USE AND MAINTENANCE HANDBOOK - TLM Pack

Traslation of Original Instruction - Edition 01 of 27/01/2017

Via Venezia, 34/N-O-P - 10088 - Volpiano (Torino) Tel. 011.9881307 – Fax. 011.9881084

www.tlmpack.com

USE AND MAINTENANCE

HANDBOOK PRIME 400 PACKAGING MACHINE

http://www.tlmpack.com/

Use and Maintenance Handbook – Prime 400 Packaging Machine Page 2 of 71

TABLE OF CONTENTS

1. PREFACE ........................................................................................................... 4

2. WARNINGS AND GUARANTEES...................................................................... 5

3. SPARE SERVICES ............................................................................................ 6

4. INTENDED USE ................................................................................................. 6

5. NON PERMITTED CONDITIONS OF USE ........................................................ 7

6. IDENTIFICATION PLATE ................................................................................... 7

7. DESCRIPTION AND TECHNICAL SPECIFICATIONS ...................................... 8

7.1 Loading floor ........................................................................................................10 7.2 Adjustable conveyor ............................................................................................10 7.3 Unwinding group ..................................................................................................11 7.4 Perforator ............................................................................................................11 7.5 Welding group .....................................................................................................12 7.6 Discharge chute ...................................................................................................13 7.7 Pneumatic system ...............................................................................................14 7.8 Electrical System .................................................................................................15 7.9 Technical specifications .......................................................................................16

8. TRANSPORT AND HANDLING ....................................................................... 17

9. INSTALLATION ................................................................................................ 19

10. SAFETY ............................................................................................................ 20

10.1 Particular recommendations ................................................................................21 10.2 Intended, unintended and improper uses .............................................................23 10.2.1 Contraindication and danger of the unexpected uses ..........................................25 10.3 Safety ..................................................................................................................26 10.3.1 Introduction ..........................................................................................................26 10.3.2 Danger of cutting and crushing ............................................................................26 10.3.3 Stability loss .........................................................................................................26 10.3.4 Electrical hazards ................................................................................................27 10.3.5 Fire hazard ..........................................................................................................27 10.3.6 Danger of cutting .................................................................................................27 10.3.7 Thermic danger ...................................................................................................28 10.3.9 Danger due to the machine handling ...................................................................29 10.4 Main protections ..................................................................................................30 10.4.1 Mobile guards, access door to the internal components ......................................31 10.4.2 Permanent guards ...............................................................................................31 10.4.3 Pneumatics guards ..............................................................................................32 10.4.4 Electrical protections............................................................................................33 10.4.5 Plate and indications ............................................................................................35 10.5 Reference standards ...........................................................................................36 10.6 Risk analysis and the safety measures adopted ..................................................37 10.6.1 Functioning in production .....................................................................................38 10.6.2 Functioning during fine tuning / Maintenance ......................................................43 10.7 Noise ...................................................................................................................44 10.8 Electromagnetic compatibility ..............................................................................45


11. INSTRUCTIONS FOR USE .............................................................................. 46

11.1 Operator ..............................................................................................................46 11.2 Safety regulations for a proper functioning ..........................................................47 11.3 Control panel .......................................................................................................48 11.4 Operator panel description ..................................................................................49 11.4.1 Main menu page ..................................................................................................49 11.4.2 Jog and homing page ..........................................................................................50 11.4.3 Piece counter page ..............................................................................................51 11.4.4 Mark setup page ..................................................................................................52 11.4.5 Bags length setup page .......................................................................................53 11.4.6 Recipe page ........................................................................................................54 11.4.7 Machine settings page .........................................................................................56 11.4.8 Jaws page ...........................................................................................................56 11.4.9 Temperature page ...............................................................................................57 11.5 Working phases ...................................................................................................58 11.5.1 Functioning cycle .................................................................................................58 11.5.2 Machine switch-off ...............................................................................................59 11.5.3 Reset after emergency stop .................................................................................59 11.5.4 Mounting the bobbin, film drawing-in and centring ...............................................60 11.5.5 Regulating mark reading .....................................................................................60 11.5.6 Regulating the length of the bag ..........................................................................60 11.5.7 Regulating Loading conveyor ..............................................................................61 11.5.8 Regulating the cut ................................................................................................61

12. MAINTENANCE................................................................................................ 62

12.1 Program maintenance .........................................................................................64 12.1.1 Daily maintenance ...............................................................................................64 12.1.2 Semi-annual maintenance ...................................................................................64 12.1.3 Annual maintenance ............................................................................................64 12.2 Extraordinary maintenance ..................................................................................65 12.2.1 Jaws resistance replacement ...............................................................................65 12.2.2 Jaws proximity sensor replacement .....................................................................65 12.2.3 Jaws sonda probe replacement ...........................................................................66 12.2.4 Roller resistance replacement and adjustment ....................................................66 12.3 Maintenance on the Pneumatic System ...............................................................67 12.3.1 Filter and pressure regulator ................................................................................67 12.3.2 Command valves with a pneumatical actuation direction .....................................68 12.3.3 Flow regulator ......................................................................................................68 12.3.4 Actuators .............................................................................................................69 12.3.5 Calibration procedure of the flow regulators ........................................................69

13. DECOMMISSIONING AND DEMOLITION ....................................................... 70

14. APPENDICES................................................................................................... 71


1. PREFACE The purpose of the information in this “Use and Maintenance Manual” is:

To show the use of the machine envisaged by the design assumptions.

Provide the instructions for transport, installation, assembly, fine tuning and

use to the operators and the maintenance personnel...

Facilitating the ordering of any spares or materials subject to wear and tear.

Provide indications of the risks involved in carrying out the tasks assigned.

Enable the personnel who use the machine, to operate in safety and

guarantee perfect efficiency throughout its life.

This is to be considered an integral part of the machine and must be “kept” until

it’s finally dismantled.

Furthermore, the content of this manual does not contemplate any risks that may

derive from coupling with other machines.

As a rule it must always be made available for consultation and duly preserved in

a dry, protected place away from the rays of the sun and be known to all the

users (machine operators and maintenance personnel).

TLM PACKAGING reserves the right to make modifications or updates to this

manual at any time and without warning.

The machine to which this manual refers complies with the following Directives:

“Machine Directives” 2006/42/ EC

“Electromagnetic Compatibility 2014/30/UE

and it also takes into account indications deriving from consulting the harmonised

UNI and CEI standards, and Guide to application of the Machinery Directive

2006/42/EC 2nd Edition – June 2010. As defined by the directive, this document

has been drawn up in Italian and has, if necessary been translated into a

community language that has to be the language of the user.

This document will be accompanied by drawings and schematics necessary for

commissioning, maintenance, checking and inspection and, if necessary, repair.


2. WARNINGS AND GUARANTEES

TLM PACKAGING, produces and designs its machines in the most complete respect

of the current safety regulations, with the purpose of ensuring the user the maximum

guarantee in carrying out all the operations envisaged and permitted, together with

the minimum possibility of incidents due to any residual risks. Even after

commissioning TLM PACKAGING shall be able to make modifications to the

machine, modifications that in its unimpeachable judgement represent improvements

for the functioning. TLM PACKAGING ensures that the machine contains no defects

in the materials or the workmanship for a period of 24 months from the date of the

purchaser’s final test, always without prejudice to different contractual conditions.

During this period, TLM PACKAGING undertakes to repair or to substitute, in the time

necessary, those parts that are damaged and/or contain defects at the origin

providing the purchaser notifies TLM PACKAGING of the fact by means of registered

letter with a notice of receipt slip, within seven days of the discovery. The above

conditions are without prejudice to different contractual conditions. In any event all

further obligation and/or indemnity on the part of TLM PACKAGING is excluded. The

warranty referred to above (or the contractual warranty) is only applied if the

purchaser has complied with the regulations in the contract and only if the installation

and the subsequent use of the system has been carried out by the purchaser in

compliance with the instructions contained in this instruction manual. The warranty

excludes all or any liability for direct or indirect injury to persons or damage to

property deriving from the inadequate or improper use or maintenance of the above

mentioned machine. This warranty does not extend to repaired or replaced parts.

Also excluded from the warranty are all the parts that because of their specific use

are subject to wear. In conclusion transport costs, inspections, dismantling and

reassembly due to the intervention of a TLM PACKAGING technician are excluded

from the warranty and will be charged to the purchaser if the flaws and/or defects

found are not covered by this warranty, the above being without prejudice to different

contractual conditions. The warranty automatically becomes null and void in the case

of repairs, modifications or removals or replacement of components aren’t previously

communicated to or agreed and approved by TLM PACKAGING.

The machine must not be used or any work must not carried out, thereon this

collection of documents as not been carefully read and fully understood.


TLM PACKAGING cannot be held responsible for failures, problems or accident

due to non-compliance with this prohibition. Tampering with or altering the

machines and the installed devices, even partially, is prohibited.

The machine is designed in order to package products from various sectors,

including food sector, into specifics bags.

Before proceeding to the product changeover due to the change belongings field,

contact the TLM to get indications.

3. SPARE SERVICES

It may be possible over time that the above mentioned machine may need the

replacement of components, for this purpose the purchaser may order the

components to be replaced. Said customer (purchaser) is obliged to always

purchase O.E.M. spares. For any request of spare parts, it is always necessary to

specify the serial number of the machine that the spare part is referring to, as

indicated on the identification plates. As regards components, please refer to the

attached layout (APPENDIX 4).

4. INTENDED USE

CAUTION

THE MACHINE IS SUPPLIED WITH PERIMETRIC PROTECTIONS AND SAFETY DEVICES,

IN ORDER TO PACKAGE PRODUCTS FROM VARIOUS SECTORS, INCLUDING FOOD

SECTOR, INTO SPECIFICS BAGS.

THE MACHINE, AS PREVISTED BY ITS INTENDED USE, IS REALIZED TO RUN WITH

THE PROTECTIONS AND THE SAFETY DEVICES ACTIVED AND INSTALLED.

TO THE USER: IT’S ABSOLUTELY PROHIBITED ALTERING OR TAMPERING THE

MACHINE, EVEN PARTIALLY, IF NOT AGREED UPON BY THE CONSTRUCTOR; IN

CASE OF NON-COMPLIANCE WITH THIS RULE, THE CONSTRUCTOR CANNOT BE HELD

RESPONSIBLE


5. NON PERMITTED CONDITIONS OF USE

The Constructor declines all responsibility in the following cases:

Use of the machine different than the one provided for.

