TBA19

Course Introduction 1
TBA/19
TBA/19 Introduction 2
020V
Advanced
Drive Unit 3
Maintenance
Training Document
This Training Document is intended for
Jaw System 4
Training purposes only, and must not be
used for any other purpose.
The Training Document does not replace
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such.
Final Folder Unit 5
Note!
For safe and proper procedures, refer to
the equipment specific documentation.
Sterile System 6
Filling System 7
Design Control 8
ASSU 9
ASU/PMI 10
Supply 11
Technical Training Centre
Lund, Sweden
WB-164-01
Issue 3/0504
12

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

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Course Content
TC-0074 - TBA/19 020V Advanced Maintenance
Course Length 2 weeks
Target Group Tetra Pak Technicians
Previous Knowledge The participants must have taken part in the TBA/19
Maintenance Course and have at least 6 months of field
experience from TBA/19.
The participant must have GE Fanuc training equal to the
training performed by TTC .
Course Objectives To get a deeper understanding of how the components of

the machine work individually and together.
To be able to carry out mechanical, and to some extent,
electrical trouble shooting.
Course- Function of the drive system.

Content/Subjects Function and setting of the jaw system.
Function of the final folder.
Function of the sterile air system.
Function of the peroxide system.
Understanding of the machine preparation phase.
Function and settings of the design correction system.
Function and setting of the filling system.
Understanding of "paper tracking", tube forming and how
the package is formed.
Function of the ASSU.
Function and evaluation of how the LS and TS sealing is
performed.

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TBA/19 020V
Technical Training Centre Machine type Issue

Lund, Sweden TBA/19 020V 1/0304 OH 1375
TBA 250 S Straw
Package volume
Related Pack. Mat. Drawing: 479641-1
Size code: 565
Nominal volume (ml) 250.0

Theoretical crease volume (ml) 263.8
Underfilling (ml) 13.8
Underfilling (%) 5.2
Web width (mm) 188.0 ± 1

Repeated length (mm) 185.0 ± 0.3
Theoretical LS-Overlap (mm) 6.0
Related documents
Packaging material specification S001
Choice of Packaging material FDM or
Sales Manual G001
Distribution See ORBIS;
Pallet Pattern
Additional material
Type Quality Consumption/pack Order number
LS-strip LHL 7.5x0.1 mm 0.129 g 8891-952-01

8893-952-01
PPP 7.5x0.080 mm 0.100 g 8840-951-01

8842-951-01
Wine 7.5x0.080 mm 0.100 g 8841-951-01

8843-951-01
LSE 7.5x0.080 mm 0.096 g 8868-951-01
Straw FDM or See ORBIS
Issued by: Marcello Barbieri Issue: 5 October 9, 2002 Page: 1.2

Package Data
TBA 250 S Straw
D W
Package dimensions
W D H
Width Depth Height
(mm) (mm) (mm)
Crease measurements 53.0 38.0 131.0

Package measurements 56.2 38.9 133.3
Filling machine
(reference filling machine is the one used during the develop-
ment phase)
Filling machine TBA/19 & TBA/21
Issued by: Marcello Barbieri Issue: 5 October 9, 2002 Page: 2.2

TBA 250 S
Packing Pattern 3x9
Distribution Unit Tray
Pallet Type Euro (1200 x 800 mm)

Opening Straw Ø 4 mm
Weight Load Tray

Gross 613 kg 7 kg
Volume 1,06 m3
1109,0
1200,0
800,0
This Pallet Pattern is theoretical only. Tests should be made with packages
in the right kind of material and filled with the right product to get the final
pattern.
Packages / pallet 2268 Litres / pallet 567 Trays / pallet 84
Trays / layer 12 Layers / pallet 7 Area efficiency 82,5 %
For more information: Sara Sjöström Tel. +46 46 364503 November 01, 2000
TBA 250 S
Packing Pattern 3x9
Distribution Unit Tray
Pallet Type Eurohalf (800 x 600 mm)

Opening
Weight Load Tray

Gross 306 kg 7 kg
Volume 0,53 m3
1100,0
600,0 800,0
pattern.
Packages / pallet 1134 Litres / pallet 283,5 Trays / pallet 42

Trays / layer 6 Layers / pallet 7 Area efficiency 78,5
For more information: Sara Sjöström Tel. +46 46 364503 November 01, 2000
TBA 250 S
Packing Pattern 3x9
Distribution Unit TRAY
Pallet Type UK (1000 x 1200 mm)

Opening
Weight Load Tray

Gross 956 kg 7 kg
Volume 1,33 m3
1109,0
1200,0
1000,0
pattern.
Packages / pallet 3591 Litres / pallet 897,8 Trays / pallet 133

Trays / layer 19 Layers / pallet 7 Area efficiency 93,3 %
For more information: Sara Sjöström Tel. +46 46 364503 March 01, 2000
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Drive system
Overview

Final folder
Drive

Drive
Jaw system

Drive unit
Electrical clutch
Disengaged
Rotating
Stationary
Shim
Engaged

Drive unit
Electrical clutch,
cranking Disengaged
Rotating
Stationary
Shim
Engaged

