Mech 1

P2 line Air pressure regulator
Main air pressure regulator (P3 line)
Pneumatic Panel
Main tab
P1 line
Lund, Sweden
Technical Training Centre
Machine type
Pressure sensor
Soft start valve

P3 line
Tetra Pak A3
P2 line
Main valve
Connection block
Air in
Issue
Ice water in
2/0909
Filter
Cold water in
Ice water out

Tab for group ASU
Supply HI
Tab for group PT ICU water in
OH 2064
Main air pressure Electrical connections dairy
Hot water in
Pneumatic
System
Lund, Sweden
Valve Panels

Machine type
Service Unit
Superstructure - side panel
Machine Body - rear module
TP A3/Speed 020V
Service Unit
Issue
4/1007
Machine Body - front module
OH 1955
Automatic Splicing Unit
Pneumatics
Valve symbol
Tetra Pak Processing & Packaging Systems AB Machine type Issue

Technical Training Centre, Lund, Sweden 1/9411 OH 511:2
Pneumatics
Control signal
4 2
14
5 1 3

14
2
3
1
4
5
5/2 monostable directional valve
14
Pneumatics
3
1
4

14
2
3
1
Valve with separate air supply to pilot valve
5
14
Pneumatics
3
1
4

14
2
3
5 1
4
12
5/2 bistable directional valve
14
Pneumatics
3
5 1
4
12

Pneumatics
3−position directional valve
4 2
4 2
5 1 3
12 14 12 14
5 1 3

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

Pneumatics
Throttle valve
Throttle check valve

Textbook
Pneumatic system
MT-83015-2

Lund, Sweden
This textbook has been compiled by the Technical
Training Centre in Lund.
Some of the pictures in the book are also available as
OH pictures.
For further information on training material, please contact
the Technical Training Centre.
Issue 1/9411
© 1994, Technical Training Centre

No part of this publication may be reproduced, stored in a retrieval system or transmitted in
any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocop-
ying, recording or otherwise, without permission in writing from Technical Training Centre.
Pneumatic system
Training Document
This Training Document is intended for
Training purpose only, and must not be
used for other purpose.
The Training Document is not replacing
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such.
Note!
For safe and proper procedures, refer to
the equipment specific documentation.

Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main air supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Function principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General
The technology of using compressed air to create movement is termed
Pneumatics. In the Tetra Pak packaging machines and distribution equipment,
compressed air is used to:make components move, operated by pneumatic
cylinders
• make components move, operated by pneumatic cylinders
• control and operate valves
• create vacuum and supply air nozzles with air
The pneumatic system consists of two parts. One part is located external to the
machine; in it, the required pressure is generated. The external pneumatics
include compressor, air conditioning unit, main air supply line, etc. The other
part is inside the machine and includes regulators, valves, cylinders, etc.
The air used in the pneumatic components must be clean and dry; pressure and
flow rate must also be as required. The recommended values are specified in
the installation manual (IM) for the machine concerned. In some systems, the
components are factory prelubricated once and for all, requiring no further oil
or grease; air for these components must be as free from oil as possible.
However, if such a component is once mist lubricated, it must always be mist
lubricated from then on.
The pneumatic system of each machine is documented in the form of a
diagram. In order to simplify its construction and make the diagram easier to
read, the various components are shown as symbols.
Pressure Shut–off Pressure regulator

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

stroke by spring.
Double–action cylinder with

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

ton rod.
Double–action cylinder without pis-

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

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

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

controlled by pressure acting
against return spring.

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


controlled by solenoid with return
spring.

controlled by solenoid valve with
separate air supply.

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

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

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

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

automatic drain.
Lubricator.
Air conditioning unit,

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

change–over contact and
variable pressure setting.
Magnetic piston sensor.
Ejector.
Hydraulic unit
Lund, Sweden
1 Oil tank
2 Gear pump
3 Accumulator
4 Oil filter
Machine type
5 Oil level sensor
6 Cutting pressure gauge
7 Oil tank breather
8 Jaw pressure gauge
9 Oil temperature sensor
Tetra Pak A3/Flex

