Poly-clip System GmbH & Co.

KG TSCA 65 D

Operating Manual

EN/04-2018 Original Instructions

 Poly-clip System GmbH & Co. KG TSCA 65 D
Delivery date:

Serial number:

P306500

Document dated: 23/04/2018

Note

The complete documentation for the TSCA 65 D machine consists of the following manuals:
• Operating Manual
• EC declaration of conformity as part of this Operating Manual
• Spare parts catalogue on a data carrier.

No part of this documentation may be reproduced or otherwise used or communicated without the consent of
the author or other authorised party.

Violations are liable to prosecution and compensation (copyright law, fair trade law, German Civil Code).
All rights reserved in the event a patent is granted or a utility model is registered.

Poly-clip System GmbH & Co. KG, Niedeckerstr. 1, 65795 Hattersheim a. M., Germany

+49 (0)6190-8886-0

www.polyclip.com

Printed in the Federal Republic of Germany, subject to change.

Declared values without tolerances are merely approximations.
The photos do not correspond in all details to the condition of the machines delivered.

Original Instructions EN/04-2018

 Poly-clip System GmbH & Co. KG TSCA 65 D
Contents
1 Safety Instructions .............................................................................. 1-1
1.1 Introductory comments ................................................................................ 1-1
1.1.1 Warning symbols on the machine ......................................................................................... 1-1
1.1.2 Warnings in manuals ............................................................................................................. 1-2
1.1.2.1 Warning sign .......................................................................................................................... 1-2
1.1.2.2 Danger levels ......................................................................................................................... 1-2

1.2 Use of this machine ...................................................................................... 1-3

1.2.1 Correct use ............................................................................................................................ 1-3
1.2.1.1 With reservation: Processing potentially explosive materials ............................................... 1-3
1.2.1.2 With reservation: Processing easily flammable materials ..................................................... 1-3
1.2.2 Improper use ......................................................................................................................... 1-4
1.2.3 Modifications and alterations ................................................................................................ 1-4

1.3 Personnel selection and qualification ........................................................... 1-5

1.3.1 Operators .............................................................................................................................. 1-5
1.3.2 Cleaning staff ........................................................................................................................ 1-5
1.3.3 Maintenance staff .................................................................................................................. 1-5

1.4 Personal protective equipment required ...................................................... 1-6

1.5 Protective devices ........................................................................................ 1-6
1.5.1 Danger points secured by a protective device: ..................................................................... 1-6
1.5.2 Work sequences protected by a protective device: .............................................................. 1-6
1.5.3 Emergency Stop pushbutton ................................................................................................ 1-8
1.5.4 Production only with sealing bar locked ............................................................................... 1-8
1.5.5 Covers ................................................................................................................................... 1-9
1.5.5.1 Protective covers on the control cabinet/supply/spray system ............................................ 1-9
1.5.5.2 Protective cover on the transformer ...................................................................................... 1-9
1.5.5.3 Right side panel on the clip head .......................................................................................... 1-9
1.5.5.4 Spray guard and inner ring .................................................................................................. 1-10
1.5.6 What happens if one of the protective devices A to F is triggered? ................................... 1-10
1.5.7 All protective devices must be checked! ............................................................................. 1-11
1.5.8 How are the protective devices checked? .......................................................................... 1-11

1.6 Set-up, care, cleaning,

maintenance and repair work on the machine ........................................... 1-13
1.6.1 Who may carry out this work? ............................................................................................ 1-13
1.6.2 What must be observed and done before this work commences? .................................... 1-13
1.6.3 Cleaning the machine .......................................................................................................... 1-13
1.6.4 Work on the electrical equipment ....................................................................................... 1-14
1.6.4.1 Machine connection ............................................................................................................ 1-14
1.6.4.2 Frequency converters and servo controllers ....................................................................... 1-14
1.6.5 Working with process materials .......................................................................................... 1-14

