warning signs
Risk of entanglement! Risk of cutting/amputation!
Risk of burns! Risk of corrosion
2.2c 81657013sp.fm
and acid burns!
Risk of intoxication! Risk of electrocution!
(Cont'd)

Safety precautions
(Cont'd)
Risk of crushing! Risk of crushing!
Risk of falling!
2.2c 81657013sp.fm

Safety precautions
Warning signs on the machine

Check the warning signs are readable. Replace any damaged or missing
signs.
1 1 1* 1 2 2 2 2 2
1 1
2
2.2c 81657013sp.fm
2
1
LH side
3 1 1 1
1 Risk of electrocution!
2 Risk of burns!
3 Risk of entanglement!
* Symbol located on the inner door
(Cont'd)

Safety precautions
(Cont'd)
signs.
1 1
3 1* 1*
RH side
2.2c 81657013sp.fm
1 3
1 1
1 2
2 Risk of corrosion!
* Symbol located on the inner door
3 Risk of burns!
4 Risk of entanglement!
(Cont'd)

Safety precautions
(Cont'd)
Warning signs on the ASU
signs.
2.2c 81657013sp.fm
1
1 Risk of crushing!
(Cont'd)

Safety precautions
(Cont'd)
Warning signs on the HI
signs.
1
2.2c 81657013sp.fm
(Cont'd)

Safety precautions
(Cont'd)
Warning signs on the PT
signs.
1
3
2
2.2c 81657013sp.fm
1
2 Risk of burns!
3 Risk of crushing!

Safety precautions
Personnel requirements
Risk of immediate danger to life!
Failure to follow the safety precautions will put your life in danger.
All personnel must regard all electrical equipment as live.
DANGER! Carry out the work so there is no risk of injury to personnel.
General
During maintenance or service work, the service technician and the
electrician are responsible for the machine and for the safety of personnel
near the machine.
It is also the responsibility of the service technician and the electrician to
ensure that the machine safety devices are fully operational, before finishing
the maintenance or service work.
Service technician
Only trained or instructed service technicians are allowed to work on the
machine.
Service technicians may be:
• technicians employed by Tetra Pak
2.2c 81657013sp.fm
Tetra Pak technicians are Tetra Pak employees who have completed
training courses at the Tetra Pak Technical Training Centres or have
equivalent knowledge.
• technicians employed by the customer
Technicians employed by the customer must have the following skills:
– capable of reading (English or native) technical information
– able to understand technical drawings
– basic knowledge of mechanics and electronics
– basic knowledge of mathematics
– capable of handling (special) tools.
(Cont'd)

Safety precautions
(Cont'd)
Electrician
Electricians should:
• be certified according to local regulations
• have experience of similar types of installations
• have proven skills in reading and working from drawings and cable lists
• have knowledge of local safety regulations for power and automation.
Work with the electrical equipment in the machine must be performed by

skilled persons only.
According to EN 60204-1:1997 clause 3.52 a skilled person is:
– a person with relevant education and experience to enable him or her
to perceive risks and to avoid hazards which electricity can create.
Machine operator
Only trained or instructed persons are allowed to operate the machine.
The machine operator is an individual that has enough training and
knowledge to run the equipment in the correct way.
Fork lift driver
2.2c 81657013sp.fm
Fork lift drivers should be certified according to local regulations.
The fork lift driver’s role during installation is:
• to unload the transport vehicle
• to plan and transport the machine or machine parts within the plant in a
safe and smooth way
• to assist when assembling Tetra Pak equipment.

Safety precautions
General safety precautions

Wear hearing protection while the equipment is running is recommended.
Hygiene
It is important to keep hands or gloves clean.
Disinfect hands or gloves before touching the packaging material, the strip(s)
or any other equipment part that may come into contact with the product.
Clean the platforms, the ladder and the area around the equipment, see the
OM.
To avoid production faults, it is important that packaging material and
strip(s) never touch the floor, the platform or the area around the equipment.
2.2c 81657013sp.fm

Safety precautions
Electrical cabinet
There is high voltage in the electrical cabinet (up to 400 V). If there is
an accident, call for medical attention immediately.
DANGER! Work inside the electrical cabinet must be performed by skilled or instructed
persons only.
Electrical cabinet doors locked with screws may be opened only by skilled or
instructed persons.
2.2c 81657013sp.fm
Electrical cabinet, ASU
(Cont'd)

Safety precautions
(Cont'd)
TPIH generator
There is high voltage in the electrical cabinet (up to 2000 V). If there is
an accident, call for medical attention immediately.
DANGER! Never open the TPIH generator. Remove and return the unit to an authorised
service centre for servicing and repair.
2.2c 81657013sp.fm

Safety precautions
Machine safety devices

Emergency stop buttons
Memorize the positions of the Emergency stop buttons to stop the
equipment immediately, avoiding danger to people or damage to the
equipment.
The Emergency stop buttons do not switch off the power at the mains power
switch.
The Emergency stop buttons reset the equipment program to Zero and
deactivate all pneumatic cylinders.
Machine with PMI
2.2c 81657013sp.fm
(Cont'd)

Safety precautions
(Cont'd)
ASU
Note! There are two Emergency stop buttons on the ASU, one inside and one
outside the RH door.
switch.
2.2c 81657013sp.fm
Rear
(Cont'd)

Safety precautions
(Cont'd)
PT
switch.
2.2c 81657013sp.fm

Safety precautions
Doors, covers and guards

Make sure that all doors, covers and guards are in place and
functioning.
WARNING! Never remove covers or guards while the equipment is operating.
Certain doors, covers and guards are fitted with safety switches. These
switches are part of the safety system and must never be bridged, by-passed
or otherwise made non-operational.
Never stop the equipment by opening a door or cover that has a safety
WARNING!
switch.
The equipment may continue movement during the first few seconds after a
stop. Some equipment parts may also be hot.
If there is an accident, call for medical attention.
Machine with PMI
2.2c 81657013sp.fm
(Cont'd)

Safety precautions
(Cont'd)
ASU
2.2c 81657013sp.fm
(Cont'd)

Safety precautions
(Cont'd)
PT
2.2c 81657013sp.fm

Safety precautions
Cooling system
(electrical cabinet - service unit)
Risk of personal injury!
Cooling media R134A.
Carefully follow the supplier’s instructions for handling and disposal of
the R134A (freon).
WARNING!
Cooling media R134A container
• Ensure good ventilation
• Keep the container well closed and in a cool and dry place away from
sources of heat
• Avoid direct contact with the product
• Wear suitable protective clothing, gloves, goggles, and eye protection
• If it comes into contact with the eyes, rinse immediately with plenty of
water for 15 minutes and call for medical attention
• Inhalation of a high concentration can cause shortage of breath and
unconsciousness
• If it is inhaled, move to fresh air; if needed use oxygen gas or artificial
respiration
2.2c 81657013sp.fm
• Very fast evaporation can cause freezing injuries.
Caution! Only specially-trained personnel are allowed to operate the

compressor unit if there are compressor leakages.

Safety precautions
Chemical products
Certain chemical products are toxic and inflammable. Carefully follow
the instructions on the container label.
WARNING!
Follow the supplier’s instructions for handling and disposal of chemical
products.
Personal protective equipment

• Safety goggles, TP No. 90303-0011
• Apron, TP No. 90303-0013
• Shoes made of PVC, PE plastic or rubber
• Protective gloves made of neoprene, TP No. 90303-0012.
Before starting work with any chemical products, make sure:

• the showers work
• a portable, TP No. 90303-6, or wall-mounted eyewash device is
available at or near each machine site
• there are additional washing facilities.
2.2c 81657013sp.fm
General emergency procedures

If you accidentally swallow chemical products, drink large amounts of
lukewarm water.
If splashes or vapour from chemical products come into contact with the
eyes, wash them thoroughly with lukewarm water for 15 minutes (keeping
eyelids wide apart).
If chemical products comes into contact with skin or clothes:
• rinse immediately with plenty of water
• if skin burns appear, call for medical attention immediately
• thoroughly wash clothes before wearing them again.
If you experience irritation or pain due to having inhaled chemical products

vapour:
• leave the affected area and breathe fresh air
• if the symptoms worsen, call for medical attention.

Safety precautions
Hydrogen peroxide
The liquid used for sterilising the packaging material consists of 35%
hydrogen peroxide (H2O2).
Hydrogen peroxide in liquid and gas form can cause irritation and
injury if it comes into contact with the skin, mucous membranes, the
eyes or clothes. Carefully follow the instructions on the can label.
WARNING! Hydrogen peroxide can

HYDROGEN PEROXIDE:
• 35% w/w Aqueous Solution UN No. 2014
• Corrosive
• Oxidizing
• Causes burns. Contact with combustible materials may cause fire.
• Keep in a cool place away from sources of heat.
• Avoid contamination.
• Wear suitable protective clothing, gloves, and eye or face protection.
• After contact with skin, wash immediately with plenty of water and call
for medical attention.
• If there is contact with the eyes, rinse immediately with plenty of water
2.2c 81657013sp.fm
and call for medical attention.
• If there is spillage or fire, drench with water.
Reference: TP document No. M 1751.80.
HYDROGEN PEROXIDE
35% w/w Aqueous Solution UN No. 2014
Corrosive
Oxidizing
CAUSES BURNS,
CONTACT WITH COMBUSTIBLE
MATERIALS MAY CAUSE FIRE
Keep in a cool place away from sources of heat.
Avoid contamination.
Wear suitable protective clothing, gloves and eye/face protection.
After contact with skin, wash immediately with plenty of water.
In case of contact with eyes rinse immediately with plenty of water

and seek medical advice.
Example of can label
In case of spillage or fire drench with water.
(Cont'd)

Safety precautions
(Cont'd)
Storage of hydrogen peroxide
Make sure the area or room used for storage is:
• cool, clean and well ventilated
• shielded from direct sunlight
• free from combustible materials.
Hydrogen peroxide must be stored only in its original container as

delivered by the suppliers.
Keep the container upright and closed with a proper ventilation cap which
allows oxygen to escape.
Risk of explosion!
During storage and transportation, the filled TP hydrogen peroxide cans
must be closed with the appropriate lid (arrow) to allow oxygen to escape.
DANGER!
2.2c 81657013sp.fm
Pumps and other equipment used for hydrogen peroxide must be used for
this purpose only.
Never put used hydrogen peroxide back into storage.
Disposal of hydrogen peroxide
Hydrogen peroxide should be sent for destruction by waste disposal
specialists according to local regulations.
Risk of explosion!
Do not pour surplus hydrogen peroxide back into its original container.
Hydrogen peroxide may decompose. If there is an accident, call for
medical attention immediately.
WARNING!
In some countries it is permitted to dilute hydrogen peroxide with water to a
concentration below 1% and to dispose of it in the normal waste water drain.
Hydrogen peroxide with a concentration below 1% is considered harmless.

Safety precautions
Ink
Ink is inflammable and can be harmful if it comes into contact with the
eyes or skin. Carefully follow the instructions on the container label.
WARNING! Ink container

• INFLAMMABLE
• Avoid direct contact with the product
• Use gloves and goggles
• Care for good ventilation
• Propylene glycol mono methyl ether >30%
• Ethanol 1-5%
• SHAKE BEFORE USE
2.2c 81657013sp.fm
BLACK MARKFLEX
MF 7011
INFLAMMABLE
Avoid direct contact with

the product
Use gloves and goggles
Care for good ventilation
Propylene glycol mono
methyl ether >30%
Ethanol 1 - 5%
Manufacturer:
G-man AB
tel. 0410-59200
Trelleborg
SWEDEN
TP No. 90299-72
SHAKE BEFORE USE

Safety precautions
Equipment for lifting and moving

loads
Make sure the capacity of lifting equipment is adequate and the
equipment itself is in good working order.
If lifting tackle has to be joined to make up the necessary lengths, make sure
WARNING! the joins are secure and have the same lifting capacity as the rest of the
tackle.
Always engage the safety clip on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and manoeuvre loads. Do not use hands or feet.
Make sure the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.
2.2c 81657013sp.fm

Safety precautions
2.2c 81657013sp.fm

3 Drawings and Technical
Data
2.2c TB036574en.fm

3.1 Installation drawings

This section includes drawings showing:
• overall dimensions
• connection positions and dimensions
• access dimensions.
Values are in millimetres unless otherwise stated. All dimensions must be
respected. The drawings show the filling machine without HI equipment
since dimensions are not affected by the presence of HI.
The following drawings are provided:
• Top view, machine with PMI or ASU

• Top view, machine with PT and ASU
• Top view, machine with PT and PMI
• Front view, machine with PMI or ASU
• LH view, machine with ASU
2.2c TB036574en.fm
• LH view, machine with PMI
• LH view, machine with PT and PMI
• LH view, machine with PT and ASU
• RH view, machine with ASU

• RH view, machine with PMI
• RH view, machine with PT and PMI
• RH view, machine with PT and ASU

(Cont'd)
Top view, machine with PMI or ASU
708
2.2c TB036574en.fm
5101
2271
(Cont'd)

(Cont'd)
Top view, machine with PT and PMI
2547.5
708
3558
5101
2.2c TB036574en.fm
435
330
300
0 435
330
300
66
1688
0 1898 520 47
3080
(Cont'd)

(Cont'd)
Top view, machine with PT and ASU
2547.5
2271
0
708
3558 0
5101
2.2c TB036574en.fm
435
330
300
0 435
330
300
66 1688
1895 520
0
3080
(Cont'd)

(Cont'd)
Front view, machine with PMI or ASU
2.2c TB036574en.fm
695
417 474
> 1960 1075 > 950
2965
0
1025
1 Re circulated cooling water in 945
2 Re circulated cooling water out 905
3 Air
4 Cold water
865
5 Hot water 785
6 Power supply 705
7 Nitrogen 640
2070
1 2 7 3 4 5 6
(Cont'd)

(Cont'd)
LH view, machine with ASU
> 4600
3705
3540
3466
2.2c TB036574en.fm
170±20
> 7100
3
> 3000
1 Packaging material reel

trolley
2 Tool locker 1
3 Recommended when
more than one machine
is in the line
4 No lifting
2
(Cont'd)

LH view, machine with PMI
> 4600
3705
3540
3466
170 ±20
2.2c TB036574en.fm
> 7100
3
> 3000
1 Packaging material reel 1

trolley
2 Tool locker
3 Recommended when 2
more than one machine
is in the line
4 No lifting
(Cont'd)

