IM-3541839-0101 SA30-500 Tetra Pak
Uploaded by
Thanh BaronIM-3541839-0101 SA30-500 Tetra Pak
Uploaded by
Thanh BaronIM
Installation Manual
Straw Applicator 30
663350-0500
WARNING
Read and follow all safety precaution instructions throughout this
document and on safety signs attached to this equipment.
Failure to follow all safety precaution instructions could result in death or
serious injury.
Doc. No. IM-3541839-0101
Copyright © 2018 Tetra Pak International S.A.
All rights reserved. No part of this document may be reproduced or copied in any form or by
any means without written permission from Tetra Pak Packaging Solutions AB.
, Tetra Pak, and all other trademarks displayed in this document are the property of the
Tetra Pak International SA. Tetra Pak Packaging Solutions AB together with Tetra Pak
International SA form part of ‘the Tetra Pak Group’. The content of this document is in
accordance with the design and construction of the machine or equipment at the time of
publishing. The Tetra Pak Group reserves the right to introduce design modifications without
prior notice.
The English language version of this document contains the original instructions. All other
language versions are translations of the original instructions.
This document was produced and printed by:
Tetra Pak Packaging Solutions AB
Ruben Rausings gata
SE-221 86 Lund
Sweden
Doc. No. IM-3541839-0101
Issue 2018-02
This document is valid for: Introduction
Safety Precautions
1 Technical Specification
Serial No. / Machine No.
Year of Manufacture Sign. 2 Preparations
3 Mechanical Completion
4 Commissioning
IM
Installation Manual
5
6
7
Performance Validation
Disassembly and Removal
General
Straw Applicator 30
663350-0500
Machine or equipment configurations that
this document is valid for are described on
the next page.
Doc. No. IM-3541839-0101
Issue 2018-02
Tetra Pak Packaging Solutions AB
Valid for:
Name Drawing Specification and Additional Information
Development Step
Straw Applicator 30 663350-0500 Package Shape:
- Tetra Brik, TB
- Tetra Brik Aseptic, TBA
- Tetra Prisma Aseptic, TPA
- Tetra Top, TT
Update Log for Doc. No. IM-3541839-0101
This table shows all changes made to this document, including installed
rebuilding kits, added or removed pages. Page numbering on added pages
begins with UP.
Date Installed Kit Added Pages Removed Pages Signature
(Doc. No.)
Date Installed Kit Added Pages Removed Pages Signature
(Doc. No.)
Introduction
®
Doc. No. IM-3541839-0101 7 (224)
Introduction
Description
This chapter contains basic information about this manual and the related
Tetra Pak® equipment.
8 (224) Doc. No. IM-3541839-0101
®
Introduction Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Abbreviations and Terminology ..............................11
Document Information ......................................... 12
Delivered Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
EM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
IM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TeM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Machine Introduction .......................................... 16
Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Identification ..................................................... 42
EAC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
China RoHS2 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Machine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Electrical Equipment Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Delivered Design Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Orientation........................................................ 47
Hygiene ............................................................ 49
Environment...................................................... 50
®
Doc. No. IM-3541839-0101 9 (224)
Table of Contents Introduction
Waste Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fluids and Chemical Products . . . . . . . . . . . . . . . . . . . . . . . . . 50
Hydrogen Peroxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Separation of Materials and Components. . . . . . . . . . . . . . . 50
Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . 51
Packaging and Additional Material . . . . . . . . . . . . . . 51
How to Use This IM ............................................. 52
Purpose of the IM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installation Workflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assistance and Inquiries...................................... 53
10 (224) Doc. No. IM-3541839-0101
®
Introduction Abbreviations and Terminology
Abbreviations and Terminology*
Abbreviation/Terminology Meaning Translation
ANSI American National American National
Standards Institute Standards Institute
BFT Bent Foil Treater Bent Foil Treater
CAT Customer Adapted Customer Adapted
Training Training
CE Conformité Conformité
Européenne/European Européenne/European
Conformity Conformity
DE Distribution Equipment Distribution Equipment
EAC Eurasian Conformity Eurasian Conformity
EEA European Economic European Economic
Area Area
EM Electrical Manual Electrical Manual
HMI Human Machine Human Machine
Interface Interface
IM Installation Manual Installation Manual
IMD Individual Machine Individual Machine
Documentation Documentation
ISO International Standards International Standards
Organization Organization
LC Line Controller Line Controller
MM Maintenance Manual Maintenance Manual
MME Machine Mechanical Machine Mechanical
Efficiency Efficiency
N/A Not Applicable Not Applicable
OM Operation Manual Operation Manual
PLC Programmable Logic Programmable Logic
Controller Controller
PLMS Packaging Line Packaging Line
Monitoring System Monitoring System
QAM Quality Assurance Quality Assurance
Management Management
SA30 Straw Applicator 30 by Straw Applicator 30 by
Tetra Pak Tetra Pak
SNP Series Ninety Protocol Series Ninety Protocol
SPC Spare Parts Catalogue Spare Parts Catalogue
TB Tetra Brik Tetra Brik
TBA Tetra Brik Aseptic Tetra Brik Aseptic
TeM Technical Manual Technical Manual
TPA Tetra Prisma Aseptic Tetra Prisma Aseptic
TPOP Tetra Pak Operator Tetra Pak Operator
Panel Panel
TT Tetra Top Tetra Top
UP Update Pages Update Pages
®
Doc. No. IM-3541839-0101 11 (224)
Document Information Introduction
Document Information
Prior to interacting with the equipment, carefully read the instructions in the
applicable documentation pertinent to the activity. Make sure that the delivered
documents are available to personnel who operate or maintain the equipment.
It is important to keep this document for the lifetime of the equipment and to pass
the document on to any subsequent holder or user.
Any item that is named specifically in this document is to be considered a
designated item for the equipment. Designated items are verified by the
Tetra Pak Group for use with the equipment.
The Tetra Pak Group will not be held responsible for any damage, loss, injury, or
death caused by not following the instructions in the documents delivered with this
equipment, or by a failure to use designated items specified in the documents
delivered with this equipment.
Delivered Manuals
Manuals delivered with this equipment:
EM
The Electrical Manual provides technicians with information about the equipment’s
electrical system.
IM
The Installation Manual provides technicians with information required to safely
install the equipment.
MM
The Maintenance Manual provides technicians with information on maintaining the
equipment.
OM
The Operation Manual provides the operator with information on handling and
operating the equipment before, during, and after production.
SPC
The Spare Parts Catalogue provides the information necessary to order spare parts
from the Tetra Pak Group.
TeM
The Technical Manual provides information that is needed during the crate handling
process when the crate is equipped with a metal folder.
This includes
• the data and information concerning the crate and crated equipment
• the information concerning lifting machinery and lifting accessories
• the procedures for receiving, opening the crate, and unpacking the equipment
12 (224) Doc. No. IM-3541839-0101
®
Introduction Document Information
Page Layout
Every main page in a manual contains a header and a footer. The page header
contains the chapter name (1) and the section name (2). The page footer contains
the page number (3), and the document number (4). See also the Page Numbering
section.
1 2
9 General 9.2 Technical Data
Doc. No. MM-2730517-0103 41 (60)
4 3
1 Chapter name
2 Section name
3 Page number
4 Document number
.
®
Doc. No. IM-3541839-0101 13 (224)
Document Information Introduction
Page Numbering
A page number has two parts:
• consecutive page number (1)
• total number of pages (2) in user manual
31 (356)
1 2
1 Consecutive page
number
2 Total number of pages
Note! The letters UP (3) may appear before the consecutive page number (4) if the
user manual includes update pages. The consecutive page number (4) and the total
number of pages (5) of update pages do not follow the existing sequential page
numbering of the user manual.
UP-11 (18)
3 4 5
3 UP
4 Consecutive page
number
5 Total number of pages
.
Typographical Conventions
Physical buttons on the operator panel, emergency stop devices, program steps,
and program tasks are printed in CAPITAL LETTERS.
Names of buttons, entry fields, menu items, or other objects that allow the user to
control the user interface are printed in Courier.
Information that is displayed on the user interface, is to be repeated in the user
manual, but is not used to control the user interface, is printed in COURIER CAPITAL
LETTERS.
Cross-references are underlined.
14 (224) Doc. No. IM-3541839-0101
®
Introduction Document Information
Symbols
Symbols used in illustrations.
A pointer arrow indicates the position of
an object.
A zoom arrow indicates that an object
view is enlarged. The arrow points
towards the enlarged view of the object.
A rotation movement arrow indicates
rotational movement of an object. The
arrow points in the direction of rotation.
A straight movement arrow indicates
movement of an object.
The arrow points in the direction of
movement.
.
®
Doc. No. IM-3541839-0101 15 (224)
Machine Introduction Introduction
Machine Introduction
Intended Use of the Equipment
The intended use of this Tetra Pak equipment is to attach drinking straws onto
Tetra Brik packages (TB and TBA), Tetra Prisma Aseptic packages (TPA), or
Tetra Top packages (TT).
All other use is prohibited. Tetra Pak will not be held responsible for injury or
damage if the equipment is used for any other purpose than the intended use
described above.
Manufacturer
This Tetra Pak® equipment is manufactured by
Tetra Pak Packaging Solutions AB
Ruben Rausings gata
SE-221 86 Lund
Sweden
EU Declaration of Conformity
A copy of the EU Declaration of Conformity can be found below. The signed EU
Declaration of Conformity is delivered separately with the equipment.
EU Declaration of Conformity
16 (224) Doc. No. IM-3541839-0101
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Doc. No. IM-3541839-0101 37 (224)
Machine Introduction Introduction
(Cont’d)
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38 (224) Doc. No. IM-3541839-0101
®
Introduction Machine Introduction
(Cont’d)
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Doc. No. IM-3541839-0101 39 (224)
Machine Introduction Introduction
(Cont’d)
Izjava EU o skladnosti
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40 (224) Doc. No. IM-3541839-0101
®
Introduction Machine Introduction
(Cont’d)
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®
Doc. No. IM-3541839-0101 41 (224)
Identification Introduction
Identification
EAC Compliance
This equipment complies with the regulations of the Eurasian Customs Union.
China RoHS2 Compliance
This equipment may contain one or more of the following substances: Pb, Hg, Cd,
Cr6+, PBB, and PBDE.
The Environmental Protection Use Period is 25 years.
The Hazardous Substances Disclosure Table can be found in the Disassembly and
Removal chapter in the IM.
42 (224) Doc. No. IM-3541839-0101
®
Introduction Identification
Machine Plate
The illustration below shows an example of the machine plate and its location on the
equipment. The machine plate carries data needed when contacting the Tetra Pak
Group concerning this specific equipment.
Make sure that the equipment data in the front pages of this manual corresponds to
the machine plate data and the machine specification.
1 2 3 4 5
10 9 8 7 6
Main machine
1 Machine type 5 Manufacturer
2 Drawing specifications 6 EAC mark
3 Machine serial number 7 China RoHS2 mark (if
4 CE mark applicable)
8 Month of manufacture
9 Assembled in
10 Year of manufacture
.
(Cont’d)
®
Doc. No. IM-3541839-0101 43 (224)
Identification Introduction
(Cont’d)
1 2 3 4 5
10 9 8 7 6
BFT
1 Machine type 5 Manufacturer
2 Drawing specifications 6 EAC mark
3 Machine serial number 7 China RoHS2 mark (if
4 CE mark applicable)
8 Month of manufacture
9 Assembled in
10 Year of manufacture
.
44 (224) Doc. No. IM-3541839-0101
®
Introduction Identification
Electrical Equipment Marking
The illustration below shows an example of the electrical equipment marking and its
location on the equipment. The electrical equipment marking specifies the electrical
characteristics for the equipment at the connection point.
1
2
3
4
9 8 7 6
1 Electrical doc. No. 4 Full-load current 7 Supply voltage
2 Electrical doc. BoM 5 Short-circuit capacity 8 Phase
3 Equipment Master No. 6 Maximum supply 9 Frequency
source impedance
.
Delivered Design Label
The illustration below shows an example of the delivered design label and its location
on the equipment. The delivered design label lists information tracking any rebuilding
done to the electrical design, and any alterations done in the electrical cabinet and to
related electrical components.
The delivered design label is filled in by the person performing the rebuilding or
alteration.
(Cont’d)
®
Doc. No. IM-3541839-0101 45 (224)
Identification Introduction
(Cont’d)
46 (224) Doc. No. IM-3541839-0101
®
Introduction Orientation
Orientation
The illustration below shows the orientation of the equipment. This orientation
information will be used throughout this manual. The arrows indicate the flow of
material.
D A
B
Main machine
A Front
B Left-hand side
C Right-hand side
D Back
.
(Cont’d)
®
Doc. No. IM-3541839-0101 47 (224)
Orientation Introduction
(Cont’d)
A D
C
BFT
A Front
B Left-hand side
C Right-hand side
D Back
.
Note! The machine can process the straw ladder band in either direction.
48 (224) Doc. No. IM-3541839-0101
®
Introduction Hygiene
Hygiene
• Never clean the floors or the machine in the filling room (area) when the machine
is in production.
• Keep your hands and gloves clean.
• Always wear some type of hair protection (cap or hairnet) and clean clothes
(preferably white).
• Do not wear a watch, ring, necklace, earrings, or any other exposed jewellery.
®
Doc. No. IM-3541839-0101 49 (224)
Environment Introduction
Environment
Waste Management
Separate, recycle, or dispose of all material and components in a safe, and
environmentally responsible way, or according to national legislation or local
regulations. If there is any uncertainty regarding what material a component is made
of, contact the Tetra Pak Group. Use a certified (ISO 14001 or similar) scrapping or
waste handling company.
Fluids and Chemical Products
Drain all liquids into collecting vessels. Do not mix different liquids into the same
vessel. Follow the instructions in the Safety Data Sheets for the disposal of the
different fluids and dispose of according to national legislation or local regulations.
Hydrogen Peroxide
Follow the instructions in the Safety Data Sheets, national legislations, and local
regulations for the disposal. Flush the hydrogen peroxide system with distilled water
to dilute any remaining hydrogen peroxide to a safe level.
For further details see the Hazardous Substances section in the Safety Precautions
chapter.
Cooling Media
Equipment containing any kind of cooling media must be dismantled, but only as far
as can be considered safe without any cooling media leakage. Follow national
legislation or local regulations. Send the cooling media to an authorized company
for proper handling.
For further details see the Hazardous Substances section in the Safety Precautions
chapter.
Separation of Materials and Components
Separate the following materials. Recycle or dispose of the materials as
appropriate. Follow specific recycling instructions, if such are given by the
component supplier.
• stainless steel (panels and doors)
• cast iron (frames)
• brass
• glass (windows, and so on)
• rubber (seals, O-rings, and so on)
• nylon and other plastics
• electrical cables
• hydraulic hoses
• central lubrication hoses
• pneumatic hoses
• electrical components
• batteries
• mercury (UV-lamp)
50 (224) Doc. No. IM-3541839-0101
®
Introduction Environment
Electrical Components
Electrical components and batteries may need to be disposed of in special waste
management systems. Follow national legislation or local regulations.
Packaging and Additional Material
Remaining packaging material and additional material such as strips, caps, tops,
corrugated cardboard, and plastic film wrapping shall be sent for recycling or
disposed of according to national legislation or local regulations.
®
Doc. No. IM-3541839-0101 51 (224)
How to Use This IM Introduction
How to Use This IM
Purpose of the IM
The IM provides technical specifications and preparatory information needed during
the quotation of the equipment and during the entire installation process. The IM
describes the equipment requirements in the packaging line. It also provides
instructions on how to mechanically install, commission, and validate the
performance of the equipment, and how to disassemble and remove the equipment.
The intended users of the IM are project engineers, installation site supervisor,
installation technicians, and other technicians involved in the equipment installation
project.
Installation Workflow
An installation of any Tetra Pak® equipment follows the Installation to Performance
process. The process consists of five main activities and the IM is structured to
support the process. See the illustration and the table below.
1 2 3 4 5
Pos. Process Activity End State Related IM Chapters Intended User
1 Preparation Equipment at prepared Chapter 1 and 2 Project
site engineer/Installation site
supervisor
2 Mechanical Completion Equipment mechanically Chapter 3 Installation
installed technician/Installation
site supervisor
3 Commissioning Equipment Chapter 4 Installation
commissioned and technician/Installation
functionally validated site supervisor
4 Performance Validation Equipment performance Chapter 5 Project
validated engineer/Installation site
supervisor
5 Hand Over Contract fulfilled - -
.
52 (224) Doc. No. IM-3541839-0101
®
Introduction Assistance and Inquiries
Assistance and Inquiries
For assistance when operating this equipment, submit your questions using the
QuTI-P tool. The QuTI-P tool shall also be used for all other inquiries, comments, or
suggestions that you may have, as well as giving feedback concerning the user
manuals delivered with this equipment.
If access to the Tetra Pak® intranet is available, access the QuTI-P tool by typing
“QuTI-P” in the address field of your browser. If access to QuTI-P is not available,
request access by contacting the Global Service Desk.
If access to the Tetra Pak intranet is not available, contact the nearest Tetra Pak
representative.
®
Doc. No. IM-3541839-0101 53 (224)
Assistance and Inquiries Introduction
This page intentionally left blank
54 (224) Doc. No. IM-3541839-0101
®
Safety Precautions
®
Doc. No. IM-3541839-0101 55 (224)
Safety Precautions
Description
Safety Precaution Instructions
WARNING
Read and understand this manual before using the machine.
Failure to follow safety precautions and instructions can result in death or serious
injury.
56 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Safety Messages Description ................................ 59
Personnel Requirements...................................... 60
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Instructed Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Safety Signs ...................................................... 61
Locations of Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Protective Devices .............................................. 66
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Indicating Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Safe Manual Handling.......................................... 71
Personal Protection ............................................ 72
Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Entanglement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Hazardous Substances ........................................ 73
Disposal of Chemical Substances . . . . . . . . . . . . . . . . . . . . . . . . . 73
Supply Systems ................................................. 74
Definition of Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Residual Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Valid for all countries except USA and
Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Valid for USA and Canada . . . . . . . . . . . . . . . . . . . . . . . 79
®
Doc. No. IM-3541839-0101 57 (224)
Table of Contents Safety Precautions
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Hotmelt Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
58 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Safety Messages Description
Safety Messages Description
A safety message is always accompanied by a safety alert symbol and a signal
word.
The safety alert symbol is used to alert about potential personal injury hazards. To
avoid hazards, obey all safety messages that follow this symbol.
The following safety alert symbols and signal words are used in this manual to inform
the user of hazards.
Danger indicates an imminently
DANGERI
DANGER hazardous situation which, if not
avoided, will result in death or serious
injury.
Warning indicates a potentially
WARNING hazardous situation which, if not
avoided, could result in death or
serious injury.
Caution indicates a potentially
CAUTION hazardous situation which, if not
avoided, may result in minor or
moderate injury. It may also be used to
alert against unsafe practices.
CAUTION Caution without the safety alert symbol
indicates a potentially hazardous
situation which, if not avoided, may
result in property damage.
®
Doc. No. IM-3541839-0101 59 (224)
Personnel Requirements Safety Precautions
Personnel Requirements
Note! Personnel includes all persons working on or near this equipment.
Only skilled or instructed persons are allowed to work with this equipment.