Drive unit
Crank mechanism
Disengaged position
Engaged position

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

Speed
7500
Time
Emergency stop/Safety stop

Speed
7500
Time

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

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

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

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

pressure flow rate
Water at high
pressure Constant
flow rate
Constant flow valve
There is a constant flow valve fitted just before the scrubber. Its purpose is to Constant flow valve
see to that the water flow coming to the scrubber is constant no matter what
the incoming water pressure is.
The working part of the valve is a thick rubber ring.
When the incoming water pressure is low, the opening of the ring will remain
unaffected. But, when the incoming water pressure is high, the ring will be
deformed and its opening will become narrower. Thus the water flow rate after
the ring will be the same, no matter what the water pressure is.
Water ring compressor
Water ring compressor The purpose of the water ring compressor is to pump the air around in the
sterile air system.
When the compressor is running, a ring of water rotates against the inside of
the compressor housing.
The rotor is fitted assymmetrically in the lower part of the compressor
housing. When the rotor chambers are in the lower position they will be almost
filled with water, whereas in the upper position they will be almost empty.
This alternately filling and emptying, causes the pumping action. One could
say that the water works as pump pistons.
Some water will follow the air out of the compressor and continue to the water
separator, and new water is continously fed from the scrubber.
Water
Air
Water separator
The purpose of the water separator is to remove the water from the air that Water separator
comes from the water ring compressor.
The separator is so designed that a whirl will arise when the air enters it. The
air is forced uppwards, through a filter, where the water will gather into bigger
drops and fall down.
On the bottom of the separator there is a float which will open and let the water
out when the level is rising, and then close again when the level is sinking. The
water that remains on the bottom of the separator works as a waterseal,
preventing air leakage during operation.
‘
1 4
3 Heat exchanger
Heat exchanger The purpose of the heat exchanger is to cool as well as to warm up the air.
The cold air coming to the air superheater 1 is used to cool the air coming
from the air superheater 3 , so that it doesn´t heat up the packaging material
nor the aseptic chamber 4 .
In its turn, the cold air is warmed up by the hot air before entering the air
superheater 2 , which reduces energy consumption.
Insulating material
Air
Preheated air
Preheated air
Hot air
Hot air
Air
Insulating material
Air superheater
2 $$ $
! 3 ( + )
Spray nozzle
Peroxide
Peroxide evaporator
Compressed air
Hot air
2 $$ $') #$ #$ $')

$) ) $') ) ( $! 44 )
#$ 2 $') #$ *
$ 3 $ ) #$ $ ) $')
'
Suction valve
Suction valve, position during Production Suction valve, position during Normal stop and Short stop
2 $$ ## ' ')
$') #$ $') + ) $ +
2 ## ( $ %( $) $
$ 2 $') #$ (
$(( 5 $ ( $ )
$ $') #$ + ') $') +*
$)
" ## ) 6 7
$ )( $)* 6
+ ') ) ) $ +
2 ) $ $((
C
A
Aseptic product valve
2 38 ## + ##; 3 * ) ##
2 $) 7 $ $)
(
AP valve, Position during production
2 $ 7 $
( $$ )(
AP valve, Position during sterilisation
2 $ ) $ 38 ## )
+ + ( ) $)
$$( 3 $
AP valve, Steam barrier
2 38 ## + $ 7 )) +# *

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

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

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

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

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

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

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

Textbook
Filling Control System

TBA/19 020V
MT-83071-1

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 2/0504
© 2005, 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 photo-
copying, recording or otherwise, without permission in writing from Technical Training
Centre.
Filling Control System
TBA/19 020V
Training Document
This Training Document is intended for
Training purposes only, and must not be
used for any other purpose.
The Training Document does not replace
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such.
Note!
For safe and proper procedures, refer to
the equipment specific documentation.

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Introduction
The Filling Control System (FCS), controls the product flow into the packag-
ing material tube of the filling machine. The flow is controlled in order to
maintain the correct level in the tube, to produce fully filled packages.
The FCS is especially designed for multi-installations of filling machines. Al-
though the product pressure to each filling machine may vary somewhat, the
system provides a constant product flow rate by means of a continuous moni-
toring of the product level inside the packaging material tube. The filling con-
trol system is automatically tuned to cope with various types of product’s
viscosity and finds the best flow control without the machine operator’s inter-
vention.
This FCS is standard equipment for the TBA/19 020V filling machines. It pro-
vides three alternative automatic filling start modes to handle different filling
machine installation conditions.
A Tube Folding Device (TFD) is included with the filling control system. The
device is folding the packaging material tube during the filling start procedure
in order to minimize product waste.
For installations where headspace in the package is wanted, an extra kit must
be mounted on the filling machine. This kit introduces sterile gas into the prod-
uct. The gas rises to the top of the package, thus creates the headspace. There
are no changes in the Filling Control System when headspace is used.
System overview
Level regulating
filling valve
Leakage
detector
TMC C 2
559810
Level Float with

