Poly-Clip System TSCA 120-M User manual

TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
EN/07-2017 Original Instructions
Operating Manual

TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
Original Instructions EN/07-2017
Delivery date:
Serial number:
TSCA 120-M: P205900
TSCA 160-L: P206000
Document dated: 01/07/2017
Note
The complete documentation for the TSCA 120-M/160-L machine consists of the following components:
• Operating Manual
• EC declaration of conformity as part of this Operating Manual
• Spare parts catalogue on a data carrier.
No part of this documentation may be reproduced or otherwise used or communicated without the consent
of the author or other authorised party.
Violations are liable to prosecution and compensation (copyright law, fair trade law, German Civil Code).
All rights reserved in the event a patent is granted or a utility model is registered.
Poly-clip System GmbH & Co. KG, Niedeckerstr. 1, 65795 Hattersheim a. M., Deutschland/Germany,
+49 (0)6190 - 8886-0
www.polyclip.com
Printed in the Federal Republic of Germany, subject to change.
Declared values without tolerances are merely approximations.
The photos do not correspond in all details to the condition of the machines delivered.

TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
EN/07-2017 1
Contents
1 Safety Information ............................................................................... 1-1
1.1 Introductory Comments ...............................................................................1-1
1.1.1 Warning signs on the machine .............................................................................................. 1-1
1.1.2 Warning notes in instructions ................................................................................................ 1-1
1.1.2.1 Warning symbol ..................................................................................................................... 1-1
1.1.2.2 Hazard stages ....................................................................................................................... 1-1
1.2 Use and Application of this Machine ............................................................1-2
1.2.1 Proper use ............................................................................................................................. 1-2
1.2.2 Improper use ......................................................................................................................... 1-2
1.2.3 Modifications and alterations ................................................................................................ 1-2
1.3 Who May Operate the Machine? ..................................................................1-2
1.4 Required Personal Protection Equipment ....................................................1-2
1.5 Protective Devices ........................................................................................1-3
1.5.1 Danger points protected by protective devices with cutouts. .............................................. 1-3
1.5.2 Work sequences secured by protective devices with cutouts .............................................. 1-3
1.5.3 Protective covers ................................................................................................................... 1-3
1.5.4 What effect do protective devices A to D have? ................................................................... 1-3
1.5.5 All protective devices must be checked! ............................................................................... 1-3
1.5.6 How can the protective devices be checked? ...................................................................... 1-4
1.5.7 Electronic hand wheel function ............................................................................................. 1-4
1.6 Setting Up, Servicing, Cleaning, Maintenance and
Repair Work on the Machine ........................................................................1-4
1.6.1 Who may carry out this work? .............................................................................................. 1-4
1.6.2 What must be observed and done before starting with such work? .................................... 1-4
1.6.3 Cleaning the machine ............................................................................................................ 1-5
1.6.4 Work on electrical equipment ............................................................................................... 1-5
1.6.4.1 Machine connection .............................................................................................................. 1-5
1.6.4.2 Frequency / Servo converter ................................................................................................. 1-6
1.6.5 Working with process materials ............................................................................................ 1-6
1.7 Residual Risks ..............................................................................................1-6
1.7.1 Risk of tripping ...................................................................................................................... 1-6
1.7.2 Electrical risks ....................................................................................................................... 1-6
1.7.3 Risk of contusion when closing the front cover .................................................................... 1-6
1.7.4 Risk of contusion when closing the protective lid ................................................................. 1-6
1.7.5 Risk of contusion when closing the clip head ....................................................................... 1-6
1.7.6 Risk of impact when closing the clip head ............................................................................ 1-7
1.7.7 Risk of contusion when closing the product outlet ............................................................... 1-7
1.7.8 Risk of cutting when changing the cutter .............................................................................. 1-7
1.7.9 Adjusting the dosage unit speed ........................................................................................... 1-7