Skilled Person
A skilled person must have relevant education and experience to enable him or her
to identify hazards, analyse risks, and avoid hazards which electricity, machinery,
chemicals, other energies, and supply systems on this equipment can create.
Skilled persons must meet local regulations, such as certifications and qualifications
for working with these energies and systems.
Instructed Person
An instructed person must be adequately advised or supervised by a skilled person.
The skilled person enables the instructed person to identify hazards, analyse risks,
and avoid hazards which electricity, machinery, chemicals, other energies, and
supply systems on this equipment can create.
60 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Safety Signs
Safety Signs
WARNING
Damaged or missing safety signs.
Safety signs are used to indicate safety hazards. If the signs are missing or
damaged, they can not fulfil this function. Replace all missing or damaged safety
signs immediately.
Safety signs are attached to the equipment. The table below lists all the signs that
are used, and illustrations show their locations on the equipment. Each position
number refers to two standards of a safety sign in the table, but only one is used on
the equipment.
• Make sure that each safety sign is legible and in its correct position after
installation and maintenance.
• Replace all missing or damaged safety signs immediately.
Pos ISO Standard ANSI Standard
4
WARNING
Moving part
can crush and cut.
Do not operate with
guard removed.
Follow lockout procedure
before maintenance.
Moving part can crush and cut.
Do not operate with guard removed.
Follow lockout procedure before maintenance.
5
WARNING
Moving parts can
crush and cut.
Do not put hands into
the machine.
Follow lockout procedure
before maintenance.
Moving part can crush and cut.
Do not put hands into the machine.
Follow lockout procedure before maintenance.
10
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Follow lockout procedure
before maintenance.
Hazardous voltage.
Will shock, burn, or cause death.
Follow lockout procedure before maintenance.
(Cont’d)
®
Doc. No. IM-3541839-0101 61 (224)
Safety Signs Safety Precautions
(Cont’d)
Pos ISO Standard ANSI Standard
11
5 MIN.
Hazardous residual voltage on capacitors.
Will shock, burn or cause death.
Disconnect power and wait 5 minutes before opening.
Follow instructions for safe work practices.
14
WARNING
Hazardous voltage could be
present with power supply
disconnector switched off.
Can shock, burn, or cause death.
Conductors supplied from
an external source. Follow lockout
procedure before maintenance.
Hazardous voltage could be present with power supply
disconnector switched off.
Can shock, burn or cause death.
Conductors supplied from an external source.
Follow lockout procedure before maintenance.
15
CAUTION
Laser Radiation.
Do not stare into
beam.
Class 2 laser product
Laser Radiation.
Do not stare into beam.
Class 2 laser product.
16
Hazardous voltage.
Can shock, burn, or cause death.
Read Maintenance Manual (MM) before using this socket outlet.
24
CAUTION
Risk of equipment
damage.
Do not let water
into this area.
Risk of equipment damage.
Do not let water into this area.
(Cont’d)
62 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Safety Signs
(Cont’d)
Pos ISO Standard ANSI Standard
27
Hot surface.
Do not touch.
Follow lockout procedure before maintenance.
35
CAUTION
Do not reach in.
Moving parts may
cause injury.
Follow instructions for
safe work practice.
Do not reach in.
Moving parts may cause injury.
Follow instructions for safe work practice.
37
WARNING
To prevent serious injury:
- Do not operate this machine unless all doors are
closed and guards are in place and operating.
- Machine starts automatically. Stay clear of machine
when it is operating.
- Read manual before first operating machine.
If manual is missing, contact Tetra Pak.
To prevent serious injury:
• Do not operate this machine unless all doors are closed and guards are
in place and operating.
• Machine starts automatically. Stay clear of machine when it is operating.
• Read manual before first operating machine. If manual is missing,
contact Tetra Pak.
38
WARNING
To prevent serious injury:
Do not operate this machine unless all doors are
closed and guards are in place and operating.
Read manual before first operating machine. If
manual is missing, contact Tetra Pak.
To prevent serious injury:
Do not operate this machine unless all doors are closed and guards are in
place and operating. Read manual before first operating machine. If
manual is missing, contact Tetra Pak.
40
Not applicable
Hazardous voltage.
Will shock, burn, or cause death.
Disconnect power before opening.
®
Doc. No. IM-3541839-0101 63 (224)
Safety Signs Safety Precautions
Locations of Safety Signs
37
35
35
24 27
4 5
27
10
10
37 40
15 24
10
11 38 14 16
16 14
(Cont’d)
64 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Safety Signs
(Cont’d)
38
10
11 40
BFT
15
Barcode scanner
®
Doc. No. IM-3541839-0101 65 (224)
Protective Devices Safety Precautions
Protective Devices
There are different kinds of protective device designed to ensure safe use of the
equipment. See the sections below.
WARNING
Hazardous zones.
Hazardous zones are safeguarded and provided with protective devices. Do not
inch or run this equipment if any protective device is inoperative.
Change inoperative components of the safety system immediately.
For the locations of safeguards and/or other protective devices not mentioned in this
section, see the Maintenance Manual.
Emergency Stop
DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Hazardous voltage remains ON after activating an EMERGENCY STOP.
Emergency stop devices are used to stop this equipment immediately in a
hazardous situation. Learn the positions of all emergency stop devices and how to
use them.
Instructions for a normal production stop are included in the Stop chapter of the
Operation Manual.
66 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Protective Devices
Emergency Stop Buttons
CAUTION
Equipment damage.
The equipment can be damaged if it is not stopped in the correct way. Use the
EMERGENCY STOP buttons in case of emergency only.
Push one of the EMERGENCY STOP buttons to stop this equipment immediately.
The location of each EMERGENCY STOP button is shown by an arrow.
®
Doc. No. IM-3541839-0101 67 (224)
Protective Devices Safety Precautions
Safeguards
WARNING
Moving machinery parts.
Never defeat or bypass the interlocking devices.
Movable guards, for example, doors and covers leading to hazardous zones, are
fitted with interlocking devices where required. These devices are usually electric
safety switches that are parts of the safety system and must never be defeated,
bypassed, or otherwise made inoperative.
Where movable guards (doors) are equipped with means to be locked in a
nonclosed position, any person with the intention to preside, for any reason, behind
such a guard must lock the guard in the nonclosed position by use of a padlock.
Note! For work on the electrical equipment, the electrical power must also be
disconnected.
CAUTION
Corners and edges.
Close the doors, guards, or parts of the equipment unless they must be open during
work.
CAUTION
Burn hazard.
Parts of the equipment protected by guards may be hot after operation. Allow
components to cool down or use personal protective equipment.
After installation and maintenance, and before this equipment is inched or run,
check that all safeguards are in place and that they operate correctly.
.
CAUTION
Equipment damage.
The equipment can be damaged if it is not stopped in the correct way. Never stop
this equipment by opening a movable guard, for example, a door or cover, equipped
with an interlocking device.
The location of each interlocking device is shown by an arrow.
68 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Protective Devices
Indicating Tower
An indicating tower is a column of light elements:
• A red light (1) indicates a hazardous condition. This is a situation that requires
immediate action.
• A yellow light (2) indicates an abnormal or impending critical condition. This is a
condition calling for action by the operator.
• A blue light (3) indicates that operator action is required.
• A green light (4) indicates a normal condition.
1
2
3
4
Main machine
1 Red light
2 Yellow light
3 Blue light
4 Green light
2
4
BFT
2 Yellow light
4 Green light
®
Doc. No. IM-3541839-0101 69 (224)
Protective Devices Safety Precautions
Protective Covers
After maintenance, check that all covers are fitted to the machine before it is run.
70 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Safe Manual Handling
Safe Manual Handling
Use mechanical lifting aids whenever possible. If mechanical lifting aids are not
available, do not attempt to lift loads over 23 kg without the assistance of a
colleague. Avoid lifting below knee height and above shoulder height. If it is
necessary to lift from the floor, follow the instructions below to reduce the risk of back
and disc injuries.
• Use safety shoes and be sure that the surface of the floor is not slippery.
• Get close to the load.
• Take a wide stance and find the best positions for your feet.
• Bend your hips and knees, and use your leg muscles.
• Keep the load close to your body.
• Do not twist your body while moving the load.
• Take small steps when turning.
In order to reduce the risk of injury to discs and back muscles, be careful to not bend
or twist your back when lifting. Keep the load close to your body to reduce the strain
on your back.
To reduce the ergonomic risks to each individual operator, job rotation is
recommended, so that recovery and variety are provided.
®
Doc. No. IM-3541839-0101 71 (224)
Personal Protection Safety Precautions
Personal Protection
This section applies to all personnel at all times when this equipment is in operation.
For special personal protective equipment required when handling hazardous
substances, see the Hazardous Substances section.
Noise
CAUTION
Hazardous noise.
May cause impaired hearing.
Hearing protection is recommended whenever this equipment is in operation.
Entanglement
WARNING
Risk of entanglement.
Do not wear jewellery or loose clothing when working on or near this equipment.
Restrain long hair with, for example, clips or rubber bands.
72 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Hazardous Substances
Hazardous Substances
WARNING
Contact with chemicals can cause death, serious injury, or illness.
Always read and follow the instructions in the safety data sheet supplied by the
manufacturer or local supplier, when handling chemicals.
Make sure that
• the safety data sheet is available
• preparations have been done to ensure that the stated safety measures in the
safety data sheet can be followed
• the locations of the first aid equipment are learned in order to act immediately in
case of an accident
Disposal of Chemical Substances
Always read and follow the disposal instructions in the safety data sheet supplied by
the manufacturer or local supplier.
It is strongly recommended that used chemical containers are
• disposed of according to the instructions immediately after use
• not used as disposal containers for other chemicals in order to avoid uncontrolled
chemical reactions within the container
.
®
Doc. No. IM-3541839-0101 73 (224)
Supply Systems Safety Precautions
Supply Systems
Definition of Lockout Procedure
A lockout procedure is a procedure to put each necessary energy isolating device in
its safe position to prevent the energisation of the equipment, such as when a
maintenance procedure should be carried out.
A lockout is the use of a device, for example, a padlock, to make sure that an energy
isolating device cannot be operated.
An energy isolating device is a mechanical device that physically prevents
transmission or release of energy, such as an electrical supply disconnecting
device.
A detailed instruction for the specific lockout procedure(s) for this equipment is
found in the Maintenance Manual.
Electrical Supply
DANGERI
DANGER
Hazardous voltage and moving machinery.
The electrical supply disconnecting device must be in position O (OFF) and secured
with a lock before any work with the equipment that requires the electrical supply to
be disconnected. See the Machine Status section of the Procedure Start Table.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
DANGERI
DANGER
Hazardous voltage can be present with the electrical supply disconnecting
device in position O (OFF).
Circuits identified by orange-coloured conductors are not disconnected by the main
electrical supply disconnecting device. The location of the electrical supply
disconnecting device of these circuits is described in the procedures that include
work on these types of circuit.
Certain procedures may require that the electrical supply disconnecting device is in
position | (ON). These exceptions are clearly stated in the manuals.
(Cont’d)
74 (224) Doc. No. IM-3541839-0101
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Safety Precautions Supply Systems
(Cont’d)
The illustrations show the electrical supply disconnecting device and its location.
Any equipment connected to the main machine will be dead when the electrical
supply disconnecting device on the main machine is switched OFF.
Main machine
.
The electrical supply disconnecting device on the BFT is coloured red and yellow,
which means that it can be used as an emergency switching off device.
BFT
.
®
Doc. No. IM-3541839-0101 75 (224)
Supply Systems Safety Precautions
Residual Voltage
DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
After the electrical supply disconnecting device is turned to position O (OFF),
residual voltage remains in the capacitor circuits. Wait five minutes before opening
the enclosure containing these circuits. Ensure that no residual voltage remains on
the capacitors before touching them.
Electrical Cabinet
DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Parts behind doors to the electrical cabinet may be live. The electrical supply
disconnecting device must be turned to position O (OFF) and secured with a lock
before performing maintenance inside the electrical cabinet.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
The use of a key or a tool is necessary to access to the electrical cabinet.
Make sure that the electrical cabinet doors are closed after working inside the
electrical cabinet. Doors with locks must be locked.
(Cont’d)
76 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Supply Systems
(Cont’d)
The location of each electrical cabinet is shown by an arrow.
Main machine
BFT
.
Socket Outlet
WARNING
Hazardous voltage.
Can shock, burn, or cause death.
Read the Maintenance Manual before using this socket outlet.
®
Doc. No. IM-3541839-0101 77 (224)
Supply Systems Safety Precautions
Valid for all countries except USA and Canada
The socket outlet (2) is connected to a residual current device (1) to protect users
against electrical shock if there is an earth fault in the connected equipment. The
residual current device must be tested each time before the socket outlet is being
used. See the Maintenance Manual for test procedure.
The illustrations show the socket outlet, the residual current device, and their
locations.
1 2
1 Residual current
device, A01F1022
2 Socket outlet,
A01X1020
.
78 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Supply Systems
Valid for USA and Canada
The socket outlet (1) has a built-in residual current device to protect users against
electrical shock if there is an earth fault in the connected equipment. The residual
current device must be tested each time before the socket outlet is being used. See
the Maintenance Manual for test procedure.
The illustration shows the socket outlet and its location.
1 Socket outlet,
A01X1020
.
®
Doc. No. IM-3541839-0101 79 (224)
Supply Systems Safety Precautions
Air Supply
WARNING
Compressed air and moving machinery.
Close the air supply valve and lock it, and safely release compressed air from the air
system before any work with the equipment that requires the air supply to be closed.
See the Machine Status section of the Procedure Start Table.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
Certain maintenance procedures may require air supply systems to be on. These
exceptions are clearly stated in the manuals.
The illustrations show the main air valve (1), the lock (2), and their location.
1 Main air valve
2 Lock
.
80 (224) Doc. No. IM-3541839-0101
®
Safety Precautions Supply Systems
Hotmelt Equipment
DANGERI
DANGER
Hazardous voltage.
The voltage is 400V inside the hotmelt unit. Risk of immediate danger to life through
electrical shock.
Never flush water or any other liquid towards the hotmelt unit when cleaning the
machine. Failure to obey will result in danger to your life.
WARNING
Risk of injuries.
All service work on the hotmelt unit must be carried out by authorized personnel.
Always wear safety glasses, protective gloves, and other protective clothing to avoid
injuries caused by splashing adhesive.
WARNING
Risk of injuries.
Never remove any part or component until air and the electrical supply to the
machine have been disconnected and the pressure of the adhesive in the system
has been relieved.
WARNING
Risk of burns.
Failure to relieve any remaining air or liquid (adhesive) pressure may cause serious
injuries from burning when the hotmelt filter is detached or flushed.
WARNING
Risk of burns.
During heating and production the unit gets hot. The hotmelt tank contains heated
adhesive which can cause serious injuries. Do not touch the adhesive.
CAUTION
Risk of burns.
During tank drainage never touch the drain shut.
.
(Cont’d)
®
Doc. No. IM-3541839-0101 81 (224)
Supply Systems Safety Precautions
(Cont’d)
WARNING
Burn hazard.
The hotmelt nozzles and their covers are very hot and there is risk of severe burns.
Never touch the hotmelt nozzles or their covers.
Note! The section Hotmelt Equipment in this manual only deals with what is
specific for this machine.
Always refer to the documentation provided from Nordson Corporation (included in
English in the delivery from Tetra Pak) before doing any kind of work on the hotmelt
equipment.
82 (224) Doc. No. IM-3541839-0101
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1 Technical Specification
®
Doc. No. IM-3541839-0101 83 (224)
1 Technical Specification
Description
This chapter describes the equipment’s technical specification and data. The
information is used during the planning and installation of the equipment.
84 (224) Doc. No. IM-3541839-0101
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1 Technical Specification Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.1 Installation Data and Specifications........................ 89
1.1.1 Installation Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1.1.1 TB/TBA/TPA/TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1.1.2 Bent Foil Treater (Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.1.1.3 Cooling Unit Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1.2 Installation Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.1.2.1 Straight Through (TB/TBA/TPA/TT) . . . . . . . . . . . . . . . . . . . . . 93
1.1.2.2 U-Discharge (TB/TBA/TPA/TT). . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.1.2.3 U-Infeed (TB/TBA/TPA/TT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.1.3 Site Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.1.3.1 Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.1.3.2 Ambient Relative Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1.3.3 Foundation Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1.3.3.1 Space Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1.3.3.2 Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1.4 Crates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1.4.1 Weight and Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.1.4.1.1 Main Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.1.4.1.2 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.1.4.2 Symbols and Markings on the Crate . . . . . . . . . . . . . . . . . . . . 98
1.2 Equipment Data ................................................. 99
1.2.1 Equipment Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2.1.1 Main Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2.1.2 Infeed and Discharge Conveyors . . . . . . . . . . . . . . . . . . . . . . . 99
1.2.1.3 Conveyor Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2.2 Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2.3 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2.4 Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2.4.1 Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2.4.2 Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2.5 Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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Doc. No. IM-3541839-0101 85 (224)
Table of Contents 1 Technical Specification
1.2.5.1 Main Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2.5.2 Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2.6 Hygiene Function Connection Data. . . . . . . . . . . . . . . . . . . . . . 101
1.2.6.1 Manual Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Product and Product Material Data and
Specifications .................................................. 102
1.3.1 Production Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.3.1.1 Hotmelt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.3.1.2 Drinking Straws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.3.2 Start Up Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.4 Utilities Specifications ........................................ 103
1.4.1 Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.4.2 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4.3 Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4.4 Electrical Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4.4.1 Main Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4.4.2 BFT (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.4.5 Precondition for the Mains Connection
Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.5 Tools, Materials and Consumables
Specifications .................................................. 108
1.5.1 Special Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.5.2 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.5.3 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.5.4 Packaging Material and Additional Material. . . . . . . . . . . . . 109
1.5.5 Lifting and Transportation Equipment and Lifting
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.5.5.1 Eyebolts and Eyelets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.5.5.2 Rotating Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.5.5.3 Lifting Ears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.5.5.4 Textile Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.5.5.5 Sling Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
86 (224) Doc. No. IM-3541839-0101
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1 Technical Specification Table of Contents
1.5.5.6 Lifting Shackles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.6 Mechanical Line Integration and Connection ........... 116
1.6.1 Infeed Conveyor Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
1.6.2 Discharge Conveyor Specification. . . . . . . . . . . . . . . . . . . . . . . .116
1.6.3 Line Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
1.7 Communication ................................................ 117
1.7.1 Signals with Line Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
1.7.1.1 From Line Controller to SA30 . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.7.1.2 From SA30 to Line Controller . . . . . . . . . . . . . . . . . . . . . . . . . 117
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Doc. No. IM-3541839-0101 87 (224)
Table of Contents 1 Technical Specification
This page intentionally left blank
88 (224) Doc. No. IM-3541839-0101
®
1.1 Installation Data and
1 Technical Specification Specifications
1.1 Installation Data and Specifications
1.1.1 Installation Drawings
Note! Conveyors and conveyor equipment are not included in the machine
configuration and must be ordered separately.
1.1.1.1 TB/TBA/TPA/TT
A = 909.5 mm E = 3528 mm I = 509 mm M = 2467 mm
B = 514.5 mm F = 41 mm J = 945 mm N = 2344 mm
C = 1446 mm G = 548 mm K = 205 mm O = 1179 mm
D =1960 mm H = 1599 mm L = 819 mm P = 942 mm
A
1 2 B
D
O
N
P
L
K K
J C
I
H
G
2
F
E
1 Cooling unit (variant)
2 Electrical power
connection
.
