Electrical System

Introduction
The electrical system in a Tetra Brik filling machine, contains a great
number of electrical components and is documented in the Electrical Manual.
This section describes the functions of the most important and common
components, and also how the Electrial Manual is designed and how it should
be used.

Components
Safety relay The safety relay is used to supervise the emergency stop function as well as
the safety stop function on the machine. The relay can have one or two input
channels, that must be activated in order to keep the safety output relay
activated. For example, an open safety door will cause the input channel to
deactivate the output relay, and this will stop the machine.
At a safety stop, the safety relay will release instantly. To be able to restart the
machine, the cause of the stop must be attended to and the relay has to be reset.
The relay and the alarm will reset simultaneously. The reset function also
implies that the safety relay is functioning.
Example of a safety relay

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The overload protection is used to protect, for example an electric motor, from Overload protection
current surges and sometimes it substitutes fuses.
Example of an overload
protection, front panel Over loadprotection, function diagram

1 3 5

2 4 6

An overload protection device is equipped with two different disconnecting

functions, one thermal and one magnetic:
• The thermal function will break when small overflows occur during a
prolonged time period, f.i. in case of an overload. The breaking limit for
this function is adjustable.
• The magnetic function will break when fast, high overflows occur, for
exampel in case of a short circuit.

A surge filter protects the electrical equipment in the machine from overvolt- Surge filter
age peaks, such as lightning. When a very powerful peak occures and the filter
trips, an indicator on the filter changes from green to red. The machine will set
an alarm, but still be working. The surge filter is used, and will have to be
exchanged to protect the equipment from another overvoltage peak.
Example of a surge filter with indicator relay function

14 12

11

13-2 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 Interference filter Interference filters are used to protect external electrical systems from
EMC=Electro Magnetic Compability disturbances created in the filling machine (EMC-filter). In general, such a
filter consists of a combination of capacitors and coils, that will eliminate
electrical disturbances from getting in or out through the incoming lines.

Solid state relay A solid state relay can be described as an optical electronic relay. In other
words, the control side is electrically disconnected from the power circuit.
LED = Light Emitting Diode Inside there is a LED that gives a light pulse to a transmitter (opto coupler).
Solid state relays are most commonly used when fast, frequent changes with
high power, are required.
Example of a solid state
Solid state relay, function diagram
relay, front panel

4 1
Zero detection

Input Photo Trigger Power

And
circuit detector circuit circuit

+
3 2

Current relay Current relays are used in filling machines to supervise that certain important
components consume power and thus function. For example the short stop
element is supervised on some of the filling machines. This function does not
need to be temperature controlled. It is enough to know that the short stop
element consumes power, in order to guarantee the function.
Current relay, front panel
A1 11 E1 E2 E3

12 14 Y2 Y1 M A2

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This card is used to amplify control signals in order to drive a DC-motor. DC - Motor Drive control
The driver has three internally presetable motor speeds choosen by two digital
input signals. One externally, analog controlled speed, is determined via three
control inputs; Ext. Speed A, B, C. Only one of them should be used.
The driver is short circuit protected on all outputs. If the motor armature
output is short circuited, the unit will switch off and indicate an alarm. This
condition is the same as if the current limit had been exceeded for more than
5 seconds. The red alarm indicator will flash at current limit and show a steady
light if the unit is switched off due to overload or short circuit. The driver is
reset by switching power off, or by clearing the logical control signals. The
motor field output is protected by a fuse.
The different internal speeds are selected with logical signals. These should be
used to control the motor.
Example of a DC motor drive control,
front panel

12. Power indicator

13. Trip, indicates an overload on the output.
Flashing at current limit. Fixed light, when
switched off due to overload.
1 14. Ext Speed, indicates that external speed is
selected.
15. Internal speed 1, indicates that internal
speed 1 is selected.
16. Internal speed 2, indicates that internal
speed 2 is selected.
2 17. Internal speed 1 + 2, indicates that internal
11 speed 3 is selected.
18. Potentiometer for setting internal speed 1.
10 3 19. Potentiometer for setting internal speed 2.
20. Potentiometer for setting internal speed 3.
7 21. Acc. Ramp, potentiometer for setting
4
acceleration ramp.
8 6
22. IxR compensation. Adjustment for
5 different motor powers. Too high settings
9 will result in unstable motion.

