Om 586382 0102 PDF

OM
Operation Manual
Tetra Rex TR/22 MAX XH with Cap Applicator
A-651953-0108
TechPub_2614345_0103 - 586382_fro.fm
WARNING
Read and follow all safety precautions before working on or near
this equipment.
Read all safety precautions throughout this manual and on safety
signs attached to this equipment. Failure to follow all safety
precautions could result in death or serious injury.
Doc. No. OM-586382-0102

TechPub_2614345_0103 - 586382_fro.fm
Copyright © 2005 Tetra Pak Group
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 Carton Chilled Inc., Tetra Rex.
and all Tetra Pak products are trademarks belonging to the Tetra Pak Group.
The content of this manual is in accordance with the design and construction of the machine or
equipment at the time of publishing. Tetra Pak reserves the right to introduce design modifications
without prior notice.
This document was produced by:
Tetra Pak Carton Chilled Inc., Tetra Rex
451 East Industrial Boulevard
Minneapolis, MN 55413
The United States of America
Additional copies can be ordered from Tetra Pak Parts or the nearest Tetra Pak office. When ordering
additional copies, always provide the document number. This can be found in the machine specification
document. It is also printed on the front cover and in the footer on each page of the manual.
Doc. No. OM-586382-0102
Issue 2005-10
This manual is valid for: i Introduction
Series No./ Machine No. Sign.

ii Safety Precautions
1 General Description
OM
Operation Manual
2 Alarms and
Troubleshooting
3 Preparation
Tetra Rex TR/22 MAX 4 Start

XH with Cap Applicator 5 Checks
A-651953-0108
6 Supply of materials
7 Volume change
TechPub_2614345_0103 - 586382_fro.fm
8 Change of product
9 Stop
10 Care and cleaning
11 Technical Data
A list of all optional equipment, optional
kits, and rebuilding kits that this manual is
valid for is found on the next page.
Doc. No. OM-586382-0102
Issue 2005-10

Optional equipment
Cap applicator
APV cluster
TechPub_2614345_0103 - 586382_fro.fm
Update Log for Doc. No. OM-586382-0102
This table shows all changes made to this manual, such as kits installed
and pages added or removed.
Date Installed Kit Added Pages Removed Pages Signature

(Doc. No.)
TechPub_2614345_0103 - 586382_fro.fm
Date Installed Kit Added Pages Removed Pages Signature
(Doc. No.)
TechPub_2614345_0103 - 586382_fro.fm
i Introduction
TechPub_2614345_0103 - Intro.fm
Doc. No. OM-586382-0102 i - 1 (14)

i Introduction
About the Introduction Chapter

This chapter contains basic information about this manual and related
Tetra Pak equipment.
i - 2 (14) Doc. No. OM-586382-0102

i Introduction Table of Contents
Manual Information . . . . . . . . . . . . . . . . . . . . . . . . i - 5
Delivered Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . i - 5
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 6
Page Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Typographical Conventions . . . . . . . . . . . . . . . . . . i - 7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Machine Introduction . . . . . . . . . . . . . . . . . . . . . . i - 8
Intended Use of the Equipment . . . . . . . . . . . . . . . i - 8
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
CE Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
Machine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 10
Hygiene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 11
Abbreviations and Terminology . . . . . . . . . . . . . i - 12
How to Use This Operation Manual . . . . . . . . . . i - 13

Purpose of the Operation Manual. . . . . . . . . . . . . i - 13
Operator Workflow. . . . . . . . . . . . . . . . . . . . . . . . . i - 13
Preparation Cycle . . . . . . . . . . . . . . . . . . . . . . . . . .i - 13
Production Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . .i - 13
Care Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - 13
Doc. No. OM-586382-0102 i - 3 (14)

i Introduction
This page intentionally left blank
i - 4 (14) Doc. No. OM-586382-0102

i Introduction Manual Information
Manual Information
Tetra Pak recommends reading all delivered manuals carefully. Make sure
that the delivered manuals are available to personnel who operate or
maintain the equipment.
It is important to keep this manual for the lifetime of the equipment and to
pass the manual on to any subsequent holder or user.
Tetra Pak will not be held responsible for any damage to the equipment
caused by not following the instructions given in this manual.
Delivered Manuals
The manuals delivered with this equipment include
• Conversion Manual (CM)
This manual provides technicians with information on converting the
equipment between different production modes.
• Electrical Manual (EM)
This manual provides technicians with information about the
equipment’s electrical system.
• Installation Manual (IM)
This manual provides technicians with information required to safely
install the equipment.
• Maintenance Manual (MM)

This manual provides technicians with information on maintaining the
equipment.
• Operation Manual (OM)
This manual provides the operator with information on handling and
operating the equipment before, during, and after production.
• Spare Parts Catalogue (SPC)
This manual provides the information necessary to order spare parts
from Tetra Pak
• Technical Manual (TeM)
– provides technicians with information required to safely install the
equipment
– provides technicians with information on maintaining the equipment
– provides technicians with information about the equipment’s
electrical system
– provides the information necessary to order spare parts from
Tetra Pak
Doc. No. OM-586382-0102 i - 5 (14)

Manual Information i Introduction
Page Layout
Every main page in a manual contains a header and a footer. The page header
contains the section name (1) and the chapter name (2). The page footer
contains the manual’s document number (3), and the page number (4). See
also the Page Numbering section.
1 2
3.4 Motor 3 Drive
(Cont'd)
a) Remove the banjo connections (2).
b) Loosen the cable to the micro switch.
c) Remove the cross bar (3) and separate the disconnection link. Lower the
link arm.
d) Remove the screws (4), apply the extractor, and pull out the shaft.
e) Remove the screws (5) and the washer.
f) Change the bearing.
g) Repeat steps g) and h) for the upper bearing.
4
2
2 Banjo connection
3 cross bar
4 Screw
5 Screw
(Cont'd)
Doc. No. MM-123457-0108 3 - 15 (102)
3 4
1 Section name
2 Chapter name
3 Document number
4 Page number
i - 6 (14) Doc. No. OM-586382-0102

i Introduction Manual Information
Page Numbering
A page number has three parts:
• chapter number (1)
• consecutive page number (2) within the chapter
• total number of pages (3) in the chapter.
4 - 11 (18) 1 Chapter number

2 Consecutive page number
1 2 3 3 Total number of pages
Typographical Conventions
Controls on the operator panel, emergency stop devices, and program steps
are printed in CAPITAL LETTERS.
Cross-references are underlined.
Symbols
The following symbols are used in illustrations:
• A pointer arrow (1) indicates the position of an object.

• A zoom arrow (2) indicates that an object view is enlarged. The arrow
points towards the enlarged view of the object.
• A rotation movement arrow (3) indicates rotational movement of an
object. The arrow points in the direction of rotation.
• A straight movement arrow (4) indicates movement of an object.
The arrow points in the direction of movement.
1 2 3 4
1 Pointer arrow
2 Zoom arrow
3 Rotation movement arrow
4 Straight movement arrow
Doc. No. OM-586382-0102 i - 7 (14)

Machine Introduction i Introduction
Machine Introduction
Intended Use of the Equipment
The intended use of this Tetra Pak equipment is to...
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.
Manufacturer
This Tetra Pak equipment has been manufactured by
451 East Industrial Boulevard
Minneapolis, MN 55413
The United States of America
Service
If you encounter problems when operating this equipment, contact the
nearest Tetra Pak office.
Contact the Liaison with other inquiries, comments, or suggestions for
improvement regarding the equipment and its documentation.
i - 8 (14) Doc. No. OM-586382-0102

i Introduction Identification
Identification
CE Classification
This equipment complies with the basic health and safety regulations of
the European Economic Area (EEA).
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 Tetra Pak 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.
Tetra Pak 1
Machine Type
Drawing Spec. 2
Machine No.
Manufacturer 3
Year of manufacture 4
6
5
1 Machine type
2 Drawing specifications
3 Machine serial number
4 Manufacturer
5 CE mark
6 Year of manufacture
Doc. No. OM-586382-0102 i - 9 (14)

Orientation i Introduction
Orientation
The illustration below shows the orientation of the equipment. This
orientation information will be used throughout this manual.
C
Operator side
D
A
Service side
A Front
B Right-hand side
C Left-hand side
D Back
i - 10 (14) Doc. No. OM-586382-0102

i Introduction Hygiene
Hygiene
Avoid microbiological pollution of the packaging material:
• Always keep the doors to the filling room (area) closed. To prevent
contamination via air streams, never open a window when the equipment
is in production.
• Never clean the floors or the equipment in the filling room (area) when
the equipment is in production.
• Compressed air used for cleaning purposes is to be used only for
cleaning filters and should only be used outside of the filling room (area)
or in the final folder compartment of the filling machine.
• Disinfect your hands before touching anything that may come into
contact with the product. Use disinfectant code H. See the Technical
Data chapter.
• 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. OM-586382-0102 i - 11 (14)

Abbreviations and Terminology i Introduction
Abbreviations and Terminology

Abbreviation/ Meaning Translation
Terminology
CIP Cleaning In Place
EM Electrical Manual
FM Filling Machine
FSU Foaming and
Sanitizing Unit
GC Gable Crease
HH High Hygiene
IM Installation Manual
LH Left Hand
MM Maintenance Manual
OC Opening Crease
OM Operation Manual
P Panel
PLC Programmable Logic
Controller
RH Right Hand
SCU Separate Cleaning
Unit
SPC Spare Part Catalogue
TPMS Tetra Pak
Maintenance System
TR Tetra Rex
UPV Universal Product
Valve
XH Extended Hygiene
i - 12 (14) Doc. No. OM-586382-0102

i Introduction How to Use This Operation Manual
How to Use This Operation Manual

Purpose of the Operation Manual
The Operation Manual provides operators with information on handling and
operating the equipment before, during, and after production.
Operator Workflow
Beginning with Chapter 3, the content is structured to follow the operator
workflow, as described below.
Preparation Cycle
a) Preparation
Production Cycle
b) Start
c) Checks
d) Supply of Materials
e) Conversion
f) Change of Product
g) Stop
Care Cycle
h) Care and Cleaning
Doc. No. OM-586382-0102 i - 13 (14)

How to Use This Operation Manual i Introduction
i - 14 (14) Doc. No. OM-586382-0102

TechPub_2614345_0102Safety.fm
Doc. No. OM-586382-0102 ii - 1 (30)

Read the Safety Precautions
WARNING
Read and follow all safety precautions before working on or near
this equipment.
Read all safety precautions throughout this manual and on safety
signs attached to this equipment. Failure to follow all safety
precautions could result in death or serious injury.
Definitions
Energy Isolating Device. A mechanical device that physically prevents
transmission or release of energy.
Power Supply Disconnector. The energy isolating device for the electrical
power supply to the equipment.
Lockout. The use of a device, such as a padlock, to make sure that an energy
isolating device, such as a power supply disconnector, cannot be operated.
Lockout Procedure. A procedure to put each necessary energy isolating
device in its safe position to prevent the energising of the equipment, such as
when a maintenance procedure should be carried out.
ii - 2 (30) Doc. No. OM-586382-0102

ii Safety Precautions Table of Contents
Safety Messages Description. . . . . . . . . . . . . . . ii - 5
Personnel Requirements . . . . . . . . . . . . . . . . . . ii - 6
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6
Instructed Person. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 7
Locations of Safety Signs . . . . . . . . . . . . . . . . . . . ii - 9
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 13
Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 13
EMERGENCY STOP Push-Buttons . . . . . . . . . . . ii - 13
Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 14
Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 15
Audible Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 15
Personal Protection. . . . . . . . . . . . . . . . . . . . . . ii - 16
Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 16
Entanglement Hazard . . . . . . . . . . . . . . . . . . . . . ii - 16
Hazardous Materials . . . . . . . . . . . . . . . . . . . . . ii - 17
Hydrogen Peroxide (H2O2) . . . . . . . . . . . . . . . . . ii - 18
Emergency Procedures. . . . . . . . . . . . . . . . . . . . . ii - 18
Personal Protective Equipment . . . . . . . . . . . . . . ii - 19
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 20
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 21
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 22
Ultraviolet Light . . . . . . . . . . . . . . . . . . . . . . . . . ii - 23
Supply Systems. . . . . . . . . . . . . . . . . . . . . . . . . ii - 24
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . ii - 24
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 25
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 26
Doc. No. OM-586382-0102 ii - 3 (30)

Table of Contents ii Safety Precautions
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 27
Steam supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 28
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 29
ii - 4 (30) Doc. No. OM-586382-0102

ii Safety Precautions Safety Messages Description
Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a
signal word.
This is the safety alert symbol. It 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
Danger indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Warning indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Caution indicates a potentially 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. OM-586382-0102 ii - 5 (30)

Personnel Requirements ii 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 electricity, mechanical systems, and so on.
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.
ii - 6 (30) Doc. No. OM-586382-0102

ii Safety Precautions Safety Signs
Safety Signs
WARNING
Damaged or missing safety signs increase the risk of death or
serious injury.
Replace all missing or damaged safety signs immediately.
There are two types of safety sign

• ISO signs are used worldwide
• ANSI signs are used in the United States only
The table shows all safety signs that are located on this equipment.
Note! The position numbers (Pos.) in the table refer to the positions in
the illustration(s) in the Locations of Safety Signs section.
Pos. ISO sign ANSI sign

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.
7
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
before maintenance.
Hazardous voltage.
12
WARNING
Chemical burn hazard.
Wear personal protective
equipment.
Chemical burn hazard.

Wear personal protective equipment.
(Cont'd)
Doc. No. OM-586382-0102 ii - 7 (30)

Safety Signs ii Safety Precautions
(Cont'd)
Pos. ISO sign ANSI sign

18
WARNING
Hot surface.
Do not touch.
before maintenance.
Hot surface.
Do not touch.
ii - 8 (30) Doc. No. OM-586382-0102

Locations of Safety Signs

Note! Make sure that each safety sign is undamaged and in its
correct position after installation and maintenance. Replace all
missing or damaged safety signs immediately.
The illustration shows where the safety signs are located on a machine with
XH options. The UV light and hydrogen peroxide options and safety signs
will not be present on HH machines. The position numbers refer to the table
in the Safety Signs section.
18
7
18
4
12
7
(Cont'd)
Doc. No. OM-586382-0102 ii - 9 (30)

(Cont'd)
18
18
18
4
7
UV
4
(Cont'd)
ii - 10 (30) Doc. No. OM-586382-0102

(Cont'd)
7
7
7
(Cont'd)
Doc. No. OM-586382-0102 ii - 11 (30)

(Cont'd)
7
7
7
ii - 12 (30) Doc. No. OM-586382-0102

ii Safety Precautions Safety Devices
Safety Devices
WARNING
Unshielded hazards.
Never inch or run this equipment if any safety device is inoperative.
Change inoperative components of the safety system immediately.
WARNING
Hazardous Voltage.
Activating a safety device, such as pressing an EMERGENCY STOP
push-button or opening a door, does not disconnect the power supply
from this equipment.
Emergency Stop
Emergency stop devices are used to stop this equipment immediately in an
emergency. 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.
EMERGENCY STOP Push-Buttons
Push one of the EMERGENCY STOP push-buttons to stop this equipment

immediately.
The illustration shows an EMERGENCY STOP push-button. The location of
each EMERGENCY STOP push-button is shown by an arrow.
Doc. No. OM-586382-0102 ii - 13 (30)

Safety Devices ii Safety Precautions
Safeguards
WARNING
Moving machinery.
Never defeat or bypass the interlocking devices.
All movable guards, such as doors and covers, leading to hazardous areas are
fitted with interlocking devices, usually electric safety switches. These
devices are part of the safety system and must never be defeated, bypassed,
or otherwise made inoperative.
CAUTION
Burn hazard.
Parts of this equipment protected by safeguards may be thermally hot
after operation.
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.
Never stop this equipment by opening a movable guard.
The location of each movable guard is shown by an arrow.
ii - 14 (30) Doc. No. OM-586382-0102

ii Safety Precautions Safety Devices
Warning Lamp
A warning lamp is a column of warning lights:
• A red light (1) indicates a hazardous condition. This is an emergency
situation that requires immediate action.
• A yellow light (2) indicates an abnormal condition. This is an impending
critical condition calling for action by the operator.
• A blue light (3) indicates that operator action is required.
1 Red light
2 Yellow light
3 Blue light
A warning light flashes when operator action is required. The light stops
flashing and remains lit when the alarm is acknowledged. After the fault is
corrected or the operator takes the appropriate action, the warning light goes
off.
Audible Alarm
The audible alarm produces a warning signal every time this equipment is
about to start (indexing). The warning signal sounds for approximately three
seconds prior to starting to alert personnel.
Doc. No. OM-586382-0102 ii - 15 (30)

Personal Protection ii Safety Precautions
Personal Protection
This section applies to all personnel at all times when this equipment is in
operation. For special personal protection required when handling hazardous
materials, see the Hazardous Materials section.
Noise Hazard
WARNING
Hazardous noise.
Risk of impaired hearing.
Wear hearing protection whenever this equipment is in operation.
CAUTION
Hazardous noise.
Risk of impaired hearing.
Hearing protection is recommended whenever this equipment is in
operation.
Entanglement Hazard
WARNING
Risk of entanglement.
Do not wear jewellery or loose clothing when working on or near this
equipment. Long hair may not be loose.
ii - 16 (30) Doc. No. OM-586382-0102

ii Safety Precautions Hazardous Materials
Hazardous Materials
WARNING
Contact with chemicals can cause death, serious injury, and
illness.
Always follow the chemical manufacturer’s instructions when handling
chemicals.
Make sure that