®
Doc. No. IM-3541839-0101 89 (224)
1.1 Installation Data and
Specifications 1 Technical Specification
1.1.1.2 Bent Foil Treater (Accessory)
A = 599 mm E = 399.5 mm H = 55.5 mm
B = 1288 mm F = 36.5 mm I = 330 mm
C = 118 mm G = 83 mm J = 365 mm
D = 573 mm
I H
G
1
E
2
J F
D A
B
C
1
1 Cable entry for
electrical supply
2 Adjustable footplate
.
90 (224) Doc. No. IM-3541839-0101
®
1.1 Installation Data and
1 Technical Specification Specifications
1.1.1.3 Cooling Unit Variant
A = 597 mm C = 415 mm
B = 375 mm
A B
Position of the cooling unit on the main machine:
D = 2467 mm
1
D
1 Cooling unit
.
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Doc. No. IM-3541839-0101 91 (224)
1.1 Installation Data and
Specifications 1 Technical Specification
1.1.2 Installation Space
A = 2808 mm I = 2646 mm N = 700
(max)
B = 3500 mm J = 925 mm O = R584
C = 1000 mm K = 5160 mm P = R559
(with BFT and SD)
D = 1600 mm K = 4620 mm Q = 1414 mm
(with SD)
E = 900 mm K = 4160 mm
(without BFT and SD)
F = 500 mm L = 200 mm
(without BFT)
G = R584 M = 200 mm
(max)
H = R630 N = 500
(min)
A
B
C D E
F G H
1 2 3
J
I
Q
N
O P
M
L
K
1 Straw magazine
2 Bent foil treater (BFT)
3 Straw detector (SD)
.
92 (224) Doc. No. IM-3541839-0101
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1.1 Installation Data and
1 Technical Specification Specifications
1.1.2.1 Straight Through (TB/TBA/TPA/TT)
D
C
F E A B
11 6 7 10
2 1 3 4 5 12
Note! Sensors must be placed on straight conveyor.
Sensors
Reference
Number designation Function Placement
1 V40B2070 Outfeed blocked A = 0.5 m
V40B2072
V40B2080
V40B2082
2 V90B2050 Queue discharge restart photocell To be placed directly on downstream DE
V90B2052 controlled conveyor
3 V40B2040 Speed B=1m
V40B2042
4 V40B2030 Overflow C = B+1.5
V40B2032
5 V10B2020 Start infeed conveyor To be placed directly on upstream DE
V10B2022 (variant) controlled conveyor
6 V90B2130 Queue second discharge restart To be placed directly on second
V90B2132 photocell downstream DE controlled conveyor
(variant)
7 V90B2140 Indication of selected discharge To be placed as indicator for gate to
(variant) second downstream conveyor
(Cont’d)
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Doc. No. IM-3541839-0101 93 (224)
1.1 Installation Data and
Specifications 1 Technical Specification
(Cont’d)
Conveyors
Reference
Number designation Status Description Nominal speed, 50 Hz
10 W40M1010 Mandatory Main conveyor Drive unit with
- PC23 Zero Gap asynchronous motor
F =4 m 39 m/min
G (with discharge conveyor) =2 m Drive unit with PM motor
G (without discharge conveyor, without 33 m/min
SD integrated) =3 m
G (without discharge conveyor, with SD
integrated) =6 m
Total maximum =13 m
Frequency converter W40T1010
(0.75 kW)
11 W90M1010 Variant Discharge conveyor 39 m/min, Speed (≥15000
- PC23 or PC23 Zero Gap packages/hour).
H (without SD integrated) ≥1 m 25 m/min, Flex (<15000
packages/hour).
H (with SD integrated) ≥4 m
Frequency converter W90T1010
(0.75 kW)
12 W10M1010 Variant Infeed conveyor
- PC23 or PC23 Zero Gap
Frequency converter W10T1010
(0.75 kW)
1.1.2.2 U-Discharge (TB/TBA/TPA/TT)
Measures and specifications for the U-discharge variant are the same as for the
straight through variant. See Section 1.1.2.1 Straight Through (TB/TBA/TPA/TT).
There is no minimum measures to consider for the U bend.
94 (224) Doc. No. IM-3541839-0101
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1.1 Installation Data and
1 Technical Specification Specifications
1.1.2.3 U-Infeed (TB/TBA/TPA/TT)
Measures and specifications for the U-infeed variant are the same as for the straight
through variant. See Section 1.1.2.1 Straight Through (TB/TBA/TPA/TT). There is no
minimum measures to consider for the U bend.
1.1.3 Site Environment
It is required that the site fulfils the following specification:
• Ambient temperatures and sufficient cooling according to the Ambient
Temperature table below.
• Ambient relative humidity according to the Ambient Relative Humidity table below.
• The ventilation can draw off any hotmelt vapours.
• Conveyor lubrication should be used according to Tetra Pak standards.
• Connections for electrical supply according to Section 1.4.4 Electrical Power
Supply.
• Connections for compressed air supply according to Section 1.4.3 Compressed
Air.
.
It is recommended that the site fulfils the following specifications:
• The site must accommodate transport of straws from storage to the machine.
• Sufficient lighting for work purposes.
• Hot and cold water should be available for cleaning the machine.
.
1.1.3.1 Ambient Temperature
Characteristic Value Reference
Minimum ambient 5 °C (41 °F) KA 2791.30-6.2.1
temperature
Maximum ambient 40 °C (104 °F).
temperature If the ambient temperature exceeds
30 °C (86 °F), a cooling system
(variant) is required for the electrical
cabinet.
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Doc. No. IM-3541839-0101 95 (224)
1.1 Installation Data and
Specifications 1 Technical Specification
1.1.3.2 Ambient Relative Humidity
Characteristic Value Reference
Minimum ambient 30%
relative humidity
Maximum ambient 50% at a maximum temperature of
relative humidity 40 °C. Higher relative humidity may
be permitted at lower temperatures
(e.g. 90% at 20 °C)
1.1.3.3 Foundation Work
1.1.3.3.1 Space Requirements
Measure and mark the designated position of the machine. For recommended
clearances around the machine.
The ceiling height must be at least 3000 mm.
Make sure that doors and passages are wide and high enough to pass with the
equipment.
1.1.3.3.2 Floor
To obtain a proper production it is necessary that the machine is standing stable on
the floor. It is important that the floor is in good condition.
The floor must have an angle of inclination of less than 4°.
<4°
.
1.1.4 Crates
The weights of the crates stated in the IM are only given as reference values. For
the actual weight of the crates, see the marking on the crates. The weights of the
crates are also stated in the packing list.
For a complete list of the crate content, see the packing list. For the location of the
packing list, see Procedure Unpacking the Crate.
(Cont’d)
96 (224) Doc. No. IM-3541839-0101
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1.1 Installation Data and
1 Technical Specification Specifications
(Cont’d)
• Crate Specifications
Gross Net
Crate weight weight Length Width Height
Identifier kg (lbs) kg (lbs) mm mm mm
Crate 1/2 7 500 6 150 6 000 2 390 2 865
Crate 2/2 2 200 1 650 3 300 2 390 1 650
.
• Crate Content
.
.
Crate Identifier Contents
Crate 2/2 Washer 315106-0178
Screw 312105-0541
Paper reel holder 440285-0100
Shim 458481-0003
Shim 458481-0002
Shim 458481-0001
Pump unit 3178511-0100
Bottom valve 3155725-0100
Strip (MPM) A885695101
Clamp 1524176
Checker plate 1524173
Pipe 269522
Cross bar 3162375-0000
Railing 2551951
Hook 1524174
Screw 312105-0622
Filler tube 551340-0000
Regular accessories 648639-0100
Personal protection 3220102-0000
Connection units 344253-0150
Tool kit Infinity 3199880-0100
Electrical materials 3199102-0100
Electrical materials 3199103-0101
Pipe 3157294-0000
Start up kit 322073-0100
Container H2O2 527898-0100
TPOP Line Supervision 3209798-0100
Cable 351422-0203
Diagram 3070193-0100
Bow clamp 3070194-0100
Installation drawing 3070195-0100
Accessories 3181843-0100
Electrical materials 3199101-0100
See the Packing List for further details.
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Doc. No. IM-3541839-0101 97 (224)
1.1 Installation Data and
Specifications 1 Technical Specification
1.1.4.1 Weight and Dimensions
1.1.4.1.1 Main Machine
Contents Weight Length Width Height
Crated machine 1375 kg* 3500 mm 1900 mm 2200 mm
(gross weight) (3031 lbs) (11 ft 6 in) (6 ft 3 in) (7 ft 3 in)
*) The crate weight will increase with approximately 35 kg (77 lbs) if cooling unit
(variant) is included.
1.1.4.1.2 Variants
BFT 2643050-0400
Contents Weight Length Width Height
Crated machine 120 kg 760 mm 630 mm 1450 mm
(gross weight) (265 lbs) (2 ft 6 in) (2 ft 1 in) (4 ft 9 in)
Cooling Unit 3424524-0100
Contents Weight Length Width Height
Crated cooling 38 kg 660 mm 440 mm 600 mm
unit (gross (83 lbs 12 oz) (2 ft 2 in) (1 ft 5 21/64 in) (1 ft 11 5/8 in)
weight)
1.1.4.2 Symbols and Markings on the Crate
Before starting to move or unpack the machine, make sure that everybody involved
understands the symbols and warnings. See Section Symbols and Warnings.
98 (224) Doc. No. IM-3541839-0101
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1 Technical Specification 1.2 Equipment Data
1.2 Equipment Data
1.2.1 Equipment Limitations
1.2.1.1 Main Conveyor
Make sure that the drive and end unit is correct and that the encoder is correct
depending on the drive and end unit that is selected. See the table.
Package Conveyor 23
Drive and End Unit Encoder
Motor below PM motor 3313606-0100 5-65 m/min 3413844-0100
Asynchronous 2807970-0300 39 m/min 3204325-0100
motor
Motor on top PM motor 3313607-0100 5-65 m/min 3413844-0100
Asynchronous 2763631-0300 39 m/min 3204325-0100
motor
1.2.1.2 Infeed and Discharge Conveyors
Note! Conveyors and conveyor equipment are not included in the machine
configuration and must be ordered separately.
Required conveyor make/model
Package Conveyor 23 or Package Conveyor chain length inside machine:
Conveyor 23 Zero Gap 6m
1.2.1.3 Conveyor Lubrication
This section is only valid for Tetra Pak conveyors in the production line, not for
conveyors inside the machine as the SA30 do not use conveyor lubrication.
Note! In order to have optimized line performance, it is very important that the
conveyor lubrication is set in accordance with the conveyor lubrication Technical
Manual (TeM).
1.2.2 Mass
Main Machine
Characteristic Value Note
Machine mass ≈825 kg (1819 lbs) net
Length 3500 mm (11 ft 6 in)
Width 1560 mm (5 ft 127/64 in)
Height 2391 mm (7 ft 10 in)
Variants
(Cont’d)
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Doc. No. IM-3541839-0101 99 (224)
1.2 Equipment Data 1 Technical Specification
(Cont’d)
BFT, 2643050-0400
Characteristic Value Note
Machine mass ≈113 kg (249 lbs) net
Length 573 mm (1 ft 109/16 in)
Width 599 mm (1 ft 1137/64 in)
Height 1288 mm (4 ft 245/64 in)
Cooling Unit, 3424524-0100
Characteristic Value Note
Machine mass ≈32 kg (71 lbs) The equipment requires a cooling
device for the electrical cabinet
Length 597 mm (1 ft 111/2 in)
when the ambient installation
Width 375 mm (1 ft 249/64 in) temperature exceeds 30 ºC
(86 ºF).
Height 415 mm (1 ft 411/32 in)
The electrical components and
the PLC must be cooled down
when running the machine in
environments warmer than
mentioned above.
Barcode Scanner, 3157213-0100
Characteristic Value Note
Machine mass ≈295 g (10.4 lbs) Cable length 1 m (3 ft 3 in)
Length 114 mm (431/64 in) extending to 2 m (6 ft 7 in).
Width 69 mm (223/32 in)
Height 207 mm (85/32 in)
1.2.3 Capacity
Packages per hour
4500 to 24000 packages/hour +25%
1.2.4 Consumption
1.2.4.1 Electrical Power
Characteristic Value Notes
Consumption 0.1 kW During IDLE.
2.8 kW ±5% During PREHEATING, including BFT.
1.5 kW ±5% During AIR ON, including BFT.
2.0 kW ±5% During PRODUCTION, including BFT,
(measured at 2000 packages per hour).
2.2 kW ±5% During PRODUCTION, including BFT,
(measured at 24000 packages per hour).
100 (224) Doc. No. IM-3541839-0101
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1 Technical Specification 1.2 Equipment Data
1.2.4.2 Compressed Air
Characteristic Value Notes
Consumption < 180 Nl/min During PRODUCTION (measured at
8 000 packages per hour).
< 385 Nl/min During PRODUCTION (measured at
24 000 packages per hour).
1.2.5 Noise
CAUTION
Hazardous noise.
Risk of impaired hearing.
Hearing protection is recommended whenever this equipment is in operation.
1.2.5.1 Main Machine
Noise level measurements at normal production speed, 24000 packages/hour.
Characteristic Value Notes
LpA: Measured A-weighted 69 dB(A) Values determined using the
Emission Sound Pressure Level basic standard ISO 11204
KpA: Uncertainty factor 2.5 dB(A) (Engineering method)
LWA 92 dB(A) Values determined using the
Measured A-weighted Sound basic standard ISO 3744
Power Level (Engineering method)
KWA 2.5 dB(A)
Uncertainty factor
Values declared in accordance with ISO 4871
1.2.5.2 Variant
BFT, 2643050-0400
Characteristic Value Notes
LpA: Measured A-weighted <70 dB(A) Values determined using the
Emission Sound Pressure Level basic standard ISO 11204
KpA: Uncertainty factor 5 dB(A) (Engineering method)
Values declared in accordance with ISO 4871
Cooling Unit, 3424524-0100
Characteristic Value Notes
LpA: Measured A-weighted 60 dB(A) Values determined using the
Emission Sound Pressure Level basic standard ISO 11204
(Engineering method)
Values declared in accordance with ISO 4871
1.2.6 Hygiene Function Connection Data
1.2.6.1 Manual Cleaning
Hot and cold water must be available for cleaning the machine. For information on
the cleaning, see Chapter Care and Cleaning in the OM.
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Doc. No. IM-3541839-0101 101 (224)
1.3 Product and Product Material Data
and Specifications 1 Technical Specification
1.3 Product and Product Material Data and
Specifications
1.3.1 Production Material
The following material is needed during production.
1.3.1.1 Hotmelt
Characteristic Note
Recommended storage 10 °C to 30 °C (50 °F to 86 °F)
temperature
Recommended storage Up to 55%
humidity
Special recommendations The hotmelt can be stored for a maximum of one
year. Avoid dust and damp in the storage facility.
The first box in should be the first box out.
Required Hotmelt See Chapter 10 Technical Data in the Operation
Manual (OM) for required hotmelt types.
Consumption Hotmelt Approximately 40 g / 1 000 straws
1.3.1.2 Drinking Straws
Characteristic Note
Supply The straws are wrapped in plastic film and joined
to a ladder band, like cartridges in a cartridge belt.
The ladder bands are packed in boxes. The
boxes are delivered on pallets.
The first box in has be the first box out.
Recommended storage 10 °C to 30 °C (50 °F to 86 °F)
temperature
Recommended storage Up to 65%
humidity
Special recommendations The boxes are to be stored indoors under dry
conditions and lying on the flat side. Never put a
box directly on the floor, and never stack pallets
on the top of each other.
1.3.2 Start Up Material
The following material is needed during start up of the equipment. A start-up kit is
included with the delivery.
Characteristic Note
Hotmelt See Chapter 10 Technical Data in the Operation
Manual (OM) for required hotmelt types.
Drinking straws See Section 1.3.1.2 Drinking Straws.
.
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1 Technical Specification 1.4 Utilities Specifications
1.4 Utilities Specifications
For information on utility consumption, see Section 1.2.4 Consumption. For
information on utility connections, see Section 3.3.1 Utility Connections.
1.4.1 Water Supply
If pressurised water is used when cleaning the machine, confirm that the water
pressure conforms to the values in the table.
Note! It is recommended to use a soft brush or cloth to clean the machine.
Characteristic Value Notes
Water quality Drinking water See Section Water Quality.
Maximum pressure 350 kPa (3.5 bar) Water pressure when cleaning the
machine.
CAUTION
Risk of damage to the equipment.
Deposits due to water of inferior quality circulating in the plant can cause malfunction
of vital parts. The hardness of the water used in the plant must conform to the
recommended value.
Water Quality
In order to ensure good equipment operation and cleanliness, as a minimum, use a
supply of water to the equipment with drinking water quality. This applies to water
used for cooling, product flushing, rinsing and cleaning. A definition and description
of drinking water may be found in the documents listed in the table.
Term Definition According to Geographic Area and Document(s)
Drinking EEA/EU:
water COUNCIL DIRECTIVE 98/83/EC
USA:
FDA Title 40 Code of Federal Regulations - CFR Part 141, 142
and 143.
All Countries except USA and EU/EEA:
WHO Guidelines for Drinking Water Quality
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Doc. No. IM-3541839-0101 103 (224)
1.4 Utilities Specifications 1 Technical Specification
1.4.2 Steam
Characteristic Value Notes
Water quality Drinking water See Section
Water Quality
Boiler additive According to
quality CFR Part
173.310 Boiler
water additives.
FDA title 21
Code of Federal
Regulations, Title
21 Tannin is
frequently added
to boiler water to
facilitate sludge
removal during
boiler blow down.
This product,
although
included in the
list of approved
boiler additives,
has been
reported to give
rise to odour
problems. For
this reason
Tannin must be
used with
caution.
1.4.3 Compressed Air
Characteristic Value Notes
Air quality Class ISO 2.4.1 According to ISO 8573-1
Maximum 50 μm
particle size
Supply pressure 0.63 to 1.0 MPa
(6.3 to 10 bar)
Connection point Dimension 1/2”
Connection G 1/2" internal
thread
1.4.4 Electrical Power Supply
1.4.4.1 Main Machine
The table below specifies the electrical characteristics for the equipment at the
connection point. The Tetra Pak equipment fulfils generic immunity requirements of
EN 61000-6-2 concerning surge protection.
(Cont’d)
104 (224) Doc. No. IM-3541839-0101
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1 Technical Specification 1.4 Utilities Specifications
(Cont’d)
Characteristic Value Notes
Supply voltage 400/230 VAC ±10%
Phase 3/N/PE Three-phase, five-wire system with a separate neutral
and protective conductor.
Frequency 50 or 60 Hz ±1% See the electrical equipment marking on the electrical
cabinet.
Full-load current value 7.3 A
Full-load power consumption 2.8 kW Machine step PREHEATING
Power factor 0.93 Machine step PREHEATING
Short-circuit breaking capacity: See the electrical equipment marking on the electrical
Other Countries 25 kA cabinet.