13-4 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 Brake card The brake card is used to control the braking force in a powder brake. It is used
for example in filling machines equipped with a PullTab unit.
Example of a brake card,
front panel

Stepping The stepping motor driver card functions as a control unit for a stepping
motor driver card motor. It generates the electric pulses, which run the motor. A stepping motor
has live voltage even when it stands still. The change of angle of the motor, is
controlled by the pulses, generated by the card. In order that the motor shall be
able to rotate correcctly, the breakers on the frontpanel of the card have to be
adjusted according to the description in the MM-book. For example filling
machines equipped with a PullTab unit, have this card.
Example of a stepping motor
driver card, front panel

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A level control relay monitors the levels of liquids. It controls the actuation of Level control relay
pumps or valves to regulate the levels. It is also suitable for protection of
submersible pumps against running empty, or for protecting tanks from
overflow.
Example of a level control relay,
front panel

The operating principle is based on a change in the resistance measured

between immersed or non immersed electrodes. The electrodes may be
replaced by other sensors or probes which transmit values representing
variations in resistance. Because of this, the sensivity of the relay is adjustable
and has to be set according to the conductivity of the liquid.

13-6 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 TMCC & Photocells
TMCC TMCC is a general control card, used for various functions. TMCC means
Tetra Pak Multipurpose Compact Controller. The figure illustrates how
TMCC is used for the purpose of design correction.

Photocells
TMCC
Register code

Angle decoding

Angle encoder
Servomotor

PID regulation

Design

Output data to DMC DMC

Communication
Terminal
with PLC and

PLC

Settings

The following functions are included in a TMCC program for design

correction:
• Register code decoding - This part of the program decodes the signals from
the photocells, converting them into a design signal.
• Angle decoding - This part decodes the angle values utilized in the design
control.
• PID regulation - Here the design deviation is computed and the stroke of
the folding flaps determined. The computation consists of a PID algoritm.
• Output data to DMC (servo motor) - This part of the program provides data
for the DMC on the folding flap stroke for some machine systems, for
example TBA/21.
• Communication with PLC and terminal (PC).
The TMCC is based on a microprocessor card. In order to use the TMCC for
various functions, a program which is adapted to the required function, must
be installed.
One reason for using a TMCC for certain specific functions, is that the TMCC
operates faster than if the function had been part of the PLC program.

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-7
There are a number of LEDs on the front panel of the TMCC card, which may
have different functions depending on the actual function of the card.
Example of a TMCC card,
frontpanel

FAULT • FAULT (red) lights up when the

POWER
TMCC is being programmed
S1
S2 • POWER (green) indicates that
S3
S4 the TMCC is powered with the
S5 voltage
S6
S8
S7
• S1 - S8 (yellow) function accord-
ing to specified application,
789
dependent on the program used
AB
23 6

(SW1)
45

CDE

F01

(Terminal)

The machine must synchronise the packaging material with the jaw system, Photocell
for correct sealing and cutting of the material, which will ensure correct pack-
age design. The photocells read a printed register code on every package.
When the register code passes the photocells, a signal is generated, which the
TMCC uses to ensure a correctly printed design.
The photocell reads tints of dark and light, which are translated into a binary
code. By adjusting the photocell, the breaking point of the photocell can be
determined, i.e. how dark will a field have to be for the photocell to generate
a logic one (1). The photocell recognises the intensity of light and translates
dark and light fields of the register code into a binary code, i.e. logic ones (1)
and zeroes (0). Dark (black) = 1, and light (white) = 0. In order that the
photocells shall be able to read the register code, it is important that the pho-
tocells are correctly focused and positioned, vertically as well as horizontally.

Printed register code and photocell

13-8 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 TPMC PLC
TPMC PLC is used as a control unit in Tetra Pak machines. TPMC is short for
Tetra Pak Machine Controller.

Addressing Each input and output has a unique address which determines its location in
the rack. The address is also a bit in the memory where status for that particular
input or output is stored so that the program can use the information.

The addresses are octal and consist of five positions. These digits have the
following significance:
The first position specifies the type of module in which the address is located:
I=input module, O=output module, E=encoder module, AI=analog input
module and AO=analog output module.
The second position specifies in which rack the address is located. It may be
0 - 7.
The third position specifies in which module position within a rack the
address is located. It may be 0 - 7. In each rack there are eight module
positions.
The fourth and fifth positions specify an input or an output within a module.
It may be 00 - 07 or 10 - 17 for input modules, output modules and encoder
modules. For analoge input and output modules, it may be 00 - 03.
O07.06
Below is shown how racks and module positions are addressed.

