EM

Electrical Manual

DB 30
622053

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,
Dynablow DB 30

Dynablow DB 30

1.couverture

TETRA PAK PET PACKAGING SYSTEMS SA

Doc N° EM 586532-0118
2 Doc N° EM 586532-0118
 Contents
Machine identification..................................................................... 4
Service ........................................................................................... 4
Manufacturer .................................................................................. 4

1. Introduction ................................................................................. 4
A word about this Electrical Manual (EM) ...................................... 5
Authorized technicians ................................................................... 5
Document producer ....................................................................... 5
Further copies ................................................................................ 5
Copyright © 1996 Tetra Pak PET Packaging Systems S.A. ........... 5

2. Safety precautions ......................................................................6

2.1 Danger warning levels ............................................................. 7
2.2 Danger signs ........................................................................... 7
2.3 Locating quick stops ................................................................ 8
2.4 Description of safety measures ............................................... 8
2.2.1 Safety in abnormal conditions of use .................... 8
2.2.2 Electrical tests ....................................................... 8

3. Operating diagram ......................................................................9

4. Location of components .......................................................... 10

4.1 The control cabinet ................................................................ 10
4.1.1 Inside the control cabinet .................................... 10
4.1.2 Control panel....................................................... 11
4.1.3 Signal lamp ......................................................... 11
4.2 List of inputs (In) and outputs (Out) ....................................... 12
4.2.1 Where the signal lamps of the inputs (In) and the
outputs (Out) are ................................................. 17
4.3 Detail of blocks A and B ........................................................ 18
4.4 Motors and heaters ............................................................... 19

5. Wiring diagram ...........................................................................21

Doc N° EM 586532-0118 3
 1. Introduction

To ensure maximum safety to the operator, always read the safety rules (Chapter 2)
DANGER! carefully before doing any work on the machine or making any adjustments.

Service
When ordering spare parts for your machine, contact the nearest Tetra Pak service station.

Manufacturer
This machine was made by:
TETRA PAK PET ITALIANA SRL
Via Garbagna, 2
15058 VIGUZZOLO (AL) / ITALIA

Machine identification

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Machine number

00
00
00

Machine type

Drawing specification Tetra Pak

Machine Type DB 00
Machine number
Drawing Spec. 000000000
Machine N° 000000000
Manufacturer
Manufacturer Tetra Pak PET Systems Italia

Place of manufacture TORTONA (AL) - ITALIA

Year of manufacture 1997
Year of manufacture 4.introduction

The plate carries data needed when contacting Tetra Pak concerning this particular machine.

4 Doc N° EM 586532-0118
About this Electrical Manual (EM)
The purpose of this Electrical Manual is to provide service technicians and electricians with all the informations on
electrical equipment required for service and maintenance to the machine.
This manual contains an operating diagram, the components location, the wiring diagrams, a list of spares parts and
an instruction manual for the heaters temperature regulator.

It is important to keep this manual for the lifetime of the equipment, and pass it on to any subsequent owner or user .

Authorized technicians
Only technicians emploied or trained by Tetra Pak are authorized to work on the machine.

Document producer
This document has been produced by:
Tetra Pak PET Packaging Systems S.A..
2, ch. Louis Hubert
1213 Petit Lancy
Geneva - Switzerland
Tel : (41 22) 879 1900
Fax : (41 22) 879-1901

Additional copies
Additional copies can be ordered from the producer (see above). When ordering technical publications, always quote
the document number printed on the front cover of the document concerned.

Copyright © 1998
Tetra Pak PET Packaging Systems S.A.

