Ulma TFS100 User manual

EU ERABILERA ARGIBIDEAK
ES INSTRUCCIONES DE USO
EN INSTRUCTIONS FOR USE
DE BEDIENUNGSANWEISUNGEN
IT ISTRUZIONI PER L’USO
FR INSTRUCTIONS D'UTILISATION
NL GEBRUIKSAANWIJZING
PT INSTRUÇÕES DE USO
PL INSTRUKCJA OBSŁUGI
RO INSTRUCTIUNI DE UTILIZARE
RU ИНСТРУКЦИЯ ПО ПРИМЕНЕНИЮ
EU BOTOIAK, PANTAILAK ETA ALARMAK
ES BOTONERA, PANTALLAS Y ALARMAS
EN BUTTON PANEL, SCREENS AND ALARMS
DE KNOPFSCHALTTAFEL, EINSTELLUNGEN – STÖRUNGSMELDUNGEN
IT PULSANTIERA, SCHERMATE E ALLARMI
FR PUPITRE DE COMMANDES - ÉCRAN – ALARMES
NL DRUKKNOPPENKAST, BEELDSCHERMEN EN ALARMEN
PT PAINEL DE BOTÕES, TELAS E ALARMES
PL USTAWIENIA - ALARMY I WIADOMOŚCI NA EKRANIE
RO ARIA BUTOANELOR, ECRANE ŞI ALARME
RU КНОПОЧНЫЙ ПУЛЬТ, ЭКРАНЫ ИТРЕВОГИ
EU SEGURTASUN GAILUAK
ES SEGURIDADES
EN SAFETY DEVICES
DE SICHERUNGEN
IT SICUREZZE
FR SÉCURITÉS
NL BEVEILIGINGEN
PT SEGURANÇAS
PL BEZPIECZEŃSTWO
RO SISITEMUL DE SIGURANŢĂ
RU БЕЗОПАСНОСТЬ
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EU SEGURTASUN GAILUAK
ES SEGURIDADES
EN SAFETY DEVICES
DE SICHERUNGEN
IT SICUREZZE
FR SÉCURITÉS
NL BEVEILIGINGEN
PT SEGURANÇAS
PL BEZPIECZEŃSTWO
RO SISITEMUL DE SIGURANŢĂ
RU БЕЗОПАСНОСТЬ
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TABLE OF CONTENTS
1INTRODUCTION...................................................................................................... 2
2GENERAL SAFETY PRECAUTIONS ...................................................................... 2
3PERSONNEL SAFETY ............................................................................................ 2
4WORK AREA SAFETY ............................................................................................ 3
5LOADING AND UNLOADING SAFETY ................................................................... 3
6SAFETY DURING SERVICING ............................................................................... 4
7OPERATING SAFETY ............................................................................................. 4
8MAINTENANCE SAFETY ........................................................................................ 4
9LOCK-OUT AND TAG-OUT PROCEDURE............................................................. 5
10 WEEKLY CHECKS............................................................................................. 6
11 AERIAL NOISE EMITTED .................................................................................. 6
12 SAFETY WITH VACUUM PUMPS ..................................................................... 6
13 PICTOGRAM SIGNAL ........................................................................................ 7

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1 INTRODUCTION
This section in the Manual was included for the user to become familiarized with the
safety measures to follow when using the machine.
2 GENERAL SAFETY PRECAUTIONS
Do not handle, install, adjust or start-up this machine without first reading the content of
this manual.
Although the machine includes the systems that are needed to ensure the safety of the
user, special care should be taken in handling, setting and maintenance operations.
When unpacking the machine, carefully inspect for any damages that may have
occurred during transportation. If any problems are found please notify the
transportation company so that your agent may make a proper evaluation.
Maintenance and servicing should only be done by qualified and properly trained
personnel.
This machine is designed to package the product indicated in the sales contract that
was signed by the client. Should any other type of product need to be packaged,
please check with ULMA.
ULMA is not responsible for any alterations or adaptations made on the machine by
personnel other than ULMA, unless previously authorized in writing.
The use of spare parts and consumable items that are not manufactured by ULMA may
have a negative effect on the functioning of our equipment, and may be a cause for
cancelling the guarantee.
3 PERSONNEL SAFETY
Machine operating and maintenance personnel must be aware that safety procedures
are included as a part of their work. Accident prevention must be one of the main
objectives in their work.
Know and respect the machine. Read and follow safety procedures and make sure that
everyone working with the machine understand and use these procedures.
Do not use neckties, handkerchiefs, loose dresses, necklaces, loose fitting clothing,
etc. near a moving machine. Protect long hair with a cap or hair net.
Use the Personal Protective Equipment required for the work to be performed and keep
this equipment in good condition.
THE SAFETY OF THE PERSONNEL INVOLVED IN HANDLING
INDUSTRIAL EQUIPMENT IS ONLY POSSIBLE WITH A PROPERLY
DESIGNED SAFETY PROGRAM, WHICH SHOULD BE STRICTLY
FOLLOWED BY THE USERS OF THE EQUIPMENT.