Example of a TPMC PLC system

Central unit
Power supply unit
3 2 1 PS
Module positions 0-7 (1-7, power supply unit fitted in position 0)

7 6 5 4
Main rack 0 Address O07.06 is output No 06 in an
output module. The module is fitted in
3 2 1 0 Module positions 0-7 position 7 in rack 0 (main rack)

7 6 5 4
Expansion rack 1

3 2 1 0

7 6 5 4
Expansion rack 2

3 2 1 0

7 6 5 4
Expansion rack 3

A TPMC system can have a maximum of

Expansion rack 7 seven expansion racks.

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-9
GE Fanuc PLC
A GE Fanuc PLC system consists of one or more racks, so called baseplates,
where the CPU is placed in the first baseplate. Each baseplate has one slot for
a power supply unit and 5 or 10 module slots, depending on the model of
the baseplate. The modules can be:
• CPU
• digital input
• digital output
• analog input
• analog output
• thermo electrical
Each module has a position number, for example A004. When a module is
given a position number, one standard to be followed is that the last two
figures of the number, correspond to rack and slot. In this example rack is 0
and slot is 4 (A004). The position number of a module is described in the
Electrical Manual (EM), mounting drawing electrical cabinet.
Example of a GE Fanuc PLC system

Rack 0 PS
1 2 3 4 5 6 7 8 9 10
CPU

Rack 1 PS
1 2 3 4 5 6 7 8 9 10

Rack 2 PS
1 2 3 4 5 6 7 8 9 10

The inputs/outputs of a module have unique references (addresses). The References

reference is the connection between the PLC program and a physical input/
output. The references of the inputs/outputs for a module, are described in the
Electrical Manual (EM), circuit diagram.

13-10 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 Electrical Manual -EM
The EM-section is built upon examples from Tetra Pak Corporate Standard
and from the EM TBA/19.

Purpose of Electrical The purpose of the Electrical Manual is to provide service technicians and
Manual electricians with all information on the electrical equipment required for
service and maintenance.
The Electrical Manual is designed according to Tetra Pak Corporate Standard.
This standard applies to processing modules, packaging machines, distribution
equipment, machine lines and converting machines.
The Electrical Manual contains a great number of various parts. Some of them
are as follows.

Mounting drawing The mounting drawings, also referred to as component location, are links
between the abstract logic of circuit diagrams and the physical dimensions and
features of electrical components.
The electrical components are located in different zones which may be defined
as:
• electrical cabinet
• operating panel
Example of a mounting drawing, el cabinet
B A

AIR DUCT AIR DUCT AIR DUCT

X25 E005
Q001
V001

V001
0080

K K K K K K K K K
S S S 100 101 102 103 104 105 106 107 108
K206 K203 K200
K204 K201
K205 K202

K206 K203 K200

Z003
Z001 X300
X001:003

K K K S S S S S S
S
S

110 111 113

S
S
S
S

X010
Z002
A A A A A A S S
300 301 302 303 305 307

A100 AIR DUCT

M003 M002 G D A A A A A A S S S M003

1 1 1 1 1 1 1 1 B
1 0 0 0 0 0 0 0 0
0 0 2 3 4 5 6 7
VIEW B−B
X003 X011 XL1b3 XL1b3
A101

G A A A A A A A A A A
1 1 1 1 1 1 1 1 1 1 1
0 1 1 1 1 1 1 1 1 1 2
1 1 2 3 4 5 6 7 8 9 0 S Q Q Q Q S S Q Q Q Q Q Q Q
013 011 010 008 012 009 007 006 005 004 003 Q003 Q002
A135

G A S S S S S S S S S
1 1
0 2 FFF FFFFFF FFFFFFFFFFFFF
2 1 S S S S 000 000000 1111111111111
0 0 0 S0 0 0 0 0 0 SS0 0 0 0 0 0 0 0 0 0 0 0 0 SSSSSS F104
1 23 59666 4 000111 2223334
AB C AB C AB C AB C AB C
F007
F008

AIR DUCT AIR DUCT

A VIEW A−A
LEFT HAND SIDE
1 FUNS MUST BE MOUNTED TO HAVE AIR FLOW
TOWARD THE BOTTOM OF THE CABINET
MOUNTING DRAWING, EL. CABINET
52710−08:07