Doc N° EM 586532-0118 5
 2. Safety precautions

• This blowing machine is designed solely for producing bottles. Any other use is not in accordance with its
purpose. The makers cannot be held responsible for any damage which may result from other use.
• The machine must be operated at a room temperature situated between 18°C and 40°C. Any use at
another temperature could damage the machine.
• PET bottles can only be filled with food products or domestic soap.
• The bottles must be cleaned before filling.
• For safety reasons, all spares parts, as well as moulds, must be of TETRA PAK origin.
• The machine may be operated and/or maintained only by authorized* personnel. Authorized
personnel consists of persons trained or instructed by Tetra Pak or Tetra Pak technicians
themselves.
• Before starting the machine, make sure that there is no one inside it.
• All personnel charged with starting, assuring the operation, maintaining and repairing the machine must
have read and understood the instruction manual, in particular this page on "safety".
• The operator must report at once any modifications carried out which affect the safety of the machine.
• The operator must keep his workplace clean and tidy. His view of the machine and access to the controls
must not be obstructed.
• The control cabinet can only be opened by electricians.
• Modifying, remove,put out of fonction or otherwise change components to anything else than specified in
this manual may influence on the safety of the machine and the manufacturer takes no responsability for
doing so. The safety contactors must on no account be bypassed.
• The measuring instruments of the compressed air system are to be watched during operation. The safety
valves settings are not to be altered.
• Repairs or maintenance may be started only if the machine is in zero energy state: without voltage and
air pressure (the compressed air lines must be vented to atmosphere). Set the main switch on the control
cabinet to OFF. If there are lines that have not been vented there will be a grave risk of accident, such
as ultra-rapid closing of the blowing mould.
• Only specialized refrigeration engineers should be allowed to repair damage to the refrigeration circuit of
the electrical cabinet cooler. The refrigerant can become toxic and extremely dangerous in the presence
of a naked flame.
• The safety precautions set out in the various chapters of the technical documentation must be observed.

The use of hearing protection is recommended.

See § 3.4 of the Installation Manual for details.

,,,,
GQ000142

,,,,
It is prohibited to spray-clean the machine and the electrical cabinet.

,,,,
If the floor around the machine needs to be washed, the doors of the machine and of
the electrical cabinet must be closed.
Danger8

6 Doc N° EM 586532-0118
2.1 Danger warning levels

DANGER! Immediate danger to life!

Failure to observe this information will result in death or serious personal
injury!

WARNING! Risk of serious personal injury!

Failure to observe this information could result in death or serious
personal injury!

Caution! Risk of minor personal injury!

Failure to observe this information may result in minor personal injury.

IMPORTANT! Risk of damage to equipment!

Failure to observe this information could result in damage to equipment!

2.2 Danger signs

This sign is a warning about a risk of burning.

These signs are warnings about a risk of electrocution with

immediate danger to life.

This sign is a warning about a risk of crushing. Do not touch

the mould or any moving parts while the machine is running or
before the compressed air tanks have been bled.

This sign is placed on certain air accumulators that remain

under pressure even after a machine stop. It is a warning about
a risk of personal injury. These accumulators must be drained
before beginning any maintenance work on the machine.
10 BAR
GQ005084

Doc N° EM 586532-0118 7
2.3 Locating quick stops

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2.4 Description of safety measures

The machine complies with the following European safety standards:

EN 292-1 : Basic principles - Methodology

EN 292-2 : Basic Principles - Technical specifications
EN 294 : Safety distances
EN 418 : Emergency stopping equipment
EN 60204-1 : Machine safety - Electrical equipment of machines

2.2.1 Safety in abnormal conditions of use

The transition from manual to the automatic operating mode is performed with a key. In manual mode, all safety
devices remain operational.

A key (held by the authorised technician) makes it possible to work with the control cabinet door open; the safety
devices remain operational in this state also.

2.2.2 Electrical tests

The following electrical tests (according to EN 60204-1) were conducted on the machine prior to delivery:
• ISO at 500 VDC
• HT at 1250 VAC + burn test at 5000V
• PE

8 Doc N° EM 586532-0118
 3. Operating diagram

3 ~ 400 V
N

X6
PE

X22 X5
X23
X1 X2

X9

X11 X12 X3 X7 X4

em 7 des sys él-30

Doc N° EM 586532-0118 9
 4. Location of components

4.1 The control cabinet

4.1.1 Inside the control cabinet

1. Main switch Main switch

2. Main cutout
3. Frequency varier for heathers fans
4. Frequency varier filter
5. Door-switch bridging key
6. Manual/Automatic card Control panel
7. AZIMON cards for adjusting heathers lamps
8. 400V triphase power supply
9. Cut-outs
10. 400/230/110/24/19V terminal board
11. 400 to 230/110/24/19V transformer 18 19
12. Basic module E.FPC-202 60.armoire
13. Extension E.EEA-202 ,@
14. 24 V supply @,,@,@,@,@,@,@,@
15.
16.
230 V socket
Clock
,@,@,@,@,@,@,@,@ 220 V