• the showers work
• an eyewash device, movable or wall-mounted, is available and
operational
• additional washing facilities are nearby
Note! Learn the locations of all washing facilities in order to act

immediately in case of an accident.
Doc. No. OM-586382-0102 ii - 17 (30)

Hazardous Materials ii Safety Precautions
Hydrogen Peroxide (H2O2)
WARNING
Corrosive chemical.
Wear personal protective equipment.
In both liquid and gas states, hydrogen peroxide may cause irritation or
damage if it comes into contact with skin, mucous membranes, eyes, or
clothes. Call for medical attention immediately if there is an accident.
Liquid hydrogen peroxide in concentrations of less than 1% is generally
considered harmless to humans.
Consult the instructions on the label of the tank or container.
Emergency Procedures
If there is an accident involving hydrogen peroxide, rinse the affected area as
soon as possible with large amounts of water.
If hydrogen peroxide is swallowed
• do not attempt to cause vomiting
• drink large amounts of lukewarm water to dilute the peroxide
• call for medical attention immediately
If splashes or vapour from hydrogen peroxide come in contact with the eyes
• wash the eyes thoroughly with lukewarm water for 15 minutes (keep
eyelids wide apart)
• call for medical attention immediately
If hydrogen peroxide comes into contact with skin or clothes

• rinse immediately with plenty of water
• call for medical attention immediately if skin burns appear
• thoroughly wash the clothes before wearing them again
If irritation or pain is experienced due to having inhaled hydrogen peroxide

vapour
• leave the affected area and get some fresh air
ii - 18 (30) Doc. No. OM-586382-0102

Personal Protective Equipment

The personal protective equipment for hydrogen peroxide is
• safety goggles (TP No 90303-11)
• protective gloves made of neoprene (TP No.90303-12)
• apron (TP No. 90303-13)
• shoes made of PVC, PE plastic, or rubber
Doc. No. OM-586382-0102 ii - 19 (30)

Handling
WARNING
Sudden and violent chemical reaction.
Avoid any contamination of hydrogen peroxide.
Hydrogen peroxide reacts suddenly and violently with many compounds or

if it is contaminated. The reaction is a violent decomposition liberating
oxygen and heat, with a big increase in volume due to the oxygen produced
by the peroxide decomposition.
Never pour surplus hydrogen peroxide back into the original container if it
contains fresh hydrogen peroxide. There is a risk of explosion when
hydrogen peroxide is in a closed container.
Ensure that equipment used for handling and diluting hydrogen peroxide is
clean before it comes in contact with hydrogen peroxide. Pumps or other
equipment used for handling hydrogen peroxide must be used for this
purpose only and must be manufactured from appropriate materials, such as
stainless steel 316 L, glass, polyethylene, or teflon. After use, make sure that
all peroxide residue is rinsed away.
If hydrogen peroxide is spilled, dilute it with large amounts of water and
flush it into a drain.
WARNING
Self-ignition.
Never wipe up hydrogen peroxide with materials such as rags or
paper as these may self-ignite several hours after contact.
If there is a fire, spray with large quantities of water.
ii - 20 (30) Doc. No. OM-586382-0102

Storage
DANGER
Containers will explode if not properly ventilated.
Keep the container upright and fitted with its proper ventilation cap. If
there is a fire, cool all containers by spraying them with large
quantities of water.
Hydrogen peroxide decomposes much faster with increasing temperature.

There is a risk of explosion at high temperatures, since the ventilation cap
cannot release the gases produced quickly enough.
Hydrogen peroxide must be stored in the original container delivered by
the supplier. Keep the container upright and fitted with its proper ventilation
cap, which allows oxygen to escape. Otherwise, there can be an explosion if
decomposition of the peroxide occurs violently.
Make sure that the container is always properly closed.

(Cont'd)
Doc. No. OM-586382-0102 ii - 21 (30)

(Cont'd)
Commercial food-grade hydrogen peroxide has been stabilized to inhibit the
catalytic decomposition effects of metals and other impurities, but it can
decompose into oxygen and water if it is exposed to heat or contaminated.
Make sure that the area used for storage of hydrogen peroxide is
• cool, clean, and well ventilated
• shielded from direct sunlight
• kept free from combustible materials
Disposal
Hydrogen peroxide should be sent to an approved facility for destruction.
Some countries allow it to be diluted with water to a concentration of less
than 1% and poured into the drain.
ii - 22 (30) Doc. No. OM-586382-0102

ii Safety Precautions Ultraviolet Light
Ultraviolet Light
WARNING
Severe burn hazard.
Ultraviolet light can cause eye and skin injuries.
The ultraviolet lamp may only be operated when it is in normal
operating position and protected by safeguards.
An ultraviolet lamp is protected by a movable guard, such as a door or cover.

If the guard is opened or removed the power to the lamp is switched off by an
attached interlocking device.
Ultraviolet light damage is cumulative. Extended exposure may cause
illnesses such as cancer. All exposure to ultraviolet light should be avoided.
CAUTION
Burn hazard.
The assembly housing and components around the ultraviolet light
assembly are hot. Allow components to cool down before
maintenance.
The location of each ultraviolet light is shown by an arrow.

Doc. No. OM-586382-0102 ii - 23 (30)

Supply Systems ii Safety Precautions
Supply Systems
Electrical Cabinet
DANGER
Hazardous voltage.
The power supply disconnector must be switched off and secured
with a lock before 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.
Make sure that the electrical cabinet doors are closed after working inside the
electrical cabinet. Doors with lock must be locked.
The location of each electrical cabinet is shown by an arrow.
ii - 24 (30) Doc. No. OM-586382-0102

ii Safety Precautions Supply Systems
Socket Outlet
WARNING
Hazardous voltage.
Can shock, burn, or cause death.
Read the Maintenance Manual before using this socket outlet.
The illustrations show the socket outlet (1). Their location in the electrical
cabinet (2) is shown bellow.
1 Socket outlet
2 Electrical cabinet
Doc. No. OM-586382-0102 ii - 25 (30)

Power Supply
DANGER
Hazardous voltage and moving machinery.
The power supply disconnector must be switched off and secured
with a lock before any maintenance.
Certain maintenance procedures may require power supply systems to be on.

These exceptions are clearly stated in the Maintenance Manual.
The illustration shows the power supply disconnector. The arrow shows its
location on this equipment.
‘
ii - 26 (30) Doc. No. OM-586382-0102

Air Supply
WARNING
Compressed air and moving machinery.
Close the main air valve and secure it with a lock before any
maintenance.
Certain maintenance procedures may require air supply systems to be on.

The illustrations show the main air valve (1) and the lock (2). Their locations
are shown by arrows.
1 Main air valve

2 Padlock
Doc. No. OM-586382-0102 ii - 27 (30)

Steam supply
WARNING
Steam! Risk of burns!
Use caution when working inside the TR/22 packaging machine.
Pressurized steam can be discharged unexpectedly. Pipes and
components can be extremely hot. Failure to observe this warning
could result in serious injury!
To prevent possible injury, turn OFF the electrical power, depressurize the
pilot valve, and vent all steam safely before servicing the valve.
Steam inlet
ii - 28 (30) Doc. No. OM-586382-0102

Water Supply
WARNING
Water under pressure.
Close the water supply valves before any maintenance.
Certain maintenance procedures may require water supply systems to be on.

The illustration shows the water supply valves (1) and their locations.
1 City water supply valve

1 2 2 Circulating (chilled) water
Doc. No. OM-586382-0102 ii - 29 (30)

ii - 30 (30) Doc. No. OM-586382-0102

TechPub_2614345_0103 - Chapter 1.fm
Doc. No. OM-586382-0102 1 - 1 (54)

Description
This chapter describes the operator’s control panel, the location and the
function of each icon/button, and all the related TPOP screens.
1 - 2 (54) Doc. No. OM-586382-0102

1 General Description Table of Contents
1.1 Glossary of terms . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
1.2 Component location . . . . . . . . . . . . . . . . . . . . . . 1 - 6

1.2.1 Valves and gauges . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
1.2.2 Carton path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
1.3 Controls and control panel . . . . . . . . . . . . . . . . . 1 - 8

1.3.1 Operator interface . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
1.3.2 Operator interface pushbuttons . . . . . . . . . . . . . . 1 - 9
1.3.3 Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Main screen all alarms . . . . . . . . . . . . . . . . . . . . . 1 - 14
Main screen all alarms . . . . . . . . . . . . . . . . . . . . . 1 - 15
Operator settings screen . . . . . . . . . . . . . . . . . . . 1 - 18
Door guard screen. . . . . . . . . . . . . . . . . . . . . . . . . 1 - 22
Supply system screen. . . . . . . . . . . . . . . . . . . . . . 1 - 23

Supply system screen (cont’d). . . . . . . . . . . . . . . 1 - 24
Electrical cabinet screen. . . . . . . . . . . . . . . . . . . . 1 - 25
Bottom forming screen . . . . . . . . . . . . . . . . . . . . . 1 - 26
Carton transport screen . . . . . . . . . . . . . . . . . . . . 1 - 27
Volume adjust screen . . . . . . . . . . . . . . . . . . . . . . 1 - 29
Top/bottom heater temp. control screen . . . . . . . 1 - 31
Heater temp. adjust screen. . . . . . . . . . . . . . . . . . 1 - 33
Tank filling screen . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 35
Aseptic Product Valve (APV) screen (machines with
APV) 1 - 37
Cleaning/CIP screen . . . . . . . . . . . . . . . . . . . . . . . 1 - 38
Screw cap applicator screen . . . . . . . . . . . . . . . . 1 - 41
XH screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 44
Clean Air System (CAS) screen . . . . . . . . . . . . . . 1 - 46
Service screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 47
Time/Date setting screen . . . . . . . . . . . . . . . . . . . 1 - 48
Machine Mechanical Efficiency (MME) screen . . 1 - 50
Machine Mechanical Efficiency (MME) survey screen1
Doc. No. OM-586382-0102 1 - 3 (54)

Table of Contents 1 General Description
- 52
“About” screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 53
Keypad screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 54
1 - 4 (54) Doc. No. OM-586382-0102

1 General Description 1.1 Glossary of terms
1.1 Glossary of terms

Abbreviation Description Translation
CIP Cleaning In Place
EM Electrical Manual
FM Filling Machine
FSU Foaming and Sanitizing Unit
GC Gable Crease
HH High Hygiene
IM Installation Manual
LH Left Hand
MM Maintenance Manual
OC Opening Crease
OM Operation Manual
P Panel
PLC Programmable Logic Controller
TechPub_2614345_0103 - General description.fm
RH Right Hand
SCU Separate Cleaning Unit
SPC Spare Part Catalogue
TPMS Tetra Pak Maintenance System
TR Tetra Rex
UPV Universal Product Valve
XH Extended Hygiene
Doc. No. OM-586382-0102 1 - 5 (54)

1.2 Component location 1 General Description
1.2 Component location

1.2.1 Valves and gauges
13 14 15
6 7 8 9
1 2 3 4 5

10 11 12
Air gauges, regulators, and main supply valves

1 Main air shut-off valve
2 Main air gauge and regulator (6.0 bar)
3 Fill system air gauge and regulator (5.0 bar)
4 Fill pump air pressure, CIP
5 Vacuum ejector air gauge and regulator (3.5 bar)
6 Screw cap applicator, horn, air gauge and regulator
7 Screw cap applicator, anvil, air gauge and regulator
8 Screw cap applicator, bowl, air gauge and regulator
9 Hydrogen peroxide heater, air gauge and regulator
10 City water chain wash/lubrication. valve
11 Chilled water, supply valve
12 Chilled water, return valve
13 UPV closing, air gauge and regulator (2 bar)
14 Resuction, low, air gauge and regulator (1 bar)
15 Resuction, high, air gauge and regulator (3 bar)
(Cont'd)
1 - 6 (54) Doc. No. OM-586382-0102

1 General Description 1.2 Component location
1.2.2 Carton path
6
5
4 7 8 9 10 11 12 13 14 15 16 22
17 18 19 20 21
3
2
1
1 Carton magazine. The operator places carton 10 Top pre-folder. The top pre-folder breaks the top of
blanks in the magazine. the carton along the score lines.
2 Carton erector and carton loader. The carton 11 Carton passes under the UV lamp.
erector opens the carton blank and places it on the 12 Carton lifter and fill pipe. The carton lifter lifts up
forming support. The carton loader lifts and the carton and the fill pipe fills it with product as
transports the opened carton onto the mandrel. carton moves back down.
3 Free 13 Free
4 Bottom heater. The bottom heater applies hot 14 Top folder. The top folder breaks the sides of the
forced air at a preset temperature to the bottom of package top to the correct “bow tie” shape prior to
the carton, so it can be sealed. the heating.
5 Bottom folder. The bottom folder holds the 15 Top heater. The top heater applies hot forced air to
triangular sides of the carton bottom in the correct the top of the package so it can be sealed.
position to secure the package seal. The bottom 16 Top former guides. The top former guides hold the
folder also keeps the package closed to enable “bow tie” shape as the package indexes through
bottom sealing. the top heater and guides and enters into the top
6 Bottom sealer. The bottom sealer applies pressure sealer.
to the bottom of the carton, to seal it. The 17 Top sealer 1. The top sealer seals the top flaps of
overlapping bottom flaps of the carton are pushed the package by application of pressure.
up against the bottom of the mandrel and is sealed
18 Top sealer 2. The same as top sealer 1.
in place.
19 Free
7 Carton puller. The carton puller pulls the carton off
the mandrel and places it in the station chain 20 Free.
conveyor. 21 Free.
8 Cap applicator (option). The cap applicator installs 22 Carton discharger. Carton discharger moves the
the cap on the carton. package from the station chain onto the dairy’s
9 Hydrogen peroxide vapour is applied. conveyor.
Doc. No. OM-586382-0102 1 - 7 (54)

1.3 Controls and control panel 1 General Description
1.3 Controls and control panel

1.3.1 Operator interface

Interface description
The TR/22 operator interface is a control panel with which the operator starts, stops, monitors, and adjusts
the packaging machine. The panel has seven hard-wired push buttons and a graphic-based, touch-sensi-
tive screen that reacts to fingertip pressure. The operator changes the touchscreen display by touching the
screen “buttons”. The push buttons and all of the touchscreen menus are described in this section.
1 - 8 (54) Doc. No. OM-586382-0102

1 General Description 1.3 Controls and control panel
1.3.2 Operator interface pushbuttons

Push buttons
EMERGENCY STOP button

Pressing the EMERGENCY STOP button immediately stops the machine.
INCHING button
Pressing and holding the INCHING button will sound the horn for five seconds. After 5
seconds, release and push the button again. The tone of the horn will change and the
packaging machine starts indexing one station at a time.
NO FILL button
Push and hold this button while the machine is in production and packages are formed and
sealed without being filled (mainly for package testing use).
ALARM ACKNOWLEDGE button
Pushing this button will acknowledge the alarm. The alarm light and the beacon light will
stop flashing and stays on solid. Once the fault (alarm) is corrected, the light goes off.
SPARE button
(Cont'd)
Doc. No. OM-586382-0102 1 - 9 (54)

(Cont'd)

Push buttons (cont’d)
SYNCHRONOUS STOP button

Pressing the STOP button stops the machine in the synchronous position.
Note! The machine will NOT stop immediately!
STEP UP button
Pressing the STEP UP button initiates the next program step, if that step is available.
STEP DOWN button

Pressing the STEP DOWN button returns the machine to the previous program step.
If machine is in production, pressing this button only once would stop the picking of
cartons. Press the button once more and the machine stops after all cartons in the chain have
been filled and have exited the machine.
1 - 10 (54) Doc. No. OM-586382-0102

1.3.3 Touchscreen
Main screen
Program ladder icons
The program ladder icons indicate the program step that is currently in progress. When an icon is
flashing, the corresponding program step is available. When the icon is illuminated but not flashing, the
corresponding program step is in progress.
CONTROL VOLTAGE ON icon
The CONTROL VOLTAGE ON icon indicates that there is power to the machine control
system. This is the lowest program step.
PREHEATING icon
The PREHEATING icon indicates that the heaters are warming up to operating
temperature.
TANK FILLING icon

The TANK FILLING icon indicates that the product tank is filling with product from
processing.
Doc. No. OM-586382-0102 1 - 11 (54)

Main screen (cont’d)

Program ladder icons (cont’d)
MOTOR START icon
The MOTOR START icon indicates that the machine is indexing, but not picking carton
blanks from the magazine.
PRODUCTION/END OF PRODUCTION icons
The PRODUCTION icon indicates that the machine is in production mode – forming,
filling, and sealing cartons. While in production, the “step up” and “step down” buttons will
be flashing. If the “step up” button is pushed once, the production icon will change to the
END OF PRODUCTION icon and starts to flash. The A-valve will close and the flow of
product to the tank will stop. The packaging machine will continue to fill and seal packages
as long as there is enough product in the tank. Once the last package exits the machine, the
machine will automatically step down to the “pre heating” position and the END OF
PRODUCTION icon stops flashing and stays on. Pushing the “step up” or “step down”
buttons or alarm acknowledge button will turn off the icon.
CIP CLEANING icon
The CIP CLEANING icon indicates that the machine is in CIP/Disinfect mode. If the icon
background is grey, the machine is not in CIP mode. If the icon background is white, the
machine is in CIP/Disinfect mode and is ready to begin the process. If the icon background
is green, the CIP/disinfect cycle is in progress.
CLOCK display
Use the SERVICE screen to set the correct time.
1 - 12 (54) Doc. No. OM-586382-0102

