WB-92-01 Tba-22

Course introduction 1
TBA/22 introduction 2
TBA/22 TPMS service system 3
Training Document Packaging material/package integrity 4
This Training Document is intended for
Training purpose only, and must not be
used for any other purpose.
The Training Document is not replacing
Supply systems 5
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such. Tube forming 6
Note!
For safe and proper procedures, refer to
the equipment specific documentation.
Sterile system components 7
Sterile system 8
Name:
................................................................................................................
Drive and jaw system 9
................................................................................................................
Design control system 10
Final folder 11
ASU 2 R 12
Sealing 13
Filling system 14
Electrical system 15
Electrical equipment 16
GE_Fanuc______________________17
Special machine functions 18
Technical Training Centre Cleaning systems 19

Lund, Sweden
WB-92-01
Issue 9909 20
1
Course
Introduction
Technical Training Centre

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

- Modena -
Via Emilia Ovest
11
10
Tetra Pak Italiana
Test Hall 5 4
Switchboard 6
Reception1 9 Warehouse 3
2 1
Via Delfini
Reception2
78 New
Building
Production
Technical Training Shool
Guard
Main Entrance
Canteen
Goods Entrance
Tel. +39 059 898222 Fax. +39 059 898134 e-mail: SwitchboardItaly@tetrapak.com
Meeting Rooms
1 Volta - video conference (ground floor New Building)
2 Archimede (first floor New Building, between New Building and Test Hall)
3 Michelangelo (first floor New Building, between New Building and Test Hall)
4 The Globe (second floor New Building)
5 Product Room (second floor New Building)
6 Video Conference (second floor New Building)
7 TPI 1st Floor (above Switchboard on the first floor of Tetra Pak Italiana)
8 TPI 2nd Floor (above Switchboard on the second floor of Tetra Pak Italiana)
9 Raffaello (above Production)
10 Galileo (near Reception 1)
11 Leonardo (near Reception 1)
Information to Course Participants at
the Technical Training Centre in Modena
Welcome to Technical Training Centre!
Here is some information which might be helpful to you as a course
participant. If you need additional information or help, feel free to ask
your instructor.
Start of course
Normally, the first day of your course begins at 09.00. Your instructor will
meet and welcome you in the coffee room.
Daily time schedule
Classes 08.30 - 10.00
Coffee-brake 10.00 - 10.20
Classes 10.20 - 12.00
Lunch 12.00 - 13.00
Classes 13.00 - 16.30
Your instructor will tell you if there are any changes in the schedule.
Lunch
Lunch is served in the canteen. You can choose among several dishes; men-
us are posted at the canteen entrance.
If you are a not from BUTB in Modena, your instructor will give you lunch-coupons.
Coffee room
You are invited to use the coffee room and the vending machine during all
breaks in classes. Instructor will provide you with “coffee key”.
Smoking
Smoking is allowed in some places marked with a sign.
Telephones
Ask your instructor for assistance.

Computers
ID card
Safety regulations
At the start of the course, your instructor will go through the Safety Regula-
tions . These regulations must be strictly observed. In case you are
uncertain about anything in the regulations, you must clarify it with your in-
structor.
Course evaluation
You are requested to write down your comments on the course on the Course
Evaluation form. At the end of the course your instructor will collect all the
forms.
Working clothes
It is necessary to wear safety shoes in the Technical Training Centre, while

working at the machines . For your use during the course, you may borrow a set of coveralls.
Each participant is given a locker in the changing-room. The instructor will
hand you the locker key. You may then select a set of coveralls from the cov-
eralls cabinet in the changing-room. Your instructor will help you if needed.
You may exchange your coveralls for clean ones every Monday morning. Ask
your instructor if you need to change at any other time. Used and soiled cov-
eralls are to be placed in the laundry basket in the changing-room.
At the end of the course you have to empty and lock your locker and return the
key to the instructor. If you wish to retain your locker for a subsequent training
course, tell your instructor.
Valuables
You are responsible for your own valuables.
Money exchange
To change currency or cash traveller’s cheques, please go to the Rollo-Bank which is close to
Tetra Pak entrance.
It is open 09.00 - 16.00.
Hotels
If you want to change hotel during the course period, please con-
tact the course co-ordinator at Technical Training Centre.
Transport
Travel arrangements
Go to the Travel agency for reservations, reservation chang-

es, or confirmation of reservations. The travel agency is located close to Reception 2
and open 07.30 - 17.30 (fridays - 17.00).
Visa
Make sure that you have Italian Visa (if needed) valid during you staying in the country.
Medical care
Ask your instructor for assistance.

Safety precautions
Machine safety devices

Emergency stop buttons
Learn the position of the Emergency stop buttons in order to stop the
equipment immediately in case of danger to people or damage to the
equipment.
The Emergency stop buttons do not switch off the power at the mains power
switch.
Pushing the Emergency stop buttons will reset the equipment program to
Zero position and deactivate all pneumatic cylinders.
LH side
2.282302014sp.fm
0-Series
RH side
Tetra Pak Doc No. MM-82302-0104 17

2
TBA/22 introduction

Lund, Sweden
Electrical carbinet Strip applicator (ASU RH side)
Superstructure
Machine type
Service unit
TBA/22
Issue
1/9905
OH 828
Automatic splicing unit Drive Jaw system Main groups

Machine body Final folder
TBA/22
High speed for added value
TBA/22 High speed packaging system
High speed that adds value
The TBA/22 creates an entirely new standard of capacity in the aseptic
packaging of liquid food. It provides a highly competitive solution for achieving
lower operating costs, higher productivity and greater space efficiency.
The capacity is a remarkable 20,000 packages per hour for the TBA 250 B
and TBA 200 B with straw openings and secondary packaging solutions. The
system offers a high speed straw applicator and a high speed cardboard packer.
The beauty of the system is that it is fast and simple. The higher capacity has
been achieved by increasing the speed of the filling machine and designing
innovative solutions such as the new jaw unit and the new final folder.
Cost-effective, productive
and space-efficient
The TBA/22 has been designed with the specific purpose of
reducing the costs and raising the productivity of producers.
Cost-effective
Savings on packaging operating costs are achieved through
lower capital costs, lower utility consumption, lower operator
costs, improved space utilisation and less waste on a per
package basis.
High productivity and space efficiency

The unparalleled capacity of 20,000 packages per hour is
achieved with a very compact footprint. Producers can expand
capacity in the space they already have available, without
having to invest in major extensions or new plants.
User-friendly
Significant steps have been made to increase user-friendliness
for operators and service technicians. The TBA/22 provides:
• Easy access;
• Efficient handling of consumables such
as packaging material and the
LS strip;
• An interactive operator interface.
TBA/22 machine functions
8
10
11
1
4
12
5
9
1. Packaging material supply 3. Aseptic system 4. Jaw unit

Two reels of packaging material are placed in Sterilisation of the packaging material is The jaw unit consists of 2 chains opposite
achieved by letting the packaging material each other driven at constant speed by a
an integrated section of the machine. The
pass through a deep bath of heated hydro- servo-motor. Each chain is made of 10 links
reels are spliced automatically by means
gen peroxide. Rollers remove the hydrogen and the links move against fixed cams. To
of induction heat. The two-reel concept en-
peroxide from the packaging material and minimise lubrication, solid oil bearings have
ables the next reel to be spliced before the
remaining residues of H2O2 are evaporated been used as much as possible. No
one currently in use is finished – an ideal fea- by hot sterile air. The temperature in the
ture for contract packing and short pro- hydraulics are needed.
aseptic chamber is monitored so that it will
duction runs of the same product with diffe- not exceed 100°C. Problems caused by
rent designs. 5. Single final folder
polyethylene sticking during short stops are
thus avoided. The aseptic chamber has been The final folder consists of a single chain dri-
designed with a minimum of slots and screws, ven at constant speed by a servo-motor.
2. Longitudinal sealing
and the surfaces are angled to enable efficient There are no hydraulics. Use of lubrication
Induction heat is used for sealing the longitu-
cleaning. grease is minimal in order to avoid the risk of
dinal seam of the packages. Preheating is not
The TBA/22 has a self-balanced sterile leakages on the packages. Individual
needed, as the inductor applies the strip
air overpressure that is automatically temperature-regulated air nozzles for the flap
immediately.
monitored and which makes for very reliable sealing improves the sealing.
operation.
6. Product filling system 11. Service unit Packaging line monitoring system (PLMS)
The product filling system has a level probe The service unit for the closed cooling sys- Automatic recording of line efficiency is made
that senses the liquid level very precisely and tem and foam cleaning is located at the front possible by the PLMS. The system records
controls it with an electronic system and a of the machine. Easy connection of all utilities data about stoppages: duration, frequency
regulating valve. simplifies installation. and waste. The data can be analysed off- line
by transferring it to a PC via a modem or
7. Platforms 12. Interactive operator’s panel diskette.
The spacious platforms and stairway make The TBA/22 has an interactive operator’s
the machine very accessible and provide a panel at floor level with a touch sensitive dis- Foam cleaning
safe working environment. The design play. It contains very extensive alarm functions Alkali foam cleaning is standard for external
complies with the directives for CE-marking. and it is also possible to switch between dif- cleaning (cleaning of jaw system, final folder
ferent languages very quickly. and aseptic chamber). Foam is dynamic and
8. Air cooling of the electrical cabinet The operator guidance supports the ope- penetrates into unseen surfaces to give a very
rator with detailed instructions, such as what
The electrical cabinet has a compressor- hygenic environment.
actions to take to reset the machine into the
controlled air cooler so that the temperature
production position. This feature helps save
will not exceed 40°C, even if the maximum CIP cleaning
labour and reduce downtime.
number of options are built in.
The operator can easily adjust the most The cleaning-in-place function (cleaning of
important sealing parameters, centering of the product valves and product piping) is
9. Waste conveyor
longitudinal seal, package volume etc. automatically switched between production
Rejected packages are discharged at the front and the cleaning configuration by a group of
of the machine, which improves waste hand- Peroxide container system valves. This feature also records the CIP para-
ling and does not affect the operator’s working meters, i.e. the concentration, temperature
The TBA/22 has a closed water system for
area. heating the hydrogen peroxide. The tank is and flow of the cleaning media, which are
insulated. To avoid overfilling, the maximum presented on a chart diagram.
10. Integrated closed water cooling level in the tank is supervised by a level probe.
system
The TBA/22 has an integrated closed water Longitudinal seal strip application
cooling system which acts as a cooling me-
dium for the transversal seal, final folder The longitudinal seal strip applicator is located
and longitudinal sealing. About 10% of the at floor level to allow easy access.
water is continously purified through an ion Sealing is done by induction heat. Two jumbo
exchange filter which means that lime reels are spliced automatically and last for
deposits are eliminated in the cooling system. about 1 hour, with one jumbo reel for TBA
250B packages.
TBA/22 packaging line
Filling machine Filling machine Straw applicator Cardboard packer

The TBA/22 creates The Tetra Straw The Cardboard
an entirely new Applicator 22 HS Packer 71 is designed
standard of capacity in applies a drinking for the high speed
Ink jet date printer the aseptic packaging straw to the package. system and makes
of liquid food. Package sizes: distribution units
TBA 200B and of 3x8 and 3x9
TBA 250B. standard trays.
Straw types: S-, Package sizes:
T- and U-straws. TBA 200B and
TBA 250B.
Straw applicator
Tray shrink
Distributor
Pallet system
Cardboard packer
What is high
speed? A high-performance
On the 16th of June 1999,
system solution
Maurice Greene shaved
0.05 of a second off the The TBA/22, the Tetra Straw Applicator 22 HS and Tetra Cardboard Packer 71
world record for the together make a complete solution that ensures high levels of performance.
men’s 100 metres. He ran The Domino A300 ink jet printing unit is used for date-printing. High-speed
the distance in 9.79 multipack packaging equipment will be available in the near future.
seconds to become the
fastest short-distance
Domino A300
sprinter in the world.
The Domino A300 offers highly flexible print capabil-
ity that can meet the ever changing demands of the
An athlete will spend
customer. The fully automated start-up and shut-
years priming his body, down functions, simple user interface and
his breathing, his running advanced fluid supply systems combine to make
style, the movement of the A300 truly operator friendly. New software
his limbs, in preparation developments, specifically designed for Tetra Brik
for that one big day when packaging lines, will enable “jaw” identification
he, hopefully, will truly hit numbers to be printed onto the packages.
his peak. If he is a world-
class athlete, he might Tetra Straw Applicator 22 HS
succeed in breaking the The applicator is small and compact, making it easy
record by a tenth or two to integrate the machine with the packaging lines.
of a second. The chances
The applicator works with the flow principle.
are he will not do it again.
To ensure a precise application of the straw, the
It is a once-in-a-lifetime
packages are lifted up from the conveyor chain to
achievement.
a transport belt when passing through the
application area.
Speed is, of course,
relative. The TBA/22 has The applicator head, containing the ladder band,
not merely “shaved” the is mechanically connected and driven by a
record for the fastest servo-motor. The straw is applied with the help of
packaging machine in the pressure pads that move with the packages.
world. At 20,000 packa-
ges an hour, it has almost Tetra Cardboard Packer 71
doubled the capacity of The Tetra Cardboard Packer 71 packs Tetra Brik
packages into cardboard trays in the 3x8 and 3x9
its nearest rival. Nor is it
packing patterns. The machine is easy to adjust
a once-in-a-lifetime
from one packing pattern to another.
achievement. The TBA/22
does it every hour, every The packages are fed through a distributor that
day–reliably, efficiently, separates the flow of packages into three parallel
convincingly. lines. The packages are then fed into the packer
and grouped in the required packing pattern.
Technical Data: Tetra Brik Aseptic filling machine TBA/22
Capacity filling machine Water supply (cold)
Packages per hour: 20000 TBA 250B Connection pressure, kPa (bar): 300-450 (3-4.5)
TBA 200B Temperature, °C (°F): Max. 20 (68)
Consumption, production:
Filled product type Sterile air compressor, l/min: 8
Sterile air compressor plus cooling
Non viscous product only
system compressor, l/min: 14-16
Product supply Water supply (hot)
Connection pressure, kPa (bar): 160±40 (1.6±0.4) Connection pressure, kPa (bar): 300-450 (3-4.5)
Temperature, °C (°F): 55-60 (130-140)
Steam Consumption
production: 0
Connection pressure, kPa (bar): 170±30 (1.7±0.3) External cleaning, l/cycle: 250
Temperature, °C (°F): 130 (266)
Consumption, kg/h: 2.4 Compressed air
Electricity Connection presssure, kPa (bar): 550–600 (5.5 –6)

Consumption, production, Nl/min: 420
Connection:
Voltage, V: 400/230±10% Detergent (external cleaning)
Frequency, Hz: 50/60±2%
Recommended main fuse, A Alkali, l/cycle: 1.2 (1.8*)
(To obtain selectivity): 125 * Only applicable for optional upgraded external cleaning.
Consumption:
Pre-heating, kW: 31 Cleaning in place (CIP)
Sterilisation, spraying, kW: 27.5
Connection pressure, kPa (bar): Max. 350 (3.5)
Sterilisation, drying, kW: 20
Flow, l/h: Min. 8000
Production, kW: 32
Cleaning, kW: 10
Noise level
Hydrogen peroxide, (H2O2) Sound pressure level, Lp dB(A): 77
Consumption, l/h: ≈4
Installation drawing No.
648571-3.
TBA 21 MACHINE PULL TAB
IKOS MODENA 5/98
FRIZIO
3906
598
7
Tetra Pak Marketing Services. Promotional Material Code 8201 en. 12.99
2340
5079
18
21
50
70 00
11
85
84
Measurements in mm
Business Unit Tetra Brik We reserve the right to introduce design modifications without
prior notice. Tetra Pak and Tetra Brik Aseptic are trademarks
belonging to the Tetra Pak Group.
Technical Data: Tetra Brik Aseptic filling machine TBA/22
Capacity filling machine
Packages per hour: TBA 250B 20000

TBA 200B
Filled product type
Non viscous product only
Product Supply
Connection pressure, kPa (bar): 160±40(1.6±0.4)
Steam
Connection pressure, kPa (bar): 170±30(1.7±03)

Temperature, C° (°F): 130(266)
Consumption, kg/h: 2.4
Electricity
Connection:
Voltage, V: 400/230±10%
Frequency, Hz: 50/60±2%
Recommended main fuse, A
(To obtain selectivity): 125
Consumption:
Pre-heating, kW: 31
Sterilization, spraying, kW: 27.5
Sterilization, drying, kW: 20
Production, kW: 32
Cleaning, kW: 10
Hydrogen peroxide, (H202)
Consumption, I/h: ≈4
Water supply (cold)
Connection pressure, kPa (bar): 300-450 (3-4.5)
Temperature, 00 (°F): Max. 20(68)
Consumption, production:
Sterile air compressor, L/min: 8
Sterile air compressor plus cooling
system compressor, l/min: 14-16
Water supply (hot)

Connection pressure, kPa (bar): 300-450 (3-4.5)
Temperature, C°(0F): 55-60 (130-140)
Consumption
production: 0
External cleaning, I/cycle: 250
Compressed air
Connection presssure, kPa (bar): 550—600(5.5 —6)

Consumption, production, NI/mm: 420
Detergent (external cleaning)
Alkali, I/cycle: 1.2 (1.8*)

* Only applicable for optional upgraded external cleaning.
Cleaning in place (CIP)
Connection pressure, kPa (bar): Max. 350 (3.5)

Flow, I/h: Min. 8000
Noise level
Sound pressure level, Lp dB(A): 77
Installation drawing No. 648571-3.

2 Machine body
2.2B3023B00en.fm

6 Service unit
2.2B3023F00en.fm

2.2B3023A00en.fm

3 Drive
3-1 Drive - description

SPC reference 648523-0400
3.6
3.5
3.3
3.2
3.1
2.2B3023C00en.fm
3.5
3.4
3.1 Drive, jaw unit

3.2 Drive, design correction
3.3 Volume adjustment
3.4 Drive, final folder
3.5 Plates
3.6 Photocell unit
176 Doc No. MM-82302-0103 Tetra Pak

3
TPMS service system

Tetra Pak Maintenance System
Broschyr 9934 en
4
Packaging material/
package integrity

Packaging material
TETRA
PAK
Lund, Sweden
Machine type
TBA/3 −8 −9
Issue
3/9003
OH 135:5
1 Outer coating (polyethylene) 5 Paper board (unbleached)

2 Paper board (Bleached) 6 Printing
3 Alifoil 7 Lamination (polyethylene)
4 Internal coating 1 8 Internal coating 2 (polyethylene)
Packaging material,
TBA/m and TBA/j
Moisture
or water
Product
Light
Micro
organism
Oxygen
Flavour
Odours
Internal coating 2 Alifoil Paper board Printing

Internal coating 1 Lamination Paper board Outer coating
Technical Training Centre Machine type Issue

Lund, Sweden Tetra Brik Aseptic 1/9501 OH 526
Lightbrown
Creases Alt. 2
1 Top fin crease 6 Double crease

2 Top crease 7 Top flap crease
3 Longitudinal crease 8 Bottom flap crease
4 Bottom crease 9 Spout crease
5 Bottom fin crease 10 Perforation

TETRA
PAK Lund, Sweden TBA/3 −8 −9 3/9003 OH 135:4
Inner coating
Paper board
Cooling water
Product
Principle of ridge inductor sealing

2
1
Tetra Pak Processing & Packaging Systems AB Machine type Issue
Technical Training Centre, Lund, Sweden 2/9402 OH 225
Longitudinal seal (LS)
Paper board
Internal coating
LS strip

Lund, Sweden 1/9501 OH 527
Longitudinal seal (LS) strips
Lund, Sweden
Machine type
LDPE LDPE LDPE LDPE

Primer Primer Primer
HDPE PET EVOH PET
Primer Primer Primer

Issue
LDPE
LDPE LDPE LDPE
1/9411
LHL−STRIPS PPP−STRIPS LSE−STRIPS WINE−STRIPS

7,5/0,1 7,5/0,075 7,5/0,075 7,5/0,075
OH 512
62125 409813 115382 144536

code number code number code number code number
Normally used for Used for most Used for products Must be used
UHT milk and water filling products sensitive to exposure when filling wine
of oxygen
Tetra Brik Aseptic
Transversal Sealing
Evaluation
5
Supply systems

Superstructure
Lund, Sweden
T4301 Y1501 Y1303
Y2104
T5306
T4230
T1501
Y1502
Y1301
Y1324
Y1401
Valve panels
T1502
Y5504 Y1302 Y1223
T4220
T1231
Y1311 Y1112
T4210
Machine type
Y5501 Y1111
T4200
Y1316 Y1107
TBA/22
Y1220 Y1325 Y1108
Y1221 Y1114:2
ASU Y1114:4
Y5306 T3109
Y3110
Y3109
Y3103
Y3111
Y3112
Y6203
Y4230
Y6205
Y4220
Service Unit
Y7303
Y4210
Issue
Y7315
Y4200
1/9905
Y7407 Machine Body

T2201 A2201
Y7408 B2201 Y2201
P2
Y7410
OH 829
Y7411
U2201
Y7412 P1
Y7413
Z2201
Y7425
Air Supply Unit
Pneumatic panel
Y 3112
Y 3111
Y 3110
T 3109 Y 3103
U 3109 Y 3109
Y 2201
B 2201
5
A 2201
T 2201
U 2201
Z 2201
Connection block
Air
2
Ice water, inlet
Cold water
Ice water, outlet

3 Supply HI−HL
4 1 Air inlet
2 Air jet gun
Central refilling of
3 Pilot air
hydrogen peroxide
4 ASU, pull tab, superstructure
and mascine body
5 Service unit Hot water

Lund, Sweden TBA/22 1/9905 OH 830
Pneumatic system
Lund, Sweden
Overview
Valve panel ASU

Machine type
Valve panel Valve panel

Superstructur Machine body
TBA/22
Valve panel
Service unit
P2
Issue
Air supply unit

1/9905
P1
OH 831:1
Flow line P1
Flow line P2
Control flow line
Return flow line
Air jet gun

Pneumatic system F1231
U1231 U1502 U1501

Lund, Sweden
Superstructure Spraying
T1231 T1502 T1501
Colum ball / lid D−valve F−valve

cleaning product sterile air
C31162
Preheating Cleaning B−valve A−valve Squee−gee Pendulum
Machine type
Step 2 sleeve roller roller
F13111
F13112
C1114 F1325 C31161 F1302 F1301 C1502 C1501
TBA/22
Y1114:4 Y1114:2 Y1325 Y3116 Y1311 Y1302 Y1301 Y1502 Y1501

Issue
1/9905
Heat exchanger valve Preheating Reference Top filling Movable lower E−valve C−valve
Step 1 Step 2 Step 1 Point H2O2 bath forming ring CIP in
C1108 C1107 C1111 C1112 F1223 C1401 F1324 F1303

OH 831:2
S1303
Y1108 Y1107 Y1111 Y1112 Y1223 Y1401 Y1324 Y1303
Regulating valve
Y1304 F1304
P2 P1
Pneumatic system
Lund, Sweden
Machine body Tube altitude

Z43012
Filling H2 O2 −tank
Z43011 U1210
Y1210
U4200 U4210 U4220 U4230 U5306 U4301 T1210

Machine type
Z1210
T4200 T4210 T4220 T4230 T5306 T4301
TBA/22
Flap heating top Flap heating bottom Package Draining Filling bath Waste box Outfeed of Flushing F.F. Tube flusher
Right Left Right Left blowing peroxide bath waete in front
F1221 F1220 C5501 C5504 S21041 S21042
Issue
1/9905
Y4200 Y4210 Y4220 Y4230 Y5306 Y1221 Y1220 Y5501 Y5504 Y2104
OH 831:3
P1 Superstructure P1 ASU
P1 P2 P2 Superstructure
Pneumatic system
Lund, Sweden
Service unit
Foaming Flushing Aseptic chamber Jaw system Final folder
cleaning cleaning cleaning
Machine type
TBA/22
Issue
3/9904
Flow line
Control flow line
P1 Return flow line
OH 831:4
Pneumatic system
Lund, Sweden
ASU
Heating Photocell Cooling Material Material Web Pressure Cutting Material Side feeder Side feeder Ventilating valve
device lock 1 lock 2 tension rail holder pos 1−2 pos 2−1
Inductor Heating
device
Machine type
TBA/22
Issue
1/9905
OH 831:5
Flow line
Control flow line
P1 Return flow line
Air conditioning units
Pneumatics
Technical Training Centre, Lund, Sweden 1/9411 OH 511:1
Seat and slide valves
Non–actuated Actuated
Seat
Valve head
Housing
Return spring
Housing
Slide
Pneumatically operated slide valve
Pneumatics
Direction of movement
Force
Speed

Pneumatics
Control signal
4 2
14
5 1 3

14
2
3
1
4
5
5/2 monostable directional valve
14
Pneumatics
3
1
4
5
14
2
3
1
Valve with separate air supply to pilot valve
5
14
Pneumatics
3
1
4
5
14
2
3
5 1
4
12
5/2 bistable directional valve
14
Pneumatics
3
5 1
4
12
Pneumatics
3−position directional valve
4 2
4 2
5 1 3
12 14 12 14
5 1 3

Pneumatics 2
Soft−start valve 3 1
12
1 2 3
12
1 2 3
12
1 2 3
12

Pneumatics
Vacuum ejector, controlled by solenoid
3
1
Vacuum ejector, controlled by compressed air
1 3

Pneumatics
Single−action cylinder
Double−action cylinder
Rod−less cylinder

Dampening
Undamped
Piston
position
To hard damped
Correctly damped
Time
Pneumatics
Throttle valve
Throttle check valve

Magnetic piston sensor
Pneumatics
Pressure gauge
Condensate water
Air user
Air user
Air user
Air user
Main air supply line
Pneumatics
Shut−off valve
Pneumatics
Function principle
Valve cabinet
Y08
1 3
U05 Suction cups

B06
Hot melt pump
T05
U04
C4
Z04
T04 Valve panel
Y03
U03
C3
T03
Y02
C2
24
5
4
3 1
22
Y01
C1
YO00
Pressure A1 Z1 T1 U1
supply
Z2

Pneumatic system TBA/3
Lund, Sweden
C14 Superstructure Machine body

Product
valve Separator Jet diverter LS- and SA- Drop Paper Air jet Air jet
heat exchanger valve hot air element chute brake drop shute pistol
C16 C15
C12 C9 C7 C2 C8 C13
Steam barrier Sterile air
valve valve
Machine type
36 3 39 32 33 41 42 37 38 9 8 35 15 24
TBA/3 87
2 2 2 4 2 4 2 4 2 4 2 2
L18 L19 L16 L41 L4 M8 L5

1 3 1 3 L34 1 3 51 3 5 1 3 L20 5 1 3 51 3 1 3
2 T7
S1 Guard
1 D2
M7
RT1
T3 A2
Issue
M3 Valve
9606
L12 3 1
L11 3 1 L9 3 1 L7 3 1 L10 3 1 panel A1 T5:2 T5:1 T5:3
2 2 2 2 2
M5:2 M5:1 M5:3
- - 13 12 11 14 27 7
OH 581
Element Element Element

C4 C3 C5
FS top left FS bottom FS top right
C6
Cut left Cut right Left Right
Design correction
Jaw system Final folder
Pneumatic system TBA/8
Technical Training Centre, Lund, Sweden
Tetra Pak Processing & Packaging Systems AB
SUPERSTRUCTURE
AIR SQUEE−GEE UPPER SUCTION AIR INLET HEAT ELEMENT MOVEMENT VACUUM LS − COUNTER PEROXIDE BATH
KNIFE ROLLER EJECTOR VALVE VALVE EXCHANGER SA LS ASEPTIC SHORT STOP ELEMENTS ROLLER TOP FILLING
LEFT RIGHT VALVE CHAMBER MOVEMENT SHORT STOP AIR
C24:2 SA LS
C21:1 C21:2 C21:3 54 C23 C44:1 C44:2 C24:1 F18 COMPENSATION
C26 VALVE
2
Y70
12
3
1
C86 C20:1 C20:2
C44:3 LOWER
SUCTION VALVE
C71:1
PREHEATING VALVE
710 711
Y71
4
2
212 210 211 540 231 230 440 441 240 241 860 861 201 200 260 261 181
1
3
5
SPRAY TANK
JAW SYSTEM M21
Y35
12
AIR
12
Y34
2
C14 Y21 Y54 Y23 Y44 Y24 Y86 Y20 Y26 Y18 3 3
4
4
2
2
2
4
2
4
2
4
2
4
2
4
2
4
2
Machine type
1 2 2 1
RIGHT 1 41
1
1
1
1
3
3
3
3
5
5
5
5
R A B C D R T21
141 M4
STEAM BARRIER
121 Y14
4
2
VALVE C
131 90
B2 C7
1
Y102
3
5
T4
1
5
3
781 GUARD
PRODUCT
TBA/8 100V
Port 14
4
2
681 VALVE A
Y12 F102 Y9
VALVE PANEL
4
2
4
2
R A B C D R
1020 C9
1
1
3
3
5
5
LEFT 1021
C13 M3 70
Y13 MACHINE BODY Y7

4
2
4
2
AUTO CORRECTION
STERILE AIR
1
1
3
3
5
5
C8 VALVE B
80
Y78 RT1 Y8
4
2
4
2
Issue
1
3
3
5
5
1/9501
A7 T1
1
1 T68 1 T84
M84 PT10 2
2 2 M1 T55
M68 Y6 Y5 Y17 Y47 Y45 Y46 Y2 Y27 Y28 Y1 1
1
1
5
3
5
3
5
3
5
3
5
3
5
3
5
3
5
3
5
3
5
3
Port 14
4
4
2
4
2
2
AIR
M55
OH 487
841 61 51 171 1 471 451 461 21 271 270 280 11 550
1 C2
M38
2 C27 AIR FLAP FINAL
T38 CLEANING
12 F6 12 F5 Y38 C47 TRAY DROP NOZZLE SEALING FOLDER
C45 C46:1 C46:2 DRAINING CHUTE AIR LOWER
12
1
3
1 2 1 2
M PART
2
PHOTO AIR SPLICER DRIVE UNIT DATING SPLICER

PEROXIDE PEROXIDE CENTRAL PRESSURE UNIT BRAKE
CELLS BATH BATH LUBRICATION JET REFILLING PRESSURE
PISTOL PEROXIDE JAW ROLL STOP
FILLING DRAINING PUMP
DRAINING
MACHINE BODY AUTOMATIC SPLICING UNIT FINAL FOLDER UNIT

General
The technology of using compressed air to create movement is termed
Pneumatics. In the Tetra Pak packaging machines and distribution equipment,
compressed air is used to:make components move, operated by pneumatic
cylinders
• make components move, operated by pneumatic cylinders
• control and operate valves
• create vacuum and supply air nozzles with air
The pneumatic system consists of two parts. One part is located external to the
machine; in it, the required pressure is generated. The external pneumatics
include compressor, air conditioning unit, main air supply line, etc. The other
part is inside the machine and includes regulators, valves, cylinders, etc.
The air used in the pneumatic components must be clean and dry; pressure and
flow rate must also be as required. The recommended values are specified in
the installation manual (IM) for the machine concerned. In some systems, the
components are factory prelubricated once and for all, requiring no further oil
or grease; air for these components must be as free from oil as possible.
However, if such a component is once mist lubricated, it must always be mist
lubricated from then on.
The pneumatic system of each machine is documented in the form of a
diagram. In order to simplify its construction and make the diagram easier to
read, the various components are shown as symbols.
Pressure Shut–off Pressure regulator

source valve with gauge Valve Cylinder
As there are many models and versions of machines, and some of them have
been rebuilt or modified to differ from their original design, it is very
important that the correct, up–dated, and currently valid pneumatic diagram is
used when working with a particular machine.
Technical Training Centre 1/9411 Training Document. For training purpose only. 3
Components
Air conditioning units
The first unit the air passes through on its way to the machine is the air
conditioning unit. It consists of a separator, pressure regulator with pressure
gauge, and, on some machines, lubricator. Normally, a shut–off valve is built
into the conditioning unit.
Pressure regulator
Shut–off valve
Air conditioning unit symbol
Pressure gauge
Separator
Lubricator
The purpose of the separator is to remove water and other pollutants that might Separator
be present in the compressed air. The separator consists of a filter element and
a reservoir with a drain valve. The filter element may be made of sintered
bronze. The input air is made to rotate, so that water drops and the larger solid
particles are flung outwards against the inner surface of the reservoir.
Condensated liquid runs down to to bottom of the reservoir, where it is
removed through the drain valve when the input air is turned off.
The purpose of the pressure regulator is to provide air at a constant pressure, Pressure regulator
independent of the load on the system. It is a form of pressure reduction valve,
and its function will be explained under the heading of Valves.
The pressure gauge indicates the pressure setting. Pressure gauge
The lubricator (mist lubricator) provides the compressed air with oil. The Lubricator
injected amount of oil is proportional to the flow rate of the air and can be
preset. In systems whose components are factory prelubricated, no oil must be
added to the compressed air, as oil would wash out the grease in the
prelubricated components.
4 Training Document. For training purpose only. Technical Training Centre 1/9411
Valves
The purpose of valves is to regulate the flow rate and pressure of the
compressed air and control its flow direction. The valves are controlled and
operated either manually, by means of electrical signals from the PLC, or
pneumatically by other valves.
Valves are subdivided into two groups – seat valves and slide valves. These
groups differ in their design.
Seat valve The seat valve controls the flow of air by means of its valve head and seat. The
valve head only has to move a short distance to change over but needs
considerable change–over force.
Seat
Valve head
Housing
Return spring
Slide valve The slide valve controls the air flow by means of a movable slide. To change
over, the slide has to move a relatively long distance, but the force needed for
it is small.
Housing
Slide
Return spring
In respect of their purpose, valves are grouped as follows:

• directional valves, controlling the flow direction of the compressed air, for
instance to operate the reciprocating movement of the piston in a pneumatic
cylinder.
• flow rate regulating valves, controlling the amount of air per time unit, for
instance to control the speed of the piston in a pneumatic cylinder.
• pressure regulating valves, controlling the pressure in the pneumatic sys-
tem.
Before proceeding, we shall take a look at the symbols for the valves, and how
they are constructed and function.
The valve symbols denote the function of the valves but not their design. This Valve symbols
means that valves that look differently, due to the way they are designed and
constructed but function in the same manner, are shown with the same symbol.
The illustration shows the working principle of a slide valve, which may be in
either of two positions.
Outlet.
Port for output air Slide
Pilot air
Pilot air
Valve
housing
Inlet. Vent.
Port for input air Port for evacuation
Position 1 Position 2
The valve has received pilot air on the The valve has received pilot air on the
lefthand side. The passage between in- righthand side. The inlet is closed, and
let and outlet is open, and the vent is the passage between outlet and vent is
closed open.
This valve can be shown simplified as a symbol.