17. Neutral terminal ,@ 3

18. Safety switches 7
19. Phase indicator lights
20. Reverser for bottles turnover
21. Terminals: 1 0 V for turning lamp 1
2 24 V for turning lamp 220 V

3 0 V filler stop 4
4 24 V filler stop
5 Earth
F1 Connection 3~400 V + neutral 5
F2 Fuse for transformer 230 - 24 V 2
F3 Fuse for 4 A supply 8
6 9
F4 Slow-blow fuse 10 A for 24 V supply 380 V

K1 Out 3.1 signal enabling turning on the heating

K2 Out 5.0 output for a turning lamp
9 10
K3 In 2.3 stop signal (from a filler for example)
K4 In 5.5 heating stop signal
K5 Indexing overload switch (Out 1.3)
K6 Separator overload switch (Out 2.6) K10 IN 0.0-1.7 IN 2.0-3.7
K7 Elevator overload switch (Out 3.2) 11
K8 Roller overload switch (Out 2.6A) 12 13
K9 Bottles turnover swicht (Out 3.0 + Out 3.6) OUT 0.0-1.7 OUT 2.0-3.7

K10 Safety relays

X6
K11 Door safety relays IN 4.0-5.7

X1 Connector for BLOCK A X1 X2 14 13

X8
X2 Connector for BLOCK B X9

OUT 4.0-5.7
X3 Connector for heater P1-P2
X4 Connector for heater P3-P4 F2 F4
K1 K2 K3 K4
1-5
X5 Connection for fans and heaters chain motor
X6 Connector for control panel
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F1 F3
X7 Connector for heater P5-P6
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K5 K6 K7 K8

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X8 Connector linking cabinet with heaters
X9 Connector for motors (Outputs 1.3, 2.6, 3.2) and
door safeguard
X5 X4 X3 X7 @@@@
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X22 Connector for bottles turnover @@@@

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17 15 16 21 X22

10 Doc N° EM 586532-0118
4.1.2 Control panel
F21
F12 F13 F14 F15 F16 F17 F18 F19 F22

F23

H20
F8
15
?
0

14 1

H19
F9 13 2

H18
12 3

11 4

10 5
H17
9 8 7 6

F4 H16
H15
0 1

H22

F1 0 1
H14
H13
F2 0 1
H12

8.panneau
F3
Tetra Pak PET Packaging Systems

F5 F6 F7 F11 F20 H10 H5

F1 Start with acknowledgement lamp for starting conditions
F2 STOP at end of machine cycle
F3 RESET
F4 Selector with/without HP blowing
F5 Selector with/without LP blowing
F6 Selector with/without preforms loading
F7 Selector automatic/manual
F8 Activator for manual functions
F9 Selector for manual functions
F11 Emergency stop
F12 Emergency stop alarm
F13 Alarm for cycle time exceeded
F14 Alarm for lack of preforms
F15 Safety door alarm: deactivating this door safeguard is forbidden
F16 Press stroke alarm
F17 Press return alarm
F18 Bottle turner alarm
F19 Indexing alarm
F20 Cycle counter
F21 Keypad
F22 Oil level alarm
F23 Bulbs test button
H5 Heaters ON-OFF
H10 Heaters automatic/manual
H12-H19 Potentiometers for adjusting the lamps
H20 Automatic temperature controller
H22 Fans controller

4.1.3 Signal lamp

green : The machine works

blue : Lack of preforms (+ buzzer and F14 alarm lit )
8.armoire

orange : The machine is stopped at cycle end

red : Emergency stop

Doc N° EM 586532-0118 11
4.2 List of inputs (In) and outputs (Out)