Main screen (cont’d)

Main screen touchbuttons/icons

The main screen buttons are used by the operator and maintenance personnel to access functional and
informational menus. The buttons are touch-sensitive and react to fingertip pressure.
OPERATOR SETTINGS button
Touching this button brings up the OPERATOR SETTINGS screen.
PACKAGE COUNTER button
Touch and hold this button to reset (zero) the package counter.
CAP APPLICATOR ENABLED icon
The CAP APPLICATOR ENABLED icon indicates that the machine is able to apply
screw cap on the package.
CAP APPLICATOR DISABLED icon
The CAP APPLICATOR DISABLED icon indicates that the machine is filling packages
without screw cap.
XH FEATURE ENABLED icon
The XH FEATURE ENABLED icon indicates that the machine is in extended hygiene
filling mode (UV lamp is on and hydrogen peroxide is applied).
XH FEATURE DISABLED icon
The XH FEATURE DISABLED icon indicates that the machine is in high hygiene filling
mode (UV lamp and hydrogen peroxide are off).
Doc. No. OM-586382-0102 1 - 13 (54)

Main screen all alarms

Main screen all alarms touchbuttons/icons
HEATER TEMPERATURE alarm button

This button will appear on the screen any time there is a fault related to the top or bottom
heater temperature. Touching the HEATER TEMPERATURE alarm button displays the
temperature controller screen. See Troubleshooting section for more information.
FILL TANK alarm button

This button will appear on the main screen any time there is a fault related to the fill tank.
Touching the FILL TANK alarm button displays the fill tank alarm screen. See
Troubleshooting section for more detail.
CAP APPLICATOR alarm button

This button will appear on the main screen anytime there is a fault related to the screw cap
applicator. Touching the CAP APPLICATOR alarm button displays the cap applicator
alarm screen. See Troubleshooting section for more detail.
1 - 14 (54) Doc. No. OM-586382-0102

Main screen all alarms

Main screen all alarms touchbuttons/icons
DOORS/COVERS OPEN alarm button

This button will appear on the main screen any time a door or cover is opened. Touching the
DOORS/COVERS OPEN alarm button displays the doors/covers alarm screen. See
XH alarm button
The Extended Hygiene (XH) alarm button will appear on the main screen anytime there is a
fault related to UV light or hydrogen peroxide systems. Touching the XH alarm button
displays the XH alarm screen. See Troubleshooting section for more detail.
CLEANING alarm button
The CLEANING alarm button will appear on the main screen any time there is a fault
related to the Cleaning /CIP system. Touching the CLEANING alarm button displays the
Cleaning /CIP screen. See Troubleshooting section for more detail
SUPPLY SYSTEM alarm button
The SUPPLY SYSTEM alarm button will appear on the main screen any time there is a
fault related to the supply system (cooling water, air, fans, and auto lube). Touching the
SUPPLY SYSTEM alarm button displays the supply system alarm screen. See
Doc. No. OM-586382-0102 1 - 15 (54)

Main screen all alarms (cont’d)

Main screen all alarms touchbuttons/icons (cont’d)
CARTON TRANSPORT alarm button

The CARTON TRANSPORT alarm button will appear on the main screen any time there
is a fault related to the carton transport system. Touching the CARTON TRANSPORT
alarm button displays the carton transport alarm screen. See Troubleshooting section for
more detail.
BOTTOM FORMING alarm button

The BOTTOM FORMING alarm button will appear on the main screen any time there is a
fault related to the bottom forming system. Touching the BOTTOM FORMING alarm
button displays the bottom forming alarm screen. See Troubleshooting section for more
detail.
ELECTRICAL CABINET alarm button

The ELECTRICAL CABINET alarm button will appear on the main screen any time there
is a fault related to a component located in the electrical cabinet.Touching the
ELECTRICAL CABINET alarm button displays the electrical cabinet alarm screen.
1 - 16 (54) Doc. No. OM-586382-0102

Main screen all alarms (cont’d)

Main screen all alarms touchbuttons (cont’d)
FORCED icon
The FORCED icon indicates that a service technician has activated certain aspect of the
program through the use of a laptop computer possibly for diagnostic purposes.
SERVICE KEY ACTIVATED icon

The SERVICE KEY ACTIVATED icon indicates that the service key is activated.
Machine will not step up but it can be stepped down. See Maintenance Manual (MM) for
more detail.
DISINFECTION REQUIRED icon
The DISINFECTION REQUIRED icon indicates that the program will not step up until
the machine is disinfected. If the machine stays in Control voltage on or lower step for an
hour or longer, this icon will appear and will not disappear until the machine is disinfected.
EMERGENCY STOP icon
The EMERGENCY STOP icon indicates that one of the emergency stop buttons is
activated.
Doc. No. OM-586382-0102 1 - 17 (54)

Operator settings screen
Operator settings screen buttons and icons

The screen is divided into two sections, upper and lower. The upper section includes the manual button
section of the screen and the lower section consists of touchbuttons that are navigation tools for
accessing corresponding screens.
Upper section (manual)
MANUAL icon
The MANUAL icon identifies the manual buttons section of the operator setting screens.
MANUAL LUBRICATION button

Touching the MANUAL LUBRICATION button activates the lubrication pump manually.
FILL SYSTEM PURGE button

Touching the FILL SYSTEM PURGE button activates the process of purging fill system of
air bubbles. A green light in the button starts to flash when purging starts and goes off when
purging is completed. The purging is possible only in tankfilling and/or motor start.
HYDROGEN PEROXIDE SYSTEM PURGE button
Touching the HYDROGEN PEROXIDE SYSTEM PURGE button when machine is in
control voltage on step activates the process of purging hydrogen peroxide system of air
bubbles. The hydrogen peroxide pump and the related air will be turned on. A green light in
the button starts to flash when purging starts and goes off when purging is completed after 5
minutes.
1 - 18 (54) Doc. No. OM-586382-0102

Operator settings screen (cont’d)

Operator settings screen buttons and icons (cont’d)
Lower section
NAVIGATION icon
The NAVIGATION icon identifies the touchbuttons that are navigation tools for accessing
corresponding screens.
DOOR GUARD button
Touching the DOOR GUARD button displays the door guard screen.
SUPPLY SYSTEM button

Touching the SUPPLY SYSTEM button displays the supply system screen.
ELECTRICAL CABINET button

Touching the ELECTRICAL CABINET button displays the electrical cabinet screen.
BOTTOM FORMING button

Touching the BOTTOM FORMING button displays the bottom forming screen.
Doc. No. OM-586382-0102 1 - 19 (54)


Lower section (cont’d)

CARTON TRANSPORT button
Touching the CARTON TRANSPORT button displays the carton transport screen.
VOLUME ADJUST button

Touching the VOLUME ADJUST button displays the volume adjust screen.
TOP/BOTTOM HEATER TEMP. CONTROL button

Touching the TOP/BOTTOM HEATER TEMP. CONTROL button displays the top and
bottom heaters temperature controller screen.
TANK FILLING button

Touching the TANK FILLING button displays the tank filling screen.
CIP/CLEANING button
Touching the CIP/CLEANING button displays the CIP/cleaning screen.
1 - 20 (54) Doc. No. OM-586382-0102


Lower section (cont’d)

SERVICE button
Touching the SERVICE button displays the service screen.
CAP APPLICATOR button

Touching the CAP APPLICATOR button displays the screw cap applicator screen.
XH button
Touching the XH button displays the XH (UV light and hydrogen peroxide) screen.
EXIT button
Touching the EXIT button will take you back to the previous screen.
Doc. No. OM-586382-0102 1 - 21 (54)

Door guard screen

Door guard screen icons
DOOR SAFETY RELAY icon

1 The DOOR SAFETY RELAY icon will appear in red color flashing, any time a door or
cover equipped with safety devices is opened. The corresponding door(s) or cover(s) that is
open will be flashing in color red on the screen. See Troubleshooting section for more
detail.
DOOR/COVER OPEN icon

2 The DOOR/COVER OPEN icon of the corresponding door(s) or cover(s) that is open will
be flashing in color red. See Troubleshooting section for more detail.
EXIT button
1 - 22 (54) Doc. No. OM-586382-0102

Supply system screen
2
1
3
Supply system screen buttons/icons
AUTOMATIC LUBRICATION SYSTEM icon

1 The AUTOMATIC LUBRICATION SYSTEM icon will appear in blue color flashing, any
time there is a problem in the autolube system of the machine. See Troubleshooting section
for more detail.
HEATER BLOWER FAN icon
2 The HEATER BLOWER FAN icon will appear in yellow color flashing, any time there is
a problem in the heater blower fan system of the machine. See Troubleshooting section for
more detail.
COOLING WATER OVER-HEATED icon
3 The COOLING WATER OVER-HEATED icon will appear in yellow color flashing, any
time the temperature of the cooling water exceeds the acceptable value. See
Doc. No. OM-586382-0102 1 - 23 (54)

Supply system screen (cont’d)

Supply system screen buttons/icons (cont’d)
COOLING WATER PRESSURE icon

4 The COOLING WATER PRESSURE icon will appear in yellow color flashing, Any time
there is a problem in the cooling water system of the machine. See Troubleshooting section
for more detail.
AIR SUPPLY PRESSURE icon
5 The AIR SUPPLY PRESSURE icon will appear in yellow color flashing, Any time there
is a problem in the air supply system of the machine. See Troubleshooting section for more
detail.
LOW SUPPLY, HYDROGEN PEROXIDE icon
6 The LOW SUPPLY, HYDROGEN PEROXIDE icon will appear in yellow color flashing,
any time there is a low level of hydrogen peroxide in the reservoir. See Troubleshooting
section for more detail.
EXIT button
1 - 24 (54) Doc. No. OM-586382-0102

Electrical cabinet screen
1
Electrical cabinet screen buttons/icons
MOTOR OVERLOAD icon

1 The MOTOR OVERLOAD icon will appear in yellow color flashing, Any time there is an
motor overload problem in the machine. See Troubleshooting section for more detail.
VFD FAULT icon

2 The VARIABLE FREQUENCY DRIVE FAULT icon will appear in yellow color
flashing, Any time there is a problem one of the VFD’s in the machine. See Troubleshooting
SERVICE KEY ACTIVATED icon
The SERVICE KEY ACTIVATED icon will appear with blue color background Any time
the service key is activated.
EXIT button
Doc. No. OM-586382-0102 1 - 25 (54)

Bottom forming screen

Bottom forming screen buttons/icons
BOTTOM FORMING FAULT icon

1 The BOTTOM FORMING FAULT icon will appear in yellow color flashing, any time
there is a carton left on the mandrel. See Troubleshooting section for more detail.
EXIT button
1 - 26 (54) Doc. No. OM-586382-0102

Carton transport screen

Carton transport screen buttons/icons
FILL STATION CARTON JAM alarm

The FILL STATION CARTON JAM alarm will appear in yellow color flashing, any time
a carton has remained in the fill station. See Troubleshooting section for more detail.
DISCHARGER CARTON JAM alarm
The DISCHARGER CARTON JAM alarm will appear in yellow color flashing, any time
there is carton jam at the discharger station. See Troubleshooting section for more detail.
CONVEYOR CARTON JAM warning
The CONVEYOR CARTON JAM warning will appear in blue color flashing, any time
there is carton jam at the conveyor. See Troubleshooting section for more detail.
DRIVE MOTOR BRAKE alarm
The drive MOTOR BRAKE alarm will appear in yellow color flashing, any time the drive
motor brake is manually activated. See Troubleshooting section for more detail.
Doc. No. OM-586382-0102 1 - 27 (54)

Carton transport screen (cont’d)

Carton transport screen buttons/icons (cont’d)
DRIVE MOTOR SPEED alarm

The DRIVE MOTOR SPEED alarm will appear in yellow color flashing, any time the
station chain speed is incorrect. See Troubleshooting section for more detail.
INDEX BOX CLUTCH alarm

The INDEX BOX CLUTCH alarm will appear in yellow color flashing, any time the index
box clutch is disengaged. See Troubleshooting section for more detail.
EXIT button
1 - 28 (54) Doc. No. OM-586382-0102

Volume adjust screen

Volume adjust screen buttons/icons
VOLUME INCREASE button

Touch and hold the VOLUME INCREASE button to increase the fill volume. The adjacent
blue square light will turn to red color and flash when the fill volume adjust reaches its
maximum position.
VOLUME DECREASE button

Touch and hold the VOLUME DECREASE button to decrease the fill volume. The
adjacent blue square light will turn to red color and flash when the fill volume adjust
reaches its minimum position.
VOLUME ADJUST COUNTER display

1 The VOLUME ADJUST COUNTER displays the approximate amount of filling volume
in percentage. This is not an accurate value and it should be used only as an indicator
confirming that the volume adjust system is operational.
SAVE button
The adjusted value for each volume can be saved for the future filling. Use the volume
increase or decrease arrow button and adjust the setting. Save the setting by pushing the
SAVE button on the screen. The saved setting will be used for that fill volume until it is
changed by the operator again.
Doc. No. OM-586382-0102 1 - 29 (54)

Volume adjust screen (cont’d)

Volume adjust screen buttons/icons (cont’d)
VOLUME RESET button

Touch the VOLUME RESET button to reset the volume adjust to the last saved value.
FACTORY SET VALUE button

Touch the FACTORY SET VALUE button to reset the volume adjust to the factory pre set
value.
EXIT button
1 - 30 (54) Doc. No. OM-586382-0102

Top/bottom heater temp. control screen

Top/bottom heater temp. control screen
BOTTOM HEATER CONTROLLER icon

Touch the area below the icon to get to the bottom heater adjust screen.
TOP HEATER CONTROLLER icon

Touch the area below the icon to get to the top heater adjust screen.
PROCESS VARIABLE icon

This represents the actual temperature at any given time.
SET POINT icon

This represents the set temperature. For details see Temperature adjust screen.
LOW TEMPERATURE alarm

The red light will come on when the temperature of the heater is below normal. See
Doc. No. OM-586382-0102 1 - 31 (54)

Top/bottom heater temp. control screen (cont’d)

Top/bottom heater temp. control screen (cont’d)
HIGH TEMPERATURE alarm

The red light will come on when the temperature of the heater is above normal. See
AUTO-TUNE alarm
The red light will come on when the auto-tune process has failed. See Troubleshooting
SENSOR FAULT alarm
The red light will come on when the sensor has failed. See Troubleshooting section for more
detail.
RELAY FAULT alarm
The red light will come on when the relay has failed. See Troubleshooting section for more
detail.
HEATING ELEMENT FAULT alarm
The red light will come on when the heating element has failed. See Troubleshooting
EXIT button
1 - 32 (54) Doc. No. OM-586382-0102

Heater temp. adjust screen
3
Heater temp. adjust screen
HEATER IDENTIFICATION icon

1 The icon changes according to the heater that is being adjusted (top, bottom, or hydrogen
peroxide).
TEMP INPUT VALUE display

2 When using “Increase” or “Decrease” button, the changing value is displayed in this area.
HEATER AUTO-TUNE button

3 Touching the HEATER AUTO-TUNE button will initiate the auto-tune process of the
heater. The red light will be flashing during the process. Heater auto-tune is used when the
heater temperature starts to fluctuate (does not stay constant).
PROCESS VARIABLE icon
This represents the actual temperature at any given time.
SET POINT icon

This represents the set temperature.
Doc. No. OM-586382-0102 1 - 33 (54)

Heater temp. adjust screen (cont’d)

Heater temp. adjust screen (cont’d)
CONTROL VARIABLE icon

This represents the output of the heater controller in percentage.
INCREASE/DECREASE buttons
Touching the up or down button with double arrows will increase or decrease the value by
one (1.0) - unit increments. Touch and hold the up or down button and the value increases
or decreases continuously.
INCREASE/DECREASE buttons
Touching the up or down button with single arrow will increase or decrease the value by
one tenth (1/10) - unit increments.
EXIT button
1 - 34 (54) Doc. No. OM-586382-0102

Tank filling screen
1
Tank filling screen buttons/icons
FIRST FILL alarm

The first fill alarm will appear at the first tank filling of the day only if the product tank is
not filled to an acceptable level and the machine is stepped up to indexing (drive motor
running). This will also appear after the tank is completely drained and the machine is
stepped back up to indexing while the tank is not filled to the acceptable level. See
FILL SYSTEM PURGE button
Touching the FILL SYSTEM PURGE button activates the process of purging fill system
of air bubbles. A green light in the button starts to flash when purging starts and goes off
when purging is completed.
TANK DRAIN button
Touching the TANK DRAIN button drains the tank. For this button to function, the machine
must be in Control voltage on step.
TANK HIGH LEVEL alarm
1 The TANK HIGH LEVEL alarm light (yellow) will flash when the product level exceeds
the maximum acceptable height in the tank. See Troubleshooting section for more detail.
Doc. No. OM-586382-0102 1 - 35 (54)