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-11
A circuit diagram illustrates the implementation of any system, piece of Circuit diagram
equipment etc.
It presents information necessary for:
• understanding the function of a circuit
• manufacture
• testing and trouble shooting
• installation or maintenance
A circuit diagram contains:
• all components and connections used on the machine
• graphic symbols representing the components or functions of the circuit
• representations of the connections among those components or functions
• item designations
• terminal designations
• information necessary to trace paths and circuits
• supplementary information necessary for the understanding of the function

Example of a circuit diagram

A104
L12
L11

L10
M.B104
X001:461 SH.45 X001 X001
02 /A1 01
X001:462 SH.45 464 X001 BN BK 463 I033 M.B104 STERILE AIR PIPE
465 BU POSITION
X001:467 SH.56
X001:468 SH.56

A305:15 SH.27
03 /A2
I034 PEROXIDE BATH
WATER LEVEL

M.B016A M.B016B
X001 M.X007 M.X007 M.X007 M.X007 X001 M.B016A JAW SYSTEM OVERLOAD, LEFT
04 /A3
241 28 NC C 29 30 NC C 31 242 I035 M.B016B JAW SYSTEM OVERLOAD, RIGHT

Q006:1 Q012:1
Q006 OVERLOAD PROTECTION
05 /A4
14 13 13 14 I036 COMPRESSOR
SH.10 SH.10 Q012 PEROXIDE BATH, WATER PUMP

M.X007 M.B062 M.X007 X001

06 /A5
32 IV II 33 243 I037 M.B062 STERILE AIR PRESSURE
P

M.B048B M.B048A
X001 X001 M.B048A PEROXIDE BATH
NO C NO C 07 /A6
157 158 159 I038 M.B048B BOTTOM COVER, POSITION

M.B045
1 2 08 /A7 M.B045 HYDRAULIC UNIT
292 t 293 I039 TEMPERATURE
C
3
B
4
A
09 /A8 LOW LEVEL
294 I040
0V
24V
24V

PLC−IN A104,OPERATION MONIT.

44384−41:02

13-12 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 Position summary A position summary is a list showing the sheet on which a component,
identified by its position number, can be found.
Example of a position summary

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-13
A connection diagram provides information on physical connections between, Connection diagram
for example, components, devices, assemblies, and installations.
It presents information necessary for:
• manufacture
• testing and trouble-shooting
• installation and maintenance
A connection diagram contains:
• graphic symbols representing components
• representations of connections between the components
• item designations
• terminal designation
Example of a connection diagram

X001
246
247

248

249

250
251
252

253

254

255
256

257

258

259

260
2

11
2

2
5
3

6
1

1
CLEANING OF
PRODUCTION VALVE

W
310

W W W W
11
2

5
3

6
1

361 405 316 317

M.X014
10

11
12
13
2

5
3

9
6
7

8
1

BU
BK
BN

BU
BK
BN

W W
314 315
2
1

2
1

1
2
1

1 2
M 1 2 1 2

M.M018 M.B116 M.B024 M.B025 M.Y041 M.Y042

PEROXIDE TANK MEMBRANE UNREELING UNREELING PULL DOWN PRESSURE

MOTOR, CONTROL MOTOR, GUARD
FILLING LEAKAGE SENSOR SPEED DEVICE DEVICE

LEAKAGE SENSOR AND SERV. UNIT

61530−25:07

13-14 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 Mains connection A mains connection drawing shows the connection between the mains and the
electrical cabinet.
Example of a mains connection diagram

F001 MAIN VOLTAGE 400/230V Z002 Q002

Q001 X300 X300
L1 (R) 1 AREA TO CABLE 4x25/16 AND 1
SETTING VALUE OF Q002 63/400 1 2 1 2 1 1
L2 (S) 2 2 3 4 5 6 2 3
L3 (T) 3 2 3 5 6 9 10 3 5
X003
N 4 4 N 13 14 N 0
PE 5 5

MAINS CUSTOMER’S FUSE BOX

X011:47
FUSES (SLOW) F001 100A

Z001

FILLING MACHINE CONNECTION

ACCORDING TO DIAGRAM "MAINS"

MAINS CONNECTION
61531−06:02

Line summary A line summary is a list showing the position numbers and internal connection
order of the control voltage lines. It may also show the sheet number and wire
size and colour.
Examplel of a line summary

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-15
A terminal summary is a list of terminals, identified by their position number Terminal summary
and sheet numbers.
Example of a terminal summary

13-16 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
Protecting bonding circuit The protecting bonding circuit drawing, also referred to as ground connection,
shows all protective bonding of components, electrical cabinets, mounting
plates, etc.
Example of a protecting bonding circuit diagram

BE-list and CE-list In the Electrical Manual a BE-list and CE-lists are included.
The BE-list consists of the main groups of the electrical equipment, such as
electrical cabinets, control panel, standard equipment, etc.
The CE-list consists of the different main groups divided into parts. It is here
that spare part numbers will be found.

