CUSTOMER TECHNICAL INFORMATION

A-MANDATORY - Corrective
MKC Software Upgrade NOV17
MKC MKC Number:: 3527998-0100
Packages affected: All

Affected Machine System A-List Material Number Standard from serial nr.
Tetra Pak® A3/Flex 648575-0400 21218/00555
Estimated machine downtime, hours: 3
*) Included the time for the installation of PLMS Centre 0400 (see section Rebuilding Kit Installation
Requirements below)
Affected Components
Software

Background
The intended use of this Upgrade Kit is to upgrade delivered Tetra Pak® A3/Flex filling machines
with the latest version of the software. These improvements are done to get the higher degree of
functionality.

Improvement / Benefits
This Kit enables the installation of the following Kits:
 MKD 3458450-0100 Bending Roller*
 MKC 3540076-0100 Control Loop*
 UK 3535128-0100 Additional Water Gun
 MKC 3525001-0100 TBA1000E TS Inductor
 Other Kits not explicitly listed here that specify, in their respective Technical Bulletins, that this
Software Upgrade Kit, or a predecessor, is a Requirement for installation.

*) = Ongoing revision of MKD 3458450-0100 Bending Roller and MKC 3540076-0100 Control Loop may
cause a new Issue of this Software Upgrade kit, or manual software modifications to be applied.

The Kit also introduces the following enhancements and corrected anomalies. Depending on the
machines software version, some of the features may be already implemented. The table is sorted by
time of introduction in the intermediate software versions, the most recent being at the top. For more
information, see the Release Notes document included in the Software media released with this kit.

Profile Loader Extension TPFU_Motion and TPFU_Process have been reconfigured in order to
have their related set of parameters included in csv files, instead of
being stored in the PLC program, when the program runs on CPU L6x
(A3/Flex 0200 and 0300 NO TGA).
The csv files are stored in the TPOP hard disk.
Depending on the recipe selected, an automatic procedure will load
the specific set of parameters from the csv files to the PLC memory.

Tetra Pak® Trademarks:

Tetra Brik® - TB Tetra Brik® Aseptic - TBA Tetra Classic® Aseptic - TCA Tetra Evero® Aseptic - TEA
Tetra Top® - TT Tetra Prisma® Aseptic - TPA Tetra Fino® Aseptic - TFA Tetra Recart®
Tetra Rex® - TR Tetra Gemina® Aseptic - TGA Tetra Wedge® Aseptic - TWA

CTI 01

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UniPack Implemented interface with the UniPack system (introduced as
Optional Kit).
TBA1000E WGC30 motion Motion profile updated to version 31.03 to avoid mechanical stress
profile 31.03 during tube empty operations.
TBA500E: Cap On Knife Parameters have been updated to avoid the “cap in jaw” issue.
parameters update
TBA 1500E parameters Updated sealing parameters.
updated
TBA1000M motion profile Introduced profile predisposition for local customization.
41.01
TBA500E LS Start Parameters for LS waste at Start Sequence modified to prevent
Sequence waste "Barcode Missing Alarm".
(CI 2000041583)
Packs Counters: IN, OUT, Corrected packs counting during preparation phase.
Waste, Inching, Tube
Sealing
TPA750Sq motion profile Parameters in profile 7.01: cantilever position, photocells height and
7.01 design setpoint, restored to values as in profile 6.01.
Note: this profile is used for local customization; profile 6.01 is the
standard for this volume. If profile 7.01 is used, the design offset
setting must be performed.
PLMS NRG Enhancements:
- Custom Stop Reason selection list
- NRG Logger can communicate with new Wonderware ABCIP I/O
server
Corrected anomalies:
- At midnight not all signals are broken correctly
- When the LC watchdog stops the LC topic is disconnected and
then reconnected
- No shifts logged and midnight break missing
- Date mismatch in SQLite log files
- SQLite files created at midnight don't start with version records
- Last Point Counter not working when set to Line Controller
(CI 2000043543)
Quality Diagnostics - Correction for MAQS USB Sampling Plan mode being modified
Service issues when loading a existing recipe
- Correction for operator sheet popups not being disabled when
switching from MAQS USB to Manual Sampling Plan mode
- Corrected visibility of columns in Single/Double modes of the JEID
configuration
(CI 2000058609)
TMCC JELID - Added a de-bouncing function on the printer photocell signal to
filter fake transitions
(CI 2000057681)
- Added a circular buffer mode in the Softscope function
MaPS functionality The MaPS functionality is active by default for the following volumes:
default activation for TBA1000UE, TBA1500E
selected volumes
TBA1400B and TBA1890S Volume configuration parameters updated.
parameters update
HMI alarms Visibility of the following alarms corrected:
- DCS Photocells alarms with MaPS functionality active
- Filling system, steam barrier high temperature warning
HI Anti Clogging New feature to prevent HI nozzle clogging.
(CI 2000012772)
TBA1500E Motion profile Motion profile updated.