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4 WORK AREA SAFETY
Always keep work area clean. Work areas with material such as oil, waste or water on
the floor, may cause personnel to fall and may result in serious injury.
Ensure that your work area is free of dangerous obstructions or dangerous protruding
parts on the machine.
Report any unsafe working conditions to your manager or supervisor.
The machine must be left at least 500 mm from the wall. This minimum distance will
avoid possible crushing.
All handling and maintenance operations on the machine must be made with the
MACHINE STOP.
5 LOADING AND UNLOADING SAFETY
If there is any doubt or uncertainty regarding procedures related to elevation and
transportation, please contact the appropriate manager or supervisor.
Before lifting or transporting anything, check the weight and dimensions by reading
labels, transportation information, and any written manuals or transportation details.
Motorized devices or other mechanical devices must be used to lift and transport heavy
or large objects. For that purpose, personnel must be trained and authorized to handle
and transport loads.
Never place an overhead load on your body or move the load over the body of
someone else.
Before lifting an object make sure that there is a safe place from which to lift.
Always check slings, chains, hoists and other lifting devices before use.
Never exceed nominal safety loads of cranes, hoists, slings, eyebolts and other lifting
equipment.
For more information on loading, unloading and transporting the machine or any of its
parts, read the instructions included in this manual (section on unpacking,
transportation and handling).
NOT FOLLOWING THE INSTRUCTIONS IN THIS SECTION MAY
RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THE MACHINE.
NOT FULFILLING THE ABOVE MAY RESULT IN SERIOUS
PERSONAL INJURY.

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6 SAFETY DURING SERVICING
Assign the work to qualified personnel.
Study and understand all safety instructions before servicing.
The doors of the main electrical cabinet must be closed before and after connecting to
electricity.
Guards, protections, barriers, covers and other devices must be connected or in
position before operating the machine.
Once the machine is installed, check that the engines are running the proper direction
(indicated with an arrow over the ventilator grid).
Check that operating devices (micros) are operating correctly.
7 OPERATING SAFETY
Do not try to start or use the machine until all safety terms, installation instructions and
maintenance procedures, have been understood.
Maintain the machine in proper operating condition.
Keep all safety systems activated permanently.
The operator must never insert his/her hands, rags, tools, etc. inside the machine while
it is running.
Do not place tools, parts or other objects on or inside the machine.
Do not use mobile telephones near the industrial computer or inside the electricity
cupboard.
8 MAINTENANCE SAFETY
Adjustments, repairs and lubrication must only be made by qualified maintenance
personnel, by following this manual's instructions and ensuring lock-out and tag-out.
Always disconnect the electrical supply, before doing any cleaning or maintenance.
Always keep the machine clean, lubricated and in good working condition.
NOT FOLLOWING THE ABOVE INSTRUCTIONS MAY RESULT IN
SERIOUS DAMAGES, INCLUDING DEATH DUE TO CRUSHING TO
THE PERSON HANDLING THE MACHINE..
NOT FOLLOWING THE ABOVE INSTRUCTIONS MAY RESULT IN
SERIOUS INJURY TO PERSONS HANDLING THE MACHINE.