Tank filling screen (cont’d)
3
2

Tank filling screen buttons/icons (cont’d)
TANK LOW LEVEL warning

2 The TANK LOW LEVEL warning light (blue) will flash when the product level pass the
minimum height in the tank. See Troubleshooting section for more detail.
TANK LEVEL indicator

3 The TANK LEVEL indicator shows the fullness of the tank in percentage of the total tank
capacity.
APV SCREEN button (present on the screen of machines with the APV option only)
Touching the APV SCREEN button displays the APV screen. If there are problems with
the APV cluster, a yellow color triangle will start flashing next to the button icon. Touching
the APV button at this time will display APV alarm screen. See Troubleshooting section for
more detail.
EXIT button
1 - 36 (54) Doc. No. OM-586382-0102

Aseptic Product Valve (APV) screen (machines with APV)
2
APV screen buttons/icons
STEAM TEMPERATURE digital read out and icon/alarm

1 The STEAM TEMPERATURE is displayed in the read out area. If the steam temperature
falls below the minimum of 125ºC, the icon background turns yellow and starts to flash. See
PRODUCT FLOW from processor icon/alarm
2 The flow of the product to the tank through the APV (A-valve) is acknowledged by the
presence of a green color circle beneath the factory icon. If the flow of product is
interrupted, the circle changes to yellow color and starts to flash. See Troubleshooting
Doc. No. OM-586382-0102 1 - 37 (54)

Cleaning/CIP screen
3
a b c

Cleaning/CIP screen buttons/icons
CLEANING STEPS indicator (using SCU only)

1 When using SCU/5 for cleaning the machine, the progress of the cleaning cycle is indicated
by the appearance of the step in process in color green.
REMAINING BATCHES/TIME indicator (true only when using SCU)
2 The REMAINING BATCHES/TIME indicator displays the number of batches left to be
done (in case of “cold water rinse to drain” step) or the remaining time, in seconds, for other
steps.
CLEANING FLOW PATH indicator
3 The CLEANING FLOW PATH indicator displays (in yellow color) the flow path of the
cleaning fluid at any given time through out the cleaning process:
a)Re circulating through spray valve
b)Re circulating through product valve
c)Draining
1 - 38 (54) Doc. No. OM-586382-0102

Cleaning/CIP screen (cont’d)
X
Cleaning/CIP screen buttons/icons (cont’d)
DRAIN icon
The DRAIN icon is displayed in the area marked by the X as the default icon at the
beginning of every CIP process.
COLD WATER RINSE icon (blue fish)
The COLD WATER RINSE icon is displayed in the area marked by the X during the
“Cold water rinse to drain” and/or “Cold water re circulating rinse”.
WARM WATER RINSE icon (red fish)
The WARM WATER RINSE icon is displayed in the area marked by the X during the
“warm water re circulating rinse”.
ALKALI CLEANING icon
The ALKALI CLEANING icon is displayed in the area marked by the X during the “Alkali
cleaning” step.
ACID CLEANING icon
The ACID CLEANING icon is displayed in the area marked by the X during the “Acid
cleaning” step.
Doc. No. OM-586382-0102 1 - 39 (54)

Cleaning/CIP screen (cont’d)

Cleaning/CIP screen buttons/icons (cont’d)
HOT WATER DISINFECTION icon

The HOT WATER DISINFECTION icon is displayed in the area marked by the X during
the “Hot water disinfection” phase.
CHEMICAL DISINFECTION icon
The CHEMICAL DISINFECTION icon is displayed in the area marked by the X during
the “Chemical disinfection” phase.
EXIT button
Touching the EXIT button displays the previous screen.
1 - 40 (54) Doc. No. OM-586382-0102

Screw cap applicator screen
1
2
3
4
Screw cap applicator screen buttons/icons
SET POINT, WELDING DURATION UPPER LIMIT in milliseconds

1 Touching this button displays a numerical pad through which the upper limit of welding
duration can be changed.
PROCESS VARIABLE, WELDING DURATION UPPER LIMIT display
2
The actual cap welding time of the last welded cap is displayed in milliseconds.
SET POINT, WELDING ENERGY in Joules (Watts x seconds)
3 Touching this button displays a numerical pad through which the welding energy can be
changed.
PROCESS VARIABLE, WELDING ENERGY display
4
The actual welding energy used for the last welded cap is displayed.
LOWER LIMIT, GENERATOR VOLTAGE alarm
The LOWER LIMIT, GENERATOR VOLTAGE alarm will appear in yellow color
flashing, any time the cap welding generator voltage is at the lower limit. See
OVERLOADED GENERATOR alarm
The OVERLOADED GENERATOR alarm will appear in yellow color flashing, any time
the cap welding generator overloaded. See Troubleshooting section for more detail.
Doc. No. OM-586382-0102 1 - 41 (54)

Screw cap applicator screen (cont’d)

Screw cap applicator screen buttons/icons
BOWL EMPTY alarm

The BOWL EMPTY alarm starts to flash when the level of caps in the bowl is too low
(bowl is empty).
SCREW CAP OPTION ON/OFF button
This button is used to turn the screw cap applicator system on or off.
CHUTE EVACUATING button

This button is used to remove the remaining caps out of the chute.
WRONG POSITION, HORN AND ANVIL CYLINDERS alarms
5
The alarm (s) will appear in yellow color flashing, any time there is a problem with the
cylinder positions. See Troubleshooting section for more detail.
CAP APPLICATOR VFD alarms
6
The alarm (s) will appear in yellow color flashing, any time there is a problem with the
Variable Frequency Drive for the CA. See Troubleshooting section for more detail.
1 - 42 (54) Doc. No. OM-586382-0102

Screw cap applicator screen (cont’d)

Screw cap applicator buttons/icons
ONE BAD WELD warning

The ONE BAD WELD warning starts to flash (blue color) when one carton is formed with
an unacceptable cap weld. That carton is not filled. See Troubleshooting section for more
detail.
THREE BAD WELDS alarm
The THREE BAD WELD alarm starts to flash (yellow color) when three cartons in a row
are formed with unacceptable cap welds. The three cartons are not filled. See
LOW LUBRICATION OIL warning
The LOW LUBRICATION OIL warning starts to flash (blue color) when the lubrication
oil supply level in the reservoir is too low. See Troubleshooting section for more detail.
LOCKED SERVICE SCREEN button

Touching the LOCKED SERVICE SCREEN button displays a numerical pad. The correct
pass word is required to access this screen (for repair technician use only).
EXIT button
Touching the EXIT button displays the previous screen
Doc. No. OM-586382-0102 1 - 43 (54)

XH screen
1 2

XH screen buttons/icons
HYDROGEN PEROXIDE VAPOUR AIR PRESSURE indicator

This indicator displays the air pressure for the hydrogen peroxide vapour system.
XH OPTION ON/OFF button

This button is used to turn the XH system on or off.
Note! During production once the XH option is selected (turned ON), the operator
can not turn it off. To turn off the XH option contact your supervisor or the service
personnel.
HYDROGEN PEROXIDE VAPOUR HEATER CONTROL icon

The information given below this icon is related to the hydrogen peroxide vapour heater. For
information about each icon in this section see Top/Bottom heater temp control screen.
CAS SCREEN button

Touching the CAS SCREEN button displays the Clean Air System (CAS) screen.
1 - 44 (54) Doc. No. OM-586382-0102

XH screen (cont’d)
1
XH screen buttons/icons
UV LIGHT POWER LEVEL INCREASE button

This button is used to increase the UV light power level which will increase the UV light
intensity.
UV LIGHT POWER LEVEL DECREASE button

This button is used to decrease the UV light power level which will decrease the UV light
intensity.
UV LIGHT AND HYDROGEN PEROXIDE SYSTEMS alarms
1 In case of any problem in the hydrogen peroxide and/or UV light systems the related
alarm(s) will flash in yellow color. See Troubleshooting section for more detail.
EXIT button
Doc. No. OM-586382-0102 1 - 45 (54)

Clean Air System (CAS) screen

CAS screen buttons/icons
CAS FAN ON/OFF button

This button is used to turn the CAS system on or off. The CAS option can be used in high
hygiene mode (without selection of XH option).
Note! During production once the CAS option is selected (turned ON), the operator
can not turn it off. To turn off the CAS option contact your supervisor or the service
personnel.
CAS FAN SPEED INCREASE button

This button is used to increase the CAS fan speed.
CAS FAN SPEED DECREASE button

This button is used to decrease the CAS fan speed.
EXIT button
1 - 46 (54) Doc. No. OM-586382-0102

Service screen
1 2
Service screen buttons/icons
MACHINE SPEED icon

1
The indicator below the icon displays the speed of the machine in packages per hour.
MACHINE POSITION ANGLE display

2 The position angle of the machine at any given time is displayed in this area (0º to 360º).
TIME/DATE SETTING button

Touching the TIME/DATE SETTING button will display the Time/Date setting screen.
MME button
Touching the MACHINE MECHANICAL EFFICIENCY (MME) button will display the
MME screen.
EXIT button
Doc. No. OM-586382-0102 1 - 47 (54)

Time/Date setting screen
1 4
2 5

Time/Date setting screen buttons/icons
HOUR SETTING button

1
Touching the HOUR SETTING button will change the hour displayed in the window on
the lower section of the button.
MINUTE SETTING button
2
Touching the MINUTE SETTING button will change minutes displayed in the window on
the lower section of the button.
TIME display
3 The hour/minutes are displayed.
YEAR SETTING button

4
Touching the button will change the year displayed in the window on the lower section of
the button.
MONTH SETTING button
5
Touching the button will change the month displayed in the window on the lower section of
the button.
1 - 48 (54) Doc. No. OM-586382-0102

Time/Date setting screen (cont’d)
7
Time/Date setting screen buttons/icons (cont’d)
DAY SETTING button

6 Touching the button will change the day displayed in the window on the lower section of the
button.
FULL DATE display

7 The full date (year/month/day) are displayed.
TIME/DATE SAVE button

Touching the TIME/DATE SAVE button after setting or changing time/date will save the
new settings.
Note! It is not possible to change one or some of the components of the Time/Date screen. All
components must be reset every time a change in time/date is necessary!
EXIT button
Doc. No. OM-586382-0102 1 - 49 (54)

Machine Mechanical Efficiency (MME) screen

MME screen buttons/icons
DATE icon
The column under this icon shows the date of each machine stop that is not related to the
“end of production”.
PRODUCTION TIME icon
The column under this icon shows the length of production in minutes.
MACHINE STOPS icon

The column under this icon shows the length of time for each “non-end of production”
related machine stop in minutes.
MME icon
The column under this icon shows the MME.
1 - 50 (54) Doc. No. OM-586382-0102

Machine Mechanical Efficiency (MME) screen (cont’d)

MME screen buttons/icons (cont’d)
NUMBER OF MACHINE STOPS icon

The column under this icon shows the number of machine stops that is not related to the
“end of production”.
MOVE UP button
The use of this button allows the operator to move up on the MME list.
MOVE DOWN button

The use of this button allows the operator to move down on the MME list.
EXIT button
Doc. No. OM-586382-0102 1 - 51 (54)

Machine Mechanical Efficiency (MME) survey screen

MME Survey screen buttons/icons
The purpose of this screen is to determine the reason for every machine stoppage. Any time the
machine is in production and it stops or is stepped down, this screen will automatically appear asking if
this is the “end of production stop”. The operator must choose “Yes” by touching the green button, or
“No” by touching the red button. All stopping incidents not related to the “end of production” will be
recorded on the MME screen. The screen will automatically disappear once the reason for the stop has
been determined.
YES button
Touch this button if the stopping of the machine is due to the “end of production”.
NO button
Touch this button if the stopping of the machine is due to reasons other than the “end of
production”.
1 - 52 (54) Doc. No. OM-586382-0102

“About” screen
“About” screen definitions

This screen contains the information regarding the Panel Application software and it’s version.
EXIT button
Doc. No. OM-586382-0102 1 - 53 (54)

Keypad screen

Keypad screen definition
The KEYPAD screen is used to alter some numerical set point such as the clock setting, pass words
and so on. To enter a new setting you may use the numeric keypad. The new set point value will appear
in the lower box on the right hand corner of the screen. The current value is displayed in the upper right
hand corner box. You may use the Backspace [BKSP] touchbutton to change or erase the new set point
before touching the [Enter] button. Once the correct set point is achieved, you may touch the [Enter]
button to transfer the new setpoint value to the current value register in the PLC. Touch the [Done]
button to exit the KEYPAD screen. The touchbutton [+/-] does not have any function at this time.
1 - 54 (54) Doc. No. OM-586382-0102

2 Alarms and
Troubleshooting
Doc. No. OM-586382-0102 2 - 1 (20)

2 Alarms and Troubleshooting
Description
This chapter describes all the alarm screens, the cause of each possible
alarm, the reaction of the machine, and the recommended steps that should
be taken by the operator to resolve the problem (alarm).
2 - 2 (20) Doc. No. OM-586382-0102

2 Alarms and Troubleshooting Table of Contents
2.1 Alarm beacon. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2.2 Alarm screens . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6

2.2.1 Heaters alarm screen. . . . . . . . . . . . . . . . . . . . . . . 2 - 6
2.2.2 Product tank alarm screen . . . . . . . . . . . . . . . . . . 2 - 7
2.2.3 APV cluster alarm screen (option) . . . . . . . . . . . . 2 - 8
2.2.4 Screw cap applicator alarm screen . . . . . . . . . . 2 - 10
2.2.5 XH alarm screen . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.2.6 Clean Air System (CAS) alarm screen . . . . . . . . 2 - 14
2.2.7 Door safety alarm screen . . . . . . . . . . . . . . . . . . 2 - 15
2.2.8 CIP alarm screen . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16
2.2.9 Utilities alarm screen . . . . . . . . . . . . . . . . . . . . . . 2 - 17
2.2.10 Carton transport alarm screen . . . . . . . . . . . . . . 2 - 18
2.2.11 Bottom former alarm screen . . . . . . . . . . . . . . . . 2 - 19

2.2.12 Electrical cabinet alarm screen . . . . . . . . . . . . . 2 - 20
Doc. No. OM-586382-0102 2 - 3 (20)

2 Alarms and Troubleshooting

2 - 4 (20) Doc. No. OM-586382-0102

2 Alarms and Troubleshooting 2.1 Alarm beacon
2.1 Alarm beacon

Whenever the normal operating condition of the machine is compromised
(i.e., due to a low supply or occurrence of a fault), a signal lamp on the
supervision panel and warning beacon on top of the forming section of the
machine will start to flash. The warning beacon consists of three independent
warning lights: red, yellow, and blue. The priority of the alarms is from top to
bottom. The red light has the highest priority and signals the activation of
the emergency stop system. The yellow light indicates the occurrence of
some abnormalities and/or faults. The blue light signals warnings of the
lowest priority such as “low level of caps in the hopper”.
When a fault has occurred, the appropriate light on the beacon and the signal
lamp on the supervision panel will start to flash. If the red or the yellow light
on the beacon illuminates, correction of the fault does NOT turn off the
warning beacon or the warning lamp on the supervision panel automatically.
To turn off the warning lights, the operator must acknowledge the fault (push
the acknowledge button which turns the flashing light into a steady light) and
then eliminate the cause of the fault at which time the warning light will go
off.
When multiple faults occur simultaneously, the highest priority alarm will
mask the others on the warning beacon (on the supervision panel, all the
related warning lamps will start flashing). When the highest level alarm no
longer exists (light turns off), then the next alarm level will light.
TechPub_2614345_0103 - 2.fm
The alarm symbols shown on the following pages are found on the
screen.The following table shows the alarms, followed by the alarms’
possible causes, as well as suggested actions for clearing the alarms.
Red light
Yellow light
Blue light
Warning beacon
Doc. No. OM-586382-0102 2 - 5 (20)

2.2 Alarm screens 2 Alarms and Troubleshooting
2.2 Alarm screens

2.2.1 Heaters alarm screen
1 2 3 4 5 6
TechPub_2614345_0103 - 2.fm
No. Alarm description Cause Machine action Instruction to operator
1 Heater temperature Defective heater Pre-production: Machine Call service technician.
below the lower limit does not step up.
Production; Machine
stops picking carton and
steps down to indexing.
2 Heater temperature Defective heater Pre-production: Machine Call service technician.
above the upper does not step up.
limit Production; Machine
3 Auto tune process Faulty auto tune Machine does not step up. Call service technician.
has failed
Repeat the process.
4 Sensor fault Faulty sensor Machine stops picking Call service technician.
carton.
5 Relay fault Faulty relay Machine stops picking Call service technician.
carton
6 Heating element Faulty element Machine stops picking Call service technician.
fault carton
2 - 6 (20) Doc. No. OM-586382-0102

2 Alarms and Troubleshooting 2.2 Alarm screens
2.2.2 Product tank alarm screen
4
3
1
2
TechPub_2614345_0103 - 2.fm

1 Tank level too high. Product level in the The indicator will change Call service technician.
tank has exceeded color to yellow and starts
the highest level to flash.
allowed. Pre-production: Machine
does not step up.
Production; Machine
2 Tank level too low. Product level in the The indicator will change Check and make sure the
tank has reached an to color blue and will start main product valve to the
unacceptable low to flash. machine is open.
level. Pre-production: Machine Allow the tank to fill up.
does not step up until tank
is filled to an acceptable
level.
Production; Machine
3 First tank filling First tank fill is not Machine does not step up Wait for tank to fill over 50%.
completed. to production.
4 APV cluster problem Steam, valve, or Pre-production: Machine Touch the APV cluster
product related. does not step up to tank button to go to APV cluster
filling. alarm screen.
During production:
Depends on the fault. See
APV cluster alarm screen.
Doc. No. OM-586382-0102 2 - 7 (20)