probe magnets
TMCC2
R S 232 R S 485
C AN
G S Z
I/P transducer
Tube Folding
Device
PLC PC TPOP
Product
Compressed air
Level probe The level probe continuously reads the product level in the packaging material
tube by sensing the level of the float with magnets. The probe output signal is
sent to the TMCC2.
TMCC2 The TMCC2 (Tetra Pak Multi-purpose Compact Controller) processes the lev-
el signal and sends a control signal to the I/P transducer.
I/P transducer The I/P transducer convert the electrical signal from the TMCC2 to an air pres-
sure, controlling the level regulating filling valve.
Level regulating The level regulating filling valve (LRF-valve) regulates the product flow into
filling valve the packaging material tube.
Leakage detector The leakage detector is connected to the level regulating filling valve in order
to detect any cracks in the membrane of the valve. This to maintain sterility in
the filling machine.
PLC The PLC (Programmable Logic Controller) provides the TMCC2 with process
parameters.
PC The PC is used for downloading the TMCC2 program and for test and service
purposes. It is possible to monitor e.g. the product level and TMCC2 output.
TPOP The TPOP (Tetra Pak Operator Panel) is the operator’s communication with
the filling machine and filling control system. It is used to select one of the
three types of filling start modes.
Tube folding device The tube folding device is folding the packaging material tube during tube
sealing, inching and the filling start procedure. The device is engaged in order
to avoid that the packaging material tube is pinched between the volume flaps,
and to minimize product waste during the filling start procedure.
Component location
The picture below shows the location of the components that make up the fill-
ing control system.
TMCC2
Leakage detector
PLC
Level regulating
filling valve
I/P transducer
Level probe
Tube folding device
TPOP
Component descriptions
Level probe and float
9.6 VDC Signal out (1.8 VDC)
0,6 V
0,6 V
0,6 V
0,6 V
0,6 V
0,6 V
Level Float with

probe magnets
0,6 V
0,6 V
90o
0,6 V
0,6 V
0,6 V
0,6 V
0,6 V
1.8 VDC 0,6 V
0,6 V
0 VDC
The float is built with several permanent magnets mounted in the centre and
inside the float. The level probe detects the product level in the packaging ma-
terial tube from the magnetic float, which activates the Hall effect elements.
There are 16 Hall effect elements, each represents approximately 0.6 VDC if
activated by the magnetic field from the float. The example in the picture
above shows that the magnetic float activates the 3rd element, thereby the sum
of analog output signal to TMCC2 is 1.8 VDC.
TMCC2
The TMCC2 is a programmable control board used for a variety of functions
in the Tetra Pak machines. The TMCC2 is used in the filling control system
and incorporates the program for the filling control.
The TMCC2 receives the signal from the level probe and determines the out-
put signal to the I/P transducer.
The diagram below shows the principal functions of the TMCC2 in the filling
control system for the TBA/19 filling machine.
Read
Level
Filter
Calculation
PID
Calculation
Output to
I/P transducer
Communication
with PLC and PC
Parameters
and Settings
The TMCC2 program consists of six principal functions:

• Read Level: This part of the program reads the level in the packaging
material tube from the level probe.
• Filter Calculation: This part calculates what is called the filtered product
level, i.e. an average product level in the packaging material tube.
• PID Calculation: This is the regulation part of the program that aims to
keep the product level close to the set point by means of a PID algorithm.
• Output to I/P transducer: Here the analogue output of 0-10 VDC to the
I/P transducer is created.
• Communication with PLC and PC: This part handles the communication
with the PLC and the PC.
• Parameters and Settings: This part stores the configuration parameters
retrieved by TMCC2 from PLC.
Terminals and indications The terminal connections and status indications of the TMCC2 are illustrated
below.
TMC C 2
559810
+ 24 VDC 1
G round 2
Level detector 3
5 I/P transducer signal
6 Filtered Level Output
S terilisation 9
Flashing ON
P roduction 10
C leaning 11 Normal or P refilling starts P roduction
12 C leaning
P refilling
S terilisation
High level alarm Level higher than 83%
P LC data / P LC clock 14 Level higher than 66%