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5.02
Non-sterile inching logging Added signals to log the execution of non-sterile inching (fast and
slow).
TBA1890S, TBA1400B Volumes TBA1890 Slim and TBA1400 Base introduction.
Water Treatment Unit Signal logic is changed to enable the unit once the KIT is activated.
enable signal
TBA1000E profile Stroke down correction limit updated on index 2.
parameter update
TBA500E and Profile selection on TBA500E and TBA1000E_QC depending on Fully
TBA1000E_QC profile Filled kit installation
selection
Design set point multiple Enabled the possibility to select different position for the design
configuration correction depending on sensors (photocells or MDR) and installed Kit
(MaPS)
TBA1500E Volume TBA1500 Edge introduction.
TBA500E Fully Filled Kit Kit introduction for different profile selection on TBA500E and
TBA1000E_QC.
Waste counting logic Updated the logic for waste counting when stop timer expires.
updated
C valve flipping C valve flipping for fix problem of product clogging.
Vent Inching sequence The purpose of the sequence is to empty the tube and eject the
packaging material with pre-application before going to Venting.
(CI 2000003720)
DIMC blow low pressure If the pressure is under a specific threshold, a new alarm will trigger
and will stop the machine.
(CI 2000039540)
DIMC Cap melted During production stops the DIMC blower stops and its frequency is
set to zero to prevent melting of caps.
(CI 2000016316)
Motor inching start Start sequence handling has been improved and machine will be
sequence commanded in stop if motor inching start sequence is interrupted
incorrectly.
(CI 2000044432)
PLMS Waste counting All the interested TPOP waste event counters are increased and only
the priority PLMS waste counter is increased after one minute of
production not to double count the waste in the allocated stop.
Sampling sequence Sampling logic updated to fix anomaly during start (first start, short stop
and normal stop).
ASSU Waste Enabled the waste for Strip Waving also when the function STRIP
SPLICE ANTICIPATION is active, if the bobbin has emptied due to
wrong setting (8 packages wasted).
ASSU empty bobbin Changed direction settings of motor for empty bobbin during automatic
rotation strip splice (CI 2000043074).
No filling after consecutive Prevent wrong management of the A valve after consecutive WERD
WERD events detected events.
(CI 2000040562)
TP Printer Layout Editor Added printer 520i to PrinterBridge.

Enhancements and corrected anomalies already introduced in predecessors of this Kit are included. For
a complete list, see either the respective Technical Bulletins, or the Release Notes document included
in the Software media released with this Kit.

Customer Impact
Notes:
- This description is referred to the software version included in the last kit of type: A-MANDATORY.
As this Software Upgrade kit includes the features of the intermediate versions, some of the

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 contents of this description may be not relevant for a machine equipped with such an intermediate
version, either installed with a previous Software Upgrade kit of type: B-UPGRADE, or delivered as
new with such version.
- The modified functionality provided by this software, aimed to enable other kits (see section
Improvement / Benefits / Enhancements), may produce impacts which, if any, are described in the
respective Technical Bulletins of the other kits and are therefore out of the scope of this description.