Input Function see the §

In 0.0 Emergency stop ABD

In 0.1 Machine start A
In 0.2 Machine stop A
In 0.3 Manual/auto selector A
In 0.4 Blowing A
In 0.5 Preblowing A
In 0.6 Infeed A
In 0.7 Manual FWD A
In 1.0 Manual BWD A
In 1.1 Manual mode selector A A
In 1.2 Manual mode selector B A
In 1.3 Manual mode selector C A
In 1.4 Manual mode selector D A
In 1.5 Supports FWD B
In 1.6 Press open C
In 1.7 Press closed C
In 2.0 Gap initial C
In 2.1 Gap arrival C
In 2.2 Bottom up C
In 2.3 Filler stop A
In 2.4 Insertion B
In 2.5 Oil monitor BC
In 2.7 Bottom down C
In 3.0 Preforms separator safeguard B
In 3.2 Bulbs test A
In 3.3 Preform present C
In 3.5 Preforms level mini B
In 3.6 Preforms present separator B
In 3.7 Machine reset A
In 4.1 Preforms sinker D
In 4.2 Ejection initial D
In 4.3 Preforms turnover D
In 4.4 Bottles turnover initial D
In 4.5 Ejection arrival D
In 4.6 Preforms level maxi B
In 5.0 Gate safeguard D
In 5.3 Doors safeguard B
In 5.4 Bottles turnover arrival D
In 5.5 Heating stop A

12 Doc N° EM 586532-0118
 Output Function see the §

Out 0.0 Machine ready A

Out 0.2 Machine running A
Out 0.3 Counting pulse A
Out 0.5 LP press C
Out 0.6 HP press C
Out 0.7 Gap C
Out 1.0 Bottom C
Out 1.1 Airtightness B
Out 1.2 Insertion B
Out 1.3 Support FWD AB
Out 1.4 Blowing B
Out 1.5 Exhaust B
Out 1.6 Stretching / Preblowing B
Out 2.0 Preforms guide D
Out 2.1 Preforms turnover D
Out 2.2 Preforms gripper D
Out 2.3 Bottles extractor D
Out 2.4 Ejection BWD D
Out 2.5 Ejection FWD D
Out 2.6 Preforms separator + Rollers AB
Out 3.0 Bottles turnover FWD AD
Out 3.1 Heating monitor A
Out 3.2 Elevator AB
Out 3.5 Preforms sinker D
Out 3.6 Bottles turnover BWD AD
Out 4.0 Emergency stop (alarm) A
Out 4.1 Cycle overtime (alarm) A
Out 4.2 Preforms supply (alarm) A
Out 4.3 Doors security (alarm) A
Out 4.4 Press closing (alarm) A
Out 4.5 Press opening (alarm) A
Out 4.6 Bottles turnover (alarm) A
Out 4.7 Support FWD (alarm) A
Out 5.0 Turning lamp A
Out 5.1 Air supply B
Out 5.2 Lack of oil (alarm) A

A. Control cabinet and panel

Out 4.0 Out 4.1 Out 4.2 Out 4.3 Out 4.4 Out 4.5 Out 4.6 Out 4.7 Out 0.2
Out 4.0
Out 4.2
In 0.7 In 1.0 Out 5.2
Out 3.0
In 3.2 Out 3.6
?
In 1.1 In 1.2
In 1.3 In 1.4 In 5.5
Out 5.0

In 0.4 Out 3.1 In 2.3

0 1

Out 0.0 In 0.1

0 1
1-6 K1 K2 K3 K4
In 0.2
0 1

In 3.7
Tetra Pak PET Packaging Systems
K5 K6 K7 K8 55.in-out

In 0.5 In 0.6 In 0.3 In 0.0 Out 0.3 Out 1.3 Out 2.6 Out 3.2 Out 2.6A

Doc N° EM 586532-0118 13
B. Machine

In 3.0

In 0.0

In 3.6
In 4.6
Out 2.6
In 3.5

Out 3.2

In 5.3
on all doors

Out 5.1

In 2.5

Out 1.4
56.in-out 30

OFF ON In 2.5
Out 1.1 Out 1.1

In 2.4
In 1.5
Out 1.6

Out 1.2
Out 1.5 Out 1.3

14 Doc N° EM 586532-0118
C. Press

Out 0.5

Out 0.6

In 3.3

In 2.5
In 2.7

In 2.2
Out 1.0

In 1.6
In 1.7 57.in-out

In 2.1
In 2.0
Note: 1
Adjust this detector
at 5.5 mm of the
press plate. 2

Out 0.7

Doc N° EM 586532-0118 15
D. Preforms and bottles return and ejection

Out 2.4
In 4.2
In 4.5
Out 2.4

Out 3.5

In 4.1 Out 2.1

Out 2.2

Out 2.6A

Out 2.0 (2x)