The symbol consists of a square, with the ducts through which the air is able
to pass shown as arrows. To the left and right of the square, the manner in
which the valve is controlled is symbolised, for instance with a horizontal line
for pneumatic control. The lines above and underneath the square represent the
ports connected to the input and output air lines.
Outlet Valve housing
Pilot air Pilot air
Inlet Vent
The valve symbol is shown with The valve symbol is shown with
open passage between inlet and open passage between outlet and
outlet, and closed vent. vent, and closed inlet.
The function of the valve is illustrated by means of symbols. Each position the
slide may be in is shown as a symbol, and the symbols are drawn after one
another. The ports are only shown on the symbol in active position in the
pneumatic diagram, which is the starting position of the valve.
Outlet
Active part of
symbol
Pilot air
Inlet Vent
Compressed air supply.
The pilot air is received on the lefthand side The pilot air is received on the right-
of the symbol, which means that the lefthand hand side of the symbol, which means
side of the symbol is active. Compressed air that the righthand side of the symbol is
passes through the valve and can actuate a active. The air in the
cylinder cylinder can be evacuated.
To make it easier to identify them, the ports are numbered: input air port – No
1; output air port – No 2; vent port – No 3. The pneumatic signal ports take
their numbers from the ports they provide passage between; for instance, port
No 12 connects input and output air.
2
12
1 3
As the valve in the example has three ports and a slide which may be in two
positions, it is termed a ”3/2 valve”. Similarly, a five–port valve with a three–
position slide becomes a ”5/3 valve”.
The valve may be operated in several ways. Other than pneumatically, it can
be operated manually, by a spring, or electrically. The different ways are
shown as symbols. In the following example, an electrically operated 5/2
valve with spring return operates a double-action pneumatic cylinder.
Cylinder
Control signal Outlet ports

4 2
14
5 1 3
Return spring
Vent port
Vent port
Inlet port
The control signal is received on the The control signal is discontinued, and
lefthand side of the symbol. Compressed the return spring moves the slide. The
air passes through the valve and into the compressed air is now directed to the mi-
plus compartment of the cylinder, while its nus compartment of the cylinder, while
minus compartment is vented. its plus compartment is vented.
The various forms of valve symbols used in our pneumatic diagrams are
explained in greater detail in the section of this text where the function of the
valves is described.
The monostable valve features spring return, i e in idle position, the slide is Monostable directional
always in the same position. One advantage of this type of valve is that it is valve
possible to operate a cylinder in both direction with only one control signal
output from the PLC.
Electrically controlled, monostable valves are used extensively in Tetra Pak
machines. The pilot air is controlled by means of an solenoid, powered by 24
or 48 V DC from a PLC output. The pilot air system is an integral part of the Electrically controlled,
directional valve. monostable directional
valve.
Cylinder
Electrically controlled,
monostable valve 4 2
Seal
Pilot valve
Solenoid
5 1 3
14
From PLC
In those cases where the valve receives air with a reduced pressure, which is
lower than the change–over pressure of the valve, the pilot valve can be
supplied separately with air from the pneumatic system. On some valves, for
instance Mecman Series 581, change–over is effected by turning the seal monostable directional
between the valve proper section and the control section upside down. Then valve with separate air
supply to pilot valve.
control port No 14 in the connection plate is connected directly to the
compressed air system.
Electrically controlled, monostable valve with sepa-
rately supplied solenoid valve
4 2
Seal
Pilot valve
Solenoid
5 1 3
14
Pressure regulator From PLC
Bistable directinal valve The valve has no spring return, and thus the slide can be in either of two idle
positions, depending on which one of the two solenoids was most recently
activated. Consequently, two outputs from the PLC are always required to
control a bistable valve.
bistable directional valve
4 2
5 1 3
12 14
From PLC
From PLC
Valves of the bistable type are used if, for instance, it is desirable that the
cylinder is to remain in the position it moved to as a result of the most recent
valve operation, even if the the output signal is discontinued. The same
standard principle for numbering the ports applies to this kind of valve. Pilot
air at port No 12 connects ports No 1 and No 2, pilot air at port No 14 connects
ports No 1 and No 4, in both cases admitting passage of input air.
This valve type is used, for instance when a cylinder is to remain in position 3-positioned directional
at an emergency stop. Below, an electrically controlled 5/3 valve is illustrated. valve
4 2
Electrically controlled, 3–
positions directional valve
with closed middle posi-
tion.
5 1 3
14 12
No control signal to ports No 12 and No 14 means that the return spring

positions the slide in the middle; all ports closed.
4 2
5 1 3
14 12
On port No 14 receiving a control signal, the slide moves to the right in the
picture. This means that port No 1 is connected to port No 4, and port
No 2 to port No 3.
4 2
5 1 3
14 12
On port No 12 receiving a control signal, the slide moves to the left in

the picture. This means that port No 1 is connected to port No 2, and
port No 4 to port No 5.
The valve can be in three positions. In addition to the two positions of a 2–

position valve, the 3–position valve has a middle position with all ports
closed(as exemplified above) or open for venting. Two PLC outputs are
required to control the valve. If there is no signal when the system is
depressurised, the return spring puts the valve in its middle position.
Soft-start valve This type of valve is used in order to make pressurisation of the pneumatic
system soft and smooth.
Variable stop Telescoping slide
1 2 3
12
Idle position.
In idle position, ports No 2 and No 3 have an
open connection. The pneumatic system is
depressurised.
1 2 3
12
Pressurisation phase.
During the pressurisation phase, the connection
between ports No 1 and No 2 is partly open, and
pressurisation has begun. The width of the open-
ing is regulated by means of a variable stop (limit
screw).
1 2 3
12
Full flow.
When the pressure has risen to approximately
75% of the pressure in the compressed air supply
line, the connection between ports No 1 and No
2 is opened all the way.
The three positions of the telescoping slide are illustrated, somewhat

simplified. When the control signal is received, the slide moves up against the
variable stop, opening a narrow connection between ports No 1 and No 2
(pressurisation phase). When the pressure has risen to approximately 75% of
the pressure in the compressed air supply line, the valve opens all the way. On
depressurisation or at an emergency stop, the valve provides full flow directly
between ports No 2 and No 3 (depressurisation).
This kind of valve is used to regulate the flow of air, which is restricted equally Throttle valve
much in both directions.
1 2
Throttle valve Throttle fitted in

directional valve
If throttles are incorporated in a directional valve, they are fitted in the outlet
ports and consist of brass screws. Normally, such throttles are factory fitted in
most of our directional valves. Normally, they provide adequate speed
regulation accuracy.
This kind of valve is used when the air is to be regulated in one flow direction Throttle check valve
only.
1 2 1 2
When the air flows from port No 1 If, on the other hand, the air flows from
to port No 2, it must pass through port No 2 to port No 1, it passes through
the throttle and can thus be regulat- the check valve without being regulat-
ed. ed.
In order to achieve better accuracy in speed regulation, throttle check valves

can be used, for instance fitted in the end sections of the cylinders. This is done
when the cylinder is located remote from the directional valve. If throttle
check valves are being used, the throttles integral with the directional valves
must be fully open; adjustment must only be made by means of the throttle
check valves.
This is a manually operated ball valve, used to shut the supply of air to the Shut-off valve
entire pneumatic system. Normally, it is built into the air conditioning unit.
The pressure switch triggers an alarm to the control system, if the pressure Pressure switch
drops below a preset value. This value can be adjusted.
Pressure regulator Correctly set pressure is a condition of correct speed control and correct force.
For this reason, a pressure regulator is a always fitted in the air conditioning
unit. To enable the pressure regulator to function well, there must be a pressure
difference between input and output air of not less than 0.8 bar. Some
machines have an extra pressure regulator within the pneumatic system for the
purpose of allowing the reduction of the air pressure to some of the cylinders.
Outlet pressure
set screw
Force spring
Diaphragm
Inlet port
Outlet port
Seat
Valve plate
The valve plate of the seat valve is operated by the diaphragm, which in its turn
is actuated by the outlet pressure of the pressure regulator. The force created
by this pressure is balanced by the spring force on the other side of the
diaphragm. By increasing the spring force by turning the set screw, the seat
valve is opened and is kept open until the outlet pressure exceeds the spring
force. Thus the diaphragm and the spring force together maintain a constant,
preset outlet pressure. If the pressure on the outlet side drops, for instance due
to air used in moving a cylinder, the seat valve opens again.
Vacuum ejector with valve This valve generates underpressure through its ejector effect. It is used, as an
example, to supply a vacuum to suction cups. There are two types of vacuum
valves. One type which is electrically controlled and generates a release pulse
when the direction of flow is reversed. The other type in entirely pneumatic
and generates the release pulse by means of a built–in accumulator.
1
3
1 3
2
Electrically controlled
vacuum ejector 2
Pneumatically controlled
vacuum ejector
Cylinders
The purpose of a pneumatic cylinder is to perform a movement, powered by
compressed air.
In simple terms, the pneumatic cylinder consists of a cylinder housing with
two end sections, a piston with piston rod, and two connections to the
pneumatic system.
Plus compartment Minus compartment
Piston rod
Rear end Connection Piston Cylinder housing Connection Front end

section section
The piston is provided with seal–rings, separating the two compartments. The
front end section has a piston rod guide and seal.
When compressed air is admitted into the plus compartment (pressurisation),
and the air in the minus compartment is vented, or evacuated
(depressurisation), the piston rod extends out of the cylinder – the piston
performs a plus stroke. If the flows of air are reversed, the piston rod is
withdrawn into the cylinder – the piston performs a minus stroke.
Plus stroke Minus stroke
The cylinder described above is a double–action cylinder with single–side Double-action cylinder
piston rod. This means that both the plus stroke and the minus stroke are
performed powered by compressed air, and that there is a piston rod at one end
only.
Single-action cylinder In the single–action cylinder, a spring effects the minus stroke.
Spring
Piston rod
Rod-less cylinder Such a cylinder is double–acting, but its piston rod has been replaced by an
attachment sliding along the outside of the cylinder shell. The movement may
be transferred to the attachment mechanically or by means of magnets.
Attachment
Connection Piston Cylinder Connection End section

End section housing
Magnetic piston sensor A magnetic piston sensor is fitted on the cylinder for the purpose of giving the
PLC information on the current piston position. This information is then
utilised by the PLC as a precondition of, for instance, the changing over a
directional valve etc.
Magnetic piston sensor
Fully electronic magnetic piston
sensor; when the magnetic field of
the piston alters the resistance in
a semiconductor element
inside the sensor, an output
signal is transmitted to the PLC;
the sensor has a switch–off delay
of 20–30 ms.
Magnetic piston
Double–action cylinder with mag-

netic piston
When replacing a cylinder with a magnetic piston, it is important that the
replacement cylinder also has a magnetic piston. A cylinder with the correct
length of stroke and diameter, but without magnetic piston, will not actuate the
magnetic piston sensors.
The direction, force, and speed of movement of the piston rod can be
controlled. To ensure that the piston rod stops moving softly and smoothly,
there are also end position dampers. The various functions are explained in the
following.
The direction of movement is controlled by directional valves.. Direction of movement
In order to control the movements of a double–action cylinder, a five–port

valve is required. As the valve is actuated by a control signal, its slide changes
over, and the compressed air is led to the plus compartment of the cylinder,
while the minus compartment is vented. The piston performs a plus stroke. If
the control signal is discontinued, the return spring of the valve moves the
slide back again, and the flow of air reverses direction; the minus compartment
is filled with air, the plus compartment is vented, and the piston makes a minus
stroke.
The force which the piston rod exerts on the load, is regulated by varying the Force
pressure of the air – reducing the pressure decreases the force. The pressure is
controlled by means of a pressure regulator.
Pressure regulator Valve Cylinder
Speed The speed of the piston is regulated by varying the flow of air on the return
side in the cylinder. This is done by means of the throttles in the valve, or with
throttle check valves fitted in the line between the valve and cylinder.
Throttle check
valve
Throttle in
valve outlet
port
Speed regulation by means

of throttles in valve
Speed regulation by means of
throttle check valves; throttles in
valve to be fully open
The reason why throttling is done on the return side of the cylinder is to make
the movement smooth.
Pressure
Correct (vented air throttled)
Wrong (input air throttled)
Time
If the cylinders used are small, or the air lines between cylinder and valve are
long, the alternative of employing throttle check valves offers better speed
regulation accuracy; the valve throttles must in this case always be fully open.
The movement of the piston is dampened at both end positions by built–in Dampening
dampers in the cylinder end sections. The dampening effect is regulated with
adjustment screws. The purpose of the dampers is to decelerate, i e slow down
and stop, the piston a smoothly. In this way, damage to the cylinders, caused
by the piston striking the cylinder end section with some force, is eliminated.
Double-action cylinder with vari-
Dampening also reduces vibrations in the machine. If, on the other hand, the able end position dampening
dampening effect is too great, the piston may bounce back and come to a stop
with a jerk.
Cylinder end Adjustment
section screw Piston
The air on the vent side of the cylinder passes through

the large, central opening in the cylinder end section
A protrusion on the piston closes the central opening in the

end section, so that the vented air is forced through the nar-
row duct, in which the adjustment screw enables the flow,
and thus dampening effect on the piston, to be regulated.
In order to successfully set both speed and dampening, it is important first to

make sure that the pressure in the system is correct. Thereafter, the cylinder
speed can be set, and lastly, the dampening effect.
Undamped
Piston
position
Damped too much
Correctly damped
Time
Main air supply line
Shut–off
valve
Pressure gauge
Air user
Air user
Condensate water
The main air supply line should form a ring main line through the premises;
this will allow the users of air to receive it from two directions. There should
be a drop of 5–10 mm per metre in the direction of flow. Underneath the
lowest point in the ring line, a condensate drain cock is to be fitted. The output
connections to the users should be fitted on the top side of the main line piping;
this will keep condensate water and dirt from following the air into the user
device. There should also be a pressure gauge to make it possible to check that
correct air pressure is being maintained.
The diameter of the main line piping depends on its length as well as the
number of pipe bends and elbows, connections, and valves in the line. The
larger the number of such components that the air must pass, the bigger the
pipe diameter must be to prevent excessive pressure drop up to the points
where the air is used.
The pipe–lines should be be installed so that they are easily accessible for
checking that they are tight.
Function principle
This is an example of a principle diagram of a pneumatic system:
Valve cabinet
Y08
1 3
U05 Suction cups

B06
Hot melt pump
T05
U04 C4
Z04
T04 Valve panel
Y03 C3
U03
T03
Y02
C2
24
5
4
1
22
3
Y01
C1
YO00
U1
Pressure
supply
Z2
A1 Z1 T1
The input compressed air passes through manual valve A1, water separation
filter Z1, and pressure regulator T1; pressure gauge U1 indicate the pressure.
If the pressure drops below a preset value, pressure switch B06 indicates a
warning by lighting a signal lamp on the control panel. The pressure switch
should be connected as the last component in the system in order to sense the
pressure drops created by the other components.
Pressurisation valve YO00 is used to make pressurisation of the system slow
in order to allow cylinders in wrong positions to return smoothly to their
correct idle positions. The pressurisation time can be adjusted by means of an
adjustment screw in this valve. Valve YO00 also has a safety function, for
instance if an emergency stop requires the system to be instantly
depressurised.
Valve Y01 is a 3–position valve with closed middle position. If, for instance,
the machine is emergency stopped, the valve moves to the middle position,
and cylinder C1 remains in the position it was in at the stop.
A manual valve
B cylinder Valve Y02 is monostable and electrically controlled. It has throttles in its
C cylinder outlet ports for regulating the speed of cylinder C2.
T pressure regulator
U pressure gauge Valve Y03 is also monostable and electrically controlled, but its pilot valve is
Y electrically controlled supplied with air separately from a line, connected before soft–start valve
valve
YO pressurisation valve YO00. This means that valve Y03 does not have to wait for the slow build–up
Z filter of pressure via the soft–start valve but changes over instantly as soon as valve
A1 opens. The separate supply of air also allows valve Y03 to be supplied with
air at a reduced pressure, for instance to limit the force of cylinder C3.
Pressure regulator T04 regulates the pressure to cylinder C4. This cylinder acts
Pressurisation as an air spring, and for this reason, an accumulator is connected to the air line.
Control line Pressure regulator T05 regulates the pressure to the hot melt pump and thus
Depressurisation controls the amount of hot melt adhesive to be extruded.
Vacuum line
Valve panel
Y08 consists of a vacuum ejector and two valves. When the righthand valve is
activated, compressed air flows from port 1 to port 3 and, due to the ejector
Valve cabinet
effect, a vacuum is generated at port 2, to which the suction cups are
connected. When the lefthand valve is activated, compressed air is supplied
directly to the suction cups, which thus are receive a blast of air, releasing their
suction and blowing their ducts clear.
Silencer Z2 is common to the whole pneumatic system.
The designations in the diagram follow a certain system, usually consisting of
a letter and a number. The components which the compressed air comes to first
are given the same number, in this case 1, but different letters to denote their
functions: A for manual valve, Z for filter, and T for pressure regulator. The
number of a valve, for instance Y02, determines the numbers of the following
components. The output lines from the valve are given numbers beginning
with 2, followed by the number of the outlet port, i e numbers 22 and 24. The
cylinder is designated C2.
Whenever setting is done in the pneumatic system, it is important to do it i the
right order:
1input pressure
2speed (throttle check valves or valve throttles)
3dampening (end position dampers in cylinders)
Symbols
The following table, which is an excerpt from the Tetra Pak Standards (DS
208.35), lists the symbols that are normally used in our pneumatic diagrams.
Symbol Meaning
Single–action cylinder with return

stroke by spring.
Double–action cylinder with

single–ended piston rod.
Double–action cylinder without pis-

ton rod.
Double–action cylinder without pis-

ton rod, with variable dampening at
both end positions.
Double–action cylinder with variab-

le dampening at both end positions.
Double–action cylinder with variab-

le dampening at both end positions
and magnetic piston.
Torque cylinder.
2/2 directional control valve,

controlled by pressure acting
against return spring.

controlled by solenoid with
return spring.
3/3 soft–start valve.


controlled by solenoid with return
spring.

controlled by solenoid valve with
separate air supply.

controlled by solenoid in both
directions.
5/3 directional control valve, closed

in middle position, controlled by
solenoid and return spring.
5/3 directional control valve, open

in middle position, controlled by
solenoid and return spring.
Variable throttle valve.
Non–return valve with variable

throttle check.
Rapid–exhaust avlve.
Pressure regulator with relief port,
spring controlled. Adjustable spring
force.
Shut–off valve with exhaust port.
Silencer
Accumulator
Separator with water trap and

automatic drain.
Lubricator.
Air conditioning unit,

consisting of filter, pressure regula-
tor, pressure gauge, and lubricator.
Pressure gauge.
Electric pressure switch with

change–over contact and
variable pressure setting.
Magnetic piston sensor.
Ejector.
Water panel
Filter
1
Ball valve
Pressure gauge
Pressure switch
B 2102
Solenoide valve
Y 2108
Connection block
Air
5 Ice water, inlet

4
3 Cold water, inlet
2
Ice water, outlet
Supply HI−HL
1 Cold water inlet Central refilling of

2 Flushing final folder hydrogen peroxide
3 Superstructure
4 Spray gun
Hot water
5 Compressor unit

Cooling water system
1
2
3
29 4
28
27
26
25
24 5
23 6
22
21 7
20 8
19 9
18
17
16
15
14
13
12
1 Expansion wessel (O 2530) 11
2 Pressure gauge (U 2501)
3 Temperature sensor (B 2510) 10
4 Conductivity sensor (B 2520)
5 Ion exchanger (O 2520)
6 Filte (Z2520) 15 Regulating valve, capacity (S 2514)
7 Ball valve (A 2530) 16 High pressure transmitter (B 2540)
8 Non−return valve (J 2530) 17 Low pressure transmitter (B 2541) 23 Flow meter, ion exchanger (S 2520)
9 Heat exchanger (K 2550) 18 Cooling compressor (P 2540) 24 Flow meter, LS transormer (S 2320)
10 Water saving valve (S 2550) 19 Pressure switch (B 2501) 25 Bleeding valve (A 2501)
11 Sight glass (U 2560) 20 Security valve (F 2530) 26 Flow meter, final folder (S 5305)
12 Filter (O 2560) 21 Cooling water pump (P 2501) 27 Flow meter, TS transformer left (S 4309)
13 Heat exchanger (K 2510) 22 Flow meter, SA transformer (S 8404) 28 Flow meter, TS transformer right (S 4310)
14 Expansion valve (S 2513) (unused in TBA/21) 29 Ball valve (A 2520)

Lund, Sweden TBA/21 TBA/22 2/0001 OH 832
Infeed slider Tube flusher
Lund, Sweden
Peroxide Sterile
system system
Guide cooling TS−sealing TS−sealing

SA−sealing LS−sealing
final folder left right
Machine type
Flushing
Spray gun final folder
Cooling water system
TBA/22
Cold water
Issue
1/9907
Heat exchanger
Heat exchanger
OH 833
Hot water
Water panel
Compressor unit
Hygenic cleaning system

Water system
Cooling Water
System
General
Tetra Brik filling machines use water to cool different components, like:
• inductors in the jaw system
• guide rails in the final folder
• oil in the hydraulic system
• air in the electrical cabinet
The cooling water system can either be open or circulating. Circulating
cooling water is used when the temperature of the ordinary water supply
is too high, over 20 ˚C. In an open system, the water is consumed, while
a circulating system uses the same water over and over again.
Chilled unit Chilled unit

From cooler
Cooler
Drain Return to cooler
Open cooling water system Circulating cooling water system
Many machines have a separate water cooling system. This means that there
is some kind of heat exchanger between incoming water and water to be
cooled. In an open separate water cooling system, the cooler is part of the
machine.
Chilled unit Chilled unit

Cold water Chilled cold water
Heat exchanger
Heat exchanger
Heat exchanger
Cooler
Open separate cooling water system Circulating separate cooling water system
The cooling system of the machine is documented by means of a diagram.

To simplify the construction and make it easier to understand, the diagram is
made up of symbols for the different components. The design of the cooling
water system varies depending on machine type, development step and
rebuilds. Thus it is important to use the correct cooling water diagram when
working on the machine.
Technical Training Centre 1/9902 TM-00075 Training Document. For training purpose only. 10-1
In order to be able to cool efficiently, the water must be of adequate quality Cooling water
and temperature. Data on water quality to be used for the different machines
can be found in the IM, MM or OM.
The kind and quality of the water differs. Below some examples:
• Raw water is a surface or ground water. Depending on where it is taken, it
contains different ingredients and impurities.
• Drinking water is produced from raw water. Drinking water must not
contain components that may cause illness.
• Deionized water is produced from drinking water. In deionized water you
control the amount of hardening ions.
• Totally desalinated water is also produced from drinking water. All salt
ions, both positively and negatively charged ions, are removed.
Components
A cooling water system is built up of many components. The most important
and frequent ones, are described below.
Manual valves are opened and closed manually. Manual valve

An electrically controlled valve receives a control signal from the machine Electrically controlled
control system when to open and close. valve
A pressure gauge displays the pressure in the cooling water system. Pressure gauge
In order to protect the cooling water system, there might be an over-pressure Over-pressure valve
valve included in the system.
Overpressure valve
The overpressure valve opens up if the pressure in the cooling water system
exceeds a preset pressure. Water is then released, causing the pressure to
decrease in order to avoid damages to the cooling water system.
The filter is used to filter off solid particles and other impurities which may Filter
clog valves and narrow passages, or in any other way affect functions in the
cooling water system.
10-2 TM-00075 Training Document. For training purpose only. Technical Training Centre 1/9902
Magnet device The magnet device prevents forming of lime deposits in the cooling water
system. It is built up of a mechanical filter and a magnet device.
3
4
1
2
• Mechanical filter - The filter basket (1) collects any solid impurities in the
water. Inserted in the filter basket there is a magnet rod (2), collecting any
magnetic impurities like iron chips. The magnet has a plastic cover to
prevent corrosion.
• Magnet separator - This consists of two permanent magnets (4) forming
a gap (3), through which the water flows.
The function of the magnet separator can be described like this:
Between the magnets (4) there is a heavy magnet field. The magnet field
affects the lime in the flowing water so that the lime deposit formed in the
cooling water system does not adhere to the cooling water channels. Instead
the lime deposit will follow the cooling water out to the return line. The
function of the magnet device is temporary.
Magnet field
4
Untreated water. The crystals gather Magnetically treated water. The

and stick easily on surfaces. crystals do not gather and do not stick
on surfaces.
Water tank There is a water tank in some machines, and it works as a reservoir for
the water.
The accumulator is a vessel containing air. The air can be compressed, to take Accumulator
up any pressure variations caused by temperature variations.
A temperature sensor monitors the temperature and signals the control system Temperature sensor
if the temperature raises above or falls under the preset values.
The thermostat is used to keep a constant temperature by regulating the flow Thermostat
and thus the supply of colling water to a component.
A pressure guard monitors the pressure and signals the control system if the Pressure guard
pressure raises above or falls under the preset values.
Heat exchangers are used in a cooling water system to transfer heat from one Heat exchanger
circuit to another, without any direct contact between the medias. The two
main types used are tube heat exchanger and plate heat exchanger.
Cold water
Hot water
Plate heat exchanger
The water pump circulates cooling water, used to cool various components. Water pump
Non-return valves are used in the cooling water system to direct the flows. Non-return valve
A throttle is used to set a desired flow through a component or a part of the Throttle
cooling water system. The throttle can be fixed or adjustable.
The flow meter is a floating body meter used to measure small liquid flows Flow meter
with high accuracy.
In the valve housing of the flow meter, made of transparent plastic, there is a
conical passage with its narrowest part turned downwards. In the passage there
is a ball affected by the flow of the water.
Low water flow High water flow
When the flow increases, the ball is lifted. Due to the fact that the passage is
conical, the ball will stabilise in a specific position, and the flow can be read
on the graduated scale.
Constant flow valve In order to make the water flow to the water ring compressor independent of
the pressure in the water line, there is a constant flow valve fitted just before
the compressor.
The constant flow valve is designed for a fixed flow.
The acting part of the valve is a soft rubber washer. In the middle of the washer
there is a hole, through which the water flows. The size of the hole varies
depending on the water pressure, and thus keeps the water flow through the
valve constant.
Low water flow High water flow
The shape of the rubber washer at low and high water pressure, respectively in a
constant flow valve.
• Low water pressure - The shape of the rubber washer makes the hole in
the middle relatively large, i e water with low pressure flows through a
large hole.
• High water pressure - The rubber washer is deformed so the diameter of
the hole is small. This will cause the rubber washer to reduce the water jet,
but as the water pressure is high, the same amount of water will flow
through the valve as when the pressure is low.
The conductivity sensor monitors the electrical conductivity in the water, and Conductivity sensor
signals the control system if the conductivity raises above or falls under the
preset values.
A softening filter is a container with a bed material, often consisting of small Softening filter
polystyrene balls. When the water gets in contact with the bed material, there
is an exchange of ions. Thus the amount of hardening ions in the water is
reduced and you get a soft, so called dehardened water.
Function
The cooling water is used to cool the inductors, the guides in the final folder,
the hydraulic oil and the sterile air. The diagram below describes a system that
may be run both open and recirculated.
Simplified cooling water system for a TBA/19 Separator
SERVICE UNIT
Scrubber Compressor M (M7) Drain
B4
Z1
VALVE PANEL
A GUARD
Cirk. cold
water inlet B7
A4
M5 Y32
B A1 Z3 Z5 FINAL FOLDER
Cold water
LIME SEPARATOR
C
E
Cirk. cold
water outlet
Sealing
JAW SYSTEM unit
(K50)
L TS− R
sealing
Cooler
hydraulic
FM2 FM3 system
A2
Water connection B shall always be connected and valve A1 open, as there

is always a need for consumption water to cool components in the service unit.
For circulated cooling water, the water connections A and E shall also be
connected, and the valves A2 and A4 be closed.
The circulating water enters the system at connection A, is filtered in filter Z1
and flows further on to the jaw system and final folder. The pressure is
monitored by the pressure guard B7. The water flow through the inductors
in the jaw system can be read on flow meters FM2 and FM3. At point D the
circulated cooling water turns back and flows out at outlet E.
For an open cooling water system only water connection B shall be
connected and the valves A1, A2 and A4 be open. The cooling water enters at
connection B, is filtered in filter Z3 and flows through the lime separator
Z5.
At point C the water flow is branched and the consumption water flows on to
the service unit. The remaining water flows pass the open valve A4 and into
the system. The pressure is indicated on the pressure gauge M5. At branching
point D the cooling water is drained through valve A2.
The following is a separate closed cooling system with three separate circuits
Simplified cooling water diagram for a TBA/21
Inductor
Jaw unit Final folder Pull Tab
TS−sealing Guide cooling
Z2
B1 O2
Water panel Q
V
Cold water C/A

T
B2
P O1 T
Heat exchanger
Heat exchanger
K2
K1
B4 B3
P P Water cooling unit
P2 B5 F1
M1 U1
M P
A2
M
M2
Compressor unit P1
One circuit is cooling the heat sources on the machine and it is called the water
cooling unit. It is a closed circuit. The water used in this circuit must be totally
deionized in order to remove all particles that could clog the cooling pipes in
the transversal sealing inductors. Approximately 10% of the total flow is
circulated through a total deionizing filter C/A.
The second circuit is called compressor unit. It is a closed circuit and it is
actually the cooler in the machine. In this system, which is identical to a
refrigerator, gas is used as media.
The third circuit is an open circuit, meaning that the water is drained off after
being used to cool the compressor unit.
When the water cooling unit is filled with water, valve V is open and the
water flows through the deionizing filter, C/A. The temperature of the water
in this circuit should be 12 ˚C. This is monitored by sensor B2 after the heat
exchanger K2. To maintain that temperature, the compressor unit takes up
the heat energy needed from the water cooling unit in the heat exchanger K2
(evaporator) in which the gas will be evaporated. This energy will then be
transferred by the gas to another heat exchanger K1 (condenser), where the
energy will be transferred to the water in the open circuit. The gas will be
condensed after the condenser.
Symbols
The table below contains the symbols that normally are used in Tetra Pak
cooling water system diagrams.
Symbol Meaning
Accumulator
Deionizing filter
C/A
Non-return valve
Electrically controlled valve
Manual valve
Filter
Throttle, adjustable
Constant flow valve
Cooler
Water pump
M Motor
Water tank
Symbol Meaning
Heat exchanger
Cooling coil
Deaerator
Flow meter
Pressure gauge
Q Conductivity sensor
T Temperature sensor
P Pressure guard
Pressure regulator
6
Tube forming

Packaging material web

Lund, Sweden TBA/21 HS 1/9905 OH 834
Constant web tension
Increase motor speed Decrease motor speed

Lund, Sweden
Machine type
TBA/22
Issue
1/9909
OH 835
Motor Motor
PLC Drive
Control M PLC Drive
Control M
Compressed air Motor, Driven roller
7
Sterile system
components

Lund, Sweden
Aseptic food processing

Machine type
Sterilized
packaging
material
Sterile
surrounding
Issue
1/9501
Commercially Aseptic
sterile food transfer
OH 525
Aseptic packages
High and Low Acid Foods
HIGH ACID LOW ACID
No Growth of Pathogenic Growth of Pathogenic
No Spore Germination Spore Germination
No Public Health Risk Public Health Risk
Commercial St erility Commercial Sterility Achieved by
Achieved by Pasteurisation Sterilsation/UHT treatment
Fruit Juices
Yoghurt
Tomato Products
Sauces
Soups
Vegetables
Milk
Meat
Egg Products
pH 2 3 4 4.6 5 6 7 8 9
97 0830 SL 14.009 Tetra Brik Packaging Systems

Sterile system overview
Lund, Sweden
Air
Peroxide
Aseptic chamber Product
Water
Machine type
TBA/21 TBA/22
Packaging material
Issue
1/0001
Peroxide bath
OH 905
Compressor Peroxide tank

Tight tube
Air superheater
Sterile system TBA/22
Pause
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Steam
Product
Water
Machine type
Peroxide
Compressed air
TBA/22
Issue
3/0003
OH 812:5
Sterile system
1 Compressor 35 Peroxide pump

2 Water separator 36 Peroxide tank
3 Air superheater 37 Valve − refilling peroxide
4 Heat exchanger 38 Peroxide container
5 Heat exchanger valve 39 Safety cap
6 Spray nozzle 40 Diluting tank
7 Preheating valve 44 Filter − spray tank
14 Sealing water valve 45 Spray tank
15 Constant flow valve 47 Pressure switch
16 Scrubber presterilization
23 Reference point valve 48 Air superheater temp.
24 Sterilization bath 49 Presterilization temp.
25 Valve − top filling peroxide bath 53 Level sensor − water bath
26 Water bath heaters 54 Level sensor − peroxide bath
27 Circulation pump − hot water 55 Water bath temp.
28 Safety valve 56 Peroxide bath temp.
31 Pressure expansion tank 57 Level sensors − peroxide tank
32 Valve − filling peroxide bath 58 Peroxide tank temp.
33 Valve − draining peroxide bath A Valve peroxide bath cooling
34 Filter

Scrubber
Water
Air

Technical Training Centre, Lund, Sweden TBA/21 1/9410 OH 503
Principle of constant flow valve
Rubber ring Constant

flow rate
of water
Water with
fluctuating
pressure
Water at low Constant

pressure flow rate
Water at high
pressure Constant
flow rate

Water separator
Water
Air

Technical Training Centre, Lund, Sweden TBA/21 1/9410 OH 504
Heat
exchanger
valve
0 0 By pass
By pass
0.0
Status
cycle
1.0 1.1
Min. Max.
cooling cooling
1 0 Min. cooling
1 1 Max. cooling
Workbook TBA/21
Heat exchange vlve
Issue 970604
C
A
AP−Valve
440630−020V
(Aseptic Product Valve)