Improper use of the machine or personnel who are not properly trained.

Incorrect installation.

Defective power supply.

Serious shortcomings with regard to the required maintenance.

Unauthorised work on the machine.

Use of non OEM spares or spares that are not specific to the model.

Total or partial non-compliance with instructions.

Dimensional or geometric inaccuracies of parts to be worked.

Work material is not loaded properly.

Work material other than the one permitted.

Exceptional events.

6. IDENTIFICATION PLATE

The following identification plate is attached to the machine:


7. DESCRIPTION AND TECHNICAL SPECIFICATIONS The machine is designed to package products into specifics bags. Loading

operation of the products to be packaged is performed manually by the operator.

The discharge chute conveys packaged products in an appropriate container.

The packaging machine is composed of :

A. Loading floor;

B. Adjustable conveyor;

C. Unwinding group;

D. Welding group;

E. Discharge chute;

D

C

E A

B

C


CAUTION

The machine has as final use purpose the productive aim described

above and so can only be used to reach such objective, following the

procedure and the indications brought back in this manual, remaining

moreover very closely to the brought back functional limits.

A different use of the machine and/or also the overcoming of an only one

limit, held the user responsible of eventual damages, failures, and

accident on things or persons, caused of its acts.

Its recommended to the user to adhere scrupulously on whats indicate in

this manual, in particular regarding the safety and the preventions of

accidents, and, in case of doubt, always consult the constructor before

acting.

Under no circumstances may the system and/or this manual be modified

or tampered with by people not delegated to do so by the manufacturer,

the manufacturer cannot be held responsible of any derived

responsabilities due to non compliance with this provision.

This machine must never be used in environment where there is

explosion risk.

Note: the machine, as previsted by its destination of use, is realized

to work with protections and safety devices activated and installed.


7.1 Loading floor

The loading floor (A) can be equipped with an optional tunnel wich allows to

maintain the alignment of the product while it reaches the packaging area. The

loading operation is performed manually by the operator.

7.2 Adjustable conveyor

The adjustable conveyor (C) is regulated according to the dimensions of the

product to be packed. Thanks to the adjustable conveyor, the packaging adheres

to the product while limiting the flexibility. The manufacturer’s technicians regulate

the conveyor during test run, the customer may change it a little.

A

C

B


7.3 Unwinding group

The unwinding group puts strain on the film and positions it into place. It is made

up of a shaft for the bobbin (A), some idler rollers (B) and a tensioning system(C).

7.4 Perforator

The perforator is an optional accessory. The machine can be equipped with a

single or multiple type perforator to realise microperforations on the film, so that

the packages have not air inside. The multiple perforator is purpose-built based

on the final customer’s need. The series of idler rollers equipped with needles to

perforate the film (A) are placed on a regulating shaft (B), and then blocked by a

threaded dowel (C). The series of idler rollers can be moved into specific

positions by the grooves on the contrast roller placed in opposition to the needles

(D). The grooves are realised in a position suitable with the type of packaging to

be realised on the machine. A protective casing is placed in the front part, to

avoid contact with the needles in rotation (E).

Example of multiple perforator

A

B

C

B

A

E

D

B C


7.5 Welding group

The welding group is composed of four rollers that weld the film along the

longitudinal axis and two jaws that weld the film on the transversal axis and cut

the packaging. These four rollers are placed over the running surface of the

product.

WELDING ROLLERS

Before the two welding rollers (A) there are two cold dragging rollers (B) that drag

the product in the welding area. Inside the welding group there are the

resistances (both for the rollers and the jaws) equipped with probes that take the

welding temperature. The rollers for welding are equipped with a machined

welding surface that enables the hermetic welding during the transportation of the

film.

A B

A B


WELDING JAWS

Inside the two jaws – the upper one (C) and the lower one (D) – there is a slot.

The cutting blade is placed on the upper jaw. During the film cutting operation,

the blade can move inside the slot present on the lower jaw.

7.6 Discharge chute

The discharge chute (E) allows the exit of the packages coming from the

packaging machine. The packaged products are collected in an appropriate

container.

D

C

E


7.7 Pneumatic system

The customer is responsible for connetting the compressed air supply next to the

system. At the assembly, all the pneumatic control needed are done and any

further adjustment are not required.

For the pneumatic supply a max. 6 Bar pressure is required (3 Bar is adequate).

In order to change the pressure, an action on the top of the knob of the installed

regulator is needed. Rotating clockwise, the increase of the pressure in the

system increase, while rotating in counter-clokckwise sense, a decrease of the

pressure is reached.

CAUTION

THE CONVEYORS, THE DRAINING FILTERS AND OTHERS ACCESSORIES MUST

NEVER BE REMOVED WHILE THE SYSTEM IS UNDER PRESSURE.

CAUTION

BEFORE CARRYING OUT ANY KIND OF INTERVENTION, TURN OFF THE

COMPRESSED AIR SUPPLY LINES AND RELEASE THE PRESSURE FROM THE

SYSTEM.

For specific information on the pneumatic system refer to the technical documentation provided with this manual.


7.8 Electrical System

The packaging machine is supplied with a complete electrical system with wiring

on the machine. The electrical cabinet (A) is located in the rear of the machine,

below the discharge chute. The customer is responsible for connecting the

factory’s electrical cabinet and the main electrical panel, as well as connecting

the main electric panel to others apparatus where there are enabling interchange

signals to synchronised operations. The characteristics of the connections are

shown on the plate on the electrical panel and in the technical documentation

attached to this manual.

CAUTION

BEFORE CARRYING OUT ANY INTERVENTION ON THE ELECTRIC SYSTEM MAKE

SURE THAT IT IS NOT LIVE AND THAT ANY ACCUMULATIONS DEVICES ARE

DISCHARGED OR DISCONNECTED FROM THE SYSTEM.

CAUTION

BEFORE CARRYING OUT THE ELECTRICAL CONNECTION MAKE SURE THAT THE

ELECTRICAL CHARACTERISTICS CORRESPOND WITH THOSE SHOWN ON THE

IDENTIFICATION RATING PLATE OF THE SYSTEM AND THAT THE MACHINE HAS

BEEN FITTED WITH EARTHING.

CAUTION

WHEN CARRYING OUT THE CONNECTIONS CAREFULLY CHECK THE NUMBERING

OF THE CABLES AND THE JAWS REFERRING TO THE WIRING DIAGRAM, THE

POLARITY OF THE POWER SUPPLIES AND THE DIRECTION THE MOTORS

ROTATE.

For specific information on the Electric/Software system refer to the technical documentation provided with this manual.

A


7.9 Technical specifications

LENGHT 860 mm

WIDTH 1300 mm

HEIGHT 1400 mm

POWER SUPPLY 220 Volt – 50/60 Hz

INSTALLED POWER 3 kW

OPERATING AIR PRESSURE 3 Bar

MAXIMUM AIR PRESSURE 6 Bar

PIECES PRODUCTS 20 for minute

ENVIRONMENTAL CONDITIONS FOR USE

LOCAL CLOSED

MIN TEMPERATURE - 10 °C

MAX TEMPERATURE 40 °C for a period of 24h average

max. temperature 35 °C

RELATIVE HUMIDITY max 50% - R.U. at 40 °C

MAX ALTITUDE 2000 m

ENVIRONMENTAL CONDITIONS FOR STORAGE

LOCAL CLOSED

MIN TEMPERATURE -10 °C

MAX TEMPERATURE 40 °C

RELATIVE HUMIDITY max 50% - R.U. at 40 °C


8. TRANSPORT AND HANDLING

For the handling and raising of the machine it is necessary to use the lower cross

beams of the frame with a forklift truck suitable for the weights indicated in the

relevant table of technical specifications.

While handling the entire surrounding area must be considered a danger area.

Make sure that nobody is in the danger area.

Do not stop or move under the suspended weights.

Keep the load at minimum distance from the ground.

! CAUTION

DURING THE MOVEMENT OPERATION, THE USE OF THE RECOMMENDED PPE IS

COMPULSORY

WITHOUT LOOSE OR HANDLING

PARTS

Handling operations must only be carried out specialised personnel taking into

account the following regulations:

Operations to be carried out with the maximum care being careful to make

sure that the instruments are efficient.

Delineate with barriers the area where the operation is carrying-out

Avoid knocks and back kicks during all the phases: during the raising and

during the movement and setting down.


Handling with a forklift truck

In order to lift the machine with a forklift truck with driver on board o with the

driver on the ground, check the capacity for the mass to be lifted.

! CAUTION

THE CAPACITY OF THE LIFTING EQUIPMENT MUST BE SUFFICIENT FOR THE

MASS TO BE HANDLED. ADHERE CLOSELY TO THE SAFETY REGULATIONS

DANGER

WHEN LIFTING AND MOVING THE MACHINES DO NOT STAND NEARBY. KEEP AT

A DISTANCE OF MORE THAN 2 METERS FROM THE LOAD.

! CAUTION

THE MANUFACTURER DECLINES ALL LIABILITY FOR ANY INJURY TO PERSONS

OR DAMAGE TO PROPERTY CAUSED BY IMPROPER HANDLING OF THE LOADS

CARRIED OUT BY UNSUITABLE PERSONS AND:OR WITH LIFTING EQUIPMENT

THAT IS NOT ADEQUATE.

The operations to be carried out for moving are:

Cut off the power supply;

Properly lock all the mobile parts in order to avoid damaging or that they

suddenly get open during the transport phases;

Protect the equipment in order to prevent it from getting damaged during the

transport;

Use the appropriate lifting pockets suitable for the handling.


9. INSTALLATION

The machine that this manual refers to is installed in a workshop environment.

For the purpose of making installation possible, the floor on which the equipment

is to be placed must be checked to make sure it is flat and solid. To get the best

results in the production cycle, the floor must not be subject to vibrations. It is

advisable to make preliminary study in such a way as to optimise the accessibility

to the machine so as to be able to:

Carry out the installation,

Obtaining the spaces for manoeuvre,

Carrying out Use and Maintenance interventions

To check the exact levelling of the machine proceed as indicated below:

Place the bubble level on the machine plan.

Check the levelling eventually insert specifics thickness

Complete the operation by pulling the fastening nuts in order that the machine

stand uniformly on the floor.


10. SAFETY The machine responds to the essential safety requisites conforming with what

has been described in Appendix 1 of the Machine Directive 2006/42/EC. In this

chapter all the possible risks that the machine in question might present including

in environmental and air and water pollution terms are considered.