USA and Canada 10 kA
Type of machine protection device Supply Equipped with overload and short circuit current
disconnecting protection.
device
Overload setting of supply 16 A
disconnecting device in machine
Short circuit setting (magnetic 350 A Fixed setting, not adjustable.
release) of supply disconnecting
device
Recommended short-circuit 20 A MCB type C For preconditions of the calculation of the overcurrent
protective device for the supply or 20 A fuse type protective device, see Section 1.4.5 Precondition for
cable gG the Mains Connection Calculation.
Recommended supply cable, 4 mm2 For information concerning maximum cable length,
minimum cross-sectional area voltage drop, and if a matching transformer is used,
see Section 1.4.5 Precondition for the Mains
Connection Calculation.
Recommended cable type for supply 4/4 mm2 If a matching transformer is used, see Section 1.4.5
cable 5 core Cu Precondition for the Mains Connection Calculation.
PVC insulation
Connectable area of the supply 2.5-16 mm2
terminals
Cable diameter to fit cable gland 11-21 mm2
Earth leakage current Depending on actual site conditions, the actual earth
leakage current value may differ considerably from
the stated value.
Information not available in this edition.
1.4.4.2 BFT (Variant)
The table below specifies the electrical characteristics for the equipment at the
connection point. The Tetra Pak equipment fulfils generic immunity requirements of
EN 61000-6-2 concerning surge protection.
BFT, 2643050-0400
Characteristic Value Notes
Supply voltage 230 VAC ±10%
Phase 1/N/PE One-phase, three-wire system with a separate neutral
and protective conductor.
(Cont’d)
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Doc. No. IM-3541839-0101 105 (224)
1.4 Utilities Specifications 1 Technical Specification
(Cont’d)
BFT, 2643050-0400
Characteristic Value Notes
Frequency 50 or 60 Hz ±1% See the electrical equipment marking on the electrical
cabinet.
Full-load current value 2.5 A
Full-load power consumption 0.6 kW Machine step PREHEATING.
Power factor 1.00 Machine step PREHEATING.
Short-circuit breaking capacity: See the electrical equipment marking on the electrical
Other Countries 15 kA cabinet.
USA and Canada 5 kA
Maximum permissible supply source 1000 mΩ
impedance
Type of machine protection device Supply Regularly connected to Straw Applicator 30.
disconnecting
device, without
overload and short
circuit current
protection
Overload setting of supply NA Regularly connected to Straw Applicator 30.
disconnecting device in machine
Short circuit setting (magnetic NA Regularly connected to Straw Applicator 30.
release) of supply disconnecting
device
Recommended short-circuit NA Regularly connected to Straw Applicator 30.
protective device for the supply
cable
Recommended supply cable, NA Regularly connected to Straw Applicator 30.
minimum cross-sectional area
Recommended cable type for supply NA Regularly connected to Straw Applicator 30 with fixed
cable cable olflex 3x2, 5 mm2.
Connectable area of the supply NA Regularly connected to Straw Applicator 30 with fixed
terminals cable. Connectable area, maximum 6 mm2.
Cable diameter to fit cable gland NA Regularly connected to Straw Applicator 30 with fixed
cable. Cable diameter to fit gland 7-13 mm.
Earth leakage current 2 mA Depending on actual site conditions, the actual earth
leakage current value may differ considerably from
the stated value.
1.4.5 Precondition for the Mains Connection
Calculation
Note! Local and national regulations must be followed. Tetra Pak only gives a
recommendation. For more detailed information see the Electrical Manual.
Cable areas in this recommendation are dimensioned according to the IEC 60364-
series (mainly IEC 60364-4-43 and IEC 60364-5-52), however, the national
regulations in each country must still be followed.
The Tetra Pak Group provides recommendations, however, the Tetra Pak Group is
not responsible for the dimensioning at installation. This implies that the installer
must review and abide by the local demands.
(Cont’d)
106 (224) Doc. No. IM-3541839-0101
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1 Technical Specification 1.4 Utilities Specifications
(Cont’d)
The mains connection calculation is based on the following preconditions:
Characteristic Value Notes
Supply impedance at supply connection 30 mΩ
point for cable supplying machine or
matching transformer
Voltage drop between the supply point for 2.85%
cable supplying machine and the machine
itself
Size of matching transformer Information not available in this edition.
Matching transformer Information not available in this edition.
impedance (Uk)
Matching transformer secondary Information not available in this edition.
impedance
Ambient temperature 40 °C
Installation method Nine or more cables without spacing in one
layer on one ladder in free air.
Type of protective device(s) Information not available in this edition.
Purpose of the protective device(s) Information not available in this edition.
Variant
BFT, 2643050-0400
Characteristic Value Notes
Supply impedance at supply connection NA Regularly connected to Straw Applicator 30.
point for cable supplying machine or
matching transformer
Voltage drop between the supply point for NA Regularly connected to Straw Applicator 30.
cable supplying machine and the machine
itself
Size of matching transformer Information not available in this edition.
Matching transformer Information not available in this edition.
impedance (Uk)
Matching transformer secondary Information not available in this edition.
impedance
Ambient temperature 40 °C Regularly connected to Straw Applicator 30.
Installation method NA Nine or more cables without spacing in one
layer on one ladder in free air.
Type of protective device(s) Information not available in this edition.
Purpose of the protective device(s) Information not available in this edition.
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Doc. No. IM-3541839-0101 107 (224)
1.5 Tools, Materials and Consumables
Specifications 1 Technical Specification
1.5 Tools, Materials and Consumables
Specifications
1.5.1 Special Tools and Equipment
The following tools and materials are needed to move and install the equipment:
Characteristic TP No. Note
Step ladder 2 m (7 ft.)
Spirit level 90243-0163 3.2.3 Levelling
90243-0165
Pneumatic or electrical
powered wrench
Crowbar or strong lever
Safety lashings Used when moving the
uncrated equipment.
Frequency meter Used for checking the timing
belt tension. See Section
Frame Housing in the MM.
Portable PC with a CD-ROM
drive
RS Logix version 20 software
.
1.5.2 Consumables
For information on lubricants and cleaning compounds, See Section 12.3
Consumables in the Maintenance Manual (MM).
1.5.3 Materials
The following materials are needed to move and install the equipment:
Characteristic TP No. Note
Cable ties 352113-0101 to 0106
.
108 (224) Doc. No. IM-3541839-0101
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1.5 Tools, Materials and Consumables
1 Technical Specification Specifications
1.5.4 Packaging Material and Additional Material
1.5.5 Lifting and Transportation Equipment and Lifting
Accessories
All third-party lifting and transportation equipment used must be in compliance with
the local regulations as well as being marked, maintained, checked, and inspected
according to the individual supplier's requirements. The instructions for use,
assembly, inspection, and maintenance in the official language for the individual
equipment must be available at the place of use. Any lifting equipment not in
compliance with the above is prohibited to use.
The following types of equipment can be used to lift and move the crate and the
uncrated equipment:
• fork-lift truck (1)
• pallet truck (2)
• textile slings (3)
Also use appropriate hand tools to open the crate, such as crow bar, hammer, and
socket wrench.
1 2 3
1 Fork-lift truck
2 Pallet truck
3 Textile slings
Specifications and Capacity
Lifting
capacity
Equipment kg (lbs) Quantity Note When Used
Fork-lift truck 1 600 1 Pallet forks must be at least as long Crate Handling
(3 530) as the crate is wide. If necessary,
use fork extensions.
Fork-lift truck or pallet 1 000 1 Pallet forks must be at least as long Positioning and
truck (2 200) as the machine is wide. If necessary, Assembly
use fork extensions.
Overhead gantry, 100 To be used when lifting Cooling unit Cooling Unit - Assemble
mobile crane, or fork-lift (220) (Variant)
truck
Textile slings 50 2 To be used when lifting Cooling unit Cooling Unit - Assemble
(100) (Variant)
(Cont’d)
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Doc. No. IM-3541839-0101 109 (224)
1.5 Tools, Materials and Consumables
Specifications 1 Technical Specification
(Cont’d)
Make sure that the lifting capacities of the equipment are sufficient for the load. For
information about gross weight and net weight, see Section Crates and Section
Mass.
Always follow the instructions from the manufacturer of the lifting equipment.
1.5.5.1 Eyebolts and Eyelets
Eyebolts/eyelets shall only be selected and fitted by trained personnel. The trained
person shall inspect the eyebolt/eyelet before fitting and verify that the
eyebolt/eyelet thread and the tapped (threaded) hole are free from debris and are
compatible. The contact surface around the tapped hole should be smooth, clean,
flat, perpendicular to the thread axis, and large enough to fit the eyebolt/eyelet.
There shall be no distortion of the eyebolt/eyelet, that is bent shank, deformed eye,
reduced diameter at the undercut, nor should any damage, that is nicks, cracks,
gouges or corrosion, be present.
The marking of the eyebolt/eyelet shall be legible. The following minimum markings
are required:
• nominal diameter of thread
• material quality
• traceability code
Additional marking requirements on eyebolts put on market after 1995 are:
• manufacturer’s identification mark or symbol
• axial working load limit in general service
Eyebolts/eyelets shall be regularly inspected. If any doubt exists as to the fitness for
use, or if any of the required markings have been lost or become illegible, the
eyebolt/eyelet shall be scrapped and replaced by new eyebolts/eyelets.
Eyebolts/eyelets shall be firmly screwed down without overtightening. When
screwing eyebolts/eyelets into blind holes, it is important to ensure that the collar of
the eyebolt/eyelet is fully seated before the eyebolt/eyelet thread reaches the
bottom of the tapped hole.
1.5.5.2 Rotating Lifting Points
The rotating lifting points shall be checked prior to each use regarding bolt
torque, wear, cracks, damaged parts, deformations, and corrosion. If any defect
that could jeopardise safety is detected, the rotating lifting point must be
adjusted, renewed, or thoroughly examined.
At least once a year thorough examination shall be carried out. Load bearing parts
shall be checked thoroughly for wear, cracks, damaged parts, deformations, and
corrosion. Wear must not exceed 10% of original dimensions. If excessive wear,
cracks, damaged parts, deformations, severe corrosion occur, or if any of the
required markings have been lost or become illegible (see below) the rotating lifting
point shall be scrapped.
The marking of the rotating lifting points shall be legible. The following minimum
markings are required:
(Cont’d)
110 (224) Doc. No. IM-3541839-0101
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1.5 Tools, Materials and Consumables
1 Technical Specification Specifications
(Cont’d)
• manufacturer’s identification mark or symbol
• required torque when assembled
• nominal diameter of thread
• traceability code
• working load limit
• CE mark (if in the EEA)
1.5.5.3 Lifting Ears
No deformations or cracks in the welds or any other visible deformations
or significant corrosion are allowed. The maximum wear at the holes in the ears or
lugs shall fulfill the following demands. A hole with a diameter up to 50 mm has an
accepted wear of 1 mm, and diameters above 50 mm have an accepted wear of 2
mm.
The marking of the lifting ears shall be legible. The following minimum markings are
required:
• working load limits
• traceability
• manufacturer’s identification mark or symbol
1.5.5.4 Textile Slings
Before each use of the sling, it shall be inspected for defects and to ensure that the
identification and specification are correct. During the sling's lifetime, frequent
checks according to the suppliers recommendations shall be made for defects or
damage, including damage concealed by soiling, which might affect the sling. These
checks shall extend to any fittings and lifting accessories used in association with the
sling. If any doubt exists as to the fitness for use, or if any of the required markings
have been lost or become illegible (see below) the sling shall be removed from
service for examination by a competent person.
The following are examples of defects or damage likely to affect the fitness of slings
for continued safe use:
• surface chafe in normal use. Chafing in surface fibres has little effect. Substantial
chafe, particularly localised, shall be viewed critically. Local abrasion caused by
sharp edges, whilst the sling is under tension, can cause serious loss of strength
• cross or longitudinal cuts, cuts or chafe damage, cuts to stitching or eyes.
Chemical attack results in local weakening and softening of the material. This is
indicated by flaking of the surface.
• heat or friction damage which is indicated by the fibres taking on a glazed
appearance and in extreme cases, fusion of the fibres can occur
• damaged or deformed fittings
The marking of the textile slings shall be legible. The following minimum markings
are required:
• working load limit, in straight lift
(Cont’d)
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Doc. No. IM-3541839-0101 111 (224)
1.5 Tools, Materials and Consumables
Specifications 1 Technical Specification
(Cont’d)
• textile material used
• grade number
• nominal length in meters
• manufacturer’s identification mark or symbol
• traceability code
• CE mark (if in the EEA)
1.5.5.5 Sling Chains
Sling chains consists of
• short link chain for lifting purposes
• master links and mechanical connectors
• hooks for sling chain assemblies
It is necessary during service of the short link chains to ensure, as far as is
reasonably practicable, that the short link chain is safe for continued use.
The examination shall be carried out by a competent person at intervals not
exceeding 12 months.
The short link chain shall be withdrawn from service and referred to a
competent person for thorough examination if any of the following are observed:
• illegible sling chain markings, see the minimum requirements below
• distortion of the upper or lower terminals
• chain stretch. If the chain links are elongated or if there is any lack of free
articulation between the links or noticeable difference in the leg length of multi-leg
chain slings, the chain may have been stretched.
• wear by contact with other objects. This usually occurs on the outside of the
straight portions of the links where it is easily seen and measured. Wear between
adjoining links is hidden. The chain shall be slack and adjoining links rotated to
expose the inner end of each link. Inter-link wear, as measured by taking the
diameter indicated (d1) and one at right angles, (d2) may be tolerated until the
mean of these diameters has been reduced to 90% of the nominal diameter (dn).
(d1 + d2)/2 > 0,9 dn.
The following minimum markings are required:
• working load limit, in straight lift
• CE mark (if in the EEA)
• manufacturer’s identification mark or symbol of assembler
• grade, all components must have the same grade
• working load limit, at a specific angle or several configurations
• chain size
• serial number or type
• number of parts (legs)
• length of unloaded accessory
(Cont’d)
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1.5 Tools, Materials and Consumables
1 Technical Specification Specifications
(Cont’d)
The marking of each link or master link shall be legible. The following minimum
markings are required:
• manufacturer’s product code
• grade number
• manufacturer’s identification mark or symbol
• traceability code
The marking of the hooks shall be legible. The following minimum markings are
required:
• manufacturer’s product code
• grade number
• manufacturer’s identification mark or symbol
• traceability code
When the opening of the hook is deformed more than 10%, or worn out more than
5%, it must be replaced. The same applies if the hook has got deep notches. The
permissible maximum wear at the connecting bolt is usually 10% of the diameter.
It is not allowed to bend the hook. It is important that the load is correctly attached in
the seat of the hook and tip loading of the hook is be avoided.
When chain slings are used in a choke hitch, each chain sling should be allowed to
assume its natural angle when the chain sling is positioned in the hook gap. The
working load limit must be reduced by 20%.
1.5.5.6 Lifting Shackles
DANGERI
DANGER
Risk of death or serious injury.
Always follow the instructions from the manufacturer of the lifting equipment.
Shackles in use should be subject to periodic thorough examination by a competent
person. The period between such examinations will depend upon the amount of use,
but should not exceed six months. The list below provides general inspection
requirements for shackles which should be checked before use and before putting
into storage.
• Inspect the shackle eye and pin holes for stretching (elongation) and wear.
Elongation indicates that the shackle has been overloaded.
• Inspect the shackle body for bending. A bent shackle indicates excessive side-
loading.
• Inspect all shackle pins for distortion, surface blemishes, wear and fractures.
• All pins must be straight and all screw pins must be completely seated. Cotter pins
must be used with all round pin shackles.
• Replace shackles that are bent, show excessive wear by more than 10% of the
original diameter, or have an elongated eye or shackle pin holes.
(Cont’d)
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Doc. No. IM-3541839-0101 113 (224)
1.5 Tools, Materials and Consumables
Specifications 1 Technical Specification
(Cont’d)
The illustration below shows the lifting shackle's critical points for wear and damage.
A
Distance A: Check that
the shackle is not
"opening up".
1 Check for wear
2 Check for wear and
straightness
3 Check that the pin is
always seated
.
Check the correct alignment of the shackle with the line of loading. See the
illustration below.
Example of correct lifting shackle usage (left) and incorrect lifting shackle usage (right).
.
(Cont’d)
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1.5 Tools, Materials and Consumables
1 Technical Specification Specifications
(Cont’d)
The marking of the lifting shackles shall be legible. The following minimum markings
are required:
• working load limit
• grade number
• manufacturer's identification mark or symbol
• traceability code
.
Marking on shackles put on the market before 1995 are:
• safe working load or working load limit
• manufacturer's identification mark or symbol
• traceability code
.
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Doc. No. IM-3541839-0101 115 (224)
1.6 Mechanical Line Integration and
Connection 1 Technical Specification
1.6 Mechanical Line Integration and
Connection
Note! In order to have optimized line performance it is very important that the
conveyor lubrication is set in accordance with the Technical Manual for the
conveyor.
For information about included conveyor parts, see Section 1.2.1.2 Infeed and
Discharge Conveyors.
1.6.1 Infeed Conveyor Specification
Characteristic Value Note
Conveyor model Package Main conveyor is inside the machine- PC23 Zero Gap.
Conveyor 23 See 1.2.1.2 Infeed and Discharge Conveyors.
Infeed height is
825 ±50 mm
Conveyor length - See Section 1.1.2 Installation Space for recommended length before curve
or transition.
See the PIM for the conveyor.
1.6.2 Discharge Conveyor Specification
Characteristic Value Note
Conveyor model Package Main conveyor is inside the machine - PC23 Zero Gap
Conveyor 23 See 1.2.1.2 Infeed and Discharge Conveyors.
Discharge height
is 825 ±50 mm
Conveyor length - See Section 1.1.2 Installation Space for recommended length before curve
or transition.
See the PIM for the conveyor.
1.6.3 Line Connection
See the following sections.
• For connection points: 1.1.1 Installation Drawings
• For infeed connection: 1.1.1.1 TB/TBA/TPA/TT
• For discharge connection: 1.1.1.1 TB/TBA/TPA/TT
• For software connection: 1.7.1 Signals with Line Controller
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1 Technical Specification 1.7 Communication
1.7 Communication
1.7.1 Signals with Line Controller
This section refers to the signal exchange between the line controller (LC) and the
Straw Applicator 30, when the machine runs towards a line controller.
1.7.1.1 From Line Controller to SA30
Signal Machine State and Conditions
Start production SA30 starts producing. The infeed conveyor starts running.
Stop immediate LC detected that a machine downstream from the SA30 stopped. The SA30
stops discharging trays immediately, but continues to take in packages until
the machine is full.
Normal stop A machine upstream from the SA30 stopped. The SA30 remains active until
it has received the fed out packages from the upstreams machine.
End production The SA30 performs an End of Production procedure.
Cleaning Starts a cleaning procedure.
Reset package counters SA30 resets LC package counters.
Command outfeed capacity Nominal capacity for theSA30, if not in speed mode.
Max allowed capacity Capacity for the SA30 should use when in speed mode.
1.7.1.2 From SA30 to Line Controller
Signal Machine State and Conditions
Blocked SA30 stopped due to a fault.
Blocking SA30 has a fault that will eventually stop the machine, but the machine is
still in Receive and/or Deliver.
Preparation SA30 is powered and is running the preparation procedure, but is not ready
to receive a start command and can not accept incoming packages.