Program documents In this chapter all necessary information of the program in the PLC will be
found. A sequence diagram will also be found here. The sequence diagram
will show what is activated in the machine and when it was activated. This
diagram is useful for trouble-shooting.

Identification of wiring Tetra Pak use wires according to a specified standard to be able to identify the
different circuits, see the sign below.

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-17
How to use the EM
How to use the EM explains how to find your way through the chapter
Circuits diagrams, Component location, Connection diagrams, Mains
connection diagrams and Program documents in the EM.
The first page in each chapter is always a table of contents, listing all
drawings included in the chapter.
The documents in the above-mentioned chapters are identified by:
• a main number (1)
• a sheet number (2)
• a version number (3)

1 Main number
1 2 3 2 Sheet number
3 Version number

The sheet number is the consecutive numbering of the sheets which belong to
the main number and is used as a reference in the diagrams.
In the circuit diagrams, the sheets(s):
• 5 - 88 are the drawings
• 89 shows the protection bonding circuit
• 90 is the line summary
• 91 is the terminal summary
• 99 is the list of alteration messages
The mains connection diagram shows how the machine should be connected
to the local supply, the dimensions of the connection cable and the connection
of the matching transformer. It is needed when the supply voltage is other than
3x230V/400V. The matching transformer drawing, shows the value of the
fuses in the customers fuse box, cable areas and connection to and inside the
matching transformer
Note!
Always follow local regulations regarding the dimensions of the connection
cable.

13-18 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 Example of a mains connection diagram
MAIN VOLTAGE 200−600V EXCEPT 400/230V

F001
U3
L1 (R) 1 1 1
1U1−1U9 2U
V3
L2 (S) 2 2 2
1V1−1V9 2V
W3
L3 (T) 3 1 3 3 2
1W1−1W9 2W
N 4
N 1
PE 5 5 5
1PE 2PE

MAINS CUSTOMER’S FUSE BOX MATCHING TRANSFORMER CONNECTION

ACCORDING TO DIAGRAM 61531−07:01

Z002 Q002
Q001 X300 X300
1 1 2 1 2 1 1
2 3 4 5 6 2 3
3 5 6 9 10 3 5
X003
4 N 13 14 N 0
5

X011:47

Z001

FILLING MACHINE CONNECTION

ACCORDING TO DIAGRAM "MAINS"

MAINS CONNECTION

The PLC-listing in the section Program documents consists of a ladder

diagram, a cross reference list, a volume depending document and a sequence
diagram.
The following pages demonstrate some examples of how to use the EM.

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-19
Numbering systems for components
The position number is divided into three parts:
• prefix (1)
• function designation (2)
• running number (3)

3
1

W V U

M
3

M.M007

M M 006
1 3 1 Prefix
2
2 Function designation
3 Running number

The prefix shows the location of the component. Position numbers without a Prefix (1)
prefix indicate that the component is fitted in the electrical cabinet.
• the prefix M indicates that the component is fitted on the machine, outside
the electrical cabinet
• the prefix P indicates that the component is fitted on a separate control
panel

The function designation is indicated in accordance with international Function designation (2)
standards, see table below.

Designation Signification in electrical diagram

A Assemblies, Subassemblies
B Transducers
C Capacitors
D Binary element, Delay devices, Storage devices
E Miscellaneous
F Protective devices
G Generators, Power supplies
H Signalling devices
K Relays, Contactors
L Inductors, Reactors
M Motors
N Analogue elements
P Measuring equipment, Testing equipment
Q Switching devices for power circuits
R Resistors
S Switching devices for control circuits selectors
T Transformers

13-20 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 Designation Signification in electrical diagram
U Modulators, Changers
V Tubes, Semiconductors
W Transmission paths, Waveguides aerials
X Terminal, Plugs, Sockets
Y Electrically operated mechanical devices
Z Terminations, Hybrids, Filters, Equalizers, Limiters

Running number (3) The electrical components are given numbers in a consecutive non-logical or-
der.