Level higher than 50%
Level higher than 33%
R S 232 R S 485
C AN Low level alarm Level higher than 16%
Main motor low speed 17 25 High level alarm
26 Low level alarm
27 Filling OK
28 Handshake / TMC C data
The brief explanation of the input and output signals are as follows.
INPUTS
+24VDC (1) 24 VDC input power supply to the card.
Ground (2) Ground connection from the electrical cabinet.
Level detector (3) This is a 0-10 VDC analog input that is connected to the level probe.
Sterilization (9) Electrical input signal sent from the PLC during the Sterilization step, that
drive the level regulating filling valve to an open position.
Production (10) Electrical input signal sent from the PLC that enables TMCC2-regulation.
Cleaning (11) Electrical input signal sent from the PLC during the Cleaning step that drive
the regulating valve to an open position.
Prefilling (12) Electrical input signal sent from the PLC to start the pre-filling sequence.
PLC data / PLC clock (14) These electrical input signals are controlled from the PLC and are used for
transmitting default parameters to/from the FCS program.
Main motor low speed (17) Electrical input signal sent from the PLC when the machine runs at the speed
of 6000 p/h. It is used to reduce the production flow value with 25%.
OUTPUTS
I/P Transducer signal (5) This is the electrical analog output signal that drives the I/P transducer.
Filtered level output (6) This is a 0-10VDC analog output that outputs the filtered level. It can be
used to display the average level through an external device, e.g. the TPOP.
High-level alarm (25) This is the alarm output that is sent to the PLC when the product level in the
tube is more than 95% for half a second.
Low level alarm (26) Electrical output signal sent to the PLC for the purposes of low level alarm
when the product level drops to the lower limit during production. It is also
used for communication during the pre-filling sequence, when the pre-fill-
ing threshold has been achieved, in order to close the A-valve.
Filling OK (27) Electrical output signal sent to the PLC as long as the mean product level is
within the acceptance window (default ±10%) around the product level set
point.
Handshake / TMCC data (28) Electrical output signal sent to the PLC, used for transmitting default pa-
rameters to/from the FCS program.
I/P transducer
The I/P transducer is a device that converts an electrical signal to an air pres-
sure.
6 bar
0 - 10 VDC I/P 0 - 4 bar Level regulating

TMCC2
transducer filling valve
The I/P transducer input signal is coming from the TMCC2 and is a regulated
electrical signal. The output signal from the I/P transducer is an air pressure
that controls the level regulating filling valve opening.
The transducer drives the level regulating filling valve with a 2-bar air pres- Sterilization
sure during sterilization. This opens the valve and allows a flow through the
valve. The proximity switch indicates that the valve is open. If the proximity
switch cannot read the open position during sterilization, the filling machine
is stepped down.
The I/P transducer drives the level regulating valve with a 4-bar air pressure Cleaning
during cleaning, to allow the cleaning liquids to have as high flow through the
valve as possible. The proximity switch indicates that the valve is open during
cleaning. If the proximity switch cannot read the open position during clean-
ing, the operation is halted.
Level regulating filling valve
The level regulating filling valve acts as a regulating and constant flow valve.
It ensures that the product flow from the valve is kept constant during produc-
tion.
The level regulating filling valve is controlled from the TMCC2, via the I/P
transducer. The air pressure from the output of the I/P transducer is used to
regulate the opening of the valve.
Proximity
switch
Air inlet
Product
Compressed air
Non-conductive
part of valve
Conductive layer
in the membrane
Non-conductive layer Leakage detector
in the membrane
If there is no air pressure supplied to the regulating valve, the shutter is in a

closed position. Most of the product then stops flowing through the valve.
Whenever there is controlled air pressure from the I/P transducer supplied to
the air inlet of the valve, the shutter moves towards and against the spring force
and thus opens the valve. This allows product to flow through the orifices be-
tween the shutter and the valve seat. The level regulating filling valve is
equipped with a proximity switch sensing an open position.
Membranes The membranes inside this valve works as barriers between the product side
and the regulating side. A membrane is made up with two joined pieces of rub-
ber. The product facing side is a non-conductive material, whereas the other
side is electrically conductive. Should the membrane facing the product crack,
exposing the conductive membrane side to the product, an electrical signal
from the leakage detector relay will trigger an alarm, and the machine will au-
tomatically jump to step Venting. This feature helps to maintain sterility in the
filling machine by preventing production with a punctured membrane.
Communication
PC TMCC2
TPOP PLC
The PC may be used to download the TMCC2 program and for test and service PC
purposes. It is possible to monitor the product level, filtered level and the
TMCC2 output. It is also possible to view status values and configuration pa-
rameters of the program.
The PLC is the control system of the filling machine. It provides the TMCC2 PLC
with production signal, volume parameter data and selection of different fill-
ing start modes required for the filling control system.
The TPOP is the operator’s communication with the filling control system. It TPOP
is used to select one of the three types of filling start modes. It is also possible
to store and select up to four sets of parameters from different productions.
Tube folding device
The tube folding device is introduced to minimize the product waste at produc-
tion start-up.
Disengaged position
Engaged position
Compressed air
Two cylinders with rollers, located just above the jaws of the filling machine,
are engaged during the product filling start-up - when packages are ejected.
The rollers are touching and folding the packaging material tube, creating less
volume inside the tube, thus reduces the product waste with the ejected pack-
ages.
Asynchronous filling The tube folding device is engaged at the filling machine motor start and dis-
engaged when the product level in the packaging material tube has reached
±10% of the product level set point, i.e. when the TMCC2 sends the Filling
OK-signal to the PLC.
Normal filling The tube folding device is engaged at the filling machine motor start and dis-
engaged when the product valve (A-valve) opens.
Filling system function
Level regulating
filling valve
Leakage
detector
TMC C 2
559810
Level Float with

probe magnets
TMCC2
R S 232 R S 485
C AN
G S Z
I/P transducer
Tube Folding
Device
PLC PC TPOP
Product
Compressed air
When product valve (A-valve) opens, the product flows to the level regulating
filling valve. The valve regulates the flow to maintain a required level and en-
sures the product flow is kept constant while the jaws continue to catch the
packaging material tube.
The level inside the tube is registered by TMCC2 from the level probe, which
correspond to the magnetic float in the lower filling pipe. The level is indicated
on the TMCC2 LED’s (S8 – S4). The TMCC2 controls the flow into the tube
by controlling the signal to the I/P transducer.
After receiving the output from the TMCC2, the I/P transducer controls the air
pressure to the regulating filling valve in order to maintain the required level.
The closed loop of this system will be able to maintain the product level within
the required range.
Filling start modes