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1.7.10 Transporting the TSCA ..........................................................................................................1-7
1.7.11 Closing and separating area ..................................................................................................1-7
1.7.12 Film inlet side .........................................................................................................................1-7
1.7.13 Product outlet side ................................................................................................................1-7
1.7.14 Electronic hand wheel function .............................................................................................1-8
1.7.15 Automatic operation ..............................................................................................................1-8
1.7.16 Stuffing process ....................................................................................................................1-8
1.7.17 Stuffing process in automatic operation ...............................................................................1-8
1.7.18 Changing over from Automatic On to Automatic Off ............................................................1-8
1.7.19 Risk of burning at the seal station .........................................................................................1-8
1.7.20 Risk of contusion at the seal station .....................................................................................1-9
1.7.21 Risk of crushing at film roll unwinder .....................................................................................1-9
1.7.22 Switch cabinet .....................................................................................................................1-10
1.7.23 Clamping core .....................................................................................................................1-10
1.8 Moving Machine and Additional Equipment ...............................................1-10
1.8.1 Measures before moving .....................................................................................................1-10
1.8.2 Loading and unloading ........................................................................................................1-10
1.8.3 Removal of transport packaging .........................................................................................1-10
1.8.4 Disposal of packaging materials .........................................................................................1-10
1.8.5 Castors ................................................................................................................................1-11
1.8.6 Front doors ..........................................................................................................................1-11
2 Machine Description ...........................................................................2-1
2.1 Applications ..................................................................................................2-1
2.2 Sealing ..........................................................................................................2-1
2.3 Closing and Clipping Process in the Clip Module ........................................2-1
2.4 Film Counter .................................................................................................2-1
2.5 Shirr Switch ..................................................................................................2-1
2.6 Ink Jet Printer (Option) ..................................................................................2-1
2.7 Hot Stamping Printer (Option) ......................................................................2-2
2.8 Print Mark Control (Option) ...........................................................................2-2
3 Installation of the Machine ..................................................................3-1
3.1 Note ..............................................................................................................3-1
3.2 Required Protective Equipment ....................................................................3-1
3.3 Machine Location .........................................................................................3-1
3.3.1 Moving the machine to its location ........................................................................................3-1
3.4 Machine connection .....................................................................................3-2

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3.5 Installation of the Filling System ...................................................................3-4
3.5.1 Adjustment elements for seal band and film transport ......................................................... 3-4
3.5.2 Positioning of sealing unit ..................................................................................................... 3-4
3.5.3 Positioning the stuffing horn ................................................................................................. 3-5
3.6 Connecting the Filling Machine ....................................................................3-5
3.6.1 Adjusting the product inlet height ......................................................................................... 3-5
3.6.2 Connecting TSCA and filling machine ................................................................................... 3-5
3.7 Setting the Operating Pressure ....................................................................3-6
3.8 Inner brake and outer brake .........................................................................3-6
3.8.1 Inner brake ............................................................................................................................ 3-6
3.8.2 Outer brake ........................................................................................................................... 3-7
4 Indicators and controls ....................................................................... 4-1
4.1 Operating panel ............................................................................................4-1
4.2 Easy-Touch display ......................................................................................4-2
4.3 Program structure .........................................................................................4-2
4.4 Operator level ...............................................................................................4-3
4.4.1 Basic selection screen of the Operator level ......................................................................... 4-3
4.4.2 Meaning and function of icon selection buttons in the Operator menu ................................ 4-4
4.4.3 Manual function buttons ....................................................................................................... 4-4
4.4.4 Clip loading position/Change positions ................................................................................ 4-5
4.4.5 Loading a product program .................................................................................................. 4-5
4.4.6 Deleting a product program and copying a product program from/to a USB stick ............. 4-6
4.4.7 “Current messages” screen .................................................................................................. 4-6
4.4.8 Language selection ............................................................................................................... 4-9
4.4.9 Maintenance - Lubrication .................................................................................................... 4-9
4.4.9.1 Lubrication ............................................................................................................................. 4-9
4.4.10 Displaying service information ............................................................................................ 4-10
4.5 Maintenance level .......................................................................................4-12
4.5.1 Basic selection screen in the Maintenance level ................................................................. 4-12
4.5.2 Meaning and function of icon selection buttons in the Maintenance menu ....................... 4-13
4.5.3 Entering product data ......................................................................................................... 4-14
4.5.4 Clip reel and die (RFID page) .............................................................................................. 4-15
4.5.5 Product counters ................................................................................................................. 4-15
4.5.6 Speed, knife ........................................................................................................................ 4-16
4.5.7 Knife, shirr, rings ................................................................................................................. 4-17
4.5.8 Separator opening, clip pressure ........................................................................................ 4-17
4.5.9 Conveyor ............................................................................................................................. 4-18
4.5.10 Pneumatic casing brake ...................................................................................................... 4-19
4.5.11 Oil/water sprayers ............................................................................................................... 4-19
4.5.12 Basic sealing, filling system, clipping process, clipping process mode screen ................. 4-20
4.5.12.1 Possible combinations of clipping process control and clipping process mode ................ 4-21