(Cont'd)
LH view, machine with PT and PMI
> 4600
3705
3540
3466
2.2c TB036574en.fm
170±20
0
3
> 3000
1 Packaging material reel trolley

2 Tool locker
1
3 Recommended when more
than one machine is in the line
4 No lifting 2
(Cont'd)

(Cont'd)
LH view, machine with PT and ASU
> 4600
3705
3540
3466
2.2c TB036574en.fm
170±20
> 7100
0
3
> 3000
1
1 Packaging material reel trolley
2 Tool locker
3 Recommended when more than 2
one machine is in the line
4 No lifting
(Cont'd)

(Cont'd)
RH view, machine with ASU
2115
3
2
4824
1
2258
2504
5696
2750
2.2c TB036574en.fm
180
300
3048
3152
2 1 3
1 Product inlet connection, Ø51
2 Steam connection, Ø12
3 Product outlet connection, Ø51
(Cont'd)

(Cont'd)
RH view, machine with PMI
2115
3
2
1
4845
2258
2504
2750
5696
2.2c TB036574en.fm
180
300
3048
3152
2 1 3

(Cont'd)

(Cont'd)
RH view, machine with PT and PMI
3
2
1
2258
2504
2750
1304 0
4824
1903
5696
2.2c TB036574en.fm
180
300
3048
3152

2 1 3
(Cont'd)

(Cont'd)
RH view, machine with PT and ASU
2115
3
2
1
2258
2504
2750
2070
1287
932.5
1903
4845
5696
2.2c TB036574en.fm
180
300
3048
3152
2 1 3
(Cont'd)

(Cont'd)
System drawings
The system drawings are attached inside the rear LH door of the filling
machine. These include:
• hydraulic system
• water system
• lubrication system
• compressed air system
• aseptic system
• valve panel
• extra equipment (if relevant).
2.2c TB036574en.fm

3.2 Basic machine data

Note! The data in this section refer to machines with or without HI.
Machine Production capacity Notes
configuration
TBA/19 TBA 020V 7500 p/h, +4%, -0%
2.2c TB036574en.fm

3.3 Mass (weight)

Machine Mass (weight)
configuration
TBA/19 TBA Approx. 5600 kg
(12400 lbs)
with ASU (14500 lbs)
PT (13200 lbs)
PT with ASU (15 400 lbs)
(Cont'd)
2.2c TB036574en.fm

(Cont'd)
Centre of gravity
The followingpicture shows the approximate location of the centre of
gravity. The table specifies the actual position according to the configuration
of the machine.
Machine Height of CofG Position of CofG Position of
2.2c TB036574en.fm
configuration from bottom of from front edge CofG in from
machine body of final folder RH side of
(mm) (mm) machine body
(mm)
TBA/19 TBA 1170 2010 470
with/without ASU
TBA/19 TBA 1250 2050 500
with PT
with/without ASU
Note! The ASU has no effect on the centre of gravity because it is supported by its
own feet.
(Cont'd)

(Cont'd)
Static load
Note! The minimum system for static load distribution requires three points of
support. A four-point system is used here because the machine frame cannot
be considered as a rigid structure. The loads given represent the maximum
possible loads at the feet. Real loads will be significantly less since the total
machine weight is distributed over ten feet.
1 4
2 3
2.2c TB036574en.fm
Machine Static load Static load Static load Static load

configuration on leg 1 on leg 2 on leg 3 on leg 4
(kg) (kg) (kg) (kg)
TBA/19 TBA 1800 - 1900 1500 - 1600 1600 - 1700 500 - 600
with/without
ASU
TBA/19 TBA 2000 - 2100 1700 - 1800 1800 - 1900 600 - 700
with PT
with/without
ASU
Note! The ASU has no effect on static load because it is supported by its own feet.

3.4 Noise
The following tables give the noise level measurements for TBA/19
machines under the following conditions:
• machine on a concrete floor supported by standard feet
• production under normal operating conditions at 7500 p/h or 6000 p/h
• PT, ASU and HI installed.
Values declared in accordance with ISO 4871.3.
Symbol Definition Declared Notes

Value
LwA Measured A-weighted 95.5 dB(A) Values determined using
sound power level basic standard ISO 3746:
1995 (survey method -
grade 3)
KwA Uncertainty factor 2.5 dB
LpA Max emission sound 78 dB(A) Values determined using
pressure level, basic standard ISO 11204:
operator position 1995 (engineering method
- grade 2)
KpA Uncertainty factor 2.5 dB
2.2c TB036574en.fm

3.5 Emissions and thermal load

Emissions
Characteristic Value Notes

Hydrogen peroxide <1 ppm TLV - Time Weighted
fumes in operator’s Average value
environment
Hydrogen peroxide <1%
concentration at outlet
to drain
Oil fumes in operator’s None
environment
Oil spillages None
Detergent spillages None
Water spillages None Except during start-up
and external cleaning
Product spillages None
Thermal load
Machine Thermal load Notes

2.2c TB036574en.fm
configuration
TBA/19 TBA Approx. 15.0 ± 1.1 kW
with/without ASU
TBA/19 TBA with PT Approx. 15.5 ± 1.1 kW
with/without ASU

3.6 Product
Supply pressure 50 - 350 kPa Range from minimum
(0.5 - 3.5 bar) permitted to maximum
[7.2 - 50.7 psi] permitted supply
pressure
Max. permitted 100 kPa Pressure may fluctuate
pressure fluctuation dur- (1 bar) by max. 100 kPa within
ing Production [14.3 psi] the range 50 – 350 kPa.
Inlet temperature 5 - 50°C (41 - 122°F)
TBA 125S and TBA
100B only
5 - 35°C (41 - 95°F)
Filling temperature 5 - 50°C Varies from inlet
(41 - 122°F) temperature by +1-2°C
(2-4°F)
Hard particles Absent Product must leave no
hard residue on a 600
µm mesh.
Citrus fibres <5% Measured as fibre
residue on a 600 µm
mesh.
2.2c TB036574en.fm
pH 2.5 - 8

3.7 Utilities
Electrical power specifications

Supply voltage to 400 VAC, Other voltages available
machine three-phase +N + PE to order with transformer.
Max. voltage -10%, +10%
fluctuation
Frequency 50/60 Hz To be specified on order.
Recommended main 100 A Value for optimum
fuse selectivity at 400 VAC.
Control circuits voltage 24 VDC
Note! The filling machine will not function with a 30 mA earth protection relay
Electrical power consumption

Note! The following values have been measured in a machine equipped with ASU,
PT and HI.
2.2c TB036574en.fm
Machine step Value ± 1.1 kW

Pre-heating I 7.5 kW
Pre-heating II 25.4- 26.6 kW
Tight Tube 15.5 kW
Pre-heating III 17.4-19.6 kW
Drying 11.6-22.8 kW
Production 19.5-28.4 kW
(Cont'd)

(Cont'd)
Sterile air

Supply pressure 30 - 35kPa
(0.3 - 0.35 bar)
[4.35 - 5.07 psi]
Compressed air specifications

Supply pressure 600 - 700 kPa
(6 - 7 bar)
[87 - 102 psi]
Max. particle size 20 µm
Max. particle content 25 mg/m3
Dew point 2°C
(35.6°F)
Oil content 0.01 mg/m3
Compressed air consumption
2.2c TB036574en.fm
Machine Average consumption Peak consumption
configuration during production (duration < 2 secs.)
TBA/19 TBA Approx. 400 Nl/min Approx. 700 Nl/min
with/without ASU
TBA/19 TBA Approx. 900 Nl/min Approx. 1100 Nl/min
with PT
with/without ASU
(Cont'd)

(Cont'd)
Cooling water

(3 - 4.5 bar)
[43.5 - 65 psi]
Max inlet temperature 20°C
(68°F)
Consumption 10 l/min Approximately 5 l/min
(2.2 imp.galls/min) (1.1 imp.galls/min) of
total consumption can be
recirculated.
pH 5-8
Steam

Water quality Drinking water Boiler additives must be
suitable for use with
drinking water.
Supply pressure 170 kPa With TCSB:
2.2c TB036574en.fm
(1.7 bar) from 2.5 to 16 bar

[25 psi]
Max pressure 30 kPa
fluctuation (0.3 bar)
[4.5 psi]
Inlet temperature 133 ±4°C Measured after APV.
(271±7°F)
Consumption 2.4 kg/h
(5.3 lbs/h)
(Cont'd)

(Cont'd)
Hydrogen peroxide

Quality Aseptic grade
Concentration 35%
Consumption 0.7 - 1.2 l/h
Nitrogen (only for machines with HI)

Quality High purity Min. purity 99.5%.
No solid particles.
No oil particles.
(6-7 bar)
[87 - 102 psi]
Consumption 2 - 5 + headspace Depends on headspace
volume Nl/min volume setting.
2.2c TB036574en.fm

3.8 Cleaning
Cleaning in place (CIP)

Maximum permitted 350 kPa
inlet pressure (3.5 bar)
[50.7 psi]
Minimum flow 8000 l/h 8000 l/h must be obtain-
able at:
- 2.03 bar on 125 cc
machines
- 1.62 bar on 250 cc
machines.
Higher flow rates are

acceptable provided that
supply pressure never
exceeds 350 kPa.
The diagram in the following page shows the pressure drop against flow rate,
measured between the B-inlet valve and the filling pipe outlet.
The diagram is related to TBA 125 S and 250 S machines. All the other
2.2c TB036574en.fm
volumes either correspond to one of the two curves or are comprised in the
area between them. If the cleaning flow pressure exceeds the maximum
value indicated on the diagram, the pressure drop has to be recalculated
proportionally.
(Cont'd)

62
Pressure drop against flow rate
10000
9730
9500 9350
9280
9210
9000 9030
8820 8830
8610
8370 8370
8165
8000 7980
7880
7765
7550
7300 7280
7000 7000
6740 6770
6510
6090 6170
Doc. No. IM-81657-0104

6000 5950
5500 5590
5265 250B
5000 4973
4700
4600
125S
4350
4000 3750
3800
3300
3000
2480
2700
2000
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2 2,4 2,6
Pressure drop (bar)
Tetra Pak
2.2c TB036574en.fm
External cleaning (hot water connection)

(3 - 4.5 bar)
[43.5 -65 psi]
Inlet temperature 60 - 70°C
(140 - 158°F)
Hot water consumption 300 l/cycle Per complete cleaning
cycle.
Detergent pH 8 - 12
Detergent consumption 0.8 l/cycle Per complete cleaning
cycle.
2.2c TB036574en.fm

3.9 Ambient temperature

Minimum ambient 5°C
temperature (41°F)
Maximum ambient 50°C
temperature (122°F)
Recommended ambient 15°C to 30°C
temperature (59°F to 86°F)
2.2c TB036574en.fm

3.10 Outfeed conveyor

Outfeed conveyor

Recommended con- Tetra Package See PIM Conveyors manual for
veyor make/model Conveyor 21 further information.
Tetra Package
Conveyor 53 The TBA/19 020V power supply
for the outfeed conveyor Drive/
End-unit is frequency controlled.
Drive/End unit motor needs to be
∆-connected.
Contact the Service Organisation

when using other conveyor types.
Recommended 21 m/min, real See MM for fine setting of outfeed
conveyor speed value conveyor speed
Ordering information 21 m/min 50 Hz Machine delivery settings are
Outfeed conveyor based on these values. See MM
Drive/End-unit for fine setting of outfeed con-
veyor speed
2.2c TB036574en.fm

2.2c TB036574en.fm

4 Crate handling
2.2c TB046571en.fm

4 Crate handling
4.1 Crate data

The filling machine and SA are shipped in one crate. Additional crates are
used to ship the ASU, the PT unit, the Straw applicator and conveying
equipment (depending on machine configuration). See the Packing List for
further details.
4.1.1 Main crate (filling machine)

Weight and dimensions
Machine Gross weight Net weight Length Width Height

type kg (lbs) kg (lbs) mm mm mm
(ft-in) (ft-in) (ft-in)
TBA 6800 - 7200 5400 - 5800 4850 2150 3200
(15000 - 15900) (11900 - 12800) (16’) (7’ ) (10’ 6’’)
Note! Crate weight varies according to presence of variable contents. See table
below. Crate weight can increase significantly if the crate becomes wet.
Contents
Contents
Standard contents:
2.2c TB046571en.fm
Machine body
Electrical cabinet cooler
Drying chamber
APV group
Hydrogen peroxide generator
Pipes
Packaging material reel holder
Packaging material covers
Packaging material reel lifting trolley
Platform frame and plates
Lateral signs
End signs
Warning beacon
Ladder
Handrails
Guards
Legs and feet
Tools
Spare parts
Accessories
Lifting unit
Machine documents
Packaging material
LS strip reel
Variable contents:
Strip applicator (depending on machine configuration)
Platform extension (depending on machine configuration
ASU connection parts (separate ASU installations only)
Ink jet printer Domino A300 (depending on machine configuration)

4 Crate handling
4.1.2 ASU crate

Gross Net Length Width Height

weight weight mm mm mm
kg (lbs) kg (lbs) (ft-in) (ft-in) (ft-in)
1400 1100 1800 1400 2350
(3000) (2500) (6’) (4’6’’) (8’)
Note! Crate weight can increase significantly if the crate becomes wet.
Contents
Contents
ASU
4.1.3 PT unit crate

Gross Net Length Width Height

weight weight mm mm mm
kg (lbs) kg (lbs) (ft-in) (ft-in) (ft-in)
2.2c TB046571en.fm
1100 750 2700 1400 1850

(2450) (1650) (9’) (4’ 6”) (6’)
Note! Crate weight can increase significantly if the crate becomes wet.
Contents
Contents
PullTab unit
IS strip and tab reels

4 Crate handling
4.2 Lifting equipment

Types of lifting equipment
The following types of equipment can be used to lift and move the crates:
• overhead gantry
• mobile crane
• fork lift
The most practical equipment is an overhead gantry.