TETRA
PAK Lund, Sweden 1/9208 OH 453:1
Regulating
Lund, Sweden
valve
Machine type
TBA/19 TB/19, TBA/21
Issue
4/9810
Product
Compressed air
Non−conductive part
of the regulator
OH 497
Conductive layer
in the diaphragm
Non−conductive layer
in the diaphragm
Non−conductive coating
Peroxide bath
Peroxide
Water

Level relay
Peroxide spray quantity
Cooling
L 52 A1
L 50
A2
B1 B3 B2 15 16 18
To PLC INPUT
L 11 (24 VDC)
RM3 LA1
A1 A2
16
15
18
500k
26
25
Function 28 R−sector
25
30
1 35 (x0.1)
Time value s R−value (x10)

Lund, Sweden TBA/22 1/9909 OH 882:1
Level relay
Filling tank
L 52 A1
L 50
A2
B1 B3 B2 15 16 18
To PLC INPUT
L 11 (24 VDC)
RM3 LA1
A1 A2
16
15
18
500k
26
25
25
30
1 35 (x0.1)

Level relay
Spraying
L 52 A1
L 50
A2
B1 B3 B2 15 16 18
To PLC INPUT
L 11 (24 VDC)
RM3 LA1
A1 A2
16
15
18
500k
26
25
25
30
1 35 (x0.1)

Tetra Brik TBA/21
Level control in peroxide tank
A306 A307
A1 A1
A2 A2
B1 B2 B3 15 16 18 B1 B2 B3 15 16 18
A121.00 A308 A121.01

L11 L11
A1
A2
B1 B2 B3 15 16 18
A121.02
L11
Level sonds
1 .Maximum level when bath is empty
and when service switch is on.
2. Maximum level when bath is filled
3. Start filling when bath is filled
4. Supervising if the level is to high.
Stops filling. ALARM
Y1210 4
2
3
Tetra Brik TBA/21

Level control in Peroxide tank
Issue 980121
Peroxide filling station
Peroxide
Compressed air
Vacuum

Lund, Sweden Tetra Brik Aseptic 1/9609 OH 594
8
Sterile system

Ladder diagram TBA/22 TPOP
10:Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design OK.
Packages made from material that was in the H2O2 bath before inching
started are ejected.
After 2 sec of inching A valve opens at filling sector and design control starts.
After 10 sec motor start and self holding.
After 9.9 sec must H2O2 temp. and level be right.
After 3 sec starts peroxide bath filling.
After 1 sec synchronization FFU-JUM.
Sound alarm for 10 sec.
9:Motor start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right temp on flap sealing element. Right temp in H2O2 tank. All doors closed
If no start attempt within 90 sec steps down to 7.
8:Flap heaters on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product at A-valve.
7:Signals to Sterilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All. doors closed. Right temp in H2O2 tank. Drying time ended 15 min.
Sterile inching is possible.
After 14 min B-valve closes.
Sterile air pressure reads on both separator and aseptic chamber.
Preheating valve open.
6:Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spraying time ended 90 sec.
..................
88 sec Reference point valve open.
Preheating valve closed.
. . . . . . Pause. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 sec Alarm limits: fast -10.5 sec slow-21 sec.
After 18 sec B-valve closing.
. . . . . . Spray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 sec Reference point valve closes.
After 8 sec: Preheat valve opens, check reg. valve pos.
Filling for 9 sec. (50 cc). Checks level after 8.5 sec.
5:Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre.ster.temp 280 °C. All doors chamber closed. Steam temperature.
When 280 °C is obtained, spraying starts automatically after 10 sec.
Heat exhanger in bypass.
Preheating valve in bypass until 280°C is obtained. However temporary
opens to keep A.C. temp at 39-40 °C.
B-valve and reg. valve opens.
Circulation on H2O2.
Heat and circulation in water bath.
Air superheater at 360 °C.
Compressor on, reads on separator pressure switch.
4:Heat sterilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water separator low level. Cleaning pipes disconnect. All doors closed.
Inching packaging material for 40 sec.
3:Tube sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling. water pressure and cleanness. All doors closed.
Power to motors to help when threading packaging material.
Strip applicator on.
Possible to slow inch without LS, draining 3 min.
2:Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power. Air pressure. Water pressure. All doors closed.
1:Step 0
Technical Training Centre 1/9610 TM-00106 Training Document. For training purpose only. 1
10:Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9:Motor start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8:Flap heaters on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7:Signals to Sterilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
6:Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..................
88 sec
. . . . . . Pause. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 sec
. . . . . . Spray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 sec
5:Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4:Heat sterilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3:Tube sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2:Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1:Step 0
14:2 External cleaning
14:1 CIP cleaning
13 Doors, Aseptic chamber
12 Venting Aseptic chamber
11 Production ended
Sequence diagram
Lund, Sweden
Heat sterilization
Pos 4 Pos Pos

Machine type
0 3 6 9 12 15 18 21 24 27 30 sec 5 6−11
TBA/22
R 1000
Seal water
Y 1104
Compressor
K 020
(25)
Air pressure separator Alarm to pos 3
B 1102 Alarm to
pos 1
Issue
1/9905
Air super heater

K 028
280 C
Temp. mon. Heat. Ster 10 sec
B 1106 delay
OH 836:1
Regulating valve
C 1314
B−valve
Y 1323
Sequence diagram
Lund, Sweden
Spraying
0 10 20 30 40 50 60 70 80 90 sec
Drying
R 1006 (88)
Filling spray tank

Y 1230
(8.5) E
Machine type
mp
Level spray tank ing tyin (21)
Fill g
B 1230:1
(10.5)
Level sensor spray tank Alarm: Drying and jump to pos 1
A 300:18
TBA/22
Alarm to pos 3 Alarm: Spray fault
Level sensor spray tank

B 1230:2
(18)
B−valve Open
Y 1323
> 1.5 sec Alarm to pos 1
Check B−valve pos
B 1302
(88)
Preheating valve Open
Issue
Pause
Y 1114:2
1/9905
(88)
Preheating valve Open
Pause
Y 1114:4
> 1.5 sec Alarm to pos 1
Check preheating
valve pos > 1.5 sec Alarm to pos 1 > 1.5 sec Alarm to pos 1
B 1111
OH 836:2
(68)
Spraying
Y 1231
(10)
(8.5)
Reference point Closed
Y 1112
Check regul. valve pos

B 1321
Pendelum roller
Y 1501
Sequence diagram
Lund, Sweden
Drying
Pos 6 Pos 7 Pos 8

Machine type
0 2 4 6 8 10 12 14 15 Signal exhange min
Drying timer
TBA/22
R 1015
B−valve
Y 1323
Drying ready
M 813
Regulating valve
Issue
C 1314
1/9905
Check reg. valve pos

B 1321
(5 sec)
Aseptic chamber pressure Alarm to pos 1
OH 836:3
B 1103
Check temp 60 sec
Alarm to pos 7
FFU Heating elements
K 033
Max 90 sec
Sequence diagram
Peroxide system
Lund, Sweden
ed
er
n
iliz
on
io
en
d
en
at
er
g
op
g
n
iliz
in
st
in
n
io
t
al
s
ar
tio
tio
at
er
ng
at
to
or
se
g
st
he
st
uc
uc
Machine
ar
in
do
ni
al
or
yin
be
y
ep
at
nt
od
od
ea
gn
ap
ra
ot
AC
He
Ve
position
Tu
Dr
Pr
Pr
Pr
Cl
Sp
Si
M
Fl
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Machine type
Circulation cooling water

K 22
Water pump (heat perox.)

TBA/22
K1
Heating water 1
K 26
Heating water 2
K 27
Maximum level when bath is filled
in
in
m
Tank filled > 1 min

6
Filling peroxide tank 20 sec 10 s 20 s

Y 1210
Issue
Peroxide container empty Alarm: Low level peroxide tank Peroxide container empty = Alarm
1/9905
15 sec
Peroxide pump Stop every time the bath is emptied
K2
10 sec 20 sec
20 sec 9 sec
Filling spray tank
Y 1230
5 sec
OH 836:4
10 sec 68 sec
Spraying
Y 1231
Check bath level 9.9 sec < 3.0 sec No level
> 9.9 sec Level
Filling peroxide bath Closed
Y 1220 3 sec
20 sec
11 sec
Draining peroxide bath Closed
Y 1221
Sterile inching 20 sec
Sequence diagram
Lund, Sweden
Heat exchanger
Heat sterilization Spraying Drying
Pos 4 Pos 5 Pos 6 Pos 7

SP2 = 107 C SP1 = 95 C
Machine type
t > 40
Top A.C. t < 107
B 1109 t > 39
TBA/22
t > 280
Temp. monitor 280 C
0 sec 8 sec 27 sec 88 sec

Pause
Y 1114:2:4 Open
Preheating 10 sec 90 sec
valve Regulating position
(inverted)
Y 1111 5 min
Issue
18 sec
1/9905
B−valve Open Closed 14 min

Y 1323
Y 1107 0 0 1 1
Heat step 1
exchangers
OH 836:5
valve
Y 1108 0 1 1 1
step 2
Max Cool
Min Cool
0.5 sec
Bypas
exchanger
Flip heat
Sterile system TBA/21 HS 49
21
23
1 Compressor 20 Aseptic chamber 29 Expansion tank

2 Water separator 21 Tunnel 30 Valve, filling peroxide bath
3 Air superheater 22 Pendulum roller 31 Valve, draining peroxide bath 57
Lund, Sweden
22 43
4 Heat exchanger 23 Squee−gee rollers
24 41
5 Heat exchanger valve 24 Reference point valve 11 12
51
6 Spray nozzle 25 Sterilization bath
7 Preheating valve 26 Water bath heaters 14 40
8 Regulating valve 27 Circulation 52
9 Product valve (A) pump, hot water 39
48 50
10 Sterile air valve (B) 28 Safety valve
14
11 Steam barrier valve (C) 20
12 Steam filter 42
13 CIP valves 13
14 Steam trap 25
15 Sealing water valve
16 Constant flow valve 9
Machine type
17 Scrubber
18 Filling pipe
19 Product level probe
28
10
TBA/21 HS
27
6 26
8
47
7
53
54 29
19
18
45
30
Issue
16 15 31
2/9908
5 32 55 56
33
17
2 34
35
OH 812:1
4 1
44
36
37
38
3
46
35 Valve, refilling 38 Diluting tank 46 Air superheater temp. 52 Level sensor, 55 Level sensors,
32 Filter peroxide 39 Spray valve 41 Filter 44 Level sensor, 47 Presterilization temp. 50 Pressure switch peroxide bath peroxide tank
33 Peroxide pump 36 Peroxide container 42 Filter water separator 48 Steam temp. 51 Level sensor, 53 Water bath temp. 56 Peroxide tank temp.
34 Peroxide tank 37 Safety cap 43 Spray tank 45 Pressure switch 49 Aseptic chamber temp. water bath 54 Peroxide bath temp. 57 Level sensors, spray tank
Sterile system TBA/21 HS
Drying before tube sealing
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Steam
Product
Water
Machine type
Peroxide
Compressed air
TBA/21 HS
Issue
2/9908
OH 812:2
Heat sterilisation
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Steam
Product
Water
Machine type
Peroxide
Compressed air
TBA/21 HS
Issue
2/9908
OH 812:3
Spraying
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Steam
Product
Water
Machine type
Peroxide
Compressed air
TBA/21 HS
Closes after
18 seconds
Issue
2/9908
OH 812:4
Pause
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Steam
Product
Water
Machine type
Peroxide
Compressed air
TBA/21 HS
Issue
2/9908
OH 812:5
Drying
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Steam
Product
Water
Machine type
Peroxide
Compressed air
TBA/21 HS
Closes after
14 minutes
Issue
2/9908
OH 812:6
Production
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Steam
Product
Water
Machine type
Peroxide
Compressed air
TBA/21 HS
Issue
2/9908
OH 812:7
Stop
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Steam
Product
Water
Machine type
Peroxide
Compressed air
TBA/21 HS
Open (no by−

pass) 0−5 min
Issue
2/9908
OH 812:8
Ventilation
Lund, Sweden
Air
Hot air
Pre−heated air
alt. cooled air
Steam
Product
Water
Machine type
Peroxide
Compressed air
TBA/21 HS
Issue
2/9908
OH 812:9
1 Compressor 20 Aseptic chamber 29 Expansion tank
2 Water separator 21 Tunnel 30 Valve, filling peroxide bath
3 Air superheater 22 Pendulum roller 31 Valve, draining peroxide bath
Lund, Sweden
4 Heat exchanger 23 Squee−gee rollers

5 Heat exchanger valve 24 Reference point valve
6 Spray nozzle 25 Sterilization bath
7 Preheating valve 26 Water bath heaters
8 Regulating valve 27 Circulation
9 Product valve (A) pump, hot water
10 Sterile air valve (B) 28 Safety valve
11 Steam barrier valve (C)
12 Steam filter
13 CIP valves
14 Steam trap
15 Sealing water valve
16 Constant flow valve
Machine type
17 Scrubber
18 Filling pipe
19 Product level probe
TBA/21 HS
Issue
2/9908
OH 812:10
35 Valve, refilling 38 Diluting tank 46 Air superheater temp. 52 Level sensor, 55 Level sensors,
32 Filter peroxide 39 Spray valve 41 Filter 44 Level sensor, 47 Presterilization temp. 50 Pressure switch peroxide bath peroxide tank
33 Peroxide pump 36 Peroxide container 42 Filter water separator 48 Steam temp. 51 Level sensor, 53 Water bath temp. 56 Peroxide tank temp.
34 Peroxide tank 37 Safety cap 43 Spray tank 45 Pressure switch 49 Aseptic chamber temp. water bath 54 Peroxide bath temp. 57 Level sensors, spray tank
Peroxide
Water
Compressed air
Air
Hot air
Peroxide
system
TBA/21 HS
Heat
sterilisation

Lund, Sweden TBA/21 HS 1/9907 OH 860: 1
Peroxide
Water
Compressed air
Air
Pre−heated air
alt. cooled air
Peroxide
system
TBA/21 HS
Filling
spray tank

Peroxide
Water
Compressed air
Air
Pre−heated air
alt. cooled air
Peroxide
system
TBA/21 HS
Spraying

Peroxide
Water
Compressed air
Air
Pre−heated air
alt. cooled air
Peroxide
system
TBA/21 HS
Alarm
spray system

Peroxide
Water
Compressed air
Air
Pre−heated air
alt. cooled air
Peroxide
system
TBA/21 HS
Filling
peroxide bath

Peroxide
Water
Compressed air
Air
Pre−heated air
alt. cooled air
Peroxide
system
TBA/21 HS
Draining
peroxide bath

Peroxide handling TBA/21 040V
Emptying
diluting tank
Emptying
peroxide tank
Peroxide
Water
Compressed air

Lund, Sweden TBA/21 040V 1/9706 OH 746:1
Peroxide handling TBA/21 040V
Filling new
peroxide
Diluting peroxide
during
compressor run
Peroxide
Water
Compressed air

Lund, Sweden TBA/21 040V 1/9706 OH 746:2
9
Drive and jaw system

TBA/21 HS Jaw system
Overview
Forming, overview
The packages are formed at the top of the jaw system. The packages are
formed by the jaws (grey) and the volume flaps (green).
Forming, pressureside
After the forming, the jaws must be closed while the seals cool.
Cut
The cut is done by knifes synchronised with the jaw system.
Folding flaps, overview
The folding flaps (blue) perform the design correction for the packages.
Folding flaps, function
The folding flap stroke is set by a cam (yellow) which is controlled by a ser-
vomotor. The servomotor affects the cam via a belt (green) and two eccentric
shafts (blue, grey).
Sealing pulse
The sealing pulse (red) arrives immediately after the jaws are closed.
Jaw pressure
The jaw pressure comes up from two springs (violet) in each pressure jaw.
Volume adjustment, overview
The position of a cam (yellow) afftects the volume flaps to close more or less.
The cam position set the volume of the packages.
Volume adjustment, function
The cam position is controlled by a stepper motor via gears (grey) and and ec-
centric shafts (violet).
3x400 V AC
K 24 Emergency stops
Lund, Sweden
safety relay
K 25
PLC Door guards

Rectifier safety relay
Crank guard
Hardware enable
Machine type
570 V DC Safety relay

TBA/22
(Positioning Greasing)
(Start greasing cycle) K4
Motor low speed
Motor high speed
Software enable
DMC Resolver Motor Jaw unit
Out ready
Position error
Issue
Home position
1/9905
Motor running
Angle encoder Zero jaw
Motor retardation
Angle encoder (bit 7)
OH 837
Synchronize
internal clocks
1
To FFU DMC
2 Control of Main motor
Troubleshot DMC
DMC Alarm
TPOP: DMC Alarm
No Hardware
disabled
?
Yes
Check 24V Yes Yes

Check 24V
Pin 6* Pin 36*
No No
Check
Yes connection
A603 L11**
safetyrelay
OK ?***
No
Check
Reset connection
Safetyrelay Pin 35 & 36
A603
Restart
Hardwaware
No
disabled
Restart
Yes
Hardware Yes
disabled
Replace DMC
* There must be 0V DC on No
pin 7A05 and 7B24
** L11 = 24V DC
*** LED "Out" must be ON Production
Continue to page 2
Restart: Switch fuse F19 Off and On.
1
Troubleshot DMC
Continue from page 1
Internal Yes Linesupply Yes Powersupply Yes

hardware L1, L2, L3 output 570Vdc
OK ? OK ?
fault
No No
No
F19, K 24, Yes Replace Replace DMC

K25, Z3
OK ?
Continue to page 3 NO
Replace defect Restart

parts
Internal Yes
hardware
fault ?
Production
2
Troubleshot DMC
Yes
Position error Restart
exceeded
No
Continue to page 4
No
Position error
exceeded ?
Replace
Yes mechanical
parts
Is it easy to turn
mechanical parts ?
No
Yes
Replace
n DMC
Restart
No
Position error
exceeded?
Yes
Replace Servo motor
Production

3
Troubleshot DMC
Internal Yes Yes Internal Yes

system Restart system
fault ?
fault ?
No
No
Production Replace DMC
Continue to page 5
Restart
Production
4
Troubleshot DMC
Temperature Yes Yes Let the motor cool

Motor
fault ? down and check for
hot ?
mechanical friction
No
No
Continue to page 6 Bridge PINS 4 & 5

(PTC) in motor
and check PTC*
Restart
Temperature
fault
No
Yes
Repair or Bridge pins

replace 4&5
cable on DMC
PTC No Temperature
broken.
fault
Replace
servo motor
Yes
Replace DMC
Production
* The resistance of the PTC should be

84 Ohm in room temperature.
5
Troubleshot DMC
Yes
Software Check 24V
disabled Pin 15*
No No
Check Yes
K120/K105
O37.10
No
Check output
module
Check connection
to DMC
Yes Function
OK ?
No
Replace DMC
Production
Continue to page 7
* Use 7A05 or 7B24 (0V DC)

6
Troubleshot DMC
Yes
Mechanical Yes
Torque limit friction *
exceeded ? ?
No
No
Replace DMC Replace

(or Servo) mechanical
parts
Continue to page 8
Restart
Production
* The torque can be measured by connecting

an oscilloscope to the analogue output on the DMC.
Set R120=10.
7B21 => 0Vdc

7B22 => Torque(1Volt = 6,85 Nm)
7B23 => Positionserror (1 volt = 102 Steps)
7
Troubleshot DMC
Yes
Cyclical
timer
interrupt* ?
No
Check
Hard- and Soft-
ware signals.
Restart
Continue to page 9
Production
* As long as the Hard- und Software signals

are low the Cyclical timer interrupt alarm
will be shown on DMC!
8
Troubleshot DMC
Volume Pin 31
Yes No
not on DMC 24V
exsist. & I11.15 ="1"
*?
No
Ja
Datatransfer
OK? No
(O40.05,O40.12)**
Continue to page 10
Ja
Repair
wires ****
No Volume value
in PLC Register
OK ?
*****
Check PLC
program*** Yes
Replace DMC
Restart
*Data request from DMC
** Description of datatransfer in
Functional Description MM21MC
***Check position of sensor for volume-

detection compared to knob on maincam.
**** 7A07 (Data), 7A08 (Data clock), 7A10 (Data enable)

7B31 (Data request)
***** Actual volume shown on TPOP.

9
Troubleshot DMC
Resolver- Restart
fault ?
No
Resolver-
fault
Yes
Continue to page 11 Check connection

Motor/DMC*
Restart
No
Resolver-
fault
Ja
Replace DMC
Restart
No
Resolver-
fault
Ja
Replace Servomotor
Production
* Cable and connections

10
Troubleshot DMC
Yes
Home-
position fault_
No Homepos. Sensor
and cables OK?
PLC I16.00
Yes
Home-
Continue to page 12 position fault
No
Replace DMC
Restart
Production
11
Troubleshot DMC
Yes
Shunt (Bleeder)
fault
*?
No
Check for
friction in gear-
box of FFU,
maincam or belts.
Shunt (Bleeder) Yes

Continue to page 13 fault
*?
No
Replace DMC
Restart
Production
* The LED 2 could flash but not more than

2-3 times during 10 seconds.
12
Troubleshot DMC
Nein
Fault Yes Angle encoder No

FFU Synchron. OK ?*
No Yes Replace
angle encoder
End
Angle encoder No
value in PLC
OK ?
Yes Replace
Encoder module
Datatransfer No
OK to DMC?
**
Yes Check data-

transfer**
Restart
Production
* Crank jaw system slowly and make sure that the

instrument is showing all values.
** See "Volumedata fault"
Restart: Switch fuse F19 Off and On
13
Electric drive systems
S
N
S N
Training Document
used for other purpose.
equipment, and must not be used as such.
Note!

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Frequency-controlled asynchronous motor . . . . . . . . . . . . . . . . . . . . . . . . 5
The squirrel-cage asynchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Frequency converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive systems with DC motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Stepping motor systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The stepping motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Servosystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control unit, drive electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Angle encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Temperature (safety) switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Introduction
By electric drive systems we mean various types of electric motors which,
together with some form of electronic controls, drive or perform mechanical
movements.
Control unit Motor Mechanics
One type of electric drive system is a variable speed motor, which drives a main
shaft. On this shaft, cams, belt pulleys, gears, sprockets, etc may be fitted, which
in their turn provide the motive power for mechanical movements.
What, in this case, is considered the electric drive system are the motor and
the speed control device.
Speed control
Motor
This textbook describes such electric drive systems as are employed in the
Tetra Pak packaging machines and process equipment:
• Frequency-controlled asynchronous motor.
• DC motor with variable speed control.
• Stepping motor systems.
• Servomotor systems.
All drive systems are described in general terms; in other words, their function
as employed in a specific machine is not being explained.
Overview
In the following, the various drive systems are described briefly and
summarily. Later on, each system is presented in detail in separate chapters.
Frequency-controlled asynchronous motors are very common and cheap drive Frequency-controlled
devices. The motor is an asynchronous squirrel-cage motor, whose speed is asynchronous motor
controlled by means of a frequency converter. The rotary speed depends on the
frequency. Such drive systems are often used to drive a main shaft which, via
cams, gears, etc, drives a number of mechanical movements.
Drive systems with DC motors can be used for a great variety of tasks, from Drive system with DC
simple speed control to advanced positioning. For instance, they are often used motor
when the speed has to be varied over a wide range. A further advantage of the
DC motor is that its speed is only slightly affected by load variations.
Stepping motors are mostly used in positioning, with small loads. It can be Stepping motor system
regarded as a digital motor which converts electric pulses into mechanical
motion. Each pulse equals a defined angle of rotation by the
motor shaft - one step.
Servosystems are capable of converting any mathematical function into a Servosystem

mechanical movement. It may be cam functions (electronic cams), speed
functions, torque functions, etc.
General
As previously mentioned, electric drive systems consist of a motor and a
control unit. The control unit may be anything from a simple speed controller
to highly advance control electronics, which may make the motor perform
virtually any function.
The motors may have either open or feed-back control. An induction motor
usually has open control, while a servosystem in itself constitutes a system
feed-back control.
In an open control system, there is no feed-back between the motor or load and Open control system
the control unit. This means that if any of the factors determining the function
of the system changes, for instance voltage, amperage, or position, the
function of the system will also change. There is no automatic correction or
compensation; if correction is required, it has to be made manually.
Input
values Control unit Motor Function
In a feed-back system, the control unit monitors the function of the motor or Feed-back control system
load. If the motor function deviates from the predetermined function, the
control system will automatically correct this condition.
Input
Control unit Motor Function
values
Feed-back
Frequency-controlled
asynchronous motor
Frequency-controlled asychronous (induction) motors are mostly used for
simple drive functions, without feed-back from the motor or load to the control
unit. Such a drive can in principle be used to regulate the speed from stand-
still upwards. The motor is a squirrel-cage asynchronous motor, and the
control unit a frequency converter.
The squirrel-cage asynchronous motor

The squirrel-cage asynchronous motor is the absolutely most commonly used
AC motor. There are many reasons for this; here follow the most important:
• it is cheap,
• it is very reliable,
• it is a standard product complying with the IEC standard.
IEC motor
P D N
M
E C B A
Amongst other things, IEC standardization means that the outside dimensions
of the motor, its mounting holes, and its shaft dimensions are standardized for
each motor power.
The diagram shows those dimensions which are subject to standardization.
Thanks to this standard, the user is not tied to a certain manufacturer or
supplier. A plentiful supply of standard motors of different makes is always
available.
Construction The rotor in the asynchronous motor has a cagelike winding (hence the term
'squirrel-cage'). It is not wired to any power source, which means that there is
no need for sliding contacts or brushes for its power supply. Besides, the rings
which short-circuit the conductors are often shaped like fan impeller vanes.
Altogether, this makes this type of motor extremely simple and robust: no
windings, no sliding contacts, no separate fan in the rotor.
In the stator are the field windings. They are designed to generate a rotating
magnetic field when connected to a three-phase alternating voltage.
Stator
Rotor
Usually, three-phase motors can be reconnected for two alternative supply

voltages. The most common way is to either D-connect (delta connect) or
Y-connect (star connect) the three phases of the field winding.
If the marker plate on a three-phase motor specifies voltage values for both
D and Y-connection, the motor may be run on, for instance, either
3×230V AC or 3×400V AC.
The diagram below shows how to place the connection links for 3×230V and
3×400V. In both cases, the potential over the windings will be 230V.
W2 U2 V2 W2 U2 V2
U1 V1 W1 U1 V1 W1
W2 U2 V2 W2 U2 V2
U1 V1 W1 U1 V1 W1
L1 L2 L3 L1 L2 L3
D-connection, 3×230V Y-connection, 3×400V
Function When the field windings are connected to a three-phase alternating voltage, a
rotating (1) magnetic field (2) is generated through the motor. The magnetic field
induces currents in the conductors (3) of the cage winding; in this way, forces (4)
are created, which cause the rotor to rotate with the magnetic field.
A B
3 Slip
S
4
S N
1
N
2
The speed (rpm) of the asynchronous motor is determined by the frequency of

Current entering plane
the voltage supplied to the motor, calculated in accordance with this formula:
Current exiting plane 2 × frequency × 60
Speed = --------------------------------------------------------
Number of motor poles
In principle, the speed can be regulated from stand-still upwards, with certain
limitations in the upper and lower sections of the speed range.
The speed determined by the frequency, as per the formula above, is called the
synchronous speed. The synchronous speed is the rotation speed of the
magnetic field, generated in the field windings when supplied with a three-
phase AC voltage.
The table below shows the synchronous speeds at various frequencies for
motors with different number of poles.
Number of Frequency (Hz)
poles 10 30 50 100
2 600 1800 3000 6000
4 300 900 1500 3000
6 200 600 1000 2000
8 150 450 750 1500
The actual, true, speed of the motor is determined not only by its synchronous speed
but also by how great a load the motor is driving. This speed is called the asynch-
ronous speed, and the difference between the synchronous and asynchronous
speeds is termed slip. The slip is directly proportional to the output motor shaft
power. The illustrated sequences, A and B above, demonstrate how the rotor lags
behind the rotating field. In a way, this can be compared to a hydraulic coupling.
Diagram A shows the motor in a random field position that may be referred to
as F. Diagram B shows the motor when the field has rotated 45 degrees:
F + 45 °. In diagram B, it can be seen that the rotor has not turned as far as
the field, i e the rotor follows the field with a certain degree of slip.
Example: a four-pole 50 Hz motor has a rated speed of 1440 rpm. Thus the slip
is 60 rpm at the rated load.
Although, as previously stated, the speed can be regulated from stand-still
upwards, this should not be done.
At 85-90 Hz, losses in the motor will, for various reasons, be so great that the
torque drops to approximately one third of the rated torque. Power consump-
tion, however, remains as high as at the rated speed. A rule-of-thumb is never
to regulate the speed beyond 87 Hz.
At low frequencies and unchanged load, the fan impellor fitted to the motor
shaft will no longer be able to cool the motor adequately. Then the danger is
considerable that the motor will overheat. As a counter-measure, a separately
driven fan may be installed.
Torque, Power
100% Power
Losses
50%
Torque
Frequency
25 50 75 100 (Hz)
Frequency converter
A frequency converter converts the mains power frequency to whatever freqency is
required for the motor. Usually, the mains power frequency is either 50 Hz or 60 Hz.
A frequency converter consists of four main parts: Function

• The rectifier, which is fed with an AC voltage from the mains grid,
produces a DC voltage.
• The intermediary circuit, in which the DC voltage is smoothed.
• The inverter, which reconverts the DC voltage into an square-waved AC
voltage of the frequency required for the motor.
• The regulation unit, which controls and monitors the other parts.
Briefly, what happens in a frequency converter can be described as follows:
Rectification, smoothing, inversion (reconversion), control.
Regulation unit
Rectifier Intermediary
circuit
Inverter
M
Pulse width modulation The predominant type of frequency converter is the PWM converter (Pulse
Width Modulated). With this converter, voltage as well as frequency are
regulated by controlling both the number of pulses and their energy. The
reason for this is to make the virtual value of the voltage conform as closely to
a sine curve as possible. Sine-shaped voltage reduces losses in the motor.
In the 50 Hz and beyond range, the motor is fed with one pulse per semi-
period, alternatingly positive and negative. The virtual value of such a squared
pulse equals the rated voltage of the motor, for instance 400 V.
50 Hz
The virtual value of the voltage is as follows:

Input frequency
--------------------------------------- × Rated voltage = Output effective value
Rated frequency
In the example above:
50Hz
------------- × 400V = 400V
50Hz
At 25 Hz, the motor is fed with a number of pulses per semi-period, and the
virtual voltage value, which drops proportionally to the reducing frequency,
will be:
25Hz
------------- × 400V = 200V
50Hz
25 Hz
A PWM frequency converter thus regulates both the voltage and frequency to
the motor.
Fault-finding
In the following, the most common faults and their causes that may appear in
asynchronous motors are described.
When fault-finding in electric drive systems, you should use a type TRMS TRMS stands for True Root Mean
measuring instrument. TRMS measuring instruments give correct values for Square.
all types of signals.
Fault; The motor hums abnormally loudly while running, or hums without
rotating:
• Loss of voltage on one phase, possibly due to a blown or tripped fuse. Note
that the overcurrent protection of small motors may not always trip when
this kind of fault occurs.
Fault: The motor does not start, or stops in mid-run:
• The overcurrent protection has tripped.
Fault: The motor runs hot:
• Worn bearings.
• One or several field windings have short-circuited.
• Excessive load.
Fault: The motor vibrates:
• Unbalanced load, for instance a pulley, sprocket, or coupling.
Fault: The motor will not start:
• No voltage to the control unit.
• Fuse in or to the control unit blown or tripped.
• External starting conditions not met.
• No setpoint provided by the regulating unit.
• Short-circuited field windings.
Drive systems with DC
motors
Drive systems with DC motors can be used for everything from simple speed
regulation without feed-back to advanced positioning. Such a system can be
used to drive and brake the motor in either direction with precisely controlled
acceleration and deceleration. In this book, only simple speed-controlled
systems are described. The motor used is either a separately or permanently
magnetized DC motor, and the control unit a DC converter.
The DC motor
For speed control with DC motors, usually a separately magnetized motor is
used. Permanently magnetized motors are more suitable for positioning duties.
The principal advantage of separately magnetized motors is their speed
stability, i e the speed is only slightly affected by load variations. Besides, the
speed can be varied within a wide range. These qualities make the separately
magnetized motor ideal for speed regulation.
Construction The component parts of the DC motor are:

• The stator, which carries the field windings.
• The rotor, which carries the rotor windings.
• The commutator with carbon brushes.
In permanently magnetized DC motors, permanent magnets have been
substituted for the field windings.
Stator
Rotor
Commutator
Carbon brushes
The principle of the function of the DC motor is illustrated below. Function
2
3
S N
Current exiting plane
A conductor (1) carrying a current, which is positioned in a magnetic field (2),

is affected by a force (3). The magnitude of the force is determined by the
strength of the field and the amperage in the conductor. The field is generated
by the field windings in the stator, and the current in the conductors is
governed by the voltage of the power supplied.
The speed of a DC motor is determined by the magnetic field strength and
the rotor voltage. In order to vary the speed, either the voltage to the field
windings or to the rotor windings can be altered. Most common is to control
the speed by regulating the rotor voltage. In principle, this can be done within
the entire motor speed range while still retaining the same torque.
In supplying direct current, constant magnetic and current flows are created Commutation
through the motor. In order to achieve continuous rotation, the windings must
be reconnected (pole reversing) as the rotor revolves. Such reconnection is
termed commutation and may be either mechanical or electronic.
The diagrams below show how a loop or winding in a DC motor is
commutated mechanically in order to make it rotate continuously.
N
S
Miscellaneous DC motors should always be connected with cables which are screened and
whose conductors (strands) are twisted. The screen is to be grounded at each
end. Screening is done in order to prevent electromagnetic interference (noise)
to enter or emerge from the system.
DC Converter
In order to regulate the voltage, and thus the speed of the DC motor, a
DC converter is used. It consists of three main parts:
• The rectifier, which turns the supply voltage into direct current.
• The power unit, which feeds the motor with direct current.
• The regulating unit, which controls and monitors the other parts.
Field
Rectifier Power unit
Rotor
Regulating unit
Fault-finding
In the following, the most common faults that may appear in DC motors and
their possible causes are described.
Fault: The motor runs hot. Note that DC motors normally get fairly hot,
70-80 °C as measured on the motor casing.
• Excessive load.
• Motor having exceeded maximum speed for a considerable length of time.
• High ambient temperature.
• Worn bearings.
• Short-circuit in field winding.
Fault: High idling current.
• Worn bearings.
• Worn or sticking carbon brushes.
Fault: High starting current.
• Worn bearings.
• Break or short-circuit in field winding.
Fault: Fluctuating speed at constant setpoint.
• Excessive load variation.
Fault: Abnormal brush wear.
• Incorrect spring force on carbon brushes.
• Dirt and/or uneven commutator.
• Short-circuit in rotor winding.
Stepping motor systems
Stepping motors are mainly used for the positioning of small loads. They may
be regarded as digital motors, converting electric impulses into mechanical
movements. Each pulse corresponds to a defined angle of movement by the
motor shaft - one step. Normally, in stepping motors there is no feed-back of
load and position.
The stepping motor

Construction A stepping motor consists of two main parts:
• A permanently magnetized rotor.
• a stator, carrying the windings.
The permanently magnetized rotor may have a varying number of poles, or, as
they are normally termed, rotor teeth. A common figure is 50. Most stepping
motors have two phases, i e two field windings. There are, however, also five-
phase motors.
The diagram below shows a two-phase motor with six rotor teeth.
Rotor
Stator
N
S
N
N
S
Field windings
N
S
Rotor tooth
This diagram (below) shows a section through a 200-step motor. It is a two-

phase motor with 50 rotor teeth. This is a very common type of motor.
Rotor
Stator
The stepping motor converts electric pulses into rotation, and each pulse Function
results in a defined angle of rotation - one step, according to the following
formula:
360°
One step = ------------------------------------------------
Steps per revolution
In the following, the function is described:

When a current flows through a pair of field windings (fig 1), the stator poles
are magnetized and attract rotor teeth with opposite stator teeth polarity. By
switching in the next pair of windings, (fig 2), the next stator pair will also
become magnetized; the change in magnetic flow will cause the rotor to turn
15 degrees. Then, as the first stator pair is disconnected (fig 3), the rotor will
turn another 15 degrees.
By connecting and disconneting the flows of current through the field
windings according to this pattern, the rotor will revolve in steps of 15 degrees
(figs 1 - 6).
For a two-phase motor with six rotor teeth, the number of steps per revolution
will equal 24:
2 × number of phases × number of rotor teeth = 2 × 2 × 6 = 24
Thus, the motor in the example will move through 24 steps per revolution, and
in accordance with the previously given formula, one step is:
360°
----------- = 15°
24
The speed at which the motor rotates depends on how rapidly the field
windings are being reconnected.
All stepping motors function as described in the above example. The only
difference is that a standard motor has more numerous stator poles and rotor
teeth. This gives smaller and more numerous steps per revolution.
1 2
N N
S S
N
N
S
N
S
S
S
N N
S S
3 4
S
N S N
S
S
S
S
N
N
N
N S S
5 6
S S
N N
S
S
N
S
N
N
S S
N N
The design of the stepping motor is such that some of its features may be Miscellaneous
misinterpreted as defects in the motor, unless the causes are known.
Stepping motors often become hotter than motors of other types. The reason
is that full motor current always flows through its windings, also at stand-still.
This is termed holding torque. The reason for this is that the motor must
remain in position, as it usually lacks feed-back. The torque imposed by the
load must not shift the motor out of position. Normally, stepping motors have
class B winding insulation, which means that the temperature of the windings
may rise to 130 °C. An motor casing temperature of 90 °C does not cause any
thermal damage to the motor.
A stepping motor cannot be operated without a load. It requires a load moment
of inertia which is at least equal to its own internal moment of inertia in order
to be able to accelerate normally. Unloaded, the motor will race.
A stepping motor may jerk, as power is switched on. The reason for this is that
it has a number of fixed positions, for instance 200. If the rotor rests between
two positions, it will jump to one of these fixed positions. The movement
cannot exceed ±0.9 degrees in a 200-step motor.
Stepping motors should always be connected with cables which are screened
and whose conductors (strands) are twisted. The screen is to be grounded at
each end. Screening is done in order to prevent electromagnetic interference
(noise) to enter or emerge from the system.
Control unit
The control unit generates the electric pulses which drive the motor. The
change of angle made by the motor is entirely controlled by the number of
pulses generated by the control unit. The control unit consists of:
• The rectifier, which converts the supply voltage into direct-current voltage.
• The power unit, which generates the pulse train to the motor.
• The pulse control logic, which determines how the power unit will
generate the pulse train.