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1.7 Residual dangers ........................................................................................1-15
1.7.1 Machine damage due to closing protective shutter B incorrectly .......................................1-15
1.7.2 Trip hazard ...........................................................................................................................1-15
1.7.3 Risk of injury through tools left attached .............................................................................1-15
1.7.4 Electrical hazards ................................................................................................................1-16
1.7.5 Product contamination ........................................................................................................1-16
1.7.6 Contact with the product being packed ..............................................................................1-16
1.7.7 Risk of injury due to heavy film rolls ....................................................................................1-16
1.7.8 Risk of crushing when closing the front door ......................................................................1-17
1.7.9 Risk of crushing when swinging the clip head into the working position ............................1-17
1.7.10 Risk of crushing when swinging the
product outlet into the working position ..............................................................................1-18
1.7.11 Cuts when changing the knife .............................................................................................1-18
1.7.12 Draw-in risk on the fan in the control cabinet ......................................................................1-18
1.7.13 Setting the dosing speed .....................................................................................................1-18
1.7.14 Transporting the TSCA ........................................................................................................1-18
1.7.15 Closing and separator area .................................................................................................1-19
1.7.16 Film inlet side .......................................................................................................................1-19
1.7.17 Product outlet side ..............................................................................................................1-19
1.7.18 Automatic mode ..................................................................................................................1-20
1.7.19 Stuffing process ..................................................................................................................1-20
1.7.20 Stuffing process in automatic mode ...................................................................................1-20
1.7.21 Switching from Automatic On to Automatic Off ..................................................................1-20
1.7.22 Sealing bar poses burn hazard ............................................................................................1-20
1.7.23 Risk of crushing when swinging the sealing bar up/down ..................................................1-21
1.7.24 Risk of crushing at the sealing station .................................................................................1-21
1.7.25 Risk of crushing at the film drive .........................................................................................1-22
1.7.26 Risk of burns on the motors for the film drive .....................................................................1-22
1.7.27 Tension core ........................................................................................................................1-23
1.7.28 Contact with the spray from the spray system (optional) ....................................................1-23
1.7.29 Fire in the control cabinet ....................................................................................................1-23
1.7.30 Moving the machine ............................................................................................................1-23
1.7.30.1 Measures before transport ..................................................................................................1-23
1.7.30.2 Pushing the machine ...........................................................................................................1-23
1.7.30.3 Loading and unloading the machine ...................................................................................1-24
1.7.30.4 Transport by ship, plane or lorry .........................................................................................1-24
1.7.30.5 After transport ......................................................................................................................1-24
1.7.31 Removal of transport packaging .........................................................................................1-24

1.8 Disposal of packaging material ..................................................................1-24

1.9 Disposing of electrical/
electronic components of the machine ......................................................1-24
1.10 Troubleshooting/test operation ..................................................................1-24

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2 Machine description ........................................................................... 2-1
2.1 Applications .................................................................................................. 2-1
2.2 Sealing .......................................................................................................... 2-2
2.3 Closing and clipping process in the clip module ......................................... 2-2
2.4 RFID system ................................................................................................. 2-2
2.5 Inner brake .................................................................................................... 2-2
2.6 Seal seam cooling: Compressed air cooling ................................................ 2-2
2.7 Overspreading .............................................................................................. 2-2
2.8 Optional equipment ...................................................................................... 2-3
2.8.1 Spray system (optional) ......................................................................................................... 2-3
2.8.2 Inkjet printer (optional) ........................................................................................................... 2-3
2.8.3 Hot stamping printer (optional) .............................................................................................. 2-3
2.8.4 Print mark control (optional) .................................................................................................. 2-3
2.8.5 Clip mark control (optional) ................................................................................................... 2-3
2.8.6 Sealing bar guard (optional) .................................................................................................. 2-3
2.8.7 Brush film guide (optional) ..................................................................................................... 2-3
2.8.8 HDP 30, HDP 40 or HDP 50 dosing pump (optional) ............................................................ 2-3
2.8.9 Upper front door position prompt (optional) ......................................................................... 2-3
2.8.10 Machine height adjustment (optional) ................................................................................... 2-4
2.8.11 Splice detection (optional) ..................................................................................................... 2-4
2.8.12 Film drive (optional) ............................................................................................................... 2-4
2.8.13 Special voltage transformer (optional) ................................................................................... 2-4
2.8.14 Filling system (optional) ......................................................................................................... 2-4

3 Installation of the machine ................................................................. 3-1

3.1 Note .............................................................................................................. 3-1
3.2 Machine location .......................................................................................... 3-1
3.3 Removing the packaging .............................................................................. 3-1
3.4 Moving machine to location ......................................................................... 3-2
3.5 Setting up the filling system ......................................................................... 3-4
3.5.1 Unbolting the sealing bar and swinging it up ........................................................................ 3-4
3.5.2 Positioning the filling system ................................................................................................. 3-4
3.5.3 Without HDP dosing pump connected: Positioning the stuffing horn .................................. 3-6
3.5.4 With HDP dosing pump connected: Positioning the stuffing horn ....................................... 3-7

3.6 Connecting the stuffer/HDP hydraulic dosing pump ................................... 3-9

3.6.1 Adjusting the product inlet height ......................................................................................... 3-9
3.6.2 Connecting the TSCA with the stuffer ................................................................................... 3-9
3.6.3 Connecting the TSCA and the HDP hydraulic dosing pump .............................................. 3-10