Equipment specifications
Make sure the lifting equipment complies with the specifications given in the
following table.
Equipment or Lifting Notes

tackle capacity
kg (lbs)
Overhead gantry 8000 9000 kg (20000 lbs) required if gantry
(18000) does not have gradual acceleration/
deceleration ramps.
Mobile crane 8000 9000 kg (20000 lbs) required if crane does
(18000) not have gradual acceleration/deceleration
ramps.
2.2c TB046571en.fm
Lifting chains, 8000 9000 kg (20000 lbs) required if lifting
cables, ropes or (18000) equipment does not have gradual
slings acceleration/deceleration ramps.
Min length hook to hook:

– Main crate:15 m (50’)
– ASU crate: 9 m (30’)
– PT unit crate: 8 m (26’)
Fork lift 9000 Higher capacity allows for reach to centre

(20000) of gravity of 1000 - 1500 mm (3’ to 5’).
Lifting forks 9000 Min. length:
(20000) – Main crate: 2000 mm (6’6’’).
– ASU crate: 1500 mm (5’)
– PT unit crate: 1500 mm (5’).
Min. setting width:

– Main crate: 2000 mm (6’6’’)
– ASU crate: 1000 mm (3’)
– PT unit crate: 1500 mm (5’)

4 Crate handling
4.3 Unloading
Make sure everybody understands the symbols and warnings.
Symbol Meaning
Centre of gravity
Lifting points for chains, cables, ropes, or

slings
This way up
Fragile
Keep dry
2.2c TB046571en.fm
Top of crate
‘Fragile’ warning
‘Handle with care’ warning
‘Not to be dropped’ warning
‘Gross weight’ value
‘Net weight’ value
4.3.1 Inspection
a) Examine the outside of the crates before starting to unload, and record
any damage. This information must later be recorded on the Transport
Damage Report (a section of the Start-up Machine Quality Report).
b) Record the readings of the humidity indicators and tipping indicators
attached to the outside of the crates (if present). This information must
later be recorded on the Transport Damage Report (a section of the
Start-up Machine Quality Report).

4 Crate handling
4.3.2 Using an overhead gantry or mobile crane

If using a fork lift, see section 4.3.3 Using a fork lift.
a) Make sure the lifting capacity of the equipment and tackle is adequate
and the tackle is the correct length. See section 4.2 Lifting equipment.
b) Manoeuvre the hook to one side of the crate.
c) Pass the lifting tackle under the crate at the points shown in the figure
below.
d) Secure the tackle to the lifting hook and fit the safety clip on the hook.
e) Manoeuvre the hook over the centre of the crate.
f) Slowly take up the slack in the lifting tackle. Make sure the tackle is
secure at the crate and hook. If necessary, adjust the tackle to distribute
the load evenly.
Main crate: L = 15000 mm

ASU crate: L = 9000 mm
2.2c TB046571en.fm
PT unit crate: L = 8000 mm
g) Prepare ropes or poles to steady and manoeuvre the load. Do not use
hands or feet.
h) Lift the crate only enough to clear the platform of the vehicle.
i) If possible, have the vehicle driven away from under the crate.
j) Lower the crate gently to the floor.
DANGER! k) Make sure the crate is firmly supported. Place blocks or plates under it if
necessary.
l) Lower the lifting hook and remove the lifting tackle.

4 Crate handling
4.3.3 Using a fork lift

If using an overhead gantry or mobile crane, see section 4.3.2 Using an
overhead gantry or mobile crane.
a) Make sure the lifting capacity of the fork lift and forks is adequate and
the fork length is correct. See section 4.2 Lifting equipment.
b) Set the lifting forks to the correct width. See section 4.2 Lifting
equipment.
c) Manoeuvre the fork lift so the forks engage the crate no further apart
than the points shown in the figure below, and at equal distances from
the centre of gravity symbol. If the crate is fitted with fork tubes,
manoeuvre the forks inside these to lift the crate.
2.2c TB046571en.fm
= =
d) Lift the crate only enough to clear the platform of the vehicle.
e) If possible, have the vehicle driven away from under the crate.
f) Lower the crate gently to the floor.
DANGER! g) Make sure the crate is firmly supported. Place blocks or plates under it if
necessary.
h) Remove the forks from under the crate.

4 Crate handling
4.4 Moving and storage

Make sure that storage areas comply with specifications. See section 4.4.2
Storage.
If installation is to start immediately, check whether it is possible to move the
crates to the installation site. Uncrating and installation can then be
performed together.
When moving crates to the installation site, deposit them so the equipment
can be lifted out and positioned without being turned around. Open the
customs inspection panel to see inside.
Wait until installation can start before unpacking.
4.4.1 Moving
a) Lift the crate as instructed above, only enough to clear the floor. See
section 4.3 Unloading.
b) Make sure the crate remains stable on the lifting equipment.
Caution! Move the crate slowly and gently.
c) Move the crate to its destination.
d) Look through the customs inspection panel to see which way the
2.2c TB046571en.fm
contents are facing. Position the crate to face in the most convenient
direction.
e) Lower the crate gently to the floor, leaving enough room around it for
easy access to all sides.
f) Make sure the crate is firmly supported. Place blocks or plates under it if
necessary.
g) Remove the lifting equipment.

4 Crate handling
4.4.2 Storage
Caution! Store the crates indoors. Exposure to damp or to high or low
temperatures may damage the equipment.
a) Make sure the storage environment respects the following conditions.

Min and max 5 - 40 If the water system is drained
temperatures °C (°F) (40 - 105) the equipment can withstand
freezing conditions.
Max relative humidity % 80 Non-condensing.
b) Store the crates with about 1000 mm (3 ft) of free space around and
above for access and ventilation.
c) If the floor is uneven, use blocks of wood to provide a steady support.
Note! The crates containing the ASU, the PT unit and conveying equipment, can be
stacked on top of the main crate. If this must be done, place wooden beams
lengthways on top of the main crate to distribute the weight.
2.2c TB046571en.fm

4 Crate handling
2.2c TB046571en.fm

5 Installation
2.2c TB056574en.fm

5 Installation
5.1 Overview
Start
Land Air
Remove crate top and crossbeams. Remove eyebolts.
Land or air
Remove sides. Remove crate top and sides.
transport?
Remove 2 longitudinal transport beams.
Fit eye bolts and lifting unit. Crane Forklift Position forklift at 2 specified points.
Lift gently 250 mm. Lift gently 250 mm.
Use crane
Lower onto 4 wooden blocks positioned at Lower onto 4 wooden blocks positioned at
or forklift?
specified points. specified points.
Remove eyebolts and lifting unit.
Remove tie rods.

Remove transport beams from under machine.
No Move
machine?
Yes
Fit Transporter
To be introduced (not yet available)
2.2c TB056574en.fm
Fit all 10 legs (screwed fully up).
Position dampers under the 4 structural legs.
Screw the 4 structural legs down to dampers, just enough to lift machine off wooden blocks.
Remove wooden blocks.
Approximate levelling
Set machine height with 4 main legs.
Fit spirit level on jaw system.
Adjust 4 main legs until machine is level.
Screw 6 remaining legs down to dampers.
Check levelling hasn’t changed.
Remove spirit level.
Fit platform, ladder and handrails.

Fit drying chamber and related equipment.
Lift strip applicator into working position.
Fit covers and guards.
Precision levelling
Fit spirit level on jaw system.
Adjust front and rear structural legs until machine is level.
Remove spirit level.
Connect outfeed, product supplies and PLMS photocells; remove TPOP holder
Stop

5 Installation
5.1.1 General requirements

Note! All pictures show TBA/19 Tetra Brik Aseptic 020V machines, unless
otherwise stated.
Personnel
Only skilled or instructed Tetra Pak installation personnel are allowed to
assemble the machine.
Personnel must know how to use the portable PC programs for modifying
GE Fanuc program parameters and downloading the TMCC2 program.
Lifting equipment, tools and materials
The equipment used for lifting and moving the crates can also be used for
unpacking the crates and installing the filling machine and ASU. See section
4.2 Lifting equipment for further details.
The following tools and materials are needed to move and install the filling
machine:
• lifting unit, TP No. 2-579899 (supplied)
• hydraulic jack, min. capacity 3 tons
• spirit level, TP No. 90243-163
• spirit level, TP No. 90243-165
2.2c TB056574en.fm
• 2 m step ladder
• min. four wooden blocks, min. 150 - max. 200 mm in height
• cable ties
• insulating tape
• hydraulic sealing tape.
The following tools and materials are needed to move and install the ASU (if
present):
• pallet trolley, capacity 800 kg
• crowbar or strong lever
• large rubber-coated mallet
• wire and lead plumbobs
• cable feed wire.
The following special tools may also be available from the local Service
Organisation:
• wheeled transporter unit, (TP No. to be determined)
• drying chamber lifting tool, TP No. 76500-101.
(Cont'd)

5 Installation
(Cont'd)
The following equipment will be needed only if the GE Fanuc PLC
parameters (for example filling sector parameters) need to be changed:
• portable PC running GE Fanuc LM90 software, V 6.01 or later
• GE Fanuc PLC serial cable, TP No. 90031-300.
The following equipment will be needed only if a new TMCC2 PLC

program needs to be downloaded:
• TMCC2 PLC serial cable (9-pin M-F, pinned F2-M3, F3-M2, F5-M5)
• TMCC2 program and communications diskette.
Unpacking area
The minimum unpacking area must be at least twice the size of the main
crate.
Minimum area: 7000 x 7000 x 4000 mm (23’ x 23’ x 13’ h)
The ideal unpacking area permits all crates to be unpacked together.
Installation area
a) Clear all obstacles away from the installation site and if necessary clean
the floor of the site before starting to install the machine.
b) Make sure there is sufficient room to move safely around the installation
2.2c TB056574en.fm
site. If machines around the site cannot be stopped, place guards around
them to prevent accidental contact.
c) Make sure that lighting is adequate. Arrange additional portable lights if
WARNING!
necessary.

5 Installation
5.2 Opening the crates

Note! The following instructions apply to all crates.
Do not open the crate until you are ready to start installation.
Note! To protect the components during transit they may have been fixed in place
with wires passing through the crate walls. Make sure all of these wires have
been cut before opening the crate.
5.2.1 Land transport crate

a) Remove the parts of the crate in the following sequence by loosening the
fixing screws:
• the top (1) and the reinforcement cross-beams (2)
• the front (3)
WARNING! • the back (4)
• the sides (5).
b) Remove all loose boxes and packages.
1 3
2.2c TB056574en.fm
4 5
1 Top
2 Cross beams
3 Front
4 Back
5 Sides
(Cont'd)

5 Installation
(Cont'd)
c) Remove the six screws fixing the transport frame under the machine, to
the floor of the crate.
2.2c TB056574en.fm
d) Remove the six screws on each side, then remove the longitudinal
transport beams (6).
6
6 Longitudinal transport beams

5 Installation
5.2.2 Air transport crate

a) Remove the parts of the crate in the following sequence:
• the eyebolts (1) top and sides (2).
• the top, front and back (3).
• the ends (4).
WARNING! b) Remove all loose boxes and packages.
2 3
4
2.2c TB056574en.fm
1 Eyebolts
2 Top and sides
3 Top, front and back
4 Ends

5 Installation
5.3 Unpacking the main crate

Note! This is the only crate, if the filling machine is not equipped with an ASU or
Pull Tab applicator.
5.3.1 Separate components

a) Remove all fixed and loose components from the floor of the crate.
Take care when working on machine platforms without railings.
WARNING!
The components fixed to the filling machine and crate weigh up to

300 Kg.
WARNING! b) Remove all components that are not bolted to the machine.
2.2c TB056574en.fm

5 Installation
5.3.2 Removing the machine body with an

overhead gantry or mobile crane
If using a fork lift, see 5.3.3 Removing the machine body with a fork lift.
a) Fit eyebolts to the two holes in the rear of the electrical cabinet (1) and to
the two flanges in the platform frame (2).
b) Make sure the lifting eyebolts on the machine are secure and are not
damaged.
c) Secure the lifting unit (3) to the hook and fit the safety clip on the hook.
Risk of tipping!
Use four separate lines. Respect minimum lengths.
d) Fit two separate lines to the two eyebolts (1) on the electrical cabinet.
WARNING! Fit another two separate lines to the two eyebolts (2) on the platform
frame.
A B C
3
1 L1 3 L2 2
1 MAX LOAD 6300 KG
2.2c TB056574en.fm
L1 = 1805 mm (5’11’’)
L2 = 1870 mm (6’1½’’)
A = 1510 mm (4’11½’’) 1 Eyebolt on electrical cabinet
B = 500 mm (1’7½’’)
2 Eyebolt on platform frame
C = 470 mm (1’6½’’)
3 Lifting unit TP No 579899
(Cont'd)

5 Installation
(Cont'd)
e) Slowly take up the slack in the lifting tackle.
The filling machine body weighs approximately 5000 kg.
WARNING!
f) Gently lift the machine 250 mm.
DANGER!
Caution! Make sure the wooden blocks support the frame members on both
sides of the machine.
g) Gently lower the machine onto wooden blocks (4). The blocks must
support the bottom of the machine, at points of structural strength.
h) Make sure the machine body is stable, then remove the lifting equipment
and eyebolts.
2.2c TB056574en.fm
4 4 Wooden block
(Cont'd)

5 Installation
5.3.3 Removing the machine body with a fork lift

If using an overhead gantry or mobile crane, see 5.3.2 Removing the machine
body with an overhead gantry or mobile crane.
The filling machine body weighs approximately 5000 kg.
a) Position the forks at the points shown
WARNING!
Caution! Do not place the forks under the final folder.

2.2c TB056574en.fm
b) Gently lift the machine 250 mm.

(Cont'd)
DANGER!