M M 006
1 Prefix
2 Function designation
3 Running number
1 2 3

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-21
How to trace a cable
Example: How to trace No. 5
• Go to the Connection diagrams chapter.
• Find cable No.5. (1)
• Note the component connected to the cable (M.M004). (2)
• Go to the Circuit diagrams chapter.
• Go to the Position summary (first page(s) in the Circuit diagrams.
• The sheet No. is located opposite the component No. (pos. M.M004). (3)
This tells you on which sheet in the Circuit diagrams the connection is
shown.
• Go to sheet 11 in the Circuit diagrams. (4)
• Find the component (M.M004). (5)
• If the component, as in this example, is controlled by a separate component,
the sheet reference for this component (sheet 62) is found in the Circuit
diagrams. (6)

13-22 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
X001

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39
2

2
3

3
1

1
W
5 1 W
304
W
308
W
301

2
3

3
1

1
U V W U V W
W V U W V U
M M
3 3 M M
3 3

M.M004
2 M.M005 M.M010 M.M007
CLEANING SYSTEM HYDRAULIC PUMP PEROXIDE PUMP COMPRESSOR,
CIRC. PUMP INLET

MOTORS
61530 - 06:05
61530−06:05

XL1
L1 3 XL2 L1 L4
L2 3 XL3 L2 Sh.14 L5
L3 3 L3 L6

A A A B B B C C C D D D E E E
LOW HIGH
1 3 5 13 1 3 5 13 SPEED 1 3 5 13 SPEED 1 3 5 13 1 3 5
Q003 Q008 Q010 Q011 Q013

14 14 14 14
SH.57 SH.57 SH.57 SH.57
2 4 6 2 4 6 2 4 6 2 4 6 2 4 6
6mm 2 BK 2,5mm 2 BK 2,5mm 2 BK 2,5mm 2 BK 2,5mm 2 BK

6
3K003 1 3 5
K008
1 3 5
K010
1 3 5
K011
1 3 5
K013
1 3 5

sh.35 sh.62 sh.62 sh.62 sh.63

2 4 6 2 4 6 2 4 6 2 4 6 2 4 6

A A A

X001 25 26 27 X001 11 12 13 X001 14 15 16 X001 46 47 48

M.X002 1 2 3

U V W U V W

M 1W M 2U M
3 1V 3 2V 3
1U 2W
M.M004 5 M.M001 M.MPLE
CLEANING SYSTEM MAIN MOTOR EXTERNAL
CIRCULATION PUMP CONVEYOR

4 MOTORS
44384 - 11:07
44384−11:07

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-23
cont´d
• Go to sheet 62 in the Circuit diagrams. (7)
• Find the controlling component (K008). (8)
• The figure 11 is a reference back to sheet 11. (9)
• The output (Q016) is a reference to the PLC-listing in the Program
documents chapter. (10)
• Go to the Program documents chapter to see the use in the program.
• Go to the cross reference list at the beginning of the PLC-listing and find
the output (Q016). (11)
• Note the rung Nos. in which the output is used (for example rung 29). (12)
• Go to the PLC-listing and find rung 29. (13)

13-24 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 K019
12
15 /B4 A2 A1 K019 BENDING ROLLER
Q012 35

16 /B5
Q013

C K111 A
5 9
1 sh.32 K011 K010
A B K010 B C 11 11 11 62
17 /B6 43 44 21 22 A2 A1 K010 MAIN MOTOR
Q014 62 35
LOW SPEED
C K111 A
6 10
2 sh.32 K010 K011
A B
A B K011 B C 11 11 11 31 62
18 /B7 43 44 21 22 A2 A1 K011 MAIN MOTOR
Q015 62 35
HIGH SPEED
P002
C
20 10 + − 9 P002 HOUR METER
K008
8 11 11 11
19 /B8 A2 A1 K008 CLEAN. SYSTEM
Q016 35
CIRC. PUMP
0V
24V

0V
PLC−OUT A114, EMERGEN. MODULE
44384 - 62: 07
44384−62:07

13

11

12

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-25
cont‘d

• The prefix M indicates that the component is fitted on the machine.

• Go to the Component location to find the position of the component
(M004). (14).