CAUTION

THE MACHINE IS SUPPLIED WITH PERIMETRIC PROTECTIONS AND SAFETY

DEVICES, IN ORDER TO PACKAGE PRODUCTS FROM VARIOUS SECTORS,

INCLUDING FOOD SECTOR, INTO SPECIFICS BAGS.

THE MACHINE, AS PLANNED BY ITS INTENDED USE, IS REALIZED TO RUN WITH




CASE OF NON-COMPLIANCE WITH THIS RULE, THE CONSTRUCTOR CANNOT BE

HELD RESPONSIBLE

CAUTION

DO NOT USE OR CARRY OUT INTERVENTIONS ON THE UNIT BEFORE READING THIS

INSTRUCTION MANUAL.

! CAUTION

ADHERE TO THE SAFETY INSTRUCTIONS IN THIS MANUAL.

! CAUTION

IT’S PROHIBITED TO USE THE MACHINE FOR ANY OTHER THINGS THAN THE ONE

INDICATED IN THIS MANUAL.

! CAUTION

THE MANUFACTURER DOES NOT ASSUME ANY LIABILITY IN THE CASE OF

FAILURES, PROBLEMS OR INJURIES DUE TO THE NON-COMPLIANCE WITH WHAT IS

SET FORTH IN THIS MANUAL

! CAUTION

THE DANGERS FOR THE PERSONNEL WORKING ON THE MACHINE CAN ONLY BE

ELIMINATED IF IT IS PROPERLY USED AS INDICATED IN THIS DOCUMENT, BY

SKILLED PERSONNEL WITH PROPER TECHNICAL TRAINING.


10.1 Particular recommendations

Before starting up and maintaining the unit the operators must have read this

Manual carefully and followed a period of training in the proper use. Only

personnel who have been trained properly regarding the dangers and safety

measures adopted may be charged with the running of the machine.

During the installation and start up phases it is necessary to properly identify

the danger zones. (notices, barriers)

All liability is declined for any accidents or harm to person or damage to

property deriving from the failure to observe the safety instruction, operations

not shown in this manual and following any modification that has not first

been authorised by the manufacturer in writing.

The safety instructions described in this manual supplement and do not

substitute the national, European and any internal safety regulations

currently in force.

Use the machine for the purposes intended and in the conditions specified in

this manual.

Periodically maintain and check all the devices directly to do with safety, not

removing the guards while the machine is in operation.

Keep all the elements subject to possible wear and tear under control. In

particular this applies to all the mechanical parts moving and all the wires

and cables moving especially those with high operating voltages.

Avoid clearing or maintaining the machine in any way while it is in operation.

Before carrying out these operations, turn off the machine in a stable

permanent manner.

In the case of fire, use adequate extinguishing agents and in any case do not

use WATER to put out fires where there are electrical parts.

Keep the electrical cabinets and junction boxes closed.

All the checks and maintenance operations and in particular those that

require the removal of safety guards and the access a safety parts must only

be carried out by skilled and properly trained personnel.

Carry out the maintenance checks as shown in the Maintenance chapter.


Do not attempt to make repairs you are unfamiliar with. Carefully follow the

Usage instructions.

If, during the clearing operations pressurised air is used, where a protective

visor.

Check the efficiency of the power supply cut off device.

Check the efficiency of the machine’s earthing.

There must NOT be people assigned to the use of the machine near the

machine when it is operating.

Do not put your hands inside the machine during functioning and, in

particular, do not insert your hands or fingers between moving parts.

Avoid making any manoeuvres that do not have anything to do with the

dosage and filling when the machine is operating.

DO NOT approach the machine with garments that can get caught; DO NOT

wear ties, shawls, scarves or loose clothing.

The sleeves of clothing must be gathered at the wrists.

Carefully read and conform with the notices applied. Do not cover them for

any reason and replace them if they are damaged.

DO NOT lean on any point of the machine for any reason.

DO NOT rest tools and objects on moving parts.

DO NOT rest containers of liquid near electrical parts.

DO NOT clean the machine with direct jets of water, liquids or corrosive

substances.

DO NOT obstruct or damage the sensors and safety devices or use them for

purposes other than those intended by the Manufacturer, but check their

efficiency often and clean them frequently.

DO NOT modify parts of the machine such as attachment points, holes,

finishings etc. for any reason to adapt them for other devices. The

Manufacturer shall not be liable for the consequences in the case of

malfunctioning due to the non-compliance with the above. We advise you to

ask the manufacturers to make any modifications.


Clean the paint coating, panels and controls with soft cloths that are dry or

slightly moistened with a bland cleaning solution. Do not use any types of

solvent or petrol as the surfaces might be damaged.

NEVER leave the machine unattended when it is in operation.

When operations have been completed turn off the electricity supply.

10.2 Intended, unintended and improper uses

The machine is designed in order to pack products on specific protective film. The

processable products can be from different sectors. Obviously it is possible to

change the type of products to pack, following an adequate cleaning in order to

avoid the product contamination. If the machine is used in the food sector, it is

necessary to proceed with an adeguate cleaning and with the substitution of

some parts of the machine that will get in contact with the food that need to be

pack.

Before proceed to the product changeover due to the change belongings field,

contact the TLM to get indications.

The machine is designed in the respect of the Machine Directive 2006/42/CE.

The machine hasn’t be provided to execute operation different than the one

mentioned on this document.


CAUTION


DEVICES, IN ORDER TO PACKAGE PRODUCTS FROM VARIOUS SECTORS,

INCLUDING FOOD SECTOR, INTO SPECIFICS BAGS.






HELD RESPONSIBLE

IF THIS INSTRUCTION IS NOT COMPLIED WITH AND THE MACHINE IS USED FOR

PURPOSES NOT INTENDED BY THE MANUFACTURER, THEREBY MAKING

IMPROPER USE THEREOF, THE MANUFACTURER DECLINES ALL LIABILITY FOR

INJURY TO PEOPLE OR DAMAGE TO PROPERTY

The machine allows to package product from various sectors into specific bags.

The actions described above relieve the manufacturer from any responsibilities

and can lead severe injuries to person and things:

Improper use of the machine,

Extraordinary maintenance not carried out by qualified and authorized

personnel,

Removing any type of label,

Removal or tampering with the protections and security,

Any other use than the one defined turn to nullify the active and passive

security of the Machine.

The Machine guarantee lapses at the moment in which, it get used out of the

limits defined above.


10.2.1 Contraindication and danger of the unexpected uses

1. Whatever operation not previously mentioned has to be considered as

improper, that can cause injuries to person and/or things

2. The types of pack film that can be used are polypropylene, coupled

together, co-extruded.

3. For whatever unexpected use of the Machine, or anyway, for whatever

maintenance that you would like to execute on it, THE USER HAS THE

OBLIGATION TO INFORM US, to the manufacturer in regards of any

contraindication or hazards caused by an improper use.

4. While the Machine is operating, never take off or avoid the system of

protections placed on the machine.

5. All the elements for which aren’t described any regulation or substitution in

this Manual, will only be regulate and substitute by a Machine Manufacture

technician or qualified personnel who will work under the supervision of the

Manufacturer technicians. In regards of the commercial components,

adhere to what its mentioned on the specific instructions manual.

6. The Machine must be used in a covered place and anyway away from

atmospherics agents and dust in general.

7. The position of the cinematic transmission and of the working one is

regulated in the Manufacturer office. The working sequence is tested

different times before the first start of the Machine by the user.

8. It is absolutely prohibited to change the Machine functional characteristics

– performance and/or of its principal components in order to increase its

production potentiality.


10.3 Safety

10.3.1 Introduction

Risk assessment includes both dangers to the operators and those to other

people who might be near the machine. Consideration is therefore given to the

dangers enshrined in UNI EN ISO 12100:2010. In compliance with what is

specified by UNI EN ISO 12100:2010, careful assessment has been made of the

risks, of the way to avoid them and the systems to avoid dangers with particular

attention to the following:

Intended use (including maintenance) and foreseeable improper use.

Identification of the significant dangers. 10.3.2 Danger of cutting and crushing

This danger is generated near moving parts: During the normal production cycles

these zones are not accessible. The solution adopted consists of the segregation

of the dangerous area with fixed guards with special interlock devices following

in compliance with the general requisites UNI EN 953:2009 and of the UNI EN

ISO 13857:2008 “Safety of machinery -- Safety distances to prevent hazard

zones being reached by upper and lower limbs”.

The fixed guards have been designed and applied in such a way that their

adjustment requires a deliberate action, e.g. the use of a tool or spanner (UNI EN

ISO 12100:2010) and also produced in such a way that without fixing elements

they cannot stay in their positions.

10.3.3 Stability loss

The machine must stand on the ground or a flat, stable surface that is strong

enough to hold it. The accessible elements do not, within the limits permitted by

their functions, have sharp corners or edges or rough surfaces that could cause

injuries (UNI EN ISO 12100:2010).


10.3.4 Electrical hazards

The contact with circuit in which high voltage go through can caused burning,

shock, unconsciousness and death by electrocution. Everything can be caused

by a lack of knowledge regarding the use of the electrical equipment. During the

maintenance operation on under tension equipment, it’s necessary to respect the

following indications:

If possible, the personnel, must not work by himself;

If possible, use only one hand to execute the work;

Periodically control the tools and the wires;

Make sure that the assigned personnel has the perfect knowledge of the

apparatus components and the maintenance procedure;

Use maintenance devices;

Open the power contact of the installation before reveal the resistance values

Check that in the low tension circuit there is no high tension;

Do not use magnetics tools near the high magnetic fields;

The personnel in charge of the operation, must not wear objects that can act

as conductors;

Check that the working area and make sure that the floor is clean and dry;

Check the intervention procedure before starting to work, by checking the circuit

diagram in such a way that you visualize how the system is structured.

10.3.5 Fire hazard

Extinguishing methods: carbon dioxide, foam, sand and synthetic materials. Do

not use jets of water that could give rise to the phenomenon of boiling. Use the

mask during the operations of extinction work upwind.

10.3.6 Danger of cutting

During the maintenance, substitution and cleaning operation, pay maximum

attention at the splitting knife placed between the horizontal welding jaws. The

operations must be done using protective gloves in order to prevent risk of

accident.


10.3.7 Thermic danger

While the machine is running, the welding group reach high level temperature:

pay maximum attention in order to avoid burning risk. Before acting on the

machine, to execute maintenance and/or cleaning operation, wait a certain period

of time (AT LEAST 30 MIN.) in order to allow the cooling at the heated elements.