5 Installation
(Cont'd)
Caution! Make sure the wooden blocks support the frame members on both
sides of the machine.
c) Lower the machine gently on to the wooden blocks (1). The blocks must
support the bottom of the machine, at points of structural strength.
d) Make sure the machine is stable, then remove the fork lift.
2.2c TB056574en.fm
1
1 Wooden block

5 Installation
5.3.4 Removing tie rods and eyebolts

a) Remove the two tie rods (1).
b) Remove the eight lifting eyebolts (2).
c) Loosen the four screws and remove the lifting bracket (3) (TP No.
1512848-0000).
d) Close the hole with the screw plug (4) (TP No. 90458-2487).
Note! Keep the tie rods (1), the eyebolts (2), the lifting bracket (3) and the screws
in a safe place, so they can be used when lifting or transporting the machine.
2 LH side view 2
1
4
2.2c TB056574en.fm
2 2
3 RH side view
1 Tie rod
2 Eyebolt
3 Lifting bracket
4 Screw plug

5 Installation
5.3.5 Removing transport beams

a) Remove the four screws (1) at each end of the transport beams (2).
b) Remove the three transport beams (2).
2.2c TB056574en.fm
1
1 Screw
2 Transport beam

5 Installation
5.4 Unpacking the PT unit crate

Note! Ignore this section if the filling machine is not equipped with PT.
An overhead gantry or mobile crane must be used to remove the PT unit from
the crate.
a) Remove all loose boxes and components from the crate.
Risk of tipping!
Use four separate lines, they must support approximately 750 Kg
b) Fit four eyebolts (M16) to the PT unit frame at the positions shown in the
WARNING! figure below. Make sure the eyebolts are secure and are not damaged or
cracked.
Fit four separate lines to the eyebolts on the PT unit frame.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
c) Unscrew the screws fixing the PT unit frame to the floor of the crate.
The PullTab unit weighs approximately 750 Kg.
d) Slowly take up the slack in the lifting tackle. Lift the PT unit only
enough to clear the crate.
WARNING! e) Remove the PT unit from the crate.
f) Make sure the PT unit is evenly supported.
Note! Leave the eyebolts on the PT unit.
2.2c TB056574en.fm

5 Installation
5.5 Unpacking the ASU crate

Note! Ignore this section if the filling machine is not equipped with an ASU.
A fork lift must be used to remove the ASU from the crate.
a) Remove all loose boxes and components from the crate.
b) Lift the ASU gently while manoeuvring the forks under it from the LH
or RH side at the points shown in the figure below.
2.2c TB056574en.fm
LH view RH view
The ASU weighs approximately 1100 Kg.

WARNING!
c) Lift the ASU only enough to clear the crate.

d) Manoeuvre the ASU out of the crate. Lower the ASU to the floor.
e) Make sure the ASU is stable and remove the fork lift.
DANGER!

5 Installation
5.6 Inspection
a) Use the Packing List(s) to check that nothing is missing from the
crate(s).
b) Inspect the filling machine for damage.
c) Inspect the PT unit for damage.
d) If present, inspect the ASU for damage.
e) Open the boxes containing the smaller machine components and inspect
these for damage.
f) Open the Machine Documents box and check the documentation.
MACHINE DOCUMENTS
NOT TO BE REMOVED
MACH. NR.................. Tetra Pak
(Cont'd)
2.2c TB056574en.fm

5 Installation
(Cont'd)
g) Check the following documents are present and they correspond to the
machine in question (see the data plate):
– Machine Specification Document
– Final Inspection Report
– Machine Deviation Report (if relevant).
– Start-up Machine Quality Report (including the Transport Damage
Report)
– Feedback from MC form
– System drawings
h) Take the spare parts to the spare parts stores.

i) Fill in the Transport Damage Report (a section of the Machine Start-up
Quality Report).
2.2c TB056574en.fm

5 Installation
5.7 Disposal or return of packing

Note! Packing materials (including the crate, wrapping, and boxes) are not
normally returned to the manufacturer.
a) Check with the customer if there is a special agreement for the return of
packing to the manufacturer.
b) If packing must be returned to the manufacturer, prepare an area to store
the crate and other returnable packing.
c) Check with the customer if there is a special arrangement for recycling
packing.
d) If packing is not to be returned or recycled, check with the customer how
to separate and dispose of packing (wood, plastic, paper, etc.).
e) Dispose of pollutant waste (bubble wrapping, plastic bags, expanded
polystyrene, etc.) in accordance with local regulations.
WARNING!
2.2c TB056574en.fm

5 Installation
5.8 Transporter
Blank section (transporter to be finalized).
2.2c TB056574en.fm

5 Installation
5.9 Positioning
Take care when working on machines without legs and dampers.
a) Fit all fourteen legs (four screws and washers per leg).
Note! If space under the machine is limited, adjust the legs fully up, or use larger
WARNING! wooden blocks.
b) Screw all non-structural legs up towards the machine frame so they will
not interfere with levelling.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
c) Check the machine is correctly positioned with respect to the customer’s
plant. See section 3.1 Installation drawings.
Caution! Only the structural legs shown below are able to hold the weight of the
machine. Do not allow the machine to rest on other legs.
d) Position four dampers under the structural legs.
2.2c TB056574en.fm
Do not unscrew the legs more than the maximum specified.
e) Screw down the four structural legs until they fit in the recesses in the
dampers.
WARNING! f) Screw down the four structural legs again just enough to lift the
machine off the wooden blocks.
max 190 mm
g) Make sure the machine is supported and stable on all four structural legs
and dampers.
h) Remove the wooden blocks.

5 Installation
5.10 Approximate levelling

Note! Perform approximate levelling before assembly. This makes sure the
machine is stable and there are no torsional forces on the frame.
Perform precision levelling when assembly is complete.
Caution! Only the structural legs shown are able to hold the weight of the
machine. Do not allow the machine to rest on other legs.
a) Adjust all four structural legs until the bottom panel of the machine is
150 mm ±20 mm from the floor.
2.2c TB056574en.fm
150 ±20 mm
(Cont'd)

5 Installation
(Cont'd)
b) Crank the machine to raise the outer LH guide of the jaw system and fit
the spirit level TP No. 90243-163 to it.
c) Adjust all four structural legs until the machine is approximately level
transversely and longitudinally.
d) Place dampers under all the non-structural legs.
2.2c TB056574en.fm
e) Screw down the ten non-structural legs until they just start to take the
weight of the machine.
Note! Do not screw down too much. This could alter the levelling of the machine.
f) Make sure the levelling of the machine has not changed.
Remove the spirit level.

5 Installation
5.11 Main installation operations

Packing
Leave the bubble wrapping on parts until they are ready for use.
Leave the plastic plugs in the pipes until they are ready to be connected, but
do not forget to remove them before connecting the pipes.
Leave ties in place until tied parts are ready to be used or connected.
5.11.1 Platform, ladder, and handrail

Rear platform extension

a) Attach the platform extension (1) using the eight plates (2). Each plate
WARNING! has four screws (3).
2.2c TB056574en.fm
2
1 Platform
extension
2 Plate
3 Screw

5 Installation
(Cont'd)
b) Fit the checker plate (4) using the twelve screws (5).
5
2.2c TB056574en.fm
4 Checker plate
5 Screw
(Cont'd)

5 Installation
(Cont'd)
Ladder
c) Fix the top of the ladder to the underside of the platform (two brackets,
two screws each). Adjust the feet so the ladder is firmly supported.
Tighten the foot lock nuts.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
Completing the platform
d) Fit the sign holders, signs, and handrail all around the machine, fitting
the corner pieces as required.
WARNING! Note! The sign holders are fixed on top of the platform frame by the handrails.
The signs are fixed in the sign holders by the corner pieces.
The corner pieces are fixed in place by the sign holders to either side.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
Caution! Do not trap the cables when tightening the screws.
e) Fit the beacon alarms (1) and connect the cables.
2.2c TB056574en.fm
1 Beacon alarm
Multi installation
To perform a multi installation with TBA/19 020V has to be installed kit
581315-0300; to perform a multi installation with TBA/19 010V has to be
installed kit 581314-0300.

5 Installation
5.11.2 Drying chamber

Caution! Make sure the sterilisation bath is adequately supported from
beneath.
a) Remove the transport plate from the top of the column and sterilisation
bath.
Note! The transport plate is a machine accessory (TP No. 3-441725). Keep it safe.
b) Either:
Fit the special lifting tool which may be available from the local Service
Organisation (TP No. 76500-0101).
or:
Pass lifting ropes or slings through the top of the drying chamber on both
sides as shown in the figure below. Do not damage the components
inside the drying chamber.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
c) Manoeuvre the drying chamber to just above the column.
Caution! Do not let the chains fall into the sterilisation bath.
d) Tie string to both ends of the two chains in the sterilisation bath. Using
the string, pass the chains over the sprockets (1) and rollers (2) in the
drying chamber.
2 2
1 1
1 Sprocket
2 Roller
Caution! Tie the strings together to prevent the chains falling into the
2.2c TB056574en.fm
sterilisation bath.
e) Lower the drying chamber on to the top of the column.
f) Make sure the four pins in the bottom of the drying chamber engage in
the two holes at the top of the sterilisation bath and in the two holes at
the top of the column. Fit the pins if necessary.
(Cont'd)

5 Installation
(Cont'd)
Inside the drying chamber
a) Loosen the screws of the chain steering blocks (1).
b) Fit the carrier (2) parallel with the rollers.
Note! The sharp edge of the carrier must face towards the rear of the machine, and
the carrier must be fitted outside the chain pins (3). See the figure below.
c) Remove any string tied to the chains. Make sure the chains rotate
correctly. Crank the carrier down into the bath.
1 2 1
2.2c TB056574en.fm
1 Steering block
2 Carrier
3 Chain pins
Front 2 Rear
Front Rear
(Cont'd)

5 Installation
(Cont'd)
d) Fit and tighten the drying chamber fixing screws (twelve screws).
e) Adjust the tension of the chains. Tighten the fixing screws of the chain
2.2c TB056574en.fm
steering blocks (1).
f) Fit the two bottom drip plates (4) (four screws each).
g) Fit the two side drip plates (5) (two screws each).
1 Steering block
5 4 1 4 Bottom drip plate
5 Side drip plate
(Cont'd)

5 Installation
(Cont'd)
LH side of drying chamber
a) Fit the LH side cable duct with the two bottom screws only.
b) Fix the cable tube (two screws at the top of the cable duct; one screw at
the top of the cable tube).
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
c) Pass the cable No. 418 through the cable tube to the rear door
microswitch (1). Connect the rear door microswitch.
d) Connect the front door microswitch (2), cable No. 416.
e) Fit the calender roller position proximity switch (3), cable No. 423 (two
screws).
f) Fit the air knife position proximity switch (4), cable No. 422 (two
screws) and the cover plate (5) (two screws).
g) Fit the pendulum roller proximity switch (6), cable No. 458.
Note! See the EM to avoid reversing the direction of motor rotation.
h) Connect the bending roller motor cable (7), cable No. 459.
i) Connect the bending roller motor cable (8), cable No. 404.
j) Arrange the cables tidily in the cable duct. Fit the cover of the cable duct
(two screws).
4 5
2.2c TB056574en.fm
7
1 8
3
6
2
1 Microswitch
2 Microswitch
3 Proximity switch
4 Proximity switch
5 Cover plate
6 Proximity switch
7 Motor cable
8 Motor cable
(Cont'd)

5 Installation
(Cont'd)
RH side of drying chamber
Fit the RH side cable duct (five screws) and run the cables from the RH side
of the column up through it.
Do not close the cable duct or make any electrical connections yet.
2.2c TB056574en.fm

5 Installation
5.11.3 Hydrogen peroxide generator

Caution! Remove all sealing plugs before fitting components and pipes.
Make sure the correct gaskets are fitted.
Fit the hydrogen peroxide generator. Use a gasket TP No. 315229-206 on
the lower flange (six screws), which connects to the heat exchanger.
2.2c TB056574en.fm

5 Installation
5.11.4 Large diameter pipes

a) Fit the pipe (1) between the top of the hydrogen peroxide generator (2)
and the pre-sterilisation valve (3) (two flanges, four screws each). Fit a
gasket TP No. 315229-205 at each end of the pipe.
3 1
2
2.2c TB056574en.fm
1 Pipe
2 Hydrogen peroxide
generator
3 Pre-sterilisation valve
(Cont'd)

5 Installation
(Cont'd)
b) Fit the pipe (4) between the suction valve (5) and the drying chamber
(two flanges, four screws each). Fit O-rings TP No. 927422-0008 at
both ends of the pipe.
4 Pipe
2.2c TB056574en.fm
5 Suction valve
(Cont'd)

5 Installation
(Cont'd)
c) Fit the pipe (6) between the pre-sterilisation valve (3) and the horizontal
pipe (7) near the platform (two flanges, four screws each). Fit a gasket
TP No. 315229-205 at the pre-sterilisation valve and a gasket TP No.
315229-105 at the bottom.
6
2.2c TB056574en.fm
7 3 Pre-sterilisation valve
6 Pipe
7 Pipe
(Cont'd)

5 Installation
(Cont'd)
d) Fit the sterile air pipe (8) between the air-knife connection (9) and the LS
nozzle (10) (top flange, three screws; bottom connection, one ring nut).
Fit a gasket TP No. 315229-203 at the air-knife connection.
2.2c TB056574en.fm
10
8 Pipe
9 Connection
10 LS nozzle
(Cont'd)

5 Installation
(Cont'd)
e) Fit the upper filling pipe inside the column.
f) Fix the connection plate (11) in place with the lock handle (12).
2.2c TB056574en.fm
11
12
11 Connection plate
12 Lock handle
Note! Wait until test production is ready to start before fitting the lower filling
pipe. See the OM for further details.
(Cont'd)

5 Installation
(Cont'd)
g) Fit the CIP pipe (13) and secure it to the platform using the bracket (14).
13
14
13 CIP pipe
2.2c TB056574en.fm
14 Bracket
h) Machines with HI:

Fit the extension (16) to the front connection on the CIP pipe.
Fit a gasket TP No. 90217-348 between the CIP pipe and the extension.
Connect the small diameter pipe from the HI valve on the platform to the
connection (17) on the CIP pipe extension.
16 17
16 Extension
17 Connection

5 Installation
5.11.5 Aseptic product valve (APV) and remaining

large pipes
a) Fit the APV (1) to the bracket (2) on the top RH side of the column (four
screws).
1
C
2
A
B
1 APV
2.2c TB056574en.fm
2 Bracket
b) Fit the product regulating valve (3) to the APV (1). Make sure the
regulating valve is supported by the two fingers of the bracket (4). Fit a
gasket TP No. 926822 between the regulating valve and the APV (1).
3 Regulating valve
4 Bracket
(Cont'd)

5 Installation
(Cont'd)
c) Fit the sterile air pipe (5), using gasket (6) TP No. 90217-347 at both
ends.
2.2c TB056574en.fm
5 Sterile air pipe
6 Gasket
(Cont'd)

5 Installation
(Cont'd)
Machines without HI
d) Fit the product pipe with a gasket TP No. 90217-348 at the regulating
valve and a gasket TP No. 90217-347 at the upper filling pipe.
Caution! When fitting the product pipe, make sure the flanges of the pipe and
regulating valve are perfectly aligned and in close contact.
If necessary, slacken off the fixing screws of the APV and APV
bracket and adjust the position of the APV and regulating valve.
Make sure the four gaskets are in place.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
e) Fit the product inlet pipe (7) and product outlet pipe (8) to the APV with
a gasket TP No. 90217-349 between both pipes and the APV.
7 Product inlet pipe