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4.5.12.2 Sealing settings, electronic jam switch, part 1 ....................................................................4-22
4.5.12.3 Sealing settings, electronic jam switch, part 2 ....................................................................4-23
4.5.12.4 Sealing settings, film counter, part 1 ...................................................................................4-24
4.5.12.5 Sealing settings, film counter, part 2 ...................................................................................4-25
4.5.12.6 Sealing settings, mechanical jam switch, part 1 .................................................................4-26
4.5.12.7 Sealing settings, mechanical jam switch, part 2 .................................................................4-27
4.5.12.8 Filling system .......................................................................................................................4-28
4.5.12.9 Clipping machine controls stuffer and clipping process mode is start-stop .......................4-29
4.5.12.10Clipping machine controls stuffer and clipping process mode is continuous ....................4-30
4.5.12.11Clipping machine controls stuffer and clipping process mode is overspreading ...............4-31
4.5.12.12Portion length controls clipping machine/stuffer and
clipping process mode is start-stop ....................................................................................4-32
4.5.12.13Portion length controls clipping machine/stuffer
and clipping process mode is overspreading .....................................................................4-33
4.5.12.14Clip mark controls stuffer and clipping process mode is start-stop ...................................4-34
4.5.12.15Clip mark controls stuffer and clipping process mode is overspreading ............................4-35
4.5.12.16Dosing pump controls clipping process and clipping process mode is start-stop .............4-36
4.5.12.17Navigation using the quick selection buttons ......................................................................4-37
4.5.13 Start-stop velocity profile ....................................................................................................4-38
4.5.14 Velocity profile for continuous mode ...................................................................................4-39
4.5.15 Velocity profile for overspreading ........................................................................................4-40
4.5.16 Film break ............................................................................................................................4-41
4.5.16.1 Setting film break control ....................................................................................................4-41
4.5.17 Printer ..................................................................................................................................4-42
4.5.17.1 Possible printer operating modes .......................................................................................4-42
4.5.18 Simulator .............................................................................................................................4-43
4.5.19 Loading a product program .................................................................................................4-43
4.5.20 Date/Time ............................................................................................................................4-44
4.6 Service level ................................................................................................4-44
4.6.1 Adjusting the rotation angle for machine functions and additional equipment ...................4-45
4.6.2 Example: Compiling and saving a product program ...........................................................4-45
4.6.3 USB connection for back-up and retrieval of product programs ........................................4-47
4.6.4 Screen configuration level 1 or 2 .........................................................................................4-48
4.6.5 Reading and saving product programs through the USB connection ................................4-48
4.7 List of possible error messages ..................................................................4-49
5 Start-up .................................................................................................5-1
5.1 Note ..............................................................................................................5-1
5.2 Start-up check list ........................................................................................5-1
5.3 Shutting the machine down ..........................................................................5-1
5.4 Filling the clip magazine ...............................................................................5-2
5.4.1 Setting the braking force on the clip magazine .....................................................................5-2
5.4.2 Inserting the clip stick ............................................................................................................5-2
5.4.3 Converting the clip transport .................................................................................................5-3

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5.5 Changing the die and punch ........................................................................5-3
5.6 Changing the separator knife .......................................................................5-5
5.7 Changing the spreading (manual) .................................................................5-6
5.8 Adjusting the clip guide for different clip sizes .............................................5-8
5.9 Setting the separator hole ............................................................................5-9
5.10 Closing pressure ...........................................................................................5-9
5.10.1 Adjust the closing pressure ................................................................................................... 5-9
5.11 Starting up the automatic GSA looper .......................................................5-10
5.12 Central lubrication ......................................................................................5-11
5.12.1 Inserting the lubricant cartridge .......................................................................................... 5-11
5.12.2 Bleeding the grease pump .................................................................................................. 5-11
5.12.3 Manually triggering the lubrication process ........................................................................ 5-12
5.13 Inserting the film .........................................................................................5-12
5.13.1 Producing the film tube ....................................................................................................... 5-15
5.14 Replacing the sealing belt ..........................................................................5-16
5.15 Splice detection ..........................................................................................5-17
5.15.1 Reading process ................................................................................................................. 5-17
7 Product Testing ................................................................................... 7-1
7.1 Note ..............................................................................................................7-1
7.2 Preparing the Product Test ..........................................................................7-1
7.3 Product Testing Before Production ..............................................................7-1
7.3.1 Inspect the film travel ............................................................................................................ 7-1
7.3.2 Inspect the sealing seam ....................................................................................................... 7-2
7.4 After Completed Product Testing .................................................................7-2
8 Troubleshooting .................................................................................. 8-1
8.1 Note ..............................................................................................................8-1
8.1.1 Before starting work .............................................................................................................. 8-1
8.1.2 After Completed Work ........................................................................................................... 8-1
8.2 List of Possible Faults and Alarms ...............................................................8-2
9 Cleaning and Maintenance ................................................................. 9-1
9.1 General Information ......................................................................................9-1
9.1.1 Working with process materials ............................................................................................ 9-1
9.1.2 Disposal of process materials ............................................................................................... 9-1