The operation must be done wearing protective gloves against high temperatures

in order to prevent risk of accident.

10.3.8 Danger due to the intended use

In manual mode or in automatic mode, it is absolutely prohibited to avoid the

safety devices while the machine is running.

IN MANUAL MODE, the machine needs the protection to be inserted, by reducing

the production speed in order to allow and make easier the machine’s fine tuning

and regulation.

IN AUTOMATIC MODE, the machine needs the protections inserted, at the end

of the fine tuning/regulation operation, the cycle is launch at the maximal speed

production.

To run, the machine needs the control of only one operator; during operation,

besides attendant operator, the operator must stand near the machine or

worse intervene on the same.

During the regulation, cleaning and maintenance, IT’S COMPULSORY TO

USE protective gloves in order to order to prevent risk of accident.

For any unintended use, or for any intervention that needs to be carried out on

the machine, THE USER HAS THE OBLIGATION TO INFORM the

manufacturer in regards of any contraindication or hazards caused by an

improper use.

The key for opening the protections, must be kept by the person in charge of

the machine. Leave the key insert in the lock, would involve the danger that an

unauthorized person enters in contact with the dangerous mobile parts of the

Machine.


10.3.9 Danger due to the machine handling

The handling phases of the machine components, can introduce dangerous

situations for the non-qualified operator, the handling procedure must be

exclusively done by operators qualified and trained by the Manufacturer.

The raising of the Machine, by trained operator, must be done by the means

of a forklift truck/transpallet.

During the handling of the machine, pay the maximum attention in order that

no one access in the area concerned, in order to prevent risk of accident on

the personnel.

Pay particular attention so that the raising speed of the machine, in order to

avoid oscillation that could determine its overturning.

To avoid dangerous displacement and excessive vibrations during the

functioning, it is necessary to proceed at the machine flooring, by acting on

the levelling feet.


10.4 Main protections

The packaging machine is equipped with fixed guards made in Lexan, in order

not to limit visibility during the production cycle. A guard prevents the access to

the welding rollers group; the internal parts of the machine are enclosed within

the front and back guards. The discharge chute of packaged products is provided

with a fixed guard, also made in Lexan.

Discharge chute guard

Front guard

Welding rollers guard

Rear guard


10.4.1 Mobile guards, access door to the internal components

The access to the internal parts of the machine is prevented by appropriate

perimetric guards, both fixed and movable, to access in case of maintenance

interventions. The guards are built complying with the technical standards of the

EN13857:2008 in order not to limit the visual productive cycle. (Made with

transparent Lexan panels and safety grating to favourite the internal control of the

automatic process). Movable guards are controlled by interlocking devices; in

case of their breakdown, all mobile parts are stopped in safety conditions.

10.4.2 Permanent guards

Fixed guards must only be removed when necessary by authorized maintenance

personnel and must always be replaced before the machine is started again.

All the fixed protections and guards are secured in such a way that deliberate

action must be required to remove them.

At the end of any maintenance work, it is necessary to replace the guards by

reinstalled them in the predetermined position.

The access, to all the others parts of the machine that can constitute a

danger for the safety of the operators are prevented by a series of

fixed/mobiles guards built in metal sheet panels.

Remember that the removal of the fixed guards by the person in

charge of the maintenance, involved his responsibility regarding his

safety and the others people safety.


10.4.3 Pneumatics guards

At the beginning of the pneumatic circuit is placed a safety valve (progressive

starter ) that has a double function of gradually increase the circuit air pression in

order to slowly bring the actuators in rest position, placed up the same valve and

to unexpectedly disperse the same pression in case of an emergency stop.

THE MACHINE CAN BE ISOLATED OF THE COMPRESSED AIR MAIN POWER BY

THE MEANS OF WIRETAP VALVE PLACED AT THE ENTRANCE OF THE

PNEUMATIC CIRCUIT.


10.4.4 Electrical protections

The commands are all clearly identifiable and marked from suitable explanatory

nameplates; the colors are the standardized one’s (EN60204-1). They guarantee

a fast, secure, and univocal operation, coherent with the associate action

(Interruption, reactivation, runs, etc.).

Their operations is such that they can’t cause additional risks (Ex. the

commissioning of the devices that are not directly associated to the command).

The commands are placed out of the dangerous zones (Ex. outside of the

guards). The activation of the manual commands only happens intentionally and

doesn’t involve additional risks.

It’s normally possible from the main starting panel to make sure that there is no

people in the exposed risk zone. Also, is installed an appropriate visual system

that inform the operator that the machine is starting (lighted column on the

electric cabinet). The start of the machine can only happen with a voluntary action

on the especially command provided for. The same action must be done to

restart the machine after a stop done independently from the cause.

The machine is equipped with emergency devices that caused the arrest,

according to the existing risks of all the mobiles parts. The emergency stop

device is clearly identifiable, well visible and quickly accessible.

Once the arrest obtained, the power source of the actuators is interrupted through

safety relays that select the commands via hardware. Stop occurs within a short

time without creating additional hazards. The emergency has a mechanical block

of the command. The unlocking of the device does not allow the restart of the

machine but it only allows restarting. This is a regulation red mushroom-headed

button that protrudes from a yellow background and it can be used to stop the

system. The service is reset from the main panel by the person in charge who

makes sure beforehand that the reason of the emergency no longer exist.


Sfondo giallo

On the machine is installed an emergency button with the function of immediate

stop of the cycle in case of operation.

The cycle selector (automatic, Manual) is prioritary on all the other commands

except the emergency stop. For more information on the function of the control

devices and safety of the electrical signalling refer to drawings and diagrams in

the attachments section.

CAUTION

IT’S FORBIDDEN TO CARRY OUT OPERATION ON LIVE EQUIPMENT, BEFORE ANY

INTERVENTION REMOVE THE POWER SUPPLY ON THE GENERAL PANEL..

CAUTION

IT’S FORBIDDEN TO USE AND/OR OPERATE WET ELECTRICAL EQUIPMENT. IN CASE

OF FOR UNRELATED REASONS TO NORMAL FUNCTION, THE ELECTRICAL

EQUIPMENT OR PART OF THEM SHOULD BE WET, THEY MUST INSPECTED BY

SPECIALIZED ELECTRICIANS AND ELECTRONICS TECHNICIANS, BEFORE USING

AND/OR STARTING-UP

CAUTION

WIRING AND CONFIGURATION SHOULD NOT BE MODIFIED. IMPROPER USE OR

INTENDED TO ASSESTS OTHER THAN THOSE SUPPLY IS FORBIDDEN

CAUTION

BEFORE OPENING ELECTRICAL CABINETS IT’S OBLIGATORY TO DISCONNECT THE

POWER SUPPLY FROM THE GENERAL FRAMEWORK.

CAUTION

THE REPLACEMENTS OF FAULTY PARTS MUST BE CARRIED BY AUTHORIZED

PERSONNEL, WITH GENUINE PARTS..

CAUTION

MONTHLY CHECK THE EFFICIENCY OF THE MACHINE PROTECTION “EARTHING”.

CAUTION

IT’S FORBIDDEN TO USE THE MACHINE AND DO ANY INTERVENTION, WITH POWER

SUPPLY ON AND ELECTRICAL CABINET OPEN.

The activation of this button causes the immediate interruption of the machine. Only with the release of this button (obtained by rotating the actuator) and after pressing the RESET EMERGENCY button on the main panel, is allowed to perform the procedure to restart the cycle.


10.4.5 Plate and indications

Notices with warning pictograms and written warnings are affixed to the cabin and

on the machine to call attention to the existence of specific risks. The person in

charge of the machine is responsible for replacing the plates if they are

deteriorated or become detached over time.

HIGH TEMPERATURE DANGER

DANGER OF CRUSHING UPPER LIMBS

DANGER OF ELECTRIC NATURE

GENERIC DANGER

EMERGENCY BUTTON

PROHIBITION OF LUBRICATE, CLEAN, MAKE ADJUSTMENTS /

RECORDINGS WITH THE MACHINE IN MOTION

PROHIBITION OF ACCESS TO ZONE INVOLVING MOVING

ELECTRICAL PANEL

Plates indicating danger and/or warnings are defined in accordance with

European standards regarding graphic symbols to be used on the plants.


10.5 Reference standards

The rig has been designed in accordance with the Machines Directive

2006/42/EC and subsequent modifications, and with the reference to the

following standards:

UNI EN ISO 14159 2008 Safety of machinery. Hygiene requirements for the design of machinery

EN 1672-1 2014 Food processing machinery. - Basic concepts - Part 1: Safety requirements

EN 1672-2 2014 Food processing machinery. - Basic concepts – Part 2: Hygiene requirements

UNI EN 415-3 2010 Safety Of Packaging Machines - Part 3: Form, fill and seal machines

UNI EN ISO 13850 2008 Safety of machinery - Emergency stop - Principles for design

UNI EN ISO 13857 2008 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs

UNI EN 842 2009 Safety of machinery - Visual danger signals - General requirements, design and testing

UNI EN 14120 2015 Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards

UNI EN ISO 13849-1 2008 Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design

UNI EN 1037 2008 Safety of machinery - Prevention of unexpected start-up

UNI EN 1032 2009 Mechanical vibration - Testing of mobile machinery in order to determine the vibration emission value

UNI EN 14119 2013 Safety of machinery - Interlocking devices associated with guards - Principles for design and selection

UNI EN 1299 2009 Mechanical vibration and shock - Vibration isolation of machines - Information for the application of source isolation

UNI EN ISO 4871 2009 Acoustics - Declaration and verification of noise emission values of machinery and equipment

UNI EN ISO 11200 2009 Acoustics - Noise emitted by machinery and equipment - Guidelines for the use of basic standards for the determination of emission sound pressure levels at a work station and at other specified positions.