Out 2.3 0
t3
ou
.in
Out 3.6 58

Out 3.0
2
In 4.4 1 In 0.0
In 5.0
In 5.4 In 4.3

16 Doc N° EM 586532-0118
4.2.1 Where the signal lamps of the inputs (In) and the outputs (Out) are

Every input and output has 2 or 3 lamps signalling whether it is ON or OFF. These lamps are situated as follows:

In 0,... In 1,... In 2,... In 3,...

Out 2,... Out 3,...

Out 0,... Out 1,...
In 4,... In 5,...

0 1 2 3 4 5 6 7

, , ,
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Out 4,... Out 5,...

,, ,,
Out5.1 In1.5 In1.6 In1.7 In2.0 In2.1 In2.2 In2.7 In3.3 In3.4
O0.01 I0.01 I0.03 I0.05 I0.07 I0.09 I0.11 I0.13 I0.15 I1.01

Out0.5 Out0.6 Out0.7 Out1.0 Out1.1 Out1.2 Out1.4 Out1.5 Out1.6

54.in-out

Doc N° EM 586532-0118 17
 ,,,,,,,,,,
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4.3 Detail of blocks A and B

59.bloc A B
B

OUT IN Block A

Out5.1 In1.5 In1.6 In1.7 In2.0 In2.1 In2.2 In2.7 In3.3 In3.4 Wiring of 72-pin connector (X11)
O0.01 In 2.4 In 2.5 I0.05 I0.07 I0.09 I0.11 I0.13 I0.15 I1.01 1-12 13-24 25-36 37-48 49-60 61-72
1 O 5.1 O 1.2 I 1.5 I 2.7
Out0.5 Out0.6 Out0.7 Out1.0 Out1.1 Out1.2 Out1.4 Out1.5 Out1.6 2 O 5.3 I 2.4
3 O 0.5 O 1.4 I 1.6 I 3.3
4 I 2.5
5 O 0.6 O 1.5 I 1.7 I3.4
6 I 2.6
7 O 0.7 O1.6 I 2.0
X11
8 I 3.0
9 O 1.0 O1.7 I 2.1
10 I 3.1
11 O 1.1 I 2.2 24V
12 0V 0V
OUT IN

OUT IN Block B

Wiring of 72-pin connector (X12)

O 5.5 I 3.5 I 3.6 I 4.3 I 4.4 I 5.0 I 0.0 I 5.4
I 4.1 I 4.2 I 4.5 I 4.6 I 4.7
1-12 13-24 25-36 37-48 49-60 61-72
1 O 5.5 O 2.5 I 3.5 I 5.4
O 2.0 O 2.1 O 2.2 O 2.3 O 2.4 O 2.5 O 3.0 O 3.5 O 3.6 O 3.7
2 O 5.6 I 4.1
3 O 2.0 O 3.0 I 3.6
4 I 4.2
5 O 2.1 O 3.5 I 4.3
6 I 4.5
7 O 2.2 O 3.6 I 4.4
X12
8 I 4.6
9 O 2.3 O 3.7 I 5.0
10 I 4.7
11 O 2.4 I 0.0 24V
12 0V 0V
OUT IN
59.bloc A B
Note concerning the output Out 2.4:
It is possible to connect bottles selection cilinders on this output.
To adjust the working time of the cilinders: select R4 on the keypad (see § 4.2.5 of Maintenance Manual (MM) for the
method), put "R4 : 20" (without cilinders, R4 = 0).