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9.2 Before Cleaning and Care Work ...................................................................9-1
9.2.1 Taking machine out of operation ...........................................................................................9-1
9.2.2 Preparing the machine for cleaning .......................................................................................9-1
9.3 Cleaning Process ..........................................................................................9-3
9.4 After Cleaning Work ......................................................................................9-4
9.5 Control, Inspection and Maintenance ..........................................................9-4
9.5.1 Control work: .........................................................................................................................9-4
9.5.2 Inspection and maintenance work ........................................................................................9-4
10.1 Technical Data .............................................................................10.1-1
10.1.1 Dimensions and weight ...........................................................................10.1-1
10.1.2 Pneumatic connection .............................................................................10.1-1
10.1.3 Electrical connection ...............................................................................10.1-1
10.1.4 Noise Level ..............................................................................................10.1-1
10.1.5 Film length, film width and film hose diameter ........................................10.1-2
10.1.5.1 Dimensions of the film roll ................................................................................................10.1-2
10.1.5.2 Flat film width ...................................................................................................................10.1-2
1.6 Verbindung Clipmaschine-Füller /
Connection Clip Machine-Stuffer ...................................................1.6-1
1.6.1 Alpina ........................................................................................................1.6-1
1.6.2 Asgo .........................................................................................................1.6-2
1.6.3 Cato ..........................................................................................................1.6-3
1.6.4 Frey ...........................................................................................................1.6-3
1.6.5 Germo .......................................................................................................1.6-4
1.6.6 Handtmann ...............................................................................................1.6-4
1.6.7 Ideal ...........................................................................................................1.6-6
1.6.8 Iozzelli .......................................................................................................1.6-6
1.6.9 Karl Schnell ...............................................................................................1.6-7
1.6.10 Kraemer & Grebe ......................................................................................1.6-8
1.6.11 Marlen .......................................................................................................1.6-9
1.6.12 Metaquina Twinvac ................................................................................1.6-10
1.6.13 Piereder ..................................................................................................1.6-10
1.6.14 Rex .........................................................................................................1.6-11

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1.6.15 Risco Brevetti .........................................................................................1.6-12
1.6.16 Schrofner ................................................................................................1.6-13
1.6.17 Schwerdtel ..............................................................................................1.6-14
1.6.18 SIA ..........................................................................................................1.6-15
1.6.19 Tecmaq ...................................................................................................1.6-15
1.6.20 Tecnotrip ................................................................................................1.6-16
1.6.21 Velati .......................................................................................................1.6-16
1.6.22 Vemag ....................................................................................................1.6-17
1.6.23 Sonderverbindungsteile / special connections parts .............................1.6-18
1.6.24 Verbindungsrohr (200 mm) Fasspresse, komplett 63840
Connecting tube (200 mm) drum press, assembly 63840 .....................1.6-18
1.6.25 Anschlusskabel Fasspresse, komplett 100985A
Connection cable drum press assembly 100985A .................................1.6-19
1.6.26 Fasspressensteuerung komplett 146285B
Drum press control assembly 146285B .................................................1.6-20
1.6.27 Initiatorsteuerung komplett 55920
Proximity switch control assembly 55920 ..............................................1.6-22

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TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
EN/10-2014 1-1
Safety Information
1 Safety Information
1.1 Introductory Comments
This Poly-clip machine is built in accordance with the
present state of the art and the applicable accident
prevention regulations.
However, this machine may
• present danger to life and limb of the user or of a
third party;
• cause impaired production and impairment of other
assets of the user if the machine
• is operated or maintained by untrained staff
• and/or is used improperly or is used for a dif-
ferent purpose from that intended.
• Note
Any person who is entrusted with commissioning, op-
eration, care, maintenance and repair of this machine
must first have read and understood the Operating In-
structions and in particular the Safety Information
chapter.
In addition, the general safety and accident prevention
regulations must be observed.
1.1.1 Warning signs on the machine
The following table displays the warning signs on the
machine and explains their meaning.
• Warning signs on the machine refer to possible dan-
ger points and must be observed in any case.
• Warning signs must not be removed from the ma-
chine.
• Damaged and illegible warning signs must be re-
placed immediately.
1.1.2 Warning notes in instructions
In the various instructions you will find warning notes
before specific actions that may involve hazards and
risks.
Here, you are explained how a warning note is struc-
tured and what it means.
1.1.2.1 Warning symbol
In the following the warning symbol is displayed. Warn-
ing notes with this symbol warn the users from injury
hazards and even death. Please always observe this
information in order to prevent any risks.
1.1.2.2 Hazard stages
The warning symbol in connection with a signal word
represents a specific hazard stage:
Warning sign Explanation/position on the
machine
Warning of dangerous electrical
voltages
Position: Protective cover of the
switch cabinet
Switch off the main switch be-
fore opening the housing!
Warning: temperatures up to
250°
Position: Seal bar
Warning: Risk of contusion
Position: Film transport
Warning
symbol and
signal word
Explanation Probabili-
ty
DANGER If this hazard is not avoid-
ed, death or severe (irre-
versible) injuries will be
the consequence.
Imminent
WARNING If this hazard is not avoid-
ed, death or severe (irre-
versible) injuries may be
the consequence.
Possibly
CAUTION If this hazard is not avoid-
ed, moderately severe or
slight injuries (reversible)
and possibly property
damage may be the con-
sequence.
Possibly
ATTENTION If this hazard is not avoid-
ed, property damage may
be the consequence.
Possibly