UNI EN ISO 11202 2009 Acoustics - Noise emitted by machinery and equipment - Determination of emission sound pressure levels at a work station and at other specified positions applying approximate environmental corrections

UNI 7543-1 2004 Safety colours and safety signs - Part 1: General instructions

UNI 7543-2 2004 Safety colours and safety signs - Part 2: Colorimetric and photometric characteristics of materials

UNI 7543-3 2009 Safety colours and signs - Part 3: Notice

UNI EN ISO 7010 2012 Graphical symbols -- Safety colours and safety signs -- Registered safety signs

UNI EN ISO 12100 2010 Safety of machinery - General principles for design - Risk assessment and risk reduction

CEI EN 61000-6-4 2007 Second edition - Generic standards - Emission standard for industrial environments

CEI EN 61000-6-2 2006 Third edition - Generic standards - Immunity for industrial environments

CEI EN 60204-1 2006 Fourth edition - Electrical equipment of machines - General

CEI EN 60439-1 2000 Degree of protection provided by enclosures

CEI EN 60529 2000 Second Edition - Safety of machinery - Indication marking and positioning

CEI EN 61310-1/2/3

2008 Second edition - Generic standards - Emission standard for industrial environments

http://webstore.uni.com/unistore/public/productdetails?productId=UNINI1384901!EEN


10.6 Risk analysis and the safety measures adopted

The charts that follow list and examine the risks in the system after it has been

designed and for each of them it specified what measures have been taken to

overcome them and what the residual risks are

Legend and definitions

Hazard description Probability Risk

A (8-4-2-1) C (4-3-2-1) R

A Potential of the hazard

A1 Slight (The injury can cause irritation or an injury that can be cured quickly)

A2 Medium-low (injury that can be cured)

A4 Medium-high (injury that cannot be cured or can only be cured in the long term)

A8 High level hazard (serious injury can cause the death of the worker)

B Probability

B1 Low

B2 Medium

B3 High

B4 Very high

R Risk coefficient

Degree of

risk Risk Consequences

1 - 2 Low Risks characterised by injury /or disorders that are quickly curable and improbable (residual risk)

3 - 4 Medium low Risks characterised by medium-serious injuries or disorders that are however improbable, or those that are slight but probable

5 - 8 Medium high Risks characterised by considerable but unlikely injuries or pathologies that are medium to serious or slight injuries that are very probable.

9 - 32 High Risks characterised by very serious accidents or fatal pathologies that are probable or very probable.

Where the probability of the injury occurring is null, the risk is 0; in this cases no

number is shown in the following table.

Key

● No risk (conformity) ● Residual risk


10.6.1 Functioning in production

CAUTION


DEVICES, IN ORDER TO PACKAGE PRODUCTS FROM VARIOUS SECTORS, INCLUDING

FOOD SECTOR, INTO SPECIFICS BAGS.






HELD RESPONSIBLE

CAUTION

IN ORDER TO WORK THE MACHINE NEEDS ALL THE SAFETY DEVICES PROPERLY

INSTALLED AND IT IS THEREFORE ESSENTIAL NOT TO REMOVE THEM OR MAKE

THEM INOPERATIVE.

CAUTION

EXPOSURE OF THE PERSONNEL TO THE MOVING PARTS OF THE MACHINE MAY

CREATE SITUATIONS OF EXTREME DANGER FOR THEIR SAFETY. TAMPERING WITH

THE GUARDS INSTALLED USING PERSONAL SPANNERS IS PROHIBITED.

CAUTION

AT THE BEGINNING OF THE CYCLE MAKE SURE THERE ARE NO FOREIGN BODIES

OF ANY SIZE ANYWHERE IN THE WORKING AREA.

Point of verification

or source of risk

Evaluation

outcome A C R Risk description

Suggested adequation meausures or temporary

and substitutive measures

Mechanical risks:

Crushing/Dragging

Severing

Cutting

Impact

Drilling/Pricking

Friction/Scraping

Flying parts

Contact with

moving parts

during the course

of the working

cycle.

These hazards are generated in the vicinity of the

moving and operating parts of the machine. The

dangerous parts of the machine are placed inside the

perimetrics guards. During the normal working cycle,

the moving parts of the machine such zones have been

made inaccessible by the adoption of fixed or mobile

guards controlled with specific interlocking devices. In

their construction are respected the requirements of EN

14120 “Guards - General requirements for the design

and construction of fixed and movable guards” and EN

13857 “Safety distances to prevent hazard zones being

reached by upper and lower limbs”. The guards are

designed and applied in a way that their adjusting of an

intentional action, for example the use of a tool or a key

and also constructed so that without the fastening

elements can not remain attached to the right place.



or source of risk

Evaluation




Mechanical risks:

Stability Overturning The machine is equipped with levelling support feet to

the ground. The machine must lay down on the ground,

on a flat, stable and sturdy surface. In this manual you

can find the necessary information on the characteristics

of the floor and the procedures for the correct levelling of

the machine before its commissioning. At the end of the

levelling procedure it is advisable to block the machine to

the ground using the holes on the levelling feet.

Control system:

Start

Normal Stop

Emergency Stop

Recognisable

control and stop

parts

Easy

manoeuvrability

of the start and

stop parts

Protection against

accidental

activation

The control devices are:

clearly visible and identifiable, arranged as to

ensure safe, univocal and rapid operation; they are

designed in such a way that the movement of the

control device is consistent with the action of the

command, they are located outside the danger

zones arranged so that their operation can not

cause additional risk,

designed or protected so that the desired effect,

where a hazard is involved, can only be achieved

by a deliberate action, made so as to withstand

foreseeable forces.

The machine is fitted with indicators as required for safe

operation. From the control position, the operator can

read these indicators A visual warning signal is emitted

before and during the cycle. In automatic mode the

machine can only be controlled from the panel in the

packaging area. In manual mode, the movements can be

controlled only at “slow speed”.

Control system:

Start Recognisable

control and stop

parts

Easy

manoeuvrability

of the start and

stop parts

Protection against

accidental

activation

It is possible to start the machine only with a voluntary

action on the control devices placed on the panel in the

packaging area.

The same goes to:

restarting the machine after a stop of any origin,

applying a modification that derives from the

operating conditions.

For automatic operation, starting, or restarting after a

stoppage, or a change in operating conditions can only

be made using the control devices in the panel and only

with a voluntary action of the operator with the operation

mode selector on AUT .

For manual operation, condition of precision

adjustment or maintenance operations, dead man

switches on the panel allow the start of the movements

with the operation mode selector on MAN.

In automatic mode all the movements of the machine

are authorized only with machine protections close and

active

In manual mode all machine movements are authorised

only in jog and at a slow speed, on the panel with dead

man switches.



or source of risk

Evaluation




Control system:

Normal stop

Recognisable

control and stop

parts

Easy

manoeuvrability

of the start and

stop parts

Protection against

accidental

activation

The machine is equipped with a control device on the

operator control panel that allows the general stop in

safety conditions. The panel is equipped with a control

device that allows to stop all the functions of the

machine, according to existing hazards, so that the

machine can be brought into safety conditions. The stop

control takes priority over the start controls. Once the

machine and its dangerous functions have been stopped,

the supply to the actuators is cut off.

Control system:

Emergency stop Recognisable

control and stop

parts

Easy

manoeuvrability

of the start and

stop parts

Protection against

accidental

activation

The machine is equipped with an emergency stop

device that avoid the development of immediate

dangerous situations or dangerous situations already

in development. This device is designed in

conformance with EN 13850:2008 “Safety of

machinery - Emergency stop - Principles for design ”.

The devices are:

easily identifiable, clearly visible and quickly

accessible,

They stop the process as fast as possible,

without creating additional risks.

After a stop command, when you quit activating the

stop device, the command is maintained by a block in

the emergency device, up to its reset. It is not

possible to block the device without it generating a

stop command. A specific manoeuvre allows the

reset of the device, but it does not restart the

machine, it just authorises its recommissioning. At

this stage it is necessary to restore the emergencies

by pushing the EMERGENCY RECOVERY button on

the operator panel. Now it is possible to restart the

operating cycle. The emergency stop function is always available and

operational regardless of the operating mode activated.

The emergency stop devices offer a back-up solution to

other protective measures and cannot substitute them.



or source of risk

Evaluation


Suggested adequation measures or temporary


Control parts related

to safety: The control systems are designed and built in such a way

as to prevent the arising of hazardous situations. They are designed and built so that :

they can withstand the intended operating stresses and external influences

A fault in the hardware or the software of the control system doesn’t lead to hazardous situations:

Errors in the logic of the control system do not lead to hazardous situations

Reasonably foreseeable human error during

manoeuvring doesn’t lead to hazardous situations; The machine cannot start in an unexpected way

The machine parameters cannot have unchecked modifications

It’s not possible to block the stop of the machine if the stop command has already been given

No mobile element or held piece can be expelled during the working cycle

Manual or automatic stop of any kind of mobile element is not hampered,

The protection devices must remain completely efficient or give a stop command to the operative cycle,

The parts of the control system that are related to security are applied in a coherent way inside the machine.

Electrical Hazard:

Differential switch Direct and

indirect electrical

contacts

Protection against

overcurrent

The machine is powered by electricity, it is designed,

constructed and equipped in such a way as to prevent or

to permit to prevent all electrical hazards The electrical

system has been designed in accordance with Technical

Standard EN 60204-1. The plant is equipped with a

differential switch with threshold of protection of 30 mA

on the supply machine of the machine.

Electrical hazards:

Ground connections Direct and

indirect electrical

contacts

Protection against

overcurrent

On the system an appropriate protective equipotential

circuit, which includes:

The conductive structural parts of the electrical

equipment and of the machine.

The protective conductors in the equipment of the

machine

The plant has been designed in accordance with

Technical Standard EN 60204-1.

Lighting:

Lighting work areas of

the machine

Dazzling The machine is equipped with a lighting device placed

inside the electrical cabinet, for any maintenance

operation. The machine is also realised in such a way so

that there is no shadow zone that can cause disturbing,

no irritating dazzle, no dangerous stroboscopic effects on

the moving parts.

Heat hazards:

Burns and scalds from

direct contact

Residual

Risk

2 2 4 Burn and scald

hazard for direct

contact with hot

parts in the

packaging area.

All elements that reach dangerous temperatures have

been protected and placed in non-accessible areas.

Signs have been placed to signal the areas that reach

high temperature. Always use protective gloves before

any intervention intended to remove any possible

stoppage in the system.

Heat hazards:

Burns and scalds from

direct contact

Residual

Risk

2 2 4 Burn and scald

hazard for direct

contact with cold

parts conveyed

on the system

The elements processed on the system reach dangerous

temperatures (Dry ice T = - 80 °C).

Signs have been placed to signal the dangerous areas.

