EM

Electrical Manual
Tetra Brik Aseptic TBA/3
640016-6000
ECM 83166
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Tetra Pak
Doc No EM-80252-0105
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ii
 Introduction 1
This document is valid for:

Series No/ Machine No Sign.

Safety Precautions 2

Electrical System Descrip- 3

tion
Electrical Manual

Tetra Brik Aseptic Trouble shooting 4

TBA/3
640016-6000 Component Location 5

Circuit Diagrams 6
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Note!Latest Electrical ECM: 83166

Equipment included:
Connection Diagrams 7

Mains Connection Diagrams 8

Program Documents 9

Draft
Design Control System 10
Doc No EM-80252-0105

Issue 2001-02

11

Tetra Brik PS AB
12
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iv
 1 Introduction

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Tetra Pak EM-80252-0105 1-1

 Table of contents
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Document information. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Machine introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Machine identification . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
How to use the EM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Numbering system for components . . . . . . . . . . . . . 1-7
How to trace a cable. . . . . . . . . . . . . . . . . . . . . . . . . 1-8
How to trace a component . . . . . . . . . . . . . . . . . . . . . . 1-14
Supply/line voltage . . . . . . . . . . . . . . . . . . . . . . . . 1-18
How to trace a terminal . . . . . . . . . . . . . . . . . . . . . 1-20
Other items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Abbreviations and terminology . . . . . . . . . . . . . . . 1-24
Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
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Left Hand side of the machine . . . . . . . . . . . . . . . . 1-25
Right Hand side of the machine. . . . . . . . . . . . . . . 1-26

1-2 EM-80252-0105 Tetra Pak

 General
! DANGER! To ensure maximum safety for the technicians, always
read the “Safety precautions” pages before doing any
work on the machine or making any adjustments.

Document information
About this Electrical Manual (EM)
The purpose of this Electrical Manual is to provide service technicians and
electricians with all information on the electrical equipment required for
service and maintenance to the Tetra Pak equipment.
It is important that you:
• keep the manual for the life of the equipment,
• pass the manual on to any subsequent holder or user of the equipment.
Document references
The documentation for this machine includes, except this EM, the following:
• Installation Manual (IM) to provide the installation technicians with
information on the on-site installation process.
• Operation Manual (OM) to provide the operator with information on

Draft
how to handle and operate the machine before, during, and after the
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production.
• Maintenance Manual (MM) to provide technicians with information on
how to perform service and maintenance.
• Spare Parts Catalogue (SPC).
Design modifications
The directives in this document are in accordance with the design and
construction of the machine at the time it was released by the Tetra Pak
machine production facility.
Document producer
This document has been produced by:
Tetra Brik Packaging Systems AB.
Technical Publications
Ruben Rausings gata
S- 221 86 LUND
SWEDEN

Tetra Pak EM-80252-0105 1-3

 Further copies
Additional copies can be ordered from nearest Tetra Pak service station.
When ordering technical publications, always quote the document number
printed on the front cover of the document concerned.
Number of pages
All chapters have a front page to indicate the beginning followed by a table of
contents (always the second page).
to make sure that you have received a complete document, please check that the
contents matches the table of contents for each chapter.
Copyright  2001
Tetra Brik Packaging Systems AB
All rights reserved. No parts of this document may be reproduced or copied in
any form or by any means without the written permission of Tetra Brik
Packaging Systems AB.

Machine introduction
Intended use of this Tetra Pak equipment
This machine is intended for packaging liquid food.
Service
Draft

In case of problems when operating the machine, contact the nearest Tetra Pak

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service station.
Manufacturer
This Tetra Pak equipment was produced by:
Tetra Brik Packaging Systems AB.
Technical Publications
Ruben Rausings gata
S- 221 86 LUND
SWEDEN

1-4 EM-80252-0105 Tetra Pak

 Machine identification
Main machine plate
The machine plate below is the type of machine plate attached to the
machine frame. The plate carries data needed when contacting Tetra Pak
concerning this particle machine.
The plate is marked with a CE symbol. It means that the machine complies
with the basic health and safety regulations of the European Economic
Area (EEA).

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Delivered design sign

The Delivered design sign is placed inside the electrical cabinet. It is very
important that all alterations of the electrical system is noted on this sign.

Tetra Pak EM-80252-0105 1-5

 How to use the EM

General
How to use the EM is an explanation of how to find your way through the
chapters Circuit Diagram, Component Location, Connection Diagram,
Mains Connection Diagrams and Program Documents in the EM.
The first page in each chapter is always a table of contents, listing all drawings
included in the chapter.
The identity of the documents in the above mentioned sections consists of a:
• main number (a),
• sheet number (b),
• version number (c).
• page number, e.g 2/3 (d)

a Main number
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b Sheet number

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c Version number
d Page number
A B C D
The sheet number is the consecutive numbering of the sheets which belong to
the main number and is used as a reference in the diagrams.
The second sheet is a position summary, where all electrical components used in
the drawings are listed as a position and with a cross reference.
Sheet 02 is the position summary
Sheet 05–88 are circuit diagrams.
Sheet 89 is the protective earth summary
Sheet 90 shows the connection of the lines.
Sheet 91 shows the connection of the terminal.
Sheet 99 describes registered “alterations.
In the Mains connection (the second connection diagram) it is shown how the
machine should be connected to the local supply, dimension of the connection
cable, connection of the matching transformer (when used).
Caution! Concerning the dimension of the feeding cable, always consider local
regulations.
The PLC-listing in the section Program documents consists of Ladder
diagram, Cross reference list, Variant depending document and Function
diagram.
Enclosed find some examples of how to use the EM.