2.2.3 APV cluster alarm screen (option)
1 2
4
3
TechPub_2614345_0103 - 2.fm
1 Steam temperature Steam inlet valve is The indicator will change Make sure the steam valve
too low. not open. color to yellow and starts is fully open.
Steam generator is to flash. Call service technician.
faulty. Pre-production: Machine
does not step up.
Production; Machine
steps down to pre heating.
2 C-valve fault. C-valve in wrong The yellow circle starts to Make sure the air valve is on
position. flash. and air hoses are not
No air pressure. Pre-production: Machine pinched or broken.
does not step up. Call service technician.
Production; Machine
3 B-valve fault. B-valve in wrong The yellow circle starts to Make sure the air valve is on
Production; Machine
(Cont'd)
2 - 8 (20) Doc. No. OM-586382-0102

(Cont'd)
4
TechPub_2614345_0103 - 2.fm

4 No product in the Problem with the The yellow circle starts to Make sure the air valve is on
line processor. flash. and air hoses are not
End of product. Pre-production: Machine pinched or broken.
Production; Machine
continues to pick, form, fill,
and seal cartons until the
tank is empty then steps
down to pre heating when
the last carton exits the
machine.
5 A-valve fault. A-valve in wrong The yellow circle starts to Make sure the air valve is on
Production; Machine
Doc. No. OM-586382-0102 2 - 9 (20)

2.2.4 Screw cap applicator alarm screen
3 4
TechPub_2614345_0103 - 2.fm
1 Low cap in the bow There are not Pre-production: Machine Check the SCA hopper for
enough caps in the does not step up. adequate amount of caps.
SCA bowl. Production; Machine Make sure that the airveyor
stops picking carton and fan is operating.
steps down to indexing. Check for obstructions or
other problems in the
airveyor.
Call a service technician.
2 CA lubrication oil Lubrication oil level Not an alarm, just a Refill the oil reservoir.
supply in reservoir too low. warning.
Production; Machine
continues the production.
3 One bad weld One carton has an Not an alarm, just a Remove the unfilled
unacceptable weld. warning. package.
Production; Machine
continues the production.
The carton with bad weld
will not be filled.
4 Three consecutive Three carton in a Production; Machine Remove the unfilled
bad welds row received stops picking carton and packages.
unacceptable welds. steps down to indexing. Call a service technician.
(Cont'd)
2 - 10 (20) Doc. No. OM-586382-0102

(Cont'd)
6
5
8 7
TechPub_2614345_0103 - 2.fm

5 Wrong position, One or more of the Production; Machine Call a service technician.
anvil air cylinder(s)l SCA anvil air stops picking carton and
cylinder(s) is in steps down to indexing.
wrong position.
6 Wrong position, One or more of the Production; Machine Call a servicetechnician.
horn air cylinder(s) SCA horn air stops picking carton and
cylinder(s) is in steps down to indexing.
wrong position.
7 SCA generator SCA generator Production; Machine Call a service technician.

overload overloaded. stops picking carton and
8 SCA voltage SCA voltage fault. Production; Machine Call a service technician.
9 Cap applicator VFD Cap applicator VFD Production; Machine Call a service technician.
fault malfunction. stops picking carton and
Doc. No. OM-586382-0102 2 - 11 (20)

2.2.5 XH alarm screen
2
5
4 3
TechPub_2614345_0103 - 2.fm
1 Hydrogen peroxide Hydrogen peroxide Production; Machine Check and adjust the air
system air system air incorrect stops picking carton and pressure.
pressure. steps down to indexing. Call a service technician.
2 H2O2 heater fault See “Heater Alarms” Pre-production: Machine Call a service technician.
indicator lights screen. does not step up.
Production; Machine
3 Clean Air System See CAS alarm Production; Machine Call a service technician.
(CAS) fault screen. stops picking carton and
4 H2O2 flow alarm Low H2O2 flow.. Pre-production: Machine Call a service technician.
does not step up.
Production; Machine
5 UV lamp ignition UV light has failed to Call a service technician.
failure ignite after three
tries.
Machine does not step up.
UV light has not Wait for the UV lamp to
reached its full reach its full intensity (5
intensity. minutes)
(Cont'd)
2 - 12 (20) Doc. No. OM-586382-0102

(Cont'd)
7 8
TechPub_2614345_0103 - 2.fm

6 UV light assembly UV light assembly Machine does not step up. Return the UV light
safety relay has been moved assembly into its production
from its production position. Push the
position. Acknowledge button to
reset the relay.
7 UV light cooling UV light cooling Pre-production: Machine Call a service technician.
water water temperature does not step up.
has exceeded the Production; Machine
acceptable stops picking carton and
temperature. steps down to indexing.
8 UV light generator The temperature of Pre-production: Machine Call a service technician.
overheated the generator is does not step up.
above the Production; Machine
acceptable safe stops picking carton and
level. steps down to indexing.
Doc. No. OM-586382-0102 2 - 13 (20)

2.2.6 Clean Air System (CAS) alarm screen
TechPub_2614345_0103 - 2.fm
1 CAS fault The XH option has Machine does not step up. Turn the CAS on.
been selected but
the CAS has not
been turned on.
2 Variable Frequency Variable Frequency Machine does not step up. Call a service technician.
Drive (VFD), CAS Drive (VFD), CAS
blower motor blower motor
malfunction.
2 - 14 (20) Doc. No. OM-586382-0102

2.2.7 Door safety alarm screen
1
2
1
TechPub_2614345_0103 - 2.fm

1 Door guard A door or cover with Pre-production: Close the door(s) or cover(s).
a safety switch has Machine does not step
been opened. up.
Production; Machine
stops and returns to
“Control voltage on”
step.
2 Door guard safety A door or cover with Pre-production: Close all doors and covers, then
relay a safety switch has Machine does not step push the reset button.
been opened up. Note: If you push the reset
Production; Machine button before closing doors,
stops and returns to (alarm lights stop flashing and
“Control voltage on” stay on) the door alarms would
step. disappear when all doors are
closed but the door safety relay
alarm stays on until you push the
reset button again.
Doc. No. OM-586382-0102 2 - 15 (20)

2.2.8 CIP alarm screen
2 4
1 5

1 Back up prevent Back up prevent Pre-CIP: Machine does not step Call a service technician.
TechPub_2614345_0103 - 2.fm
valve valve in wrong up to cleaning.
position. During CIP; CIP process stops.
2 Product drain valve Product drain valve Pre-CIP: Machine does not step Call a service technician.
in wrong position. up to cleaning.
During CIP; CIP process stops.
3 Spray (divert) valve Spray (divert) valve Pre-CIP: Machine does not step Call a service technician.
in wrong position. up to cleaning.
4 Product valve Product valve in Pre-CIP: Machine does not step Call a service technician.
wrong position. up to cleaning.
5 Cleaning pipe Cleaning pipe in Pre-CIP: Machine does not step Call a service technician.
wrong position up to cleaning.
(missing if CIP is During CIP; CIP process stops.
desired, or present
when production is
desired).
6 CIP drain valve CIP drain valve in Pre-CIP: Machine does not step Call a service technician.
wrong position. up to cleaning.
7 Main drive in wrong Machine has been When the machine is in the Acknowledge the alarm.
position stopped in wrong “Ready for cleaning” step, the CIP Push and hold Step Up
position alarm icon starts to flash. On the button. The alarm will
CIP alarm screen, the motor icon sound for 5 seconds and
will be flashing. the machine will move
into correct position.
2 - 16 (20) Doc. No. OM-586382-0102

2.2.9 Utilities alarm screen
No. Alarm Cause Machine action Instruction to operator

TechPub_2614345_0103 - 2.fm
description
1 Low oil level, The auto-lube oil This is a warning and not an Follow all safety precautions.
central auto lubri- reservoir is empty. alarm. Fill the tank with the correct
cation Machine will continue working. type of oil.
2 Heater fan Heater fan is not Pre-production: Machine does Call service technician.
bowler working. not step up to production.
Production; Machine stops
picking carton and step down to
indexing.
3 Cooling water Secondary (re- Machine steps down to control Check to make sure the re-
temperature too circulating) cooling Voltage On. circulating cooling water
high water too warm. valves are open.
Call service technician.
4 Low flow, cooling The flow of cooling Pre-production: Machine does Fill the tank with distilled
water water is not suffi- not step up to production. water with correct additives
cient and/or cooling Production; Machine stops (see IM for more informa-
water tank is empty. picking carton and step down to tion).
control voltage on.. Use distilled water!
5 Low pressure, The air pressure Pre-production: Machine does Check the main air supply
compressed air supply to the not step up to production. valve and regulator.
machine is low. Production; Machine stops Call a service technician.
picking carton and step down to
control voltage on.
6 Low level, Hydro- Hydrogen peroxide Pre-production: Machine does Follow all safety precautions.
gen peroxide tank (reservoir) is not step up to production. Fill the tank with the correct
tank (reservoir) empty. Production; Machine stops type and the correct
picking carton and step down to concentration of hydrogen
indexing. peroxide solution.
Doc. No. OM-586382-0102 2 - 17 (20)

2.2.10 Carton transport alarm screen
3
2
1
TechPub_2614345_0103 - 2.fm
1 Drive motor brake Drive motor brake is Machine will not step Engage the drive motor brake.
manually up.
disengaged.
2 Drive motor speed The drive motor Machine stops and Call a service technician.
speed has returns to “Control
exceeded the voltage on” step.
acceptable speed.
3 Index box clutch The index box clutch Machine stops and Call a service technician.
is disengaged. returns to “Control
voltage on” step.
4 Carton jam, fill sta- A Carton jammed in Machine stops and Remove the jammed carton,
tion the fill station (has returns to “Control volt- clean the machine and resume
not returned back age on” step. production.
into the station
chain.
5 Conveyor, carton A carton jam has Machine stops picking Clear the carton jam on the
jam warning occurred on the con- cartons and will resume conveyor.
veyor. when the conveyor is
cleared.
6 Discharger carton Cartons are jammed Machine stops and Clear the carton jam and resume
jam at the discharger returns to “Control volt- production.
station. age on” step
2 - 18 (20) Doc. No. OM-586382-0102

2.2.11 Bottom former alarm screen

TechPub_2614345_0103 - 2.fm
1 Bottom forming Carton has Machine will stop Step down and stop the
remained on the picking carton and will machine. Remove the carton,
mandrel. step down to “Tank sterilize the mandrels with
filling” once all the alcohol, and resume production.
cartons have exited the
machine.
Doc. No. OM-586382-0102 2 - 19 (20)

2.2.12 Electrical cabinet alarm screen
TechPub_2614345_0103 - 2.fm
1 Variable Frequency Main motor has Machine will not step Call a service technician.
Drive (VFD), main faulted. up.
motor
If running, the machine
will step down to
“Control voltage on”.
2 Variable Frequency Discharger motor Machine will not step Call a service technician.
Drive (VFD), dis- has faulted. up.
charger motor
will step down to
3 Motor overload pro- One (or more) motor Machine will not step Call a service technician.
tection production device up.
has been activated.
will step down to
2 - 20 (20) Doc. No. OM-586382-0102

3 Preparation
Doc. No. OM-586382-0102 3 - 1 (20)

3 Preparation
Description
This chapter describes required activities for preparing the machine for
production.
3 - 2 (20) Doc. No. OM-586382-0102

3 Preparation Table of Contents
3.1 Preparing the machine . . . . . . . . . . . . . . . . . . . . . . .3 - 5
3.2 Internal sterilization . . . . . . . . . . . . . . . . . . . . . . . .3 - 12
3.2 Manual disinfection . . . . . . . . . . . . . . . . . . . . . . . .3 - 16

Doc. No. OM-586382-0102 3 - 3 (20)

3 Preparation

3 - 4 (20) Doc. No. OM-586382-0102

3 Preparation
3.1 Preparing the machine

1
Turn on the main power to the machine.
2
Open the main valves for:
a) Compressed air
b) Chainwash/lub
c) Chilled water, return
d) Chilled water, supply
Note! If machine is equipped with the
a optional APV cluster, check to make
TechPub_2614345_0103 - 3.fm
sure the steam supply is available to

the machine.
b c d
3
If you are running Extended Hygiene
(XH) product, make sure that there is
sufficient 2.0% hydrogen peroxide
solution available for the production run.
Use only low-residue, non-stabilized,
food-grade hydrogen peroxide (see IM
for detail). DO NOT use hydrogen
peroxide recommended for Tetra Brik
systems!
Doc. No. OM-586382-0102 3 - 5 (20)

3 Preparation
4
Disconnect the hydrogen peroxide supply
line from the carboy and remove the
carboy from the machine.
Follow plant policy regarding handling
the used carboy and obtaining carboy
filled with fresh 2.0% hydrogen peroxide
for the production run.
5
Install the filled carboy and connect the
hydrogen peroxide supply line.
TechPub_2614345_0103 - 3.fm
6
Make sure that all doors and covers are
closed and all emergency stops are reset.
Push the Acknowledge button.
7
Push the Step up button and step up the
program to Control voltage on.
3 - 6 (20) Doc. No. OM-586382-0102

3 Preparation
8
Make sure that machine is in Control
voltage on step.
Touch the Operator settings panel
button.
The Operator settings panel will
appear.
9
Touch the XH screen button. The XH
screen will appear.
Make sure the CAS is on. If not, touch
CAS screen access button to turn the
CAS on.
Touch the ON/OFF button to turn the XH
option on.
TechPub_2614345_0103 - 3.fm
Note! If the XH option is turned on

and the CAS option is not on, CAS
fault alarm will appear on the screen.
Note! Once the XH option or CAS is

turned on, the operator will not be
able to turn it off.
Touch Exit button and return to the

Operator settings screen.
10
On the Operator settings screen touch
the Hydrogen peroxide purge button.
A green light in the touchbutton starts to
flash and hydrogen peroxide pump and
the related compressed air are turned on.
The hydrogen peroxide system starts
purging for 5 minutes. The water and old
peroxide in the system starts dripping out
of the nozzle.
Doc. No. OM-586382-0102 3 - 7 (20)

3 Preparation
11
Examine the level in the cooling water
tank.
The level must not drop below the middle
of the tank.
Add correctly treated distilled water if
necessary (see MM for water treatment).
TechPub_2614345_0103 - 3.fm
12
Check the oil level in the central
lubrication tank for the machine.
The oil level must be between “min” and
“max” marks.
Use high pressure oil TP part# 90296-75.
If the ambient temperature at the
production site is below 5° C use high
pressure oil TP part# 90296-73.
3 - 8 (20) Doc. No. OM-586382-0102

3 Preparation
13
If you are running packages with screw
cap option, clean the cap applicator
hopper with soft cloth and 70% reagent
alcohol and fill it with correct caps.
14
cap option, make sure that the screw cap
option is enabled.
On the main screen touch the Operator
settings button.
The Operator settings screen will appear.
TechPub_2614345_0103 - 3.fm
15
Touch the Screw cap screen button on the
Operator settings screen.
Enable the screw cap option.
Return to the main screen.
Doc. No. OM-586382-0102 3 - 9 (20)

3 Preparation
16
Check the oil level in the lubrication tank
for the cap applicator.
Do NOT allow the oil level to drop below
half in the reservoir.
Use food grade oil only (TP part 90296-
96.)
TechPub_2614345_0103 - 3.fm
17
Lubricate the anvil with two shots of
food grade grease.
Use food grade grease TP part# 90296-
95.
3 - 10 (20) Doc. No. OM-586382-0102

3 Preparation
18
Move the anvil by hand and remove any
cap left inside the horn.
CAUTION
Take care not to damage the horn
surface when removing the caps.
Clean and disinfect the inner part of the

horn, the anvil, and the nest by means of
a cloth and 70% reagent ethanol.
TechPub_2614345_0103 - 3.fm
19
Reset the Package counter.
Touch and hold the Package counter
reset button until it resets to zero.
Doc. No. OM-586382-0102 3 - 11 (20)

3 Preparation
3.2 Internal sterilization

1
Install cleaning pipe.
Note! Since “Cleaning” is the last
function performed after each
production, the cleaning pipe may still
be in place.
Check and make sure that the sensor light

is ON (sensor is activated).
If not, call the repair technician.
TechPub_2614345_0103 - 3.fm
2
Check to make sure that all doors and
covers are closed and all emergency
stops are reset.
Push the Acknowledge button.
3
Check to make sure that the machine is at
Control voltage on step and the SCU/5
is on.
Cleaning (CIP) icon will be flashing.
3 - 12 (20) Doc. No. OM-586382-0102

3 Preparation
4
On the operator panel push the Step up
button three times rapidly.
The Cleaning icon stops flashing and
stays on.
The background color of the cleaning
icon will be white.
X3
TechPub_2614345_0103 - 3.fm
5
Push the Step up button one more time.
If machine is in synchronized stop
position:
The Cleaning icon color changes to
green.
The machine is now ready for CIP to
start.
If machine is NOT in synchronized
stop position:
Continue pushing the Step up button, the
horn will sound for three seconds.
Continue pushing the Step up button and
the machine automatically will inch into
synchronized position.
green.
start.
Doc. No. OM-586382-0102 3 - 13 (20)