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9 LOCK-OUT AND TAG-OUT PROCEDURE
Purpose
This procedure establishes the minimum requirements for the lock-out and tag-out of
power supply devices. It will be used to make sure that the machine or equipment is
disconnected from any power source that is potentially dangerous and that it is locked
and tagged before any personnel carries out any type of maintenance work or repair.
Responsibility:
Personnel responsible for work to be performed in dangerous areas must be instructed
as to the meaning of safety through the lock-out/tag-out procedure.
Preparation for Lock-out/Tag-out
All affected operators must be notified that the lock-out/tag-out procedure will be
performed.
Lock-out/Tag-out Sequence
Identify all devices and power sources that must be disconnected (switches, valves and
others).
- Electrical Cabinet. Cut the power using the input disconnecting switch and
remove the fuses (this blocks the air and water system).
- Air. Empty the cooling system (only if needed).
- Water (only with cooling system). Interruption of water intake if needed.
Add sign on machine prohibiting reconnection.
After ensuring that no one is exposed and to check that the power sources
disconnection was made correctly, press the activation buttons that control the
operation of the isolated section to make sure that the disconnection was efficient.
After performing the above operations, the machine will be in lock-out/tag-out and the
work may be performed without risk of an unexpected start-up.
If the process involves more than one person
In the steps shown in the above sections, if there is more than one person involved,
each person involved will lock-out and tag-out the power-cutting devices.
No one may remove it, except the person adding the lock-out and tag-out. The
equipment will not be connected while there is a lock-out and/or tag-out.
REPAIR AND MAINTENANCE OPERATIONS MUST BE PERFORMED
WHILE THE MACHINE IS STOPPED, ONCE ALL EXTERNAL POWER
SOURCES ARE DISCONNECTED AND AFTER DISCHARGING THE
RESIDUAL ENERGY FROM ACTUATORS.
REPLACE ACTIVATION BUTTONS TO THE OFF POSITION AFTER
THIS CHECK.

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Return the machine to its normal operating condition
Reconnection may be made after performing the repair, maintenance, connection or
other operations and once the equipment is prepared for use.
Inspect the work area and rest of the machine affected by the lock-out/tag-out, to
ensure that no one is exposed.
Remove additional protections, if any.
Remove all tag-outs and other lock-outs.
Reconnect all switches that were disconnected.
The machine is now in service again for normal production.
10 WEEKLY CHECKS
Main switch operation.
Operation of emergency stop.
Correct operation of all safety guard micros.
Guards prevent access to dangerous points on the machine.
The guards are perfectly secured to ensure that there is no danger whatsoever for the
user.
The doors on the electrical cabinet and junction boxes are closed properly.
11 AERIAL NOISE EMITTED
The equivalent continuous A-weighted sound pressure level experienced by this
machine is 74 dB (A).
12 SAFETY WITH VACUUM PUMPS
This section shall only apply to machines that include vacuum pumps.
IMPORTANT WARNING
IN STANDARD VERSIONS, THIS EQUIPMENT IS NOT PREPARED TO BE
OPERATED WITH A MIXTURE OF GASES THAT CONTAIN OXYGEN OVER 21%
IN ITS COMPOSITION.
If a gas is to be injected in the package that contains oxygen exceeding the indicated
proportion (21%), the vacuum pump must be adapted so that it may work under these
conditions. There is a risk of ignition, with the possibility of explosion, due to the
reaction between the oils in the pump and the gas enriched with oxygen
If you wish to work under these conditions, please contact ULMA

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13 PICTOGRAM SIGNAL
DESCRIPTION PICTOGRAM
EU Temperatura handiko eremua
ES Zona a temperatura elevada
EN Higher temperature area
DE Hochtemperaturbereich
IT Zona a temperatura elevata
FR Température élevée dans cette zone
NL Zone met hoge temperatuur
PT Zona com temperatura elevada
PL Strefa wysokiej temperatury
RO Zonăcu temperaturăridicată
RU Зона свысокой температурой
EU Elektrizitate arriskua
ES Peligro eléctrico
EN Electricity danger
DE Vorsicht! Elektrizität!
IT Rischio elettrico
FR Risque d'électrocution
NL Elektrisch gevaar
PT Perigo elétrico
PL Zagrożenie elektryczne
RO Pericol electric
RU Опасность поражения электрическим током
EU Arriskua
ES Peligro
EN Danger
DE Gefahr
IT Pericolo
FR Danger
NL Gevaar
PT Perigo
PL Uwaga
RO Pericol
RU Опасность
EU Arrapatzeko arriskua
ES Peligro de atrapamiento
EN Danger of being trapped
DE Klemmgefahr
IT Rischio di schiacciamento
FR Risque d'écrasement
NL Gevaar op verstrikking
PT Perigo de prisão de partes
PL Niebezpieczeństwo wciągnięcia
RO Pericol de strivire
RU Опасность захвата