1-6 EM-80252-0105 Tetra Pak

 Numbering system for components
The position number is divided in three parts:
• prefix
• function designation
• running number.
Prefix (a)
The prefix (a) is showing the location of the component. Position numbers
without prefix indicates that the component is mounted inside the electrical
cabinet.
The prefix M indicates that the component is mounted on the machine.
Function designation (b)
The function designation (b) is indicated according to international standard.
Running number (c)
The electrical components are given numbers in a consecutive logical order.

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a Prefix
b Function designation
c Running number

M . M 001
a b c

Tetra Pak EM-80252-0105 1-7

 How to trace a cable
Example: How to trace cable No. 203
• Go to chapter 7, Connection Diagrams.
• In the Connection Diagrams find cable No. 203.
• Note the component connected to the cable (M.M001).
• Go to chapter 6, Circuit Diagrams.
• Go to the Position Summary (first page(s) in the Circuit Diagrams.
• The sheet No. is located opposite the component No (pos M.M001). This
tells you on which sheet in the Circuit Diagrams the connection is shown.
• Go to sheet 14 in the Circuit Diagrams.
• Find the component (M.M001).
• If the component, as in this example, is controlled by a separate component,
the sheet reference for this component (sheet 45) is found in the Circuit
Diagrams.
• If you want to know type, TP component No or length of the cable see list
of cable in chapter 5
In order to make it easier to find a cable we also have numbered the cables As
shown below.
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Cable No Where used
W1 - W99 Inside El. Cabinet
100 - 109 Belong to the Final folder
210 - 293 Belong to the Machine body
300 - 375 Belong to the Superstructure
600 - 607 Belong to process signals e.g. steri-
lizer

(Cont’d)

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 (Cont’d)

Draft
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POSITION SUMMARY

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 (Cont’d)
• Go to sheet 45 in the Circuit Diagrams.
• Find the controlling component.
• 014 is a reference back to sheet 014.
• The output (Q0001) is a reference to the PLC-listing in chapter Program
Documents.
• Go to chapter 9, Program Documents to see the use in the program.
• Go to the cross reference list at the end of the PLC-listing and find the
output (Q0001).
• Note the rung Nos. in which the output -( )- is used (block 10 rung 21).
• Go to the PLC-listing and find block 10 rung 21.
(Cont’d)
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 (Cont’d)

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Tetra Pak EM-80252-0105 1-11

 (Cont’d)
• The prefix M indicates that the component is mounted on the machine.
• Go to chapter 5, Component Location, to find the position of the
component (M.001).
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 How to trace a component
Example: How to trace sensor B002
• Go to chapter 6, Circuit Diagrams.
• Go to the Position Summary (first page(s) in the Circuit Diagrams).
• The sheet No. (sh36) is located opposite the component No (pos M.B002).
This tells you on which sheet in the Circuit Diagrams the connection is
shown.
• Go to sheet 36 in the Circuit Diagrams.
• Find the component (M.B002).
• Note the connection (X005, 42 - 43).
• Go to chapter 7, Connection Diagrams.
• Find the connection (X005, 42 - 43).
• The Connection Diagram shows how the sensor is connected (e g via a
connection box or as in this case direct to the lower terminal for in/out
cables).
• The input (I0049) is a reference to the PLC-listing in section Program
Documents.
• If you want to know the TP component No for a component see CE-41221-
0X0V where all components inside the Electrical Cabinet are specified.
Draft

External components are shown in the SPC.

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(Cont’d)

1-14 EM-80252-0105 Tetra Pak

 (Cont’d)

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Tetra Pak EM-80252-0105 1-15

 (Cont’d)
• Go to chapter 9, Program Documents to see the use in the program.
• Go to the cross reference list at the end of the block 1 and find the input
(I0049).
• Note the rung Nos. in which the input are used (e g block 6 rung 10 / block
13 rung 5,7).
• Go to the blocks and find rungs.
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 Draft
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Tetra Pak EM-80252-0105 1-17

 Supply/line voltage
Supply voltage/Line connection order
The supply voltage in the electrical cabinet is named:
• N: Neutral
• PE: Protecting earth
• L1–L3:Power voltage
• L10: 24V DC minus (connected to Earth) Common for L11 - L13
• L11: +24V DC Provides PLC and sensors with power
• L12 +24V DC Provides solenoid valves with power
• L13 +24V DC Provides alarm panel, display, lamps and beacon with
power
• L20: 240V minus Power supply controlled by the safety module. This
line is only life as long as the total safety chain is not open or broken.
• L21: 24V DC Power supply controlled by the safety module. This line is
only life as long as the total safety chain is not open or broken.
• L50: 230V AC, phase always life.
• L51: 230V AC, phase controlled by relay K101. (“Control voltage on”)
• L52: 230V AC, common neutral for line L50, L51.
Draft

In chapter 6, Circuit Diagrams, the line connection logical sequence is shown

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in the Line Summary (sheet 90).