8 Product outlet pipe
f) Fit the three sterile air L pipes (9) between the B-valve connection (10)
and the air knife connection (11) (top flange, four screws; other three
2.2c TB056574en.fm
flanges, one clamp each). Fit a gasket TP No. 315229-204 at the air-
knife connection and a gasket TP No. 90217-348 at all joints.
11
9 Pipe
10 10 Connection
11 Connection
(Cont'd)

5 Installation
(Cont'd)
With OE Temperature Control Steam Barrier (TCSB)
a) Fit pipes (1) and (2) to the steam traps (3). Fit the connections (4)
and (5).
2
2.2c TB056574en.fm
5
1
3
1 Pipe
2 Pipe
3 Steam trap
4 Connection
5 Connection
(Cont'd)

5 Installation
(Cont'd)
Without OE Temperature Control Steam Barrier (TCSB)
a) Fit pipes (1) and (2) to the steam traps (3). Fit the connections (4)
and (5).
2
5
1
2.2c TB056574en.fm
3
1 Pipe
2 Pipe
3 Steam trap
4 Connection
5 Connection
(Cont'd)

5 Installation
(Cont'd)
Machines with HI
Preparing for production with HI bypassed:
– Fit the extension pipe (1) with gaskets TP No. 90217-347.
– Fit the lid (2) on the HI stop valve with an O-ring TP No. 315204-
207.
1
2.2c TB056574en.fm
1 Extension pipe
2 Lid
(Cont'd)

5 Installation
(Cont'd)
Preparing for production with HI:
– Fit the T-Connection pipe (1) with a gasket TP No. 90217-347 at
both ends.
Note! Various injection nozzles (2) are supplied. Fit the correct nozzle according to
the product specification.
– Fit the injection nozzle (2) with a O-ring TP No. 315204-207 at the
upper side and a gasket TP No. 90217-347 in the nozzle seat.
– Fit the HI pipe (3) with an O-ring TP No. 315204-207 at the HI stop
valve side.
2.2c TB056574en.fm
1
1 T-Connection pipe
2 Injection nozzle
3 HI pipe

5 Installation
5.11.6 Small diameter pipes

Make sure the air and hydrogen peroxide pipes are fitted to the
correct connections on the hydrogen peroxide generator. Check the
‘AIR’ and ‘LIQUID markings on the valve on top of the generator.
a) Fit the pipe (1). One end connects to the air side of the connection
valve (2) on the hydrogen peroxide generator. The other end connects to
the ‘T’ connection (3) on the pipe between the solenoid valve MY4 and
the spray tank MB43BA.
b) Fit the pipe (4). One end connects to the liquid side of the connection
valve (2) on the hydrogen peroxide generator. The other end connects to
the bottom of the solenoid valve MY35 (5).
3
2.2c TB056574en.fm
1 Pipe
1 2 Connection valve
3 Connection
4 Pipe
5 Solenoid valve MY35
(Cont'd)

5 Installation
(Cont'd)
c) Fit the pipe (6) between the bottom of the solenoid valve MY4 (7) and
the connection (8) at the bottom of the peroxide bath.
7
7
2.2c TB056574en.fm
8
8 6 Pipe
7 Solenoid valve
MY4
8 Connection
(Cont'd)

5 Installation
(Cont'd)
d) Fit pipe 70 (9) between the bottom of the C-valve and connection 70 at
the bottom of the drying chamber.
e) Fit pipe 71 (10) between the top of the C-valve and connection 71 at the
bottom of the drying chamber.
10
9 Pipe 70
10 Pipe 71
2.2c TB056574en.fm
f) Fit pipe 90 (11) between the LH side of the A-valve and connection 90 at
g) Fit pipe 91 (12) between the RH side of the A-valve and connection 91 at
11 12
11 Pipe 90
12 Pipe 91
(Cont'd)

5 Installation
(Cont'd)
h) Connect pipe 80 (13) to the top of the B-valve.
i) Connect pipe 90 (14) to the bottom of the B-valve.
13
13 Pipe 80
14 Pipe 90
14
2.2c TB056574en.fm
j) Fit pipe 1071 between the regulating valve and connection 1071 at the
bottom of the drying chamber.
View of filling machine

without HI
(Cont'd)

5 Installation
(Cont'd)
k) Machines without HI only:
Fit the pipe (15) between the connection at the front of the solenoid
valve MY34 and the connection (16).
15
16
2.2c TB056574en.fm
15 Pipe
16 Connection
(Cont'd)

5 Installation
(Cont'd)
l) Machines with HI only:
Make sure the pipe (17) is fit from the bottom of the T connection at the
front of the solenoid valve (18) MY34 to the connection (19).
Fit the pipe (20) from the front of the solenoid valve (18) MY34 to HI
main cabinet as shown.
Fit the pipe (21) from solenoid valve (22) MY4 to the T-connection (23)
as shown.
18 21 22
17
17 19
20
20
21
2.2c TB056574en.fm
23 17 Pipe
18 Solenoid valve
19 Connection
20 Pipe
21 Pipe
22 Solenoid valve
23 T-connection
(Cont'd)

5 Installation
(Cont'd)
Note! The following pipes are connected at the bottom of the drying chamber.
m) Fit pipe 40 (24) from solenoid valve MY4.
n) Fit pipe 190 (25) from the front of the pre-sterilisation air inlet valve.
o) Fit pipe 191 (26) from the rear of the pre-sterilisation air inlet valve.
24
26
25
2.2c TB056574en.fm
24 Pipe 40
25 Pipe 190
26 Pipe 191
(Cont'd)

5 Installation
(Cont'd)
p) Fit pipes 213 (27) and 211 (28) from the calender roller and air knife
cylinders.
q) Fit the pneumatic pipe 1840 (29) to the pendulum roller cylinder.
28
27 29
2.2c TB056574en.fm
27 Pipe 213
28 Pipe 211
29 Pipe 1840

5 Installation
5.11.7 Electrical connections

Note! See the EM for further details on the following operations.
a) Connect the following thermocouples:
• pre-sterilisation thermocouple (1), cable No. 407.
1
2.2c TB056574en.fm
1 Thermocouple
• air-knife thermocouple (2), cable No. 411.

• steam thermocouple (3), cable No. 412.
3
2 Thermocouple
3 Thermocouple
(Cont'd)

5 Installation
(Cont'd)
b) Connect the following solenoid valves:
• MY34 (4), cable No. 430.
• MY35 (5), cable No. 431.
• MY4 (6), cable No. 432.
c) Connect the position sensor (7) of valve B71, cable No. 454.
6 4
2.2c TB056574en.fm
5
4 Solenoid valve
5 Solenoid valve
6 Solenoid valve
7 Sensor
(Cont'd)

5 Installation
(Cont'd)
Caution! Do not change the setting of the proximity switch.
d) Fit the regulating valve position proximity switch (8), cable No. 413
(one screw).
e) Connect the regulating valve leakage detector cable No. 405 to the
regulating valve leakage detection terminals (9).
Note! Connect one wire to the terminal on the metal section of the valve body and
the other wire to the terminal on the nylon section of the valve body; the
polarity is not important.
f) Fit and set:
• the product pipe detection proximity switch (10), cable No. 421
• the B-valve position proximity switch (11), cable No. 424 (two screws)
• the cleaning pipe detection proximity switch (12), cable No. 440 (two
screws)
• the sterile air pipe detection proximity switch (13), cable No. 456 (two
screws).
2.2c TB056574en.fm
10
8 Proximity switch
9 Terminals
10 Proximity switch
11 Proximity switch
12 Proximity switch
8 9 13 11 12 13 Proximity switch
(Cont'd)

5 Installation
(Cont'd)
g) Fit and set the HI pipe detection switch (14), cable No. 709 (only for
machines equipped with HI)
14
2.2c TB056574en.fm
14 Proximity switch
(Cont'd)

5 Installation
(Cont'd)
h) Connect level sensor cable No. 425 to spray tank MB43BA.
Note! Connect the two level sensor wires to the correspondingly-numbered studs
on the tank cover. Refer to the numbers on the collars, not on the cables
themselves. The two remaining wires connect to the earth stud.
2 1
2.2c TB056574en.fm
Caution! Make sure all cables and flexible hoses are kept clear of pipes which
may become hot.
i) Arrange the cables tidily in the cable duct. Fit the cover of the cable duct
(four screws).

5 Installation
5.12 Strip applicator

a) Remove the screws (1) on both sides and the plates (2) on both sides.
b) Lift up the strip magazine into position.
2
1
2.2c TB056574en.fm
1 Screw
2 Plate
(Cont'd)

5 Installation
(Cont'd)
c) Fasten it in place the strip magazine using the screws (1).
d) Make sure the pneumatic hoses (3) are connected to the pipes (4).
2.2c TB056574en.fm
1
4
3
1 Screw
3 Hose
4 Pipe

5 Installation
5.13 PullTab unit

Installation
Note! Ignore this section if the filling machine is not equipped with a PullTab unit.
a) If not already done, fit four eyebolts to the PT unit frame. See section 5.4
Unpacking the PT unit crate for further details.
b) Fit separate lifting lines to the eyebolts. See section 5.4 Unpacking the
PT unit crate for further details.
c) Screw down the nuts on the central studs (1) so they will not interfere
with the levelling of the PullTab unit. Make sure there are washers on top
of the nuts.
2.2c TB056574en.fm
1 Stud
(Cont'd)

5 Installation
(Cont'd)
Caution! Secure the doors of the PT unit when manoeuvring it.
d) Lift the PT unit into position on top of the electrical cabinet.
Lower the unit gradually, making sure the fixing studs (1) and (2) enter
the slot (3) in the bottom of the PT unit frame.
Lower the unit fully, making sure the support cones guide the Pulltab
unit into position.
3 3
3
2.2c TB056574en.fm
1 Stud
2 Stud
3 Slot
(Cont'd)

5 Installation
(Cont'd)
e) Screw the nuts of the central fixing studs (1) up until they just support
the PT unit frame. Take care not to lift the PT unit frame off the support
cones.
f) Fit a set of washers and nuts on all five studs (1) and (2) on top of the PT
unit frame (see arrows). Tighten fully.
Note! The eyebolts are machine accessories. Keep them safe.
g) Remove the lifting equipment and eyebolts.
h) Fix the PT unit frame to the infeed unit with two screws (4) on both
sides.
2.2c TB056574en.fm
2 1 2
1 Stud
2 Stud
4 Screw
(Cont'd)

5 Installation
(Cont'd)
Connections
a) Connect all the connectors and cables to the electrical cabinet inlets
according to the EM and labelling.
2.2c TB056574en.fm
Rear view
without PT unit
(Cont'd)

5 Installation
(Cont'd)
Inside the PT unit connect:
• The two packaging material loop photocells (1): W522 with MB024 and
W523 with MB025.
• The infeed motor (2): W306 with M.M014.
• The bar code photocells (3): W520 with MB081 and W521 with
MB082.
1 3
2.2c TB056574en.fm
2
1 Loop photocell
1 2 Infeed motor
3 bar code
photocell
(Cont'd)

5 Installation
(Cont'd)
Inside the PT unit connect:
• Fit the bracket (4) and the connectors MX027 (5), MX028 (6) and
MX046 (7)
• Fit the bracket (8) and the connectors MX047 (9) and MX029 (10)
• Fit the bracket (11) and connect the motor connections MX076 (12) and
W543 with MM002 (13).
12
13
2.2c TB056574en.fm
11
10
8
9 6
5
4
4 Bracket 9 Connector
5 Connector 10 Connector
6 Connector 11 Bracket
7 Connector 12 Connection
8 Bracket 13 Connection

5 Installation
(Cont'd)
Note! Make sure to connect the air pipes (14), (17), (20) to the connection
plates (16) and (19) using the pipe connector and the holes indicated, see
arrows.
b) Connect the air pipe marked 1000 (14) between the pipe holder (15) and
the connection plate (16).
c) Connect the air pipe marked 1052 (17) between the pipe holder (18) and
d) Connect the air pipe marked 1054 (20) between the pipe holder (18) and
15
2.2c TB056574en.fm
14
18
17
20 16 19
16
19
14 Pipe 1000 18 Holder
15 Holder 19 Connection plate
16 Connection plate 20 Pipe 1054
17 Pipe 1052
(Cont'd)

5 Installation
(Cont'd)
e) Thread the flexible pipe (21) from the punch unit (22) passing through
the infeed unit frame and the hole in the platform, so that the flexible
pipe (21) is placed over the waste box (23).
22
2.2c TB056574en.fm
21
21 Flexible pipe
22 Punch unit
23 23 Waste box

5 Installation
5.14 Covers and guards

5.14.1 Covers
a) Make sure the packaging material cover (1) is in place.
2.2c TB056574en.fm
1 Packaging
material cover
(Cont'd)

5 Installation
(Cont'd)
Machines with PullTab unit
Make sure the packaging material cover at the front of the PT unit is in
position.
2.2c TB056574en.fm

5 Installation
5.14.2 Protective guards

Assemble the guards as indicated below:
• the main RH top guard (1)
• the front RH top guard (2)
• the RH bottom guard (3)
2 1
2.2c TB056574en.fm
3
1 Main RH top guard
2 Front RH top guard
3 RH bottom guard

5 Installation
(Cont'd)
Machines without HI
• The LH guard (4).
4 LH guard
2.2c TB056574en.fm

5 Installation
5.15 Precision levelling

Caution! Do not raise the machine more than 170 mm from the floor when
levelling, or it may be impossible to connect the product supply pipes
later.
a) Fit the spirit level to the outer LH guide of the jaw system again. See
section 5.10 Approximate levelling.
b) Adjust the front structural legs until the machine is level transversely and
longitudinally ± 0.2 mm/m.
2.2c TB056574en.fm
150 ±20 mm
(Cont'd)

5 Installation
(Cont'd)
c) Only standard machines:
Fit the spirit level (TP No. 90243-163) across the roller at the rear of the
SA.
Rotate the roller to obtain the average spirit level value.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
d) Only machines with Pulltab unit:
Fit the spirit level (TP No. 90243-1631) across the bending roller (1) in
the centre of the PT unit.
e) Fit the spirit level (TP No. 90243-1631) on the machined surface (2).
f) If any adjustment is required, perform the following procedure:
• loosen the four screws (3) of the infeed unit brackets
• adjust using the five screws (4)
• at the end tighten the four screws (3).
1 2
2.2c TB056574en.fm
3 4 3 4 4
1 Screw
2 Surface
3 Screw
4 Screw
(Cont'd)

5 Installation
(Cont'd)
g) Adjust the two rear structural legs (if necessary) until the rear of the
machine is level transversely ±0.2 mm/m.
150 ±20 mm
2.2c TB056574en.fm
h) Check that all the other legs are in firm contact with their dampers.
Screw them down if necessary, taking care not to alter the levelling of
the machine.