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DESCRIPTION PICTOGRAM
EU Arrapatzeko arriskua
ES Peligro de atrapamiento
EN Danger of being trapped
DE Klemmgefahr
IT Rischio di schiacciamento
FR Risque d'écrasement
NL Gevaar op verstrikking
PT Perigo de prisão de partes
PL Niebezpieczeństwo wciągnięcia
RO Pericol de strivire
RU Опасность захвата
EU Makina martxan egonik konponketaren debekua
ES Prohibición de reparación en funcionamiento
EN Repair forbidden when functioning
DE Reparatur bei laufender Maschine verboten
IT Divieto di riparare mentre è in funzione
FR Interdiction de réparer la machine en fonctionnement
NL Verboden te machine te repareren terwijl die aan het werken
is
PT Proibição de reparação em funcionamento
PL Zakaz naprawiania maszyny w czasie pracy
RO Interzisărepararea în timpul funcţionării
RU Запрещается производить ремонт во время работы
машины
EU Baimen gabeko langileria debekatuta dauka makina
konpontzea
ES Prohibido reparar la máquina a personal no autorizado
EN Unauthorized personnel are forbidden to repair the machine
DE Reparatur durch unbefugte Personen verboten
IT È vietato riparare la macchina al personale non autorizzato
FR Interdiction à toute personne non autorisée de réparer la
machine
NL Verboden de machine te laten repareren door onbevoegd
personeel
PT Proibida a reparação da máquina por pessoal não
autorizado
PL Zakaz naprawiania maszyny przez niewykwalifikowany
personel
RO Interzisărepararea de către personal neautorizat
RU Запрещается производить ремонт неразрешенному
персоналу

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DESCRIPTION PICTOGRAM
EU Makina martxan egonik koipeztatzearen debekua
ES Prohibido engrasar la máquina en funcionamiento
EN Forbidden to lubricate the machine when functioning
DE Schmierung bei laufender Maschine verboten
IT È vietato lubrificare la macchina quando è in funzione
FR Interdiction de graisser la machine en fonctionnement
NL Verboden de machine te smeren terwijl die aan het werken is
PT Proibido lubrificar com a máquina em funcionamento
PL Zakaz smarowania maszyny w czasie pracy
RO Interzisăungerea maşinii în timpul funcţionării
RU Запрещается смазывать машину во время ее работы
EU Makinan manipulazio puntuak
ES Puntos de manipulación de máquina
EN Machine handling points
DE Bedienpunkte der maschine
IT Punti di manovra della macchina
FR Points de manipulation de la machine
NL Manipuleerpunten op de machine
PT Pontos de manipulação da máquina
PL Punkty czynności przy maszynie
RO Puncte de manipulare a maşinii
RU Места захвата машины