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Tetra Pak EM-80252-0105 1-19

 How to trace a terminal
Example: Connection in terminal M.X005,
terminal No 58-60
• Go to chapter 6, Terminal Summery.
• Find the terminal X005 terminal No 58-60.
• Note on which Circuit Diagram they are used
• Go to chapter 6, Circuit Diagrams. (sh 36) and find the termials.
• The input (I0056) is a reference to the PLC-listing in chapter Program
Documents.
(Cont’d)
Draft

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1-20 EM-80252-0105 Tetra Pak

 Draft
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Tetra Pak EM-80252-0105 1-21

 (Cont’d)
• The prefix M indicates that the component is mounted on the machine.
• Go to chapter 5, Component Location, to find the position of the
component (M.B008) on the machine.
• Go to chapter 9, Program Documents, to see the use in the program.
• Go to the cross reference list at the end of the block 1 and find the input
(I0056).
(Cont’d)
Draft

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1-22 EM-80252-0105 Tetra Pak

 (Cont’d)

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Tetra Pak EM-80252-0105 1-23

 Other items

Abbreviations and terminology

This is a list of approved abbreviations on Tetra Pak products. The source for
this material is the sales manual “FDM Filling & Distribution Machines” valid
for 1994.
Abbreviation Explanation Abbreviation Explanation
AUX Auxiliary Equipment
CIP Cleaning In Place
DE Distribution Equipment
FFU Final Folding Unit
HF High Fin
IH Induction Heating
IS Inner sealing strip
LCF Level Controlled filling
LS Longitudinal Sealing
LS-STRIP Longitudinal Sealing - Strip
MUPP Multi-purpose Potentiometer
OE Optional Equipment
Draft

OK Optional Kit

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p/h Packs per hour
PH Perforation Heater (Zone Heater)
PIM Project and Installation Manual
RCW Recirculation of Cooling Water
R Right
RK Rebuilding Kit
RS Revolving stand
S Straight - in conn with infeed/outfeed
SA Strip Applicator
SAS Sterile Air System
SASP Sales Administration Spare Parts
SCU Separate Cleaning Unit
Std Standard
TB Tetra Brik
TBA Tetra Brik Aseptic
TMCC Tetra Multi-purpose Compact Con-
troller
TPIH Tetra Pak Induction Heating
TS Transversal sealing
UPV Universal Product Valve
DCS Design Control system

1-24 EM-80252-0105 Tetra Pak

 Machine orientation
In this section an orientation of the main machine parts will be shown.

Left Hand side of the machine

2
8

10

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7
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2
6 3

5 4

1 Control panel 6 Packaging material reel

2 Emergency stop button 7 Electrical cabinet
3 Final folder 8 Compressor
4 Machine plate with machine identification 9 Strip Applicator (SA)
data 10 Warning beacon
5 Electrical cabinet

Tetra Pak EM-80252-0105 1-25

 Right Hand side of the machine

3
Draft

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4

1 Door to valve panel

2 Product valve
23 Dating unit
24 Packing material magazine

1-26 EM-80252-0105 Tetra Pak

 2 Safety Precautions

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Tetra Pak EM-80252-0105 2-1

 Table of contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Use of hazard information. . . . . . . . . . . . . . . . . . . . . . . . 2-3
Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Requirements on personnel . . . . . . . . . . . . . . . . . . . . . 2-4
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Doors, hoods and safety covers . . . . . . . . . . . . . . . . . . 2-6
Electrical cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
TPIH generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Sterilization liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Chemical products . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Hearing protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
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2-2 EM-80252-0105 Tetra Pak

 General
To ensure maximum safety for the operator, always read this section
carefully before doing any work on the machine or making any
adjustments.

Use of hazard information

Hazard information in this document has the following significance:

! DANGER! Failure to observe this information results in immediate

danger of life!

! WARNING! Failure to observe this information can result in personal

injury!

Caution! Failure to observe this information can result in damage to or

destruction of equipment!

Warning signs
Enclosures which do not clearly show that they contain electrical devices are
marked with a black lightning flash on a yellow background within a black

Draft
triangle, (see below).
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This warning sign is fixed to electrical control enclosures which:

• do not have the supply disconnecting device integral with the enclosure;
• enclosure more than electrical device; and
• are not connection or junction boxes.

Tetra Pak EM-80252-0105 2-3

 Requirements on personnel
All personnel must regard all electrical equipment as alive. Before carrying
out maintenance and repair, switch off Mains Power. and lock it.
Electricians should be certified according to local regulations with
experience of similar types of installations. Proven skills in reading and
working from drawings and cable lists. Knowledge of local safety
regulations for power and automation. Work with the electrical equipment
must be performed by skilled or instructed technicians only. According to
EN 60204.3,55 skilled person:
– An individual with technical knowledge or sufficient experience to
enable that individual to avoid hazards which electricity can create.
The use of a key or tool is necessary for access by skilled or instructed
persons to carry out operations for which it may not be appropriate to
disconnect the equipment. The supply disconnecting means may be operated
as needed while the door is open.
Examples of such operations are:
• replacement of fuse elements (i.e. those not requiring the use of a tool);
• replacement of plug-in devices and sub assemblies;
• resetting of protective devices; (fuses and overload protection)
Draft

• adjustment of device settings (e.g. preset timers); and

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• fault finding and diagnostic testing
The work is to be carried out in such a way that there will be no risk of
personnel injury.
During maintenance or service work, the technicians is responsible not for
the machine only, but for the personnel in the vicinity of the machine as well!
It is also the responsibility of the technician to assure that the machine safety
devices are fully operational before he finishes the maintenance or service
work.
Caution! If the Safety Precautions are not followed, there is risk of personal
injury.