M
Pulse control
logic
External control signals
The pulse train, or rather pulse trains, is generated by the power unit, which is
controlled by the pulse control logic. A pulse train must be generated for each
motor phase. The pulse trains are fed into the field windings, offset in time. In
this way, the windings fitted around the stator are receiving power in
succession. A revolving magnetic field is thus created, which turns the
permanently magnetized rotor with the flow of magnetism.
The speed of rotation of the motor is proportional to the frequency of the pulse
trains.
The position of the motor is based on the fact that it always turns one step per
pulse. This, together with the lack of feed-back between the motor and the
control unit, is the reason why, if a pulse is being missed, there will be no
correction made by the control unit. The most common cause of missed pulses
is that the motor is underdimensioned and has not the power to shift the load
at the preset acceleration and speed parameters. A further cause of missed
pulses is that there may appear resonant oscillations in couplings between
motor and load.
Fault-finding
In the following, some faults that may appear in stepping motor systems are
described.
Note
In order to be able to carry out fault-finding in a stepping motor system, it is
necessary to fully understand in general terms how the entire system and its
various components parts function. One should also know how the particular
system concerned is supposed to work as well as knowing, or being in a
position to find out, the normal or rated values (voltage, amperage, etc) of the
control and communication signals.
TRMS stands for True Root Mean When fault-finding in electric drive systems, you should use a type TRMS
Square. measuring instrument. TRMS measuring instruments give correct values for
• External starting conditions not fulfilled.
• No setpoint from the pulse control logic.
• Motor windings short-circuited.
Fault: Motor races:
• Load too light or disconnected.
Servosystems
A servosystem is capable of transforming any mathematical function into
a mechanical movement. This means that servosystems can replace mecha-
nical elements, such as cams and cam shafts, indexing gears, differentials, etc.
A servosystem consists of a servomotor with its control unit.
Servosystems can be used for the following kinds of control functions:
• Speed control; the motor speed follows a predetermined speed function.
• Positioning; the position, linear or angular, follows a predetermined function.
• Torque control; the torque of the motor follows a predetermined function.
• Hybrid control; the system alternates between different kinds of control
functions, for instance motor speed control during one part of the working
cycle and positioning during another part.
Motors and control units for servosystems cannot be combined in just any
way. They comprise integrated systems, and the same supplier should be
selected for both motor and control unit.
The servomotor
The servomotor, which is a permanently magnetized brushless AC motor, is a
relatively new type of motor. It has been specially designed for use in servo-
systems. Characteristic of this motor is its high performance in every respect,
but principally that it provides much higher output power in relation to its
size than other types of motors.
Servomotors have great overload capacities and can cope with rapid load
fluctuations. The overload capability also provides a torque reserve which is
needed for quick acceleration and braking of a load. Sine-shaped motor
current and electronic commutation give, in addition to a very wide speed
range, also silent and smooth running and high efficiency rating.
As can be seen, servomotors possess excellent qualities; in addition to what
has already been enumerated, they provide high torque and have a low internal
moment of inertia. They are, however, expensive. In order to achieve all these
good features, it is necessary to use very rare and costly magnetic materials in
the permanently magnetized rotor. Samarium, cobalt, and neodymium are
examples of typical rotor materials.
In principle, a servomotor consists of a permanently magnetized rotor and Construction

a stator of iron, which carries the windings.
Stator
Field winding
Rotor
Permanent magnet
In a motor of this design and construction, nearly all motor losses take place
in the stator. This means that the transfer of heat to the surrounding becomes
short and quick. Electronic commutation and the absence of motor slip also
contribute to the generation of less heat, which thus is easier to get rid of than
in other motor types.
Heat
Function The windings in the stator generates a rotating (1) magnetic field (2) through
the motor. The permanently magnetized rotor (3) is attracted by the poles of
the field and will rotate (4) synchronously with it .
S
N
1
S N S N
S
3
N
4
The rotating field is generated by the electronic commutation of the field

windings. If the motor is to be at stand-still, for instance to maintain a torque
or a position, the field windings are made to generate a static field.
Electronic commutation Electronic commutation means that the current to the motor windings is being
switched electrically.
Resolver Beside the rotor and stator, the resolver forms a vital part of the servomotor.
The resolver is an angle encoder, which all the time senses the angle position
of the motor and feeds this information back to the control unit. The control
unit uses the information to commutate the field windings so that the motor
performs the required function. As an example, the field windings are to
generate a rotating field of a defined strength for the motor to drive a load at a
specific speed.
In principle, a resolver is a rotating circular transformer, supplied with a
carrier (AC voltage) of 1 - 20 kHz. The carrier induces one sine and one
cosine signal in the fixed windings. The sine and cosine signals are modulated
on the carrier. These signals specify the absolut angle position of the rotor.
Carrier
Sine
Cosine
The sine and cosine signals are converted into a digital signal, and with this,
get the resolver into a certain resolution. A two-pole resolver produces 8 192
pulses per revolution, and a four-pole resolver produces 16 384 pulses per
revolution. In addition to the resolver specifying the absolute angle position,
the control unit is capable to calculate, with the aid of the pulses:
• the direction of rotation, by determining whether the sine or cosine signal
comes first.
• the position (change of angle), by counting the number of pulses,
• the rotational speed (rpm), by counting the number of pulses per second,
• the acceleration, by counting the number of pulses per second squared.
The servomotor and resolver should always be connected with cables which Miscellaneous
are screened and whose conductors (strands) are twisted. The screen is to be
grounded at each end. Screening is done in order to prevent electromagnetic
interference (noise) to enter or emerge from the system.
Control unit, drive electronics

The control system for a servomotor consists of three main parts:
• Program
• Regulating unit
• Power unit
Program Regulating unit Power unit Servomotor
Position Speed Torque

regulator regulator regulator
Resolver
External control signals 3 x 400 VAC
Program The program contains information on the movement cycle of the motor. It can
also be said to describe the functions which the motor is meant to perform.
Often the program communicates with an external control system, for instance
the PLC of a packaging machine.
The regulating unit The regulating unit controls the movement cycle of the motor utilizing the
information from the program and the resolver, as well as by measuring the
current between the power unit and servomotor. The regulating unit usually
contains three regulators, or as they may also be termed, regulating loops.
The position regulator counts the pulses from the resolver. The total number
of pulses provides information on the position of the load, its angle position,
and change of angle.
The speed regulator regulates the speed by counting the number of pulses per
second. The speed regulator also regulates the acceleration.
The torque regulator measures the current from the power unit to the motor.
The amperage of the current is directly proportional to the torque of the motor.
The power unit The power unit supplies the motor with electric power (current). It is normally
fed by three-phase AC from the mains. The supply voltage is rectified and
connected to a transistor bridge with six transistors. By means of the transistor
bridge, controlled by the control unit, the motor windings are commutated, so
that the motor performs as required. The switching frequency is 3 - 20 kHz,
depending on make and system selected.
The power unit supplies the motor with three sine-shaped currents, which are
offset 120 electrical degrees relative one another. Sine-shaped current
contributes towards smooth running and small losses.
The power unit also regulates the amperage of the currents. The size of the
currents is proportional to the torque of the motor.
Fault-finding
In the following, some of the faults that may appear in servosystems are
described.
Note
In order to be able to carry out fault-finding in a servomotor system, it is
• No setpoint from the regulating unit.
• Motor short-circuited.
Miscellaneous
In this section are described certain components which are common in electric
drive systems but which are not specific to a particular type of system.
Angle encoders
Angle encoders are used in many drive systems to record or monitor the
angular and linear positions of the system, its direction of rotation, speed, etc.
An absolute encoder converts the angle position of a shaft into an electric sig- Absolute encoder
nal. The electric signal is a digital code of some kind, for instance a binary
code, BCD code, or gray code. The mostly used is gray code and the number
of bits in the code determines how precisely the angle encoder can record the
angle position. An eight-bit code has a resolution of 256 and can record the
angle position within ±0.7 degrees.
The key component of the angle encoder is a code disc, fitted to a shaft. On
the disc, there is a pattern of tranparent and opaque areas. These areas
comprise the actual code. For each angle value, there is a unique combination
of areas, which can be transscribed into logic ones and zeroes.
Code disc with gray code
One one side of the code disc, there are light-emitting diodes and on the other
side phototransistors.
The light-emitting diodes shine their light on the code disc, and the photo-
transistors sense light or non-light, depending on which position the disc is in.
The phototransistors give the position of the disc in the form of a binary signal.
As the disc rotates, a signal is continuously being registered, corresponding to
the absolute angle position of the shaft on which the code disc is fitted or
connected with.
Phototransistors
LEDs
0
1
0
1
Incremental encoders An incremental encoder converts a defined angle turn into an electric pulse.
By counting the number of pulses, the encoder records how big the turn is. The
number of pulses per revolution determines how precisely the angle encoder
can record a change of angle. An encoder, giving 10 000 pulses per revolution,
can record an angular change within ±0.036 degrees.
Just as absolute encoders, incremental encoders have a code disc. On the code
disc, there is a pattern of bars with the same resolution as the encoder has. The
bar pattern is often divided into two channels, offset half a pulse relative one
another. By sensing which channel comes first, the direction of rotation can be
determined. Often, there is a reference pulse, a so-called zero pulse, which
generates one pulse per revolution.
Channel 1
Channel 2
Reference pulse
Just as in absolute encoders, the pulses are sensed by light-emitting diodes

and phototransistors.
As the code disc rotates, a pulse train is created. The number of pulses
indicates how big a change of angle the shaft has made.
Temperature (safety) switches
Under certain circumstances, it is suitable to supplement the regular motor
protection with temperature safety switches. These switches protect the
motors from overheating, caused by overloading, insufficient cooling, too
high ambient temperature, high starting frequency, or similar faults.
The temperature switches are fitted in or on the windings in the stator and
ensure that power to the motor is cut if a preset temperature is being exceeded.
There are several types of temperature safety switches; below, three of them
are described:
• Bimetal types of temperature switches usually work on the principle of the
bimetal element tripping and cutting power at a given temperature. Such a
switch is wired into the control circuit of the motor, or, in the case of
motors of low power, directly into the power circuit of the motor. No
separate control unit is required.
• Thermistors are temperature-dependent semiconductors. Thermistors of
PTC (Positive Temperature Coefficient) type are the most common ones.
These offer the advantage of very slight increase of resistance on rising
temperature right up till the reference has been reached. Then the resistance
increases sharply, up to 1000 times. Thermistors must be connected to a
separate control unit, which cuts the power supply to the motor.
• Resistor elements are temperature-dependent resistors. Resistor elements,
for instance PT 100, are mainly used in large motors, where they are wired
into the motor windings. PT 100 signifies that the element is made of
platinum and has a resistance of 100 ohm at 0 °C. Resistor elements must
also be connected to a separate control unit.
10
Design control system

Design control
TBA/21
Textbook MT-83018-2
TMCC
Design control system
1
+ 24 VDC
2
TMCC
DC common 558230
3
TPOP design position
FAULT
POWER
S 1 Reg mark DCS
9 S 2 Design OK
Bit 0 S3
10 S4 25
S5 Data request
11 S6
S 7 > 192
S 8 < 64
12 27
Precorrection out
Encoder 13
345
14 31
EF 2
67 A
01
89
BCD SW 1 Register mark signal

15
16 32
Bit 7 Design OK
17 5
Register mark photocell 4 bars Analog output to DMC
18
Register mark photocell 3 bars
20 RS232
Enable TMCC
22
Enable data communication
23
Clock signal
24
Data signal

TMCC
ASU
1
+ 24 VDC
2
TMCC
DC common 558230
FAULT
POWER
S 1 Reg mark ASU
S2
S3
S4
S5
S6
S7
S8
27
Design signal ASU
345
EF 2
67 A
01
89
BCD SW 1
17
Bar code photocell 4 bars
18
Bar code photocell 3 bars
RS232

Design Control
Lund, Sweden
Servo motor positioning 0.7 mm*

Mechanical stop, 0.5 mm*
Machine type
TBA/22
Precorrection
Issue
1/0004
Home position sensor

OH 959
Regulation area
* Distance to inductor
Home position Mechanical stop
PHOTOCELL
Cable:
COLORS & PURPOSE
+24V
POWER
0V
OUTPUTS
0.7-2.0V
(analog)
0-24V
(digital)
screen
Photocell
Adjustment of sensitivity on photocell
Sensitivity knob
Run
Program selector switch
Memorize
Adjustment
Indicating lamp (LED)
1 Set Photocell reading on "White" background
2 Set Photocell memorize "White"
3 Set Photocell reading on "Black" background
4 Adjust LED lights up (Black background)
5 Adjust LED Out (Black background)
6 Set "RUN" Position

Textbook
MT-83033-1
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This textbook has been compiled by the Technical
Training Centre in Lund.
Some of the pictures in the book are also available as
OH pictures.
For further information on training material, please contact
the Technical Training Centre.
Issue 1/0005
© 2000, Technical Training Centre

No part of this publication may be reproduced, stored in a retrieval system or transmitted in
any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocop-
ying, recording or otherwise, without permission in writing from Technical Training Centre.
Training Document
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Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TMCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Design control offset adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Folding flaps and eccentric shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reading a register code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General
Most Tetra Brik packaging machines produce packages from FUHDVHG
packaging material. The creases are folding impressions to facilitate the
forming of the package.
&UHDVHGSDFNDJLQJPDWHULDO
The shaded area shows the part of

the packaging material used to make
RQH package.
7RSFUHDVH
%RWWRPFUHDVH
5HJLVWHUFRGH
On a finished package, the creases coincide with the edges of the package.
This means that the package must be made from a particular section of the
packaging material web. In order to achieve this, the machine must:
synchronise the material web with the jaw system, so that the jaws seal and
cut the package in the right places,
feed the material one package at a time in order to maintain synchronisation
with the jaws.

Feed one package

at a time
Synchronise packaging ma-
Jaw Jaw
terial and jaws
Jaw Jaw
It is the GHVLJQFRQWURO which synchronises material and jaws and causes one
package at a time to be fed forward. When this is done, the creases of the
package are correctly placed as the jaws move against the tube, so that the
machine produces packages of the ULJKWVKDSH.
This package is well shapen and folded On this package, the creases in the web
along the creases; it has been made and the edges (folding) of the package
from the appropriate section of the ma- do not coincide; it has been made from
terial web. the wrong section of the web.
However, the jaws do not have to hit the tube at an exact spot for the packages
to be correctly formed. The positions of the creases relative the jaws may
fluctuate within a VPDOOUDQJH without affecting the shape of the packages. The
design control device endeavours to place the creases in the PLGGOH of this
range by continually PDNLQJVOLJKWDGMXVWPHQWVRIWKHWXEHIHHG.
Construction
This picture shows the components that make up the design control.
TMCC
PLC
DMC
Photocells
TPOP
Folding flaps
Folding flap
mechanism
Servomotor Angle encoder
The SKRWRFHOOV sense the register code, a mark printed on every package.
When the register code moves past the photocells, signals are generated which
are decoded by TMCC. The decoded signal is referred to as GHVLJQVLJQDO.
The GHVLJQFRQWURORIIVHW, on the TPOP, is used to regulate the crease position
manually relative the jaws.
The DQJOHHQFRGHU is connected to the drive of the machine and continually
reads the machine position in the form of an electric signal. As the jaws are
connected with the drive, this signal also defines the position of the jaws. The
position of the machine (machine angle) can be read on the display of the angle
encoder.
The 70&& (Tetra Pak Multi-Purpose Controller) incorporates the program
for the design control. It receives the signals from the photocells and the angle
encoder. The TMCC then determines, based on these signals, whether to
increase or decrease the feed rate of the packaging material web (tube).
The 3/& comprises the control system of the machine. For instance, it
provides the TMCC with certain data, required for the design control function.
The '0& (Digital Motion Controller) converts information received from the
TMCC to the required servomotor position.
The VHUYRPRWRU is a kind of motor capable of stopping in a defined position
with great precision. It is mechanically connected to the folding flaps and thus
determine how far they move, i e their stroke.
The IROGLQJIODSV regulate the feed rate of the packaging material web. They
can assume any one of 256 positions (steps 0 - 255).
• 6WHSV constitute the regulation range during production. At step 0,
feed of packaging material is at a minimum, while step 255 gives the highest
feed rate.
• 3UHFRUUHFWLRQ, a folding flap position utilised during start that affects the
feed rate very little.
Photocells
Servomotor Folding flaps
DMC
Angle encoder
TMCC
Design control
offset PLC
Function
:KDWKDSSHQV" Through its in-movement, the jaws provides the fixed and major feed of
packaging material. The design control then adds a small amount of web feed
by means of the folding flaps.
If the crease position is high relative the jaws, the design control increases the
feed of material, i e the additional feed is greater.
If the crease position is low, the design control reduces the feed of material, i
e the additional feed is less.
The feed rate is regulated by DOWHULQJWKHVWURNHRIWKHIROGLQJIODSV.
Folding flap
The folding flap stroke increases when the The folding flap stroke decreases when the
creases are positioned high (→ step 255). creases are positioned low (→ step 0)
The design control device endeavours to regulate the speed (feed rate) of the
tube, so that it is as close to the machine speed as possible. )ROGLQJIODS
VWURNHV (regulation range) SURYLGHVYLUWXDOO\OLQHDUUHJXODWLRQRIWKH
IHHGUDWH. How much the design control device is to add to the feed depends
on where the creases are positioned relative the jaws.
Folding flap stroke

3UHFRUUHFWLRQ
Feed rate
To determine whether to increase or decrease the feed rate, the machine must
compare the crease position with the jaw position. The design signal is a pulse in-
dicating the crease position, and the angle encoder indicates the jaw position.
The design signal is generated by the photocells sensing the register code,
which is being decoded into a design signal in the TMCC. The register code is 1
printed on the packaging material in a defined place relative the creases.
Consequently, the register code defines the crease position as well. In order for 2
the packages to be well–shapen, and thus acceptable, the signal must be
received while the machine is positioned within a certain range. This range is
called the SURGXFWLRQVHFWRU, or the range for acceptable packages.
Production sector (1)

Decoding Design signal Production angle (2)
TMCC
The production sector is symmetrically located around the SURGXFWLRQ

DQJOH*. The production angle is the value of the angle retrieved by the TMCC see page 21 (terminology list)
from the PLC. The design control endeavours to place the design signal at the
production angle.
Design deviation is a measure of how the creases are located relative the 'HVLJQGHYLDWLRQ
FRUUHFWSRVLWLRQ. Correct position means that the design signal is received
precisely at the production angle.
The design deviation is expressed as a length, and must during production not
exceed ±1,5 mm. If the deviation is kept within ±1,5 mm, the packages are
correctly formed, indicating the design signal has come within the production
sector. This ±1,5 mm limits the production sector; there are no angle values
received from the PLC.
The TMCC computes the design deviation value by measuring when, in
relationship to the correct position, the design signal is received. 0 mm design
deviation means that the design signal comes at the production angle (in the
middle of the production sector).
Design signal $ %
Production sector
Machine position
$ %
Production angle,
Correct position
Design deviation
mm
-1,5 -1 -0,5 0 0,5 1 1,5
'HVLJQVLJQDO$ is coming early, relative the production angle. The design

deviation is -0.6 mm (low creases), and the folding flaps are to decrease the
feed rate in order to raise the crease position.
'HVLJQVLJQDO% is coming late. The design deviation is 1.1 mm (high creases),
and the folding flaps are to increase the feed rate in order to lower the crease
position.
The orientation and magnitude of the design deviation determines how the
stroke of the folding flaps is to be altered. Positive deviation, i e high crease
position, increases the folding flap stroke; towards step 255. Negative
deviation, i e low crease position, decreases the folding flap stroke; towards
step 0. The stroke is altered by the number of steps which corresponds to the
current design deviation. The design control endeavours to minimize the
design deviation.
([DPSOH Below, an example is illustrated of how the design is regulated, reaching a

stable position; two cases are shown with different initial premises and precon-
ditions (A and B)
The upper part of the diagram shows the feed provided by the folding flaps,
and the lower part shows the fixed feed provided by the jaws. The jaws provide
the major proportion of the total feed.

Feed rate
-1,5 mm
$
)HHGE\IROGLQJIODSV
+1,5 mm
-1,5 mm
%
+1,5 mm
Time
The graphs for examples A and B show how the folding flap stroke is altered
in order to regulate the design. The shaded areas above and below the curves
represent the design deviation.
In example A, the folding flaps add relatively much to the feed in order to
minimize the design deviation. The stroke is being stabilized around step 180.
)HHGE\MDZV
In example B, the folding flaps add relatively little to the feed in order to
minimize the design deviation. The stroke is being stabilized around step 80.
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DPLQLPXPDWIROGLQJIODSVWURNHVWHSLHKDOIZD\WKURXJKWKHUHJXODWLRQ
UDQJH,QERWKWKHDERYHH[DPSOHVPLQLPXPGHVLJQGHYLDWLRQLVUHDFKHGDW
GLIIHUHQWVWHSVZLWKLQWKHUHJXODWLRQUDQJHH[DFWO\ZKHUHGHSHQGVRQSUHYDLO
LQJFRQGLWLRQVPDFKLQHPDWHULDOSURGXFWSUHVVXUHHWF,IWKHIROGLQJIODSV
KDYHWRFRQWULEXWHPXFKWRWKHIHHGWKHIROGLQJIODSVWURNHHQGVXSLQWKH
KLJKHUSDUWRIWKHUHJXODWLRQUDQJHDQGYLFHYHUVD
TMCC
TMCC is a programmable control board used for a variety of functions in the
Tetra Pak machines. The diagram below shows how TMCC works in the
design control device for TBA/22. The front of the board is illustrated
overleaf, where there are also explanations of the various LEDs, switches, etc.
on the board.
Photocells
TMCC
Register code
decoding
Angle decoding
Angle encoder
Servomotor
PID regulation
Design control
offset
Output data to DMC DMC
Communication
Terminal with PLC and ter-
(PC) minal (PC)
PLC
Settings
DCS22 Design Control System 22

The TMCC program (DCS22) consists of six principal functions:
• 5HJLVWHUFRGHGHFRGLQJ: This part of the program decodes the signals from
the photocells, converting them into a design signal.
• $QJOHGHFRGLQJ: This part decodes the angle values utilized in the design
control.
• 3,'UHJXODWLRQ: Here the design deviation is computed and the stroke of
the folding flaps determined. The computation consists of a PID algoritm.
• 2XWSXWGDWDWR'0& (servomotor): This part of the program provides data
for the DMC on the folding flap stroke.
• &RPPXQLFDWLRQZLWK3/&DQGWHUPLQDO (PC).
• 6HWWLQJV: Here are stored volume-dependent parameters (values) retrieved
by the TMCC from the PLC.
TMCC, front
TMCC LEDs explained:
)$8/7 (red) not used in this application.
TMCC 32:(5(green) indicates that the TMCC is powered with the correct voltage.
6(yellow) flashes when the register code is being decoded.
FAULT 6 (yellow) lights up when acceptable packages are being produced. (Design OK.)
POWER
66(yellow) not used in this application.
S1
6 (yellow) lights up when the design control works in the upper part of the regulation
S2
S3 range, 75-100% of the range.
S4
S5
6 (yellow) lights up when the design control works in the lower part of the regulation
S6 range, 0-25% of the range.
S7
S8
An identical TMCC is used for all package volumes. Volume-dependent data,

(SW1) needed by the TMCC, are collected from the PLC.
It is possible to communicate with the TMCC via TIT (terminal, PC).
Upon the command 5 (on-line), the following is displayed continuously:
• Design deviation for the current package
• Mean deviation for the ten latest packages produced
(Terminal) • Folding flap stroke, mean position for the ten latest packages produced
Upon the command 6 (status), further information on design control can be
obtained, for instance volume-dependent parameters which the TMCC
collects from the PLC:
• Machine speed, in terms of packages per hour
• Web cutting pitch, also called Repeat length, volume-dependent parameter
collected from the PLC
• Production angle, volume-dependent parameter collected from the PLC
• Design control offset setting (±500 scale units, about ±5 mm)
• Control parameters P, I, and D
The TMCC also has an analogue output 0-10V (terminal), from which it is
possible to transmit one of the parameters listed above, for instance to a
recorder. With the selector 0 - F (SW1), the parameter to be transmitted from
the output is selected. 1RWH that the selector must never be set at 0 during
operation. 0 is a programming position which zeroes all the parameters in the
TMCC.
The TMCC also communicates with the TPOP via the PLC. These are the
alarms available:
• 0DOIXQFWLRQSKRWRFHOOV: if the photocells fail to sense the register code,
this alarm is triggered. The machine runs on with the same folding flap
stroke for another five register codes. If the photocells have not resumed
sensing the register code, the machine will stop.
• 3ULQWHGGHVLJQRXWRIOLPLW: If the design deviation of six consecutive
packages exceed ±1,5 mm, this alarm is triggered and the packages are
discarded. If the design deviation continues to exceed ±1,5 mm the machine
will stop after 100 such packages. Just five package with a deviation ex-
ceeding ±1,5 mm is allowed and led into the final folder.
• 6HUYRV\VWHPIDXOW: in case of a servo system fault, an alarm indicates this
fact on the TPOP.
Design control offset adjustment
The position of the creases can be adjusted manually by means of the design
control offset adjustment (on the TPOP). Everything described in the
foregoing (pages 3 - 11) refers to the automatic part of the design control. In
order to make it easier to understand the function of the design control offset
adjustment, one should deal with this separately from the automatic control.
• The DXWRPDWLFFRQWURO endeavours to achieve the correct position (design
signal at the production angle).
• 0DQXDOUHJXODWLRQ, by means of the design control offset adjustment, de-
termines where this position is.
Together, this makes the packages obtain the correct shape, i e with the creases
in the right places.
Then, what does a correctly formed package look like? Correctly formed, the &RUUHFWVKDSH
package material is folded along the top and bottom creases, as illustrated
below.
The crease is designed to fold in this precise manner. That is why the crease
does not have to be in the exactly correct position in order to fold correctly.
In order to determine whether the package is correctly formed, one has to look
at a ILQLVKHGSDFNDJH, i e one that has come out of the final folder. Such a
check is part of the package checking procedure by the machine operator.
The automatic control is unable to determine how the creases are actually
folded. All it is able to is to sense how the GHVLJQVLJQDO relates to the jaws;
thus is it only LQGLUHFWO\¶DZDUH¶RIKRZWKHFUHDVHVDUHEHLQJIROGHG.
There are always variations in the packaging material, tolerances in the
machine, etc, which cause packages sometimes to be incorrectly formed in
spite of the fact that the design signal comes within the production sector.
Faults, like the one illustrated above, may occur, for instance if the register
code location relative the creases is close to the limit of what the packaging
material specification accepts. In the example below, the distance between the
register code and the bottom crease is on the long side but still within the
tolerance.
Crease position Crease position
too low on the too high on the
package package
Register code
Bottom crease, correct position as per specification

Tolerance range
Bottom crease, actual position
The automatic design control device will endeavour to fold the packaging
material at the correct position, as specified, as that is where the TMCC
assumes the crease to be. The design correction offset adjustment is now used
to shift the correct position so that it coincides with the actual position, i e shift
the position towards which the automatic design control aims.
&RQFOXVLRQ If the crease position is not correct, in spite of design signal
within the production sector, the crease position must be adjusted by means of
the design control offset. It is possible to shift the crease position about ±5 mm.
Increasing the value raises the crease position on the package, decreasing the
value lowers it.
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HDOWHULQJWKHUHODWLRQVKLSEHWZHHQWKHGHVLJQVLJQDODQGWKHMDZV
$OVRQRWHWKDWWKHSDFNDJHVDUHPDGHXSVLGHGRZQLQWKHMDZV\VWHP/RZ
FUHDVHSRVLWLRQRQWKHSDFNDJHPXVWQRWEHFRQIXVHGZLWKORZFUHDVHSRVLWLRQ
UHODWLYHWKHYROXPHIODSV
In order to show what happens on changing the offset, we shall go through an ([DPSOH
example. It presumes that the creases are 1.5 mm too high on the finished
packages, in spite of the design signal close to the production angle. The folding
flap stroke fluctuates around step 160, and the offset value is set at 0.
Design signal
Machine position
Production angle,
Correct position
Design deviation
-2 -1 0 1 2 3 4
Crease position
+3 +2 +1 0 -1 -2 -3
The design deviation is close to 0, but the crease position on the finished
packages is offset by +1.5 mm, i e too high crease position on the finished
packages.
In order to compensate this fault, the offset should be decreased by appr 150
scale units. This will shift the production angle so that a design deviation close
to zero will place the creases correctly on the finished packages. The design
deviation will now, temporarily, be -1.5 mm, but is quickly being regulated
and closes in on zero again (1, 2, 3, and 4 in the diagram below).
1 2 3 4
Machine position
Production angle,
Correct position
Design deviation
-3 -2 -1 0 1 2 3
Crease position
+3 +2 +1 0 -1 -2 -3
On changing the offset, the folding flap stroke is temporarily decreased in

order to raise the crease position. After a while, the folding flap stroke will
stabilize around step 160 once again.
The diagrams below illustrate LQSULQFLSOH what happens when the offset is
being changed, in accordance with the example on the previous page.
1 2 3 4 Produced packages
200
100
2IIVHW 0
-100
-200
1
'HVLJQGHYLDWLRQ 0
-1
-2
-1
&UHDVHSRVLWLRQ 0
+1
+2
180
170
)ROGLQJIODS 160
VWURNH 150
140
130
120
1 2 3 4 Produced packages
Start
The machine always start and stop with the design in correct position, except
at the first start after WLJKWWXEH and when VWHULOHLQFKLQJ has been performed.
)LUVWVWDUW
After WLJKWWXEH and VWHULOHLQFKLQJ has been performed the folding flaps are
in SUHFRUUHFWLRQ. When the machine is started the folding flaps consequently
affect the feed very little, and the packaging material web is fed forward
slowly relative the machine.
The folding flaps will remain in precorrection position until the design signal Precorrection
appears within the precorrection out sector. This will cause the flaps to assume
a position within the normal regulating range, step 0-255.
Design signal Design signal
Precorrection Precorrection out Machine

position
Precorrection out sector

Production sector
The precorrection out sector is made quite wide, corresponding to a design

deviation of ±10 mm. When the design signal enters the sector the folding flaps
will go to step 0 or step 255, depending on if the sector is entered when +10
mm or -10 mm of design deviation. The design control system will then
quickly correct the deviation toward 0 mm.
2WKHUVWDUWV
All other starts are performed when the correct design position is maintained
from the preceding stop. The folding flaps are kept in a step between 0 and
255. This allow the machine to make correctly formed packages immediately
after the start with the design in correct position.
The diagram illustrates an example of the starting sequence.