B55
M13 B50

B116
B51
B117
B53
B104

E1C

E1C
B61
B80,1−2

E1A E1B
X71 L1 L2 X72

X73 X74

B44

X2 14
X8
M4

13-26 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
How to trace a component
Example: How to trace sensor M.B104
• Go to the Circuit diagrams chapter
• Go to the Position summary (first page(s) in the Circuit diagrams).
• The sheet No. (sh.41) is located opposite the component No. (pos M:B104).
This tells you on which sheet in the Circuit diagrams the connection is
shown. (1), ( 2)
• Go to sheet 41 in the Circuit diagrams. (3)
• Find the component (M:B104). (4)
• Note the connections (X001, 463-465). (5)
• Go to the Connection diagrams chapter,
• Find the connection (X001, 463-465). (6)
• The Connection diagram shows how the sensor is connected (in this case
via a connection box).
• The input (1033) is a reference to the PLC-listing in the chapter
Program documents. (7)

13-28 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 457
458
459

460
461
462

463
464
465

466
467
468
BK
BN 6
BU

BK
BN
BU

BK
BN
BU

BK
BN
BU
W W W W
454 455 456 413

M.B071 M.B094 M.B104 M.B117

AIR INLET VALVE SUCTION VALVE STERILE AIR REGULATING VALVE
POSITION POSITION PIPE POSITION OPEN POSITION

TOWER, INDUCTIVE SENSORS

61530−44:04

2 1

5 4 5
A104
L12
L11

L10

M.B104
X001:461 SH.45 X001 X001
02 /A1 01
X001:462 SH.45 464 X001 BN BK 463 I033 M.B104 STERILE AIR PIPE
465 BU POSITION
X001:467 SH.56
X001:468 SH.56 7
A305:15 SH.27
03 /A2
I034 PEROXIDE BATH
WATER LEVEL

M.B016A M.B016B
X001 M.X007 M.X007 M.X007 M.X007 X001 M.B016A JAW SYSTEM OVERLOAD, LEFT
04 /A3
241 28 NC C 29 30 NC C 31 242 I035 M.B016B JAW SYSTEM OVERLOAD, RIGHT

Q006:1 Q012:1
Q006 OVERLOAD PROTECTION
05 /A4
14 13 13 14 I036 COMPRESSOR
SH.10 SH.10 Q012 PEROXIDE BATH, WATER PUMP

M.X007 M.B062 M.X007 X001

06 /A5
32 IV II 33 243 I037 M.B062 STERILE AIR PRESSURE
P

M.B048B M.B048A
X001 X001 M.B048A PEROXIDE BATH
NO C NO C 07 /A6
157 158 159 I038 M.B048B BOTTOM COVER, POSITION

M.B045
1 2 08 /A7 M.B045 HYDRAULIC UNIT
292 t 293 I039 TEMPERATURE
C
3
B
4
A
09 /A8 LOW LEVEL
294 I040
0V
24V
24V

PLC−IN A104,OPERATION MONIT.

44384 -41: 02
44384−41:02 3

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-29
cont’d
• Go to the Program documents chapter to see the use in the program. (8)
• Go to the cross reference list at the end of the PLC.listing, find the input
(I0033) and note the rung Nos. of the block in which the inputs are used (for
example rung 26). (9),
• Go to the PLC-listing and find rung 26. (10)

13-30 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 9
8

10

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-31
Supply voltage
The supply voltage in the electrical cabinet is named:
• L01 - L09: power voltage
• L10 -: control voltage
L10 is reserved for 0 V, control voltage
L11 is reserved for 24 V, control voltage
L20 is reserved for 0 V, safety circuits
L21 is reserved for 24 V, safety circuits
L30 is reserved for 0 V, safety circuits
L31 is reserved for 24 V, safety circuits

How to find out about line connection order

Example: Line connection order of supply line 30.
• Go to the Circuit diagrams chapter. The line connection order is shown in
the Line summary (sheet 90). (1)
• Find the line (L 30) and its terminal position (XL30,2). (2), (3)
• The position list shows the connection order of the supply line
(K019,A1). The sheet No. (sh.62) is located opposite the terminal No.
(pos. K019,A1). (4)
• Go to the Circuit diagram and find the component (K019). (5)
• Find the supply line for the component. (6)