2-4 EM-80252-0105 Tetra Pak

 Emergency stop
In case of danger to people or risk of damage to the machine, one of the
emergency stop buttons must immediately be depressed.
The exact location of the emergency stop buttons must be known so that
the machine can be stopped immediately when there is risk of personal
injury or damage to the machine.
Emergency stop must only be used in case of danger to people or machine.
To stop production in the normal way, see the Stop-section in the OM-book.
Note! Emergency stops don’t cut the “Mains Power Switch “off. emergency stop
will only stop rotating motors but does not switch off heating elements, etc.

Draft
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Emergency stop buttons.

Tetra Pak EM-80252-0105 2-5

 Doors, hoods and safety covers

! WARNING! Moving parts and hot surfaces can cause serious injuries.
Never inch or run the machine if any safety switch is non-
operational or any safety cover is not fitted.

The doors and hoods shown in the picture are provided with safety switches.
These switches form part of the safety system of the machine and must
under no circumstances be bridged or by-passed or otherwise made
non-operational.
Do not open doors or remove covers during production. Never stop the
machine by opening a door with a safety switch. The machine may perform a
reciprocating movement during the first few seconds after a stop; a.lso some
machine parts may still be hot.
After maintenance, check that all safety covers are fitted to the machine
before it inched or run.
Draft

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2-6 EM-80252-0105 Tetra Pak

 Electrical cabinet

! DANGER! Risk of electric shock!

The voltage is 400V inside the electrical cabinet. can cause
electroshock or serious injury. In case of accident,
immediately call for medical attention.

Work inside the electrical cabinet must be performed by skilled or instructed

persons only.
Caution! Always make sure that those electrical cabinet doors, locked with
bolts, are closed before you enter the superstructure.

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Tetra Pak EM-80252-0105 2-7

 TPIH generator

! DANGER! Risk of electric shock!

The voltage is 400V inside the generator section. Can
cause electroshock or serious injury. In case of accident,
immediately call for medical attention.

Work inside the generator section must be performed by skilled or instructed

persons only.
It is not allowed to open the generator.
Draft

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2-8 EM-80252-0105 Tetra Pak

 Sterilization liquid

! WARNING! Risk of corrosion injuries! In both liquid and gas form,

hydrogen peroxide may cause irritation or damage if in
contact with skin, mucous membranes, eyes, or clothes.

! WARNING! Risk of fire! Causes burns. Contact with combustible

materials may cause fire.

The sterilization liquid used for sterilizing the packaging material consists of
35% hydrogen peroxide (H2O2).

Hydrogen peroxide can

Carefully follow the instructions on the can label (see picture).
Hydrogen peroxide:
• 35% w/w Aqueous Solution UN No 2014
• Corrosive. Oxidizing.
• Causes burns. Contact with combustible materials may cause fire
• Keep in a cool place away from sources of heat.

Draft
• Avoid contamination
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• Wear suitable protective clothing, gloves, and eye/face protection

• After contact with skin, wash immediately with plenty of water and seek
medical advice
• In case of spillage or fire, drench with water.
Reference:
TP document No M 1751.80.

Example of can label

Tetra Pak EM-80252-0105 2-9

 Storage of hydrogen peroxide

! WARNING! Risk of explosion! When contaminate, pouring back in

original container, or decomposition of hydrogen peroxide,
risk of explosion can arise.

The hydrogen peroxide has been stabilized but may nevertheless decompose
into oxygen and water, if exposed to heat, pollution, or strong sunlight.
For this reason, the room or area used for storage must be:
• cool, clean, and well ventilated
• shielded from direct sunlight
• kept free from combustible materials
Avoid contamination of hydrogen peroxide. It may react to, or form
explosive products with many organic substances (for instance acetone,
cellulose, and ethanol).
Hydrogen peroxide must be stored only in the original container as
delivered by the supplier.
Do not pour surplus hydrogen peroxide back into the original container. Risk
of explosion!
Draft

2.1802520105sp.fm
The container must be kept upright and must only be closed with a
ventilation cap (arrow in picture), which allows oxygen to escape. If not,
there may be an explosion if decomposition of the peroxide occurs violently.
Always make sure that the container is properly closed.
Pumps or other facilities, used for hydrogen peroxide, must be used for this
purpose only.

2-10 EM-80252-0105 Tetra Pak

 Disposal of hydrogen peroxide
The hydrogen peroxide should be sent for destruction, or be diluted with
water to a concentration below 1% and poured into drainage.’
Hydrogen peroxide with a concentration below 1% is considered harmless
when poured into the drain.
Never put used hydrogen peroxide back into storage.
Spillage of sterilization liquid

! WARNING! Risk of fire! Never wipe with combustible material, such as

rags or paper, as these may self-ignite.

! WARNING! Risk of short-circuit! Do not allow hydrogen peroxide to get

in contact with live electrical parts. Risk of short circuit.

If peroxide is spilt on the floor or a table, dilute it with large amounts of

water and flush it into the drain.
In case of fire, cool the peroxide containers by hosing with large quantities of
water.

Draft
Make sure that areas or rooms used for handling or storing hydrogen
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peroxide are well ventilated.