In the TPOP it is possible to select between three types of filling start modes:
Normal filling Asynchronous Pre-filling

filling
Normal filling is filling of the packaging material tube while the

machine is running synchronous with the design.
Asynchronous filling is filling of the packaging material tube while the
machine is running. The filling machine finds the
design position after the filling is OK.
Pre-filling is filling of the packaging material tube while the
filling machine is standing still.
Normal filling mode The Normal filling start mode can be selected from the TPOP.
In normal filling the product valve opening is synchronized with the design
position and is recommended when the product line pressure is stable.
When starting the filling machine in normal filling mode, it runs with pre-de-
fined amount of packages to be ejected. When the filling position is found the
product valve opens and, at the same time, the PLC sends a signal to enable
the filling control system to regulate.
Note:
The machine starts in Asynchronous filling mode the first time, even if Normal
filling mode is selected. If the filling of ’Time to level’ is fulfilled within the
start time set point, then, the subsequent start will be Normal filling mode.
The Asynchronous filling mode can be selected from the TPOP. This mode is Asynchronous filling
recommended when the product line pressure is fluctuating.
Asynchronous filling begins to fill the packaging material tube immediately
after the pre-defined amount of packages are ejected, without waiting for the
correct printed design position.
The design position is enabled only after the filling has been completed. This
mode may take longer time than Normal filling mode.
The ’Time to level’ is the time taken from the product valve opens until 15% Common for Normal and
or higher level in packaging material tube is reached. This time is compared Asynchronous filling
with the start time set point, and the Start flow value will automatically be
modified. The new Start flow value will be kept for the next start, if the devi-
ation is greater than ±1second of the start time set point parameter. The reason
is to achieve a correct start flow, in order to prevent overflow or eject more
packages than necessary.
During the normal and the asynchronous filling sequence, the filling machine
is reduced to a speed of 6000 p/h and the start flow value used is about 25%
less than the production flow.
Speed
A-valve opens Design OK
7500
6000
Time
8 pkgs
Eight packages after the design OK signal is received by the PLC, the machine
speed is increased to 7500 p/h and the FCS program restores the normal pro-
duction flow value.
Pre-filling The Pre-filling mode can be selected from the TPOP. This mode is recom-
mended when product capacity is insufficient at start, but sufficient for all fill-
ing lines that are connected to the same supply during production.
The filling of the packaging material tube is performed when the machine is
standing still.
In Pre-filling mode the FCS program drives the I/P transducer with a fixed
Start flow value - the level regulating valve is partially open. The Start flow
value in this case is 90% of the Production flow.
The Product valve opens when the step up button is pressed, and closes when
the pre-filling level is obtained.
The Pre-filling start sequence ends within 15 seconds and the filling machine
starts. At the same time, the Start flow value is replaced by the Production flow
value.
If the Pre-filling sequence ends without reaching the Pre-filling level, a Nor-
mal start is performed. This in order to reach the level set point in any case,
when the filling machine reaches Production.
Common for all filling The Start flow is used to send an output current to the I/P transducer in order
modes to regulate the air pressure to the level regulating valve. This flow is used only
during the start of the filling sequence, until 15% product level is reached.
Thereafter the Production flow is used.
In order to regulate the level regulating filling valve, to keep the level close to
the set point (default value of 40%), the production flow value is changed au-
tomatically by the PID calculations of the TMCC2. This is called the auto-tun-
ing function. Once the level in the tube is within ±10% of the product level set
point, the TMCC2 sends a filling OK signal to the PLC.
After 45 seconds of the fillings starts, when the level is stabilized in the pack-
aging material tube, the FCS program starts to record the mean production
flow, in order to use it for the next start. In this way the production flow fol-
lows the possible process plant variations, e.g. changes in the product pressure
due to different number of running machines at the same time.
During production, if the filtered level stays at the lowest limit or the actual
level stays above 95%, the respective low level alarm or the high level alarm
are set. The alarm signals are sent to the PLC and displayed on the TMCC2
front panel LED’s. In both these situations the TMCC2 turns OFF the I/P
transducer, in order to stop the filling. In case of overfilling, the Start flow and
the Production flow values are reduced for the next filling attempt.
Filling controller status
When communicating with TMCC2 through a PC using window’s hyper ter-
minal, typing S and enter will bring up the filling controller status. Here, e.g.
start and production flow values are specified. A status display example is
shown below.
** Filling controller status **
Output status = Normal
P constant = 24.00
I constant = 40.00
D constant = 100.00
Start flow = 49
Production Flow = 46
Cleaning flow = 255
Sterilisation flow = 126
Minimum output = 0
Mean Production Flow = 54
Set point (0-1000) = 400
PreFilling (0-1000) = 200
Prefil. Start Flow = 36
Starting Level = 0
Current Level = 63
Max Level = 720
Start Time (*0.1s) = 0
Prefilling Time *0.1s = 0
Normal start - block diagram
Start sequence
Motor starts
Run X packages
(according to timer)
Look for filling position
A-valve opens
First start use default value