Always use protective gloves.



or source of risk

Evaluation


Suggested adequation measures or temporary


Ergonomics:

Incorrect positions

during use

Excessive and

repetitive efforts during

use

Absent Under the intended conditions of use, any possible

discomfort, fatigue, psychic and physical tension

(stress) of the operator have been minimised, taking

into account the following ergonomics principles:

the variability of the physical dimensions, strength

and stamina of the operators was taken into

account;

enough space for movement of the operator’s

body parts has been kept;

a working rhythm conditioned by the potentiality

of the machine has been avoided;

machine control that requires prolonged

concentration has been avoided;

the human/machine interface has been adapted

to the foreseen operators’ characteristics.

Materials and

products

Biological risk

The materials used for the construction of the plant

do not pose a risk to people’s safety and health

Movement Overturn and

danger during

operatios for

displacing the

machine

The machine and its components do not allow

manual displacement, there are several holes in the

machine to allow a crane to lift it with bands.

You can find in the manual information for a correct

displacement of the machine and which PPE are

required during such operations.

Noise Absent The noise level emitted by the machine ranges

between 76 and 78 dB.

Vibrations

Presence of vibrations Absent The machine does not produce hazardous vibration

to the operator's health

Recommended personal protection equipment

During the use of the machine it is necessary to wear the following PPE:

Work clothes with no hanging or loose parts.

Safety footwear.

Protective gloves against hot/cold temperature.

Protective glasses.


10.6.2 Functioning during fine tuning / Maintenance

! CAUTION

NO ADJUSTMENT, FINE TUNING OR MAINTENANCE OF THE MACHINE MAY BE CARRIED

OUT BY TWO OPERATORS AT THE SAME TIME UNDER ANY CIRCUMSTANCES.

! CAUTION ALWAYS CUT OFF ALL THE POWER SUPPLIES (PADLOCK THE ON/OFF SWITCH OF THE

ELECTRICAL AND PNEUMATIC SYSTEM) BEFORE PERFORMING MAINTENANCE

OPERATIONS MAINTENANCE. AFFIX SPECIFIC NOTICES WARNING THAT THE

“MACHINE IS UNDERGOING MAINTENANCE- DO NOT TURN ON THE POWER” IN THE

PROXIMITY OF THE GENERAL ON/SWITCH.

verification or risk

source Result A C R Description of the risk

Adaptation measures suggested or

temporary and replacement measures

Mechanical risks:

Crushing / Pinching

with moving parts of

the machine.

2 2 4 Crushing / Pinching

During the movement

test operation.

Training maintenance personnel in the correct

way use of the machine. The zone must only

be accessible to the person assigned to

maintenance and after the due precautions

have been taken.

Mechanical risks:

Cut/ Entanglement

Mechanical risks:

Friction / Abrasion

2 2 4 Possible

cut/entanglement /

friction/abrasion by

contact with operating

parts during movement

test.

Train the operator on the right intervention

procedure for fine tuning operations.

Burning and

scalding:

Burning and scalding

by direct contact with

parts of the machine or

with incandescent

liquid splashes.

4 2 8 Possible burning or

scalding by contact with:

Welding jaws

station

Welding rollers

station

Use appropriate protective gloves against the

risk of burn/scalding by contact during the

restarting operation as a result of stop for

breakage or jamming. On the machine, next to

the danger zone where are applied warnings

signs

Alta temperatura

Burning and

scalding:

Burning and scalding

by direct contact with

cold parts of the

machine.

4 2 8 Possible burning or

scalding by contact with:

dry ice when the

machine is jammed

Use appropriate protective gloves against the

risk of burn/scalding by contact with the

product manufactured (dry ice -80 °C)

during the restarting operation as a result of

stop for breakage or jamming.

On the machine, next to the danger zone

where are applied warnings signs.

Control parts:

Protection against

accidental operation.

2 2 4 Crushing / Pinching

during the fine tuning

operation.

Check that during the fine tuning operations

there are no persons in the vicinity of the

danger zone you intend to move.

Lighting of the work

area

special lighting in work

areas.

insufficient lighting The machine is equipped with lighting devices

inside the electrical cabinet and of the rotating

table for potentials handling operations.

Recommended personal protection equipment

During the use of the machine it is necessary to wear the following PPE:

Work clothes with no hanging or loose parts

Safety footwear

Protective glasses

Protective gloves.


10.7 Noise

Determination and indication of the weighted equivalent continuous acoustic

pressure A at the workstations as required by the “Machine Directive”.

At the design stage, “TLM PACKAGING” produced the machine using the best

technology that can be actually activated.

Reference standards

UNI EN ISO 11200 – UNI EN ISO 11202 – UNI EN ISO 4871

Acoustic environment

Industrial unit: concrete walls and floors. Environment around the machine

subject to measurement occupied by other machinery.

Considerations

The noise measurements were taken in accordance with the provisions of the

standards currently in force. The daily exposure of the operating personnel to this

noise may be reduced with the application of a few simple measures. The level of

noise emitted by the machine largely depends on the conditions of installation

and the environment in which it is situated.

The continuous equivalent acoustic pressure level measured: 76 - 78 dB (A).

The parts of the machine involved, such as gearmotors, motors etc. as well as

the dampening, antivibration systems etc, must be periodically checked and

substituted with the same ones used by “TLM PACKAGING “ in the materials list.

You are advised to of carry out these checks every time that an increase in noise

is detected.


10.8 Electromagnetic compatibility The WIRING of the machine is carried out in compliance with the instructions in

the current standards and in particular to the requirements of the standard CEI

EN 60204-1:2006 “Safety of machinery – Electrical equipment on machines”.

The MOTORS used do not produce large-scale noise when functioning normally.

Engines are adopted that do not cause significant voltage drops during power up

and used in their rated conditions as well as being marked CE by the

Manufacturer.

The signalling ELECTRONIC COMPONENTARY may be subject to

electromagnetic interferences in the surrounding environment. It is therefore

possible to have problems of electromagnetic immunity. To overcome the use is

made of products conforming to this EMC requirement, as required by this

Directive marked EC.


11. INSTRUCTIONS FOR USE

DURING ANY OPERATION CARRIED OUT ON THE SYSTEM, THE OPERATOR MUST

COMPLY WITH ALL THE ACCIDENT PREVENTION PRECAUTIONS, SAFETY

REGULATIONS AND THE WARNINGS SHOWN ON THE PLATES ON THE MACHINE. NO

EXCEPTIONS TO THE ABOVE MENTIONED REGULATIONS AND WARNINGS ARE

ALLOWED: THE MANUFACTURER DECLINES ALL LIABILITY FOR ANY INJURY TO

PERSONS OR MATERIAL CAUSED BY FAILURE TO OBSERVE THE ACCIDENT

PREVENTION REGULATIONS AND THE SAFETY STANDARDS.

The machine has been designed reducing any risks to the operator to the

minimum. Even though it is impossible to foresee all possible hazardous, the risk

of injury to persons and damage to this machine will be reduced considerably by

adhering to the safety regulations in this manual.

DO NOT ACTIVATE THE MACHINE IF THE PROTECTIONS INSTALLED HAVE BEEN

REMOVED OR TAMPERED WITH

The operators assigned to the machine must be aware of the safety operating

procedures and apply them at all times during its operation. In particular make

sure that all the protective devices are present, are in good condition and fixed

properly.

11.1 Operator

Operator means qualified personnel able to carry out the following operations:

Operation through the use of the installed controls.

Any materials used for feeding operations.

Any discharge of materials used.

Simple adjustment functions and starting up of the production cycle.

The restoration of production following enforced downtime.

Inspection, cleaning and lubrication.


11.2 Safety regulations for a proper functioning Never work with the casing dismantled.

Always keep the machine clean and efficient.

Never touch buttons or switches with wet hands.

The machine must only be used by operators trained in its use.

The clothing of the assigned operators must correspond to these safety

standards: it is compulsory to wear gloves, safety footwear and overalls

without loose or hanging parts.

Turn the machine on sticking strictly to the sequence described.

If during operation you hear noises that point to faulty operation (increase in

noise, whistling, discharges etc.) promptly press the EMERGENCY button,

consult the manual or call in a representative of TLM PACKAGING.

If the fault persists, turn the general on off switch to 0 and call maintenance

operative.

A floor that is greasy, wet or covered in oil may cause accidents. Dry and

clean the floor of oil patches that have formed during work on the machine or

normal operation of the machine.

When non operational, the machine, should be left with the Emergency button

pressed.

Make sure that the machine is positioned and secured properly. Leave

enough space around to prevent contact with other machines and to facilitate

any maintenance operations.

Make sure that all the wiring is in its raceways.

Make sure that the electrical system is grounded.

Always keep the electrical junction boxes closed.

Do not position the wires in the passage area to avoid contact with the

water/oil.


11.3 Control panel

N° Description

1 Mitsubishi touch panel

2 Emergency Stop button

3

Green button “START”, it is used to start the cycle of the machine: - In AUTOMATIC cycle mode, it is pressed to start the automatic

packaging cycle at time intervals. - In MANUAL cycle mode, it is pressed to perform a single packaging.

4 Button “RIGHT ARROW”. It is used to lower the welding rollers group.

5 Button “LEFT ARROW”. It is used to raise the welding rollers group.

6 Blue button “RESET”. It is used to reset emergencies, following an emergency stop.

7 The ACTIVE RECIPE is showed on the upper part of the screen.

1

3

4

2

5 6

7


11.4 Operator panel description

11.4.1 Main menu page

This is the screen that is displayed when the

machine is turned on. On it you can only

press the Forward button to access the Main

Menu page.

By pressing the button on the home page you can access to the main menu,

where there are activation and redirection to other screens buttons. If the lower

part of the button is green marked, the respective indicated function will be active.

The redirection buttons are common to most of the pages.

A Manual Cycle I Alarms

B Automatic Cycle J Recipes

C JOG Movements K Settings

D STOP Cycle L Jaws

E Pieces Counter M Temperature

F Packaging film mark N Jog and Homing

G Bag Length O Home

H Entry Password

A

B

C

E F

G

I

D

J K L M N O

7

H


In manual cycle mode, by pressing the START button the products will be packed

one by one. When the automatic cycle is active, by pressing the START button

will be performed the first bagging; in an autonomous way the machine will

continue to package products with an adjustable time interval. On top of the

screen is showed the active program. (7)

SOME FEATURES / SETTINGS IN THESE FOLLOWING SCREENS ARE ACCESSIBLE

ONLY BY INSERTING APPROPRIATE ACCESS PASSWORD.

OTHER SETTINGS ARE ACCESSIBLE ONLY BY TLM PACKAGING SPECIALIZED

PERSONNEL, BECAUSE THEY OPERATE SUBSTANTIAL CHANGES TO SETTINGS FOR

A PROPER FUNCTIONING OF THE MACHINE.