Ready for production SA30 is ready to start, and waits for a start signal from the LC. The infeed
and normally also the discharge conveyor stopped. The SA30 does not
accept nor deliver any packages.
Receive The machine is waiting to receive or receiving packages but not delivering.
Receive and deliver SA30 delivers trays and can also receive or is receiving packages from an
upstream machine.
Deliver SA30 is in production and is delivering packages but can not receive any
packages.
Overflow SA30 is in overflow on the infeed section.
End production concluded The machine received End production command, and has finished to deliver
packages (i.e. less than one packing pattern of unprocessed packages are
inside the machine).
Normal stop concluded The machine received a Normal Stop and finished to deliver packages (i.e.
emptied all sections that can be emptied without running end production).
Not connected The bit is on when the Line Controller control commands are bypassed in
the Equipment (by a function in the TPOP).
Material request Need to refill material: hotmelt, cardboard or lubrication oil.
Max capacity The machines maximum capacity.
Actual capacity outfeed The speed that SA30 uses out of the two available.
(Cont’d)
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1.7 Communication 1 Technical Specification
(Cont’d)
Signal Machine State and Conditions
Packages in Number of packages counted in (different from PLMS counters).
Packages out Number of packages counted out (different from PLMS counters).
Recipe list The list of recipes in the SA30, together with the maximum capacity for each
recipe.
Machine number Sends the machine number to the LC.
Machine development step Sends the development step to the LC.
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2 Preparations
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Doc. No. IM-3541839-0101 119 (224)
2 Preparations
Description
This chapter describes preparatory requirements and recommendations to ensure a
good installation. Its purpose is to help the installation technicians and other
involved in the installation project to quickly locate information about the site
preparation, including requirements for utility, space, tools, and other required
installation equipment, and specific construction details.
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2 Preparations Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.1 Planning Preparation.......................................... 123
2.2 Ensure Site Preparation ...................................... 124
2.3 Prepare Customer ............................................. 125
2.3.1 Special Practices and Procedures . . . . . . . . . . . . . . . . . . . . . . . 126
2.3.2 Tools, Materials and Consumables . . . . . . . . . . . . . . . . . . . . . . 126
2.3.2.1 During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.3.2.2 During Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.3.2.3 During Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.4 Prepare Site ..................................................... 128
2.4.1 Building Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.4.2 Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.4.2.1 Main Compressed Air Supply Line . . . . . . . . . . . . . . . . . . . . 129
2.5 Prepare Tetra Pak .............................................. 130
2.5.1 Special Practices and Procedures . . . . . . . . . . . . . . . . . . . . . . . 130
2.5.1.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.5.1.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.5.1.3 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.5.2 Tools, Materials and Consumables . . . . . . . . . . . . . . . . . . . . . . 130
2.5.2.1 During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.5.2.2 During Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.5.2.3 During Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.5.3 Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.6 Check and Store Goods ...................................... 132
2.6.1 Goods Reception . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.6.1.1 Lifting and Unloading the Crated Equipment. . . . . . . . . . . 132
2.6.1.2 Moving the Crated Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.6.1-1 Delivery Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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2 Preparations
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122 (224) Doc. No. IM-3541839-0101
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2 Preparations 2.1 Planning Preparation
2.1 Planning Preparation
Ensure that the Installation Preparation form (PD-ID 2-1366) available in Tetra Pak®
Process Centre is fulfilled.
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Doc. No. IM-3541839-0101 123 (224)
2.2 Ensure Site Preparation 2 Preparations
2.2 Ensure Site Preparation
Ensure that Tetra Pak® personnel and customer personnel are familiar with the
structure and content in this IM.
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2 Preparations 2.3 Prepare Customer
2.3 Prepare Customer
Tetra Pak® Maintenance System (TPMS)
To ensure uninterrupted production, it is strongly recommended to use TPMS
(Tetra Pak Maintenance System) provided by the Tetra Pak Group. TPMS is the
maintenance system for Tetra Pak® packaging solutions to support system
performance.
The overall scope includes:
Process
The Maintenance Process describes in six steps how Maintenance should be
handled by the Tetra Pak Group and our Customers
a) Create Maintenance Recommendations - Documenting the individual tasks that
must be performed
b) Configure Line Maintenance - Consolidating the tasks need for a particular
packaging line configuration
c) Generate Maintenance Event - Generating the exact tasks for a particular
packaging line at a particular time
d) Plan/Schedule Maintenance Event - Agreeing on the start date and the duration
for a particular maintenance occasion
e) Perform Maintenance Event & Feedback - Carrying out the physical
maintenance and feeding back the results to the TPMS
f) Analyse Feedback - the Tetra Pak Group uses the feedback to correct and
update global maintenance tasks
Steps a) to c) are carried out by the Tetra Pak Group based on Tetra Pak Group and
Customer inputs. Steps d) to f) are carried out by both the Tetra Pak Group and the
Customer, together or separate.
Customers using the Tetra Pak® planned maintenance system receive checklists
from their local Tetra Pak® office whenever planned maintenance is due. These
checklists are individualised for each of Tetra Pak’s customers, according to the type
of machine, equipment usage, and maintenance occasion. In addition, the system
recommends spare parts, maintenance units, tools, and templates according to the
statistics collected.
Methodology
A reliability centred maintenance approach is built on Failure Mode Effect &
Criticality Analysis (FMECA) resulting in a mix of condition based, predetermined,
and corrective maintenance tactics.
Competence
These are the skills and competencies required to set the overall strategy,
establish the maintenance recommendations, administer the process, and to
perform the physical work. If needed, depending on the sales agreement, make sure
that customer personnel take part in TPMS training.
Tools
(Cont’d)
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Doc. No. IM-3541839-0101 125 (224)
2.3 Prepare Customer 2 Preparations
(Cont’d)
• TPMS On-Line - The global web based maintenance application
provides seamless end-to-end flow of information to facilitate improvements
• Capturing of all maintenance data performed by the Tetra Pak Group and the
Customer
• Analysis of facts consolidated in a global database for continuous improvement
• Maintenance Recommendations - When and which activities to be performed
• Maintenance & Operation Manual - How to perform the activities.
2.3.1 Special Practices and Procedures
Make sure that the premises are in compliance with the Good Manufacturing
Practices (GMPs). The Good Manufacturing Practices are guidelines (and to some
extent in some countries regulations) used by food processing and packaging
facilities.
Below are some examples of GMPs:
• Keep facilities clean and in good repair.
• Use well constructed trash receptacles and keep them clean and in good repair.
• Provide adequate ventilation to minimise odours and vapours.
• Identify toxic cleaning compounds and sanitation agents and store them carefully,
so that they cannot contaminate product, product-contact surfaces, or packaging
materials.
• Clean and decontaminate all product-contact surfaces regularly. See the
Operation Manual for information about cleaning procedures.
• Also the non-product contact surfaces should be clean. Clean as needed to
protect against contamination of product.
• Make sure that sewage and liquid waste are drained from the product processing
and packaging areas.
• Provide adequate floor drainage for water, cleaning solutions, and product that is
released onto the floor.
• Sewers and drains must be accessible for cleaning. Drains should never be
located directly underneath the packaging machine.
• Provide convenient hand washing facilities with warm running water.
• Provide properly designed heating, venting, and air conditioning (HVAC) systems
to reduce the risk of airborne contamination.
• Provide proper personal hygiene apparel as described in your facility’s GMPs
and operating and safety procedures.
2.3.2 Tools, Materials and Consumables
See also 1.5 Tools, Materials and Consumables Specifications.
2.3.2.1 During Installation
See Section Tools.
• Spirit lever
(Cont’d)
126 (224) Doc. No. IM-3541839-0101
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2 Preparations 2.3 Prepare Customer
(Cont’d)
• Step ladder
• Pneumatic or electric powered wrench.
• Frequency meter.
2.3.2.2 During Start-up
See Section Tools and Production Material.
2.3.2.3 During Production
• Hotmelt, see Section Hotmelt.
• Drinking straws, see Section Drinking Straws.
For information on lubricants and cleaning compounds, see Chapter 10 Technical
Data in the OM.
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Doc. No. IM-3541839-0101 127 (224)
2.4 Prepare Site 2 Preparations
2.4 Prepare Site
This section describes important construction details of the premises. Always make
sure that the premises is in compliance with the Good Manufacturing Practices.
The choice of installation site largely depends on local operating conditions. The
decision should be made in co-operation with the local Tetra Pak Company.
It is recommended that Tetra Pak technical consulting services is involved during the
planning stages. This ensures that all necessary changes to the building and plant
layout are identified as early as possible.
For machine dimensions, space requirements, and ground load, see chapter 1
Technical Specification.
For machine dimensions, space requirements, and ground load, see chapter
Technical Specification in the IM.
See document QAM-588013-01XX Guidelines for the Hygienic Production of Liquid
Food – Site & Building Recommendations.
2.4.1 Building Requirements
See QAM-588013-010X Guidelines for the Hygienic Production of Liquid Food –
Site & Building Recommendations for recommendations regarding the following:
• Design for sanitations
• Floors
• Drains and gutters
• Walls
• Ceiling
• Pipe support system
• Doorways
• Lighting
• Associated equipment
• Water supply
• Chemical storage
• Sewage and liquid waste
• Waste
• Sanitary waste
• Hand washing facilities
• Toilets
2.4.2 Utilities
See QAM-588013-0102 Guidelines for the Hygienic Production of Liquid Food - Site
& Building Recommendations for recommendations regarding utilities.
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2 Preparations 2.4 Prepare Site
2.4.2.1 Main Compressed Air Supply Line
The main air supply line should be in the form of a ring which runs through the
premises; this will allow the users of air to receive it from two directions (see
illustration).
There should be a drop of 5 to 10 mm per metre in the flow direction. Underneath the
lowest point in the ring, a condensate drain cock (3) is to be fitted.
The output connections (2) to the users should be fitted on the topside of the main
line piping; this will keep condensation and dirt from following the air into the user
device.
There should also be a pressure gauge (5) to make it possible to check that correct
air pressure is maintained.
3
4
1 Shut-off valve
2 Output connection
3 Condensate drain
cock
4 Condensate water
5 Pressure gauge
The diameter of the main line piping depends on its length as well as the number of
pipe bends and elbows, connections, and valves in the line. The higher the number
of components through which the air must pass, the larger the pipe diameter must be
to prevent excessive pressure drop up to the points where the air is used.
For precise calculations, always consult experts on the subject. The pipe lines
should be installed so they are easily accessible to check that they are airtight.
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Doc. No. IM-3541839-0101 129 (224)
2.5 Prepare Tetra Pak 2 Preparations
2.5 Prepare Tetra Pak
Only trained and experienced Tetra Pak® personnel are allowed to
lead commissioning and performance validation.
2.5.1 Special Practices and Procedures
The Tetra Pak Group recommends that Tetra Pak® staff and the final users
cooperate during installation, commissioning, and validation of the equipment. The
cooperation is a part of the training on how to operate and maintain the equipment.
2.5.1.1 Transport
It is recommended to engage the services of a transport company to take care of all
transport and handling related problems until the equipment is on the place in the
building where it shall be assembled.
2.5.1.2 Start-up
During the start-up of the equipment, a person with the ability to program a PLC
system must be available.
2.5.1.3 Training
All operators of the equipment must have participated in a Tetra Pak® operator
training. Contact the Tetra Pak Technical Training Centre for more information about
Customer Adapted Training (CAT).
2.5.2 Tools, Materials and Consumables
See also 1.5 Tools, Materials and Consumables Specifications.
2.5.2.1 During Installation
See Section Tools.
• Spirit lever
• Step ladder
• Pneumatic or electric powered wrench.
• Frequency meter.
2.5.2.2 During Start-up
See Section Tools and Production Material.
2.5.2.3 During Production
• Hotmelt, see Section Hotmelt.
• Drinking straws, see Section Drinking Straws.
For information on lubricants and cleaning compounds, see Chapter 10 Technical
Data in the OM.
2.5.3 Resources
During Installation
Personnel No. Note
Technicians 1
(Cont’d)
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2 Preparations 2.5 Prepare Tetra Pak
(Cont’d)
Electrician 1
During Production
Personnel No. Note
Operators 1
Technician 1 For troubleshooting purposes.
During Maintenance
Personnel No. Note
Technicians 1
Electrician 0
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2.6 Check and Store Goods 2 Preparations
2.6 Check and Store Goods
The information given below is given for planning purposes only.
The equipment will be delivered in crates. Please note that the purpose of packing
the equipment is solely to protect it during transportation. The crates are not
designed for storage. The Machine Documents box contains the equipment
manuals and is placed inside the crate. If the equipment is delivered in more than
one crate, the Machine Documents box is placed inside the crate marked with the
text "No.1".
A metal folder located on the outside of one of the crates, and marked with the text
"to be opened first", contains the instructions for crate handling and crate opening at
the installation site.
2.6.1 Goods Reception
The crates are designed to protect the equipment during transportation only. When
the crates are delivered to the site, unpack the crates as soon as possible.
Always take delivery of the goods.
It is important to check the goods immediately upon delivery whether they appear
damaged or not. The purpose of this is to minimise the extent of any possible
damage, prevent further aggravation of the damage, secure the rights of recovery
against the carrier, and enable a swift and correct handling of the claim.
Take the following steps immediately upon receipt of the goods:
Note! Never sign for damaged goods without making a written remark about the
damage on the freight document, for example, the way bill, or the delivery receipt.
Make a written remark on both the customer’s and the carrier’s copies. Get the
signature from the carrier representative, for example, the driver, on both
documents.
Take at least one detailed picture and a broad picture, to show the arrival condition
of the goods.
a) Investigate the external condition of the wooden crates. Follow the Procedure
How to Document Damage and use the Capital Equipment Logistics Checklist.
Any evident irregularities must also be noted on the freight document.
b) Check the contents of the consignment and verify that they conform to the way
bill, invoice, and packing list. Follow the Procedure Unpacking the Crate to
locate the packing list. If any evident irregularities, the content of consignment
must be checked. Open the crates immediately upon delivery or as early as
possible thereafter. Follow the Procedure How to Document Damage and use
the Capital Equipment Logistics Checklist. Any evident irregularities must also
be noted on the freight document.
2.6.1.1 Lifting and Unloading the Crated Equipment
See 1.5.5 Lifting and Transportation Equipment and Lifting Accessories before lifting
and unloading.
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2 Preparations 2.6 Check and Store Goods
2.6.1.2 Moving the Crated Equipment
WARNING
Risk of death or serious injury.
Read the entire lifting instructions before lifting the crate. Failure to obey may result
in immediate danger to life and/or major damage to the equipment.
For information on space requirements, see Section Installation Data and
Specifications.
Moving equipment specifications, see Section 1.5.5 Lifting and Transportation
Equipment and Lifting Accessories.
For weight and dimensions of the crate, see Section Crates.
If installation is to start immediately, check whether it is possible to move the crates
to the installation site. Uncrating and installation can then be performed together.
When moving crates to the installation site, deposit them so the equipment can be
lifted out and positioned without being turned around. Open the customs inspection
panel to see inside.
Wait until installation can start before unpacking.
DANGERI
DANGER
Risk of crushing.
Can cause death or personal injury. The crate is heavy. Use advised lifting
equipment and make sure that the crate is well balanced while it is being lifted. Do
not lift higher than necessary. Do not lift the crate outdoors unless the wind velocity is
below 13 m/s.
CAUTION
Risk of damage to the equipment.
Move the crate slowly and gently.
a) Lift the crate with the lifting equipment specified in Section 1.5.5 Lifting and
Transportation Equipment and Lifting Accessories, only enough to clear the
floor.
b) Make sure the crate remains stable on the lifting equipment.
c) Move the crate to its destination.
d) Look through the customs inspection panel to see which way the contents are
facing. Position the crate to face in the most convenient direction.
e) Lower the crate gently to the floor, leaving enough room around it for easy
access to all sides.
f) Make sure the crate is firmly supported. Place blocks or plates under it if
necessary.
g) Remove the lifting equipment.
2.6.1-1 Delivery Checks
Delivery Checks - How to Document Damage
(Cont’d)
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2.6 Check and Store Goods 2 Preparations
(Cont’d)
a) Take pictures of the damaged goods. If damage is apparent at the delivery of
the goods, take pictures to show the arrival condition of the goods, preferably
before the goods have been unloaded.
b) Make a note on the freight document, for example, on the way bill or the
delivery receipt, if you observe or suspect any of the following:
• apparent damage
• evident irregularities
• any delay encountered with the deliver
• the wooden crates are damaged
• seals are missing, broken, or differ from those advised in the freight
documents. Save the seals until a survey has taken place.
c) Do not sign for damaged goods without making a written remark about the
damage on the freight document, for example, on the way bill or the delivery
receipt.
d) Make an estimate of any possible damage by investigating the wooden crates,
packaging, and goods. Use the Capital Equipment Logistic Checklist as a
reference to identify the Defect Mode code.
Note! Using the Defect Mode code when reporting the issue to the Tetra Pak
Group will help to systematically collect data.
e) Try to mitigate the damage as much as possible. For instance, place wet,
damaged goods in a dry and heated area and protect damaged goods.
f) Report the issues to the Tetra Pak Group:
• The sites using the QuTI-P tool should report the issues in QuTI-P,
describing the issue, enclosing pictures, and classifying the issue with a
proper Defect Mode code, part of the Supply defect area.
• The sites not using the QuTI-P tool should report the issues in the R/3 tool,
describing the issue in claim notification, enclosing pictures, and classifying
the claim with a proper Defect Mode code, part of the Supply defect area
in the Damage field of the claim notification.
Capital Equipment Logistic Checklist
The Defect Mode codes are used by the Claim Administrator for reporting the
damage.
Fill in and submit the form to the Claim Administrator together with relevant pictures.
The forms can be found in both the IM and the Crate Handling Manual. Fill in the
Capital Equipment Logistic Checklist located in the Crate Handling Manual.
Outside the Box - the Primary Package
Check No/Not applicable Yes Defect Mode
1.1 Is the shock warning tag activated? Cracked (411)
1.2 Is one or more of the crate corners Cracked (411)
visibly damaged?
(Cont’d)
134 (224) Doc. No. IM-3541839-0101
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2 Preparations 2.6 Check and Store Goods
(Cont’d)
Check No/Not applicable Yes Defect Mode
1.3 Is one or more of the crate sides Cracked (411)
visibly damaged?
1.4 Is the crate lid visibly damaged? Cracked (411)
1.5 Are any documents missing? Missing part (401)
1.6 Is the centre of gravity marking Wrong marking (407)
missing from one or more crate
sides?
1.7 Is the crate marking incorrect? Wrong marking (407)
1.8 Are there any crates missing? Missing part (401)
Inside the Box - the Goods
Check No/Not applicable Yes Defect Mode
2.1 Is there any broken glass panel? Cracked (411)
2.2 Is there any part broken off the Cracked (411)
machine?
2.3 Is there any material not blocked? Displaced (404)
2.4 Is there any crushed or visibly Crushed (410)
damaged carton?
2.5 Is there any visible rust on any part of Oxidised/corroded
the machine (including inside)? (406)
2.6 Is there any detached or loose part? Loose (405)
2.7 Is the machine wet? Water inside (413)
2.8 Is there any water inside the Water inside (413)
machine?