5 Installation
5.16 Outfeed conveyor connections

a) Connect the package outfeed conveyor according to the plant installation
and connection drawings.
See the outfeed conveyor installation manual for instructions.
Pass the outfeed conveyor electrical cables through the cable tube under
the LH side of the final folder.
Make all necessary electrical connections. See the EM for further details.
2.2c TB056574en.fm
b) Set the conveyor speed to the recommended 25 m/min. See the conveyor
documentation for further details.
c) Position the eject bin under the eject chute where it will catch all ejected
packages.

5 Installation
5.17 Utility, product, and drain

connections
Electrical power connections
a) Switch the machine’s main power switch off.
b) Switch the mains power supply off.
DANGER!
2.2c TB056574en.fm
c) Pass the power cable through the cable guide.

Caution! Leave a length of slack cable inside the electrical cabinet to ensure
there is no pull on the cable terminals if the cable is accidentally
pulled.
d) Connect the wires of the power cable to the power terminal board inside
the cabinet. See the EM for further details.
Note! Optional kits require separate power connections

(Cont'd)

5 Installation
(Cont'd)
Utility connections
a) Connect the cold water hose to the cold water inlet (1), with the blue fish
symbol.
b) Connect the recirculated water inlet hose to the recirculated water
inlet (2) (if used).
c) Connect the recirculated water outlet hose to the recirculated water
outlet (3) (if used).
d) Connect the compressed air hose to compressed air inlet (4).
e) Connect the hot water supply hose to the hot water inlet (5), with the red
fish symbol.
f) Pass the power cable through the cable gland (6), through the cable gland
on the electrical cabinet, and connect it according to the EM.
g) Only machines with HI:
Connect the nitrogen supply line to the nitrogen inlet (7), with the N2
symbol.
2 3 7 4 1 5 6
2.2c TB056574en.fm
1 Cold water inlet
2 Recirculated water inlet
3 Recirculated water outlet
4 Compressed air inlet
5 Hot water inlet
6 Power supply cable gland
7 Nitrogen inlet
(Cont'd)

5 Installation
(Cont'd)
Note! Remove the main RH top guard if necessary to access the steam filter.
h) Connect the steam hose to the steam filter on the APV.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
Product connections
Caution! Make sure the product supply and forwarding lines are connected to
the correct connections.
Note! It may be necessary to remove the main RH top guard to gain access to the
connections.
a) Flush the product supply and forwarding pipes with clean water to
remove any welding residue.
b) Connect the product supply pipe to the inlet pipe (1), with a gasket in the
joint.
c) Connect the product forwarding pipe to the product outlet pipe (2), with
a gasket in the joint.
1 2
2.2c TB056574en.fm
1 Inlet pipe
2 Outlet pipe
Drain connections
a) Connect the cleaning pump outlet to the waste water drain.
(Cont'd)

5 Installation
(Cont'd)
Caution! Check the legal requirements concerning disposal of diluted hydrogen
peroxide. It may be necessary to connect the dilution tank drain
connection to a separate drain.
b) Connect the water overflow (1) and the dilution tank drain
connection (2) to the waste water drain.
2
2.2c TB056574en.fm
1 Water overflow
2 Dilution tank drain
connection

5 Installation
5.18 PLMS photocells

Note! The photocell brackets supplied by Tetra Pak fit only Tetra Package
Conveyors 53 and 21.
a) Mount the Package Counter photocell (1) M.B091 on the machine
conveyor, as close as possible to the final folder. Leave enough space to
let the package pairs separate before they reach the Package Counter
photocell.
b) For machines without external Domino dating unit:
Mount the Queue Guard photocell (2) M.B093 at a distance of 2 - 2.5
meters from the conveyor connection point on the final folder.
For machines equipped with external Domino dating unit:
Mount the Queue Guard photocell (2) M.B093 at a distance of 2.5 - 3
meters after the Domino belt brake.
c) Mount the Last Point DE photocell (3) M.B092 after the last DE.
If there are different filling machines converging in the same packaging
line, the Last Point DE photocells (3) should be placed at the end of each
respective conveyor, before the converging point. See the picture below.
View from above
1 2 3
2.2c TB056574en.fm
TBA/19
DE1 DE2 Last DE
TBA/19 3
Last DE
1 Package Counter
photocell
2 Queue Guard photocell
TBA/19 3 Last Point DE photocell
3
(Cont'd)

5 Installation
(Cont'd)
d) Mount the connection boxes M.X020 (4), M.X021 (5) and M.X022 (6)
close to the respective photocells as shown in the picture below.
LH side view
Distribution
Equipment
1 6 2 3
4 5
1 Package Counter photocell 4 Connection box M.X020

2 Queue Guard photocell 5 Connection box M.X021
2.2c TB056574en.fm
3 Last Point DE photocell 6 Connection box M.X022
(Cont'd)

5 Installation
(Cont'd)
e) Connect the Package Counter Photocell (1) M.B091 with cables W250
and W251 to the Connection Box (4) M.X020.
f) Connect the Package Counter Photocell (2) M.B093 with cables W28
and W29 to the Connection Box (6) M.X022.
g) Connect the Last Point DE Photocell (3) M.B092 with cables W252 and
W253 to the Connection Box (5) M.X021.
h) Thread the cable (7) W954 from the Connection Box (4) M.X020 to the
Connection Box (8) M.X002.
i) Thread the cable (10) W958 from the Connection Box (6) M.X022 to the
j) Thread the cable (9) W955 from the Connection Box (5) M.X021 to the
Note! See the Electrical Manual for details.
Distribution
7 1 6 2 Equipment 3
2.2c TB056574en.fm
8 4 10 9 5
1 Package Counter Photocell 6 Connection Box M.X022
2 Queue Guard Photocell (not 7 Cable
present in Tetra Wedge) 8 Connection Box M.X002
3 Last Point DE Photocell 9 Cable
4 Connection Box M.X020 10 Cable
5 Connection Box M.X021
(Cont'd)

5 Installation
(Cont'd)
After assembly, carry out the following operations:
• Set the Queue Guard Photocell delay, refer to the filling machine MM,
PLC section, PLC - set Queue Guard Photocell delay.
• Set the transmitter and receiver, refer to the filling machine MM, PLMS
section, PLMS - set transmitter and receiver.
• Carry out Line Supervision checks, refer to the filling machine MM,
PLMS section, PLMS - Line Supervision checks.
• Carry out the Serial Communication checks, refer to the filling machine
MM, PLMS section, PLMS - Serial Communication checks.
• Set the time and date, refer to the filling machine MM, PLMS section,
PLMS - set date and time.
• Set the desired language (where applicable), refer to the filling machine
OM, PLMS section, Language setting.
• Set the production shifts, refer to the filling machine OM, PLMS section,
Production shift setting.
• Set the number of packages per tray, refer to the filling machine OM,
PLMS section, Packages per tray setting.
2.2c TB056574en.fm

5 Installation
5.19 Line supervision - DE connection

5.19.1 Single DE unit
a) Prepare the cable (1) according to the measures A and B.
b) Perform the electrical connections inside the DE unit connector (2)
according to the table below.
c) Thread the cable (1) from the DE unit connector (2) to the filling
machine Connection Box M.X002 (3).
1
A = 30 mm
B = 10 mm
3
A B
2 9 10 11 12 13 14 15
2.2c TB056574en.fm
1 2 3 4 5 6 7 8
1 Cable
2 Connector
Cable-IN Contact
90220-0091 90110-0518
Screen Cover
Brown Pin :10
White Pin :11
Yellow Pin :12
Green Pin :13
Connect 6-15
Connect 8-14
Connect 9-10

5 Installation
5.19.2 Multiple DE units

Note! It is possible connect up to 5 DE units to the filling machine.
Intermediate DE units
a) Prepare the cables (1), (2) and (3) according to the measures A and B.
b) Perform the electrical connections inside the intermediate DE unit
connectors (4) and (5) according to the table below.
c) Thread the cable (1) from the DE unit connector (4) to the filling
machine Connection Box M.X002 (6).
Note! Repeat item b) for the intermediate DE units connected between the last DE
unit and the filling machine.
See the Electrical Manual for details.
6 1 2 3
2.2c TB056574en.fm
9 10 11 12 13 14 15
9 10 11 12 13 14 15 9 10 11 12 13 14 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
1 Cable
2 Cable
4 A B 5 3 Cable
4 Connector
A = 30 mm
B = 10 mm 5 Connector
Cable-IN Contact Cable-OUT

90220-0091 90110-0518 90220-0091
Screen Cover Screen
Brown Pin :10 Brown
White Pin :11 White
Yellow Pin :12 Yellow
Green Pin :13 Green
Connect 6-15
Connect 8-14
(Cont'd)

5 Installation
(Cont'd)
Last DE unit
d) Connect the cable (3) to the Last DE unit connector (7) by the electrical
connections, according to the table below.
9 10 11 12 13 14 15
9 10 11 12 13 14 15 9 10 11 12 13 14 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
2.2c TB056574en.fm
3 Cable
7 7 Connector
Cable-IN Contact
90220-0091 90110-0518
Screen Cover
Brown Pin :10
White Pin :11
Yellow Pin :12
Green Pin :13
Connect 6-15
Connect 8-14
Connect 9-10

5 Installation
5.20 External dating unit (Domino)

Place the external data unit close to the filling machine along the conveyor
system.
a) Connect the external data unit according to the plant installation and
connection drawings, see the external data unit own installation manual
for instructions.
b) Make all necessary electrical connections, see the EM and Domino
dating unit TeM for further details.
Note! The external data unit main power supply must be separated from the
machine.
c) Set the external data unit, see the external data unit own installation
manual for instructions.
2.2c TB056574en.fm

5 Installation
5.21 Final folder outfeed conveyor

Make sure the final folder outfeed conveyor (1) is DELTA connected to the
motor.
a) Open the motor connection box (2) and check the connections, see the
picture below.
Note! Use shielded cables to connect the motor to the filling machine.
b) Make all electrical connections, see the filling machine MM and the
conveyor TeM for further details.
TBA/19
2.2c TB056574en.fm
W2 U2 V2
U1 V1 W1

5 Installation
5.22 ASU on filling machine

Note! Ignore this section if the filling machine is not equipped with an ASU for
installation on the filling machine.
5.22.1 Positioning
Note! Use a pallet trolley to position the ASU.
If possible, push the pallet trolley under the ASU from the rear. If space is
limited, push the pallet trolley under the ASU from the most convenient side.
If the filling machine is only accessible from the LH side, remove the ladder
to gain access.
a) Manoeuvre the pallet trolley under the ASU.
b) Manoeuvre the ASU under the platform, to about one metre from the
rear of the filling machine body. Screw the legs of the ASU up if
necessary.
2.2c TB056574en.fm
View without
ladder
(Cont'd)

5 Installation
(Cont'd)
c) Remove the brackets (1) from the platform.
1
1 Bracket
d) Connect the ASU to the machine body using the indicated holes.
Level the ASU, see 5.22.2 Levelling, then tighten the screws.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
e) Connect the ASU to the platform using the indicated holes.
Level the ASU, see 5.22.2 Levelling, then tighten the screws.
2.2c TB056574en.fm
f) Pass the compressed air line from the hole in the ASU cover, through the
machine body, then to the pneumatic panel.
g) Pass the ASU electrical cables from the hole in the ASU cover, through
the cable guide in the machine body, then to the electrical cabinet.
(Cont'd)

5 Installation
(Cont'd)
h) Connect the cables to the electrical cabinet according to the EM.
2.2c TB056574en.fm
i) Connect the pneumatic supply to the valve panel according to the
pneumatic diagram.
(Cont'd)

5 Installation
5.22.2 Levelling
a) Fix the spirit level (1) (TP No. 90243-163) to the top bending roller
inside the ASU.
1 2
2.2c TB056574en.fm
1 Spirit level
2 Wooden block
b) Fine adjust the legs of the ASU until the ASU is level transversely, ± 0.2
mm/m to the same value as the filling machine.
c) Tighten the six (see 5.22.1 Positioning) fixing screws and check the
levelling has not changed. Adjust if necessary.
d) Remove the spirit level and the wooden block (2) holding the splicing
device in position. Close the ASU doors.