Tetra Pak EM-80252-0105 2-11

 Personal protective equipment
Whenever there is risk of contact with the sterilization liquid, always wear:
• safety glasses
• protective gloves
• shoes made of PVC or PE plastic, or rubber
• apron
In case of accident involving hydrogen peroxide, always make sure that:
• the showers work
• that an eyewash device is available at or near each machine site
• there are additional washing facilities
Draft

Safety glasses (TP No 779130-102)

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Protective gloves (TP No.90303-4)
Shoes
Apron (TP No. 90303-5)
Shower
Eyewash device (TP No. 90303-6)

2-12 EM-80252-0105 Tetra Pak

 Emergency procedures
In case of accident involving hydrogen peroxide the basic rule is to rinse as
soon as possible with as much water as possible.
If you happen to swallow hydrogen peroxide:
• Drink large amounts of lukewarm water (in order to dilute the peroxide)
• then seek medical attention immediately

If you get splashes or vapour from hydrogen peroxide in your eyes:

• wash the eyes thoroughly with lukewarm water for 15 minutes (keep
eyelids widely apart)
• then seek medical attention immediately

Draft
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If hydrogen peroxide gets in contact with skin or clothes:

• immediately rinse with plenty of water
• if skin burns appear, seek medical advice immediately
• thoroughly wash the clothes before they are worn again

Tetra Pak EM-80252-0105 2-13

 If you experience irritation or pain due to having inhaled peroxide vapour:
• leave the affected area and get some fresh air
• if the symptoms get worse; seek medical advice
Draft

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2-14 EM-80252-0105 Tetra Pak

 Ink

! WARNING! Flammable and harmful. Carefully follow the warning text

on the bottle label (see picture).

Warning text on ink bottle

The following warning is written on the ink bottle:
INFLAMMABLE
Avoid direct contact with the product
Use gloves and goggles
Care for good ventilation
Propylene glycol mono methyl
ether >30%
Ethanol1-5%
SHAKE BEFORE USE
Use gloves as the ink can irritate the skin.
In case of contact with eyes, rinse immediately with plenty of water and seek
medical care.

Draft
2.1802520105sp.fm

Tetra Pak EM-80252-0105 2-15

 Chemical products

! WARNING! Risk of personal injury! Can be flammable or hazardous to

health. Read the warning texts!

When handling hydraulic oil, lubricants, and cleaning solutions, carefully

follow the warning texts on the container labels.
Always use safety equipment according to the instructions on the container
labels.
For final handling of solutions, follow the instructions from the supplier.
Draft

2.1802520105sp.fm

2-16 EM-80252-0105 Tetra Pak

 Hearing protection

! WARNING! Risk of impaired hearing! Use hearing protection to

minimize the risk of impaired hearing.

Always wear hearing protection while the machine is running.

Draft
2.1802520105sp.fm

Tetra Pak EM-80252-0105 2-17

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2-18 EM-80252-0105 Tetra Pak

 3 Electrical System
Description

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Tetra Pak EM-80252-0105 3-1

 Table of contents
Machine control system 3-3
Block diagram, control system . . . . . . . . . . . . . . . . 3-3
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Safety System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Draft

2.1802520105en.fm

3-2 EM-80252-0105 Tetra Pak

 Machine control system

Block diagram, control system

Power CPU I/O

supply

Draft
2.1802520105en.fm

PLC
Programming
Package

GBAFAA17

Tetra Pak EM-80252-0105 3-3

 PLC
Draft

2.1802520105en.fm
Via the Operator panel, the operator gives the machine commands what
operations to perform. The PLC keeps track of what step the machine is in,
when the next step can be entered, turns on and off supply systems, and
executes non-time critical tasks.

3-4 EM-80252-0105 Tetra Pak

 Operator Panel
The Operator Panel consists of a display, and a number of push-buttons.
All machine control functions (Step up, Step down, Short stop, etc.) are
executed by means of hard wired push-buttons on the panel.

Draft
2.1802520105en.fm

Tetra Pak EM-80252-0105 3-5

 Safety System

Emergency Emergency
Stop Stop

PLC
Output
Draft

2.1802520105en.fm
Safety
Module Power
Supply
Motor

+ -
24V DC
GBAFAA19

3-6 EM-80252-0105 Tetra Pak

 4 Trouble shooting

Draft
2.1TB042521en.fm

Tetra Pak EM-80252-0105 4-1

 Table of contents
Draft

2.1TB042521en.fm

4-2 EM-80252-0105 Tetra Pak

 5 Component Location

Draft
2.1TB052521en.fm

Tetra Pak EM-80252-0105 5-1

 Table of contents
CE-list 41215-0100 Electrical document
ECM 83166
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Location of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Location of Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Location of Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
El. Cabinet TBA/3 . . . . . . . . . . . . . . . . . . . 41212-0100
Mounting drawing El.cabinet. . . . . . . . . . 52628-05:05
Swing frame . . . . . . . . . . . . . . . . . . . . . . . 52628-06:05
Mounting drawing . . . . . . . . . . . . . . . . . . 52628-07:01
Mounting drawing . . . . . . . . . . . . . . . . . . 52628-08:01
Mounting drawing . . . . . . . . . . . . . . . . . . 52628-09:02
Control panel . . . . . . . . . . . . . . . . . . . . . . 52628-10:01
Cable lead in plates . . . . . . . . . . . . . . . . . 52628-11:01
Circuit board front rack . . . . . . . . . . . . . . 52628-12:01
Draft