Feed rate
-1.5 mm

+1.5 mm
)ROGLQJIODSV
Design deviation within ±10 mm
3UH
FRUU
-DZV
Time
Folding flaps and eccentric
shafts
The stroke of the folding flaps affect the feed rate of the packaging material
web; consequently, it is the stroke that controls the design. How great the
folding flap stroke becomes, depends on the position of the servomotor.
Folding flaps Folding flap cam

Stop block
Gearing ratio
Eccentric shafts
Servomotor
The position of the servomotor actuates, via a timing belt reduction gearing,
the eccentric shafts, which in its turn shifts the folding flap cam sideways. The
sideways, or lateral, position of this cam determines how far the mechanism is
to pull the folding flaps and thus the magnitude of the folding flap stroke.
In order to further explain how the design control device works, we shall take (FFHQWULFVKDIWV
a closer look at the eccentric shaft. But before that, we shall briefly explain
how the servomotor works, as the position of the eccentric shafts is
proportional to the servomotor position.
The URWDWLRQRIWKHVHUYRPRWRU is controlled by positions, and to turn it
through one full revolution, 16 384 positions are required. Characteristic of the
servomotor is that it has extremely exact positions.
When the TMCC says that the folding flaps are to go to, for instance, step 0,
the following happens: The DMC converts step 0 into the value 25 000 and
starts the servomotor. The motor then feeds back continuous information to
the DMC in its current position, and when the motor position equals 25 000, it
stops. It has now rotated one revolution + 8616 positions.
The diagram overleaf describes the different positions of the eccentric shafts.
Step 255, 0.7 mm*
Closed position, 0.5 mm*
Step 0 Regulating range
Precorrection
Stop block
Home position sensor
* Distance to inductor
Home position Mechanical stop
0HFKDQLFDOVWRS
The mechanical stop prevents the eccentric shaft from rotating further in that
direction. The stop also functions as calibration position for the servomotor.
When the machine is started, the servomotor rotates until the eccentric shaft
reaches the mechanical stop.
+RPHSRVLWLRQ(reference position)
The home position is located 400 positions from the stop.
3UHFRUUHFWLRQ
Precorrection, 18875 positions from the stop.
6WHS
Step 0, 29000 positions, the position in the regulating range where the feed of
material is increased the least.
6WHS
Step 255, 41750 positions, the position in the regulating range where the feed
of material is increased the most.
&ORVHGSRVLWLRQ
In this position, the folding flaps reach 0.5 mm from the inductor. This
position is used for mechanical settings and is never reached during
production.
Reading a register code
The register code is a printed mark on the packaging material. When it passes
the photocells, the cells read the 26 digital information bits in a particular
order. These bits are decoded into a pulse, the design signal, in the TMCC.
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DJLQJPDWHULDOEXWWKHUHDGLQJRIWKHUHJLVWHUFRGHELWVLQWKHULJKWRUGHU
LVUHTXLUHGWRHQDEOHWKHGHFRGLQJRIDGHVLJQVLJQDO
When one of the photocells reads a flank on the register code, both photocells :KDWKDSSHQV"
register what they ’see’: blank, white, positive flank, or negative flank. This is
translated into a binary code (ones and zeroes) as follows:
%ODFN
:KLWH
3RVLWLYHIODQN (white to black)
1HJDWLYHIODQN (black to white)
The binary code is stored in a shift register as it is read when the register code
passes the photocells. The contents of the shift register are compared
continuously with the contents of another register with fixed contents. When
the lines of ones and zeroes are identical in both registers, the register code has
been decoded, and a pulse, the GHVLJQVLJQDO, is generated.
Shift register where the binary

code from the photocells is
stored

Register with fixed contents
The design signal is generated when the

contents of the two registers are identical.
Below, an example is shown of how the photocells read the register code.
Here photocell B reads a negative

flank and A reads black (A, B)
is transmitted to the shift register.
Here photocell B reads a posi-

tive flank and A reads white
(A, B) is transmitted to the shift
register.
$ %
Glossary
:HEFXWWLQJSLWFK The length of the cut-off piece of packaging material
required to make one package. Also called Repeat
length.
$XWRPDWLFUHJXODWLRQ The automatic regulation endeavours to reach the
correct position, with the design signal within the
production sector.
&UHDVHSRVLWLRQ The position of the creases on the finished package.
Correct crease position results in correctly formed
packages.
'HVLJQGHYLDWLRQ A measure of where the design signal is relative the
production angle (correct position); must not exceed
±1.5 mm during production. In other contexts also
termed design error.
'HVLJQVLJQDO Pulse generated each time the register code passes
the photocells. It indicates the crease position indi-
rectly. In other contexts also termed photocell puls,
photocell signal or register mark.
3UHFRUUHFWLRQ The folding flap position used during start and inch-
ing.
&RUUHFWSRVLWLRQ No (0) design deviation, design signal exactly at the
production angle.
0DQXDOUHJXODWLRQ Manual regulation (design control offset) is used in
order to adjust the crease position ZKHQWKHGHVLJQ
VLJQDOLVZLWKLQWKHSURGXFWLRQVHFWRU.
0DFKLQHSRVLWLRQ The angle position of the main shaft of the machine;
indicates through mechanical connection the posi-
tion of the jaws.
1HJDWLYHIODQN When a photocell reads the change from black to
white, it registers a negative flank; a negative flank
produces a logic zero (0).
3RVLWLYHIODQN When a photocell reads the change from white to
black, it registers a positive flank; a positive flank
produces a logic one (1).
3URGXFWLRQVHFWRU Corresponds to an angle sector in which the design
deviation lies within ±1.5 mm; also termed range for
acceptable packages.
3URGXFWLRQDQJOH The positive flank of the angle value with which the
design signal is compared in order to enable the
TMCC to compute the design deviation. The produc-
tion angle is a volume-dependent parameter collect-
ed by the TMCC from the PLC.
5HJLVWHUFRGH Mark on the packaging material which the photocells
read. In other contexts also termed register mark,
photocell mark, or bar code.
5HJXODWLRQUDQJH Step 0-255. Used to control the design during pro-
duction.
)ROGLQJIODSVWURNH Folding flap steps 0 - 255; how much the folding
flaps affect the feed of packaging material.
Tetra Pak Description
1. Table of Content
1. TABLE OF CONTENT .............................................................................................................................1
2. ABBREVIATIONS....................................................................................................................................1
3. INTRODUCTION .....................................................................................................................................1
4. DESIGN CONTROL SYSTEM OVERVIEW ...............................................................................................2
5. TMCC CONNECTIONS...........................................................................................................................3
6. BASIC PROGRAM FUNCTIONS ..............................................................................................................5
7. OTHER PROGRAM FUNCTIONS ............................................................................................................6
8. TMCC FRONT PANEL SWITCH .............................................................................................................7
9. TMCC FRONT PANEL LEDS .................................................................................................................8
10. ENCODER FUNCTION AND GRAY CODES .............................................................................................8
11. OUTPUT SIGNAL ...................................................................................................................................8
12. DESIGN ADJUSTMENT SIGNAL .............................................................................................................8
13. TERMINAL (PC) COMMUNICATION ........................................................................................................9
14. VOLUME PARAMETER TRANSFER ......................................................................................................11
15. PROGRAM DOWNLOAD.......................................................................................................................12
16. APPENDICES .......................................................................................................................................13
2. Abbreviations
DCS22 Design Control System for TBA/22 filling machines
DCS21 Design Control System for TBA/21 filling machines
DCU Design Correction Unit (68 457-010V)
EEPROM Electrically Erasable/Programmable Read-Only Memory
LED Light Emitting Diode
PC Personal Computer
PID Proportional, Integral and Derivative control algorithm
PLC Programmable Logic Controller, (like TPMC or GE-Fanuc)
TMCC Tetra Pak Multi-Purpose Compact Controller (558 230-0300)
TPOP Tetra Pak Operator Panel
Flexbox Industrial Computer Interfacing the TPOP and logging the machine events
3. Introduction
The DCS22 program is intended for the TBA/22 filling machines, and the program runs on the TMCC,
Tetra Pak Multi-purpose Compact Controller, hardware. The program reads the register mark photocells
at the paper tube and the machine angle encoder. From these parameters the output is calculated via a
PID-algorithm. This output value is sent, through the analog output 0, to a servomotor system which
moves the folding flaps.
The DCS22 program is based on the DCS21 program and it’s intended for TBA/22 filling machines.
This Functional Description is intended for users of the DCS22 "function", i.e. electrical designers, test
engineers, service engineers and alike. Its purpose is to give a full understanding of the behaviour of the
DCS22 program together with the TMCC as a system. (The internal structures of the DCS22 program will
not be discussed. For electronic system development purposes a special report covering these areas is
available.)
Tetra Brik PS S.p.A. Functional Description

Issued by / Date: Approved by / Date: ECN 73343
Fabio Bassissi / 10-Feb-2000 Fabio Bassissi / 10-Feb-2000
Identity Document type Version Page
4-58716-0000 DSC 00 1 (14)
4. Design Control System Overview

The design control system can be illustrated as below, where TMCC is the central part in the system, and
all other parts in the system are connected to the TMCC. Inside the TMCC symbol is a simple
representation of the functional blocks of the software:
Photocells TMCC
Read
Photocells
α Angle Encoder Servo Motor

Read
Angle Encoder
TPOP
Calculation
(PID)
Servo Driver
Output to
Flexbox
Servo Driver
PLC
Communication Terminal, (PC)
with PLC
and Terminal
Parameter
Settings
The connections and the functions are explained in the following pages. The DCS22 program flow is
further explained in the "Basic Program Functions" chapter.

4-58716-0000 DSC 00 2 (14)
5. TMCC connections
The TMCC is a general purpose hardware and its inputs and outputs are fully controlled by the software,
in this case the DCS22 program. The connections below have been chosen for the DCS22 function (a pin
connection diagram is available in the appendices):
+24V
1 TMCC
2 Power Supply 25 Volume Acknowledge
Ground 26
HighOut0-3 Not used
9 27
Angle Encoder, bit0 Regulating Mode Signal
10 28
Not used
11
12 AnalogOut0 5
Analog Output to Servo Driver
13 LowIn0-7
14 31
HighOut6-7 Register Mark Photocell Pulse
15 32
Design OK
16
Angle Encoder, bit7 6
AnalogOut1 Diagnostic Analogue Output
17
Register Mark Photocell, (4bar)
18 HighIn0-1
Register Mark Photocell, (3bar)
3
Design Adjustment Signal AnalogIn0
20
DCS22 Enabled HighIn3
7
Not used FastIn0
22
Volume Enable
23
Volume Clock HighIn5-7
24
Volume Data HighIn/LowOut2 19
Not Used
HighIn/LowOut4 21
Not Used
HighOut4 29
4 Not Used
Not Used AnalogIn1 HighOut5 30
8 Not used
Not Used FastIn1
The functions of these signals are as follows (some functions are further explained in the
following chapters):
+24V +24 Volt power supply. From the Electrical Cabinet +24V supply.
Ground Ground power supply. From the Electrical Cabinet ground connection.
Angle Encoder, bit0 - bit7

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

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

4-58716-0000 DSC 00 3 (14)
Register Mark Photocell, (3bars)
24V input from the register mark photocell positioned beside the paper tube above the jaw
system. The (3bars) indicates that this photocell reads the 3 bars part of the register mark
(also called data).
DCS22 Enabled
24V input from the PLC. When this signal is:
• LOW (0V) - the DCS22 sets the precorrection mode.
• HIGH (24V) - the DCS22 runs in the regulating mode.
(Refer to next chapters for explanation of the precorrection and regulating modes).
Volume Enable
Volume Clock
Volume Data
These 24V input signals are controlled from the PLC. They are used for transmitting the
Repeat Length and Production Sector values to the DCS22 program. Refer to the chapter
below describing this transmission protocol.
Analog Output To Servo Driver

Analog (0-10V) output signal connected to the servo driver. The servo driver reads this
analog signal and moves the folding flaps in order to actuate the corrections requested by
P.I.D. algorithm of the TMCC. For more information related to the relationship between the
analog voltage (0…10V) and the mechanical position of the folding flaps, refer to the
servomotor application program description or the maintenance manual.
Register Mark Photocell Pulse

24V output to the PLC. This is a 40 ms long pulse sent when the DCS22 program has
decoded a register mark.
Design OK
24V output to the PLC. This signal is HIGH (24V) as long as the design error of a package
is less than ±1.5.
Diagnostic Analog Output

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

8 Design error of current package (∗ ∗ ).
A Filtered design error ("90% old + 10% new"-algorithm). (∗ ∗)
B Output signal to the servo driver.
C Filtered output signal.
D Design Adjustment potentiometer.
∗ 0…10V on this output equals to -5…+5 mm.
Refer to the appropriate chapter below for a complete description of this function.
Volume Acknowledge
This is a 24V output to the PLC. Refer to the chapter below describing the transmission
protocol for volume parameters.
Regulating Mode Signal

This is a 24V output to the PLC. When the DCS22 program is in precorrection mode status
this signal is low. This signal goes high only when the DCS22 program enters into regulating
mode.

4-58716-0000 DSC 00 4 (14)
Design Adjustment Analog Input

Analog (0-10V) input which is connected to the PLC analog output. A voltage close to 0V
means that the paper tube position (compared with the jaws) will be higher than with a
voltage close to 10V (in other words: an increasing voltage on this input will move the
paper tube downwards in the jaw system).
The total tube adjustment range is ± 5 mm.
Not Used
These inputs and outputs are not used in the DCS22 program. They should be left
unconnected.
6. Basic Program Functions

The DCS22 program for the TMCC is written in the C-language and it is not possible to modify this
without the proper knowledge and development tools (this must be done in a technical development
facility). The parameters that need to be changed (e.g. volume parameters) are controlled from the PLC.
Program flow:
At start-up or reset (the TMCC may be reset manually by setting the SW1 switch on the front panel in
position "0" for a few seconds, then back to its previous position and finally turning off and on the TMCC
card) the DCS22 program initiates all its internal variables and reads the volume parameters sent from
the PLC. After this first step the program enters an eternal loop, i.e. it repeats the program over and over
again. This loop has the following basic functions:
• Wait for a valid photocell reading of the register mark. This routine decodes the edges of the register
mark (and of the other part of the design as well) and for every edge (black to white, white to black) it
stores the photocell values in a shift register. The shift register is a 26-bit single register (compared to
the first MultiStep routine that used two separate shift registers with 6 and 7 bits respectively, which in
some cases could cause a false decoding). This shift register is compared with a special pattern that
corresponds to a correct register mark. If they are equal a register mark has been detected and the
program can proceed with its calculations.
• When the register mark has been detected the DCS22 program reads the machine angle encoder. To
get an acceptable accuracy of the machine angle an interpolation is done by comparing the remaining
time of the current angle (i.e. until the angle encoder changes to a new value) with the time for a
complete angle. This gives a decimal number (for example, 72.95) telling where the register mark is in
relation to the machine jaw system.
• When the register mark has been detected the DCS22 program also sends the Register Mark
Photocell Pulse signal to the PLC without any delay.
• The calculated register mark angle is now compared with the preferred design angle, i.e. the
production sector set from the PLC offset by the Design Adjustment value (for example, 74 - 1.25 =
72.75). The comparison gives the angle error and together with the repeat length it is possible to
calculate the design error in millimetres for the current package (the example: 72.95 - 72.75 = 0.20;
0,20 * 245(repeat length) / 256(no of sectors per package) = 0.19 mm design error). The design error
is positive if the register mark (the design) is too "high" in relation to the jaw system, and vice versa.
• The design error is used as an input to the PID control algorithm. The algorithm uses a quadratic P-
part, which means that it has a faster response for larger design errors. Otherwise, it is a standard
P.I.D. with integral and output range limitations. The P, I and D factors have been tested on filling
machines to give a well working design control in both normal production and start/stop sequences.
In order to achieve the better performances of the controlling action, all P.I.D. parameters are scaled
differently according to the design error. If the design error is outside the ±5 mm window the regulator

4-58716-0000 DSC 00 5 (14)
output drives directly the analog output of the TMCC. In this way the DCS22 is capable to minimize
the time needed to reach the design position. When the design error enters into the previous window
the regulator output is divided by 8. This means a smother controlling action and a better stability of
the design control system.
• When the P.I.D. algorithm has calculated a new output value, ranging from 0 (precorrection) to 255
(maximal paper pull), this is converted into an analogue signal 0…10 V to the Servo Driver which
relies the folding flaps movement.
• From the calculated design error the DCS22 program also decides whether it should accept the
package or not. If the package is accepted the DesignOK signal to the PLC is set. The decision is
based upon the following rules:
Design Error Package Accepted

Design error of last package is less than ±1.5 mm YES
Otherwise NO
• The DCS22 program then start again to search for a new register mark.
Besides this main program flow the DCS22 program also checks if anything is sent from a terminal
through the RS-232 serial interface. If so, it returns the appropriate answers to the terminal, refer to the
"Terminal communication" chapter.
7. Other Program Functions

Besides the basic program functions described above the DCS22 program performs some other
functions and decisions:
Precorrection vs. Regulating mode:

• The TMCC analog output, which drives the Servo motor driver, works in the range 0…10 Volts. The
value displaied by the TMCC, thought the serial port, can therefore be from 0 to 255.
• The precorrection mode is used when the paper tube is far out of design, to move it as fast as
possible to the correct position. The precorrection position lets the paper tube "move upwards" in
relation to the jaws.
• A normal production start always begins in the precorrection mode. The DCS22 program continuously
calculates the design error, also during precorrection mode. A number of packages are thrown away
before the PLC turn on the signal DCS22 enabled. From this moment the DCS22 stays in
precorrection mode until the design error becomes less than ±10 mm; when this condition is fulfilled
the DCS22 enters in regulating mode and turns on the Regulating mode signal.
• When in regulating mode the DCS22 program tries to keep as low design error as possible. When the
design error is less than ±1.5 mm then the Design OK signal (and front panel LED) is turned on. The
filling machine is "in production".
• When the DCS22 program runs in the regulating mode it continues in this mode until:
• more that five consecutive packages have a design error greater than ±10 mm,
• more than four Register Marks should have passed the photocells, i.e. they are missed,
• the PLC resets the DCS22 Enable signal.
When one, or more, of these condition is true the DCS22 program switches to precorrection mode
(and consequently the Regulating mode signal turns off).

4-58716-0000 DSC 00 6 (14)
• When the filling machine is in short stop the design control system remains in regulating mode. When
started again the DCS22 program tries to keep the design control as good as possible, just like in
normal production mode.
Volume Parameters:
• Normally the volume parameters are sent from the PLC, refer to the "Volume Parameter Transfer"
chapter. In this case the SW2 of the TMCC card must be set to position '0'.
• However, for test purposes and in special cases, it is possible to set a default Repeat Length and
Production Angle with the SW2 switch on the TMCC side (the TMCC must be pulled out of the rack
system). The Repeat Length and production angle may be set to one of:
SW2 Pos. Repeat Length, mm Production Angle

0 Reserved Reserved
1 140 32
2 140 34
3 140 36
4 140 38
5 140 40
6 140 42
7 140 44
8 160 68
9 160 69
A 160 70
B 160 71
C 160 72
D 160 73
E 160 74
F 160 75
8. TMCC Front Panel Switch

The front panel switch SW1 is used for selecting one of the available formats for the diagnostic output.
The following table resumes the variable which can be monitored though the diagnostic analog output.
SW1 Function
0 Programming mode: in this position it is possible to download the DCS22 program. Refer to
the "Program Download" chapter.
1 to 7 Not used.
A ∗)
Filtered design error ("90% old + 10% new"-algorithm). (∗
B Output signal to the servo driver.
C Filtered output signal.
D Design Adjustment signal.
E Not used.
F Not used.
∗ ) 0…10V on this output equals to -5…+5 mm.
(∗
NOTE: In normal production mode the SW1 should be set to position 8.

4-58716-0000 DSC 00 7 (14)
9. TMCC Front Panel LEDs

The TMCC front panel LEDs have the following meaning in normal production mode:
LED Function
FAULT Not used in this program
POWER Should be turned on (Green). Indicates that the power supply to the TMCC is correct.
S1 Flashes when a Register Mark is detected, the flash being approx. 40 ms.
S2 Turns ON when the design is within ±1.5 mm i.e. "in production".
S3 Not used.
S4 Not used.
S5 Not used.
S6 Not used.
S7 ON = The analog output signal is set at its upper range ( greater than 192 = 7.5 V).
S8 ON = The analog output signal is set at its lower range ( less than 64 = 2.5 V).
10. Encoder Function and Gray Codes

The angle encoder is connected to the machine main shaft and outputs 256 degrees (values) for each
package. The encoder is a 256 degrees version which means that one package range from 0 to 255 and
then back to 0 again.
The value sent to the TMCC is Gray-coded, which means that only one of the eight signals (bits) changes
for each change in degree (this prevents erroneous angle values on the signal lines.) This also means
that the DCS22 program must convert the value into a "normal" representation before it can be used in
calculations. A conversion table is given in the appendices.
11. Output Signal

The PID algorithm calculates a new output value for every package. The calculated output value ranges
from 0 to 255. This value is converted into an analogue signal for the Servo motor driver that moves the
folding flaps accordingly. When the machine goes in precorrection the analog output signal is frozen.
12. Design Adjustment Signal

The TPOP is used to move (fine-adjust) the design position in relation to the jaw system. The TPOP is
connected via Flexbox to an analog output of the PLC. The DCS22 program converts the voltage level
into an angle offset that is then added to the constant production angle set by the PLC. The adjustment
range ±500 on TPOP corresponds to a movement of ±5 mm on the design position, this range being the
same for all volumes.
Negative settings will move the design downwards in relation to the jaw system, and vice versa.

4-58716-0000 DSC 00 8 (14)
13. Terminal (PC) communication

A terminal, or a PC with a terminal program, is not necessary during normal production, but may be used
for test and service purposes. Through the serial interface it is possible to see the design error, output
values and other DCS22 status values.
The communication is a standard RS-232 serial interface. Use a cable suitable for the TMCC and the PC
(terminal). Necessary pin connections are:
PC 9-pin TMCC 9-pin

female male
2 3
3 2
5 5
If you are using a PC, any terminal program may be used, like "TIT" or other terminals such as
Hyperterminal, windows 3.11 terminal etc. . Configure the program for:
• Baudrate: 9600
• Parity: None
• Bits: 8
• Stopbits: 1
• Flow Control: None
The commands and parameters, if any, to the DCS22 program is entered on the keyboard, and the
command is executed when the RETURN key is entered. (The commands and parameters are not
echoed on the terminal). The functions described below are available:
Annn Angle nnn. The Production Angle (=machine angle) may be set with this command. nnn is
the new angle value, ranging from 0 to 255 decimal degrees. Normally the Production Angle
is set from the PLC, but this command overrides the PLC setting. It may be used in test
purpose to find the correct nominal Production Angle, which will later be set from the PLC.
Note that the Design Adjustment Value set by the potentiometer is added to this value.
For example: A72 sets the Production Angle to 72 degrees.
Dddd D-constant: Sets the D parameter in the PID controller algorithm, in 1/100 units. The original
value will be restored after a TMCC reset.
E Displays the current Encoder value, first the hexadecimal Gray code, then converted to
decimal.
Fooo Force ooo. This command forces the analog output signal to a certain value which is (ooo).
F0 resets the forcing:
F0 Reset (disable) output force.
F1 Force to output = 0.
...
Iiii I-constant: Sets the I parameter in the PID controller algorithm, in 1/100 units. The original
Pppp P-constant: Sets the P parameter in the PID controller algorithm, in 1/100 units. The original

4-58716-0000 DSC 00 9 (14)
Rn Reporting ON/OFF. This command enables and disables the automatic reporting of the
design error and output value for every package.
R0 Disable reporting.
R1 Enable reporting.
S Status: This command displays a list of parameters that may be of interest for test and
service purposes:
***** DCS22 Status *****

DesignError, mean : 0.00
Output, mean : 0
Machine Speed, p/h: 65535
Repeat Length, mm : 0.00
Prod Angle, const : 0
Pot: 128
Pc: 1.29, Ic: 0.05, Dc: 0.10
H Displays the available commands as follows:
******************* DCS22 Help Menu *******************

S shows the status of the parameters
P<value> changes the P constant in 1/100 units
I<value> changes the I constant in 1/100 units
D<value> changes the D constant in 1/100 units
F<value> forces the analog output. F0 = disable forcing
R<value> R1=reporting ON R0=reporting OFF
A<value> changes the production angle
E shows the encoder position: gray, decimal
H shows the available commands

4-58716-0000 DSC 00 10 (14)
14. Volume Parameter Transfer

The Repeat Length, the Production Angle may be sent from the PLC to the DCS22 program. This
sending uses four digital +24V signals and the protocol is as follows:
From PLC:
VolumeEnable
VolumeClock
VolumeData
From TMCC:
VolumeAcknowledge
8. Repeat the message until

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

• The output bits are shifted with the least significant bit (LSB) first:
<LSB>Repeat Length<MSB><LSB>Production Angle<MSB>
• The Repeat Length is in 1/10 of mm, i.e. a repeat length of 245 mm is sent as 2450.
• The Production Angle is in integer degrees, i.e. a sector of 123 is sent as 123.
Other features:
• The signal VolumeAcknowledge in the protocol is useful when, for example, the PLC starts up earlier
than the TMCC, or if the TMCC is replaced or reset during power on. In these cases the
VolumeAcknowledge is reset to low and the PLC should start to send the message again.
• The DCS22 program must receive at least two complete message that are exactly the same before is
sets the VolumeAcknowledge signal.

4-58716-0000 DSC 00 11 (14)
15. Program Download

The DCS22 program should be downloaded to the TMCC during machine production, but it may be
necessary to do a new download if the TMCC has been replaced or if a new release of the DCS22
program is available. The download is done from a PC with at least one diskette station and one serial
RS-232 interface. Refer to the "Terminal (PC) Communication" chapter for a description of the
communication parameters.
Download procedure:
1. Connect the cable between the PC and the TMCC front panel connector.
2. Set the SW1 front panel switch to position "0"
3. Insert the program diskette marked "48197 - x01" (x = current revision) into the PC diskette station.
4. Start the download program TMCC11.EXE by entering the command: A:TMCC11<enter>
5. When the program menu appears enter the communication port in use, normally "1".
6. Now a directory listing will appear. Select the A: drive by pressing the <HOME> key.
7. A list of the files on diskette A: will appear. Select the file D48197.x01 (x = current revision) by
using the arrow keys. (First use the right arrow to select the file window).
8. When the file is selected press the function key <F2>, and the automatic download starts.
9. The progress of the download may be monitored in the lower part of the screen.
10. When the new program is downloaded without errors press the function key <F10> to exit the
TMCC11.EXE download program.
11. If a label (with the program number and LED functions) is supplied together with the diskette this label
should be affixed to the TMCC front panel, aligned with the LEDs.
12. Set the TMCC front panel switch SW1 to production position "8" and the download procedure is
finished.
13. Cycle the power OFF/ON by removing the TMCC card from the rack.

4-58716-0000 DSC 00 12 (14)
16. Appendices
Gray Code Table
Gray Dec Gray Dec Gray Dec Gray Dec
---- ---- 0 -••- ---- 64 ••------ 128 •-•----- 192
---- ---• 1 -••- ---• 65 ••-----• 129 •-•----• 193
---- --•• 2 -••- --•• 66 ••-- --•• 130 •-•- --•• 194
---- --•- 3 -••- --•- 67 ••----•- 131 •-•---•- 195
---- -••- 4 -••- -••- 68 ••-- -••- 132 •-•- -••- 196
---- -••• 5 -••- -••• 69 ••-- -••• 133 •-•- -••• 197
---- -•-• 6 -••- -•-• 70 ••-- -•-• 134 •-•- -•-• 198
---- -•-- 7 -••- -•-- 71 ••---•-- 135 •-•--•-- 199
---- ••-- 8 -••- ••-- 72 ••-- ••-- 136 •-•- ••-- 200
---- ••-• 9 -••- ••-• 73 ••-- ••-• 137 •-•- ••-• 201
---- •••• 10 -••- •••• 74 ••-- •••• 138 •-•- •••• 202
---- •••- 11 -••- •••- 75 ••-- •••- 139 •-•- •••- 203
---- •-•- 12 -••- •-•- 76 ••-- •-•- 140 •-•- •-•- 204
---- •-•• 13 -••- •-•• 77 ••-- •-•• 141 •-•- •-•• 205
---- •--• 14 -••- •--• 78 ••-- •--• 142 •-•- •--• 206
---- •--- 15 -••- •--- 79 ••-- •--- 143 •-•- •--- 207
---• •--- 16 -••• •--- 80 ••-• •--- 144 •-•• •--- 208
---• •--• 17 -••• •--• 81 ••-• •--• 145 •-•• •--• 209
---• •-•• 18 -••• •-•• 82 ••-• •-•• 146 •-•• •-•• 210
---• •-•- 19 -••• •-•- 83 ••-• •-•- 147 •-•• •-•- 211
---• •••- 20 -••• •••- 84 ••-• •••- 148 •-•• •••- 212
---• •••• 21 -••• •••• 85 ••-• •••• 149 •-•• •••• 213
---• ••-• 22 -••• ••-• 86 ••-• ••-• 150 •-•• ••-• 214
---• ••-- 23 -••• ••-- 87 ••-• ••-- 151 •-•• ••-- 215
---• -•-- 24 -••• -•-- 88 ••-• -•-- 152 •-•• -•-- 216
---• -•-• 25 -••• -•-• 89 ••-• -•-• 153 •-•• -•-• 217
---• -••• 26 -••• -••• 90 ••-• -••• 154 •-•• -••• 218
---• -••- 27 -••• -••- 91 ••-• -••- 155 •-•• -••- 219
---• --•- 28 -••• --•- 92 ••-• --•- 156 •-•• --•- 220
---• --•• 29 -••• --•• 93 ••-• --•• 157 •-•• --•• 221
---• ---• 30 -••• ---• 94 ••-• ---• 158 •-•• ---• 222
---• ---- 31 -••• ---- 95 ••-• ---- 159 •-•• ---- 223
--•• ---- 32 -•-• ---- 96 •••• ---- 160 •--• ---- 224
--•• ---• 33 -•-• ---• 97 •••• ---• 161 •--• ---• 225
--•• --•• 34 -•-• --•• 98 •••• --•• 162 •--• --•• 226
--•• --•- 35 -•-• --•- 99 •••• --•- 163 •--• --•- 227
--•• -••- 36 -•-• -••- 100 •••• -••- 164 •--• -••- 228
--•• -••• 37 -•-• -••• 101 •••• -••• 165 •--• -••• 229
--•• -•-• 38 -•-• -•-• 102 •••• -•-• 166 •--• -•-• 230
--•• -•-- 39 -•-• -•-- 103 •••• -•-- 167 •--• -•-- 231
--•• ••-- 40 -•-• ••-- 104 •••• ••-- 168 •--• ••-- 232
--•• ••-• 41 -•-• ••-• 105 •••• ••-• 169 •--• ••-• 233
--•• •••• 42 -•-• •••• 106 •••• •••• 170 •--• •••• 234
--•• •••- 43 -•-• •••- 107 •••• •••- 171 •--• •••- 235
--•• •-•- 44 -•-• •-•- 108 •••• •-•- 172 •--• •-•- 236
--•• •-•• 45 -•-• •-•• 109 •••• •-•• 173 •--• •-•• 237
--•• •--• 46 -•-• •--• 110 •••• •--• 174 •--• •--• 238
--•• •--- 47 -•-• •--- 111 •••• •--- 175 •--• •--- 239
--•- •--- 48 -•-- •--- 112 •••- •--- 176 •--- •--- 240
--•- •--• 49 -•-- •--• 113 •••- •--• 177 •--- •--• 241
--•- •-•• 50 -•-- •-•• 114 •••- •-•• 178 •--- •-•• 242
--•- •-•- 51 -•-- •-•- 115 •••- •-•- 179 •--- •-•- 243
--•- •••- 52 -•-- •••- 116 •••- •••- 180 •--- •••- 244
--•- •••• 53 -•-- •••• 117 •••- •••• 181 •--- •••• 245
--•- ••-• 54 -•-- ••-• 118 •••- ••-• 182 •--- ••-• 246
--•- ••-- 55 -•-- ••-- 119 •••- ••-- 183 •--- ••-- 247
--•- -•-- 56 -•-- -•-- 120 •••- -•-- 184 •--- -•-- 248
--•- -•-• 57 -•-- -•-• 121 •••- -•-• 185 •--- -•-• 249
--•- -••• 58 -•-- -••• 122 •••- -••• 186 •--- -••• 250
--•- -••- 59 -•-- -••- 123 •••- -••- 187 •--- -••- 251
--•- --•- 60 -•-- --•- 124 •••- --•- 188 •--- --•- 252
--•- --•• 61 -•-- --•• 125 •••- --•• 189 •--- --•• 253
--•- ---• 62 -•-- ---• 126 •••- ---• 190 •--- ---• 254
--•- ---- 63 -•-- ---- 127 •••- ---- 191 •--- ---- 255