11.4.2 Jog and homing page

This page includes the selection keys of cycle mode: MAN (A), AUTO (B), JOG

(C) and STOP (D).

Only when JOG mod is set (JOG button green marked) is possible to move the

jaws up and down and perform the rotation of the welding rollers. The movements

are performed by pressing on the picture related to the movement:

- Jaws up (E);

- Jaws down (F);

- Welding rollers rotation (I).

CAUTION

THE WRONG USE OF BUTTONS (E) AND (F) TO HANDLING THE JAWS CAN BRING

THE JAWS OUT OF STROKE.

USE THIS BUTTONS ONLY IF NECESSARY.

A

B

C

D

E

F

G

I

H


By pressing the Force Homing button (G) you can return the machine to the

Home position. The force homing is only available in manual mode. After

reaching the home position, the Homing OK dot (H) will be green marked (if the

dot is already green, then the machine is already in home position and not need

to redo the force homing).

11.4.3 Piece counter page

In this page there is the button (A) that allows you to enable/disable the piece

counter; if enabled the lower part of the button is green marked.

In this screen there are some counters : value of pieces to be produced (C) wich

can be set, the partial production (D) and the total production (E). The RESET

button (B) resets the counters and the button (F) shows if there are reports of

anomalies on produced pieces or products to be packaged are finished.

A B

C

D

F

E


11.4.4 Mark setup page

The page contains the button (A) that allows to enable/disable the reading of

mark of the film; if enabled the lower part of the button is green marked. In this

screen you can directly entry the distance between the marks in the box (B), and

set the correction factor (D). The value (C) cannot be set.

MARK SETTING PROCEDURE

The reading of the mark setting procedure is as following:

- Measure the actual distance between the marks;

- Set the distance value measured in the box (B);

- Assign the value 0 to the correction factor (D);

- From the home page, turn on the MANUAL cycle mode;

- Return to the setup page of the mark;

- Produce bags until the value (C) reachs 0 (± 6 mm);

- Measure the actual distance measured from the last bag produced and enter

the measured value as correction factor (D).

A

B

D

C

D

Discharge Chute

Mark

D

Last bag produced

(C=± 6 mm)


11.4.5 Bags length setup page

In this screen you can set the length of the bags (A), the length of the bag

correction value (B), the value (C) that indicates each number of bags takes place

the programmed cut. And the pause time value (from a welding and the other

one) in automatic cycle mode (D).

BAGS LENGTH SETTING PROCEDURE

The bags setting procedure i sas following:

- Set the length value of the bag (A);

- Set the correction value (B), expressed as percentage, in case of the bag is

longer or shorter than the value (A) (initial value = 100%);

- Produce a few bags and measure the actual length of the bag;

- If the bag is shorter than the set length, set a correction value higher than

100%, up to reach the correct desired length;

- If the bag is longer than the set length, set a correction value lower than

100%, up to reach the correct desired length.

A

C

D

B


11.4.6 Recipe page

In this screen there is a window with three redirecting buttons to the same

number of recipe management screens: save (A), load (B) and delete (C).

SAVE

This screen allows you to save in a recipe the parameters previously set. The line

(A) indicates the name and the number of the set recipe, currently in production.

In the line (B) you can assign a name and a number (C) at the new recipe to be

saved on the list. At the center of the page there is a list of recipe.

To save a new recipe with previously set parameters:

- Enter the number (C) to assign at the recipe to be saved;

- Enter in the line (B) the name to the recipe;

- Enter the password (D);

- Save the recipe by pressing the SAVE button (E).

THE PASSWORD TO BE ENTERED TO SAVE NEW RECIPES IS : “1964”

A C B

C

B A

D

E


LOAD

This screen allows you to select the recipes to work with:

- With the scroll keys (A) select the desired recipe from the list (if you already

know the recipe number, entry it directly in the box (B) );

- The number of the selected recipe will be shown in the BOX (B);

- The selected recipe will be displayed in the “LOAD” line (C);

- Press the LOAD button (D) to begin working with the selected recipe.

DELETE

This screen allows you to delete saved recipes from the list:

- With the scrolling keys (A) select the recipe from the list (if you already know

the recipe number, entry it directly in the box (B) );

- The number of the selected recipe will be shown in the box (B);

- The selected recipe will be displayed in the line (C);

- Enter the password (D);

- Press the DELETE button (E) to delete the recipe from the list.

THE PASSWORD TO BE ENTERED TO DELETE NEW RECIPES IS : “1964”

A

D

B

A

C

A E

B

A

C

D


11.4.7 Machine settings page

This screen is dedicated to the machine settings.

You can set the language (Italian or English), using buttons (A). The button (C)

shows the section dedicated to the contacts of TLM PACKAGING.

The button (B) allows access to the machine data page; access to this page is

restricted to only TLM PACKAGING specialized personnel.

The button (D) is used for updates or in case of corruption machine data files, as

a result of assistance from TLM PACKAGING.

SOME OF THESE SETTINGS IN THESE SCREENS ARE PROTECTED BY PASSWORD

AND ACCESSIBLE ONLY BY SPECIALIZED PERSONNEL TLM PACKAGING, BECAUSE

THEY OPERATE SUBSTANTIAL CHANGES TO SETTINGS FOR A PROPER

FUNCTIONING OF THE MACHINE.

11.4.8 Jaws page

This screen allows you to change settings of the welding jaws. The welding time

of the film (A) can be set. The selector (B) allows to set the welding mode

E

D

C B C A

C

A

B


before/after the advancement of the film. The selector (C) allows you to select the

cutting mode after welding or cutting immediately at cutting quote.

11.4.9 Temperature page

This screen allows you to manage the machine's resistance. The

activation/deactivation buttons of the resistances relating to the jaws (A) and the

rollers (B); resistances are active if the bottom of the buttons are green marked,

(gray when inactive).

The boxes (C) and (D) represent the status of the resistances: if marked green

indicate that the resistances are in the heating phase, until reaching the set

temperature; if marked gray indicate that the resistances have reached the

desired temperature.

The boxes (E) and (F) respectively indicate the temperature value detected on

the jaws and on the rollers.

In the box (G) you can set the desired temperature on the resistance of the jaws;

the box (H) allows setting the temperature value related to the resistance of the

welding rollers.

The (I) button displays presence of alarms.

G C E

A

B

D F H

I


11.5 Working phases

11.5.1 Functioning cycle

1. Place ON (I) THE GENERAL SWITCH placed on the ELECTRICAL

CABINET: in this way the machine is supplied with electrical power;

2. Wait a few seconds in order to load the machine PLC;

3. When it appears, press HOME on the touch screen;

4. If the emergency button was pressed at the shutdown of the machine, unlock

it and reset the machine.

5. Wait 10 seconds in order to let time to PLC to communicate with the motors;

6. Wait until rollers and jaws reach the setted temperature;

7. Check the recipe currently in work is the desired one.

8. When is turned on the packaging machine will perform the HOMING;

9. Select the MANUAL CYCLE on the Touch Panel (in manual mode the

machine will package products one by one);

10. Load a product and press the START button in order to execute a packaging

cycle and check that the product is correctly packaged in case it is not.

11. Carry out the regulations while maintaining power supply on the machine. Be

extremely careful when approaching the parts or the machine that include

mobile elements (pushing teeth, welding rollers and welding jaws);

12. Select AUTOMATIC CYCLE on the Touch Panel;

13. Launch the working cycle by acting on the START button and manually load

the product on the loading plan.

14. The machine will automatically proceed to packing products at previously

setted time intervals.

15. Press the STOP button on Touch Panel to stop the working cycle.


11.5.2 Machine switch-off

At the end of the day, or at the end of the production, the operator must:

1. Press the STOP BUTTON placed on the TOUCH PANEL in order to interrupt

the working cycle (the STOP BUTTON will stop the cycle even if the jaws are

in closing positions).

2. Wait until the end of the cycle and press the emergency button;

3. Rotate in POSITION (0) THE GENERAL SWITCH placed on the electrical

cabinet of the machine.

4. It is advisable to accurately clean the machine at the end of a working cycle.

5. It is also possible to stop the functioning cycle by acting on the emergency

button placed on the machine.

6. For the resumption of the correct working cycle of the machine act as

previously described.

11.5.3 Reset after emergency stop

Following an emergency stop (ex: jamming of the packaging film), before

resuming the normal production cycle, you need to follow the following procedure:

1. Eliminate the cause that caused the operator to act on the emergency button;

2. If you removed the protections on the machine, restore them in the right

place;

3. Unlock the button by rotating it in the way indicated by the arrow till the auto

retention device is released (if the button has been pressed);

4. Press the RESET BUTTON placed on the COMMAND AND CONTROL

PANEL to reinsert the electrical auxiliaries of the Machine and restart the

working cycle (the blue light signal switches off);

5. After have pressed the RESET BUTTON wait 10 seconds;

6. If the emergency button has been pressed with jaws in closing position, open

the jaws in JOG mode (approx. 50 mm).

7. Select MANUAL mode and the machine will perform the HOMING;

8. Press the START BUTTON placed on the COMMAND AND CONTROL

PANEL to restart a working cycle.


11.5.4 Mounting the bobbin, film drawing-in and centring

In order to proceed with mounting the bobbin and drawing-in the film along the

packaging machine, the operator must proceed as indicated below:

1. Place the film bobbin on the shaft according to its dimension, by taking as

reference the graduated scale placed on the shaft (the bobbin dimension

must correspond with the one reported on the graduated scale);

2. Block the film bobbin ;

3. Draw-in the film on the idler rollers as schematized in the following figure (the

film must be under tension ; it is possible to regulate the drawing-in idler

rollers position by acting on the device placed on the side);

11.5.5 Regulating mark reading

Regarding the adjustment procedure of the mark on packaging film reading,

position the photocell (A) at the mark on the film and refer to the paragraph

11.4.4 .

11.5.6 Regulating the length of the bag

Regarding the length of the bag regulation procedure, refer to the paragraph

11.4.5 .

A


11.5.7 Regulating Loading conveyor

The loading conveyor allows various regulations. The conveyor width can be

adjusted by turning the knob (A).

The conveyor can be adjusted longitudinally by acting on four knobs (B). Loosen

the knobs, moving the supports along the slots until the choosen position and

tighten the knobs.