Mounting drawing connection boxes. . . . 52628-13:01

2.1TB052521en.fm
Mounting drawing TPIH . . . . . . . . . . . . . 52628-14:01
Mounting drawing ext. components . . . . 52628-15:01
Mounting drawing ext. components . . . . 52628-16:01
Mounting drawing ext. components . . . . 52628-17:01
Mounting drawing ext. components . . . . 52628-18:01
Valve panel. . . . . . . . . . . . . . . . . . . . . . . . 52628-19:02
Valve panel. . . . . . . . . . . . . . . . . . . . . . . . 52628-20:01
Del. Design label 50Hz . . . . . . . . . . . . . . 52628-25:01
Del. Design label 60Hz . . . . . . . . . . . . . . 52628-25:02
Terminal X002, X004 . . . . . . . . . . . . . . . . . . 578871-1
Neutral terminal X003 . . . . . . . . . . . . . . . . . . 578871-2
Terminal X005 . . . . . . . . . . . . . . . . . . . . . . . . 578871-3
Terminal X008 . . . . . . . . . . . . . . . . . . . . . . . . 578871-4
Terminal X.L . . . . . . . . . . . . . . . . . . . . . . . . . 578871-5
Circuit protection label . . . . . . . . . . . . . . . . . . 578872
Index TBA/3-6000 . . . . . . . . . . . . . . . . . . . . . . 578873
(Cont’d)

5-2 EM-80252-0105 Tetra Pak

 (Cont’d)
Machine display . . . . . . . . . . . . . . . . . . . . . . . . 580351
CONTR.PANEL CIRCB.+COMP . . . . . . 580350-001
DISPLAY Circ. Board Comp.Side . . . . . . 580350-003
DISPLAY Circ.board Solder side . . . . . . . 580350-004
List of cables TBA/3 . . . . . . . . . . . . . . . . . 41213-0100
Standard Equipment . . . . . . . . . . . . . . . . . 41214-0100
Spare Part Kit . . . . . . . . . . . . . . . . . . . . . . 41217-0100
El. Cabinet Mech Drwgs . . . . . . . . . . . . . 971678-0100
El. Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . 4212-0100
El. Equipment . . . . . . . . . . . . . . . . . . . . . 649187-6000

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Tetra Pak EM-80252-0105 5-3

 Location of Valves

Valve No Function Sheet No

M.Y3 Air blowing 52628-19:02
M.Y7 Steam Barrier “C” 52628-19:02
M.Y8 Sterile Air Valve “B” 52628-19:02
M.Y9 Product Valve “A” 52628-19:02
M.Y12 Design pre-correction 52628-19:02
M.Y13 Design correction left 52628-19:02
M.Y14 Design correction right 52628-19:02
M.Y17 Central lubrication 52628-19:02
M.Y24 Movement LS/SA 52628-19:02
M.Y27 Drop chute 52628-19:02
M.Y31 Sprinkler 52628-20:01
M.Y32 Compressor water 52628-20:01
M.Y33 Forced cooling 52628-20:01
M.Y36 Manual flushing in final folder 52628-20:01
M.Y37 Filling lubrication oil 52628-15:01
M.Y41 Jet diverter air 52628-19:02
Draft

M.Y44 Separator water heat exchanger 52628-19:02

2.1TB052521en.fm
M.Y51 Air injection in cooling water 52628-19:02
M.Y60 Cutting right side 52628-19:02
M.Y61 Cutting right side 52628-19:02

Location of Motors

Motor No Function Sheet No

M1 Cooling fan control cabinet 52628-05:05
M.M1 Drive motor with brake 52628-15:01
M.M9 Vacuum cleaner paper web 52628-16:01
M.M31 Motor sterile bath 52628-16:01
M.M32 Motor bending roller 52628-16:01
M.M33 Sterile air compressor 52628-16:01

5-4 EM-80252-0105 Tetra Pak

 Location of Switches

Switch No Function Sheet No

M.B1 Angle encoder 52628-15:01
M.B2 Main air pressure 52628-20:01
M.B3 Water pressure 52628-20:01
M.B6 Lubrication oil pressure 52628-18:01
M.B8 Paper supply monitor 52628-18:01
M.B9 Rotation monitor paper web 52628-18:01
M.B10 Crank guard 52628-15:01
M.B11 Door guard left 52628-16:01
M.B12 Door guard right 52628-15:01
M.B14 Splicer 52628-18:01
M.B15 Door guard front 52628-17:01
M.B16 Product pipe position 52628-17:01
M.B17 C-valve position 52628-17:01
M.B18 Sterile air low pressure 52628-15:01
M.B20 Overload final folder unit 52628-16:01
M.B22 Package monitor in drop chute 52628-15:01

Draft
M.B24 Lubrication oil high level 52628-15:01
2.1TB052521en.fm

M.B26 B-valve position 52628-17:01

M.B27 Thermocouple steambarrier 52628-17:01
M.B31 Thermocouple sterile air 52628-17:01
M.B32 Strip supply monitor 52628-15:01
M.B33 Broken strip 52628-16:01
M.B34 Low level peroxide bath 52628-16:01
M.B35 Splice monitor paperweb 52628-15:01
M.B36 Thermocouple SA-element 52628-16:01
M.B37 Thermocouple LS-element 52628-17:01
M.B39 Thermocouple air superheater 52628-15:01
M.B40 Reference electrode 52628-16:01
M.B41 Sliding electrode 52628-16:01
M.B44 Thermocouple tube heater 52628-17:01
M.B54 Design correction data photocell 52628-17:01
M.B55 Design correction clock photocell 52628-17:01
M.B90:1 Package supervision
M.B90:2 External conveyor
M.B115 Speed monitor bending roller 52628-16:01