2.9 Is there any water inside the crate? Water inside (413)
2.10 Is the machine dirty (not tidy and Dirty (409)
clean)?
2.11 Is there any part of the machine Bent (408)
bent?
2.12 Is there any part of the machine Scratched (412)
scratched?
2.13 Is there any truncated cable? Truncated (414)
2.14 Is there any worn cable? Worn (415)
2.15 Check the content of the packing list: Wrong part (402)
- Is there any part not listed?
2.16 Check the content of the packing Missing part (401)
list: - Is there any part missing?
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Doc. No. IM-3541839-0101 135 (224)
2.6 Check and Store Goods 2 Preparations
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136 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion
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Doc. No. IM-3541839-0101 137 (224)
3 Mechanical Completion
Description
This chapter describes the mechanical completion of the equipment. The
mechanical completion covers all activities from receipt of the equipment until the
equipment is mechanically installed. The mechanical completion activity is finalized
when a mechanical completion certificate is signed.
The chapter includes procedures to receive, assemble, and install the equipment. It
also includes a checklist used to verify that the equipment is mechanical correctly
installed.
Make sure any local lifting regulations are observed.
138 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.1 Crate Handling .................................................. 141
3.1.1 Goods Reception . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.1.1.1 Lifting and Unloading the Crated Equipment. . . . . . . . . . . 141
3.1.1.2 Moving the Crated Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.1.1.3 Delivery Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.1.2 Opening the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.1.2-1 Unpacking the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.1.2-2 Check the Drive and End Unit and the
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
3.1-1 Disposal of Reusable Material and Waste . . . . . . . . . 142
3.2 Positioning and Assembly................................... 143
3.2.1 Moving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.2.2 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2.3 Levelling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.2.4 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.2.4.1 Indicating Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.2.4.1-1 Indicating Tower - Assemble . . . . . . . . . . . . . . . . . . . . . 147
3.2.4.2 Conveyors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.2.4.2-1 Conveyor (TB/TBA/TPA/TT) - Assemble . . . . . . . . . . 149
3.2.4.2-2 Infeed Conveyor (TB/TBA/TPA/TT) -
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
3.2.4.2-3 Discharge Conveyor (TB/TBA/TPA/TT) -
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
3.2.4.2-4 Encoder (TB/TBA/TPA/TT) - Assemble. . . . . . . . . . . . 153
3.2.4.3 Main Conveyor Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.2.4.3-1 Conveyor Chain Link (TB/TBA/TPA/TT) -
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
3.2.4.4 Photocells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.2.4.5 Tunnels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.2.4.6 Bottom Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.2.4.6-1 Bottom Panel (TB/TBA/TPA/TT) - Assemble . . . . . . . 163
3.2.4.7 Cooling Unit (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.2.4.7-1 Cooling Unit - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . 163
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Doc. No. IM-3541839-0101 139 (224)
Table of Contents 3 Mechanical Completion
3.3 Equipment Interfaces and Connections.................. 167
3.3.1 Utility Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.3.1.1 Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.3.1.2 Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.3.1.2.1 Main Supply Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.3.1.2.2 External Conveyors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.3.1.2.3 Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.3.1.3 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.3.1.3.1 Ethernet Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.3.1.3.2 SNP Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.3.1.3.3 Line Communication (X90 Relay) Cable. . . . . . . . . 170
3.4 Restore Tools and Site........................................ 171
3.4-1 Restore Tools and Site . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.5 Procedures Describing the Use of Industrial Trucks
(Forklift Trucks) ................................................ 172
3.6 Procedures Describing the Use of Lifting Slings ...... 173
3.7 Mechanical Completion Review ............................ 174
3.7.1 Mechanical Completion Review Checklist . . . . . . . . . . . . . . 174
3.7.1.1 Positioning and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.7.1.1.1 Main Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.7.1.1.2 BFT (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.7.1.2 Equipment Interfaces and Connections . . . . . . . . . . . . . . . 176
3.7.1.2.1 Main Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.7.1.2.2 BFT (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.7.1.3 Mechanical Completion Inspection . . . . . . . . . . . . . . . . . . . . 177
140 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.1 Crate Handling
3.1 Crate Handling
For crate handling instructions, see 2.6 Check and Store Goods.
3.1.1 Goods Reception
For goods reception instructions, see Section 2.6.1 Goods Reception.
3.1.1.1 Lifting and Unloading the Crated Equipment
3.1.1.2 Moving the Crated Equipment
For instructions see Section 2.6.1.2 Moving the Crated Equipment.
3.1.1.3 Delivery Checks
For instructions regarding delivery checks, see 2.6.1-1 Delivery Checks
3.1.2 Opening the Crate
3.1.2-1 Unpacking the Crate
If not already done, investigate the condition of the equipment during unpacking.
Follow applicable parts of the Procedure How to Document Damage and use the
Capital Equipment Logistics Checklist.
DANGERI
DANGER
Risk of crushing.
Components may be heavy and may move unexpectedly when loosened. Take care
when loosening fixed components.
a) Remove all fixed and loose components from the floor of the crate, and from the
machine.
Note! Leave the bubble wrapping on parts until they are ready for use.
Note! Leave ties in place until tied parts are ready to be used or connected
b) When unpacking, do the following:
• Use the Packing List(s) to check that nothing is missing from the crate(s).
• Inspect the machine for damage.
• Open the boxes containing the smaller machine components and inspect
these for damage.
• Take the spare parts to the spare parts stores.
• If any damage to the crate contents has occurred during transportation,
create a discrepancy notification in SAP/R3 using transaction code IW51
(Create Service Notification).
Take photographs of the damage and enclose the photographs with the
discrepancy notification.
c) See Section 3.2.1 Moving for instructions on how to move the equipment to the
installation site.
d) See Section Moving in the IM for instructions on how to move the equipment to
.
the installation site.
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Doc. No. IM-3541839-0101 141 (224)
3.1 Crate Handling 3 Mechanical Completion
3.1.2-2 Check the Drive and End Unit and the Encoder
Make sure that the drive and end unit is correct and that the encoder is correct
depending on the drive and end unit that is selected. See the table.
Package Conveyor 23
Drive and End Unit Encoder
Motor below PM motor 3313606-0100 5-65 m/min 3413844-0100
Asynchronous 2807970-0300 39 m/min 3204325-0100
motor
Motor on top PM motor 3313607-0100 5-65 m/min 3413844-0100
Asynchronous 2763631-0300 39 m/min 3204325-0100
motor
.
3.1-1 Disposal of Reusable Material and Waste
Note! Packing materials (including the crate, wrapping, and boxes) are generally
not returned to the manufacturer.
a) Check with the customer if there is a special agreement for the return of
packing to the manufacturer.
b) If packing must be returned to the manufacturer, prepare an area to store the
crate and other returnable packing.
c) Check with the customer if there is a special arrangement for recycling packing.
d) Separate, recycle or dispose of all material and components in a safely and
environmentally responsible way, or according to local regulations. If there is
any uncertainty regarding what material a component is made of, contact the
Tetra Pak Group. Use a certified (ISO 14001 or similar) scrapping/waste
.
handling company.
142 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.2 Positioning and Assembly
3.2 Positioning and Assembly
3.2.1 Moving
DANGERI
DANGER
Immediate danger to life.
The machine may tilt if not observing thecentre of gravity (1) or the fork lift points (2).
Do not lift the machine outdoors unless the wind velocity is below 13 m/s. Secure the
load with safety lashings. Failure to obey may result in immediate danger to life and
major damage to equipment.
CAUTION
Possible machine damage.
Do not move the machine with pallet forks after assembling the bottom panel. See
Section Bottom panel.
Use the correct lifting equipment. See the section Lifting and Transportation
Equipment.
a) Check that the machine can be transported to the assembly site without any
problems regarding ceiling height, doors, passages and so on.
b) Remove the machine from the crate. Lift only enough to clear the crate. When
lifting the machine using a fork lift truck, use the fork lift positions.
c) Manoeuvre the machine out of the crate.
d) Lower the machine feet approximately 85 mm to facilitate the levelling later on.
Type A (mm) B (mm) C (mm) D (mm) E (mm)
Main machine 636 942 644 509 945
1 1
2 2 B
D E C
A
1 Centre of gravity
2 Fork lift points
.
(Cont’d)
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Doc. No. IM-3541839-0101 143 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
Type A (mm) B (mm) C (mm)
BFT 625 100 226
A
1
B
1 C
BFT Variant
1 Centre of gravity
.
3.2.2 Positioning
DANGERI
DANGER
Immediate danger to life.
The machine may tilt if not observing thecentre of gravity (1) or the fork lift points (2).
Do not lift the machine outdoors unless the wind velocity is below 13 m/s. Secure
the load with safety lashings. Failure to obey may result in immediate danger to life
and major damage to equipment.
(Cont’d)
144 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.2 Positioning and Assembly
(Cont’d)
CAUTION
Possible machine damage.
Do not move the machine with pallet forks after assembling the bottom panel. See
Section Bottom panel.
Use the correct lifting equipment. See the section Lifting and Transportation
Equipment.
a) Check that the machine can be transported to the assembly site without any
problems regarding ceiling height, doors, passages and so on.
b) Remove the machine from the crate. Lift only enough to clear the crate. When
lifting the machine using a fork lift truck, use the fork lift positions.
c) Manoeuvre the machine out of the crate.
d) Lower the machine feet approximately 85 mm to facilitate the levelling later on.
Type A (mm) B (mm) C (mm) D (mm) E (mm)
Main machine 636 942 644 509 945
1 1
2 2 B
D E C
A
1 Centre of gravity
2 Fork lift points
.
(Cont’d)
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Doc. No. IM-3541839-0101 145 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
Type A (mm) B (mm) C (mm)
BFT 625 100 226
A
1
B
1 C
BFT Variant
1 Centre of gravity
.
146 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.2 Positioning and Assembly
3.2.3 Levelling
Make sure that the machine is positioned horizontally by, for example, using a spirit
level. Place the spirit level on the cross beams as well as on the longitudinal beams
as shown in the illustration below. If necessary, adjust the level by turning the
machine feet. Hydraulic jacks can be used to facilitate the setting.
3.2.4 Assembly
3.2.4.1 Indicating Tower
.
3.2.4.1-1 Indicating Tower - Assemble
The indicating tower have been mounted upside down in order for the machines to fit
their crates.
(Cont’d)
®
Doc. No. IM-3541839-0101 147 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
a) Loosen the indicating tower (1).
b) Turn the indicating tower and assemble it in the same holes as it was
assembled before, with the same screws on the same place. The indicating
tower should be assembled to the machine at position (2).
2
1
Main machine
2 1
BFT (Variant)
1 Indicating tower
2 Position of indicating
tower
.
3.2.4.2 Conveyors
CAUTION
Risk of damage to equipment
To comply with safety demands, the chain drive motor has to be supplied and
controlled according to the Electrical Manual (EM). See Connection diagrams.
Note! The drive motor for the chain is not part of the machine.
148 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.2 Positioning and Assembly
3.2.4.2-1 Conveyor (TB/TBA/TPA/TT) - Assemble
Note! The conveyor has twisted side plates at the first section on the infeed side,
and on the last section on the discharge side. The side plates are marked with
numbers and arrows corresponding to the product flow.
(Cont’d)
®
Doc. No. IM-3541839-0101 149 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
a) Use the screws (1) to assemble the conveyor part (2) with the discharge side of
the conveyor (3) inside the machine.
b) Tighten the screws (1).
1 1
2
1
3
1 Screw
2 Conveyor part
3 Conveyor
.
150 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.2 Positioning and Assembly
3.2.4.2-2 Infeed Conveyor (TB/TBA/TPA/TT) - Assemble
Assemble the infeed conveyor (1) with the conveyor section (2). Assemble holders
and rails. See the documentation belonging to the infeed conveyor.
1 Infeed conveyor
2 Conveyor section
.
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Doc. No. IM-3541839-0101 151 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
3.2.4.2-3 Discharge Conveyor (TB/TBA/TPA/TT) - Assemble
a) Assemble the conveyor (1) to the bracket (2).
1 2
1 Conveyor
2 Bracket
.
(Cont’d)
152 (224) Doc. No. IM-3541839-0101
®
3 Mechanical Completion 3.2 Positioning and Assembly
(Cont’d)
b) Assemble the discharge conveyor (3) to the conveyor (1). See the
documentation belonging to the discharge conveyor (3).
1 Conveyor
3 Discharge conveyor
.
3.2.4.2-4 Encoder (TB/TBA/TPA/TT) - Assemble
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Special Equipment Assembly Tool, 3225072-0000
Torx size 10
SPC Reference 3413844-0100
3204325-0100
Make sure that the drive and end unit is correct and that the encoder is correct
depending on the drive and end unit that is selected. See the table.
Package Conveyor 23
Drive and End Unit Encoder
Motor below PM motor 3313606-0100 5-65 m/min 3413844-0100
Asynchronous 2807970-0300 39 m/min 3204325-0100
motor
Motor on top PM motor 3313607-0100 5-65 m/min 3413844-0100
Asynchronous 2763631-0300 39 m/min 3204325-0100
motor
(Cont’d)
®
Doc. No. IM-3541839-0101 153 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
Note! Do not throw the away cover (1) without reading the machine plate to check
the version of the drive unit (2).
Drive Unit with Motor Below
a) Loosen the screws (3).
b) Remove the cover (1) from the drive unit (2).
1
3
1 Cover
2 Drive unit
3 Screw
.
(Cont’d)
154 (224) Doc. No. IM-3541839-0101
®
3 Mechanical Completion 3.2 Positioning and Assembly
(Cont’d)
c) Remove the two screws (4) from the protective casing (5) on the encoder (6).
6 6
5 5
4 4
Main conveyor 5-65 m/min Main conveyor 39 m/min
4 Screw (2 pieces)
5 Protective casing
6 Encoder
.
(Cont’d)
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Doc. No. IM-3541839-0101 155 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
d) Loosen the screw (7) on the incremental encoder (8) with the assembly tool.
e) Remove the extension shaft (9) from the incremental encoder (8).
9 9
8 8
7
Main conveyor 5-65 m/min Main conveyor 39 m/min
7 Screw
8 Incremental encoder
9 Extension shaft
.
(Cont’d)
156 (224) Doc. No. IM-3541839-0101
®
3 Mechanical Completion 3.2 Positioning and Assembly
(Cont’d)
f) Screw the extension shaft (9) into the centre of the sprocket (10).
10 9
9 Extension shaft
10 Sprocket
.
g) Loosen the two screws (11).
11 11
Main conveyor 5-65 m/min Main conveyor 39 m/min
11 Screw
.
(Cont’d)
®
Doc. No. IM-3541839-0101 157 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
h) Position the incremental encoder (8) on the extension shaft (9).
9 9
8 8
Main conveyor 5-65 m/min Main conveyor 39 m/min
8 Incremental encoder
9 Extension shaft
.
i) Tighten the screws (12) to assemble the cover (13).
2 2
12 12
13 13
12 12
Main conveyor 5-65 m/min Main conveyor 39 m/min
2 Drive unit
12 Screw
13 Cover
.
(Cont’d)
158 (224) Doc. No. IM-3541839-0101
®
3 Mechanical Completion 3.2 Positioning and Assembly
(Cont’d)
j) Tighten the two screws (11).
k) Tighten the screw (7) with the assembly tool (3225072-0000).
l) Assemble the cable from the SA30 to the incremental encoder (8). See the
arrow.
11 11
8 8
7
Main conveyor 5-65 m/min Main conveyor 39 m/min
7 Screw
8 Incremental encoder
11 Screw
.
(Cont’d)
®
Doc. No. IM-3541839-0101 159 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
m) Assemble the protective casing (5) and tighten it with the two screws (4).
5 5
4 4
Main conveyor 5-65 m/min Main conveyor 39 m/min
4 Screw (2 pieces)
5 Protective casing
.
(Cont’d)
160 (224) Doc. No. IM-3541839-0101
®
3 Mechanical Completion 3.2 Positioning and Assembly
(Cont’d)
Drive Unit with Motor on Top
a) Loosen the screw (1) and remove the chain guard (2).
b) Loosen the screw (3) and remove the sprocket (4).
c) Perform item a) to b) in section Drive Unit with Motor Below on page 154.
d) Loosen the screws (5) and remove the sprocket (6).
e) Loosen the screws (7) and remove the hub (8).
f) Remove the shaft (9) and change to the new shaft.
g) Assemble in the reverse order. Do not assemble the cover (10).
h) Assemble the encoder as described in item b) to m) in section Drive Unit with
Motor Below on page 155.
2 7
3 5
4 9
10
8
6
1 Screw 6 Sprocket
2 Chain guard 7 Screw (3 pieces)
3 Screw 8 Hub
4 Sprocket 9 Shaft
5 Screw (3 pieces) 10 Cover
.
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Doc. No. IM-3541839-0101 161 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
3.2.4.3 Main Conveyor Chain
CAUTION
Risk of damage to equipment.
To comply with safety demands, the chain drive motor has to be supplied and
controlled according to the Electrical Manual (EM). See Connection diagrams.
Assemble the chain through the machine. See the documentation belonging to the
conveyor.
Note! The drive and end unit for the chain is not part of the machine.
.
3.2.4.3-1 Conveyor Chain Link (TB/TBA/TPA/TT) - Assemble
Assemble the encoder synchronization conveyor chain link shaft head (3). Proceed
as follows.
a) Remove a few links from the conveyor chain (1) by removing a conveyor
shaft (2) in each end.
b) Put the removed piece of conveyor chain in a vice and replace a conveyor
shaft (2), from a link in the middle, with the new shaft. Make sure that the shaft
head (3) will be facing towards sensor W40B2182.
c) Assemble the conveyor chain.
1 2 3
1 Chain feed conveyor
2 Conveyor shaft
3 Conveyor shaft head
.
3.2.4.4 Photocells
Assemble the photocells. See for placements.
To set the photocells, see instructions in the Maintenance Manual (MM).
162 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.2 Positioning and Assembly
3.2.4.5 Tunnels
Assemble the tunnels.
Straight trough
.
3.2.4.6 Bottom Panel
.
3.2.4.6-1 Bottom Panel (TB/TBA/TPA/TT) - Assemble
Assemble the bottom panel (1) to the machine body.
CAUTION
Possible machine damage.
Do not move the machine with pallet forks after assembling the bottom panel.
1 Bottom panel
.
3.2.4.7 Cooling Unit (Variant)
.
3.2.4.7-1 Cooling Unit - Assemble
Note! Do not use a cooling unit if the electrical cabinet is equipped with a door with a
fan in it.
.
(Cont’d)
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3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
WARNING
Ergonomic hazard
The cooling unit is heavy. Avoid lifting the cooling unit without a lifting device. If this
is not possible, make sure to have two persons available for lifting the heating unit.
a) Lift the cooling unit with textile slings. Use an overhead gantry, mobile crane, or
fork lift. See the illustration.
(Cont’d)
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3 Mechanical Completion 3.2 Positioning and Assembly
(Cont’d)
b) Put the slings around the cooling unit (2) and lift it above the electrical
cabinet (1) with a lifting device.
c) Place the cooling unit (2) on top of the electrical cabinet (1).
d) Tilt the cooling unit (2) from side to side to release the slings.