10 Oil cooler
11 Tank draining/filling pipe
12 Tray draining pipe
Issue
13 RH jaw pressure transducer
14 System low pressure switch
1/0807
15 Block filter pressure switch
16 LH jaw pressure transducer
17 LH jaw pressure pipe
18 RH jaw pressure pipe
19 LH cutting pressure pipe
20 RH cutting pressure pipe
21 Valve cutting LH/RH
22 Valve jaw pressure RH
23 Valve jaw pressure LH
OH 2050:1
Water panel
Filter
1
Ball valve
Pressure gauge
Pressure switch
Solenoide valve
Connection block
Air in
Ice water in
5 Cold water in
4
3 Ice water out
2
Supply HI
ICU water in
1 Cold water inlet
2 Flushing final folder
3 Superstructure Hot water in
4 Spray gun
5 Cooling water system Electrical connections dairy
Technical Training Centre Machine type Issue

Lund, Sweden Tetra Pak A3/Speed 3/0909 OH 1455
1 2 3
27
26
Cooling water system
25
1 Expansion vessel
24 2 Pressure gauge
3 Temperature sensor
4 Deioniser
23
Lund, Sweden
5 Ball valve (refilling)
6 Non−return valve
7 Filter
22 8 Sight glass

9 Water saving valve
21 10 Filter
4 11 Heat exchanger (circulating cooling water)
20 12 Expansion valve (circulating cooling water)
13 Regulating valve, capacity
Machine type
19 5 14 High pressure transmitter
15 Cooling compressor
16 Pressure switch (circulating cooling water)
6 17 Safety valve
18 18 Cooling water circulation pump
19 Flow meter (SA)
TP A3/Flex 020V
7 20 Flow meter (circulating cooling water)
17 21 Flowmeter (LS)
22 Flow meter (FFU)
23 Bleeding valve
Issue
16
24 Flow meter (TS left)
25 Flow meter (TS right)
26 Flow switch (TS right)
1/0809
15
27 Flow switch (TS left)
Cooling media
14
OH 2053
Circulating cooling water
13
Tap water
12
11
10 9 8
Central lubrication system
Lubrication points Lubrication points
Metering valve
Manifold
Junction block
To next junction block
Main line
Filter Pressure switch
Level monitor
Lubrication oil tank
PLC
Central lubrication pump
PLC (Supervision
Solenoid valve lubrication program)
TPOP Service and settings

Manual lubrication

Lund, Sweden 2/0108 OH 901
and dosing valve
Rest position
Lubrication oil
Compressed air

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

and dosing valve
Discharge pressure
Lubrication oil
Compressed air

Central lubrication system
Temeto AB
P Figure 1
Is there air supply Manometer
to the pump
P = approx. = 0 bar
Is there oil in the
tank
Faulty pump
T
Always use a manometer
fault−detecting.
P Figure 2
Pressure area 0−60 bar
Is there air supply
to the pump
Check the pump by:
Is there oil in the
tank Repeated manoeuvrings without
Air in the system connected pressure pipe, until oil
free from air is received.
Leakage in the system Connect the manometer to the oil
connection on the pump, thread M10x1.
Faulty pump Connect the air approx. 60 seconds
2 10 T make sure that the pump does not
losen in pressure.
P Figure 3 Connect the oil pipe to the pump.

Leakage in the system Connect the manometer to the oil pipe
50 check the pressure acc to figure 1−4.
Carry through the measures needed to

Is there air supply receive a correct pressure curve.
to the pump See figure 4.
The venting of the main pipe shall be

Faulty pump done systematically.
5 10 T Open all ventilating plugs.
Close them as oil free from air is
received.
P Normal running Figure 4

40
35 P lubr 9x P air
30 T libr appr. 10 sec
25 T pause appr. 60 sec
20 18 bar
15
10 Min. demand
5
1 10 sec
5 10 15 20 T

Lund, Sweden 1/0001 OH 902
Run lubrication cycle
1000 packages
10 s
Lund, Sweden
5 s (time out no pressure). Pressure check for all types of lubrication cycels
10 s

Machine type
Cleaning lubrication cycle (4 cycles)
120 s 10 s 120 s 10 s 120 s 10 s 120 s 10 s
Manual lubrication cycle (1 cycle)

12 s 10 s
Tetra Pak A3/Flex 020V

Issue
Lubrication
Checking pressure
1/0807
Alarms:
Blue, low level + 1000 packages = Yellow, low level
Yellow, low level + 288000 packages = Stop request
Yellow, low pressure + 5 s delay = Fast stop request
PLC
OH 2040
Lubrication cycles
Packaging Material Web
Tetra Pak A3/Flex with PT Flex