Tetra Pak EM-80252-0105 5-5

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2.1TB052521en.fm

5-6 EM-80252-0105 Tetra Pak

 6 Circuit Diagrams

Draft
2.1TB062521en.fm

Tetra Pak EM-80252-0105 6-1

 Table of contents
CE-list 41215-0100 Electrical document
ECM 83166
Circuit diagram position summary
Circuit diagram position summary. . . . . . 44291-02:06
Circuit diagram drawings
Circuit diagram Mains . . . . . . . . . . . . . . . 44291-05:01
Circuit diagram IH-generators . . . . . . . . . 44291-06:02
Circuit diagram Elements . . . . . . . . . . . . 44291-07:01
Circuit diagram Elements . . . . . . . . . . . . 44291-08:01
Circuit diagram Elements . . . . . . . . . . . . 44291-09:05
Circuit diagram Lighting, fan air cooler . 44291-10:01
Circuit diagram Control voltage . . . . . . . 44291-11:05
Circuit diagram motor . . . . . . . . . . . . . . . 44291-12:02
Circuit diagram motor . . . . . . . . . . . . . . . 44291-13:02
Circuit diagram Drive motor 50Hz . . . . . 44291-14:03
Draft

Circuit diagram Drive motor 60Hz . . . . . 44291-14:04

2.1TB062521en.fm
Circuit diagram PLC . . . . . . . . . . . . . . . . 44291-16:05
Circuit diagram Peroxide bath . . . . . . . . . 44291-17:05
Circuit diagram Temperature regulator . . 44291-18:01
Circuit diagram Temperature regulator . . 44291-19:05
Circuit diagram Temperature regulator . . 44291-20:01
Circuit diagram Sterilizer. . . . . . . . . . . . . 44291-22:01
Circuit diagram Process signal. . . . . . . . . 44291-23:01
Circuit diagram DE-signal . . . . . . . . . . . . 44291-24:01
Circuit diagram Printed design correction 44291-25:01
Circuit diagram Miscellaneous . . . . . . . . 44291-26:01
Circuit diagram Safety module . . . . . . . . 44291-28:01
Circuit diagram Angle encoder PLC fast. 44291-30:01
Circuit diagram PLC fast input . . . . . . . . 44291-31:01
Circuit diagram PLC input. . . . . . . . . . . . 44291-32:01
Circuit diagram PLC input. . . . . . . . . . . . 44291-33:01
Circuit diagram PLC input. . . . . . . . . . . . 44291-34:01
(Cont’d)

6-2 EM-80252-0105 Tetra Pak

 (Cont’d)
Circuit diagram PLC input . . . . . . . . . . . .44291-35:01
Circuit diagram PLC input . . . . . . . . . . . .44291-36:01
Circuit diagram PLC input . . . . . . . . . . . .44291-37:02
Circuit diagram PLC input . . . . . . . . . . . .44291-38:02
Circuit diagram PLC input . . . . . . . . . . . .44291-39:01
Circuit diagram PLC output . . . . . . . . . . .44291-45:05
Circuit diagram PLC output . . . . . . . . . . .44291-46:01
Circuit diagram PLC output . . . . . . . . . . .44291-47:05
Circuit diagram PLC output . . . . . . . . . . .44291-48:01
Circuit diagram PLC output . . . . . . . . . . .44291-49:05
Circuit diagram PLC output . . . . . . . . . . .44291-50:01
Circuit diagram PLC output . . . . . . . . . . .44291-51:01
Circuit diagram PLC output . . . . . . . . . . .44291-52:02
Circuit diagram PLC output . . . . . . . . . . .44291-53:01
Circuit diagram PLC output . . . . . . . . . . .44291-54:01

Draft
2.1TB062521en.fm

Circuit diagram Alarm Display. . . . . . . . .44291-56:05

Circuit diagram Alarm Display. . . . . . . . .44291-57:05
Circuit diagram Alarm Display. . . . . . . . .44291-58:05
Circuit diagram Alarm Display. . . . . . . . .44291-59:05
Circuit diagram earth summary
Summary protective bonding . . . . . . . . . .44291-89:05
Circuit diagram line summary
Line summary . . . . . . . . . . . . . . . . . . . . . .44291-90:06
Circuit diagram terminal summary
Terminal summary. . . . . . . . . . . . . . . . . . .44291-91:06
Circuit diagram alteration description
Circuit diagram Alteration description . . .44291-99:08

Tetra Pak EM-80252-0105 6-3

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2.1TB062521en.fm

6-4 EM-80252-0105 Tetra Pak

 7 Connection Diagrams

Draft
2.1TB072521en.fm

Tetra Pak EM-80252-0105 7-1

 Table of contents
CE-list 41215-0100 Electrical document
ECM 83166
Connection Diagrams
Cable Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Connection Diagram . . . . . . . . . . . . . . . . 61421-05:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-06:01
Connection Diagram 50Hz . . . . . . . . . . . 61421-07:03
Connection Diagram 60Hz . . . . . . . . . . . 61421-07:04
Connection Diagram . . . . . . . . . . . . . . . . 61421-08:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-09:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-10:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-12:05
Connection Diagram . . . . . . . . . . . . . . . . 61421-13:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-14:02
Connection Diagram . . . . . . . . . . . . . . . . 61421-15:05
Draft

Connection Diagram . . . . . . . . . . . . . . . . 61421-16:01

2.1TB072521en.fm
Connection Diagram . . . . . . . . . . . . . . . . 61421-20:02
Connection Diagram . . . . . . . . . . . . . . . . 61421-21:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-23:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-24:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-25:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-26:02
Connection Diagram . . . . . . . . . . . . . . . . 61421-27:01
Connection Diagram . . . . . . . . . . . . . . . . 61421-30:02