5 Installation
5.23 Other operations

5.23.1 Levelling regulating valve
a) Place a spirit level TP No. 90243-165 (1) across the body of the
regulating valve as shown below and make sure the metal body of the
regulating valve is level. The bubble must be within the two marks on
the transparent tube.
b) If necessary, slacken the nuts (2) at both sides of the regulating valve and
rotate the valve as required. For further adjustment, slacken the screws
securing the positioning bracket (3) and slide the bracket up or down its
slots.
3 2
2.2c TB056574en.fm
1 Spirit level
TP No. 90243-165
2 Nut
3 Positioning bracket
(Cont'd)

5 Installation
(Cont'd)
5.23.2 Fit accessories

c) Make sure all ties have been removed all around the machine
(i.e. splicing table).
d) Fit the air gun to its connection on the pneumatic pipe work plate. Fit the
water gun to its connection on the final folder.
2.2c TB056574en.fm
(Cont'd)

5 Installation
(Cont'd)
e) Fill the detergent bottle with detergent of the correct pH. See section 3.8
Cleaning. Also see the OM for further details.
f) Fit the ink bottle in the dating unit. See the OM for further details.
g) Fit and connect the hydrogen peroxide container. See the OM for further
details.
h) Thread the packaging material and strip, and prepare the machine for
start-up. See the OM for further details.
i) Remove the TPOP holder (4) by removing the screws (5); the screws (5)
have to be re-used to anchor the cover (6).
2.2c TB056574en.fm
6
4 Holder
5 Screw
6 Cover

5 Installation
5.23.3 Check transformers

Hazardous voltage.
Will cause death or serious injury.
Disconnect power before servicing.
Lockout machine.
DANGER!
Check the main power connection for SA PSSU transformer (1) and the ASU
TPO bar transformer (2) as follows:
Check the plant main power supply voltage and connect the transformer
consequently to the most appropriate (200, 220 or 240) connector.
1
2.2c TB056574en.fm
240
230
220
0
1 SA PSSU transformer
2 ASU TPO bar transformer

5 Installation
2.2c TB056574en.fm

2.2c TB066571en.fm

6.1 Installation and connection checks

See section 5 Installation and the OM for further details on the following
checks.
No. Check Done

1 The machine is level transversely and longitudinally,
±0.2 mm/m.
The ASU (if present) is level ±0.2 mm/m.
2 The outfeed conveyor is correctly connected.
The eject bin is correctly positioned.
3 The drain connections are secure:
– external cleaning pump
– water overflow
– dilution tank.
4 The utility connections are secure:
– cold water inlet
– hot water inlet
– re circulated cooling water inlet (plugged if not used)
– re circulated cooling water outlet (plugged if not used)
– compressed air inlet
– steam inlet.
– nitrogen inlet (only machines with HI)
5 The product inlet and outlet connections are secure.
2.2c TB066571en.fm
6 The product regulating valve is level.
7 The electrical power cable is correctly connected:
– cable guide secure
– loop of cable inside cabinet
– terminals correct and secure.
8 The hydrogen peroxide container is in place.
9 The detergent bottle is installed and filled.
10 Supply valves or switches are open or on:
– electrical power
– cold water
– hot water
– re circulated cooling water supply and return (if relevant)
– compressed air
– steam.
– nitrogen (only machines with HI)
11 All ties have been removed.

6.2 Lubricant level checks

See the OM and MM for further details on the following checks.
No. Check Done

1 Drive unit worm gear
2 Central lubrication
3 Hydraulic system
4 Final folder indexing unit
5 Final folder worm gear
6 Outfeed unit
2.2c TB066571en.fm

6.3 Valve checks

No. Check Done
1 The hydrogen peroxide tank drain

valve is closed.
2 The hydrogen peroxide sampling

valve is closed.
2.2c TB066571en.fm
3 The dilution tank drain valve is
closed.
The air valves and water valves are

set correctly:
– filling machine air valve: open
– PT unit air valve (if present): open
4 – standard cooling water: all valves
open
– re circulated cooling water: A1,
A3 open; A2, A4 closed.

6.4 Safety checks

No. Check Done
1 All doors open and close correctly.
2 All door micro switches are correctly operated by the blades on
the doors.
3 All removable hatches and covers are secure.
4 All Emergency stop buttons engage and release correctly.
5 All protective guards are in place and secure.
2.2c TB066571en.fm

2.2c TB066571en.fm

7 Preparation for
commissioning
2.2c TB076571en.fm

Perform the following checks even if an actual commissioning test is not

required.
Note! Commissioning covers only the functioning of the individual machine. A
line performance test is required to check the functioning of the machine as
part of a complete line. Check with the local Service Organisation what
arrangements have been made for a line performance test.
2.2c TB076571en.fm

7.1 Presence and correctness checks

No. Check Done
1 The TP No. on the program diskette corresponds to the TP No.
in the EM.
2 The spare parts have been deposited in the spare parts stores.
3 The accessories are available to the operator:
– apron
– gloves
– goggles.
4 All the documents correspond to the specific machine.
– EM
– IM
– OM
– MM
– SPC
– System drawings
– Machine Specification Document
– Final Inspection Report
– Machine Deviation Report (if relevant).
5 The tool locker is conveniently positioned and the tools are all
in place (if relevant).
6 The packaging material reel trolley is conveniently positioned
and functioning correctly.
2.2c TB076571en.fm
7 The supply and quality of product is sufficient for the purposes

of commissioning.
8 All supplies are of the correct type and are available in sufficient
quantities for the purpose of commissioning:
– Packaging material
– LS strip
– Hydrogen peroxide
– Ink
– Detergent.
– Nitrogen (only machines with HI)
– IS patch strip (only machines with PT unit)
– Tab strip (only machines with PT unit)
(Cont'd)

(Cont'd)
No. Check Done

9 The compressed air valve keys are
present:
– Filling machine valve panel
– PT unit valve panel (if present)
10 The electrical cabinet keys are

present.
2.2c TB076571en.fm

7.2 Product and utility value checks

Make sure the product and utility values are correct. Ask for the assistance of
the customer’s technical personnel if necessary. If values are incorrect,
inform the customer’s technical personnel and the local Service
Organisation. See section 3 Drawings and Technical Data.
No. Check Done

1 Product supply:
– pressure
– max pressure fluctuation
– inlet temperature
– max particle size
2 Electrical power supply:
– voltage
– max voltage fluctuation
– frequency
– fuse rating
3 Cold water supply:
– pressure
– max inlet temperature
– pH
4 Hot water supply:
– pressure
2.2c TB076571en.fm
5 Detergent supply:
– pH
6 Compressed air supply:
– pressure
– max particle size
– max particle content
– dew point
– oil content
7 Steam supply:
– water quality
– pressure
– max pressure fluctuation
8 Hydrogen peroxide supply:
– aseptic (food) grade
– concentration (35%)
9 Nitrogen supply (only machines with HI):
– purity
– pressure

7.3 Function checks

7.3.1 Preparation
a) Make sure the PLC program on the diskette corresponds with the one in
the machine. See the EM for further details.
b) If the product pipes have been welded:
Disconnect the product supply pipe from the inlet pipe (1). Disconnect
the product forwarding pipe from the product outlet pipe (2). Flush the
supply and forwarding pipes with clean water to remove any welding
residue. Connect the two pipes again.
1 2
2.2c TB076571en.fm
1 Inlet pipe
2 Outlet pipe
Caution! Press the Inch button only very briefly to avoid damaging the
equipment if the direction of movement is incorrect.
c) Switch on the mains power and step up to Preheating I. Wait until the
PT unit heating elements reach operating temperature. Very briefly press
the Inch button and check the direction of movement of the final folder
conveyor or jaw system.
If necessary, invert two phases in the mains power connections.
d) Perform CIP. See the OM for further details.
e) Connect a cold water supply to the product inlet connection.
(Cont'd)

(Cont'd)
f) Prepare the machine for production. See the OM for further details.
g) Make sure that start-up from cold takes less than 45 minutes at an
ambient temperature of no less than 20°C (68°F).
h) Start up the package outfeed conveyor.
i) Step up the machine to Production.
7.3.2 Normal operating checks

No. Check Done
1 The packaging material and LS strip move freely through the
machine and are correctly aligned.
If a PullTab unit is present, the strips (IS patch, tab, move freely
through the machine and are correctly aligned.
2 The package outfeed conveyor removes the packages cor-
rectly.
3 Finished packages are correct in terms of:
– size and shape
– longitudinal and transversal sealing
– date code printing
– filled package weight/volume
– hole positioning and punching (only machines with PT unit)
2.2c TB076571en.fm
– tab application and sealing (only machines with PT unit)

See the OM for further details.
If necessary change the PLC parameters. See section 7.3.3
Changing PLC parameters.
If necessary change the HI nozzle (only machines with HI). See
section 5.11.5 Aseptic product valve (APV) and remaining large
pipes; see also Selecting injection nozzle size (only machines
with HI).
4 Production capacity is as specified (count the packages
produced in six minutes and multiply by ten).
5 All pressures remain within tolerance. See the OM.
6 There are no fluid leaks.
7 There are no unusual noises which could indicate loose or
misaligned parts.
8 There are no unusual smells which could indicate internal leaks
or burning electrical circuits.
(Cont'd)

(Cont'd)
Selecting injection nozzle size (only machines with HI)
Apply the following criteria when selecting a new injection nozzle size.
Larger nozzles:
• increase the volume of injected gas
• increase the effect of pressure changes
• produce a coarser foam (with larger, short-life bubbles—useful for
products which foam easily).
Smaller nozzles:
• reduce the volume of injected gas
• reduce the effect of pressure changes
• produce a finer foam (with finer, long-life bubbles—useful for products
which do not foam easily).
Tp. No. Nozzle diameter mm

1539606-6 0.60
1539606-5 0.50
1539606-4 0.40
2.2c TB076571en.fm
1539606-3 0.30
1539606-2 0.25
2545134 0.20 (multy hole nozzle)

7.3.3 Changing PLC parameters

Caution! Do not change the PLC parameters unless absolutely necessary.
Make a copy of the existing parameters before modifying them. Also
keep a copy of the new parameters for future reference.
GE Fanuc PLC
Note! Only follow this procedure if the mechanical volume regulation knobs
provide insufficient adjustment.
If package filling is incorrect, the filling sector parameters in the GE Fanuc
PLC can be changed:
a) Connect the GE Fanuc serial cable (TP No. 90031-300) between the
portable PC running GE Fanuc LM 90 software (V 6.01 or later) and the
15 pin connector on the PLC.
b) Run the LM 90 program and display the filling sector settings.
c) Increase the values to increase package volume.
Decrease the values to decrease the package volume.
See the EM for further details on the program listing.
(Cont'd)
2.2c TB076571en.fm

(Cont'd)
TMCC2 PLC
Note! TMCC2 parameters cannot be modified individually. The entire program
must be down loaded. This is only done if major changes are required.
a) Connect the TMCC2 serial cable between the portable PC and the
RS232 9-pin serial connector on the TMCC2.
b) Run the TMCC2 program on the communications diskette to down load
the parameters.
2.2c TB076571en.fm

7.4 Health and safety checks

No. Check Done
1 The door micro switches on the filling machine and PullTab unit
activate an alarm and stop the machine.
2 All the Emergency stop buttons stop the machine immediately
and activate the alarm.
3 Filled packages and outlet water samples have the correct
hydrogen peroxide residue or content as measured using:
– Test kit 90298-31 for packages
– Test kit 90298-30 for outlet water.
4 The manual strip splice button is disabled when the SA doors
with micro switches are opened.
5 Check that the warning signs are applied and readable, see
Safety precautions chapter Warning signs on the machine.
2.2c TB076571en.fm

7.5 Documentation
Note! No claims will be accepted for machines in commercial production if the
Start-up Machine Quality Report has not been returned to the
manufacturer.
a) Compile the Transport Damage Report (a section of the Start-up
Machine Quality report).
If no damage has occurred during transport, state “NO TRANSPORT
DAMAGE”.
b) Compile the Feedback from MC form only in case of claims on the
equipment.
For further information about claims see the Claim and Complaint
Handling procedure, available from the local Service Organisation.
c) Compile the Start-up Machine Quality Report.
List all work (other than installation work) performed to ensure correct
functioning.
The installation work covered by this manual is now complete.
2.2c TB076571en.fm

2.2c TB086571en.fm

Important!
Caution! If the equipment is going to stand or travel in freezing conditions, the
water circuits must be drained to avoid freezing damage.
The equipment can be moved for short distances without being drained or
disassembled, but only if no freezing conditions will be encountered. The
equipment must be drained before long-distance moves or long-term storage.
If draining is necessary, perform the draining procedure before disconnecting
the equipment from the mains power supply.
Only skilled or instructed installation technicians are allowed to disassemble
the equipment for moving to other installation positions.
2.2c TB086571en.fm

8.1 Draining
8.1.1 Draining methods
To drain certain circuits, the solenoid valves controlling them must be
energised. This can be done in two ways:
• electronically (using a PC)
• by manually bridging terminals in the electrical cabinet.
The following is needed for the electronic procedure:

• Portable PC running GE Fanuc LM90 software, V 6.0 or later
• GE Fanuc PLC serial cable, TP No. 90031-300
• EM.
The following is needed for the manual bridging procedure:

• EM
• Piece of cable, approx. 2 metres in length.
2.2c TB086571en.fm

8.1.2 Draining preparations

Risk of injury and damage!
Make sure that water expelled under pressure cannot cause damage
or injury.
WARNING!
Air expelled under pressure is very noisy. Wear hearing protection.
a) Disconnect the rapid coupling to the pressure accumulator, on top of the

separator.
2.2c TB086571en.fm
b) Leave the compressed air supply to the machine connected, and connect
a second compressed air supply line to the cold water inlet.
(Cont'd)

(Cont'd)
Note! The compressed air circuit must be pressurised to perform the following
procedure.
If the second air supply pressure cannot be adjusted, open the water valves
very slowly to avoid pressure surges.
c) Adjust the compressed air supply pressure to approx. 4 bar.
d) Make sure that no Emergency stops are engaged, all doors with micro
switches are closed, and no error conditions are present.
e) Switch the mains power supply on.
f) Switch the machine’s main power switch on.
g) Step up to Preheating I.
DANGER!
2.2c TB086571en.fm
(Cont'd)

(Cont'd)
h) On a machine with standard cooling system make sure:
water valves A1 (1), A2 (2), A3 (3), and A4 (4) are open;
On a machine with re circulated cooling water make sure:

water valves A1 (1) and A3 (3) are open
water valves A2 (2) and A4 (4) are closed.
2.2c TB086571en.fm
3
1 Valve A1
2 Valve A2
2
3 Valve A3
4 Valve A4
i) Position a splash guard and warning notices in front of the connection

panel if possible.