11.5.8 Regulating the cut

To adjust the cutting pressure, act evenly on the dowels, to avoid irregular

wear of the blade. (C)

The adjustment phase of the cut must be performed with open jaws. To

regulate the pressure of the blade, act on the dowels (D) in the same way;

while adjusting the blade doesn’t come out from the slot.

If the cut isn’t optimal, because the package isn’t severed, operate on the

involved dowels, as stated above.

A

D

C

B A


12. MAINTENANCE

Proper periodic preventative maintenance ensures long-term, constant efficiency

of the machine.

CAUTION

BEFORE PERFORMING MAINTENANCE OPERATIONS, MAKE SURE YOU HAVE CUT-

OFF AIR SYSTEM

Always cut-off all power supplies (electrical, pneumatic and hydraulic) before

carrying out maintenance operations before carrying out maintenance

operations on the machine and on the individual machines. Place specific

warnings near the general on/off switches saying “DEVICE UNDERGOING

MAINTENANCE – DO NOT TURN ON THE POWER”.

Avoid carrying out any maintenance operation with bare hands, always use

protective gloves.

Always use tools in a perfect state of repair and produced specifically for the

operation to carry out; the 'Use of equipment that is not suitable and not

efficient can cause serious damage.

Before replacing an assembly, always smear the internal pieces and coupling

surfaces with a film of oil. Replace all the gaskets/seals with OEM pieces

before refitting the component.

During the cleaning operations, where compressed air is used, always wear

the special protective masks and glasses provided.


Information regarding the maintenance and planned

Ordinary servicing involves mechanical interventions (adjustments, lubrication,

and cleaning) and electrical interventions to be carried out periodically on the

system consulting the charts on the following pages.

COMPLETE MAINTENANCE IS ADVISED EVERY TIME PRODUCTION HAS TO BE

SUSPENDED FOR A LONG TIME.

AS REGARDS THE MAINTENANCE OPERATIONS RELATIVE TO THE COMMERCIALLY-

SOURCED COMPONENTS IN THE MACHINE, REFER TO THE SPECIFIC TECHNICAL

DOCUMENTS.

General regulations for the maintenance of the Mechanical Components

During the dismantling of the component prevent dust residuals getting into

the work areas and the components themselves.

Do not use compressed air to clean mechanical parts. Dust must only be

removed with a vacuum device or cloths.

Do not use petrol or flammable solvents such as detergent but always use

authorised non-inflammable commercially available components that are

non toxic.

General regulations for the maintenance of the Electrical Components

Pay attention to the general regulations for the mechanical components.

Do not make holes in electrical wires or raceways when wires are in them.

Do not use water, pieces of sponge, moist cloths and/or abrasives to clean

the machine and the electrical components.


12.1 Program maintenance

12.1.1 Daily maintenance

Clean the work area and clean the machine.

Check for leaks in the pneumatic piping.

Check the tightness of the connectors and of the air clutches.

Check that the safety devices work properly.

Check that the limit switches work properly.

Clean the Lexan protections on the machine.

12.1.2 Semi-annual maintenance

Perform a thorough cleaning of the machine.

Check that guards and safety devices are correctly installed.

Check the functioning of the emergency buttons installed.

Check the integrity of symbols and labels applied.

Check the overall functioning of the machine.

12.1.3 Annual maintenance

Perform a thorough cleaning of the machine.

Check the tightening of all nuts and bolts on the machine.

Check that guards and safety devices are correctly installed.

Check the functioning of the emergency buttons installed.

Look for any leaks from pipes and pneumatic components.

Check the functioning and wear of the motion transmission parts.

IT IS ADVISABLE TO HAVE THE MANUFACTURER’S PERSONNEL PERFORMING ALL

THESE CHECKS, IN ORDER TO HAVE A COMPLETE REPORT ABOUT THE MACHINE

FOR ANY MAINTENANCE OPERATION CONCERNING THE COMMERCIAL

COMPONENTS, REFER TO THE TECHNICAL DOCUMENTATIONS ATTACHED TO THE

MANUAL.


12.2 Extraordinary maintenance

12.2.1 Jaws resistance replacement

To replace the resistance (A), cut power off and wait till the machine cools down.

Remove the rear guard and the top guard of the machine.

Remove the fixing screws of the upper jaw (C).

Remove the screws and remove the blade (D).

Remove the fixing screws and remove the jaw (E).

Remove the two screws that tighten the two cables of the resistance to the

terminal.

Pull resistance cables to remove it from the jaw. (F)

Insert the new resistance in the slot.

Repeat the operations in a similar way for the other resistance.

To reassemble everything, repeat all operations backwards.

12.2.2 Jaws proximity sensor replacement

To replace the proximity sensor (B), cut power off and wait till the machine cools

down :

Remove the rear guard.

Remove the top guard of the machine.

Remove the sensor by acting on the nut and locknut through the use of two

hexagonal keys.

Install new sensor and tighten the nuts.


A A

B F

C

C

D

D E

E


12.2.3 Jaws sonda probe replacement

To replace the probe (A – see procedure 12.2.1), cut power off and wait till the

machine cools down:

Remove the rear guard.

Remove the top guard of the machine.

Remove the fixing screws of the upper jaw (C).

Remove the screws and remove the blade (D).

Remove the fixing screws and remove the jaw (E).

Remove the two screws that tighten the two cables of the resistance to the

terminal.

Pull out the probe from the jaw.

Insert a new probe in the slot.


12.2.4 Roller resistance replacement and adjustment

Cut power off and wait till the machine cools down:

Remove the guards to access to the welding rollers.

Unscrew the wires of the burnt resistance from the terminal.

Remove the roller lid and the resistance.

Install a new resistance.

To regulate the pressure of the rollers, act on the selectors placed in the front of

the machine (A).

A A


12.3 Maintenance on the Pneumatic System

Below they are brought back detailed indications regarding the operation and the

operating way in order to solve eventuals anomalies in the components parts of

the pneumatic equipment.

12.3.1 Filter and pressure regulator

Anomaly Probable Cause Solutions

It isn’t possible to bring down the pressure value.

Lack held by the stopper against its center

Take apart and clean the valve seal-sealing

Change the component

It isn’t possible to obtain the wanted pressure value

Perforated membrane Change the membran

Collapsed spring Change the spring


The outlet air flow from the filter is insufficient

The filtering cartridge is saturated

Clean or change the filtering cartridge.

The condensation level is too high

Clean the automatic drain tank


In the filter outlet can be found condensation traces.

Diaphragm breakage Change the diaphragm



12.3.2 Command valves with a pneumatical actuation direction

Anomaly Probable Cause Solution

The valve doesn’t invert

Low-power pilotage pressure

Check the pilotage pressure (between 3 and 6 bar)

Stopper or cursors glued

Take apart and carefully clean

It reveals a lack of air from the holes

Wear of the internal seals.

Change the internal seals


Centering spring collapsed

Change the springs


Leakage from the pilotage part

Take apart and clean, if necessary change the component

12.3.3 Flow regulator


Doesn’t succeed to obtain the regulation of the speed required.

Wear of the adjusting cone



12.3.4 Actuators


Doesn’t do his job in the requested time.

Wrong regulation of the speed regulator.

Rectify the regulation

Speed regulation damaged

Change the speed regulators

The command of the solenoïd valve is damaged.

See previous point

Change the solenoïd valve

The piston seals are weared ( A leak of air through the exhaust part).

Change the seals

The pistons are weared (A leak of air in the environment)

Change the seals

Non effettua il suo lavoro con la forza dovuta

Reduction of the power pressure

See the previous points

Reactivate the correct pressure value

The piston seals are weared

Change the seals

The piston seals are weared

Change the seals

Severe impacts when it contacts

Internal decelerators are broken or worn out

Change the decelerators

External decelerators are decalibrated

Reactivate the correct pressure of the decelerators

12.3.5 Calibration procedure of the flow regulators

For the calibration of the unidirectional or bidirectional regulators of flow, it’s

necessary to:

Open the air.

Identify and activate the solenoïd valve (or valve) that control the stopper

gear in which it intends to regulate the speed.

During the gear of the stopper, operate on the appropriate regulation screw

In case that the results set aren’t reached on the first attempt, repeat the

operations till you reach the speed desired.

Once the regulation reached, lock the screw regulation with the appropriate

lock nut (if it exists).


13. DECOMMISSIONING AND DEMOLITION

Any demolition of the machine must be entrusted to specialised and equipped

personnel. If the customer does not have suitable and sufficient personnel or

instrumentation to be able to carry out the demolition procedure in conditions of

absolute safety and in such a way as to guarantee the safety of the operators

refer to the technical personnel of the TLM PACKAGING

DURING THE DEMOLITION OPERATIONS IT IS NECESSARY TO PAY PARTICULAR

CAUTION TO THE DISPOSAL OF THE COMPONENT.

FOR SOME TYPES OF MATERIAL IT WILL BE ESSENTIAL TO COMPLY WITH THE

LAWS CURRENTLY IN FORCE IN THE COUNTRY WHERE THE CUSTOMER LIVES.

BEFORE STARTING TO DISMANTLE THE MACHINE IT IS NECESSARY TO CREATE

ENOUGH SPACE AROUND IT TO ENSURE THAT ALL HANDLING AND MOVEMENT

CAN BE CARRIED OUT WITHOUT POSING A RISK TO THE PERSONNEL.

A number of phases that are fundamental before carrying out the demolition are:

Disconnecting all the electrical power and the pneumatic supplies;

Disconnecting the different components separating them as far a possible

by type of material.

It is necessary for example to separate the plastic parts that must be sorted

separately from all the rest in order to respect the current regulations. The same

thing happens to the electrical, pneumatic and hydraulic components, while for

most of the metal it is sufficient to subdivide between the steel parts and those in

other metals and alloys to send them correctly for recycling for casting.

BEAR IN MIND THAT SOME VERY LARGE AND HEAVY PARTS CAN ONLY BE

MOVED USING ADEQUATE HOISTING EQUIPMENT.

THE POSSIBLE FALL OF PARTS OR COMPONENTS DURING THE DEMOLITION

PHASES MAY POSE A SERIOUS RISK FOR THE OPERATORS.


14. APPENDICES

APPENDIX 1 DECLARATION OF CONFORMITY

APPENDIX 2 ELECTRICAL DOCUMENTATION

APPENDIX 3 PNEUMATIC DOCUMENTATION

APPENDIX 4 MACHINE LAYOUT AND LUBRIFICATION POINT

Documents

USE AND MAINTENANCE HANDBOOK - TLM Pack