EU ERABILERA ARGIBIDEAK
ES INSTRUCCIONES DE USO
EN INSTRUCTIONS FOR USE
DE BEDIENUNGSANWEISUNGEN
IT ISTRUZIONI PER L’USO
FR INSTRUCTIONS D'UTILISATION
NL GEBRUIKSAANWIJZING
PT INSTRUÇÕES DE USO
PL INSTRUKCJA OBSŁUGI
RO INSTRUCTIUNI DE UTILIZARE
RU ИНСТРУКЦИЯ ПО ПРИМЕНЕНИЮ
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INDEX
1MACHINE WORKING DESCRIPTION.................................................................................3
1.1 INTRODUCTION – WORKING DESCRIPTION ..............................................................3
1.2 MACHINE WORKING DESCRIPTION ............................................................................3
1.3 THERMOFORMING MOULD...........................................................................................4
1.4 SEALING MOULD............................................................................................................4
1.5 DIVISION PER TRAY UNIT.............................................................................................4
2MACHINE INSTALLATION...................................................................................................5
2.1 MACHINE LOCATION .....................................................................................................5
2.2 MACHINE DIMENSIONS.................................................................................................5
3VERIFICATIONS BEFORE INSTALLATION........................................................................7
3.1 TRANSPORT INSTRUCTIONS.......................................................................................7
3.2 INSTALLATION SCHEME ...............................................................................................8
3.3 ELECTRICAL CIRCUIT....................................................................................................9
3.4 VACUUM CONNECTION.................................................................................................9
3.5 PNEUMATIC CONNECTION...........................................................................................9
3.5.1 AIR TREATMENT ...............................................................................................9
3.6 COOLING WATER CONNECTION ...............................................................................11
3.7 GAS CONNECTION.......................................................................................................11
3.8 ELECTRONIC CABINET................................................................................................12
4MACHINE OPERATION.....................................................................................................13
4.1 CONTROLS....................................................................................................................13
4.2 FILM COIL INSERTION.................................................................................................14
4.3 OPERATION ..................................................................................................................16
5FORMAT AND MOULD CHANGE .....................................................................................17
5.1 FORMING MOULD CHANGE........................................................................................17
5.2 SEALING MOULD CHANGE .........................................................................................17
5.3 FORMAT CHANGE IN THE LONGITUDINAL CUTTING..............................................18
6CHANGE OF DRAGGING GRIPS .....................................................................................19
6.1 DETECTORS. LOCATION OF DETECTORS ...............................................................20
6.2 WARNINGS AND DANGEROUS AREAS FOR THE OPERATOR...............................21
7MAINTENANCE..................................................................................................................25
7.1 GENERAL MAINTENANCE AND CLEANING...............................................................25
7.1.1 CLEANING THE MACHINE..............................................................................25
7.1.2 GENERAL OBSERVATIONS............................................................................27
7.1.3 CLEANING PROCEDURES..............................................................................28
7.2 MECHANICAL MAINTENANCE.....................................................................................28
7.3 LUBRICATION ...............................................................................................................30
7.3.1 TABLE OF LUBRICATION EQUIVALENTS MANUAL.....................................31
7.4 VACUUM PUMP ............................................................................................................33
7.5 FILTROS ........................................................................................................................35
8PRODUCT LOCATION.......................................................................................................37

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8.1 FILM COIL STORAGE AND TRANSPORT...................................................................37
8.2 INSERTION OF PRODUCTS IN TRAYS.......................................................................38

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1 MACHINE WORKING DESCRIPTION
1.1 INTRODUCTION – WORKING DESCRIPTION
Thermoforming machines are included within the group formed by wrapping
machines.
This machine uses two film coils. The interior coil is made of plastic material
(usually a complex one, that is to say, formed by more than one component) that, by
means of different systems, when it meets the thermoforming mould adapts itself to the
shape of a fitting so creating a cavity.
Once the film cooled, it reaches the loading area, where the product to be
packed is introduced in the abovementioned cavities by means of adequate devices
that adapt themselves to the machine.
Then, the upper film is placed on the cavities and both enter a camera or
welding mould where the sealing of both plastic materials takes place. Previously, and
if the product so requires and the moulds are prepared to do so, we can create an
atmosphere modification into the package.
Finally, at the cutting unit, packs are divided by unit or by group and so they
come out of the machine ready to be presented to consumers.
1.2 MACHINE WORKING DESCRIPTION

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1.3 THERMOFORMING MOULD
Thermoforming is one of the oldest methods of plastic material processing. The
film, which is placed over the thermoforming mould held by grips, must be:
1. Preheated.
2. Moulded.
3. Cooled.
The previously heated material is softened and then pushed against a mould
surface, so adapting itself to the shape of the surface (this process is called forming or
moulding). When the hot film touches the cooled fitting, the film cools and its new
shape is stable. The thickness of the mould surface will always be below the starting
thickness of the film.
1.4 SEALING MOULD
Once the thermoforming finished and after having put the product to wrap in the
cavity, the product will enter the heat-sealing unit together with the upper film, where
both materials will be joined together.
The heat- sealing unit varies depending on the processes that will take place
inside it:
The simplest case is a welding mould where both materials are welded.
2) Then you can have a welding mould designed to make a previous
vacuum.
3) Finally, you may want the sealing mould to inject gas into the wrapping. In
this case, a previous vacuum will be made.
1.5 DIVISION PER TRAY UNIT
So far, we have trays with a product inside and closed by means of an upper
film. These trays reach the cutting area, where the units will be divided.
Depending on the shape and material of the tray, we can use one system or
another, depending on whether we have used a flexible or stiff film.
DIFFERENT TYPES OF CUTTING DEPENDING ON PACKING MATERIAL
FLEXIBLE FILM (MATERIALS)
-CROSS-CUTTING
Guillotine cutting.
-LONGITUDINAL CUTTING
Pneumatic edge cutting.