3 Preparation
6
On the SCU/5 Control panel, choose
Disinfection cycle, see SCU/5 OM.
The cycle for disinfecting the fill system
starts.
If a pause in CIP/disinfecting cycle is
desired:
Push the Step down button once.
The cleaning process will stop (pause)
and the Cleaning icon changes color to
white.
If a door is opened or Emergency Stop
button is activated during the CIP/
disinfecting cycle:
white.
To restart the Cleaning/disinfecting
TechPub_2614345_0103 - 3.fm
cycle:
Push the Step up button once.
green.
The cleaning process will resume from
the beginning of the last interrupted step
or the end of the last completed step.
7
Once the Disinfection cycle is
completed, the Step up and the Step
down buttons on the operator panel start
to flash.
The background color of the Cleaning
icon changes to white
3 - 14 (20) Doc. No. OM-586382-0102

3 Preparation
8
Push Step down button once.
Program will return to Control voltage
on step.
9
While wearing disinfected gloves,
remove the Cleaning tube from the
machine.
TechPub_2614345_0103 - 3.fm
10
Remove the fill pipe and fill nozzle from
the disinfection solution and install them
on the machine.
Do NOT rinse the fill pipe or fill nozzle!
11
Re-disinfect the fill pipe and fill nozzle
with 70% reagent grade ethanol.
Doc. No. OM-586382-0102 3 - 15 (20)

3 Preparation
3.2 Manual disinfection

1
WARNING
Risk of eye injury!
Disinfectant sprayed into eyes can
cause injury. Wear eye protection
when using disinfectant.
Note! Never touch disinfected

surfaces with your hands. If you have
to touch a disinfected surface, put on
sterile gloves, then dip your hands in
a disinfectant solution.
The packaging machine fill system

should have been cleaned at the end of
the previous production run by using
SCU/5 or plant provided Cleaning In
Place.
TechPub_2614345_0103 - 3.fm
2
Wash and disinfect your hands and then
put on sterile gloves.
Dip your hands in a disinfectant solution.
Repeat this step any time you must touch
a disinfected surface.
3 - 16 (20) Doc. No. OM-586382-0102

3 Preparation
3
Inch the machine and disinfect all the
mandrels with 70% reagent grade
ethanol.
WARNING
Risk of serious injury!
Parts may move suddenly and
without warning if the door safety
system is not operational. To avoid
serious injury, do NOT disable the
door safety system.
WARNING
Risk of eye injury!

surfaces with your hands.
TechPub_2614345_0103 - 3.fm
4
Disinfect the top prefolder anvils with
70% reagent grade ethanol.
WARNING
Risk of serious injury!
Parts may move suddenly and
without warning if the door safety
system is not operational. To avoid
serious injury, do NOT disable the
door safety system.
WARNING
Risk of eye injury!

surfaces with your hands.
Doc. No. OM-586382-0102 3 - 17 (20)

3 Preparation
5
Load the magazine with correct size
blanks.
Make sure that the cartons are stacked
evenly and that they are facing the right
way.
Notice the position of the sixth panel.
TechPub_2614345_0103 - 3.fm
6
Make sure the dairy supply valve to the
machine is open and correct product is
available.
3 - 18 (20) Doc. No. OM-586382-0102

3 Preparation
7
e f g h Recheck air pressure gauges for main air,
fill system, vacuum ejectors, and cap
applicator.
a) Main air (6.0 - 7.0 bar)
b) Fill system (5 bar)
c) Fill pump, CIP (4.25 bar)
d) Vacuum ejector (3.5 bar)
e) Screw cap applicator, horn, air gauge
and regulator
f) Screw cap applicator, anvil, air gauge
and regulator
a b c d g) Screw cap applicator, bowl, air gauge
and regulator
h) Hydrogen peroxide heater, air gauge
and regulator
TechPub_2614345_0103 - 3.fm
8
Close all doors and covers.
9
Touch Acknowledge button.
Machine is now ready for starting the
production.
Doc. No. OM-586382-0102 3 - 19 (20)

3 Preparation
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3 - 20 (20) Doc. No. OM-586382-0102

4 Start
Doc. No. OM-586382-0102 4 - 1 (8)

4 Start
Description
This chapter describes the required activities necessary for starting the
production.
4 - 2 (8) Doc. No. OM-586382-0102

4 Start Table of Contents
4.1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Doc. No. OM-586382-0102 4 - 3 (8)

4 Start

4 - 4 (8) Doc. No. OM-586382-0102

4 Start
4.1 Start
1
Make sure that all of the steps from the
section “Preparation” have been
completed
2
Push the Step up button once.
The HEATER indicator light stops
flashing and stays on (solid) meaning the
heaters are on.
TechPub_2614345_0103 - 4.fm
3
If the yellow warning light is flashing,
touch the Acknowledge button.
4
Touch the Operator settings screen
button.
Operator settings screen will appear.
Doc. No. OM-586382-0102 4 - 5 (8)

4 Start
5
Touch the Heater temperature adjust
button.
Heaters temperature controller screen

will appear.
• Top heater
• Bottom heater
TechPub_2614345_0103 - 4.fm
6
If temperature settings need adjustment:
Touch the set point for the top or the
bottom heater.
The temperature adjustment screen for
that heater will appear.
Use the “arrow” buttons to increase or
decrease the temperature setting for the
heaters.
Single arrow changes settings in 1/10
increments.
Double arrow changes settings in 1
increments.
Hold the double arrow button for 5
seconds and settings will change in 10
increments at a time.
Touch Exit and return to the main screen
4 - 6 (8) Doc. No. OM-586382-0102

4 Start
7
When the heaters are up to the
temperature and the Tank fill icon starts
to flash, push the Step up button one
more time.
The Tank fill light stops flashing and
stays on solid.
The Step up button goes off and the Step
down button flashes.
8
Allow the tank to fill up.
Touch the Operator settings screen
button.
TechPub_2614345_0103 - 4.fm
9
Touch the Fill system purge button.
The fill system starts to purge air from
pump cylinder and fill tube.
10
After the purge cycle is completed, push
the Step up button and hold it.
The horn will sound and after a brief
delay the machine starts indexing.
Doc. No. OM-586382-0102 4 - 7 (8)

4 Start
11
Push the Step up button once more and
allow the machine to pick eight cartons
(one carton per mandrel). After eight
cartons are picked, push Step down
button once and bring the machine to
indexing step.
12
Collect the eight packages.
WARNING
Moving parts!
Keep hands clear of the discharger
and conveyor when removing the
test packages. Failure to do so can
lead to serious injury.
TechPub_2614345_0103 - 4.fm
13
Check the package shape and the weight,
see section 5 “Checks”.
14
Once packages meet all the quality
standards (fill volume, seal, appearance,
and so on), the actual production process
will start.
Push the Step up button and start
production.
Repeat volume fill, seal, and appearance
checks every half hour through out the
production process.
4 - 8 (8) Doc. No. OM-586382-0102

5 Checks
Doc. No. OM-586382-0102 5 - 1 (20)

5 Checks
Description
This chapter describes the necessary checking procedures (machine and
packages) to be performed during production.
5 - 2 (20) Doc. No. OM-586382-0102

5 Checks Table of Contents
5.1 Production checks . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5
5.2 Package checks . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 6

Doc. No. OM-586382-0102 5 - 3 (20)

5 Checks

5 - 4 (20) Doc. No. OM-586382-0102

5 Checks
5.1 Production checks

1
During the production frequently check
the following:
a) Visually check to make sure no
condensation is forming on
mandrels. Use the thermostat (a) to
adjust the temperature of the chilled
water.
Note! If machine is not equipped with
the heat exchanger (option), use the
cooling water “in” and “return” valves
to eliminate condensation.
a b) Visually check to make sure that the
chain wash/lubrication water is
flowing in a steady stream.
c) Visually check the flow of carton
through the machine to make sure
nothing is out of normal.
TechPub_2614345_0103 - 5.fm
Doc. No. OM-586382-0102 5 - 5 (20)

5 Checks
5.2 Package checks

Package checks should be performed at
production start-up and at regular
intervals, according to plant policy. Tetra
Pak recommends performing these
checks every 30 minutes.
If any packages fail any of these checks,
the problem must be isolated and
remedied before continuing production!
Refer to the Package Test Manual (PTM)
for instructions on performing package
checks.
WARNING
Infeeds automatically start.
Keep hands clear of all moving parts of
the magazine and infeed sections.
TechPub_2614345_0103 - 5.fm
5.2.1 H2O2 residual test
1
To perform this procedure, you will need
a Chemetrics test kit.
Part TP No.
Test kit 90298-0031
Refills 90298-0032
5 - 6 (20) Doc. No. OM-586382-0102

5 Checks
2
a) Push the Step up button.
b) Push and hold the NO FILL button.
c) Allow the machine to pick eight
cartons (one carton per mandrel).
d) After eight cartons are picked, push
Step down button once and bring the
machine to indexing step.
e) Hold the NO FILL button until all
cartons pass the fill station.
Cartons are formed and sealed but they

are not filled.
TechPub_2614345_0103 - 5.fm
3
Collect the empty packages in the
sequence they have exited from the
machine.
WARNING
Moving parts!
Keep clear of the machine
magazine, infeed, discharger and
other moving parts. Do not operate
the machine with the guard doors
open. Failure to follow these
warnings can lead to serious
injury.
Doc. No. OM-586382-0102 5 - 7 (20)

5 Checks
4
Good manufacturing practices restrict the
use of glass testing equipment in food
processing or preparation areas.
Take the packages to a non-processing
area for the remainder of the test.
WARNING
Moving parts!
TechPub_2614345_0103 - 5.fm
5
Open the Chemetrics test kit.
6
Test the fifth through eighth packages to
exit from the machine. Discard the
others.
Open a test package and fill with distilled
water up to the lower top crease.
Note! Use distilled water only. Do not
use tap water.
5 - 8 (20) Doc. No. OM-586382-0102

5 Checks
7
Carefully swirl the package to mix the
distilled water with any hydrogen
peroxide that may remain in the package.
Do not allow any of the water to spill
from the package.
8
Open the package and pour a small
amount of the water into the test vial
provided with the Chemetrics test kit.
TechPub_2614345_0103 - 5.fm
9
Insert the small end of a Chemetrics test
tube into the water in the test vial.
Press the tube against the bottom of the
vial to break off the end.
CAUTION
The broken end of the test tube is
sharp. Handle with care.
CAUTION
The glass shard from the top of the
test tube is sharp. Dispose of
properly.
Doc. No. OM-586382-0102 5 - 9 (20)

5 Checks
10
Allow water to fill the tube.
Tilt the tube gently so that the air bubble
travels from one end of the tube to the
other. This will mix the sample with the
chemicals in the tube.
11
Insert the tube into the color standards
container provided with the test kit.
Compare the color in the test vial with
the color standards tubes.
Residual hydrogen peroxide should not
exceed 0.5 ppm. However, acceptable
levels will vary from country to country.
TechPub_2614345_0103 - 5.fm
12
Repeat the testing procedure for each of
the remaining packages.
Follow plant policy regarding how many
packages should be tested; however, you
must test at least two packages.
All packages must pass the test and meet
governmental hygiene standards.
Standards will vary from country to
country.
5 - 10 (20) Doc. No. OM-586382-0102

5 Checks
5.2.2 Package integrity test

1
Push the Step up button and allow the
machine to pick eight cartons (one carton
per mandrel). After eight cartons are
picked, push Step down button once and
bring the machine to indexing step.
2
Collect the eight packages.
WARNING
Moving parts!
TechPub_2614345_0103 - 5.fm
3
Visually examine the cap weld and make
sure that:
• The cap is firmly attached to the
carton
• The cap is positioned correctly and
the cap is sealed
• The impression from the ultrasonic
welder horn should be visible and
even all the way around the cap.
Doc. No. OM-586382-0102 5 - 11 (20)

5 Checks
4
Make sure that there is sufficient dye
solution to perform the dye test. Dye
solution should be remade every two
weeks or when the supply is 50%
depleted
Follow these directives to prepare a new
dye solution:
Standard packaging material:
Ingredients:
• 5 grams methylene blue dye powder
• 1 liter warm water (80° C)
• 5 ml Tee Pol solution (wetting agent)
• 200 ml ethanol (70% solution)
Mixing procedure:
1) Dissolve the dye powder in the warm
water.
2) Mix well.
3) Let the solution cool
TechPub_2614345_0103 - 5.fm
4) Add the ethanol and Tee Pol solution.
WARNING
Chemical hazard!
Dye powders may cause injury if
they contact eyes, skin, or mucous
membranes. Wear protective
equipment when working with dye
powders.
5
Select at least two packages for the dye
test. The number of packages tested is
dependent on plant policy.
Cut the packages in half.
WARNING
Take care when cutting the
package. Failure to do so could
5 - 12 (20) Doc. No. OM-586382-0102

5 Checks
6
Pour dye into both the package top and
the package bottom to a height of 3-4
mm.
Let stand for three minutes.
7
Pour the dye solution back into the
container.
Rinse the package with water. Shake well
to remove excess water. Blow dry tops
and bottoms of cartons with clean air.
TechPub_2614345_0103 - 5.fm
8
Unfold the package top and bottom.
Look for indications of leakage. The
arrows indicate probable leakage paths.
If the seals are not acceptable, stop
production and contact your supervisor.
Doc. No. OM-586382-0102 5 - 13 (20)

5 Checks
9
Push the STEP UP button.
Let the machine to pick 30 cartons then
step down to indexing.
WARNING
Moving parts!
Make sure all guards are in place
before starting the carton feed.
Failure to do so could lead to
serious injury.
TechPub_2614345_0103 - 5.fm
10
Follow the passage of the packages
through the machine.
Make sure that the machine is
functioning properly.
5 - 14 (20) Doc. No. OM-586382-0102

5 Checks
11
Let 20 packages pass through the
machine and then remove the next 10
packages.
TechPub_2614345_0103 - 5.fm
12
Weigh each of the 10 packages
individually.
Calculate the average weight of each
package for fill volume accuracy.
Doc. No. OM-586382-0102 5 - 15 (20)

5 Checks
13
If fill volume needs adjustment:
Touch the OPERATOR screen button.
Operator screen will appear.
TechPub_2614345_0103 - 5.fm
14
Touch the Volume adjust button.
The Volume adjust screen will appear.
15
On the Volume adjust screen touch the
Fill volume increase or the Fill volume
decrease button.
Run 30 packages. Allow 20 packages to
pass through the machine, then pick the
last 10 packages for fill volume check.
5 - 16 (20) Doc. No. OM-586382-0102

5 Checks
16
peat the above four steps until correct fill
volume is obtained.
TechPub_2614345_0103 - 5.fm
17
Examine the appearance and the shape of
the package. Make sure that the date is
correctly placed and is legible.
Gently squeeze the package for five to
ten seconds to make sure that the bottom
and top seals are tight.
Doc. No. OM-586382-0102 5 - 17 (20)

5 Checks
18
Open a package. Verify that the package
can be opened easily (non-cap machines
only).
Pour out the product.
Make sure that:
• the package contains the correct
product.
• the product meets established quality
standards.
TechPub_2614345_0103 - 5.fm
19
Make sure that the bottom flaps are
sealed along their entire length.
Make sure that the bottom flaps are close
to each other at the middle seal. The flaps
must not overlap, nor can there be a
visible channel.
Perform a dye check (as directed in this
chapter) every 30 minutes to ensure
bottom seal integrity.
5 - 18 (20) Doc. No. OM-586382-0102

5 Checks
20
Unfold the bottom of the package
completely.
Inspect the sealing surfaces on the inside
and the outside of the package bottom for
heat activation and fiber tearing.
TechPub_2614345_0103 - 5.fm
21
Unfold the top of the package.
Inspect the sealing surfaces for proper
heat activation and fiber tearing.
22
Check packages for leakage by stacking
them in five-tier pyramid.
If there are unacceptable number of
leaking packages, stop the production
and inform your supervisor. Otherwise
continue the production.
Doc. No. OM-586382-0102 5 - 19 (20)

5 Checks
TechPub_2614345_0103 - 5.fm
5 - 20 (20) Doc. No. OM-586382-0102

Doc. No. OM-586382-0102 6 - 1 (6)

Description
This chapter describes activities related to handling packaging material and
caps (optional cap applicator).
6 - 2 (6) Doc. No. OM-586382-0102

6 Supply of materials Table of Contents
Packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 5
Doc. No. OM-586382-0102 6 - 3 (6)


6 - 4 (6) Doc. No. OM-586382-0102

Packaging material
1
Make sure that enough packaging
material and caps are available in the
storage room.
Note! Packaging materials and caps
should be held under optimal
conditions for at least two weeks (see
Packaging material section in the
Installation Manual).
CAUTION
Risk of damage to packaging
material!
Do not double stack pallets of
packaging material.
TechPub_2614345_0103 - 6.fm
2
After the production run, re-seal the
remaining boxes of packaging material
and caps and return them to the storage
room.
CAUTION
Risk of damage to packaging
material!
Do not double stack pallets of
packaging material.
Doc. No. OM-586382-0102 6 - 5 (6)

TechPub_2614345_0103 - 6.fm
6 - 6 (6) Doc. No. OM-586382-0102

7 Volume change
Doc. No. OM-586382-0102 7 - 1 (6)

7 Volume change
Description
This chapter describes procedures to be performed when changing the
package size and fill volume.
7 - 2 (6) Doc. No. OM-586382-0102