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

Production 1:st time
(from A-valve open)
2:nd time
Normal stop
Asynchronous start - block diagram

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MDCS19
1. Table of contents 12. DESIGN ADJUSTMENT SIGNAL 13

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

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

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

MDCS19
4. Design Control System Overview

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

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

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

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

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

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

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

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

MDCS19
Register Mark Photocell Q, (3bars)

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

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

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

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

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

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

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

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

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

MDCS19
MDCS Left step pulse

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

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

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

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

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MDCS19
6. Basic Program Functions

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

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

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

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

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

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

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

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

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

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

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

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MDCS19
10. Photocells Management

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

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

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

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

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MDCS19
12. Design Adjustment Signal

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

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

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

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MDCS19
PC 9-pin TMCC2 9-pin

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

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

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

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

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MDCS19
15. Volume Parameter Transfer

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

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

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

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

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

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MDCS19
17. I/P Transducer Setting

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

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

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

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MDCS19
18. Setting Criteria

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

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

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MDCS19
20. Program Download

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

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MDCS19
21. Grey Code Table

Gray O D Me Gray O D Me Gray O D Me Gray O D Me
-------- 0 0 0.0 -¤¤----- 1 6 90,0 ¤¤------ 2 1 180, ¤-¤----- 3 1 270,
-------¤ 1 1 1,4 -¤¤----¤ 1 6 91,4 ¤¤-----¤ 2 1 181, ¤-¤----¤ 3 1 271,
------¤¤ 2 2 2,8 -¤¤---¤¤ 1 6 92,8 ¤¤----¤¤ 2 1 182, ¤-¤---¤¤ 3 1 272,
------¤- 3 3 4,2 -¤¤---¤- 1 6 94,2 ¤¤----¤- 2 1 184, ¤-¤---¤- 3 1 274,
-----¤¤- 4 4 5,6 -¤¤--¤¤- 1 6 95,6 ¤¤---¤¤- 2 1 185, ¤-¤--¤¤- 3 1 275,
-----¤¤¤ 5 5 7,0 -¤¤-- 1 6 97,0 ¤¤--- 2 1 187, ¤-¤-- 3 1 277,
-----¤-¤ 6 6 8,4 -¤¤--¤-¤ 1 7 98,4 ¤¤---¤-¤ 2 1 188, ¤-¤--¤-¤ 3 1 278,
-----¤-- 7 7 9,8 -¤¤--¤-- 1 7 99,8 ¤¤---¤-- 2 1 189, ¤-¤--¤-- 3 1 279,
----¤¤-- 1 8 11,3 -¤¤-¤¤-- 1 7 101, ¤¤--¤¤-- 2 1 191, ¤-¤-¤¤-- 3 2 281,
----¤¤-¤ 1 9 12,7 -¤¤-¤¤- 1 7 102, ¤¤--¤¤- 2 1 192, ¤-¤-¤¤- 3 2 282,
----¤¤¤¤ 1 1 14,1 -¤¤- 1 7 104, ¤¤-- 2 1 194, ¤-¤- 3 2 284,
----¤¤¤- 1 1 15,5 -¤¤- 1 7 105, ¤¤-- 2 1 195, ¤-¤- 3 2 285,
----¤-¤- 1 1 16,9 -¤¤-¤-¤- 1 7 106, ¤¤--¤-¤- 2 1 196, ¤-¤-¤-¤- 3 2 286,
----¤-¤¤ 1 1 18,3 -¤¤-¤- 1 7 108, ¤¤--¤- 2 1 198, ¤-¤-¤- 3 2 288,
----¤--¤ 1 1 19,7 -¤¤-¤--¤ 1 7 109, ¤¤--¤--¤ 2 1 199, ¤-¤-¤--¤ 3 2 289,
----¤--- 1 1 21,1 -¤¤-¤--- 1 7 111, ¤¤--¤--- 2 1 201, ¤-¤-¤--- 3 2 291,
---¤¤--- 2 1 22,5 -¤¤¤¤--- 1 8 112, ¤¤-¤¤--- 2 1 202, ¤-¤¤¤--- 3 2 292,
---¤¤--¤ 2 1 23,9 -¤¤¤¤-- 1 8 113, ¤¤-¤¤-- 2 1 203, ¤-¤¤¤-- 3 2 293,
---¤¤-¤¤ 2 1 25,3 -¤¤¤¤- 1 8 115, ¤¤-¤¤- 2 1 205, ¤-¤¤¤- 3 2 295,
---¤¤-¤- 2 1 26,7 -¤¤¤¤- 1 8 116, ¤¤-¤¤- 2 1 206, ¤-¤¤¤- 3 2 296,
---¤¤¤¤- 2 2 28,1 -¤¤¤ 1 8 118, ¤¤-¤ 2 1 208, ¤-¤¤ 3 2 298,
---¤ 2 2 29,5 -¤¤¤ 1 8 119, ¤¤-¤ 2 1 209, ¤-¤¤ 3 2 299,
---¤¤¤-¤ 2 2 30,9 -¤¤¤¤¤- 1 8 120, ¤¤-¤¤¤- 2 1 210, ¤-¤¤¤¤- 3 2 300,
---¤¤¤-- 2 2 32,3 -¤¤¤¤¤- 1 8 122, ¤¤-¤¤¤- 2 1 212, ¤-¤¤¤¤- 3 2 302,
---¤-¤-- 3 2 33,8 -¤¤¤-¤-- 1 8 123, ¤¤-¤-¤-- 2 1 213, ¤-¤¤-¤-- 3 2 303,
---¤-¤-¤ 3 2 35,2 -¤¤¤-¤- 1 8 125, ¤¤-¤-¤- 2 1 215, ¤-¤¤-¤- 3 2 305,
---¤-¤¤¤ 3 2 36,6 -¤¤¤- 1 9 126, ¤¤-¤- 2 1 216, ¤-¤¤- 3 2 306,
---¤-¤¤- 3 2 38,0 -¤¤¤- 1 9 128, ¤¤-¤- 2 1 218, ¤-¤¤- 3 2 308,
---¤--¤- 3 2 39,4 -¤¤¤--¤- 1 9 129, ¤¤-¤--¤- 2 1 219, ¤-¤¤--¤- 3 2 309,
---¤--¤¤ 3 2 40,8 -¤¤¤-- 1 9 130, ¤¤-¤-- 2 1 220, ¤-¤¤-- 3 2 310,
---¤---¤ 3 3 42,2 -¤¤¤---¤ 1 9 132, ¤¤-¤---¤ 2 1 222, ¤-¤¤---¤ 3 2 312,
---¤---- 3 3 43,6 -¤¤¤---- 1 9 133, ¤¤-¤---- 2 1 223, ¤-¤¤---- 3 2 313,
--¤¤---- 4 3 45,0 -¤-¤---- 1 9 135, ¤¤¤¤---- 2 1 225, ¤--¤---- 3 2 315,
--¤¤---¤ 4 3 46,4 -¤-¤---¤ 1 9 136, ¤¤¤¤--- 2 1 226, ¤--¤---¤ 3 2 316,
--¤¤--¤¤ 4 3 47,8 -¤-¤--¤¤ 1 9 137, ¤¤¤¤-- 2 1 227, ¤--¤--¤¤ 3 2 317,
--¤¤--¤- 4 3 49,2 -¤-¤--¤- 1 9 139, ¤¤¤¤-- 2 1 229, ¤--¤--¤- 3 2 319,
--¤¤-¤¤- 4 3 50,6 -¤-¤-¤¤- 1 1 140, ¤¤¤¤- 2 1 230, ¤--¤-¤¤- 3 2 320,
--¤¤- 4 3 52,0 -¤-¤- 1 1 142, ¤¤¤¤- 2 1 232, ¤--¤- 3 2 322,
--¤¤-¤-¤ 4 3 53,4 -¤-¤-¤-¤ 1 1 143, ¤¤¤¤-¤- 2 1 233, ¤--¤-¤-¤ 3 2 323,
--¤¤-¤-- 4 3 54,8 -¤-¤-¤-- 1 1 144, ¤¤¤¤-¤- 2 1 234, ¤--¤-¤-- 3 2 324,
--¤¤¤¤-- 5 4 56,3 -¤-¤¤¤-- 1 1 146, ¤¤¤¤ 2 1 236, ¤--¤¤¤-- 3 2 326,
--¤¤¤¤- 5 4 57,7 -¤-¤¤¤- 1 1 147, ¤¤¤¤ 2 1 237, ¤--¤¤¤- 3 2 327,
--¤¤ 5 4 59,1 -¤-¤ 1 1 149, ¤¤¤¤ 2 1 239, ¤--¤ 3 2 329,
--¤¤ 5 4 60,5 -¤-¤ 1 1 150, ¤¤¤¤ 2 1 240, ¤--¤ 3 2 330,
--¤¤¤-¤- 5 4 61,9 -¤-¤¤-¤- 1 1 151, ¤¤¤¤¤- 2 1 241, ¤--¤¤-¤- 3 2 331,
--¤¤¤- 5 4 63,3 -¤-¤¤- 1 1 153, ¤¤¤¤¤- 2 1 243, ¤--¤¤- 3 2 333,
--¤¤¤--¤ 5 4 64,7 -¤-¤¤--¤ 1 1 154, ¤¤¤¤¤-- 2 1 244, ¤--¤¤--¤ 3 2 334,
--¤¤¤--- 5 4 66,1 -¤-¤¤--- 1 1 156, ¤¤¤¤¤-- 2 1 246, ¤--¤¤--- 3 2 336,
--¤-¤--- 6 4 67,5 -¤--¤--- 1 1 157, ¤¤¤-¤--- 2 1 247, ¤---¤--- 3 2 337,
--¤-¤--¤ 6 4 68,9 -¤--¤--¤ 1 1 158, ¤¤¤-¤-- 2 1 248, ¤---¤--¤ 3 2 338,
--¤-¤-¤¤ 6 5 70,3 -¤--¤-¤¤ 1 1 160, ¤¤¤-¤- 2 1 250, ¤---¤-¤¤ 3 2 340,
--¤-¤-¤- 6 5 71,7 -¤--¤-¤- 1 1 161, ¤¤¤-¤- 2 1 251, ¤---¤-¤- 3 2 341,
--¤-¤¤¤- 6 5 73,1 -¤--¤¤¤- 1 1 163, ¤¤¤- 2 1 253, ¤---¤¤¤- 3 2 343,
--¤- 6 5 74,5 -¤-- 1 1 164, ¤¤¤- 2 1 254, ¤--- 3 2 344,
--¤-¤¤-¤ 6 5 75,9 -¤--¤¤-¤ 1 1 165, ¤¤¤-¤¤- 2 1 255, ¤---¤¤-¤ 3 2 345,
--¤-¤¤-- 6 5 77,3 -¤--¤¤-- 1 1 167, ¤¤¤-¤¤- 2 1 257, ¤---¤¤-- 3 2 347,
--¤--¤-- 7 5 78,8 -¤---¤-- 1 1 168, ¤¤¤--¤-- 2 1 258, ¤----¤-- 3 2 348,
--¤--¤-¤ 7 5 80,2 -¤---¤-¤ 1 1 170, ¤¤¤--¤- 2 1 260, ¤----¤-¤ 3 2 350,
--¤--¤¤¤ 7 5 81,6 -¤---¤¤¤ 1 1 171, ¤¤¤-- 2 1 261, ¤----¤¤¤ 3 2 351,
--¤--¤¤- 7 5 83,0 -¤---¤¤- 1 1 173, ¤¤¤-- 2 1 263, ¤----¤¤- 3 2 353,
--¤---¤- 7 6 84,4 -¤----¤- 1 1 174, ¤¤¤---¤- 2 1 264, ¤-----¤- 3 2 354,
--¤---¤¤ 7 6 85,8 -¤----¤¤ 1 1 175, ¤¤¤--- 2 1 265, ¤-----¤¤ 3 2 355,
--¤----¤ 7 6 87,2 -¤-----¤ 1 1 177, ¤¤¤----¤ 2 1 267, ¤------¤ 3 2 357,
--¤----- 7 6 88,6 -¤------ 1 1 178, ¤¤¤----- 2 1 268, ¤------- 3 2 358,