Wiring of 4-pin connectors for the two blocks

2 . Free 1 . Free 2 . Free 1 : 24V

3 : 0V 4 : Out (24V) 3 : 0V 4 : In

18 Doc N° EM 586532-0118
4.4 Motors and heaters
Connections of the lamps, fans motors and chain motor.
P1 P2 P6 P5 P3 P4

61.Moteurs et four

X5 X4 X7 X3
Fan 3
Motor 3: Fans 1 and 2
chain
Heaters lamps wiring
Connectors : In the control cabinet : 3 x 16 terminals X3, X4 and X7
On the heaters : 6 x 10 pins (8 used) P1, P2, P3, P4, P5 and P6

X 3.01 P 1.1 X 4.01 P 3.1 X 7.01 P 5.1

X 3.02 P 1.2 X 4.02 P 3.2 X 7.02 P 5.2
X 3.03 P 1.3 X 4.03 P 3.3 X 7.03 P 5.3
X 3.04 P 1.4 X 4.04 P 3.4 X 7.04 P 5.4
X 3.05 P 1.5 X 4.05 P 3.5 X 7.05 P 5.5
X 3.06 P 1.6 X 4.06 P 3.6 X 7.06 P 5.6
X 3.07 P 1.7 X 4.07 P 3.7 X 7.07 P 5.7
X 3.08 P 1.8 X 4.08 P 3.8 X 7.08 P 5.8
X 3.09 P 2.1 X 4.09 P 4.1 X 7.09 P 6.1
X 3.10 P 2.2 X 4.10 P 4.2 X 7.10 P 6.2
X 3.11 P 2.3 X 4.11 P 4.3 X 7.11 P 6.3
X 3.12 P 2.4 X 4.12 P 4.4 X 7.12 P 6.4
X 3.13 P 2.5 X 4.13 P 4.5 X 7.13 P 6.5
X 3.14 P 2.6 X 4.14 P 4.6 X 7.14 P 6.6
X 3.15 P 2.7 X 4.15 P 4.7 X 7.15 P 6.7
X 3.16 P 2.8 X 4.16 P 4.8 X 7.16 P 6.8

1234567890123456789 1234567890123456789 1234567890123456789

Zone 8 P1.8 1234567890123456789
1234567890123456789
P2.8 P3.8 1234567890123456789
1234567890123456789
P4.8 P5.8 1234567890123456789
1234567890123456789
P6.8
Zone 7 P1.7 P2.7 P3.7 P4.7 P5.7 P6.7
1234567890123456789 1234567890123456789 1234567890123456789
Zone 6 P1.6 1234567890123456789 P2.6 P3.6 1234567890123456789 P4.6 P5.6 1234567890123456789 P6.6
1234567890123456789 1234567890123456789 1234567890123456789
Zone 5 P1.5 P2.5 P3.5 P4.5 P5.5 P6.5
1234567890123456789 1234567890123456789 1234567890123456789
Zone 4 P1.4 1234567890123456789
1234567890123456789 P2.4 P3.4 1234567890123456789
1234567890123456789 P4.4 P5.4 1234567890123456789
1234567890123456789 P6.4
Zone 3 P1.3 P2.3 P3.3 P4.3 P5.3 P6.3
1234567890123456789
1234567890123456789 123456789012345678
123456789012345678 1234567890123456789
1234567890123456789
Zone 2 P1.2 1234567890123456789 P2.2 P3.2 123456789012345678 P4.2 P5.2 1234567890123456789 P6.2
Zone 1 P1.1 1234567890123456789 P2.1 P3.1 123456789012345678 P4.1 P5.1 1234567890123456789 P6.1

Motors :
Fan1 Fan 2 Fan 3 + motor 3
X 5.1 X 5.4 X 5.7
X 5.2 X 5.5 X 5.8
X 5.3 X 5.6 X 5.9

Doc N° EM 586532-0118 19
20 Doc N° EM 586532-0118
 5. Wiring diagram

1. Pages numbered 00055-

2. Pages numbered 00061-
3. Pages numbered 00085-

3
1

GQ005126

Doc N° EM 586532-0118 21
1

GQ005127
2

GQ005128
 3

GQ005129