4-58716-0000 DSC 00 13 (14)
Connection Diagram
LowIn0 9
+24V
1 +24V TMCC 10
AngleEncoder0 (LSB)
2 LowIn1 AngleEncoder1
Ground 0V 11
LowIn2 AngleEncoder2
LowIn3 12
AngleEncoder3
LowIn4 13
AngleEncoder4
LowIn5 14
Design Adjustment 3 AnalogIn0 AngleEncoder5
LowIn6 15
4 AnalogIn1 AngleEncoder6
LowIn7 16
AngleEncoder7 (MSB)
Servo Driver Signal 5 AnalogOut0
HighIn/LowOut0 17
DiagnosticOutput 6 AnalogOut1 RegisterMarkPhotocell, 4bar (clock)
HighIn/LowOut1 18
RegisterMarkPhotocell, 3bar (data)
HighIn/LowOut2 19
7 FastIn0
HighIn/LowOut3 20
8 FastIn1 DCS22 Enabled
HighIn/LowOut4 21
HighIn/LowOut5 22
VolumeEnable
HighIn/LowOut6 23
VolumeClock
RS-232/CAN HighIn/LowOut7 24
VolumeData
FP3 Transmit
FP2 Receive HighOut0 25 VolumeAcknowledge
FP4 StatusOut HighOut1 26
FP6 StatusIn HighOut2 27
FP5 28 Regulating Mode Signal
Ground HighOut3
FP7 +10V HighOut4 29
FP1 CANhigh HighOut5 30
FP9 CANlow HighOut6 31
Photocell pulse
FP8 NoConnect HighOut7 32
DesignOK

4-58716-0000 DSC 00 14 (14)
Description of how to download
an application program for
TMCC from Windows95/98
From main menu select Start - Programs - Accessories - Hyper Terminal,

Double click on Hypertrm
Enter a name and choose an icon to be able to continue. Press OK
In the square for ”Connect using” choose Com 1
Press OK
Set the port setting to the following:
Bits per second: 9600

Data bits: 8
Parity: None
Stop bits: 1
Flow control: None
Press OK
From the menu choose File, click on Properties
Click on Settings
Press ASCII Setup
Choose:
Send line ends with line feeds
Echo typed characters locally
Line delay: 100 milliseconds
Character delay: 0 milliseconds
Wrap lines that exceed terminal width
Press OK
Press OK
Set the multi-switch on the TMCC card to 0

Print: P1 Press: Enter
Print: E_FLASH Press: Enter
Print: D Press: Enter
From the menu choose Transfer - double click on Send Text File
Choose:
Look in: 3½Floppy (A:)
Files of type: All Files (*.*)
Double click on D48197.101
(example of a program name)
11
Final folder

Final folder
Package
Air for heating

Pressure
Movement

Swing frame Flap sealing

Lund, Sweden
Squeezer
Discharge unit
Machine type
TBA/22
Drive shaft
Conveyor
Chain support
Issue
1/9905
Station chain
Final folder
OH 806:2
Description
Final folder
Drive
Synchronisation
Final folder
Final folder
Conveyor
Final folder
Swing frame
Final folder
Infeed
Final folder
Flap sealing
X
Final folder
X
Squeezer
Package
Check temperature
Final folder
Home position FFU
Alarms
3x400 V AC
K 24 Emergency stops
Lund, Sweden
safety relay
K 25
Door guards
PLC Rectifier safety relay
Hardware enable
Machine type
570 V DC Safety relay

TBA/22
Find Home position

Synchrons drive K4
High speed inching
Low speed inching
Software enable
DMC Resolver Motor Final folder
Out ready
Position error
Issue
Home position Resolver signal

1/9905
Motor is running main motor

Home position
Home position
OH 839
Synchronize
internal clocks
1
To FFU DMC
2 Control of Final folder motor
12
ASU 2 R

ASU 2R
Packaging material web
Lund, Sweden TBA/21 HS 1/9905 OH 840:1
B 72234
B 6107
B 7512
B 7501 B 7412
B 72102
B 72112
B 72233
B 7403:1
B 7403:2
B 7401
B 72232
ASU 2R
Automatic splicing unit
PLC
Jog Jog
P P
MICRO MASTER MICRO MASTER
ASU 2R
Drive motor control
0 1000 2000 3000 4000 5000 6000 7000 8000 Time (mS)/Stroke (mm)
Reel 1 empty/
Lund, Sweden
manual signal splicing

B 74011 / S 7402
Reg. code sensor

Data B 74031
Clock B 74032
19000
Drive roller loop ASU 14000
M 7208 13000
1135 6235 7000
Loop full 0
A
DC brake
Machine type
5035
Web tension 10
Y 7407, C 74071, C 74072 0
5935
TBA/22
Pressure rail 10
Y 7408, C 7408 1170 4630
0
Lock cylinders 1 15
Y 7303, C 73031, C 73032 1170
0
1510
Cutting 24
Sequence diagram ASU

Y 7410, C 7410 1255
0
1510 6235
Material holders 100
Y 7411 C 7411, B 7411 4165
0
C 7414, B 7414
3835
Side feeder 1 − − − 2 488
2035
Issue
Y 7412, Y 7413, C 7412 0

1/9905
2395 3775
B 7412
B 7512
5275
Power switch ASU
K 7416 SA
4720 5170
Sealing
OH 841
A 7417, L 7417
5035
Lock cylinders 2 15
Y 7315, C 73151, C 73152 0
17500
Drive roller magazine ASU 14000
M 7217 13000
0
Web magazine full
A = 370 ms at 250 B 1 2 3 4 5 6 7 8 Splice sequence
A = 345 ms at 200 B finished
Basic function of the ASU
Production
Pressure rail cylinders Photocell, reading bar code Drive roller
C 7408 B 7403 M 7208
Web tension cylinders

C 7407 M
Inductor
L 7417
Knife
Cutting cylinder
C 7410
Side feeder cylinder Loop
C 7412, C 7413
Lock cylinders
C 7303, C 7315
Photocell,
start splice sequence
B 7401
Material holder cylinders

C 7411, C 7414
Packaging material

Technical Training Centre, Lund, Sweden TBA/21 1/9409 OH 500:1
Splicing, step 1
M 7208
C 7407 M
C 7411, C 7414 B 7401

Splicing, step 2
M 7208
C 7408
M
B 7403
C 7303

Splicing, step 3
C 7410

Splicing, step 4
C 7410
C 7411, C 7414

Splicing, step 5
C 7408
M
Prepared
station
C 7412 Prepared
C 7413 station

Splicing, step 6
C 7411, C 7414

Splicing, step 7
L 7417
C 7408

Splicing, step 8
C 7407 M
C 7315

13
Sealing

TPIH-2000
Textbook MT-83014-2
Longitudinal sealing
Strip applicator
Guide wheel
Adjusting screw Pressure roller

Automatic strip splicing unit
Bobin 1
B6208
Strip rotation monitor
B6207
Stripbreak
B6201
Indicator strip end bobin 1
B6204
Indicator stop of splicehed
Splicer ASSU
B6202 Cutting wire Air cooled channel

Bobin 2
Sealing band Strip holder

Textbook
TPIH-2000
MT-83014-2

Lund, Sweden
General information on IH
TPIH-2000 is a generator, which generates a high–frequency current. This
Induce = to bring current is utilized to induce heat in the packaging material, for instance in
about, to produce
transversal sealing. TPIH stands for Tetra Pak Induction Heating.
IH = induction heating The TBA machines are equipped with IH generators, and the high–frequency
current induces heat in the aluminium foil layer of the packaging material. The
heat causes the plastic (PE layers) to melt, and thus the packages can be sealed.
The induced heat causes the

Heat induced in the plastic (PE) to melt, so that the
aluminium layers packages can be sealed.
PE Al PE Paper PE
PE Paper PE Al PE
PE=Polyethylene Al=Aluminium
Induction heating is also employed to heat the PE layer at the opening arrange-
ment of the package. The heat changes the structure of the PE layer, making
the plastic more brittle. For this reason, the package becomes easier to open.
The method of heating a material without a direct source of heat, i e to produce
heat in the material, is based on a current of high frequency. One could say that
the high–frequency current transfers energy to the material,
There are two ways of producing heat by means of high–frequency current:
• Induction heating (for instance transversal sealing in TBA machines)
• Dielectric heating (for instance in a microwave oven)
Technical Training Centre2/9608 Training Document. For training purpose only. 5

Induction heating is used to heat materials which are electrically conductive Induction heating
(metals). This is the method employed in the TBA machines for transversal se-
aling, zone heating at the opening arrangement of the package, longitudinal se-
aling (TBA/21), strip application (TBA/21), and splicing of the packaging
material (TBA/21).
The diagram below shows the principle of this method.
High–frequency current
Coil
Magnetic field
Electric conductor
Induced current
The high–frequency current creates a magnetic field around the coil. This
magnetcic field oscillates in time (at the same frequency) with the current, in-
ducing a current in an electric conductor placed in the magnetic field. In its
turn, the induced current oscillates in time with the magnetic field and produ-
ces the energy that heats the material.
In the TBA machines, induction heating works as shown in the diagram below.
IH generator
Current path in the

aluminium foil
Inductor
The IH generator (TPIH-2000) generates a current of high frequency. The in-

ductor functions as a coil and creates a magnetic field. Heat is induced in the
packaging material as a result of a current being induced in the aluminium foil.
This leads to the melting of the PE layers, so that they can be sealed.
Dielectric heating Dielectric heating is used to heat non–conductive materials, such as wood.
This method is also employed in microwave ovens.
The diagram below shows the principle of this method.
High–frequency current
Electric field
Plates
Material, e g wood
The high–frequency current produces an electric field between the plates. The
field oscillates in time with the current, and the molecules of the material will
in their turn also oscillate in time with the field. The oscillations produce en-
ergy, which heats the material.
Note
In order for this method to work, the material must contain ions or polar mo-
lecules, i e molecules which are influenced by electric fields. Water molecules
are polar, and as wood always contains a certain amount of moisture, it is
perfectly possible to heat wood according to this method.

TPIH-2000
An IH system incorporating a TPIH generator is designed as the diagram be- IH system
low shows.
Potentiometer
IH generator, TPIH-2000
Current rail
Inductor
Transformer
Coaxial cable
The generator converts the mains voltage to a high–frequency voltage. The

magnitude of the high–frequency voltage is set by means of the potentiometer
as a percentage of the maximum voltage; for instance, 850 translates as 85%
of the maximum voltage. In its turn, the high–frequency voltage determines
the power in the inductor. This relationship of the voltage is proportional to the
square of the power; for instance, if the potentiometer is set at 850, the power
in the inductor becomes 0.85 x 0.85 = 0.72, i e 72% of the maximum power.
On page 10, more can be found on the relationship between voltage and power.
The coaxial cable conducts the high–frequency current to a transformer near
the inductor. The transformer has a transformation ratio of 5:1, i e it reduces
the voltage and increases the current by a factor of 5. Consequently, the power
remains unchanged, but low voltage in the inductor cuts down the danger of
spark–over and improves safety.
The last part of the passage of the current to the inductor goes through a current
rail. In the current rail, power losses occur, and for this reason, the rail is made
as short as possible.
The inductor functions as a coil and creates a magnetic field which induces
current in the packaging material.
Usually, a TBA machine is equipped with several IH generators, for instance
three, one for each pair of jaws and one for the zone heater.
Generator TPIH-2000 On the front of the generator, there is an alarm panel, connections for control
signals and power inputs, and an output for high–frequency current. The light–
emitting diodes on the alarm panel indicate faults and errors etc, and can be
used to facilitate fault–finding.
Alarm panel
Connections for
control signals
Connections for po-

wer inputs
Output for HF current

HF=high frequency

Explanation of the light–emitting diodes on the alarm panel:
Output Voltage Low (red). If this is the only red light–emitting diode that is
on, one of the following faults has occurred: 1) The generator is defective and
must be replaced. 2) 10 V DC is not being supplied to the potentiometer. 3)
The potentiometer has been set at too low a value. 4) The potentiometer is de-
fective.
Mains Voltage Low (red). Power feed to the generator is insufficient. At least
one of the phases supplies less than 85% of the nominal power, and the gene-
rator cannot in its turn provide the correct power. Check the input power fuses.
Temperature High (red). The temperature inside the generator is too high.
Most likely, the fan is defective. If this is the case, the complete generator as-
sembly must be replaced.
Load Error (red). There is an error in the load, i e the coaxial cable, current
rail, transformer, or inductor.
Output On (green). Lights up when a pulse is being converted into the correct
load, i e when the system functions correctly.
Control Voltage On (green). The power feed to the control section functions
correctly.
The diagram below shows the connections for the control signals and input po-
wer. The No at each connection, shows how the cable concerned is marked.
30 Power alarm. Common alarm to PLC for: Output

30 28 Voltage Low, Mains Voltage Low, and Load Error.
28
26 26
24 Temperature alarm to PLC.
22 24
20
16 22 Power setting from POT.
14 20 10 V DC to POT
12 16 0V
8
14 24 V DC
12 0V
8 Sealing pulse from PLC
30 30 Neutral
26 26, 230 V AC 50/60 Hz
22 Three–phase 230/400 V AC 50/60 Hz
18 22 Phase R
18 Phase S
10 Phase T
10 6 Neutral
6
4 4 Ground
Function The TPIH-2000 generator works in accordance with the block diagram below.
It comprises an power section and a control section.
TPIH-2000
Control section
Temperature alarm PLC

Power alarm PLC
Sealing pulse PLC
Power setting POT
24 V DC
230 V AC
Power section
Triple pulse Voltage re- Output

Power step Filter
rectifier gulator transformer
The control section is powered by 230 V AC and 24 V DC. It controls, for in-
stance, voltage and frequency, and monitors the unit. It also controls the alarm
panel.
The power section is powered by 3x400 V AC and incorporates the following
functions:
Triple pulse rectifier, which converts the alternating voltage (AC) into a di-
rect current (DC) of appr 325 V.
Voltage regulator, which stabilises the direct voltage at appr 350 V.
Power step, which converts the direct voltage into a high–frequency square
pulse of 350 V, 0.5 MHz.
Filter, which generates a sinus–shaped high–frequency alternating voltage of
300 V, 0.5 MHz.
Transformer, with a ratio of 1:1, which is used to isolate the load from the
generator. The load comprises the coaxial cable, transformer, current rail, and
inductor.

As previously mentioned, the power in the inductor is determined by the out- Power regulation
put voltage from the generator. In order to understand how the output voltage
is regulated, we have to take a closer look at what happens in the filter section
of the generator.
Uin Filter Uout
In order to regulate the output voltage, the fact is exploited that the ratio bet- At the resonance frequency,
ween the output and input voltages (Uout /Uin) in the filter is not constant. This the ratio between output and
input voltage reaches maxi-
ratio depends on the frequency, as shown in the diagram below. mum.
Uout /Uin Resonance frequency

Maximum power
Minimum power
Regulation range
Frequency
0.485 0.550 (MHz)
The 0.485-0.550 MHz frequency range is utilized to regulate the output volta-
ge and thus the output power. Within this frequency range, the ratio between
output and input voltage is virtually linear. Thus it is the frequency which is
altered in order to regulate the power. The setting of 999 on the potentiometer
is equal to a frequency of 0.485 MHz, which gives maximum power (2kW).
The setting of 850 corresponds to a frequency which gives the power of 0.852 x
maximum power (0.852 x 2=1.4 kW), etc.
Note
This way of calculating disregards the fact that the phase angle, cosine ϕ, varies
with the power. At low power, cosine ϕ is reduced; for instance, at a potentio-
meter setting of 440, the power may be 0.9 x 0.442 x maximum power.
Comparison between TPIH-
2000 and older IH generators
TPIH-2000 has been installed in the following machines from the develop-
ment step specified.
• TBA/8 060V
• TBA/9 140V
• TBA/10 120V
• TBA/21
The significant difference between TPIH-2000 and the older model generator
is that TPIH-2000 is a transistor generator, while the older model is an electro-
nic valve generator. A comparison between the two generator types shows the
following differences:
• The output power of TPIH-2000 is adjustable while the machine is run-
ning. This is not possible with the older IH generator.
• In TPIH-2000, the output power is not dependent on the mains voltage
(within a range of -15 to +10 per cent of the nominal value). In the old
model, there is a direct relationship between mains voltage and output
power.
Much of the loss occurs in the • TPIH-2000 consumes 1.5 kW while the old model uses up appr 4 kW.
current rail. In the TPIH-2000 Nevertheless, the inductor power is equally high, appr 1 kW, which is due
system, a major part of the to the losses in the TPIH-2000 system being lower.
current rail has been replaced by
a coaxial cable. But the coaxial
TPIH-2000
cable cannot cope with as high an
amperage as a rail, so therefore
the current is transformed in a
transformer near the inductor
Generator
instead of in the generator itself.
Inductor
Coaxial cable
Current rail
Transformer
Old model IH generator
Generator
Inductor
Current rail
• The voltage across the inductor in the TPIH-2000 system is 40-50 V; in the
old IH generator it is appr 90 V. Low voltage is preferable as it reduces the
danger of spark–over and improves safety.
• The frequency in TPIH-2000 is 0.5 MHz, compared with 1.8 MHz in the
old generator.
• TPIH-2000 is based on transistor technology, and the old model IH genera-
tor on electronic valves. Transistors are very reliable with a long working
life, while valves have a limited life.
• Inside TPIH-2000, there is no high-tension. Maximum voltage is 400 V,
while the high-tension section of the old model generator carries 5000 V.

TPIH test instrument
For TPIH-2000, there is a special test instrument (TP 68462-101). It can be
used for the measuring of:
• HF voltage
• HF current
• Load phase angle (cosine ϕ)
• Pulse time (duration)
The test instrument is intended to be connected in series with the coaxial cable
from the generator, as shown in the diagram below.
Printer socket
Display
Selector
To be connected to generator
To be connected to
coaxial cable Note that a user’s manual for the
instrument is being supplied.
The measuring results can be used to calculate the power and impedance of the
load.
P=U x I x cosϕ (Power = Voltage x Amperage x Cosine ϕ)
Z=U/I (Impedance = Voltage/Amperage)
Impedance is to be roughly 50 Ω. Normal value is 40-65 Ω.
Note
The pulse time is determined by the machine PLC and does not require adjust-
ment.
If the special test instrument for TPIH-2000 is not available, the pulse time can Pulse time meter
be measured by means of a pulse time meter (TP 102 90243-90) and the HF HF voltmeter
voltage by means of an HF voltmeter (TP 103 90243-114). In this case, mea-
suring is done at the copper rail by the inductor (secondary transformer side).
Instruction manual Note: The following is copy of the instruction manual enclosed to the TPIH
test instrument 68462.
TPIH test instrument 68462

Instructions (rev Sep 91)
The TPIH test instrument is used for checking the high frequency part of a
TPIH system.
1 Connecting
The instrument is connected in series with the coaxial cable between the
generator and the IH-transformer, usually closest to the generator.
NOTE: Connection and disconnection of the test instrument must be done,
when the generator is not pulsing e g with the machine in the short stop po-
sition.
2 On and off
The instrument is started with a rotary switch. Approximately five minutes
after the latest activation of the switch, the instrument is automatically
turned off.
3 Measuring
Voltage (V), Current (A), Phase angle between voltage and current (de-
grees) and Pulsetime can all be measured. Disregard any numbers that are
displayed prior to the measurements. When the measurement is finished
note the values directly.
a Pulses
The toggle switch to the right is put in position ”pulse”. The instrument
measures and stores pulse time after every pulse. The voltage, current and
phase angle are measured and stored after half the pulse time. In order for
the instruments to make correct measurements, i e in the middle of the puls-
es, at least 2 pulses are needed. The LED ”pulse” lights up during the
pulse and ”sample” lights up when a measurement is taking place. Put the
toggle switch in position ”hold” when no more new measurements are
needed.
b Continuous signals
The toggle switch to the right is put in position ”Continuous”. The instru-
ment shows the measurements for voltage, current and phase angle appr. 3
times/second. If, at a certain point, the measurements are to be stored, the
toggle switch is put in position ”hold”.
c Single pulse
The rotary switch is turned to position ”pulse time” and the toggle switch
to the right to position ”Continuous”. The toggle switch to the left is used
to preset an expected pulse time (N.B.! Pos. values). Change the toggle
switch to the right to position ”pulse”. It is now possible to measure a sin-
gle pulse.

4 Power, energy etc
By using the measured values several others can be calculated.
Power = Voltage x Current x Cos (phase angle) (W).
Pulse energy = Power x Pulse time (mWs).
The Impedance’s absolute value = Voltage/Current (ohm).
Cos 0° = 1 Cos ±5 = 0.996 Cos ±10 = 0.985
Cos X 1 - x : 6700 -40° < x < 40°
2
5 Trouble shooting for load error

If there is a load problem only short pulses are delivered by the generator.
The results from the measurements will be approximate but they could
make trouble shooting easier. During a pulse with load problem the LED
”sample” is lit up during the entire pulse, while LED ”pulse” is off.
Load examples Phaseangle Voltage/Current
(Test instrument connected (Degrees) (Ohm)
closest to the generator)
Optimal load (no load problem) 0 50
Normal load (no load problem) ±15 40 - 65
Short circuit in coax. cable, pos (3) 1 - 10 (1)
contacts, primary of IH-transf.
Open circuit in same as above. neg (3) 200 - 2000 (2)
Short circuit in inductor, pos 10 - 20
current rail, secondary of IH-
transformer.
Open circuit in same as above neg 2-5
No packaging material on the neg 5 - 15
inductor.
(1) = The greater value, the greater distance between problem and
instrument.
(2) = The greater value, the shorter distance between problem and
instrument.
(3) = The greater phase difference, the greater distance between
problem and instrument.
6 Connection of chart recorder

To record voltage, current and phase as a function of time a chart recorder
e g Brush can be connected.
1 Connect the included cable to the recorder.
marking ”V” : Voltage 100 mv = 100 V
marking ”C” : Current 50 mv = 1 A
marking ”P” : Phase 10 mv = 1 ˚
marking ”O” : O
2 Isolate cables that are not used.
3 Connect to the instrument. The toggle switch to the right is put in
position ”pulse”.
7 Battery
The instrument is powered with a standard 9 V battery e g 6LR61. An al-
caline battery gives approximately 40 hours operation. When approximate-
ly 5 hours operation are left, ”batt” is displayed. The instrument gives
correct values until 000 is displayed and it switches off automatically. The
battery eliminator is used when you want to measure during long time, e g
with a recorder. With the battery eliminator connected and the rotary
switch in position ”batt” the display should show 8,5 V - 14 V.
8 Accuracy
Accuracy for new instruments used according to 3a and 3b.
Voltage ± (2 % + 1 V) 100 - 350 V
Current ± (2 % + 0,03 A) 2-7A
Phase ± (5 % + 2 ˚) -30° - +30°
Pulse time ± (2 % + 2 ms) 10 - 1000 ms
To compare two instruments, connect them in series. Then interchange
them since the values depend on the distance from the load, especially if
the load differs from 50 ohm.
9 General
The instrument can operate in temperatures from 0 to 45 ˚C.
It should not be used immediately after major temerature change.
Store the instrument in a dry place.
Temporary storage temperature: -20 to +60 ˚C
Do not use the instrument if water has penetrated into it.
Do not dismantle the instrument when the coaxial cables are connect-
ed.
The panel can be opened if the lower screw in the middle is loosened.

14
Filling system

Regulating
Lund, Sweden
valve
Machine type
TBA/19 TB/19, TBA/21
Issue
4/9810
Product
Compressed air
Non−conductive part
of the regulator
OH 497
Conductive layer
in the diaphragm
Non−conductive layer
in the diaphragm
Non−conductive coating
Principle of filling system
A1 A2
RM3 LA1 Leakage
15
16
18
26
500k
detector
25
25
30
1 35 (x0.1)
PLC Level
transmitter
U/P Transducer
Product
Compressed air

Lund, Sweden TBA/21 HS 1/9905 OH 847
UP−Transducer
Lund, Sweden
FM = Magnetic force
FR = Feedback force
Principle
P1 = Supply pressure
P2 = Outlet pressure
1 = Exhaust
Machine type
TBA/21
FM FM
FM
1
FR
FR
FR
Issue
1/9609
P2 P2
OH 612
P1 P1 P1
FM = FR FM > FR FM < FR
Level Transmitter Type PMS
(Potentiometric Measuring System)
http://www.helios-level.ch/level/pms_e.html
Features For Training purpose ONLY!
• Linear level signal transmission
• No calibration in wide product conductivity range
• Suited for products with conductivity > 1 mkS*cm
• Mesearing independed of pressure, temperature,dielectric and density
Basic principles
The level probe ¬ is immersed in the earthed liquid (product) ¯ and consists of a
stainless tube (see picture 1). The ends of the probe are connected via two
insolated leads - with an off-eath generator ® . This generates AC voltage with
frequency of 5 kilohertz to energise the probe ¬ .
High resistance amplifier ® is connected thrue the matching transformer (not
shown) to the container wall (filling pipe) and generator terminal. The amplifier
converts the milli-volt signal to a 0-20 mA signal.
- G ® f=5 kHz
¬ To PLC
¯ 0-20 mA
¯ ° ±
Picture 1.
Please note that resistors ° are just simbolical representation of product

resistence . However, during the Level Probe sensitivity settings two real 1.75K
resistors are used to simulate the product (see correspondent MM page).
The purpose of usind AC current is:

a) to minimise zero drift;
b) to simplify level signal amplification and transmission;
c) to utilize "skin effect" when the AC current has a tendency to flow on the
conductor surface rather then in its bulk. This increases an effective resistance of
foam between the probe and container wall and therefore minimizes its effect on
level reading. The foam still can create a false level signal when the product is
absent. This situation should be avoided.
Does the level signal depend on product resistance?
The resistance of product (Rprod) and the immersed part of probe (Ri)
together form a Wheatstone bridge (see picture 2), in which the voltage drop
(Uprod) in the product is equal to the half of the voltage drop on the immersed part
of the probe (Ui).
G f=5 kHz
Lp
Rni
To PLC
U0 L
Ui Ri Rprod Uprod
Picture 2.
If U0 is the generator output voltage, Lp is the total length of the probe and L is
the product level, then:
Ui =U0*L/Lp ;
Uprod=Ui/2=U0*L/(2*Lp)
Assuming that U0 and Lp are constants then:
Uprod=k*L
where k is a constant equal to U0/(2*Lp)
So, level signal Uprod does not depend on the conductivity of the product but
depends linear from the product level.
Evgeny Lavrentiev BUTB Modena
15
Electrical system

Pos. in Line/ GE Page N Location
EM Voltage Fanuc Function El. diagr. Part N Terminal N on the
In/Out machine
B4200
Design
signal
ASU
X1003
127- ,127,
127+
Q0122
I0025
G101
TS sealing
pulse
16
Electrical equipment

Emergency stop
A1 S13 S24 X2 41 13 23 33
module 24VDC
Reset
/Test
In
B 1 1 1 1
In order to make the safety output On
close, the reset circuit must be In

Type: JSBR4
Out
closed and then opened.
In 2 2 2 2
A
A2 S14 S23 X3 42 14 24 34
A1 X2
S13
K2
S14
Protec-
tion Reset and supervision circuit
circuit
S24
K1
S23
A2 X3
13 23 33 41
K1 K1 K1
K1 K2
K2 K2 K2
14 24 34 42
Technical Training Centre 1/9609. Tm-00003 Training Document. For training purpose only.
Safety relay
A1 S13 S24 X2 41 13 23 33
Reset
/Test
24VDC
In 1 1 1 1
B
On JOKAB SAFETY
In TYPE: JSBR4 24 VDC
Out
In 2 2 2 2
A
A2 S14 S23 X3 42 14 24 34
A1 S13 S24 X2 41 13 23 33
Reset
/Test
Emergency switch
24VDC
In 1 1 1 1
B
On JOKAB SAFETY
In TYPE: JSBR4
Out
In 2 2 2 2
A
A2 S14 S23 X3 42 14 24 34
A1 S13 S24 X2 41 13 23 33
Reset
/Test
Alarm reset
24VDC
In 1 1 1 1
B
On JOKAB SAFETY
In TYPE: JSBR4
Out
In 2 2 2 2
A
A2 S14 S23 X3 42 14 24 34

ASU
A 602 Y7407 Web tention
TBA/22 Supply Safety
Controlled
Y7408 Pressure rail
Y7410 Cutting
Safety Modules Output Y7411 Material holder
Safety chain
input
ASU
Door
Guard
Emerg. Stop Module
Door Guards Main Motor, FF motor
24VD
A 600 A 601 A 603
Supply Safety Supply Safety Supply Safety
Controlled Controlled Controlled
Output Output Output
Reset Reset 0.5S Delay

Safety chain
Safety chain input
input
Top, Bottom front door Auxil. Door

Reset Guards
Contact
Auxil.
Reset B1505 B1506
Contact Bottom covers
B1224 B1225 K4 Main Motor
K 115
K6 FFU Motor
Emerg. Stop Buttons K3 Clean pump
K9 Tran. Waste
Y3101 Hot W.
K007 Drive roller K002 Hydr. Perox. Pump

K002:1 Hydrogen peroxide Pump
K004:1 Main motor
K006:1 Final folder
K007:1 Drive roller
K008:1 Drive loop ASU
K010:01 External conveyer
K036:1 Drive magazine ASU
K034:1 Control voltage/ Time recorder
K118 Reset relay
B2810 Door guard 10
B2811 Door guard 11
B2812 Door guard 12
B2813 Door guard 13
B2830 Door guard 30
B2831 Door guard 31
B2832 Door guard 32
S1 Control cabinet outside
S5 Control cabinet inside
S1801 Front platform
S1802 Top platform
S2803 Right side panel
S2804 Left side panel
S7813 ASU bar
S900 Control panel
K3 Cleaning pump
K4 Main motor
K6 FFU motor
K9 Transport of waster
K118 Reset relay
Safety Relay for:
Two Hand Control

Emergency Stop
Interlocked Gate/Hatch
Enabling Device
Safety Strips
SCALE 1:1
Safety Mats
Approvals:
Foot Switches
Area Restriction
Machine I/O
EMC
Category 4
(NRTL/C=USA & Canada)
SAFETY RELAY JSBR4

UNIVERSAL RELAY test/supervision to ensure that contac-
JSBR4 is used to: tors or valves have returned to their ini- Dual Input Channels
• Comply with safety levels for tial off "stop" position before a new
safety devices start can be allowed by the safety relay.
3NO/1NC Outputs
• Give safe stops to dangerous When the JSBR4 is used as a Two
machines and processes
Short circuit supervised
Hand relay both buttons have to be
• Supervise the internal safety pressed within 0.5 seconds of each reset
of machines other in order to close the outputs.
• Fulfil regulations When the JSBR4 is used for Safety LED Indication of Power
Mats and Safety Strips the ”stop” condi-
MACHINES & PROCESSES tion is given following detection of a on, Inputs and Outputs
Safety relays can be used for a wide short circuit between input channels A
range of applications including: Industrial and B. Neither the safety mat, safety Available in wide range
Robots, Presses, Automatic Production strip or the relay will be damaged by a
Systems, Paper Machines, X-Ray Ma- continuous short circuit. This also gives
of voltages
chines, Bakery Machines, Printing Ma- the advantage that if there is a failure
chines, Automatic Warehouses, Laser Ma-
DIN-rail Mounting
between the inputs in the installation,
chines, Handling Equipment, Power the safety relay will not be damaged. 45 mm in width
Shears etc.
SAFETY LEVEL
FUNCTION The JSBR4 has a twin supervised safety
The JSBR4 has two inputs, both of which function. Neither component failure, short REGULATIONS & STANDARDS
have to be closed to keep the safety out- circuit or external disturbances (power The JSBR4 is designed and approved in
put contacts closed. A short circuit loss etc) will prevent the safe function of accordance to relevant standards. Exam-
across the inputs will cause the output the relay. This is valid both for the inputs ples of relevant standards are EN 292-
contacts to open. The inputs can how- A and B as well as for the reset input. 1/2, EN 60 204-1, IEC 204, VDE 0110,
ever be subjected to a continuous short The JSBR4 operates at the highest safety VDE 0113, BS 2771…
circuit without damaging the safety relay. level for safety relays (category 4).
In order to make the safety outputs The true two channel safety function CONNECTION HANDBOOK
close the reset input must be closed and has the advantage that the installation de- In our connection handbook are
opened. In this way an unintentional re- mands for safety can be reduced depend- numerous circuit diagrams showing
set is prevented in the case of a short ing on the fact that a short circuit be- examples of Safety Relay combinations
circuit in the reset button cable or if the tween the input opens the safety outputs solving safety problems eg:
button gets jammed in the actuated posi- directly. • Time reset of safety devices
tion. The reset input can also be used for • Safe time delay of stop function
Simple - Safe - Reliable

980315
Expansion relays provide:
More safe outputs
Delayed safe outputs
Indicating outputs
SCALE 1:1
Approvals:
*
EMC
(NTRL/C=USA & Canada)

* Approvals applied for
EXPANSION RELAY JSR1T

MORE OUTPUTS our Connection Handbook.The drop
By connecting expansion relays to a time delay on a JSR1T can as stan-
safety relay it is easy to increase dard be selected from 0 to 8
Width: 45 mm
the number of safe outputs. This seconds. By connecting several Power supply: 24V DC
means that an unlimited number of JSR1T´s in series even longer times
dangerous machine operations and can be achieved. Function indicating
functions can be stopped from one
safety relay. WHEN ARE DELAYED SAFE 4 NO 1 NC Outputs
STOPS USED?
SAFE SOFT STOP Delayed safety stop signals can be
When a gate is opened a program used for emergency stops ac-
stop is first given to the machine’s cording to EN418 § 4.1.5. Stop
PLC/servo which brakes the category 1, i.e. a controlled stop
dangerous operations in a soft and with power to the actuator(s)
controlled way. The safety outputs available to achieve the stop and that is, two relays with mechanically
then break the power to the mo- then removal of power when stop operated contacts. A monitored stop
tors, that is, when the machine has is achieved. function is achieved by connecting
already stopped. Normally between Stop category 1 may also be the test output (terminals X1 and
0.5 and 1 second is needed to permitted when it is not possible to X2) to the test or reset input on the
brake a dangerous machine opera- gain physical access to the safety relay which is expanded.
tion softly. machine before the safe stop is One condition for a safe delayed
Soft stop ensures many adv- affected eg: stop is that the delay cannot in-
antages: Gates, access time is 1 sec. crease in the event of a fault. The
The machine lasts longer. Covers and gates which are JSR1T complies with this
Parts being processed are not locked until dangerous opera- requirement.
damaged. tions and functions have been
Restart from stopped position stopped. CONNECTION HANDBOOK
is enabled and simplified. Long distances between a safety In our connection handbook are nu-
A safe soft stop is achieved by device and a dangerous machine merous circuit diagrams showing
means of a safety relay which gives function. examples of Safety Relay combina-
the program stop, and an expansion tions solving safety problems e g:
relay, JSR1T, which gives safe de- SAFETY LEVEL • Time reset of safety devices
layed stop signals. See examples in The JSR1T has twin stop functions, • Safe time delay of stop function
Simple - Safe - Reliable

980316
Safety relay
A1 S13 S24 X2 41 13 23 33
Reset
/Test
24VDC
In 1 1 1 1
B
On JOKAB SAFETY
In TYPE: JSBR4 24 VDC
Out
In 2 2 2 2
A
A2 S14 S23 X3 42 14 24 34
A1 S13 S24 X2 41 13 23 33
Reset
/Test
Emergency switch
24VDC
In 1 1 1 1
B
On JOKAB SAFETY
In TYPE: JSBR4
Out
In 2 2 2 2
A
A2 S14 S23 X3 42 14 24 34
A1 S13 S24 X2 41 13 23 33
Reset
/Test
Alarm reset
24VDC
In 1 1 1 1
B
On JOKAB SAFETY
In TYPE: JSBR4
Out
In 2 2 2 2
A
A2 S14 S23 X3 42 14 24 34

A 103
0 C
RD
Lund, Sweden
03 TC1− 01
B1106 A133 0 C
05 TC1+ 02
YD
RD
07 TC2−
B1222 A134
09 TC2+
YD
Machine type
TBA/22
A 137
01 02/A1
PROGRAM TABLES STATUS PRINT
Q0193
1 insert 2 edit 3 modify 4 search 5 6 10 zoom
−
Air super heater 03/A2 ALW ON LOOP 6
Q0194 P ID ( )
IND
SV L6 CV
SP CV L6
Issue
PV L6 PV
1/9905
ALW OFF
MAN
ALW OFF
L10 UP
ALW ON
OH 842
DN
0 FFL INE
C:\DAT I\LM90\NEW PT\SIMONET PRG: SIMONET RUNG 0068
REPLACE %S0007 : ALW ON : :
Temperature control overview

PID Function Block Data
Data Item Description

Output This is a signed word value representing the output of the function block before the
application of the optional inversion. If no output inversion is configured and the output
polarity bit in the control word is set to 0, this value will equal the CV output. If inver-
sion is selected and the output polarity bit is set to 1, this value will equal the negative of
the CV output.
Diff Term Storage Used internally for storage of intermediate values.