1
1 Electrical cabinet
2 Cooling unit
.
e) Connect the hose (3) with a hose clip (4) to the connection on the back of the
cooling unit. There are two connections on the cooling unit. The one that is not
used shall be plugged.
f) Connect the elbow pipe (5) with the hose (3).
g) Connect the hose (6) with the elbow pipe (5).
h) Let the hose (6) follow the air hose (7) inside the machine down to the floor.
3 Hose
4 Hose clip
5 Elbow pipe
6 Hose
7 Air hose
.
(Cont’d)
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Doc. No. IM-3541839-0101 165 (224)
3.2 Positioning and Assembly 3 Mechanical Completion
(Cont’d)
i) Open the doors to the electrical cabinet.
j) Attach the cooling unit to the electrical cabinet with the fastening brackets (8).
k) Assemble the , the , and the anchor plate (11) with the .
l) Assemble the limit switch (9), the limit switch (10), and the anchor plate (11).
m) Install the in the electrical cabinet.
n) Make the electrical connections from the cooling unit and the limit switches to
the electrical cabinet according to the Electrical Manual (EM) and connect the
earth braid to the earth screw of the cooling unit.
o) Secure the cables from the limit switches with a strip to the anchor plate (11).
8 Fastening bracket
(5 pieces)
9 Limit switch,
A01B0400
10 Limit switch,
A01B0402
11 Anchor plate
.
p) If cooling unit is not selected on the HMI, the fan in the cooling unit will run
without cooling the air. See Section Configuration - Set Cooling Unit Option in
the Maintenance Manual (MM) for instructions.
q) The basic controller (12) on the cooling unit supervises and regulates the
cooling system. Set the temperature to 35 °C (95 °F). See Section Cooling Unit
in the Maintenance Manual (MM) for instructions.
13
12 Basic controller
.
166 (224) Doc. No. IM-3541839-0101
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3.3 Equipment Interfaces and
3 Mechanical Completion Connections
3.3 Equipment Interfaces and Connections
3.3.1 Utility Connections
The illustration below shows the location of the air connection (1) and the electrical
connection (3).
The illustration also shows a connection (4) intended for an additional protective
bonding conductor due to high earth leak current. See the EM.
The weld bolt (2) is intended for a supplementary bonding to the building’s
equipotential net. See the EM.
1
2
3
4
1 Air connection
2 Weld bolt
3 Electrical connection
4 Connection
.
3.3.1.1 Compressed Air
WARNING
Risk of personal injury.
Make sure that air supply to the machine is switched OFF before performing any
connection work.
Connect the compressed air to the air inlet valve. See the pneumatic diagram. See
also Section 1.4.3 Compressed Air.
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3.3 Equipment Interfaces and
Connections 3 Mechanical Completion
3.3.1.2 Electricity
DANGERI
DANGER
Risk of electrical shock and short circuits.
Make sure that power is switched OFF upstream before performing any work on
cables and electrical components.
Make the electrical connections according to Electrical Manual (EM) that belongs to
the machine.
See also Section 1.4.4 Electrical Power Supply.
3.3.1.2.1 Main Supply Cable
The main supply cable must be routed 1 m (3 ft 3/8 in) straight up from the top of the
machine before it turns away. The main supply cable must never be routed through
the machine.
3.3.1.2.2 External Conveyors
DANGERI
DANGER
Risk of electrical shock and short circuits.
The electrical supply cables to the external conveyor motors must be connected to
the motors before the cables are installed in the electrical cabinet. Secure the
connections before main power is switched ON.
3.3.1.2.3 Variant
WARNING
Risk of electrical shock and short circuits.
Make sure that power is switched OFF before performing any work on cables and
electrical components.
The electrical supply cables should be connected in the electrical cabinets. See the
Electrical Manual (EM).
Make the electrical connections according to the EM.
(Cont’d)
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3.3 Equipment Interfaces and
3 Mechanical Completion Connections
(Cont’d)
The machines are prepared for supplementary bonding to the building’s
equipotential net. Use a cable shoe (25 mm2, M8) to connect to the welding bolt (1).
The cable gland (2) is reserved for this. See the circuit diagrams in the EM.
2 1
BFT
1 Welding bolt
2 Cable gland
.
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3.3 Equipment Interfaces and
Connections 3 Mechanical Completion
3.3.1.3 Communication
3.3.1.3.1 Ethernet Cable
a) If using line controller, connect the incoming Ethernet cable to the WAN port of
the NAT router (1).
b) Perform the electrical connection according to the Electrical Manual.
1 NAT router A01X2114
.
3.3.1.3.2 SNP Cable
If using SNP, connect the SNP cable at the quickserver gateway (1) according to the
Electrical Manual.
1 Quickserver gateway
A01X2121
.
3.3.1.3.3 Line Communication (X90 Relay) Cable
If using Line communication (X90 relay), connect the upstream and/or downstream
signals according to the Electrical Manual.
170 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.4 Restore Tools and Site
3.4 Restore Tools and Site
3.4-1 Restore Tools and Site
Special Equipment Soft cloth
Consumables Stainless steel cleaner & polish (3M)
Installed Equipment
a) Remove the plastic film on all doors and plates.
b) Use Stainless steel cleaner & polish and a soft cloth to wipe off the doors,
.
covers, and plates.
Site Area
Make sure that:
a) all lifting tools and other installation tools are removed.
b) the area around the equipment is properly cleaned.
c)
.
the site is restored to production status.
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Doc. No. IM-3541839-0101 171 (224)
3.5 Procedures Describing the Use of
Industrial Trucks (Forklift Trucks) 3 Mechanical Completion
3.5 Procedures Describing the Use of
Industrial Trucks (Forklift Trucks)
172 (224) Doc. No. IM-3541839-0101
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3.6 Procedures Describing the Use of
3 Mechanical Completion Lifting Slings
3.6 Procedures Describing the Use of Lifting
Slings
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3.7 Mechanical Completion Review 3 Mechanical Completion
3.7 Mechanical Completion Review
The purpose of the mechanical completion review is to align with the customer that
all steps in this phase have been completed. Any remaining issues should be
addressed in regards to ownership and completion time.
Defects or faults together with necessary actions and timing to correct the deviations
must be recorded in the checklist. See Section Mechanical Completion Checklist.
Commissioning must not be started until the mechanical completion inspection has
been completed.
Use the checklist as follows:
• Under Note, document any deviations, incorrect values, or comments.
• Under Value, document the actual value.
• Under Signature, sign that the check is performed.
3.7.1 Mechanical Completion Review Checklist
SA30 Machine No. Country Final User Site
Checklist completed by Checklist completion date
Reference
No. Check Document Note Value Sign.
1 All equipment is delivered according to Packing list
packing list.
All delivered equipment is checked for
transport damages.
All transport damages are reported.
2 The packaging material to be used for tests is IM
taken care of and stored according to the
instruction in the IM.
3 Ensure that the documents below are available Receipt of
as paper in the correct EU language, as DVD in Documentation (ItP)
the correct EU language and in English, and
correspond with the specific machine.
• IM
• MM
• OM
• SPC
• EM
All documentation is stored as agreed with the
user.
(Cont’d)
174 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.7 Mechanical Completion Review
(Cont’d)
Reference
No. Check Document Note Value Sign.
4 Secure that the IMD (Individual Machine Receipt of
Documentation) is included in the delivery Documentation (ItP)
containing the following:
• Machine specification
• Machine Deviation (if relevant)
• Declaration of Conformity SA30
The binder is stored as agreed with the user.
5 Ensure that the Machine Program Binder is Receipt of
included in the delivery. Documentation (ItP)
The binder is stored as agreed with the user.
6 The disposal/return of crates, and so on, is IM
taken care of as agreed with the user.
3.7.1.1 Positioning and Assembly
3.7.1.1.1 Main Machine
Reference
No. Check Document Note Value Sign.
1 The main machine is positioned according to Layout drawing
approved layout and without interference with
service area.
2 The electrical cabinet work is finished: IM
• The flanges are mounted and tightened.
• All the cables are connected to the terminals.
• All quick connections are in place and
locked.
3 The machine legs/feet are mounted and the IM
machine is levelled.
4 The machine body work is finished: IM
• The doors and door stops are fitted.
• The doors open and close correctly
• The covers are fitted.
5 The warning lamp and alarms are fitted and IM
connected.
6 The conveyors are mounted: IM
• The discharge conveyor
7 The conveyor chain is mounted IM
8 The photocells are mounted IM
9 The tunnels are mounted. IM
10 The protective plastic film on all doors and IM
covers is removed and disposed of.
11 The Individual Machine Documentation (IMD IM
binder) has been reviewed (machine
deviations, last minute updates for
implementation, and so on).
12 The transport equipment is stored at the user IM
site or sent to Tetra Pak according to
agreement.
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3.7 Mechanical Completion Review 3 Mechanical Completion
3.7.1.1.2 BFT (Variant)
Reference
No. Check Document Note Value Sign.
1 The machine legs/feet are mounted and the IM
machine is levelled.
3.7.1.2 Equipment Interfaces and Connections
Note! It is important that the fuses to sensitive equipment (PLC etcetera) are
switched off before any welding is performed on the filling machine/line. It’s also
important that the welding machine is correctly earthed as close as possible to the
welding area.
3.7.1.2.1 Main Machine
Reference
No. Check Document Note Value Sign.
1 Matching transformer (if applicable) N/A
2 Electrical supply: IM
• fuse rating checked
• cable installation finished
• connection of phases, neutral, and earth are
checked
• all protective covers are in place and secure.
3 The main supply cable is not routed through IM
the machine. It is routed 1 m straight up from
the top of the machine before it turns away
4 The electrical supply cables to the external IM
conveyors are connected before the main
power is switched ON.
5 There is no leakage from the utility IM
connections:
• compressed air
6 Check which communication is needed for the IM
distribution equipment in the installation.
7 Electrical site test has been performed. KA 2727.10
3.7.1.2.2 BFT (Variant)
Reference
No. Check Document Note Value Sign.
1 The electrical supply cable is connected in the IM
electrical cabinet.
2 Electrical site test has been performed. KA 2727.10
DE-P458
DE-P459
176 (224) Doc. No. IM-3541839-0101
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3 Mechanical Completion 3.7 Mechanical Completion Review
3.7.1.3 Mechanical Completion Inspection
Reference
No. Check Document Note Value Sign.
1 Position and assembly of equipment verified. IM/Layout drawing
2 Layout drawing(s) updated to “as built” status if IM
applicable.
3 Risk and safety assessment completed. IM
4 Mechanical completion certificate issued. IM
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3.7 Mechanical Completion Review 3 Mechanical Completion
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4 Commissioning
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Doc. No. IM-3541839-0101 179 (224)
4 Commissioning
Description
This chapter describes the commissioning of the equipment. The commissioning
covers all activities from the first start up of the equipment until the equipment is
validated and ready for commercial production. The commissioning activity is
finalized when a commissioning certificate is signed.
The chapter includes procedures to start up and validate the function of the
equipment. It also describes the commissioning validation of the equipment, and
how to verify the packages with package integrity tests and microbiological
validation.
Note! Commissioning covers only the functioning of the individual machine. A line
performance test is required to check the functioning of the machine as part of a
complete line. Check with the local service organisation as to what arrangements
have been made for a line performance test.
Make sure any local validation requirements are observed.
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4 Commissioning Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.1 Validate Equipment Function ............................... 183
4.1.1 Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.1.1.1 Preparations before Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.1.1.2 Electrical Supply and Electrical Functions. . . . . . . . . . . . . 183
4.1.1.2-1 Prepare the Machine and the Test Area . . . . . . . . . . . 183
4.1.1.2-2 Verify the Continuity of the Protective Bonding
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
4.1.1.2-3 Preparations of the Test Equipment . . . . . . . . . . . . . . 185
4.1.1.2-4 Verify the Fault Loop Impedance . . . . . . . . . . . . . . . . . 185
4.1.1.2-5 Verify the Electrical Power Supply . . . . . . . . . . . . . . . . 185
4.1.1.2-6 Verify the Function of Emergency Stop
Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
4.1.1.2-7 Verify the Function of the Interlocking Guards
and Other Safeguarding Means . . . . . . . . . . . . . . . . . .186
4.1.1.2-8 Verify the Function of the Residual Current
Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
4.1.1.2-9 Verify Other Electrical Functions. . . . . . . . . . . . . . . . . . 186
4.1.1.3 Air Supply and Pneumatic Functions . . . . . . . . . . . . . . . . . . 186
4.1.1.3-1 Air Valve - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.1.1.4 Machine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.1.1.4-1 Basic Settings - Check . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.1.1.4-2 Control Panel - Set TPOP. . . . . . . . . . . . . . . . . . . . . . . . 187
4.1.1.4-3 PLMS – Install Configuration File . . . . . . . . . . . . . . . . . 188
4.1.1.4-4 Machine - Check before Test Run . . . . . . . . . . . . . . . . 188
4.1.2 Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.1.3 Verify Site Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.2 Commissioning Validation................................... 190
4.3 Commissioning Review ...................................... 191
4.3.1 Commissioning Review Checklist . . . . . . . . . . . . . . . . . . . . . . . 193
4.3.1.1 Result Table for Verification of the Continuity of the
Protective Bonding Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
4.3.1.2 Result Table for Verification of the Emergency
Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
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Table of Contents 4 Commissioning
4.3.1.3 Result Table for Verification of the Safeguards. . . . . . . . . 194
4.3.1.4 Result Table for Residual Current Protective
Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
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4 Commissioning 4.1 Validate Equipment Function
4.1 Validate Equipment Function
This section describes how to start up the equipment for the first time, step by step,
and the checks to be performed during the start up.
Make sure to have the Operation Manual and the Maintenance Manual delivered
with the equipment available for finding setting values and machine start instructions.
4.1.1 Start Up
This section contains instructions on how to prepare the equipment for start up and
how to safely start up the equipment for the first time.
Perform the procedures in this section in the order below. The result of the
procedures will be validated in the commissioning review checklist, see Section 4.3.1
Commissioning Review Checklist.
4.1.1.1 Preparations before Start Up
• Check that the spare parts are deposited in the spare parts stores.
• Check that all tools and templates are located at their specified place in the
machine.
For information about tools and templates, see the Maintenance Manual, Section
Tools and Templates.
• Check that all consumables are available on site. For information about
consumables, see the Maintenance Manual, Section Consumables.
4.1.1.2 Electrical Supply and Electrical Functions
This section contains procedures for checks of the electrical supply and checks of
electrical safety functions.
The results of the procedures must be reported in the checklists, see Section 4.3
Commissioning Review on page 191.
.
4.1.1.2-1 Prepare the Machine and the Test Area
Identification of Test Personnel
Note! The different tests may be carried out by different test persons. The name of
the person carrying out the verification shall sign the checklists. See Section
Commissioning Review Checklist.
Machine Preparation
Note! The tests shall be performed in a dry area.
• Where tests are performed in a wet area with an obvious risk for splashing water
from nearby machines or from pressurized water hoses the following
requirements applies:
.
a) Doors and covers of electrical enclosures must be closed.
(Cont’d)
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4.1 Validate Equipment Function 4 Commissioning
(Cont’d)
The following safety requirements must be complied with:
• Unauthorized persons must be prevented from access to the test area by
means of chains, ropes, walls, bars or similar barriers.
• The barrier must be provided with the appropriate number of warning signs "No
access for unauthorized persons"
• Test installations must be provided with means for emergency switching off
• Assembly work, preparation for test, and actual testing shall not be performed
simultaneously
• Test instructions shall be available during the test
Warning sign
.
4.1.1.2-2 Verify the Continuity of the Protective Bonding Circuit
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
All tests and verifications shall be completed with the result "pass" in
the result tables and signed on the checklists.
a) Inspect visually all dismantled or site assembled protective conductor
terminations.
b) Test any screw terminations connected at the site for protective conductors.
Test the newly connected cables by applying a pulling force by hand on each
conductor. The required test objects are pre entered in the result table. See
Section Result Table for Verification of the Continuity of the Protective Bonding
Circuit. Enter the results in the checklist. See Section Commissioning Review
Checklist.
Any replaced cable that carries a protective conductor requires the connected parts
to be tested for the continuity of the protective bonding circuit. If needed, use the
procedure below.
a) Prepare the test equipment according to Section Preparations of the Test
Equipment.
b) Enter the name of the test object (reference designation) that the replaced
cable is connected to in the column “Test Object”.
c) Enter the test point of the Test Object in the “Test Point” column.
(Cont’d)
184 (224) Doc. No. IM-3541839-0101
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4 Commissioning 4.1 Validate Equipment Function
(Cont’d)
d) Enter the cable area of the replaced cable in the column “Area”.
e) Depending on the cable area, enter the test limit value in the “Test limit column”
according to the table below.
Note! Tetra Pak® machinery normally has very low resistance in the protective
circuit. Therefore, to simplify testing, use the 6 mm² limit for lower conductor
areas where possible.
Conductor area (mm²) Max R PE (mΩ)
1,5 256
2,5 196
4 145
6 111
10 83
16 62
25 48
f) Set, if applicable the PE conductor tester in accordance with the conditions
depending on the conductor area.
g) For each replaced cable, press the probe to the test point. Keep the probe
pressed against the test point until a stable reading is obtained. Read and enter
the resistance value in the Test Result table.
h) Check that the measured value is lower than the test limit value.
After the test, turn off the power on the PE conductor tester.
4.1.1.2-3 Preparations of the Test Equipment
a) Connect the test equipment to the incoming PE point of the machine.
b) Check visually on the test equipment that the connection of the PE probe, the
probe and the cable are intact.
c) Turn ON the power switch on the PE Conductor Tester.
d) To verify the test equipment, press both probes to the metallic structure of the
machine and check that the resistance is sufficiently low (direct contact between
the two probes should give < 1 mΩ).
4.1.1.2-4 Verify the Fault Loop Impedance
a) Check if the power supply source impedance at the site ZSS, including the site’s
power transformer internal impedance and the site’s power supply cable(s) to
the machine, is lower than the maximum allowed. See Section Electrical Power
Supply.
b) Enter the results in the checklist. See Section Commissioning Review Checklist.
4.1.1.2-5 Verify the Electrical Power Supply
Make sure that the incoming electrical power supply to the machine has the correct
voltage and frequency in according with the specifications in Section Electrical
Power Supply.
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4.1 Validate Equipment Function 4 Commissioning
4.1.1.2-6 Verify the Function of Emergency Stop Devices
Machine Status Electrical supply disconnecting device in position I
(ON)
Note! All safety functions to be tested (identified by their safety function
designations) and the safety devices (identified by their reference designations) are
pre-entered into the result table. See Section Result Table for Testing the Safety
Functions.
a) Stop the machine.
b) All emergency stop devices to be tested are pre-entered into the result table.
See Section Result Table for Verification of the Emergency Stops. Check that
the emergency stop devices, identified by their reference designation, are
connected to the correct input by operating them one by one. Check that the
corresponding input LED is lit before the EMERGENCY STOP button is
pressed, and not lit when the EMERGENCY STOP button is pressed.
c) Enter the results in the checklist. See Section Commissioning Review
.
Checklist.
4.1.1.2-7 Verify the Function of the Interlocking Guards and
Other Safeguarding Means
Machine Status Electrical supply disconnecting device in position I
(ON)
a) Stop the machine.
b) All safety functions to be tested are pre-entered into the result table. See
Section Result Table for Verification of the Safeguards. Check that the safe
guards, identified by their reference designation, are connected to the correct
input by checking that the input LED is lit when the door is closed and not lit
when the door is opened.
c) Enter the results in the checklist. See Section Commissioning Review
.
