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

TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
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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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Poly-clip System GmbH & Co. KG
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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

TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
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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

TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
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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

TSCA 120-M/160-L
Poly-clip System GmbH & Co. KG
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