Impact:
- Valid only for filling machines with installed and enabled HI OPTION:
HI NOZZLE ANTI CLOGGING feature is added.
This feature integrates, in HI management, a ramp starting from maximum injection pressure that
decreases to the set point value at Production start; it also activates an injection pulse at maximum
pressure at Production stop.
Can be activated/deactivated by the operator and is saved as a Recipe parameter.
It is aimed at preventing HI nozzle clogging, anyway gives benefit only for thick or sticky and no
foaming products (eg. drinks with high protein content, nutritional drinks, drinks with high sugar
content, medical food). To get stronger anti clogging effect, the use of new designed nozzles is
recommended. The new nozzles are available as Optional Accessories.
The feature activation could affect on a slight increasing of the level at stop if the product is thin.

- The PRODUCTION FINISHED STOP/END PRODUCTION phases are modified by the introduction
of the VENT INCHING sequence.
The purpose of the sequence is to ensure that the tube is effectively emptied before going to the
VENTING phase, and if a DIMC unit is installed, that the packaging material with moulded caps is
ejected.
The sequence can be bypassed by the operator.
The Vent Inching functionality solves issues related to “Steam Trap Clogging” and preserves the TS
inductors life time, avoiding mechanical interactions with the Jaw System during the next Tight Tube
phase.
The new functionality has no impact on PME (Package Material Efficiency).
There is impact on total waste due to the execution of the sequence.

- Valid only when the function STRIP SPLICE ANTICIPATION is selected.

Already introduced by MK Software Upgrade JUN15, to solve possible “strip waving” issues when
the ASSU splice was activated by the empty bobbin sensor, the function activates the splice when
the bobbin motor exceeds a pre-defined speed.
The function can anyhow be disabled by a technician.
In case the splice gets activated by the sensor due to the function having been disabled, or for
wrong setting of the function-triggering motor speed, the waste for the ASSU Splice event is
increased from three to eight packs.

- Valid only for Volume: TBA500S

Added package waste (minimum one, maximum four packages, depending on the Jaw System stop
position) during stop ramp to avoid package crash in the Final Folder Unit.

Impact starting from UK Software Upgrade FEB17

- Machine Aided Quality Sampling (MAQS) is added. MAQS is a system combining package
sampling operations, production data and defective package data for commercial sterility to enable
expert analysis.
MAQS is the enabler for the Quality Diagnostics Service. The service allows finding the right
balance between cost of quality control and cost of non-quality by identifying improvement
opportunities through expert analysis on the quality data collected for commercial sterility.

- Valid only for Volume: TBA1000E

During deceleration at stops, the synchronization between the Drop Chute and the Final Folder is
not optimal and the last package being sent to the Final Folder may crash. As a precaution, the last

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 two packages of the deceleration sequence are now set for waste (the very last package may be
wasted at the next restart).

Impact starting from UK Software Upgrade JUN16

- Possibility to set on the TPOP the maintenance (TPMS) interval and keep track of the maintenance
status is added. A warning will activate when maintenance becomes due.

Impact starting from UK Software Upgrade DEC15

- When the Short Stop maximum time has elapsed, the packaging material in the machine must be
renewed by inching, or by restarting Production; Operators are informed of this need by the alarm
EXCEEDED SHORT STOP TIME WARNING on the TPOP. With this Software Upgrade, the
machine’s hooter will also play continuously to catch the attention of the Operators.

- Valid only for Volume: TBA1000S

Corrected anomaly prevents unnecessary waste of four packages at packaging material splice
when running at 6000 packs/hour capacity.

RK MSTK Material number Machine variant

3527998-0101 Tetra Pak® A3/Flex 0400

Translation date:
Translation issued by:

For further technical information, please, contact your local Tetra Pak Representative.

Disclaimer
This Technical Bulletin is issued to help the Customer to meet a certain regulatory requirement or to otherwise enable functionality
or other features of certain equipment in the Customer’s installed base to meet certain industry standards. The Customer is aware
and confirms that following the instructions herein is not necessarily adequate to meet such requirements and standards and that
it is ultimately the Customer’s sole responsibility to ensure that its equipment is and remains compliant with laws and regulations.
In addition hereto, the kit is supplied subject to the terms and conditions set out in Tetra Pak’s Terms and Conditions for Genuine
Parts on Time which can be accessed at www.tetrapak.com and such terms are incorporated herein by reference.
www.tetrapak.com

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