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Safety Information
EN/10-2014
Example for a warning note:
1.2 Use and Application of this Ma-
chine
1.2.1 Proper use
The TSCA is intended for sealing of films from a roll to
form a fillable film hose in various calibre sizes and for
closing the filled film hose and separating of both small
portions and large calibre sausages.
Room temperature at place of use 0°C to 50 °C.
1.2.2 Improper use
This machine must not be taken into operation without
stuffer horn system, casing brake and without dis-
charge tray at the product outlet.
The stuffer horn system comprises stuffer horn, seal-
ing pipe and molding shoulder.
The machine must not be operated without its covers.
The machine is not suitable for use in potentially explo-
sive atmospheres. The operator must check whether
the machine is suitable for processing his/her specific
potentially explosive materials.
1.2.3 Modifications and alterations
a Unauthorised modifications or alterations to the ma-
chine, as well as attachment or installation of addi-
tional equipment or other models that are not sold
by Poly-clip System are not permitted due to safety
reasons. Any welding or cutting work at the base
frame are also prohibited - any such work must only
be carried out by Poly-clip System.
b Protective devices prevent operators from reaching
into danger points during operation of the machine
and must not be removed, modified or bypassed.
c The safety of the machine may be impaired by clips
and spare parts which do not meet the standards
specified by Poly-clip System and which have not
been supplied by Poly-clip System.
Therefore, only original Poly-clip System clips may
be used with the machine and only original Poly-clip
System spare parts may be attached or installed.
In case of unauthorised modifications or alterations (a
and b), use of non-original Poly-clip System clips (c)
and attachment or installation of non-original Poly-clip
System spare parts (c) the EC declaration of conform-
ity for this machine will become null and void.
1.3 Who May Operate the Machine?
• Only trained and authorised staff may operate this
machine.
• Training must be carried out in accordance with the
Operating Instructions, in particular the Safety Infor-
mation chapter, direct at the machine.
• During training the danger points on the machine
and all possible dangerous situations which may oc-
cur during operation of the machine must be ex-
plained to the operators direct at the machine (see
section 1.7).
• The machine must only be operated by one member
of staff at a time.
1.4 Required Personal Protection
Equipment
Please always read the product data sheets about the
consumable goods used with the machine - you can
obtain the product data sheets from the suppliers of
the respective consumables. The product data sheets
will contain additional information about the required
personal protection equipment. Always use the re-
quired and recommended personal protection equip-
ment - it serves for your own safety.
• Goggles
During cleaning of the machine with the steam jet.
• Safety shoes
Safety shoes are required during assembly and instal-
lation of the machine, during insertion of heavy film
rolls, during disassembly and transport of the machine.
• Hearing protection
Hearing protection must be worn in work places with a
noise level equal to or higher than 85 dB(A).
• Protective equipment for electrical specialists
The mandatory protective equipment must be worn by
electrical specialists.
Warning:Injurieswhenliftingheavy
film rolls
You may do yourself injury while lifting and there is a
risk of contusion when lifting film rolls with a weight of
more than 25 kg without lifting aids.
• Film rolls weighing more than 25 kg must only be
placed onto the tensioning shaft with the help of lift-
ing equipment.
• Wear safety shoes.

TSCA 120-M/160-L
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EN/10-2014 1-3
Safety Information
• Lifting equipment
For lifting of larger and heavier loads, a lifting aid is re-
quired, e.g. for insertion of film rolls with a weight of
more than 25 kg.
1.5 Protective Devices
• Note
The installed protective devices are provided for stand-
ing operation!
1.5.1 Danger points protected by protective
devices with cutouts.
AProduct outlet, by means of a protective screen.
BSeparating area, by means of a protective lid at the
front.
Fig. 1-1 A Protective screen
B Protective lid
1.5.2 Worksequencessecuredbyprotective
devices with cutouts
COpen product outlet.
DOpen clip head.
1.5.3 Protective covers
The protective cover at the switch cabinet prevents
reaching into the area in which live parts are present.
1.5.4 What effect do protective devices A to
D have?
If one of the protective devices A to D is triggered - for
example when the protective screen at the product
outlet is lifted, the clip head or the product outlet is
opened, or the protective lid is opened - an electric cir-
cuit is interrupted. The machine stops immediately and
is no longer operational.
The following message is displayed in the text display
area on the control panel: „170.6 Safety guard", also
see section 4.7.
1.5.5 All protective devices must be
checked!
• Before each start-up of the machine!
• Before any work is started on the machine!
• After all setting up, servicing, cleaning, maintenance
and repair work on the machine!
• Verification of presence and correct function!
AB