Lund, Sweden TP A3/Flex 020V 1/0804 OH 2012
Strip applicator
Encoder Pressure roller
Strip guide
Inductor
Matching
transformer
Splice detector
Technical Training Centre Machine type TP A3 Issue

Lund, Sweden Speed/020V, Flex/020V 2/0910 OH 1990
ASSU Components
B6202
B6201
M6202
M6201
B6204
B6205
B6208

Lund, Sweden ASSU 1/0410 OH 1590
Preparing for strip splice
ASSU

Lund, Sweden ASSU 2/0409 OH 1394:1
Preparing for strip splice
ASSU

ASSU
Splicing

Cooling and unlocking
ASSU

Splice sequence completed
ASSU

Constant web tension
Increase motor speed Decrease motor speed
Lund, Sweden
Machine type
Tetra Pak A3/Flex
Issue
U/P U/P
Trans Main air Trans
Main air ducer ducer
1/0601
Motor Motor
PLC Drive PLC Drive
Control M Control M
OH 1737
Constant web tension
Control of bending roller speed and
pendulum roller force
Counter
roller
Motor drive control
FQ_DriveRoller.OUT.Speed-
Reference
U70M2422
PLC
Position
Regulator
U70B3480
AI_U70B3480
PIO_70A314_Value_1
Speed control The speed of the driven bending roller motor is controlled by a frequency con-
verter. The sensor U70B3480, which is connected to the pivot shaft of the pen-
dulum roller, transmits the actual vertical position of the roller to the PLC. A
PID function in the PLC calculates continously the required speed value, and
transmits it via DeviceNet to the frequency controller. The tag name of the out-
put is FQ_DriveRoller.OUT.SpeedReference and the value is within the range
from 0-600 x 0.1 Hz, i.e. 0 - 60 Hz.
Technical Training Centre 2/0803 TM-01302 Training Document. For training purpose only. 1
U70M2422 PIO_70A213_value_1
U70P2422
U70T2540
U70K2420
P1
Pendulum roller control
Pendulum Roller The pendulum roller force cylinder U70M2422 applies a force to the pendu-
lum roller against the drag of the packaging material. The pressure on the cyl-
inder is controlled by a proportional valve U70T2540 (I/P Transducer). The
analogue input of the valve is connected to an analogue PLC output which is
controlled by the value of the tag AO_U70T2540. The range of that value is
0-10000 (mV) which will result in a proportional valve output pressure from
0 - 6 bar. There are volume dependent factory settings for the pressure, how-
ever, they can be altered from the TPOP. During Spraying and Drying the pen-
dulum roller is in its upper mechanical stop position, in order to expose the
roller and packaging material to peroxide vapor and sterile air. This movement
is done by the solenoid valve DO_U70K2420.
U70M2410
U70P2422
U70K2410
U70R2414
P1
Counter roller control
Counter roller A counter roller is used to enhance the friction between the driven bending
roller and the packaging material. The force on the counter roller is acheived
by a cylinder which is controlled by the pressure regulator U70R2414. The
pressure is fixed to 2.5 bar.
Speed calculation
Jaw speed
Automatic Manual
(Calculated speed) (Constant speed)
Diameter roller (100mm)
Gear box (10:1)
Motor pole number

Error
Repeat length PID
G013.OUT.SpeedReference

Set point pendulum
(CST_LoopSetPointPerc/100)

Max (Par_LoopMaxPosition)
U70B3480 range
Min (Par_LoopMinPosition)
Alarms
The following alarms are related to the constant web tension:
• Pendulum low position (U70B3480 is less than 1400 mV)
• Pendulum high position (U70B3480 is greather than 3600 mV)
• Frequency converter alarm (see alarm code table in MM)
Superstructure
Tube forming

Lund, Sweden Tetra Pak A3/Flex 020V 2/0810 OH 2013
Longitudinal sealing inductor

Lund, Sweden Tetra Pak A3 1/0508 OH 1714
Variable Matching Network (VMN)
Tetra Pak A3
From TPIH
generator
Coaxial
cable
Technical Training Centre 4/1205

TM-01364
VMN Transformer LS inductor
The four electronic switches of the VMN allow

adjustment of the capacitance value of the
matching network.
Reducing capacitance shifts the phase angle
towards positive values, while adding capacitance
shifts it towards negative.
Training Document. For training purpose only.