7-2 EM-80252-0105 Tetra Pak

 Cable Index

Cable No: Sheet No: Cable No: Sheet No:

101 07:03/07:04 245 14:02
102 07:03/07:04 246 14:02
103 07:03/07:04 247 14:02
104 07:03/07:04 250 15:05
105 07:03/07:04 251 15:05
106 07:03/07:04 252 15:05
107 07:03/07:04 253 15:05
108 09:01 254 15:05
109 09:01 260 12:05
201 07:03/07:04 261 12:05
202 07:03/07:04 273 30:02
203 07:03/07:04 274 30:02
204 08:01 275 30:02
205 08:01 276 30:02
206 08:01 277 30:02

Draft
207 23:01 278 30:02
2.1TB072521en.fm

208 23:01 280 21:01

209 23:01 281 21:01
210 23:01 290 16:01
211 25:01 291 16:01
212 25:01 292 16:01
214 09:01 293 10:01
215 09:01 294 27:01
216 23:01 301 20:02
217 09:01 302 20:02
218 09:01 303 30:02
219 10:01 304 20:02
220 12:05 305 20:02
230 13:01 306 20:02
231 13:01 307 21:01
232 13:01 308 21:01
233 13:01 309 23:01
234 13:01 312 24:01
235 13:01 313 24:01
236 13:01 314 24:01
240 14:02 315 25:01
241 14:02 316 25:01
242 14:02 317 25:01
243 14:02 318 25:01
244 14:02 319 25:01

Tetra Pak EM-80252-0105 7-3

 Cable No: Sheet No:
320 25:01
321 26:02
322 26:02
323 26:02
324 26:02
325 26:02
326 26:02
327 26:02
328 26:02
329 26:02
330 26:02
335 26:02
373 30:02
374 30:02
375 30:02
601 05:01
602 05:01
603 05:01
605 06:01
Draft

2.1TB072521en.fm
606 06:01
607 06:01
608 06:01
609 06:01
W98 21:01
W99 21:01

7-4 EM-80252-0105 Tetra Pak

 8 Mains Connection
Diagrams

Draft
2.1TB082521en.fm

Tetra Pak EM-80252-0105 8-1

 Table of contents
CE-list 41215-0100 Electrical document
ECM 83166
Mains Connection Diagram
Mains Connection Diagram . . . . . . . . . . 61461-04:01
Mains Connection Diagram . . . . . . . . . . 61461-05:01
Draft

2.1TB082521en.fm

8-2 EM-80252-0105 Tetra Pak

 9 Program Documents

Draft
2.1TB092521en.fm

Tetra Pak EM-80252-0105 9-1

 Table of contents
CE-list 41215-0100 Electrical document
ECM 83166
PLC Prog.block 01. . . . . . . . . . . . . . . . . . 47921-01:07
PLC Prog.block 02. . . . . . . . . . . . . . . . . . 47921-02:02
PLC Prog.block 04. . . . . . . . . . . . . . . . . . 47921-04:06
PLC Prog.block 05. . . . . . . . . . . . . . . . . . 47921-05:01
PLC Prog.block 06 . . . . . . . . . . . . . . . . . 47921-06:01
PLC Prog.block 07. . . . . . . . . . . . . . . . . . 47921-07:01
PLC.prog.block 08 . . . . . . . . . . . . . . . . . . 47921-08:01
PLC.prog.block 09 . . . . . . . . . . . . . . . . . . 47921-09:02
PLC.prog.block 10 . . . . . . . . . . . . . . . . . 47921-10:03
PLC Prog.block 11. . . . . . . . . . . . . . . . . . 47921-11:02
PLC Prog.block 12. . . . . . . . . . . . . . . . . . 47921-12:04
PLC Prog.block 13. . . . . . . . . . . . . . . . . . 47921-13:01
PLC Prog.block 14. . . . . . . . . . . . . . . . . . 47921-14:02
Draft

PLC Prog.block 15. . . . . . . . . . . . . . . . . . 47921-15:06

2.1TB092521en.fm
Volume Adaption Document . . . . . . . . . . 47921-90:03
Function Diagram . . . . . . . . . . . . . . . . . . 47921-91:03

9-2 EM-80252-0105 Tetra Pak

 10 Design Control System

Draft
2.1TB102521en.fm

Tetra Pak EM-80252-0105 10-1

 Table of contents
CE-list 47837-010V Design Control System
ECN 22325 Date 951129
Short Form Information . . . . . . . . . . . 57552 one page
Document Description . . . . . . . . . . . . 57549 one page
Functional Description . . . . . . . . 57553 sixteen pages
Draft

2.1TB102521en.fm

10-2 EM-80252-0105 Tetra Pak

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Tetra Pak
EM binder labels. 30mm Halfwidth Note! This page is generated automatically.
using the variable definitions made in the front page file!!

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000
Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000
Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000
Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000
Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000
Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000
Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000
Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000
Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105
EM binder labels. 40 mm Full width Note! This page is generated automatically.
using the variable definitions made in the front page file!!

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000

Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000

Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000

Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000

Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000
Issue 2001-02 EM-80252-0105
Issue 2001-02 EM-80252-0105

Tetra Brik Aseptic TBA/3 Tetra Brik Aseptic TBA/3

640016-6000 640016-6000

Issue 2001-02 EM-80252-0105 Issue 2001-02 EM-80252-0105