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Safety Information
EN/10-2014
1.5.6 How can the protective devices be
checked?
Prerequisite: The machine is ready for operation.
For the test, the protective devices
A, B, C and D (see 1.5.1 and 1.5.2) are to be triggered
one after the other.
Example: To check protective device Aat the product
outlet:
- Lift protective screen at product outlet.
Fig. 1-2
The machine is no longer ready for operation.
- Close protective screen.
The displayed message „170.6 Safety guard“ disap-
pears.
The machine is again ready for operation.
• If the test result differs from that described above,
the machine must be taken out of operation immedi-
ately and the maintenance staff must be called.
• The machine must only be operated under the pre-
requisite that all protective devices are installed and
function correctly.
1.5.7 Electronic hand wheel function
Using the two-hand operation on the control panel,
the machine can be run forwards or backwards in
slow operation mode.
The machine will stop immediately if any of the two-
hand operation buttons is released.
While the safety circuit of all safety devices (A and B)
and of all work sequences (C and D) is inoperative, the
"electronic hand wheel function" is activated.
All protective devices can be opened and the clip
head and sausage outlet can be swung out.
Never reach into the machine during operation.
1.6 Setting Up, Servicing, Cleaning,
Maintenance and Repair Work on
the Machine
1.6.1 Who may carry out this work?
Cleaning and maintenance work must only be carried
out by instructed operators.
Installation work, production change, maintenance
and repair work may only be carried out by trained and
expert persons.
1.6.2 What must be observed and done be-
fore starting with such work?
Setting up, servicing, cleaning, maintenance and re-
pair work must only be carried out when the machine
has stopped.
• The main power supply must be disconnected at the
machine.
• Swivel the lever at the heating bar to the right (posi-
tion red dot). See Fig. 1-3.
• The main compressed air supply must be discon-
nected at the machine.
• It must be confirmed that the air pressure has been
released by operating an air operated device on the
machine. For this purpose move release valve (1,
Fig. 1-4) on supply connection in the direction of ar-
row to open.
• The clip machine - stuffing machine control cable
must be disconnected.