7 Volume change Table of Contents
7.1 Volume change . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5

Doc. No. OM-586382-0102 7 - 3 (6)

7 Volume change

7 - 4 (6) Doc. No. OM-586382-0102

7 Volume change
7.1 Volume change

Note! The TR/22 MAX XH is a single volume (2-liter) packaging machine. No other volumes
are available.
TechPub_2614345_0103 - 7.fm
Doc. No. OM-586382-0102 7 - 5 (6)

7 Volume change
TechPub_2614345_0103 - 7.fm
7 - 6 (6) Doc. No. OM-586382-0102

8 Change of product
Doc. No. OM-586382-0102 8 - 1 (10)

8 Change of product
Description
This chapter describes activities that are needed to be performed when
changing product.
8 - 2 (10) Doc. No. OM-586382-0102

8 Change of product Table of Contents
8.1 Change of product . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 5

Doc. No. OM-586382-0102 8 - 3 (10)

8 Change of product

8 - 4 (10) Doc. No. OM-586382-0102

8 Change of product
8.1 Change of product

1
Stop the flow of product to the machine
product tank.
2
Continue packaging until the tank empty
warning light starts to flash.
Machine will continue to fill packages
until a pre-determined low product level
in the tank is reached and then it stops
picking cartons
TechPub_2614345_0103 - 8.fm
3
Weigh the last several packages and
make sure that the fill weight is accurate
4
Step down the machine to Control
voltage on.
Doc. No. OM-586382-0102 8 - 5 (10)

8 Change of product
MME screen
5
The MME screen will appear.
Touch the green “check mark” button to
acknowledge that this is the end of
production.
The MME screen will disappear
6
If so desired, place a suitable container
under the drain pipe to collect the left
over product in the tank.
TechPub_2614345_0103 - 8.fm
7
settings screen button.
8
Touch the Tank filling screen button.
The Tank filling screen will appear.
8 - 6 (10) Doc. No. OM-586382-0102

8 Change of product
9
Touch and hold the DRAIN button until
all product is out.
Note! Some product will be left in the
fill pipe.
10
Remove all the cartons from previous
production.
TechPub_2614345_0103 - 8.fm
11
If screw cap option is not needed or
different caps would be used for the new
product:
– Make sure machine is in Control
voltage on step.
– Place a bag under the cap chute.
– Touch and hold Chute evacuating
button until all old caps have been
discharged.
Note! Touching the Chute evacuating
button only once discharges one cap.
Holding the button for few seconds
will discharge several caps.
Doc. No. OM-586382-0102 8 - 7 (10)

8 Change of product
12
cap option:
– Empty the spinner bowl and clean
it with soft cloth and 70% reagent
alcohol
– Empty the hopper from the
previously used caps and clean it
with soft cloth and 70% reagent
alcohol
– Fill hopper with the new correct
caps.
TechPub_2614345_0103 - 8.fm
13
Fill the magazines with cartons for the
new product. Make sure that the cartons
are stacked evenly and face the correct
way.
Notice the position of the sixth panel.
8 - 8 (10) Doc. No. OM-586382-0102

8 Change of product
14
WARNING
Risk of serious production fault
Clean the pump system in case of
changing of production from a
fermented to a fresh product.
When changing between similar

products, follow plant policy regarding
the need for an intermediate rinse using
SCU or the in-plant CIP disinfection
system.
See “Cleaning” section.
If rinsing is not necessary, continue with
step 13.
TechPub_2614345_0103 - 8.fm
15
Wear sterile gloves and dip your hands in
a disinfectant solution before touching
the machine.
Note! Repeat this step any time that
you have to touch a disinfected
surface.
Doc. No. OM-586382-0102 8 - 9 (10)

8 Change of product
16
Check the filling table for product spills.
Clean if necessary.
17
CAUTION
Cleaning compounds!
Chemical products.
Wear protective equipment.
Follow the Safety precautions.
Disinfect the fill area of the table top

after cleaning using 70% ethanol.
TechPub_2614345_0103 - 8.fm
18
Open the dairy supply valve to the
machine and make sure that the correct
(new) product is available.
19
Start production of the new product.
See “Start” section.
8 - 10 (10) Doc. No. OM-586382-0102

9 Stop
Doc. No. OM-586382-0102 9 - 1 (14)

9 Stop
Description
This chapter describes different methods of stopping the machine.
9 - 2 (14) Doc. No. OM-586382-0102

9 Stop Table of Contents
9.1 Regular stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 5
9.2 Synchronous stop . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 7
9.3 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 - 8
9.4 End of production stop . . . . . . . . . . . . . . . . . . . . . 9 - 11

Doc. No. OM-586382-0102 9 - 3 (14)

9 Stop

9 - 4 (14) Doc. No. OM-586382-0102

9 Stop
9.1 Regular stop

1
For non-emergency machine stops:
– Push the STEP DOWN button
and carton feed will stop.
– Once remaining packages in the
machine are filled and sealed, the
STEP DOWN starts flashing.
– Push the STEP DOWN button
once more and step the machine
down to the desired step.
Note! The “stop time” has to be
recorded for the Machine Mechanical
Efficiency (MME) calculations.
TechPub_2614345_0103 - 9.fm
MME screen
2
The panel must be used to register the
stop time as “the end of production” or as
a “temporary stop”.
Touch the green “check mark” button if it
is the end of production.
Touch the red “X” button if it is not the
end of production stop.
The MME screen will disappear.
Doc. No. OM-586382-0102 9 - 5 (14)

9 Stop
Restart after regular stop

3
Push the STEP UP button and start
picking cartons again.
Note! You may have to push the
STEP UP button more than once
depending on the step that the
machine is in.
Tip! The machine will not start if any

doors are open.
TechPub_2614345_0103 - 9.fm
9 - 6 (14) Doc. No. OM-586382-0102

9 Stop
9.2 Synchronous stop

1
Push the SYNCHRONOUS STOP
button.
The machine stops and steps down to
tank filling step. The mandrels will be
positioned away from the bottom heaters.
Note! Use the Inching button to
discharge all the cartons in the machine.
MME screen
2
The panel must be used to register the
stop time as “the end of production” or as
a “temporary stop”.
Touch the green “check mark” button if it
is the end of production.
Touch the red “X” button if it is not the
end of production stop.
TechPub_2614345_0103 - 9.fm
The MME screen will disappear.
Restart after synchronous stop

3
Remove all remaining packages from the
mandrels.
Spray mandrels with disinfectant (70%
reagent grade ethanol).
Push the STEP UP button and start
picking cartons again.
Note! You may have to push the
STEP UP button more than once
depending on the step that the
machine is in.
Tip! The machine will not start if any

doors are open.
Tip! Run a package integrity test

immediately after restart.
Doc. No. OM-586382-0102 9 - 7 (14)

9 Stop
9.3 Emergency stop

1
CAUTION
The emergency stop must be used
in the case of danger to personnel
or equipment only.
Push the Emergency button on either
side of the machine.
The machine will stop and the ovens will
shut down.
Restart after emergency stop

2
Eliminate the cause of the emergency.
Remove all remaining packages from the
mandrels.
Remove all damaged packages from the
machine.
TechPub_2614345_0103 - 9.fm
3
Reset the emergency stop button by
turning the button clockwise.
Close all machine doors.
4
Push the alarm Acknowledge button to
clear any alarms
9 - 8 (14) Doc. No. OM-586382-0102

9 Stop
5
Push the Step up button once and step up
to Control voltage on.
6
The machine may have to be inched to
allow the removal of all the packages.
WARNING
Moving parts!
Doors must be closed while
inching the machine. Failure to do
so can lead to serious injury.
TechPub_2614345_0103 - 9.fm
WARNING
Fire hazard!
Carton left above the bottom
heaters may catch fire if not
inched past the heaters.
WARNING
Burn hazard!
The bottom ovens are hot. Take
care when working around these
assemblies. Failure to do so can
Doc. No. OM-586382-0102 9 - 9 (14)

9 Stop
7
Clean the machine as warranted by the
nature of the emergency.
Use warm low pressure water for
cleaning.
CAUTION
Do not spray water on top and
bottom heaters.
Spray the product contact areas with

disinfectant (70% reagent grade ethanol).
Note! Run a package integrity test
immediately after restart.
TechPub_2614345_0103 - 9.fm
9 - 10 (14) Doc. No. OM-586382-0102

9 Stop
9.4 End of production stop

1
Stop the flow of product to the machine
product tank.
2
Continue packaging until the tank empty
warning light starts to flash.
Machine will continue to fill packages
until a pre-determined low product level
in the tank is reached and then it stops
picking cartons
TechPub_2614345_0103 - 9.fm
3
Weigh the last several packages and
make sure that the fill weight is accurate
4
Step down the machine to Control
voltage on.
Doc. No. OM-586382-0102 9 - 11 (14)

9 Stop
MME screen
5
The MME screen will appear.
Touch the green “check mark” button to
acknowledge that this is the end of
production.
The MME screen will disappear
6
If so desired, place a suitable container
under the drain pipe to collect the left
over product in the tank.
TechPub_2614345_0103 - 9.fm
7
settings screen button.
8
9 - 12 (14) Doc. No. OM-586382-0102

9 Stop
9
all product is out.
fill pipe.
Clean the machine according to

“Cleaning” chapter.
TechPub_2614345_0103 - 9.fm
Doc. No. OM-586382-0102 9 - 13 (14)

9 Stop
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9 - 14 (14) Doc. No. OM-586382-0102

Doc. No. OM-586382-0102 10 - 1 (22)

Description
This chapter describes procedures to be followed for correctly cleaning and
maintaining the machine.
10 - 2 (22) Doc. No. OM-586382-0102

10 Care and cleaning Table of Contents
Daily cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 5
Weekly cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 5
10.1 Cleaning In Place (CIP/SCU5) . . . . . . . . . . . . . . .10 - 6
10.2 Manual cleaning (daily) . . . . . . . . . . . . . . . . . . . 10 - 11
10.3 Manual cleaning (weekly). . . . . . . . . . . . . . . . . .10 - 16
10.4 Cleaning cap applicator . . . . . . . . . . . . . . . . . . .10 - 20

Doc. No. OM-586382-0102 10 - 3 (22)


10 - 4 (22) Doc. No. OM-586382-0102

WARNING
Risk of serious production fault
Clean the packaging machine at
the end of each production shift or
every 24 hours. Perform all the
steps to clean the machine unless
indicated with the caption Weekly
Care.
Daily cleaning
After a production run, or after 24 hours
of continuous production, perform the
following post-production cleaning and
maintenance steps
• Internal cleaning (also see the
Operation Manual for the SCU/5).
• Manual cleaning.
TechPub_2614345_0103 - 10.fm
Weekly cleaning
In addition, more comprehensive
maintenance procedures must be
performed once a week. These
procedures are marked with the caption
“Weekly care.”
CAUTION
Use only non-chlorinated
detergents for cleaning the
packaging machine. Detergents
containing chlorine will corrode
and pit aluminum parts. Once
these parts are damaged, it is not
possible to clean them to the
necessary level of hygiene.
Use a soft-bristled brush and detergent to

clean the filling machine, unless a special
product is specified.
Doc. No. OM-586382-0102 10 - 5 (22)

10.1 Cleaning In Place (CIP/

SCU5)
1
Make sure that the valve that controls the
flow of the product to the machine is
closed.
2
Place a suitable container under the drain
pipe to recover the product left over in
the tank.
TechPub_2614345_0103 - 10.fm
3
4
all product is drained out.
fill pipe.
10 - 6 (22) Doc. No. OM-586382-0102

5
Remove the fill pipe and the fill nozzle.
Note! Some leftover product will spill
out.
6
Install the cleaning pipe.
Check and make sure that the sensor light
is ON (sensor is activated).
If not, call the repair technician.
TechPub_2614345_0103 - 10.fm
7
Make sure that:
• all doors and hatches are closed and
the machine is stepped down to step
to Control voltage on,
• the cleaning pipe (s) is installed and
sensor is activated,
• cooling water, city water, and
compressed air are on.
8
Touch the ACKNOWLEDGE button.
Doc. No. OM-586382-0102 10 - 7 (22)

9
Check to make sure that the machine is at
Control voltage on step and the SCU/5
is on.
Cleaning (CIP) icon will be flashing.
TechPub_2614345_0103 - 10.fm
10
On the operator panel push the Step up
button three times rapidly.
The Cleaning icon stops flashing and
X3 stays on.
The background color of the cleaning
icon will be white.
10 - 8 (22) Doc. No. OM-586382-0102

11
If machine is in synchronized stop
position:
green.
The CIP will start.
If machine is NOT in synchronized
stop position:
The Motor icon starts to flash.
Acknowledge the alarm. Push and hold
the Step up button, the horn will sound
for three seconds. Continue pushing the
Step up button and the machine
automatically will inch into synchronized
position.
green.
TechPub_2614345_0103 - 10.fm

start.
12
On the SCU/5 Control panel, choose
Short cleaning cycle (recommended for
daily cleaning) or Long cleaning cycle
(recommended for weekly cleaning), see
SCU/5 OM.
The internal cleaning of the fill system
starts.
Doc. No. OM-586382-0102 10 - 9 (22)

13
If a pause in CIP/disinfecting cycle is
desired:
Push the Step down button once.
white.
If a door is opened or Emergency Stop
button is activated during the CIP/
disinfecting cycle:
white.
To restart the Cleaning/disinfecting
cycle:
Push the Step up button once. The
Cleaning icon color changes to green.
The cleaning process will resume.
The cleaning process will resume from
TechPub_2614345_0103 - 10.fm
the beginning of the last interrupted step
or the end of the last completed step.
14
Once the CIP cycle is completed, the
Cleaning icon and the Step up and the
Step down buttons on the operator panel
start to flash.
15
Push Step down button once.
Program will return to Control voltage
on step.
The machine is now ready for manual
cleaning.
10 - 10 (22) Doc. No. OM-586382-0102

10.2 Manual cleaning (daily)

1
Turn the main power switch to the OFF
position.
2
Turn off the following valve:
a a) Air
TechPub_2614345_0103 - 10.fm
3
Pre-rinse the inside of the machine and
the table top. Be especially thorough
around the fill area.
Use low pressure warm water and mild
detergent.
4
Flush the gutters and drains with hot
water. Be sure to flush gutters and drains
on both sides of the machine.
Doc. No. OM-586382-0102 10 - 11 (22)

5
Use a vacuum cleaner to clean the
magazine and then wipe the assembly
with 70% reagent ethanol.
Note! To control the spread of
contaminants do NOT use
compressed air.
Weekly care: Clean the magazine with a

brush and detergent.
6
Use a vacuum cleaner to clean the
suction cups on the carton picker. Make
sure the suction cups are not damaged.
TechPub_2614345_0103 - 10.fm
7
Remove any paper and plastic deposits
that may remain on the mandrels.
Clean the mandrels with alcohol (70%
reagent grade ethanol).
WARNING
Severe burn hazard!
Alcohol is extremely flammable.
Do not spray into the machine
unless all the components,
especially the heaters, are cool to
the touch. Failure to follow this
instruction will result in serious
burns and injuries
10 - 12 (22) Doc. No. OM-586382-0102

8
WARNING
Burn hazard!
Bottom heater is very hot during
production. Make sure that the it is
cool before handling. Failure to do so
can lead to serious injury.
Clean the surfaces of the bottom heater

with a stainless steel brush to remove
deposits, especially those that restrict air
flow through the nozzle holes.
Make sure to remove any built-up
polyethylene residue.
CAUTION
Do not spray water into or around the
bottom heaters.
TechPub_2614345_0103 - 10.fm
9
Scrape all remnants of polyethylene from
the flaps and guides of the bottom pre-
folder.
Clean the exterior surfaces of the bottom
pre-folder with a sponge and detergent.
Clean the folding fingers and flaps with
alcohol (70% reagent grade ethanol).
Blow dry them with clean, oil-free
compressed air.
10
Clean the bottom sealer contact surfaces
with a brush and detergent.
Remove any plastic deposits which may
have been left by the carton.
Doc. No. OM-586382-0102 10 - 13 (22)

11
Clean the top pre-folder with alcohol
(70% reagent grade ethanol) and blow
dry with oil-free compressed air.
Remove oil and water which may collect
on top surfaces. Do NOT remove oil with
compressed air.
12
Scrub the bottom rail with a brush and
detergent. Remove any deposits
(especially under the top oven).
TechPub_2614345_0103 - 10.fm
13
Clean around the carton puller with a soft
brush and a mild detergent solution.
Rinse with clean water.
Weekly care
Inch the machine until the carton puller is
accessible.
Make sure that the suction cup is not
damaged, worn, or loose, and that it is
properly tightened.
14
Inch the machine forward and scrub the
conveyor chain with a brush and
detergent. Clean the entire conveyor
chain.
Inch the machine as needed to access all
areas of the conveyor chain.
10 - 14 (22) Doc. No. OM-586382-0102

15
Clean the fill pipe with a soft brush and a
mild detergent solution. Rinse with clean
water. Clean the fill nozzle.
Immerse the fill nozzle and the fill pipe
in a solution of disinfectant code F.
16
WARNING
Burn hazard!
The ultraviolet lamp assembly is
very hot. To avoid serious burns,
allow the unit to cool down before
handling.
Note! Take care not to scratch or
crack the ultraviolet light lens.
TechPub_2614345_0103 - 10.fm
Remove knobs and remove both sides of