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

"
!==@

Strip Magazine
Splice sequence
Step 3a

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

Strip Magazine
Splice sequence
Step 3c

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Automatic Splicing Unit
Overview

ASU
Automatic Splicing Unit

Lund, Sweden TBA/19 020V 1/0403 OH 1409:1
ASU
Starting splice sequence

ASU
Register code found

ASU
Cutting packaging
material

ASU
Cylinder retraction

Lund, Sweden TBA/19 020V 10403 OH 1409: 5
ASU
Changing packaging
material reel

ASU
Sealing

ASU
Splicing sequence
completed

Packaging Material
Infeed


=' ='

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

Hydraulic diagram TBA/19

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

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

Lubrication diagram TBA/19

Central lubrication system
Lubrication oil
Compressed air
PLC

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

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

and dosing valve
Discharge pressure
Lubrication oil
Compressed air

Lubrication cycles
Lund, Sweden
Single lubrication pulse

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

TBA19

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Course Introduction 1

Technical Training Centre 1/9701 TM-00001

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TC-0074 - TBA/19 020V Advanced Maintenance

Course Length 2 weeks

Target Group Tetra Pak Technicians

Course Objectives To get a deeper understanding of how the components of

Course- Function of the drive system.

Technical Training Centre Machine type Issue

Nominal volume (ml) 250.0

Web width (mm) 188.0 ± 1

LS-strip LHL 7.5x0.1 mm 0.129 g 8891-952-01

PPP 7.5x0.080 mm 0.100 g 8840-951-01

Wine 7.5x0.080 mm 0.100 g 8841-951-01

LSE 7.5x0.080 mm 0.096 g 8868-951-01

Straw FDM or See ORBIS

Issued by: Marcello Barbieri Issue: 5 October 9, 2002 Page: 1.2

Crease measurements 53.0 38.0 131.0

Filling machine TBA/19 & TBA/21

Issued by: Marcello Barbieri Issue: 5 October 9, 2002 Page: 2.2

Pallet Type Euro (1200 x 800 mm)

Weight Load Tray

Pallet Type Eurohalf (800 x 600 mm)

Weight Load Tray

Packages / pallet 1134 Litres / pallet 283,5 Trays / pallet 42

Pallet Type UK (1000 x 1200 mm)

Weight Load Tray

Packages / pallet 3591 Litres / pallet 897,8 Trays / pallet 133

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Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Technical Training Centre Machine type Issue

Normal stop/Short stop

Emergency stop/Safety stop

Technical Training Centre Machine type Issue

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