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Fig. 1-3 1 Lever
Fig. 1-4 1 Release valve
1.6.3 Cleaning the machine
• The machine must be cleaned in accordance with
the local hygiene and accident prevention regula-
tions.
• When using cleaning equipment the safety instruc-
tions of the equipment manufacturer must be ob-
served.
1.6.4 Work on electrical equipment
Persons who carry out work at the electrical equipment
without authorisation, risk an electric shock.
Work on electrical equipment of the machine must only
be carried out by a qualified electrician or by a trained
person under supervision of a qualified electrician, in
accordance with the electrical regulations.
A qualified electrician is a person who is able to assess
the work allocated to them and to identify potential
hazards on the basis of their electrotechnical qualifica-
tion, their knowledge and experience and knowledge
of the relevant standards and regulations.
Before starting work:
- Isolate,
- Secure against re-connection, (e.g. through a pad-
lock at the main switch)
- Verify isolation from supply,
- Make connection to earth and short-circuit,
- Cover or bar access to neighbouring live parts!
1.6.4.1 Machine connection
• The machine must only be connected to earthed
power supplies. Before start-up it must be checked
whethertheprotectiveearthingconductorfunctions.
• The machine must not be operated without circuit
breaker. The fault current circuit breaker must be all-
current sensitive. In wet conditions only the use of
all-current sensitive fault-current circuit breakers of
type B according to IEC 60755 is permitted.
• A sufficiently protected socket (this does not form
part of the scope of supply) must be provided near
the machine by the purchaser.
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TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
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1.6.4.2 Frequency / Servo converter
After disconnection of the Frequency / servo converter
from the voltage supply, live parts and power terminals
must not be touched immediately because of possibly
energized capacitors. Therefore, contact with these el-
ements results in danger to life! The corresponding
signs on frequency /servo converters as well as the op-
erating manual of the manufacturer must be complied
with during all such work.
All covers and doors must be closed during operation
of the machine.
1.6.5 Working with process materials
Observe the manufacturers information on safety and
quantities and general regulations in force when work-
ing with oil, grease, cleaning agents and other chemi-
cal substances.'
Residues from oil, grease, cleaning agents and other
chemical substances must be collected in accordance
with the legal provisions for recycling or disposal.
Local authority regulations pertaining to waste water
disposal apply.
1.7 Residual Risks
1.7.1 Risk of tripping
Cables that are running between the TSCA and other
machines must be laid such that there is no danger of
tripping and falling.
1.7.2 Electrical risks
Persons who carry out work at the electrical equipment
without authorisation, risk an electric shock.
Work on electrical equipment of the machinemust only
be carried out by a qualified electrician or by a trained
person under supervision of a qualified electrician, in
accordance with the electrical regulations.
There is an electrocution hazard at damaged cables!
When moving of machinery, e.g. during cleaning, it
must be considered that the machine must not move or
stand on cables. Damaged cables must be replaced
immediately.
1.7.3 Risk of contusion when closing the
front cover
When closing the front cover there may be risk of con-
tusion. Carefully open and close the front cover, carry
out work in the area of the front cover as one-man op-
eration.
Fig. 1-5 1 Front cover
1.7.4 Risk of contusion when closing the pro-
tective lid
When closing the protective lid there may be risk of
contusion. Touch and close the protective lid at the
handle rail only. Carry out work in the area of the pro-
tective lid carefully and as one-man operation.
Fig. 1-6 Handle rail on the protective lid
1.7.5 Risk of contusion when closing the clip
head
Closing of the clip head is pneumatically supported.
There are numerous points of contusion for your fin-
gers around the clip head, particularly when the clip
head is closed. Carry out work in the area of the clip
head carefully and as one-man operation.
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TSCA 120-M/160-L
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Safety Information
1.7.6 Risk of impact when closing the clip
head
Closing of the clip head is pneumatically supported.
Before opening the clip head make sure no-one is in
the swivel range of the clip head. Carry out work in the
area of the clip head carefully and as one-man opera-
tion.
1.7.7 Risk of contusion when closing the
product outlet
There are numerous points of contusion for your fin-
gers around the product outlet, particularly when the
outlet is closed. Carry out work in the area of the prod-
uct outlet carefully and as one-man operation.
Fig. 1-7 Product outlet
1.7.8 Risk of cutting when changing the
cutter
When changing the cutter, you may cut yourself with
the sharp blade of the cutter.
Please always carry out work carefully and intently. Do
not touch the blade of the cutter.
1.7.9 Adjusting the dosage unit speed
The speed of the dosage unit must be selected such
that the operator can remove the finished portions from
the TSCA without getting in a hurry.
1.7.10 Transporting the TSCA
For details, see section 1.8.
1.7.11Closing and separating area
At this point the separating jaws gather the film into a
small diameter and the contents (e.g. sausage meat)
are squeezed out of the resulting twist. Subsequently
the clips are placed around the twist by means of the
closing mechanism.
The danger point at the closing and separating area is
covered during operation of the machine.
a) at the product inlet side by means of the stuffing
horn system and the casing brake;
b) at the front by means of protective device B, the
protective lid.
c) at the product outlet side by means of protective de-
vice A, the protective screen.
• Before reaching into the machine, it must be
stopped. For this purpose the protective screen at
the product outlet must be lifted.
1.7.12Film inlet side
At this point, the closing and separating area danger
point is covered by the stuffing horn system and the
casing brake.
• Therefore, the machine must never be operated
without the stuffer horn system and casing brake.
1.7.13Product outlet side
At this point, the closing and gathering area danger
point is covered by the product outlet and the protec-
tive screen.
If the product outlet (protective device with cutout C) is
opened or if the protective screen (protective device
with cutout A) is lifted, the machine is stopped.
• Never reach underneath the protective screen with-
out first having lifted the protective screen.
There is great danger of injury at this point.