Do not write to this location.
Int Term Storage Used internally for storage of intermediate values.

Slew Term Storage Used internally for storage of intermediate values.

Clock Used elapsed time storage (time last executed).

Lower Range Lower range for SP, PV for faceplate display.
Upper Range Upper range for SP, PV for faceplate display.
Reserved Reserved for GE Fanuc use. Cannot be used for other purposes.
Initialization Values
The following table lists typical initialization values for the PID function block.
Suggested
Register Purpose FB Units Range
Default
%Ref+0 Loop Number 1
%Ref+2 Sample Period 10 msec 100 msec (10) 0 to 10.9 min
%Ref+3 Dead Band Selection + Counts 320 0 to 100% of error
%Ref+4 Dead Band Selection - Counts 320 0 to -100% of error
%Ref+5 Proportional Gain 0.01%/% User Tuned 0 to 327.67%/%

%Ref+6 Derivative 0.01 seconds User Tuned 0 to 327.67 sec
%Ref+7 Integral Rate Repeats per 1000 sec User Tuned 0 to 32.767 repeats/sec
%Ref+8 Bias Counts 50% (16,000) -100% to +100%

%Ref+9 Upper Output Clamp Counts 100% (32,000) -100% to +100%
%Ref+10 Lower Output Clamp Counts 0% (0) -100% to +100%
%Ref+11 Minimum Slew Time Seconds per full travel 0 0 to 32. 767
Technical Training Centre 1/9905 TM-00100

Temperature settings TBA/21 HS
Alarmlimits temp controller are all relative value within [xx] = not used as an alarmlimit
Technical Training Centre 1/9905
Al high Al Low
Conn PWM
Description C/M Setvalue (C)/High (C)/Low Sample P I D Comment
ection timebase
lim (M) lim (M)
B1106 Heat sterilization M 280°C
B1222 H2O2-bath M 68°C Not possible to change from TPOP
B1208 Water temp H2O2 M 90°C

system
TM-00101
B1212 Temp H2O2-tank C 72°C [2°C] 2°C 500 19000 220 3000 10 s Setvalue range (69°C-76°C)
(5 sec) (190%/%) (0.22 repeats/s) (30 s)
B1109 Temp top aseptic M 95°C Controls the switching of the heatex-
chamber changer. Not possible to change for the
operator.
B2510 Cooling water M 12°C 7°C High limit value will start cooling, low limit
value will stop the cooling. Range high and
low 2°C-20°C.
B001 Cooling electrical M 34°C 28°C High limit value will start cooling, low limit
cabinet value will stop the cooling. Range high and
low 20°C-24°C.
B5307 Flap heating top left
B5308 Flap heating top right

C 450°C [15°C] 15°C 25 2000 3000 2000 500 msec Setvaluerange <= 550°C
B5309 Flap heating bottom
left
B5310 Flap heating bottom

right
B1310 Steam temp M 120°C Rangelimit <= 15°C
B1105 Air super heater C 360°C 15°C 20°C 60 5500 2300 1500 1 sec Setvalue range (350°C-390°C)
B6001 SA splice head C To be tested To be tested

Thermocouple type K
Material: Nickel−Cromium v Nickel−Aluminium (NiCr − NiAl)

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

Lund, Sweden
Step motor driver

Volume adjustment
Tube positioning
SW 1 F SW 8 Right
Machine type
SW 2 Right SW 9 0
SW 3 Right SW 10 0
TBA/22
SW 4 Open SW 11 0
SW 5 Right SW 12 0
SW 6 Open SW 13 0
SW 7 Closed SW 14 Open
Issue
1/9907
Time constant Off On Internal clock frequency Current set

Speed 1: SW6 Open Close Sped 1: (22+SW9x22+SW10x320)Hz SW:13 0:2.5A 3:1.9A 6:1.3A
Speed 2: SW7 Open Close Sped 2: (22+SW11x22+SW12x320)Hz 1:2.3A 4:1.5A 7:1.2A
OH 863
2:2.0A 5:1.4A 8:1.0A

Clock Int Ext Analog input Analog control Indirect Direct Gain
SW:8 Left Right 0−10V 0−20mA On Off SW2:Left Right (12+6+SW1) x
SW14: Open Close SW5: Left Right SW3: Left Right
SW4: Close Open
Issue 980122
Overvoltage Protection
Overvoltage Protection
12 14 11
L/N L/N L/N L/N
PU 4 C-R PU 4 C-R PU 4 C-R PU 4 C-R PU 4 C-R
UH : 230 V~ UH : 230 V~ UH : 230 V~ UH : 230 V~

UH : 230 V~ Umax : 275 V~ / Umax : 275 V~ / Umax : 275 V~ / Umax : 275 V~ /
IN : 6 A 350 V- 350 V. 350 V- 350 V-
802 152 802 152 802 152 802 152 802 152
Textbook
S
N
S N
MT-83025-2

Lund, Sweden
This textbook has been compiled by the Technical
Training Centre in Lund.
Some of the pictures in the book are also available as
OH pictures.
For further information on training material, please contact
the Technical Training Centre.
Issue 1/9706
© 1997, Technical Training Centre

No part of this publication may be reproduced, stored in a retrieval system or transmitted in
any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocop-
ying, recording or otherwise, without permission in writing from Technical Training Centre.
S
N
S N
Training Document
Note!

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Frequency-controlled asynchronous motor . . . . . . . . . . . . . . . . . . . . . . . . 5
The squirrel-cage asynchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Frequency converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive systems with DC motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Stepping motor systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The stepping motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Servosystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control unit, drive electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Angle encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Temperature (safety) switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Introduction
By electric drive systems we mean various types of electric motors which,
together with some form of electronic controls, drive or perform mechanical
movements.
Control unit Motor Mechanics
One type of electric drive system is a variable speed motor, which drives a main
shaft. On this shaft, cams, belt pulleys, gears, sprockets, etc may be fitted, which
in their turn provide the motive power for mechanical movements.
What, in this case, is considered the electric drive system are the motor and
the speed control device.
Speed control
Motor
This textbook describes such electric drive systems as are employed in the
Tetra Pak packaging machines and process equipment:
• Frequency-controlled asynchronous motor.
• DC motor with variable speed control.
• Stepping motor systems.
• Servomotor systems.
All drive systems are described in general terms; in other words, their function
as employed in a specific machine is not being explained.
Overview
In the following, the various drive systems are described briefly and
summarily. Later on, each system is presented in detail in separate chapters.
Frequency-controlled asynchronous motors are very common and cheap drive Frequency-controlled
devices. The motor is an asynchronous squirrel-cage motor, whose speed is asynchronous motor
controlled by means of a frequency converter. The rotary speed depends on the
frequency. Such drive systems are often used to drive a main shaft which, via
cams, gears, etc, drives a number of mechanical movements.
Drive systems with DC motors can be used for a great variety of tasks, from Drive system with DC
simple speed control to advanced positioning. For instance, they are often used motor
when the speed has to be varied over a wide range. A further advantage of the
DC motor is that its speed is only slightly affected by load variations.
Stepping motors are mostly used in positioning, with small loads. It can be Stepping motor system
regarded as a digital motor which converts electric pulses into mechanical
motion. Each pulse equals a defined angle of rotation by the
motor shaft - one step.
Servosystems are capable of converting any mathematical function into a Servosystem

mechanical movement. It may be cam functions (electronic cams), speed
functions, torque functions, etc.
General
As previously mentioned, electric drive systems consist of a motor and a
control unit. The control unit may be anything from a simple speed controller
to highly advance control electronics, which may make the motor perform
virtually any function.
The motors may have either open or feed-back control. An induction motor
usually has open control, while a servosystem in itself constitutes a system
feed-back control.
In an open control system, there is no feed-back between the motor or load and Open control system
the control unit. This means that if any of the factors determining the function
of the system changes, for instance voltage, amperage, or position, the
function of the system will also change. There is no automatic correction or
compensation; if correction is required, it has to be made manually.
Input
values Control unit Motor Function
In a feed-back system, the control unit monitors the function of the motor or Feed-back control system
load. If the motor function deviates from the predetermined function, the
control system will automatically correct this condition.
Input
Control unit Motor Function
values
Feed-back
Frequency-controlled
asynchronous motor
Frequency-controlled asychronous (induction) motors are mostly used for
simple drive functions, without feed-back from the motor or load to the control
unit. Such a drive can in principle be used to regulate the speed from stand-
still upwards. The motor is a squirrel-cage asynchronous motor, and the
control unit a frequency converter.
The squirrel-cage asynchronous motor

The squirrel-cage asynchronous motor is the absolutely most commonly used
AC motor. There are many reasons for this; here follow the most important:
• it is cheap,
• it is very reliable,
• it is a standard product complying with the IEC standard.
IEC motor
P D N
M
E C B A
Amongst other things, IEC standardization means that the outside dimensions
of the motor, its mounting holes, and its shaft dimensions are standardized for
each motor power.
The diagram shows those dimensions which are subject to standardization.
Thanks to this standard, the user is not tied to a certain manufacturer or
supplier. A plentiful supply of standard motors of different makes is always
available.
Construction The rotor in the asynchronous motor has a cagelike winding (hence the term
'squirrel-cage'). It is not wired to any power source, which means that there is
no need for sliding contacts or brushes for its power supply. Besides, the rings
which short-circuit the conductors are often shaped like fan impeller vanes.
Altogether, this makes this type of motor extremely simple and robust: no
windings, no sliding contacts, no separate fan in the rotor.
In the stator are the field windings. They are designed to generate a rotating
magnetic field when connected to a three-phase alternating voltage.
Stator
Rotor
Usually, three-phase motors can be reconnected for two alternative supply

voltages. The most common way is to either D-connect (delta connect) or
Y-connect (star connect) the three phases of the field winding.
If the marker plate on a three-phase motor specifies voltage values for both
D and Y-connection, the motor may be run on, for instance, either
3×230V AC or 3×400V AC.
The diagram below shows how to place the connection links for 3×230V and
3×400V. In both cases, the potential over the windings will be 230V.
W2 U2 V2 W2 U2 V2
U1 V1 W1 U1 V1 W1
W2 U2 V2 W2 U2 V2
U1 V1 W1 U1 V1 W1
L1 L2 L3 L1 L2 L3
D-connection, 3×230V Y-connection, 3×400V
Function When the field windings are connected to a three-phase alternating voltage, a
rotating (1) magnetic field (2) is generated through the motor. The magnetic field
induces currents in the conductors (3) of the cage winding; in this way, forces (4)
are created, which cause the rotor to rotate with the magnetic field.
A B
3 Slip
S
4
S N
1
N
2
The speed (rpm) of the asynchronous motor is determined by the frequency of

the voltage supplied to the motor, calculated in accordance with this formula:
Current exiting plane 2 × frequency × 60
Speed = --------------------------------------------------------
Number of motor poles
In principle, the speed can be regulated from stand-still upwards, with certain
limitations in the upper and lower sections of the speed range.
The speed determined by the frequency, as per the formula above, is called the
synchronous speed. The synchronous speed is the rotation speed of the
magnetic field, generated in the field windings when supplied with a three-
phase AC voltage.
The table below shows the synchronous speeds at various frequencies for
motors with different number of poles.
Number of Frequency (Hz)
poles 10 30 50 100
2 600 1800 3000 6000
4 300 900 1500 3000
6 200 600 1000 2000
8 150 450 750 1500
The actual, true, speed of the motor is determined not only by its synchronous speed
but also by how great a load the motor is driving. This speed is called the asynch-
ronous speed, and the difference between the synchronous and asynchronous
speeds is termed slip. The slip is directly proportional to the output motor shaft
power. The illustrated sequences, A and B above, demonstrate how the rotor lags
behind the rotating field. In a way, this can be compared to a hydraulic coupling.
Diagram A shows the motor in a random field position that may be referred to
as F. Diagram B shows the motor when the field has rotated 45 degrees:
F + 45 °. In diagram B, it can be seen that the rotor has not turned as far as
the field, i e the rotor follows the field with a certain degree of slip.
Example: a four-pole 50 Hz motor has a rated speed of 1440 rpm. Thus the slip
is 60 rpm at the rated load.
Although, as previously stated, the speed can be regulated from stand-still
upwards, this should not be done.
At 85-90 Hz, losses in the motor will, for various reasons, be so great that the
torque drops to approximately one third of the rated torque. Power consump-
tion, however, remains as high as at the rated speed. A rule-of-thumb is never
to regulate the speed beyond 87 Hz.
At low frequencies and unchanged load, the fan impellor fitted to the motor
shaft will no longer be able to cool the motor adequately. Then the danger is
considerable that the motor will overheat. As a counter-measure, a separately
driven fan may be installed.
Torque, Power
100% Power
Losses
50%
Torque
Frequency
25 50 75 100 (Hz)
Frequency converter
A frequency converter converts the mains power frequency to whatever freqency is
required for the motor. Usually, the mains power frequency is either 50 Hz or 60 Hz.
A frequency converter consists of four main parts: Function

• The rectifier, which is fed with an AC voltage from the mains grid,
produces a DC voltage.
• The intermediary circuit, in which the DC voltage is smoothed.
• The inverter, which reconverts the DC voltage into an square-waved AC
voltage of the frequency required for the motor.
• The regulation unit, which controls and monitors the other parts.
Briefly, what happens in a frequency converter can be described as follows:
Rectification, smoothing, inversion (reconversion), control.
Regulation unit
Rectifier Intermediary
circuit
Inverter
M
Pulse width modulation The predominant type of frequency converter is the PWM converter (Pulse
Width Modulated). With this converter, voltage as well as frequency are
regulated by controlling both the number of pulses and their energy. The
reason for this is to make the virtual value of the voltage conform as closely to
a sine curve as possible. Sine-shaped voltage reduces losses in the motor.
In the 50 Hz and beyond range, the motor is fed with one pulse per semi-
period, alternatingly positive and negative. The virtual value of such a squared
pulse equals the rated voltage of the motor, for instance 400 V.
50 Hz
The virtual value of the voltage is as follows:

Input frequency
--------------------------------------- × Rated voltage = Output effective value
Rated frequency
In the example above:
50Hz
------------- × 400V = 400V
50Hz
At 25 Hz, the motor is fed with a number of pulses per semi-period, and the
virtual voltage value, which drops proportionally to the reducing frequency,
will be:
25Hz
------------- × 400V = 200V
50Hz
25 Hz
A PWM frequency converter thus regulates both the voltage and frequency to
the motor.
Fault-finding
In the following, the most common faults and their causes that may appear in
asynchronous motors are described.
Fault; The motor hums abnormally loudly while running, or hums without
rotating:
• Loss of voltage on one phase, possibly due to a blown or tripped fuse. Note
that the overcurrent protection of small motors may not always trip when
this kind of fault occurs.
Fault: The motor does not start, or stops in mid-run:
• The overcurrent protection has tripped.
Fault: The motor runs hot:
• Worn bearings.
• One or several field windings have short-circuited.
• Excessive load.
Fault: The motor vibrates:
• Unbalanced load, for instance a pulley, sprocket, or coupling.
• External starting conditions not met.
• No setpoint provided by the regulating unit.
• Short-circuited field windings.
Drive systems with DC
motors
Drive systems with DC motors can be used for everything from simple speed
regulation without feed-back to advanced positioning. Such a system can be
used to drive and brake the motor in either direction with precisely controlled
acceleration and deceleration. In this book, only simple speed-controlled
systems are described. The motor used is either a separately or permanently
magnetized DC motor, and the control unit a DC converter.
The DC motor
For speed control with DC motors, usually a separately magnetized motor is
used. Permanently magnetized motors are more suitable for positioning duties.
The principal advantage of separately magnetized motors is their speed
stability, i e the speed is only slightly affected by load variations. Besides, the
speed can be varied within a wide range. These qualities make the separately
magnetized motor ideal for speed regulation.
Construction The component parts of the DC motor are:

• The stator, which carries the field windings.
• The rotor, which carries the rotor windings.
• The commutator with carbon brushes.
In permanently magnetized DC motors, permanent magnets have been
substituted for the field windings.
Stator
Rotor
Commutator
Carbon brushes
The principle of the function of the DC motor is illustrated below. Function
2
3
S N
Current exiting plane
A conductor (1) carrying a current, which is positioned in a magnetic field (2),

is affected by a force (3). The magnitude of the force is determined by the
strength of the field and the amperage in the conductor. The field is generated
by the field windings in the stator, and the current in the conductors is
governed by the voltage of the power supplied.
The speed of a DC motor is determined by the magnetic field strength and
the rotor voltage. In order to vary the speed, either the voltage to the field
windings or to the rotor windings can be altered. Most common is to control
the speed by regulating the rotor voltage. In principle, this can be done within
the entire motor speed range while still retaining the same torque.
In supplying direct current, constant magnetic and current flows are created Commutation
through the motor. In order to achieve continuous rotation, the windings must
be reconnected (pole reversing) as the rotor revolves. Such reconnection is
termed commutation and may be either mechanical or electronic.
The diagrams below show how a loop or winding in a DC motor is
commutated mechanically in order to make it rotate continuously.
N
S
Miscellaneous DC motors should always be connected with cables which are screened and
whose conductors (strands) are twisted. The screen is to be grounded at each
end. Screening is done in order to prevent electromagnetic interference (noise)
to enter or emerge from the system.
DC Converter
In order to regulate the voltage, and thus the speed of the DC motor, a
DC converter is used. It consists of three main parts:
• The rectifier, which turns the supply voltage into direct current.
• The power unit, which feeds the motor with direct current.
• The regulating unit, which controls and monitors the other parts.
Field
Rotor
Regulating unit
Fault-finding
In the following, the most common faults that may appear in DC motors and
their possible causes are described.
Fault: The motor runs hot. Note that DC motors normally get fairly hot,
70-80 °C as measured on the motor casing.
• Excessive load.
• Motor having exceeded maximum speed for a considerable length of time.
• High ambient temperature.
• Worn bearings.
• Short-circuit in field winding.
Fault: High idling current.
• Worn bearings.
Fault: High starting current.
• Worn bearings.
• Break or short-circuit in field winding.
Fault: Fluctuating speed at constant setpoint.
• Excessive load variation.
Fault: Abnormal brush wear.
• Incorrect spring force on carbon brushes.
• Dirt and/or uneven commutator.
• Short-circuit in rotor winding.
Stepping motor systems
Stepping motors are mainly used for the positioning of small loads. They may
be regarded as digital motors, converting electric impulses into mechanical
movements. Each pulse corresponds to a defined angle of movement by the
motor shaft - one step. Normally, in stepping motors there is no feed-back of
load and position.
The stepping motor

Construction A stepping motor consists of two main parts:
• A permanently magnetized rotor.
• a stator, carrying the windings.
The permanently magnetized rotor may have a varying number of poles, or, as
they are normally termed, rotor teeth. A common figure is 50. Most stepping
motors have two phases, i e two field windings. There are, however, also five-
phase motors.
The diagram below shows a two-phase motor with six rotor teeth.
Rotor
Stator
N
S
N
N
S
Field windings
N
S
Rotor tooth
This diagram (below) shows a section through a 200-step motor. It is a two-

phase motor with 50 rotor teeth. This is a very common type of motor.
Rotor
Stator
The stepping motor converts electric pulses into rotation, and each pulse Function
results in a defined angle of rotation - one step, according to the following
formula:
360°
One step = ------------------------------------------------
Steps per revolution
In the following, the function is described:

When a current flows through a pair of field windings (fig 1), the stator poles
are magnetized and attract rotor teeth with opposite stator teeth polarity. By
switching in the next pair of windings, (fig 2), the next stator pair will also
become magnetized; the change in magnetic flow will cause the rotor to turn
15 degrees. Then, as the first stator pair is disconnected (fig 3), the rotor will
turn another 15 degrees.
By connecting and disconneting the flows of current through the field
windings according to this pattern, the rotor will revolve in steps of 15 degrees
(figs 1 - 6).
For a two-phase motor with six rotor teeth, the number of steps per revolution
will equal 24:
2 × number of phases × number of rotor teeth = 2 × 2 × 6 = 24
Thus, the motor in the example will move through 24 steps per revolution, and
in accordance with the previously given formula, one step is:
360°
----------- = 15°
24
The speed at which the motor rotates depends on how rapidly the field
windings are being reconnected.
All stepping motors function as described in the above example. The only
difference is that a standard motor has more numerous stator poles and rotor
teeth. This gives smaller and more numerous steps per revolution.
1 2
N N
S S
N
N
S
N
S
S
S
N N
S S
3 4
S
N S N
S
S
S
S
N
N
N
N S S
5 6
S S
N N
S
S
N
S
N
N
S S
N N
The design of the stepping motor is such that some of its features may be Miscellaneous
misinterpreted as defects in the motor, unless the causes are known.
Stepping motors often become hotter than motors of other types. The reason
is that full motor current always flows through its windings, also at stand-still.
This is termed holding torque. The reason for this is that the motor must
remain in position, as it usually lacks feed-back. The torque imposed by the
load must not shift the motor out of position. Normally, stepping motors have
class B winding insulation, which means that the temperature of the windings
may rise to 130 °C. An motor casing temperature of 90 °C does not cause any
thermal damage to the motor.
A stepping motor cannot be operated without a load. It requires a load moment
of inertia which is at least equal to its own internal moment of inertia in order
to be able to accelerate normally. Unloaded, the motor will race.
A stepping motor may jerk, as power is switched on. The reason for this is that
it has a number of fixed positions, for instance 200. If the rotor rests between
two positions, it will jump to one of these fixed positions. The movement
cannot exceed ±0.9 degrees in a 200-step motor.
Stepping motors should always be connected with cables which are screened
and whose conductors (strands) are twisted. The screen is to be grounded at
each end. Screening is done in order to prevent electromagnetic interference
(noise) to enter or emerge from the system.
Control unit
The control unit generates the electric pulses which drive the motor. The
change of angle made by the motor is entirely controlled by the number of
pulses generated by the control unit. The control unit consists of:
• The rectifier, which converts the supply voltage into direct-current voltage.
• The power unit, which generates the pulse train to the motor.
• The pulse control logic, which determines how the power unit will
generate the pulse train.

M
Pulse control
logic
External control signals
The pulse train, or rather pulse trains, is generated by the power unit, which is
controlled by the pulse control logic. A pulse train must be generated for each
motor phase. The pulse trains are fed into the field windings, offset in time. In
this way, the windings fitted around the stator are receiving power in
succession. A revolving magnetic field is thus created, which turns the
permanently magnetized rotor with the flow of magnetism.
The speed of rotation of the motor is proportional to the frequency of the pulse
trains.
The position of the motor is based on the fact that it always turns one step per
pulse. This, together with the lack of feed-back between the motor and the
control unit, is the reason why, if a pulse is being missed, there will be no
correction made by the control unit. The most common cause of missed pulses
is that the motor is underdimensioned and has not the power to shift the load
at the preset acceleration and speed parameters. A further cause of missed
pulses is that there may appear resonant oscillations in couplings between
motor and load.
Fault-finding
In the following, some faults that may appear in stepping motor systems are
described.
Note
In order to be able to carry out fault-finding in a stepping motor system, it is
• No setpoint from the pulse control logic.
• Motor windings short-circuited.
Fault: Motor races:
• Load too light or disconnected.
Servosystems
A servosystem is capable of transforming any mathematical function into
a mechanical movement. This means that servosystems can replace mecha-
nical elements, such as cams and cam shafts, indexing gears, differentials, etc.
A servosystem consists of a servomotor with its control unit.
Servosystems can be used for the following kinds of control functions:
• Speed control; the motor speed follows a predetermined speed function.
• Positioning; the position, linear or angular, follows a predetermined function.
• Torque control; the torque of the motor follows a predetermined function.
• Hybrid control; the system alternates between different kinds of control
functions, for instance motor speed control during one part of the working
cycle and positioning during another part.
Motors and control units for servosystems cannot be combined in just any
way. They comprise integrated systems, and the same supplier should be
selected for both motor and control unit.
The servomotor
The servomotor, which is a permanently magnetized brushless AC motor, is a
relatively new type of motor. It has been specially designed for use in servo-
systems. Characteristic of this motor is its high performance in every respect,
but principally that it provides much higher output power in relation to its
size than other types of motors.
Servomotors have great overload capacities and can cope with rapid load
fluctuations. The overload capability also provides a torque reserve which is
needed for quick acceleration and braking of a load. Sine-shaped motor
current and electronic commutation give, in addition to a very wide speed
range, also silent and smooth running and high efficiency rating.
As can be seen, servomotors possess excellent qualities; in addition to what
has already been enumerated, they provide high torque and have a low internal
moment of inertia. They are, however, expensive. In order to achieve all these
good features, it is necessary to use very rare and costly magnetic materials in
the permanently magnetized rotor. Samarium, cobalt, and neodymium are
examples of typical rotor materials.
In principle, a servomotor consists of a permanently magnetized rotor and Construction

a stator of iron, which carries the windings.
Stator
Field winding
Rotor
Permanent magnet
In a motor of this design and construction, nearly all motor losses take place
in the stator. This means that the transfer of heat to the surrounding becomes
short and quick. Electronic commutation and the absence of motor slip also
contribute to the generation of less heat, which thus is easier to get rid of than
in other motor types.
Heat
Function The windings in the stator generates a rotating (1) magnetic field (2) through
the motor. The permanently magnetized rotor (3) is attracted by the poles of
the field and will rotate (4) synchronously with it .
S
N
1
S N S N
S
3
N
4
The rotating field is generated by the electronic commutation of the field

windings. If the motor is to be at stand-still, for instance to maintain a torque
or a position, the field windings are made to generate a static field.
Electronic commutation Electronic commutation means that the current to the motor windings is being
switched electrically.
Resolver Beside the rotor and stator, the resolver forms a vital part of the servomotor.
The resolver is an angle encoder, which all the time senses the angle position
of the motor and feeds this information back to the control unit. The control
unit uses the information to commutate the field windings so that the motor
performs the required function. As an example, the field windings are to
generate a rotating field of a defined strength for the motor to drive a load at a
specific speed.
In principle, a resolver is a rotating circular transformer, supplied with a
carrier (AC voltage) of 1 - 20 kHz. The carrier induces one sine and one
cosine signal in the fixed windings. The sine and cosine signals are modulated
on the carrier. These signals specify the absolut angle position of the rotor.
Carrier
Sine
Cosine
The sine and cosine signals are converted into a digital signal, and with this,
get the resolver into a certain resolution. A two-pole resolver produces 8 192
pulses per revolution, and a four-pole resolver produces 16 384 pulses per
revolution. In addition to the resolver specifying the absolute angle position,
the control unit is capable to calculate, with the aid of the pulses:
• the direction of rotation, by determining whether the sine or cosine signal
comes first.
• the position (change of angle), by counting the number of pulses,
• the rotational speed (rpm), by counting the number of pulses per second,
• the acceleration, by counting the number of pulses per second squared.
The servomotor and resolver should always be connected with cables which Miscellaneous
are screened and whose conductors (strands) are twisted. The screen is to be
grounded at each end. Screening is done in order to prevent electromagnetic
interference (noise) to enter or emerge from the system.
Control unit, drive electronics

The control system for a servomotor consists of three main parts:
• Program
• Regulating unit
• Power unit
Program Regulating unit Power unit Servomotor
Position Speed Torque

regulator regulator regulator
Resolver
External control signals 3 x 400 VAC
Program The program contains information on the movement cycle of the motor. It can
also be said to describe the functions which the motor is meant to perform.
Often the program communicates with an external control system, for instance
the PLC of a packaging machine.
The regulating unit The regulating unit controls the movement cycle of the motor utilizing the
information from the program and the resolver, as well as by measuring the
current between the power unit and servomotor. The regulating unit usually
contains three regulators, or as they may also be termed, regulating loops.
The position regulator counts the pulses from the resolver. The total number
of pulses provides information on the position of the load, its angle position,
and change of angle.
The speed regulator regulates the speed by counting the number of pulses per
second. The speed regulator also regulates the acceleration.
The torque regulator measures the current from the power unit to the motor.
The amperage of the current is directly proportional to the torque of the motor.
The power unit The power unit supplies the motor with electric power (current). It is normally
fed by three-phase AC from the mains. The supply voltage is rectified and
connected to a transistor bridge with six transistors. By means of the transistor
bridge, controlled by the control unit, the motor windings are commutated, so
that the motor performs as required. The switching frequency is 3 - 20 kHz,
depending on make and system selected.
The power unit supplies the motor with three sine-shaped currents, which are
offset 120 electrical degrees relative one another. Sine-shaped current
contributes towards smooth running and small losses.
The power unit also regulates the amperage of the currents. The size of the
currents is proportional to the torque of the motor.
Fault-finding
In the following, some of the faults that may appear in servosystems are
described.
Note
In order to be able to carry out fault-finding in a servomotor system, it is
• No setpoint from the regulating unit.
• Motor short-circuited.
Miscellaneous
In this section are described certain components which are common in electric
drive systems but which are not specific to a particular type of system.
Angle encoders
Angle encoders are used in many drive systems to record or monitor the
angular and linear positions of the system, its direction of rotation, speed, etc.
An absolute encoder converts the angle position of a shaft into an electric sig- Absolute encoder
nal. The electric signal is a digital code of some kind, for instance a binary
code, BCD code, or gray code. The mostly used is gray code and the number
of bits in the code determines how precisely the angle encoder can record the
angle position. An eight-bit code has a resolution of 256 and can record the
angle position within ±0.7 degrees.
The key component of the angle encoder is a code disc, fitted to a shaft. On
the disc, there is a pattern of tranparent and opaque areas. These areas
comprise the actual code. For each angle value, there is a unique combination
of areas, which can be transscribed into logic ones and zeroes.
Code disc with gray code
One one side of the code disc, there are light-emitting diodes and on the other
side phototransistors.
The light-emitting diodes shine their light on the code disc, and the photo-
transistors sense light or non-light, depending on which position the disc is in.
The phototransistors give the position of the disc in the form of a binary signal.
As the disc rotates, a signal is continuously being registered, corresponding to
the absolute angle position of the shaft on which the code disc is fitted or
connected with.
Phototransistors
LEDs
0
1
0
1
Incremental encoders An incremental encoder converts a defined angle turn into an electric pulse.
By counting the number of pulses, the encoder records how big the turn is. The
number of pulses per revolution determines how precisely the angle encoder
can record a change of angle. An encoder, giving 10 000 pulses per revolution,
can record an angular change within ±0.036 degrees.
Just as absolute encoders, incremental encoders have a code disc. On the code
disc, there is a pattern of bars with the same resolution as the encoder has. The
bar pattern is often divided into two channels, offset half a pulse relative one
another. By sensing which channel comes first, the direction of rotation can be
determined. Often, there is a reference pulse, a so-called zero pulse, which
generates one pulse per revolution.
Channel 1
Channel 2
Reference pulse
Just as in absolute encoders, the pulses are sensed by light-emitting diodes

and phototransistors.
As the code disc rotates, a pulse train is created. The number of pulses
indicates how big a change of angle the shaft has made.
Temperature (safety) switches
Under certain circumstances, it is suitable to supplement the regular motor
protection with temperature safety switches. These switches protect the
motors from overheating, caused by overloading, insufficient cooling, too
high ambient temperature, high starting frequency, or similar faults.
The temperature switches are fitted in or on the windings in the stator and
ensure that power to the motor is cut if a preset temperature is being exceeded.
There are several types of temperature safety switches; below, three of them
are described:
• Bimetal types of temperature switches usually work on the principle of the
bimetal element tripping and cutting power at a given temperature. Such a
switch is wired into the control circuit of the motor, or, in the case of
motors of low power, directly into the power circuit of the motor. No
separate control unit is required.
• Thermistors are temperature-dependent semiconductors. Thermistors of
PTC (Positive Temperature Coefficient) type are the most common ones.
These offer the advantage of very slight increase of resistance on rising
temperature right up till the reference has been reached. Then the resistance
increases sharply, up to 1000 times. Thermistors must be connected to a
separate control unit, which cuts the power supply to the motor.
• Resistor elements are temperature-dependent resistors. Resistor elements,
for instance PT 100, are mainly used in large motors, where they are wired
into the motor windings. PT 100 signifies that the element is made of
platinum and has a resistance of 100 ohm at 0 °C. Resistor elements must
also be connected to a separate control unit.
17
GeFanuc