UV tunnel. Tilt up the ultraviolet lamp
assembly housing.
Clean the quartz lens with warm water
and a soft cloth. Then wipe the lens with
70% reagent ethanol. Do NOT leave
fingerprints on the lens.
CAUTION
Do NOT spray water directly onto
the ultraviolet (UV) lamp.
17
Carefully return the ultraviolet lamp
assembly housing to its correct position
over the station chain.Clean the outside
of the ultraviolet lamp housing with a
damp cloth and a mild detergent solution.
CAUTION
Do NOT spray water at or into the
housing.
Doc. No. OM-586382-0102 10 - 15 (22)

10.3 Manual cleaning (weekly)

1
Begin at the top of the fill system. Clean
all external surfaces in the fill system
down to and including the condensate
plates. Use a soft brush and a mild
detergent solution.
Rinse with clean water.
2
Clean the hydrogen peroxide vaporizing
nozzles with a soft brush and a mild
detergent solution. Rinse with clean
water.
WARNING
Burn hazard!
The hydrogen peroxide vapor
TechPub_2614345_0103 - 10.fm
system operates at very high
temperatures. allow the nozzles to
cool before cleaning them.
3
Clean the top rebreaker with a brush and
detergent. Use care not to damage the
small return springs.
10 - 16 (22) Doc. No. OM-586382-0102

4
Clean the surfaces of the top heater with
a stainless steel brush.
Remove the cover plates and clean the
top heater nozzles with a steel brush.
Remove all deposits, especially those
that affect air flow through the nozzle
holes.
TechPub_2614345_0103 - 10.fm
5
Remove all polyethylene residue from
the top forming guides.
Use care not to bend or change the
adjustment of the guides during cleaning.
Doc. No. OM-586382-0102 10 - 17 (22)

6
Clean the top squeezer jaws:
a) Remove the cooling water hoses
from the top squeezer jaws.
b) Remove the top squeezer jaws.
c) Clean with a soft brush and a mild
detergent solution.
d) Clean the surfaces marked by arrows
thoroughly.
e) Rinse with clean water.
f) Reinstall the squeezer jaws and hoses
into production position.
TechPub_2614345_0103 - 10.fm
7
Clean the machine table with a soft brush
and a mild detergent solution. Rinse with
clean water.
Install the sides of the tunnel and tighten
the knob.
10 - 18 (22) Doc. No. OM-586382-0102

8
Check the clean air filters.
If a filter is dirty or clogged, remove the
filter and put in a new filter.
9
Additional weekly care
De-lime all stainless steel doors and
covers. Polish afterward.
Wipe the glass panes with a rubber
squeegee.
TechPub_2614345_0103 - 10.fm
Doc. No. OM-586382-0102 10 - 19 (22)

10.4 Cleaning cap applicator

1
WARNING
Cleaning Compound! Chemical
products.
Follow the Safety precautions in
the front of this manual.
CAUTION
Risk of serious production fault!
When performing the CIP of the
equipment, follow the instructions
described in the CLEANING
section of this manual, using the
recommended product described
in the TECHNICAL DATA section.
Failure to follow these instructions
could cause damage to equipment
and risk contamination of the
package.
Empty the caps from the Hopper.
TechPub_2614345_0103 - 10.fm
Clean the inside of the Hopper with a soft
cloth and 70% reagent ethanol.
2
WARNING
Risk of personal injury!
Before starting any operation
make sure that the main power and
the compressed air have been
turned Off. Bleed the pneumatic
circuit from eventual residue of
compressed air in the hoses.
WARNING
Cleaning compound!
Chemical products. Follow the
Safety precautions.
Open the door and empty the spinner

bowl.
Clean the spinner bowl by means of a
cloth and 70% reagent alcohol.
Take care to not move or damage the
airjets inside the spinner bowl.
10 - 20 (22) Doc. No. OM-586382-0102

3
Evacute remaining caps from the chute:
– Make sure machine is in Control
voltage on step.
– Place a bag under the cap chute.
– Touch and hold Chute evacuating
button until all caps have been
discharged.
Note! Touching the Chute evacuating
button only once discharges one cap.
Holding the button for few seconds
will discharge several caps.
TechPub_2614345_0103 - 10.fm
4
WARNING
Cleaning compound!
Chemical products. Follow the
Safety precautions.
Clean the chutes by means of a cloth and

70% reagent ethanol.
Doc. No. OM-586382-0102 10 - 21 (22)

5
Move the anvil by hand and remove cap
eventually left inside the horn.
CAUTION
Take care not to damage the horn
surface when removing the caps.
Clean the inner part of the horn, the anvil,

and the nest by means of a cloth and 70%
reagent ethanol.
TechPub_2614345_0103 - 10.fm
10 - 22 (22) Doc. No. OM-586382-0102

11 Technical Data
Doc. No. OM-586382-0102 11 - 1 (10)

11 Technical Data
Description
This chapter lists the technical data needed for the correct operation of the
machine. Lists of common lubricants and cleaning chemicals are also
included in this chapter.
11 - 2 (10) Doc. No. OM-586382-0102

11 Technical Data Table of Contents
Setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
Cleaning compounds . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7
Lubricant recommendations . . . . . . . . . . . . . . . . . . . . 11 - 8
Doc. No. OM-586382-0102 11 - 3 (10)

11 Technical Data

11 - 4 (10) Doc. No. OM-586382-0102

11 Technical Data
Setting values
The settings listed below are given as reference points. When troubleshooting, these settings should be
confirmed, and then adjusted according to situational needs.
Main Unit/Value
Main air 6.0 - 7.0 bar
Secondary cooling water 15 - 20ºC

temperature (option)
Clean Air System (CAS) fan 50/60 Hz
Fill system
Fill system air (fill pump) 5.0 bar
Vacuum ejector air 3.5 bar
CIP low pressure 4.25 bar
UPV closing pressure 2.0 bar

TechPub_2614345_0103 - 11.fm
Resuction high 3.0 bar
Resuction low 0.8 bar
Ovens (heaters)
Bottom oven air pressure 14.0 mm of water column using a manometer
Bottom oven temperature 355ºC
Top oven air pressure 35.0 mm of water column using a manometer
Top oven temperature 375ºC
Carton sterlization
H2O2 concentration 2.0%
H2O2 flow 0.6 l/min
H2O2 heater temperature 130ºC
H2O2 air pressure (on screen) 133 kPa
H2O2 air pressure (supply gauge) 2.0 bar
(Cont'd)
Doc. No. OM-586382-0102 11 - 5 (10)

11 Technical Data
(Cont'd)
The settings listed below are given as reference points. When troubleshooting, these settings should be
confirmed, and then adjusted according to situational needs.
APV cluster Unit/Value
A-valve operating air pressure 6.0 bar
B-valve operating air pressure 6.0 bar
C-valve operating air pressure 6.0 bar
Steam temperature 125ºC minimum
Cap applicator Unit/Value
Horn air pressure 4.5 - 5.5 bar
Anvil air pressure 3.5 bar
Bowl air pressure 2.75 bar
TechPub_2614345_0103 - 11.fm
Welding energy (W X sec) 90 Joules
Welding duration, high 260 milliseconds
Welding duration, low 80 milliseconds
11 - 6 (10) Doc. No. OM-586382-0102

11 Technical Data
Cleaning compounds
CAUTION
Do not use chlorine or iodine based cleaning compounds when cleaning parts which
will come into contact with hydrogen peroxide.
Comparable qualities from other suppliers may be selected in compliance with the technical
requirements listed in the table.
All cleaning compounds must comply with local legal requirements.
The supplier recommendations for concentration and temperature should be followed.
When dosing the products automatically, their concentrations should be checked.
Cleaning Code Example

Type of Pure Formulated products
product Chemicals Henkel DiverseyLever
Cleaning A Alkali NaOH 1.5% P3-mip RC VC13 (Soft water)
CIP P3-N 421 VC7 (Hard water)
B 1 Acid HNO3 1% P3-Horolith L31 VA5 (2%)
2 Acid H3PO4 1% P3-Horolith FPC VA3 (2%)
P3-Horolith
TechPub_2614345_0103 - 11.fm
MSW
3 Acid HNO3 + H3PO4 VA4
External C 1 Alkali foam P3-Topax 12 VF9
cleaning TBA/21, 22
(Automatic) 2 Alkali solution P3-mip FPC VK12
TBA/8, 19 P3-FPC
Manual D 1 Alkali solution P3-mip FPC VK12
cleaning P3-FPC
(Wiping) E 1 Acid solution HNO3 0.5% VA5 (1%)
2 Acid solution H3PO4 0.5% VA3 (1%)
3 Acid solution Acetic Acid 0.5% VF12
Manual F 1 Low alkali foam P3-Topax 99 VS1
disinfection 2 Low alkali P3-Steril BG VT1
(Immersion) solution KL-HC 34 UKES
3 Acid Solution Hydrogen Oxonia Aktiv 30 VT6
peroxide
Peracetic acid
Manual G 1 Alcoholic Isopropanol 70% Al-des VT10
disinfection solution Alcodes
(Spray) 2 Alcoholic Ethanol 70%
solution
3 Acid Solution Hydrogen Oxonia Aktiv 30 VT6
peroxide
Peracetic acid
Hand H Spitacid H4
disinfection H5
Doc. No. OM-586382-0102 11 - 7 (10)

11 Technical Data
Lubricant recommendations
The table below lists only a selection of lubricants with their respective designations.
Comparable lubricants from other suppliers may be selected with the aid of the lubricant specifications
(document No in the table).
Lubricant specifications may be ordered from:
Tetra Pak ComTec AB
Ruben Rausings gata - S-221 86 LUND, Sweden.
Lubricant Document Material No Part No (used Example

code No (internal TP when ordering Supplier Product designation
designation from Tetra
for material Pak)
type)
A M 1251.122 51122-85 90 296-28 BP Vanellus FE 10W-30
Motor oil Esso Essolube XD-3 10W-30
Statoil PowerWay D2 10W-30
Mobil Delwac 1400 Super 10W-
30
Shell Myrina TX 10W-30
Caltex/ Ursa LA 10W-30
Texaco
Optimol Non Plus Ultra 10W-40
B M 1254.322 54322-220 90 296-73 BP Energol GR-XP 220
TechPub_2614345_0103 - 11.fm
High- 90 296-78 Esso Spartan EP 220
pressure oil Statoil LoadWay EP 220
Mobil Mobilgear 630
Shell Omala oil 220
Caltex/ Meropa Lubricant 220
Texaco
Imperial Tribol ET 280-220
Kluber Lamora 220
Optimol Optigear 5150 VG 220
B 54322-150 90 296-72 BP Energol GR-XP 150
High- Esso Spartan EP 150
Mobil Mobilgear 629
Shell Omala oil 150
For use in production plant with Caltex/ Meropa Lubricant 150
start temperature below 5°C Texaco
Kluber Lamora 150
C M 1252.122 52122-32 90 296-53 BP Bartran HV 32
Hydraulic oil Esso Univis N 32
Statoil HydraWay HV 32
Mobil DTE Oil 13
Shell Tellus T 32
(Cont'd)
11 - 8 (10) Doc. No. OM-586382-0102

11 Technical Data

code No (internal TP when ordering Supplier Product designation
designation from Tetra
for material Pak)
type)
D M 1251-822 51822-37 90 296-80 BP Autran GM-MP
Mist Esso ATF Dextron
lubrication Statoil TransWay DX II
oil Mobil ATF 220
Shell ATF Dextron II
Caltex/ Texamatic fluid
Texaco (DEXTRON II)
E M 1254.922 54922-460 90 296-77 BP Energol AC-C460
Comp- 90 296-2 Esso Cylesso TK 460
ounded Statoil CylWay FZ 460
cylinder oil Mobil 600W Super Cylinder Oil
Shell Valvata Oil J460
Caltex/ Vanguard Cylinder Oil
Texaco
F M 1255.115 55115-20 90 296-68 BP Energrease LS EP 2
Lithium Esso Esso MP Grease/
grease, Beacon EP 2
EP type Statoil UniWay EP 2 N
Mobil Mobillux EP 2
TechPub_2614345_0103 - 11.fm
Shell Grease 1344 LiEP 2

Kluber Centoplex 2 EP
Optimol Longtime PD 2
H M 1254.322 54322-320 90 296-75 BP Energol GR-XP 320
For use in production plant with Mobil Mobilgear 632
start temperature below 5°C Shell Omala oil 320
Texaco
Kluber Lamora 320
H M 1254.322 54322-220 90 296-73 BP Energol GR-XP 220
Mobil Mobilgear 630
Shell Omala oil 220
Texaco
Kluber Lamora 220
(Cont'd)
Doc. No. OM-586382-0102 11 - 9 (10)

11 Technical Data
(Cont'd)

code No (internal TP when Supplier Product designation
designation ordering
for material from Tetra
type) Pak)
K M 1254.942 54942-100 90 296-15 BP Energol CS 100
Circulation Esso Turbesso 100
oil Statoil TurbWay 100
Mobil DTE Oil Heavy
Shell Tellu Oil 100
Caltex/ Regal Oil R & O 100
Texaco
Imperial Tribol 775
Kluber Crucolan 100
L M 1255.322 55322-30 90 296-9 Dow Dow Corning 7
Silicon Compound
grease Kluber Unisilikon L 250L
M M 1255.112 55112-10 90 296-70 BP Energrease LS EP 1
Lithium Esso Beacon EP 1
grease, EP Statoil UniWay EP 1
type Mobil Mobillux EP 1
Kluber Centoplex 1 EP
Optimol Longtime PD 1
TechPub_2614345_0103 - 11.fm
N M 1255.622 55622-20 90 296-91 Sikema Fluolub 175
PTFE
grease
O M 1255.122 55122-30 90 269-61 BP Energrease LS 3
Lithium Esso Unirex N3
complex Statoil UniWay HT-63
grease Imperial Molub-Alloy ET 860-220
P M 1254.632 54632-68 90 296-54 BP Energol RC-R68
Synthetic Esso Compressor oil 68
compressor Statoil CompWay 68
oil Mobil Rarus 427
Shell Corena Oil H68
Caltex/ Compressor oil VDL 68
Texaco
11 - 10 (10) Doc. No. OM-586382-0102


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OM

Doc. No. OM-586382-0102

Series No./ Machine No. Sign.

Tetra Rex TR/22 MAX 4 Start

10 Care and cleaning

Doc. No. OM-586382-0102

Tetra Pak Carton Chilled Inc., Tetra Rex

Date Installed Kit Added Pages Removed Pages Signature

Doc. No. OM-586382-0102 i - 1 (14)

About the Introduction Chapter

i - 2 (14) Doc. No. OM-586382-0102

Abbreviations and Terminology . . . . . . . . . . . . . i - 12

How to Use This Operation Manual . . . . . . . . . . i - 13

Doc. No. OM-586382-0102 i - 3 (14)

i - 4 (14) Doc. No. OM-586382-0102

• Maintenance Manual (MM)

Doc. No. OM-586382-0102 i - 5 (14)

3.4 Motor 3 Drive

Doc. No. MM-123457-0108 3 - 15 (102)

i - 6 (14) Doc. No. OM-586382-0102

4 - 11 (18) 1 Chapter number

• A pointer arrow (1) indicates the position of an object.

Doc. No. OM-586382-0102 i - 7 (14)

i - 8 (14) Doc. No. OM-586382-0102

Doc. No. OM-586382-0102 i - 9 (14)

i - 10 (14) Doc. No. OM-586382-0102

Doc. No. OM-586382-0102 i - 11 (14)

Abbreviations and Terminology

i - 12 (14) Doc. No. OM-586382-0102

How to Use This Operation Manual

h) Care and Cleaning

Doc. No. OM-586382-0102 i - 13 (14)

i - 14 (14) Doc. No. OM-586382-0102

Doc. No. OM-586382-0102 ii - 1 (30)

Read the Safety Precautions

ii - 2 (30) Doc. No. OM-586382-0102

Safety Messages Description. . . . . . . . . . . . . . . ii - 5

Doc. No. OM-586382-0102 ii - 3 (30)

ii - 4 (30) Doc. No. OM-586382-0102

Safety Messages Description

Doc. No. OM-586382-0102 ii - 5 (30)

ii - 6 (30) Doc. No. OM-586382-0102

There are two types of safety sign

Pos. ISO sign ANSI sign

Moving part can crush and cut.

Chemical burn hazard.

Doc. No. OM-586382-0102 ii - 7 (30)

Pos. ISO sign ANSI sign

ii - 8 (30) Doc. No. OM-586382-0102

Locations of Safety Signs

Doc. No. OM-586382-0102 ii - 9 (30)

ii - 10 (30) Doc. No. OM-586382-0102

Doc. No. OM-586382-0102 ii - 11 (30)

ii - 12 (30) Doc. No. OM-586382-0102

Push one of the EMERGENCY STOP push-buttons to stop this equipment

Doc. No. OM-586382-0102 ii - 13 (30)

After installation and maintenance, and before this equipment is inched or

The location of each movable guard is shown by an arrow.

ii - 14 (30) Doc. No. OM-586382-0102

Doc. No. OM-586382-0102 ii - 15 (30)

ii - 16 (30) Doc. No. OM-586382-0102

Make sure that

Note! Learn the locations of all washing facilities in order to act