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Poly-clip System GmbH & Co. KG
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EN/10-2014
1.7.14Electronic hand wheel function
Using the two-hand operation on the control panel,
the machine can be run forwards or backwards in
slow operation mode.
The machine will stop immediately if any of the two-
hand operation buttons is released.
While the safety circuit of all safety devices (A and B)
and of all work sequences (C and D) is inoperative, the
"electronic hand wheel function" is activated.
All protective devices can be opened and the clip
head and sausage outlet can be swung out.
• Never reach into the danger zone during operation.
• The machine must only be operated by one person
at a time.
1.7.15Automatic operation
The product outlet side is partly closed by the emerg-
ing product. However, the inside diameter of the prod-
uct outlet is larger than that of the emerging product.
• Nevertheless, the operator must not reach inside
the danger area during operation of the machine.
1.7.16Stuffing process
The cycle step of separating and closing is started by
the clip pulse generated by the stuffer unit.
After each completed stuffing step, the clip machine
cycle step takes place.
• The operator must never reach inside the danger ar-
eas without first having stopped the machine.
1.7.17Stuffing process in automatic opera-
tion
If, during automatic operation, the stuffer becomes
empty during the stuffing process and does not stuff a
complete portion, the TSCA remains in "Automatic On"
mode.
After completion of the stuffing time selected on the
stuffing machine, the clip signal is transmitted to the
clip machine despite the portion not being completed.
• The clip machine cycle step is carried out.
•Note
With the stuffer empty, for safety reasons the clip ma-
chine should be switched to "Automatic Off" mode or
the Emergency-Stop button must be pressed.
1.7.18Changing over from Automatic On to
Automatic Off
During this action the cycle that has already started is
not interrupted.
After the stuffing process, the clip pulse starts and
completes the clip machine cycle step.
However, the clip pulse also causes changing over of
the clip machine to Automatic Off.
No further cycles take place after the started cycle has
been completed.
• The operator must never reach inside the danger ar-
eas without first having stopped the machine.
1.7.19 Risk of burning at the seal station
With the heating switched on, the seal band will reach
up to 180° C during normal operation, depending on
the preselected temperature.
The seal band is protected by a protective cover on the
front side. However, this protective cover may heat up
during continuous operation.
There is a risk of burning when touching. Do not touch
seal band and protective cover!
Fig. 1-8 1 Seal band
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TSCA 120-M/160-L
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1.7.20 Risk of contusion at the seal station
Risk of contusion between seal bar (1, Fig. 1-9) and
seal pipe (2, Fig. 1-9). Never reach between the seal
bar and the seal pipe!
Fig. 1-9 1 Seal bar
2 Seal pipe
Risk of contusion between film transport unit (1, Fig.
1-10) and seal pipe (2, Fig. 1-10). Never reach be-
tween the film transport unit and the seal pipe; upon
ejection of a portion, the film transport unit will abrupt-
ly approach the seal pipe!
Fig. 1-10 1 Film transport unit
2 Seal pipe
1.7.21 Risk of crushing at film roll unwinder
Fig. 1-11 1 Motor
2 Film roll unwinder
3 Film roll
4 Tension core
Danger! Upon actuation, the film roll unwinder (2, Fig.
1-11) moves upwards by means of compressed air. At
this point, there is a risk of crushing between the film
roll unwinder and the motor (1). Never reach into this
zone when the film roll unwinder is actuated!
Fig. 1-12 (here: without film roll)
1 Film roll unwinder
2 Front area od tension core
Caution! Upon renewed actuation of the roll unwinder,
the roll unwinder moves downwards without means of
compressed air and there is a risk of crushing between
the film roll unwinder (1, Fig. 1-12) and the tension
core and/or film roll. When lowering the film drive, hold
the roll in the front area of the tension core (2) only and
not in the area of the tension core onto which the film
roll unwinder lowers.
1
2
1
1
2
1
2
3
4
2
1

TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
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EN/10-2014
1.7.22 Switch cabinet
• In case of fire
• Do not open the switch cabinet door;
• Disconnect the mains plug!
1.7.23 Clamping core
The bellows of the clamping core may tear or burst
when air is blown inside without a roll being placed
onto the clamping core.
This may lead to risk of injury due to escaping com-
pressed air or flying rubber parts.
Fig. 1-13 1 Clamping core
1.8 Moving Machine and Additional
Equipment
The machine and its additional equipment is very
heavy. In order to move the machine on a level sur-
face, minimum two persons are required. The ma-
chine can only be moved in a controlled manner on a
level surface; on inclined surfaces the machine must
be additionally secured. Special care is required when
moving the machine across sills or groves.
Suitable points for sliding the machine are the
short sides of the machine.
In order to lift the machine, a fork lift with appropriate
load-bearing capacities is required.
1.8.1 Measures before moving
- Disconnect the complete power supply of the ma-
chine - even for short distances.
- Secure the front doors and covers, see Fig. 1-16.
- Open the left side cover and secure the clip head of
the machine with the screw, see Fig. 1-14.
Fig. 1-14 1 Screw
1.8.2 Loading and unloading
- Be careful when loading with or without lifting equip-
ment!
- When loading the machine by means of lifting equip-
ment, ensure that lifting capacity is sufficient.
• Do not stand underneath suspended loads of in the
loading area.
Danger to life!
- Only use suitable transport vehicles with sufficient
carrying capacity.
- Secure the load on the transport vehicle so that it is
protected against sliding or falling.
1.8.3 Removal of transport packaging
-Remove all parts attached for transport purposes
and all packaging before the machine is started up.
• Transport ropes must be secured tightly and will
snap off when cut.
With incorrect handling there is danger of injury.
- All parts or equipment removed fro transport purpos-
es must be properly refitted in accordance with their
intended use, before the machine is started up.
1.8.4 Disposal of packaging materials
Packaging materials must be collected in accordance
with the legal provisions for recycling and/or disposal.
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