8.1.3 Draining procedure

Note! Make sure Draining preparations are performed before this procedure.
If a portable PC running GE Fanuc LM90 software V 6.0 or later is available,

connect it to the PLC using the GE Fanuc PLC serial cable, TP No. 90031-
300. See the EM for further details.
Caution! When bridging two terminals, connect the cable to the control terminal
first and then to the power terminal. Do not cause short circuits.
If the solenoids have to be energised manually, connect the piece of cable to
the +24 VDC power terminal XL.11.30 for all the bridging operations. See
the EM for further details.
The force symbol on the operator panel lights when an output is forced on,
and goes out when the output is forced off again.
The following instructions list the PLC outputs. The control terminals for the
manual procedure are shown in brackets.
Water gun circuit
Operate the water gun until only dry air comes out.
Compressor circuit (solenoid valve M.Y032)
2.2c TB086571en.fm
a) Open (switch off) contact breaker K006 to prevent the compressor motor
starting up.
b) From the PC, force PLC output Q19 on.
c) Wait 5 to 10 seconds and force the output off.
Final folder sprinkler circuit (solenoid valve M.Y031)

a) From the PC, force PLC output Q72 on.
b) Wait 5 to 10 seconds and force the output off.
Tube flusher circuit (solenoid valve M.Y039)

b) Wait 5 to 10 seconds and force the output off.
(Cont'd)

(Cont'd)
Cooling water circuit (solenoid valve M.Y033) (standard cooling
system)
For machines with standard cooling system.
b) Wait until all the water from the cooling circuit drains to the cleaning
tray under the final folder.
c) Close valve A4.
2.2c TB086571en.fm
(Cont'd)

(Cont'd)
d) Remove the re circulated cooling water outlet plug.
e) Open valve A4.

f) Wait until only dry air comes out of the re circulated cooling water
outlet.
g) Close valve A4.
h) Fit the re circulated cooling water outlet plug.
i) Remove the re circulated cooling water inlet plug.
2.2c TB086571en.fm
j) Open valve A4.

k) Wait until only dry air comes out of the re circulated cooling water inlet.
l) Close valve A4.
m) Fit the re circulated cooling water inlet plug.
n) From the PC, force output Q73 off.
(Cont'd)

(Cont'd)
o) Remove the compressed air connection from the cold water inlet and fit
the cold water inlet plug.
(Cont'd)
2.2c TB086571en.fm

(Cont'd)
Cooling water circuit (solenoid valve Y33) (re circulated cooling
water)
For machines with re circulated cooling water.
a) Remove the re circulated cooling water inlet and outlet connections (1)
and (2).
b) Remove the compressed air supply line from the cold water inlet (3) and
connect it to the re circulated cooling water inlet (1).
c) Fit the cold water inlet plug (3).
1 2 3
1 Re circulated cooling water inlet

2.2c TB086571en.fm
2 Re circulated cooling water outlet

3 Cold water inlet
d) From the PC, force PLC output Q73 on. (Control terminal X1.372.)
e) Wait until only dry air comes out of the re circulated cooling water
outlet.
f) From the PC, force output Q73 off.
g) Remove the compressed air connection from the re circulated cooling
water inlet (1).
h) Fit the re circulated cooling water inlet plug (1).
i) Fit the re circulated cooling water outlet plug (2).
(Cont'd)

(Cont'd)
Sterilisation bath
a) Make sure the valve (1) is closed.
b) Drop the bath water by pulling upwards the valve (2).
c) Wait until the pressure on the gauge drops to zero.
Note! To fully clear the circuit perform the following items:
d) Make sure the main water supply to the machine is closed.
e) Disconnect the hose (3).
f) Open the valve (1).
2.2c TB086571en.fm
1
1 Valve
3 Valve
4 Hose
(Cont'd)

(Cont'd)
Sterilisation bath water pump (M.M017)
a) Remove the plug from the pump and dry inside the pump.
b) Fit the plug.
2.2c TB086571en.fm
Hot water circuit (solenoid valve M.Y029)

a) Close valve A2 (only machines with standard cooling system).
(Cont'd)

(Cont'd)
b) Connect the compressed air supply line to the hot water inlet.
c) From the PC, force PLC output Q71 on.

d) Wait 5 to 10 seconds and force the output off.
e) Remove the compressed air supply line from the hot water inlet.
Fit the hot water inlet plug.
Cleaning system water circulation pump (M.M004)
a) From the PC, force PLC output Q16 on. (Close contactor K008.)
b) Wait for 5 to 10 seconds and force the output off.
(Cont'd)
2.2c TB086571en.fm

(Cont'd)
Compressor (M.M007)
a) Remove the drain plug from the bottom of the compressor flange.
b) Wait for all the water to drain out and fit the plug securely.
2.2c TB086571en.fm
(Cont'd)

(Cont'd)
Separator
a) Unscrew the float chamber at the bottom of the separator.
b) Drain off all the water and fit the float chamber.
2.2c TB086571en.fm
Peroxide tank
Hydrogen peroxide!
Follow the Safety Precautions.
a) Disconnect and remove the hydrogen peroxide container.

WARNING!
(Cont'd)

(Cont'd)
b) Open the drain valve under the hydrogen peroxide tank and wait for all
the hydrogen peroxide to drain into the dilution tank (15 minutes).
c) From the PC, force PLC output Q110 on.

2.2c TB086571en.fm
d) Wait 5 to 10 seconds and force the output off.

e) Close the valve under the hydrogen peroxide tank.
f) Place a suitable container under the dilution tank drain outlet (1), open
the drain valve (2) and drain the tank into the container for disposal in
compliance with local regulations.
1 Drain outlet
2 Drain valve
(Cont'd)

(Cont'd)
Final checks
a) Make sure all connections on the connections panel are plugged.
b) Make sure all cables used for the draining procedure (electronic
procedure or bridge procedure) are disconnected.
c) Make sure all valves on the valve panel, dilution tank, water and
hydrogen peroxide circuits are set to the correct operating position.
d) Make sure the drain plug on the compressor is tight.
e) Make sure the separator float chamber is fitted and tight.
f) Make sure the flange of the sterilisation bath water pump is tight.
2.2c TB086571en.fm

8.2 Moving and transporting the

equipment
Note! The fully assembled equipment can be moved either on the wheeled
transporter (TP No. to be determinate) or by fork lift.
Overhead gantries and mobile cranes cannot be used in any case.
8.2.1 Short moves and short term storage

See section 5 Installation for further details.
To disassemble parts, follow the assembly instructions in the reverse order.
a) Switch the machine’s main power switch off. Padlock the switch.
b) Switch the mains power supply off.
2.2c TB086571en.fm
(Cont'd)

(Cont'd)
c) Shut off all the utility and product supplies to the machine:
– electrical power
– cold water
– hot water
– re circulated cooling water in and out (only machines with re
circulated cooling water)
– compressed air
– steam
– product
d) Release pressure from the water and air circuits by operating the water
and air guns.
Close all the utility and drain valves on the machine:
– compressed air valve (A2, compressed air system)
– water valve (A1, water system)
– steam valve (at APV)
– dilution tank drain valve
e) Disconnect the power, utility, drain, and product lines:
2.2c TB086571en.fm
– electrical power (disconnect at power terminals and remove cable
from electrical cabinet)
– cold water
– hot water
– re circulated cooling water in and out (only machines with re
circulated cooling water)
– compressed air
– steam
– product
– water overflow
– dilution tank drain
– external cleaning pump outlet
f) Plug or protect all open connections.
g) Disconnect the package outfeed conveyor and remove the eject bin.
h) Remove the ladder and ladder handrails.
i) Move the machine to its new position.
Level the machine approximately.
j) Cover the equipment with a suitable protective covering.
k) Make sure the storage conditions comply with specifications.
See section 4.4 Moving and storage.

8.2.2 Long moves and long term storage

See section 5 Installation for further details on the operations in this section.
To disassemble parts, follow the assembly instructions in the reverse order.
a) Drain the equipment. See section 8.1 Draining.
b) Lubricate all sliding components (rods, cams, etc.).
c) Drain the hydraulic system and refill with a suitable flushing fluid. See
the MM for further details.
d) Perform the operations listed in section 8.2.1 Short moves and short term
storage as far as step g).
e) Remove the protective guards and packaging material covers.
f) Disconnect the electrical connections on the RH side of the drying
chamber.
g) Remove all small diameter pipes.
h) Remove the regulating valve and APV.
i) Remove the large diameter pipes.
j) Remove the hydrogen peroxide generator.
k) Remove the cable duct on the RH side of the drying chamber.
l) Disconnect the electrical connections on the LH side of the drying
2.2c TB086571en.fm
chamber and remove the cable duct.

m) Disconnect and secure the sterilisation bath chains, remove the drip
plates, and remove the drying chamber.
n) Fit the transport plate across the top of the column and sterilisation bath.
o) Only machines with strip applicator:
Bend the strip applicator.
p) Only machines with PT unit:
Remove the PT unit.
q) Remove the warning beacon.
r) Remove the handrail.
(Cont'd)

(Cont'd)
s) Remove the platform panels, side frame, and rear platform extension (if
present).
t) Remove the ladder and ladder handrails.
u) Support the filling machine on wooden blocks. Remove the feet and
legs.
v) Wrap small components in bubble wrapping to prevent damage.
w) Pack the equipment in suitable crates. Use the original crates and
transport frame if available. Make sure that all groups and components
are adequately protected. Fix any loose sub-crates or boxes to the floors
or walls of the crates to prevent them moving during transport.
2.2c TB086571en.fm

8.3 Return to the manufacturer

a) Prepare the equipment for transport. See section 8.2 Moving and
transporting the equipment.
b) Contact the local Service Organisation for further instructions and to
arrange shipment.
2.2c TB086571en.fm

8.4 Disposal
If the equipment is to be permanently disposed of, perform the following
operations.
a) Drain the equipment. See section 8.1 Draining.
b) Drain the hydraulic tank and dispose of the hydraulic fluid in compliance
with local regulations. See the MM for further details.
c) Remove the packaging material, LS strip, (and PullTab strip reels if
present) and dispose of these in compliance with local regulations.
d) Disassemble the machine as far as possible and separate the following
materials:
– stainless steel (panels and doors)
– cast iron (frames)
– glass (windows, etc.)
– rubber (seals, O-rings, etc.)
– nylon and other plastics
– electrical cables
– hydraulic and pneumatic hoses
– electrical components.
2.2c TB086571en.fm
e) Recycle or dispose of all materials, groups, and components in
compliance with local regulations.

Tetra Pak
MM binder labels. 40 mm Full width Note! This page is generated automatically.
using the variable definitions made in the front page file!!
TBA/19 Tetra Brik TBA/19 Tetra Brik

Aseptic 020V Aseptic 020V
648160-2000 ........................... 648160-2000 ...........................
Issue 2003-09 Doc. No. IM-81657-0104 Issue 2003-09 Doc. No. IM-81657-0104

648160-2000 ........................... 648160-2000 ...........................

648160-2000 ........................... 648160-2000 ...........................

648160-2000 ........................... 648160-2000 ...........................

648160-2000 ........................... 648160-2000 ...........................
Issue 2003-09 Doc. No. IM-81657-0104
Issue 2003-09 Doc. No. IM-81657-0104

648160-2000 ........................... 648160-2000 ...........................
If the text does not fit; change the font on
! “B TitleFull” to min 18 p, and the left indent to 0.5 cm (on all

three components). Make “Update All”
2.281657011lab.f
MM binder labels. 30mm Halfwidth Note! This page is generated automatically.
using the variable definitions made in the front page file!!

648160-2000 ........................... 648160-2000...........................

648160-2000 ........................... 648160-2000 ...........................

648160-2000 ........................... 648160-2000 ...........................

648160-2000 ........................... 648160-2000 ...........................

648160-2000 ........................... 648160-2000 ...........................

648160-2000 ........................... 648160-2000 ...........................

648160-2000 ........................... 648160-2000 ...........................
If the text does not fit; change the font on “B TitleHalf” to min 18 p,
TBA/19 Tetra
Aseptic 020V
648160-2000
! “Update All”
Brik TBA/19 Tetra
and the left indent to 0.5 cm (on all three components). Make
Aseptic 020V
648160-2000
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Im 81657 0104

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Copyright:

Available Formats

Im 81657 0104

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Copyright:

Available Formats

IM

Series No/ Machine No Sign.

Temperature Control Steam Barrier

PullTab Unit PT19

Headspace by Gas Injection HI19

Tetra Pak Carton Ambient S.p.A.

General safety precautions . . . . . . . . . . . . . . . . . . . . . 19

Machine safety devices . . . . . . . . . . . . . . . . . . . . . . . . 22

Equipment for lifting and moving loads . . . . . . . . . . . 33

Tetra Pak Doc. No. IM-81657-0104 I

3 Drawings and Technical Data

3.2 Basic machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.3 Mass (weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.5 Emissions and thermal load . . . . . . . . . . . . . . . . . . . . 55

3.9 Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.10 Outfeed conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4.2 Lifting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.4 Moving and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

II Doc. No. IM-81657-0104 Tetra Pak

5.2 Opening the crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

5.3 Unpacking the main crate . . . . . . . . . . . . . . . . . . . . . . 84

5.4 Unpacking the PT unit crate . . . . . . . . . . . . . . . . . . . . 91

5.5 Unpacking the ASU crate. . . . . . . . . . . . . . . . . . . . . . . 93

5.7 Disposal or return of packing . . . . . . . . . . . . . . . . . . . 96

5.10 Approximate levelling . . . . . . . . . . . . . . . . . . . . . . . . 100

5.11 Main installation operations . . . . . . . . . . . . . . . . . . . 102

5.12 Strip applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Tetra Pak Doc. No. IM-81657-0104 III

5.13 PullTab unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

5.14 Covers and guards. . . . . . . . . . . . . . . . . . . . . . . . . . . 152

5.15 Precision levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

5.16 Outfeed conveyor connections. . . . . . . . . . . . . . . . . 160

5.17 Utility, product, and drain connections . . . . . . . . . . 161

5.18 PLMS photocells . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

5.19 Line supervision - DE connection . . . . . . . . . . . . . . 170

5.20 External dating unit (Domino) . . . . . . . . . . . . . . . . . . 173

5.21 Final folder outfeed conveyor . . . . . . . . . . . . . . . . . . 174

5.23 Other operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

6 Final installation checks

6.2 Lubricant level checks. . . . . . . . . . . . . . . . . . . . . . . . 187

6.3 Valve checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

6.4 Safety checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

IV Doc. No. IM-81657-0104 Tetra Pak

7 Preparation for commissioning

7.2 Product and utility value checks. . . . . . . . . . . . . . . . 195

7.3 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

7.4 Health and safety checks. . . . . . . . . . . . . . . . . . . . . . 201

7.5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

8 Disassembly and removal

8.1.2 Draining preparations . . . . . . . . . . . . . . . . . . . . . 206

8.2 Moving and transporting the equipment . . . . . . . . . 221

8.3 Return to the manufacturer . . . . . . . . . . . . . . . . . . . . 225

8.4 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Tetra Pak Doc. No. IM-81657-0104 V

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VI Doc. No. IM-81657-0104 Tetra Pak

Tetra Pak Doc. No. IM-81657-0104 1

2 Doc. No. IM-81657-0104 Tetra Pak

Machine without ASU

Tetra Pak Doc. No. IM-81657-0104 3

Additional copies can be ordered from TP Global Technical Support AB,

4 Doc. No. IM-81657-0104 Tetra Pak

Tetra Pak Doc. No. IM-81657-0104 5