Checklist.
4.1.1.2-8 Verify the Function of the Residual Current Protective
Devices
Machine Status Electrical supply disconnecting device in position I
(ON)
a) All test objects are pre-entered into the result table. See Section Result Table
for Residual Current Protective Devices. Perform the verification according to
Procedure Procedure to Manually Check Residual Current Protective Devices
in the MM.
b) Enter the results in the checklist. See Section Commissioning Review
Checklist.
4.1.1.2-9 Verify Other Electrical Functions
4.1.1.3 Air Supply and Pneumatic Functions
This section contains instructions about starting up and checking the air supply.
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4 Commissioning 4.1 Validate Equipment Function
4.1.1.3-1 Air Valve - Check
Machine Status Electrical supply disconnecting device in position I (ON)
Main air valve LOCKED in OFF position
a) Turn on the main air valve.
b) Check that the air pressure is according to the specification.
c) Step up the machine to machine ladder step AIR ON.
d) Check that the machine has air pressure on sensor (1).
1 Sensor
.
4.1.1.4 Machine Functions
These procedures are performed to check for smooth mechanical movement and to
verify that no components have come loose ore moved out of alignment during
shipping.
.
4.1.1.4-1 Basic Settings - Check
Make sure all basic settings have been performed on the equipment. The basic
settings are listed in Section Settings Sequence in the Maintenance Manual.
4.1.1.4-2 Control Panel - Set TPOP
Machine Status Electrical supply disconnecting device in position I (ON)
Configure the TPOP on the machine by entering information. See the Maintenance
Manual (MM) and the Operation Manual (OM) for descriptions and detailed
explanations of the TPOP.
(Cont’d)
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4.1 Validate Equipment Function 4 Commissioning
(Cont’d)
• Set user, see Procedure User Management - Log On as User in the MM.
• Set the date and time, see Procedure Machine Setup - Set Date, Time and
Regional Settings in the MM.
• Set language group (if necessary), see Procedure Machine Setup - Load
Application Program in the MM.
• Set start-up language, see Procedure Machine Setup - Set Start-Up Language
in the MM.
• Check the machine number and set the distribution equipment configuration,
see Chapter TPOP HMI in the MM.
• If a cooling unit has been installed, check that it is selected on the TPOP, see
.
Procedure Configuration - Select Cooling Unit Option in the MM.
4.1.1.4-3 PLMS – Install Configuration File
Machine Status Electrical supply disconnecting device in position I
(ON)
Main air valve LOCKED in OFF position
Install the configuration file into the filling machine, see the Maintenance Manual
belonging to the filling machine. The PLMS configuration file for SA30 is located on
the Software media.
4.1.1.4-4 Machine - Check before Test Run
Machine Status Electrical supply disconnecting device in position O
(LOCKED in OFF position)
Main air valve LOCKED in OFF position
Before the test run of the equipment, complete the following checks. Make sure that:
• all installation checks have been completed.
• all required production personnel are available.
• the operators have been trained and informed about:
a) machine operation
b) use of the Operation Manual
c) emergency stops and utility supply shut-off devices
d) safety and hazard information
• all site preparation is finished.
• the utility pipes have been pressure tested.
• the floor work is finished, including gutters and drains.
• work with pipe supports, guides, and fixing points is finished.
• the utility supplies are sufficient and stable, regarding:
a) compressed air
b) electrical power
• the utility supply shut-off devices are working properly.
(Cont’d)
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4 Commissioning 4.1 Validate Equipment Function
(Cont’d)
• all consumables are available in sufficient supply and properly stored, regarding:
a) packaging material
b) cleaning chemicals
• connections to the cleaning system have been made, regarding:
a) cleaning solution
b) communications
• product is available, stable, and of the correct quality.
• the machine is clean.
4.1.2 Test Run
The machine’s operation must be verified. This verification must include all functions
of the machine.
• Run the machine, see the OM for instructions. Check that all functions, machine
programs, and alarms are working.
• Make sure that the machine stops when an EMERGENCY STOP button is
pushed. Test all EMERGENCY STOP buttons. See Chapter Safety Precautions.
WARNING
Risk of serious injuries.
Never run the machine if any of the EMERGENCY STOP buttons is non-operational.
• Make sure that the machine stops when the covers fitted with safety switches are
opened. This should be tested for all safety switches. Make sure that all covers
are fitted to the machine before it is run. If the machine is equipped with tunnels,
also check the safety switches on the tunnels. See Chapter Safety Precautions.
WARNING
Risk of serious injuries.
Never run the machine if any safety switch is non-operational or any safety cover is
not fitted.
• Check that the conveyor speed is equal to the “Tested conveyor speed” on the
enclosed Final test report. If it is not, the conveyor speed must be adjusted, see
the MM.
• Make sure that there are no abnormal noises, vibrations, etcetera when the
machine is running.
4.1.3 Verify Site Conditions
This section describes how to verify the complete site. The site should be verified
according to applicable good manufacturing practices for liquid food production and
manufacturers' specifications. See Section 1.1.3 Site Environment.
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4.2 Commissioning Validation 4 Commissioning
4.2 Commissioning Validation
The commissioning validation consists of a verification of the plant conditions. The
commissioning validation must be done in cooperation with the Tetra Pak installation
project. The validation must be performed in accordance with the recommendations
from the Tetra Pak Quality Assurance Management (QAM).
.
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4 Commissioning 4.3 Commissioning Review
4.3 Commissioning Review
This section contains the checklists and result tables needed under the
commissioning review. During the commissioning review the activities described in
the procedures above are confirmed.
Use the checklists in this section as follows:
• Use a permanent pen when filling out the checklists.
• Under Note, document any deviations, incorrect values, or comments.
• Under Value, document the actual value.
• Under Signature, sign that the check is performed.
• The checklist pages shall be extracted from the Installation Manual and stored in
the project files with the market company.
The purpose of the commissioning review is to align with the customer that all steps
in this phase have been completed. Any remaining issues should be addressed in
regards to ownership and completion time.
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4 Commissioning 4.3 Commissioning Review
4.3.1 Commissioning Review Checklist
SA30 Machine No. Country Final User Site
Checklist completed by Checklist completion date
4.3.1.1 Result Table for Verification of the Continuity of the
Protective Bonding Circuit
Test Object Test Point Check
Incoming supply cable A01X0001:PE
Additional protective bonding A01X0001:E2
cable
Building equipotential bonding Chassis
If a cable needs to be replaced, the continuity of the protective bonding circuit has to
be verified. Enter the test results in the table below.
RPE
Test Object Test Point Area (mm2) Test limit (mΩ) Test value (mΩ)
(Reference
Designation)
4.3.1.2 Result Table for Verification of the Emergency Stops
Result table for emergency stop check.
Safety function Emergency stop Safety PLC Check
designation input LED
Emergency stop chain F09S2020, F09S2022 F09K2010:I0
Test result table for safeguard check.
Safety function designation Safeguard Safety PLC Check
input LED
Door guard F09B2026 F09K2010:I1
.
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4.3 Commissioning Review 4 Commissioning
4.3.1.3 Result Table for Verification of the Safeguards
The results in the result table below correspond to the Procedure X.X.X.
Safety function Safeguard Safety input LED Check
designation
4.3.1.4 Result Table for Residual Current Protective Devices
The results in the result table below correspond to the Procedure X.X.X.
Residual Current Device Note Check
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5 Performance Validation
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5 Performance Validation
Description
This chapter describes the performance validation of the equipment. The
performance validation covers the activities from when the equipment is ready for
commercial production until the equipment is handed over to the final user.
The chapter includes information on how to verify that the equipment achieves the
performance targets during commercial production.
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5 Performance Validation Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
5.1 Performance Preconditions ................................. 199
5.2 Commercial Production ...................................... 200
5.3 Monitor and Improve Performance ........................ 201
5.4 Performance Test .............................................. 202
5.5 Performance Validation Review ............................ 203
5.5.1 Performance Validation Review Checklist . . . . . . . . . . . . . . 203
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5 Performance Validation 5.1 Performance Preconditions
5.1 Performance Preconditions
To ensure an effective and successful performance validation, the following has to be
in place prior to the execution of the performance validation:
• Commercial production: commercial production must have started.
• Attendance: both Tetra Pak and the final user company must have appointed
representatives to participate in the performance validation.
• Operation: the equipment must be operated according to the OM for each
component in the line.
Qualified personnel from the final user company should operate the equipment
during the performance validation.
• Production plan: a production plan covering the entire performance validation
must be available and agreed between Tetra Pak and the final user company,
before starting of performance validation.
The production plan should reflect the normal constant running conditions,
including the range of products and packaging material that the final user
company intends to use with the equipment, as well as any expected product
changes.
The production plan should include, in particular:
- preparation schedule
- production schedule and resources
- volume to be produced
- number of product changes and product availability
- number of design changes and packaging/additional material availability
• Consumables: all relevant consumables (adhesive, lubricants, and so on) must be
available.
• Parts: an adequate supply of spare parts must be maintained on site according to
Tetra Pak recommendations.
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5.2 Commercial Production 5 Performance Validation
5.2 Commercial Production
The performance validation is performed when the equipment runs in commercial
production. See the sales agreement for more information.
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5 Performance Validation 5.3 Monitor and Improve Performance
5.3 Monitor and Improve Performance
During the performance monitoring period, the actual performance of the equipment
is measured and any non-performance issues are solved. See the sales agreement
for more information.
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5.4 Performance Test 5 Performance Validation
5.4 Performance Test
During the performance test, the actual performance of the equipment during a pre-
defined period is measured. The result of the performance test is recorded as the
certified performance in the performance certificate. See the sales agreement for
more information.
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5 Performance Validation 5.5 Performance Validation Review
5.5 Performance Validation Review
The purpose of the performance validation review is to align with the customer that
all steps in this phase have been completed. Any remaining issues should be
addressed in regards to ownership and completion time.
Defects or faults together with necessary actions and time to correct them must be
recorded in the checklist. See Section 5.5.1 Performance Validation Review
Checklist.
Use the checklist as follows:
• Under Note, document any deviations, incorrect values, or comments.
• Under Value, document the actual value.
• Under Signature, sign that the check is performed.
5.5.1 Performance Validation Review Checklist
SA30 Machine No. Country Final User Site
Checklist completed by Checklist completion date
Reference
No. Check Document Note Value Sign.
1 Commercial production started. IM
2 The General Performance Preconditions are Sales agreement
fulfilled. with schedules
3 The Special Performance Preconditions are Sales agreement
fulfilled (if applicable). with schedules
4 A production plan for the performance Sales agreement
validation period is established and with schedules
communicated.
5 The Machine Mechanical Efficiency (MME) and IM
Line Machine Mechanical Efficiency (LMME)
has been monitored and optimised.
6 Performance Test has been carried out (if PLMS, Performance
applicable). specification
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5.5 Performance Validation Review 5 Performance Validation
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6 Disassembly and Removal
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6 Disassembly and Removal
Description
This chapter describes how to safely disassemble and remove the equipment for
reuse in another location or for final disposal.
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6 Disassembly and Removal Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.1 Preparation ...................................................... 209
6.2 Disconnect Utilities............................................ 210
6.2-1 Utilities - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
6.3 Moving ............................................................ 211
6.3.1 Short Distance Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
6.3.2 Long Distance Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
6.4 Packing ........................................................... 213
6.5 Return to Manufacturer ....................................... 214
6.6 Final Disposal................................................... 215
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6 Disassembly and Removal
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6 Disassembly and Removal 6.1 Preparation
6.1 Preparation
DANGERI
DANGER
Risk of crushing.
The equipment can be heavy and can cause injury and death if it falls.
Make sure that the capacity of the lifting equipment is adequate and that the
equipment itself is in proper working order.
Follow all the general safety precautions when lifting, moving, and positioning the
parts of the machine. See Chapter Safety Precautions on page 55.
Before work starts, note the location of the nearest first aid kit and emergency
telephone. Always keep a list of important telephone numbers such as first aid
station, ambulance, and so on.
Only qualified assembly personnel are authorized to disassemble the machine for
moving to other operating location. See Section Personnel Requirements on page
60.
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6.2 Disconnect Utilities 6 Disassembly and Removal
6.2 Disconnect Utilities
6.2-1 Utilities - Disconnect
DANGERI
DANGER
Hazardous voltage.
Risk of electrocution. See Chapter Safety Precautions.
a) Switch the machine’s electrical supply disconnecting device OFF. Padlock the
switch.
b) Make sure that the main power cable to the machine is not connected to the
power supply unit on site.
c) Disconnect the cable. See Section 3.3.1 Utility Connections and the Electrical
Manual for further details.
Note! Optional kits might require separate power disconnecting.
d) Close the main air valve and padlock the switch. Check that the air pressure is
zero, see Procedure Air Supply - Shut Off Air Pressure in the MM.
e) Disconnect the compressed air, see Section 3.3.1 Utility Connections.
f)
.
Plug or protect all open connections.
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6 Disassembly and Removal 6.3 Moving
6.3 Moving
DANGERI
DANGER
Immediate danger to life.
The machine may tilt if the centre of gravity or the forklift points is not observed.
Secure the load with safety lashings. Failure to observe these may result in
immediate danger to life and/or major damage to equipment.
Follow instructions in Section 3.2.1 Moving.
Prior to lifting and moving the machine from its production site, do the following:
• check that the machine can be transported without any problems with ceiling
height, doors, passages, and so on.
To disassemble parts, follow the assembly instructions in the reverse order.
See Chapter 3 Mechanical Completion for further details.
CAUTION
Possible machine damage.
Do not move the machine with pallet forks without removing the bottom panel. See
Section 3.2.4.6 Bottom Panel.
6.3.1 Short Distance Moving
DANGERI
DANGER
Hazardous voltage.
Risk of electrocution. See Chapter Safety Precautions.
a) Disconnect the utilities as described in Section 6.2 Disconnect Utilities.
b) Remove the eject bins.
c) Disconnect the conveyors and conveyor chains.
d) Move the machine to its new position. Level the machine approximately.
e) Cover the equipment with a suitable protective covering.
f) Make sure the storage conditions comply with specifications.
Note! Data for lifting equipment are available in Section 1.5.5 Lifting and
Transportation Equipment and Lifting Accessories.
6.3.2 Long Distance Moving
DANGERI
DANGER
Hazardous voltage.
Risk of electrocution. See chapter Safety Precautions.
a) Disconnect the utilities as described in Section 6.2 Disconnect Utilities.
b) Remove the eject bins.
c) Remove the cooling unit.
d) Remove the bottom panel.
e) Remove the tunnels.
f) Remove the photocells.
(Cont’d)
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6.3 Moving 6 Disassembly and Removal
(Cont’d)
g) Remove the conveyors and conveyor chains.
h) Remove the indicating tower.
i) Fit the transport bracket to the TPOP panel.
j) Fit tie rods, eyebolts and lifting brackets to support when lifting.
k) Wrap small components in bubble wrapping to prevent damage.
Note! Data for lifting equipment are available in Section 1.5.5 Lifting and
Transportation Equipment and Lifting Accessories.
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6 Disassembly and Removal 6.4 Packing
6.4 Packing
CAUTION
Risk of serious equipment damage and personal injury.
Do not stack the crates on top of each other.
CAUTION
Risk of serious equipment damage.
Make sure to completely drain the water from the cooling system if there is a risk of
freezing.
a) Wrap small components in bubble wrapping to prevent damages.
b) Pack the equipment in suitable crates. Use the original crates and transport
beams if available.
c) Make sure that all groups and components are adequately protected. Fix any
loose sub-crates or boxes to the floors or walls of the crates to prevent them
moving during transport.
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6.5 Return to Manufacturer 6 Disassembly and Removal
6.5 Return to Manufacturer
a) Prepare the equipment for transport. See Section 3.2 Positioning and
Assembly.
b) Contact the local Service Organisation for further instructions and to arrange
shipment.
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6 Disassembly and Removal 6.6 Final Disposal
6.6 Final Disposal
If the machine is to be permanently disposed of, perform the following operations:
a) Remove all packaging material and straws, and dispose of these according to
local regulations.
b) Empty the hotmelt from the hotmelt equipment according to the Nordson
Manual. Dispose of the hotmelt according to local regulations.
c) Disassemble the machine as far as possible and separate the following
materials:
• stainless steel (panels and doors)
• cast iron (frames)
• brass
• glass (windows, and so on)
• rubber (seals, O-rings, and so on)
• nylon and other plastics
• electrical cables
• hydraulic hoses
• pneumatic hoses
• central lubrication hoses
• electrical components
• batteries
• mercury (UV-lamp)
d) Separate, recycle or dispose of all material and components in a safely and
environmentally responsible way, or according to local regulations. If there is
any uncertainty regarding what material a component is made of, contact the
Tetra Pak Group. Use a certified (ISO 14001 or similar) scrapping/waste
handling company.
e) Electrical components and batteries may need to be disposed of in special
waste management systems. Follow local regulations.
f) For handling of chemicals, see Section Hazardous Substances in Chapter ii
Safety Precautions.
If there is any uncertainty regarding what material a component is made of, contact
Tetra Pak.
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7 General
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7.1 Hazardous Substances Disclosure
7 General Table
7.1 Hazardous Substances Disclosure Table
The information in this table is made available to comply with MIIT Order 32 -
Administrative Measures for the restriction of the use of hazardous substances in
electrical and electronic products valid for Tetra Pak® equipment in China.
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7.1 Hazardous Substances Disclosure
Table 7 General
7.1.1 Hazardous Substances Disclosure Table
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Index of Procedures
A R
Air Valve - Check .................................................. 187 Restore Tools and Site .......................................... 171
B U
Basic Settings - Check .......................................... 187 Unpacking the Crate ............................................. 141
Bottom Panel (TB/TBA/TPA/TT) - Assemble ........... 163 Utilities - Disconnect ............................................. 210
C V
Check the Drive and End Unit and the Encoder....... 142 Verify Other Electrical Functions ............................ 186
Control Panel - Set TPOP ..................................... 187 Verify the Continuity of the Protective Bonding
Conveyor (TB/TBA/TPA/TT) - Assemble................. 149 Circuit ................................................................ 184
Conveyor Chain Link (TB/TBA/TPA/TT) - Verify the Electrical Power Supply.......................... 185
Assemble........................................................... 162 Verify the Fault Loop Impedance............................ 185
Cooling Unit - Assemble........................................ 163 Verify the Function of Emergency Stop Devices ...... 186
Verify the Function of the Interlocking Guards and
Other Safeguarding Means.................................. 186
Verify the Function of the Residual Current
D Protective Devices .............................................. 186
Delivery Checks ................................................... 133
Discharge Conveyor (TB/TBA/TPA/TT) -
Assemble........................................................... 152
Disposal of Reusable Material and Waste............... 142
E
Encoder (TB/TBA/TPA/TT) - Assemble .................. 153
I
Indicating Tower - Assemble.................................. 147
Infeed Conveyor (TB/TBA/TPA/TT) - Assemble ...... 151
M
Machine - Check before Test Run .......................... 188
P
PLMS – Install Configuration File ........................... 188
Preparations of the Test Equipment ....................... 185
Prepare the Machine and the Test Area.................. 183
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