13-32 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 2 3
4

A114 6

L30
L30
L31

M.X034 M.X034
X001 M.X034:8− SH.61
11 12 /B1
Q009 408 9 9−

13 /B2
Q010 409 10 10−

14 /B3
Q011
5
K019
12
15 /B4 A2 A1 K019 BENDING ROLLER
Q012 35

16 /B5
Q013

C K111 A
5 9
1 sh.32 K011 K010
A B K010 B C 11 11 11 62
17 /B6 43 44 21 22 A2 A1 K010 MAIN MOTOR
Q014 62 35
LOW SPEED
C K111 A
6 10
2 sh.32 K010 K011
A B
A B K011 B C 11 11 11 31 62
18 /B7 43 44 21 22 A2 A1 K011 MAIN MOTOR
Q015 62 35
HIGH SPEED
P002
C
20 + − P002 HOUR METER
K008
11 11 11
19 /B8 A2 A1 K008 CLEAN. SYSTEM
Q016 35
CIRC. PUMP
0V
24V

0V

PLC−OUT A114, EMERGEN. MODULE

44384 - 62:
44384−62:07 07

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-33
How to trace a terminal
Example: Connection in connection terminal box M.X007, block 14-15.
• Go to the Connection diagrams chapter.
• Find the connection box (M:X007) terminal block 14-15). (1), (2)
• Note the component connected (M.Y043). (3)
• Go to the Circuit diagrams chapter.
• Go to the Terminal summary (after the Circuit diagrams drawings).
• The sheet No. (sh. 71) is located opposite the terminal No. (pos M:X007),
terminal block (14-15). This tells you on which sheet in the Circuit
diagrams the connection is shown. (4), (5), (6)
• Go to sheet 71 in the Circuit diagrams. (7)
• Find the component (M:Y043). (8)
• Note the connections (X007, 14-15). (9)
• The output (%Q082) is a reference to the PLC-listing in the Program
documents chapter. (10)

13-34 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 M.X007

10

11

12

13

14

15
2

5
3

9
6

8
1
1 2

BU

BK

BN

BU

BN

BU

BN

2
1

1
W W W W W
102 010 011 106 107

BU

BK

BN

BU

BN

BU

BN

2
1

1
5 2 5 2

C NO 1 2 1 2
NC

M.B010 M.B011 M.B012 M.Y022 M.Y043

3
CRANK SIDE PROTECTOR, MAIN DRIVE UNIT,
POSITION POSITION MACHINE, BRAKE
CLUTCH
LEFT RIGHT

M.X007 BODY AND DRIVING UNIT

61530−23:02

6 4

A119
L10
L11

L10

01 02 /A1
Q081

10 M.Y043 M.X007:13 SH.69

X001 M.X007 M.X007
03 /A2 M.Y043 DRIVE UNIT, BRAKE
Q082 236 14 1 2 15 M.X007:16 SH.39

9 8 9
A001:26 SH.12
04 /A3 BENDING ROLLER
Q083 ENABLE

A400:20 SH.33
05 /A4 DESIGN ENABLE
Q084

06 /A5
Q085

A400:22 SH.33
07 /A6 VOLUME ENABLE
Q086

A400:23 SH.33
08 /A7 VOLUME CLOCK
Q087

10

A400:24 SH.33
09 /A8 VOLUME DATA
Q088
24V
0V

0V

PLC−OUT A119
44384
44384−71:02- 71: 02
7

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-35
cont’d
• The prefix M indicates that the component is fitted on the machine.
• Go to the Component location chapter to find the position of the
component (Y043) on the machine. (11)
• Go to the Program documents chapter to see the use in the program. (12)
• Go to the cross reference list at the end of the PLC-listing and find the
output (%Q0082). (13)

13-36 TM-00078 Training Document. For training purpose only. Technical Training Centre 2/9909
 B21C B21A
B47
B236 B46

M16

S4
B85

B21B

B37A B37B

B9

B112
B108
R36
B38
B4
X32 X34 B48B
Y1 Y27
Y102 Y26
Y24 Y32
Y21
Y20
Y86 Y31
SPLICING TABLE Y25
Y23 R5
Y19 Y51 Y29 A−B−C
B14 Y17 B7 B15
Y9 Y105 Y39 B11 Y109
R1 Y8 Y106 B118
Y7
Y6
Y5
Y14
Y13 S28
B2
B30 11 B119
Y12 S14 Y33 Y22 B20
Y3 B6
Y2 B10 Y43
X33 X35
M5 B45
B1 B16A
Y107 X1 B13
M6
Y41 Y42

12

10-23-96 15:21

13

Technical Training Centre 2/9909 TM-00078 Training Document. For training purpose only. 13-37