57871
Functional Description 1(21)
PLC TBA/21 HC LSP
Tetra Pak GE-Fanuc PLC-program TBA/22 1997-05-08
Modena, Italy 48191 - 0200 ECN 70798
1. Table of Content
PRELIMINARY
1.TABLE OF CONTENT ...................................... 1 12. PENDULUM ROLLER .................................... 9
2. INTRODUCTION ............................................. 1 13. ALARMS ..................................................... 9
3. GENERAL DESCRIPTION. ............................... 1 14. TPOP...................................................... 10
4. MACHINE LADDER......................................... 2 15. LEVEL-CONTROLLER ................................. 11
5. MACHINE STOPS .......................................... 3 16. TEMP CONTROLLERS. ............................... 14
6. PREPARING.................................................. 4 17. SERVO MOTOR CONTROL. ......................... 17
7. TUBE SEALING. ............................................ 4 18. STEPPER MOTORS.................................... 18
8. MACHINE STERILISING AND PEROXIDE 19. W ASTE (DUMPING OF PACKAGES). ............ 18
SYSTEM.. ......................................................... 4 20. CLEANING (EXTERNAL AND CIP). .............. 20
9. PRODUCTION . ............................................. 6 21. GREASINIG (JAW AND FFU) ...................... 21
10. LONGITUDINAL AND STRIP SEALING. ............ 6
11. ASU.......................................................... 7
2. Introduction
The PLC program for this machine is distributed only on a diskette. If a printout is
desired it is possible to make one from the diskette. The documentation of the PLC
program is located in chapter 3 under PLC program .
By copying the PLC program folder from the diskette into the lm90-folder on a
computer all lists, addresses, comments and logic is possible to access both On-line
and Off-line.
Any change applied to the PLC-program by a third party is not supported by TP and
third party must take full responsibility to document and maintain every change.
3. General description.
The PLC-program is the master of the machine i.e. it controls more or less all the
functions in the machine. In fact in this machine much more than previously.
This means the program is a very vital part

of the machine and anyone making changes must be aware of the risk of jeopardising
the machine function.
With the implementation of the TPOP a lot of new possibilities came along and
the goal is to utilise these possibilities so all parameters and alterations to the PLC-
program should be made from the TPOP.
A TP service engineer should be able to set the machine (according to volume

product and so on) for a specific customer site without using a PC.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
However block in the PLC program is prepared with some free inputs, outputs memory
cells and registers to be used for special customer demands. Blockname “CUSTOM”
4. Machine ladder
The machine ladder is basically built in the same way as on all other TB machines
it contains 14 steps:
Step Name Adress.
14 Cleaning/Greasing G014
13 Doors OK G011
12 Venting G012
11 Production ended G011
10 Production G010
9 Motor-start G009
8 Start FFU heaters G008

7 Signals steriliser G007
6 Drying G006
5 Spraying G005
4 Heat sterilising G004

3 Tight tube G003
2 Preparing G002
1 OFF G001
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
Step up in the ladder is allowed if the proper step-up conditions are set. These are
collected in one memory-cell in the main block ,when this is true it is ok to step up.
The step up conditions are collected in several rungs (STP1-8 and 9-11) and in the end all is collected in the rung ST_COND.
5. Machine stops
Machine stops are collected to memory cells which is normally true and when they
become false the machine stops. They are also step up conditions.
In this machine there is four stop types:
Jump to pos. 1 Emergency stop, If machine loose some sterile condition

and when PLC is stopped.
The machine stops as fast as possible.
Jump to pos. 6 Protection stop, door open or condition in which the

machine must stop as fast as possible without loosing
sterility. Example crash in the final folder
Normal stop Normal stop in this machine is equal to a short stop

in a normal TB machine. The machine stops with product in
the tube and the final folder is emptied. Initiated by the
operator pressing step down button or stop-condition
“Demand for normal stop” becomes false.
End of production stop The tube is emptied of product before the machine stops
Note: this machine always stops with product inside the tube.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
6. Preparing.
In this step the machine is turned on i.e. all power-supplies to IH-generators DMC’s
and so on.
Drive roller motors are activated so when the operator pulls paper through the machine
the motors will help.
To activate the squee-gee roller motor, the top door aseptic chamber has to be closed.
During the first three minutes the compressor is started, the B and regulating valves
are open. This will drain the system from remaining water (left from CIP).
This is a must otherwise while spraying a lot of water will be collected in the last
package, the peroxide will be sprayed into the water and never dried up .
7. Tube sealing.
The tube sealing is made in low speed when started it will stop when two conditions is
fulfilled:
1. Min time for tube sealing reached (to ensure that strip is sealed all the way
from the strip applicator.
2. The machine has to stop in “design” which means that the barcode signal
must be in a predefined sector before it stops.
During tight tube the B-valve and regulating valve is open and the compressor is
running . This is to ensure a good drainage of cleaning liquid (water).
Filling of H2O2 from ring-container to peroxide tank starts in step tube sealing
8. Machine sterilising and peroxide system..
The machine sterilising is made in 3 steps, Heat sterilising, spraying and drying all 3
steps is executed in the subroutine “ASEPTIC”
The peroxide system is also included in sub “ASEPTIC”.
Step Heat sterilising:
When entering step:
• Seal water and compressor already started.

• B-valve closes
• Air super heater starts
• H2O2 circulation and heating starts
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
During Step
• The preheating valve will open and close to maintain 30 °C in the top of the
aseptic chamber
Step ends:
• When Temperature monitor “Heat sterilising” reaches it’s low limit (280 °C).
If air super heater temperature is not reached in 700 sec (11,6 min) the machine is
stepped down to 0
Step Spraying:
The spray-sequence:
1. Filling of spray tank ( Time (T) to fill must fulfil 1s < T < 8s )
2. Emptying of spray container ( Time (T) to empty must fulfil 1s < T < 11s )
the B-valve (spraying of filling pipe and tube) is open the first 8 seconds.
3. Spray pause 1 min (Preheating valve is closed)
If filling of spray-tank fails the machine steps down one step and it is possible to retry to
make the spraying.
If emptying of spray-tank fails following sequence is executed:
drying ⇒ venting ⇒ Jump to 0
Step drying events:
• Preheating valve opens

• B-valve opens
To avoid overheating in the aseptic chamber the heat exchanger is kept in bypass until
the temperature top aseptic chamber reaches 110 °C then it is switched to max cooling
and will keep that position until the drying time has expired (15 min).
When the drying time expires the step ends and the “DRY_OK” signal is set.
When “DRY_OK” = true:
• Heat exchanger switch between max cooling and heating to maintain 95°C in top
aseptic chamber
• Pressure in the aseptic chamber is monitored
• Machine is ready for production
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
9. Production .
When the machine has communicated signals to the process it is possible to enter
the step “START FFU HEATERS” and the heaters will start heating, after app. 30 sec
the temperatures should be reached and the machine can be started. to avoid
overheating of the station chain the machine will stay in this step for 1,5 min then it will
automatically go down one step.
When the start-sequence is started the FFU goes to the home position, after 9 seconds
the A-valve opens and pre-filling of the tube is started. When the product reaches the
level probe the LS-inductor makes the short stop movement and 600 ms after the
machine starts.
Note: The first start after a tight tube is different since the tube is empty the A-valve
opens immediately in the start-sequence.
The filling of the perxoide bath starts so that it is always filled up at least 1 second
before the product level.
10. Longitudinal and strip sealing.
When starting the machine both the power for LS and SA is ramped up.
The power for both sealings is set from the TPOP ,The power is read and divided into
proper increments for the ramps. The ramps always start from a MIN value which is
fixed and then ramped up to the set value. The increment is calculated considering the
motor speed variation and the ramp up time set in the DMC or in the inverter. With that
data is possible to know how many plc scan the motor needs to reach the final speed
and the increment is calculated dividing the power variation by the plc scans. All logic
except the ramps is located in the subs “LS_SEAL” and “STRSEL”. The ramps is in the
sub “RAMPS” which is prepared to be a time interrupted subroutine (The ramps are
based on count of programscans)
Ex1 Calculation of power multiple LS-ramp. LS_POW2 is setvalue from TPOP (production). LO_SHPW is the start power(Min
setting for TPIH) The difference is divided with 29 because the motor accelerates up to full speed in 1 sec (29*35 =1015ms ≈ 1S)
the scantime is fixed to 35ms.
This rung creates the ramp.

57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
This rung checks when the right power is reached and stops the ramp.
11. ASU
In the sub “ASU” all functions related to the ASU is collected. The functions and subs
are:
Function Subroutine
Motor control of loop and magazine motors “ASU_MOT”

Packaging material splice “PAPERSP”
Strip splice “STRIPSP”
Strip sealing “STRSEL”
ASU_MOT Subroutine
The paper in the ASU is pulled by the “loop” motor, that controls the loop length
unwinding paper from the jumbo and by the “magazine” motor that controls the
magazine length. For each main motor speeds(high, low) two speeds are defined: high
and low. The status of the sensor that control the loop/magazine length switch the
motor speed from high to low in order to maintain the nominal length. An automatic
speed tuning checks the time of the loop/magazine oscillation around the nominal
position and shifts both speeds up or down when this time is bigger than the
predefined one. This value is related to the motor ramp up and ramp down set in the
inverter.
If the status of the sensor is not changed within 0,5 sec the speed values will be changed.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
If the sensor (magazine) is true when the time expires the speed values will be subtracted.
If the sensor is false The speed values will be added.
PAPERSP Subroutine
To perform a paper splice two conditions must to be fulfil: new paper jumbo prepared
and top door closed. In case of machine stop during the splice sequence is possible to
complete the splice pushing the manual splice button when all the alarms are reset.
The paper splice sequence is devised in 9 step:
Step0 The speed control stop and the motors run at a predefined constant
speed.
Step1 The material holders move up and the web tension is activated. At the
first bar code signal the magazine motor stops and the loop motor start
to run slowly. Two bar code signals later, when the loop speed is
stable, the loop motor runs few more milliseconds to reach the right
paper position to make the splice in design. Then the loop motor stops
and the paper is locked by the pressure rail.
Step2 It is checked if the material holders are in the upper position.
Step3 The paper is locked in the paper table by the lock cylinder.
Step4 The paper is locked by the pressure rail and cut then the material
holders go down.
Step5 The paper splice head change side and the TPIH output is switched to
the splice inductor.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
Step6 The material holders move up.
Step7 The paper is locked by the pressure rail then the sealing pulse is
activated. After the lock cylinder and the web tension are released, the
TPIH output is switched back to the S.A.
Step8 The loop and the magazine motor restart to run and the holders move
down.
Step9 Reset parameters, sequence ends
STRIPSP Subroutine
The strip door closed and a new strip bobbin prepared are the needed condition to
perform the strip splice. When one bobbin is ended or the manual splice button is
pushed the magazine motor stops then the splice head go down for 1 sec. (sealing
time). Ended the sealing phase the head moves up slowly than after 0,5 sec. (cooling
time) the magazine motor restarts.
STRSEL Subroutine
See the “Longitudinal and strip sealing” chapter
12. Pendulum roller
The control of the pendulum roller is made by the driven squee_gee roller. The control
of that is in the sub “P_FEED”.
The pendulum roller is connected to an pneumatic cylinder which will give the paper-
web in the forming-section a constant web tension. The position of the roller is read
with an inductive sensor and that one is used to control the speed of the motor.
When the machine is standing still (From step2 and up) the motor will feed paper with
a fixed speed when the inductive sensor is true.
In production the speed control is the same as for the ASU-motors.
13. Alarms
The alarms is collected in subroutines, each subroutine includes alarms for one alarm-
window on the TPOP and should represent one module of the machine.
Each subroutine includes the required logic for the alarms and memory-cells for each
alarm. The memory cell is used for machine actions and is transferred to the TPOP in
a register.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
There is two types of alarms in this machine A-alarms and other alarms.
A-alarms is alarms stopping the machine and these are activating the alarm lock to
lock the transfer to the TPOP and only display the alarm that stop the machine.
A-Alarm mask alarm-window if an A-alarm occurs the cell A_ALDET is set and check for other A-alarms is stopped
Safety_1
The alarms is divided in A-alarms and others in the sub AL_MASK.
The alarm transfer to the TPOP is made in the sub AL_LOCK

The alarm lock is set the first time an A-alarms appears and it is then deactivated by
the alarm reset button (The transfer is opened and all present alarms is transferred.
The lock is activated again when no A-alarm exists).
A-alarm lock. When first A-alarm arrives the lock is activated and the cell
Alarms is always transferred to A_AL_EX is set. The lock is unlocked when alarm-reset is pressed or when
the TPOP when the alarm-lock is no A-alarm exits. The lock is not activated again until all A-alarms has
not activated disappeared
14. TPOP
From the TPOP all changeable parameters could be changed . When a change is
made in the TPOP the register is read by the PLC and transferred to the actual unit.
In the case of TPIH generators DCS offset and so on the signals are connected to an
analogue voltage output and connected to the actual unit.
In case of Temp-controllers and so on it is only internal parameters.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
Example of setting from TPOP, TSLEFT = %R491 and it’s set in the TPOP. P_TS_L = %AQ001 is the output connected to the
potentiometer-input on the TPIH-generator.
All registers are read/write in both directions which means that changes can be made
both in the PLC and on the TPOP. However all changes should be made from the
TPOP.
Default values could be retrieved from the PLC for each controller by pressing the
default button.
Default values general is stored in the sub DEF_PAR ,for temp-controllers the default
values is in the sub DEFAULT.
When the D (Default button) is pressed on the TPOP (in this example for the volume cams) Bit 1 in register DEF_JUM is set
unless an actual change of the position is going on the default value will be loaded from The PLC to the TPOP.
15. Level-controller
In this machine the product control is made in two parts one flow-control and one level-
control.
The flow control is pure mechanic and taken care off by the regulating valve.
The valve works as a constant pressure valve and will for a certain position keep a
constant pressure (theoretically). The position of the valve is given by the pressure
supplied by the I/P-transducer . A certain position gives a certain flow and the valve
tries to keep the pressure constant, the variations during normal production will be
quite small.
However if the pressure is varying on the product-line the valve will respond fast on this
but for every pressure peak there will be a certain level-deviation.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
The level controller has two functions:
1. Control of level (valve pos) during start and stop.

2. Control of level during production.
During the start-up the output signal must be controlled so the level is stabilised as fast
as possible. When it is stabilised around the set-value it should act as a slow controller
taking care of the accumulated level-deviation the regulating valve cannot handle.
The level controller is a home made PID algorithm written in ladder logic. It is a
modified linear algorithm and the parameters in this should not be changed.
To adapt to different product-pressures and products there is a Flow offset value that
could be changed. This should be changed from The TPOP.
The start-flow value can as well be change from the TPOP
function:
When the A-valve opens the level-controller is off and a fixed value is transferred to the
regulating valve. This is the start-flow value.
When ≈ 50% level is read on the probe the controller sets the “LEV_OK” signal closes
the regulating valve and waits 1,4 sec
(The machine is standing still making the short stop movement for the LS).
When the product-level reaches the value 18000 the LEV_OK signal is set.
When LEV_OK becomes true the start sequence is ended and short stop sequence starts (600ms later the machine starts).
1,4 seconds later the output to the regulating valve is set to the mean-value of the
output calculated during previous production. And the level-controller is started.
The level controller is sampling the level 4 times for each package. Every sample uses
a calculated mean-value of the level.
For each part the P ,I and D parts are calculated before transfer the result to the output
an offset is added.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
Calculation of the output value P,I and D-part is summarised and then the offset is added.
The P,I and D-gain is fixed and should not be changed.
P-part:
The Proportional part is calculated directly on the last levelreading.
The deviation is first divided and the multiplied. This is to have the possibility to set the
p-gain to for instance to a decimal value with 2 decimals (this is used P,I and D part
when it comes to apply the gain).
I-Part:
The I-part is applied on the accumulated error of the level. This is the modified part of
the PID function. The best behaviour of the level controller tested so far is to let the I-
part be the base of the controller during production. It should be almost filled
in fact if it the value of “I_ACK” is oscillating between 30000-32767 the value keeps the
level around the set-value in a very stable way.
D-part:
D-part is applied on the difference of the Level-deviation on present package and

level-deviation on package before.
The Gain is applied by first dividing the error and then multiplying In this case P-gain.
If the controller is oscillating or has a stationary control deviation that is to big it should
be corrected by adjusting the Flow offset. If the level is oscillating the offset should be
increased and if the level is too much below the setvalue it should be decreased.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
The behaviour of the level-controller is checked in the subroutine “DIA_LEV”

This subroutine checks both if the oscillation is to much or if the level is too much
below the set-value.
When one of these two conditions are detected a alarm is set on the TPOP. It exists
one alarm for each condition.
Check of stationary control deviation.
Check for oscillations in level controller.
16. Temp controllers.
The temp-controllers are made with the existing PID block function. The output value
from the controller is converted to a PWM-signal in the sub PWM.
Common for all loops is that the output is scaled from 0-32000 this is converted to
0-100% in the PWM sub. The different loops uses different time-bases for the PWM
outputs
All the loops are prepared for 2 set-values. But in this program all loops are using only
one setvalue.
All alarm-limits (low and high setval 1 and 2) are relative. They are set from the TPOP
and calculated to an absolute value in the PLC program
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
Calculation of alarmlimits for setvalue 1 ex L1_SV1 = Setvalue 1 loop 1, AL1H_L1 = Alarmlimit high setval 1 loop 1, CAL1_1H =
Calculated high alarmlimit setvalue 1 loop1.
Except two special-cases the temperatures is controlled with the GE PID function.
Specialcase 1:
Loop 1 (Heating Peroxide) The system is very slow. This could give some unwanted
effects if heating of the peroxide is started and then for some reason interrupted before
it reaches 72°C. If the PID is turned off the I part is reset and has to be recalculated on
the other hand if the PID is on but the heating is off the I-part will grow and also in this
case has to be recalculated.
If the temp in the tank is 60°C or more this will result in an heavy overshoot before the
controller stabilises( it will turn on 80°C.)
The tank is well isolated so the temp will remain for several hours.
The solution for this is to put the PID into manual mode when the heating is turned off
if the temperature in the tank is higher than 55°C and the output from the PID is higher
than 50%. In manual mode the controller freezes the calculated values for P,I and D
gain and the controller will restart with the correct values and stabilise around 72°C.
Check if temp in tank is higher than 55°C and the output is higher than ≈50% the cell L1_man is activated.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
The PID is put into manual mode with the cell L1_man
Special case 2:
Loop 6 (Air super heater).
During Heat sterilising, spraying and first phase of the drying the air blown through the
air super heater has ambient temperature. In drying when top aseptic temperature
reaches 110°C the heat-exchanger valve is switched and the air is passing through the
heat-exchanger before entering the air super heater. The air feed into the super heater
is no longer ambient temp but much higher and the result is that the PID output is
much to high for the new load. The result is an big overshoot and heavy oscillations
before it stabilises again. To avoid this a feed forward control is active in this phase:
1.When the air super heater is started in Heat sterilising the BIAS = 0
2.A few seconds before the heat exchanger valve is switched the BIAS is
set to 15000. This results in that the output value (CV) is decreased with this
amount and the controller will bump-less start to control the temp around
this value more or less at the same time that the hot air arrives.
When the TOP AC low limit (110 °C) is reached the BIAS is set to 15000.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
17. Servo motor control.
This machine has 3 servo motors, the PLC control of this is in the subs MMOTOR
,FFU_MOT and DCS.
To enable the servos both a Hardware enable and a software enable signal is required.
For the Main motor and FFU the Hardware enable is connected directly from the safety
relays.
In addition to that a contactor is present (Main and FFU) between the Servo amplifier
and the motor. These are connected to the PLC through the safety relays.
Enable signals and contactor outputs is always false when motors is not running and
every time a motor should run first the contactor output is set and then the enable.
When the motor stops the sequence is reversed.
Main and FFU motors options:
• Could be running separately high or low speed by setting High speed or low signal
from PLC.
• Run synchronously when machine is in production.
Sequence to run synchronously :
1. Contactors and enable-signals are set according to description above

2. Set output “HP_SEAR” and the FFU will go to home position.
3. When FFU reaches Home pos “FFU_HP” is true when true set output
“D_SYNCH”.
4. Now the two motors is electronically synchronised (FFU as the slave)
5. When output “MMHSPD” is set and both motors start to run
DCS motor.
The DCS motor positions the cam for the folding flaps. The setvalue is sent directly
from the TMCC DCS card on an analogue output.
The PLC controls the following.
1. In tube-sealing the Servo is enabled. Immediately when the enable signals are set
the motor start home-pos search.
2. When the motor reach the home position it is waits for the signal “PRE_1” which is
set from the PLC, when “PRE_1” = true the motor is positioned to make half
prestepped packages.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
3. When the tube sealing ends the signal “PRE_2” is set and the motor is positioned
to the beginning of the working range (packages produced will be ≈ nominal lenght -
1,5 mm .
In production the movement of the motor must be synchronised with the machine it is
made with the signals “ST_POS” and “J_RDY” .
ST_POS: Start positioning of the motor (on true)
J_RDY: True when jaw in-movement are ready or machine stops,

the servo controller turns off the I-gain for the current
regulator on true . (IMPORTANT if this signal is missing
the motor can burn when machine is in normal stop).
18. Stepper motors.
The movable forming ring in the superstructure and the volume cams in the jaw system
are controlled with stepper motors.
The pulse-train for the motors are generated by the PLC program scan. In the case of
the volume cams the fast scan (Due to the big amount of pulses it takes to make one
complete stroke of the cam).
When the machine is stepped up to preparing both motors are going one complete
stroke backwards (To calibrate against a mechanical stop) and then positioned
according to the setting on the TPOP.
If the setting is changed while the machine is not running it will make the same
sequence as above if instead it is changed while running it will calculate the new
position starting from the present and then go to the new position.
19. Waste (Dumping of packages).
The control for the waste box valve (Y5501) is in the fast scan it is synchronised with
the machine by two angle sectors: WB_ON and WB_OFF.
The decoding of packages to waste is in the sub “WASTE”

The waste is controlled with a shift-register (10 registers are used to cover all
machine).
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
The packages to be wasted is represented with a logical 0 in one of the waste registers
which corresponds to the position of the package to be wasted.
Ex . Splice guard in superstructure when it is activated 3 logical zeros are masked into waste register 4 which corresponds to the
position of the splice guard.
Some events (Like strip-splice) creates packages to waste which is physically before
the magazine in the ASU. This requires a special solution since the magazine could be
filled ,empty or half-filled by the time of the event. To make sure the right packages are
wasted packages in and packages out of the machine is counted. This counter is reset
when the loop and magazine is filled and the pendulum roller is in its nominal position.
In production the difference is kept in a register.
Register PW_DEV is reset when the sensors The deviation is calculated on the readings of bar-code signal ASU
is in their nominal position and bar-code signal for design correction
PW_DEV is reset when the machine contains the maximum amount of packages so
the deviation is always 0 or negative.
When the event takes place the mask-constant is rotated the in an register-array.
How many steps to move the mask in the array is calculated based on the nominal
position added with the PW_DEV (0 or negative value gives an actual subtraction of
the nominal value).
calculation of how many steps to rotate the mask (FFF8) in this case for a strip splice. Nominal pos is 140 (140 packages from th
waste box if the magazine is not filled the register PW_DEV contains a negative value and the position will be subtracted.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
Rotation of the mask to the right position. The size of the magazine is covered with 4 registers
20. Cleaning (External and CIP)
The logic for the cleaning are in the following subroutines:”HC” for External cleaning
“CIP” for CIP cleaning
HC subroutine
The External cleaning is made in sequence after the chosen from the TPOP. When all
the start conditions are fulfil and the selection of the type of cleaning is done, it’s
allowed to start the cycle by pushing the step up button. If there is an alarm, the cycle
will be interrupted and, when it‘s restart ,it start from the breaking point. During the
sequence it is also possible stop the cleaning cycle by using the step down button.
CIP subroutine
The CIP cleaning is chosen from TPOP.When it’s select and all the start condition are
fulfil, the CIP is activate using the step up button. When CIP is on, the D,E,F valves
and the regulation valve are open, the CIP recorder is on and the signal the external
CIP unit is on. To stop the CIP cleaning you have to use the step down button.
57871
PLC TBA/21 HC LSP
Modena, Italy 48191 - 0200 ECN 70798
21. Greasing (Jaw and FFU)
The logic for the cleaning are in the following subroutines:”GRE_JUM” greasing JUM
“GRE_FFU” greasing FFU
GRE_JUM subroutine
The greasing of the jaw system is made in automatic sequence link by link after the
chosen from the TPOP. When all the start conditions are fulfil and the selection
is done, it is possible start the greasing cycle by pressing the step up push button that
should be flashing. The cycle is divided in the following main steps:
1.Positioning of the jaw system
2.Positioning of the greasing pistons
3.Pumping of grease
This action is made two times for each link (20 times totally), starting from link number
zero. If the cycle stop or is stop, by pressing the step down push button, it will restart
from the last link that was greased (to avoid to much grease in the same links).
GRE_FFU subroutine
The greasing of FFU is made automatically during production : the greasing pump
makes 6 strokes every 15 minutes. It could also be initiated manually from the TPOP
when the machine is in production.
18
Special machine
functions

TPOP
Tetra Pak Operator Panel
Flexbox
Cable LVDS
Panel

TPOP connections
Lund, Sweden
Control cabinet
GeFanuc
Ext. keyboard
SNP
Control panel
Machine type
IR−Bezel
12" TFT LCD
TBA/22
Ext. keyboard Mouse
Flex box SNP TFT adaptor

Clips CPU
"Remote" LVDS
Flash IR−data
CLIPS TIO
PCB terminal
RSI module
LVDS (25 core) Display data
"Local" LVDS
VGA data Back light power
Issue
1/9908
Hard disc Keyboard

Power unit
Floppy disc Touch (mouse)
Push buttons
24 VDC
OH 864
Terminal
24 V control signals
24 V control signals
Lamp signals
Push button signals
RSI fault signals
Flexbox
Circuit board
Hardware look
Processor card
Com. ports
LDS−PCB card
Power supply
Back−up battery
Fan
Hard disk
Floppy unit

Back piece
Shild plate
Panel
Lund, Sweden
Clips−tio
Display
Panel
Machine type
TBA/21
Issue
1/9609
RSI plinth General:

Used in the long distance system to indicate
PLC faults and monitoring panel temperature
OH 605
Led 4 indicates output short circuit (not used) (colour red)

Led 1 indicates backlight fault (colour red)
Led 2 indicates temperature OK (colour green)
Led 3 indicates panel OK (colour green)
19
Cleaning systems

1 2 3
C
D
F
A E
4
5
6
7
8
1 Conductivity sensor
2 Flow meter (CIP)
3 Steam valve (C)
4 CIP valve (E)
10 5 CIP valve (D)
6 CIP valve (F)
7 Product valve (A)
11 8 Steril air valve (B)
9 Regulating valve
12 10 Filling pipe
11 Level sensor
12 Cleaning sleeve
Filling system
CIP cleaning valve group
Aseptic product valve
MP 3
Filling system − Automatic CIP
Machine C
sterilisation Steam
Hot (sterile) air

A
Product
D B
E
F
Drain Cleaning liquid
Production C
Steam
Pre−heated air
alt. cooled air
A
Product
D B
E
F

Lund, Sweden TBA/21 TBA/22 3/0002 OH 529:1
Filling system − Automatic CIP
C
Intermediate Steam
cleaning
A
Product
D B
E
F
Final C
cleaning Steam
A
Cleaning
liquid
D B
E
F

Lund, Sweden TBA/21 TBA/22 3/0002 OH 529: 2
Filling system − Manual CIP
C
Intermediate Steam
cleaning
A
Product
Cleaning liquid
Final C
cleaning Steam
A
Cleaning
liquid
Cleaning liquid

Lund, Sweden TBA/21 TBA/22 3/0002 OH 529: 3
External cleaning system
1 Compressed air
2 Cold water
3 Warm water
4 Upper cleaning circuit
5 Superstructure circuit
6 Dosing pump
7 Chemical supply
8 Cleaning pump
9 Lower cleaning circuit
4 1
8
3

M 3102
C 3105
Lund, Sweden
Mixing tank
O 3108
J 31081
Dosing pump
Flow meter P 3105
B 3105 5
Overpressure valve
Machine type
J 31042 J 3109
F 3111 J 31082
TBA/22
F 3112 Pressure gauge

F 3110
Alkali
Regulator
T 3104
4
Issue
J 31041
1/9905
2 3
1 Warm water
OH 844
J 3102 2 Superstructure
B 3102 3 Jaw system and final folder lower circuit
Y 3101 4 Jaw system and final folder upper circuit
A 3101 5 Compressed air
Z 3101
Pump
P 3102
Rinse valve
F 3103
External cleaning unit
External cleaning diagram
Lund, Sweden
El−cabinet
Machine
Machine type
J31041
J31081
J31042
T3104
F3110
TBA/22
O3108
El−cabinet
F3111 J31082
B3105
J3102 Machine
M3102
Superstructure P3102 M
J3109
F3112
To final folder / jaw system
Upper F3103
To final folder / jaw system B3102
Lower
Issue
Y3101
1/9905
P3105 C3105
Pneumatic diagram Z3101

OH 845
U3109 A3101
T3109
J / Z 3106
Air Alkali foam

Detergent Warm water
FFU 10
Jaw 10
Column 10
FFU 10
Jaw 10
Column 10
Draining air 60
FFU 10
Jaw 10
Column 10
FFU 10
Jaw 10
Column 10
Warm rinsing 60
Pump 60
Hot water 60
Stop motors 200
FFU 15
Jaw 15
Column 15
Foaming 45
Alcali 45
Pump 45
Hot water 45
Stop motors 200
FFU 15
Jaw 15
Column 15
Foaming 45
Alcali 45
Pump 45
Hot water 45
Stop motors 200
FFU 15
Jaw 15
Column 15
Foaming 45
Alcali 60
Jaw 15
Column 10
FFU 20
Jaw 20
Pump 120
Hot water 120
Warm rinsing 60
Column 10
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Training Document Training Document
TBA/22 TBA/22
Doc. No. WB-92-01 Doc. No. WB-92-01
Technical Training Centre, Lund, Sweden Technical Training Centre, Lund, Sweden
TBA/22 TBA/22
TBA/22 TBA/22

WB-92-01 Tba-22

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WB-92-01 Tba-22

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Course introduction 1

Design control system 10

Special machine functions 18

Technical Training Centre Cleaning systems 19

Technical Training Centre

Technical Training Centre 1/9701

Via Emilia Ovest

Technical Training Shool

Daily time schedule

Classes 08.30 - 10.00

Coffee-brake 10.00 - 10.20

Classes 10.20 - 12.00

Lunch 12.00 - 13.00

Classes 13.00 - 16.30

Smoking is allowed in some places marked with a sign.

Ask your instructor for assistance.

It is necessary to wear safety shoes in the Technical Training Centre, while

You are responsible for your own valuables.

Go to the Travel agency for reservations, reservation chang-

Ask your instructor for assistance.

Machine safety devices

Tetra Pak Doc No. MM-82302-0104 17

Technical Training Centre

Electrical carbinet Strip applicator (ASU RH side)

Automatic splicing unit Drive Jaw system Main groups

High productivity and space efficiency

1. Packaging material supply 3. Aseptic system 4. Jaw unit

TBA/22 packaging line

Filling machine Filling machine Straw applicator Cardboard packer

Product supply Water supply (hot)

Electricity Connection presssure, kPa (bar): 550–600 (5.5 –6)

Capacity filling machine

Packages per hour: TBA 250B 20000

Filled product type

Non viscous product only

Connection pressure, kPa (bar): 160±40(1.6±0.4)

Connection pressure, kPa (bar): 170±30(1.7±03)

Hydrogen peroxide, (H202)

Water supply (hot)

Connection presssure, kPa (bar): 550—600(5.5 —6)

Detergent (external cleaning)

Alkali, I/cycle: 1.2 (1.8*)

Cleaning in place (CIP)

Connection pressure, kPa (bar): Max. 350 (3.5)

Sound pressure level, Lp dB(A): 77

Installation drawing No. 648571-3.

Tetra Pak Doc No. MM-82302-0103 149

Tetra Pak Doc No. MM-82247-0103 293

Tetra Pak Doc No. MM-82302-0103 39

3-1 Drive - description

3.1 Drive, jaw unit

176 Doc No. MM-82302-0103 Tetra Pak

Technical Training Centre

Technical Training Centre

1 Outer coating (polyethylene) 5 Paper board (unbleached)

Internal coating 2 Alifoil Paper board Printing

Technical Training Centre Machine type Issue

1 Top fin crease 6 Double crease

Technical Training Centre Machine type Issue

Principle of ridge inductor sealing

Technical Training Centre Machine type Issue

LDPE LDPE LDPE LDPE

HDPE PET EVOH PET