The new version of the TPIH2500 generator (M10)
optimizes the phase angle by changing the
capacitance in the transformer.
Questionnaire: A3/Flex 020V – Mech 1
Participant:
Instructor:
Date:
Cross-mark the checkbox () in front of the correct answer. More than one answer can be correct
for each question.
1. Which information can be found in the SPC?

 A Set values.
 B How to operate the machine.
 C Spare part numbers.
 D How to install the machine.
2. Where can distributed PLC I/O be found?

 A In the PLC main rack.
 B Only in the electrical cabinet of the filling machine.
 C On the pneumatic valve panel.
 D In the terminal boxes on the different machine modules and in the electrical
cabinets.
3. What is the difference between P1 and P2 air?

 A P2 air has a higher pressure.
 B P1 air has an extra filter.
 C Different compressors supply P1 and P2 air.
 D P1 air is controlled by the machine, P2 only by a shut-off valve.
4. What is the use of the accumulator in the hydraulic unit?

 A To increase the pressure.
 B To keep the pressure more constant.
 C To supply the unit with oil when the tank is empty.
 D To accumulate surplus hydraulic oil.
Technical Training Centre 1/0805 QU-00313 1

5. The cooling water flow rate is too low in all circuits.
A possible reason is:
 A the cooling water temperature is too high.
 B the circulation pump is not properly bled.
 C the pressure is too high.
 D the ion exchanger is clogged
6. How can the function of the dosing valves be checked?

 A By dismantling them.
 B There is no need to check them.
 C They must be replaced regularly.
 D By using colored test oil.
7. What is the purpose of the splice detector in the ASU?

 A To disable the rotation monitor when the splice is passing.
 B To increase the power of the strip applicator when the splice is passing.
 C To decrease the force on the calendar rollers when the splice is passing.
 D To detect a strip splice.
8. How can the strip splice function be adjusted?

 A By changing the temperature.
 B By changing the sealing wire.
 C By changing the sealing time.
 D It is not adjustable.
9. The speed of the driven bending roller in aseptic chamber depends on:
 A the design control system.
 B the speed of the drive roller magazine.
 C the volume adjuster.
 D the position of the pendulum roller.
10. How is the force of the LS pressure roller to be adjusted?

 A By changing the position of the filling pipe.
 B By carefully bending the spring close to the pressure roller.
 C By carefully bending the spring close to its upper bracket.
 D By mounting plus or minus rollers.
Technical Training Centre 1/0805 QU-00313 2

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P2 line Air pressure regulator

Main air pressure regulator (P3 line)

Soft start valve

Ice water out

Tab for group PT ICU water in

Technical Training Centre

Machine Body - rear module

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Throttle check valve

Tetra Pak Processing & Packaging Systems AB Machine type Issue

Technical Training Centre

© 1994, Technical Training Centre

Technical Training Centre

Pressure Shut–off Pressure regulator

Air conditioning unit symbol

The pressure gauge indicates the pressure setting. Pressure gauge

In respect of their purpose, valves are grouped as follows:

This valve can be shown simplified as a symbol.

Pilot air Pilot air

Control signal Outlet ports

Pressure regulator From PLC

No control signal to ports No 12 and No 14 means that the return spring

On port No 12 receiving a control signal, the slide moves to the left in

The valve can be in three positions. In addition to the two positions of a 2–

The three positions of the telescoping slide are illustrated, somewhat

Throttle valve Throttle fitted in

In order to achieve better accuracy in speed regulation, throttle check valves

Rear end Connection Piston Cylinder housing Connection Front end

Connection Piston Cylinder Connection End section

Double–action cylinder with mag-

The direction of movement is controlled by directional valves.. Direction of movement

In order to control the movements of a double–action cylinder, a five–port

Pressure regulator Valve Cylinder

Speed regulation by means

Wrong (input air throttled)

The air on the vent side of the cylinder passes through

A protrusion on the piston closes the central opening in the

In order to successfully set both speed and dampening, it is important first to

Damped too much

U05 Suction cups

Single–action cylinder with return

Double–action cylinder with

Double–action cylinder without pis-

Double–action cylinder without pis-

Double–action cylinder with variab-

Double–action cylinder with variab-

2/2 directional control valve,

3/2 directional control valve,

3/3 soft–start valve.

5/2 directional control valve,

5/2 directional control valve,

5/2 directional control valve,