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3.7 Mains connection .......................................................................................3-11
3.7.1 Establishing the main connection ........................................................................................3-12

3.8 Setting the operating pressure ...................................................................3-13

3.9 Setting the distance between the discharge plate
and the separator .......................................................................................3-15

4 Indicators and controls .......................................................................4-1

4.1 Control panel ................................................................................................4-1
4.1.1 Sealing station and film transport adjustment controls .........................................................4-2

4.2 Main switch, air release valve and

compressed air supply connection ..............................................................4-3
4.3 Pressure gauge and pressure reducer with filter ..........................................4-3
4.4 Easy-Touch display ......................................................................................4-4
4.5 Program structure and passwords ...............................................................4-4
4.5.1 Changing the menu level .......................................................................................................4-4

4.6 Basic selection screens of the Operator and

Supervisor menu levels ................................................................................4-5
4.6.1 Design of the basic selection screens ...................................................................................4-5
4.6.2 Operating modes/Operating status display ...........................................................................4-6
4.6.3 Navigation using the quick-selection buttons .......................................................................4-6
4.6.4 Navigation in the basic selection screens and the screens
for functional parameters ......................................................................................................4-7
4.6.4.1 The following icons may appear together with functional parameters ..................................4-7
4.6.5 Meaning and function of icon selection buttons ...................................................................4-8
4.6.6 Menu bar ...............................................................................................................................4-9
4.6.7 Password input and icon selection screen in the Operator menu level ..............................4-10
4.6.8 Current messages ...............................................................................................................4-10
4.6.9 Manual function buttons ......................................................................................................4-11
4.6.9.1 Statuses of the function buttons .........................................................................................4-11
4.6.9.2 Overview: Manual function buttons .....................................................................................4-12
4.6.10 Tool change screen .............................................................................................................4-12

4.7 Settings in the password input screen .......................................................4-14

4.7.1 Set language ........................................................................................................................4-14
4.7.2 Display service information .................................................................................................4-14
4.7.3 Lubricate TSCA ...................................................................................................................4-15
4.7.3.1 Meaning of icons .................................................................................................................4-15
4.7.3.2 Button for calling up the image sequence for manual lubrication .......................................4-16
4.7.4 Clean screen ........................................................................................................................4-16
4.7.5 Lubricate HDP .....................................................................................................................4-17
4.7.5.1 Meaning of icons .................................................................................................................4-17

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4.8 Parameter settings in the Operator menu level .......................................... 4-18
4.8.1 Load recipe ......................................................................................................................... 4-18
4.8.2 View recipe data .................................................................................................................. 4-18
4.8.3 Stuffer coupling ................................................................................................................... 4-19
4.8.3.1 Clipping process control .................................................................................................... 4-19
4.8.4 Speed .................................................................................................................................. 4-20
4.8.5 Length stop (optional) ......................................................................................................... 4-20
4.8.6 Clip mark (optional) ............................................................................................................. 4-21
4.8.7 HDP (optional) ..................................................................................................................... 4-21
4.8.8 Filling device (optional) ........................................................................................................ 4-22
4.8.9 Separator hole, clip pressure, spreading ............................................................................ 4-22
4.8.10 06500 Check clip transport/Separator hole/Clip height/
Spreading message screen ................................................................................................. 4-23
4.8.11 Knife, film end ...................................................................................................................... 4-24
4.8.12 Sealing bar .......................................................................................................................... 4-25
4.8.13 Sealing bar heating .............................................................................................................. 4-25
4.8.14 HDP ..................................................................................................................................... 4-26
4.8.14.1 HDP 30 ................................................................................................................................ 4-26
4.8.14.2 HDP 40 and HDP 50 ............................................................................................................ 4-30
4.8.15 Spray system (oil sprayers) ................................................................................................. 4-34
4.8.16 Discharge tray (optional) ..................................................................................................... 4-35
4.8.17 Read RFID data and transfer it into the recipe .................................................................... 4-35
4.8.18 Product counters ................................................................................................................. 4-38
4.8.19 Portion weight, calibre, stuffing horn diameter ................................................................... 4-38
4.8.20 Printer (optional) .................................................................................................................. 4-39
4.8.21 TSA drives ........................................................................................................................... 4-40
4.8.22 Drive overview, part 1 .......................................................................................................... 4-40
4.8.23 Film drive (optional) ............................................................................................................. 4-41

4.9 Supervisor menu level ................................................................................ 4-41

4.9.1 Password entry and icon selection screen ......................................................................... 4-41
4.9.2 Display service information ................................................................................................. 4-42
4.9.3 Current messages ............................................................................................................... 4-42
4.9.4 Message history .................................................................................................................. 4-43
4.9.5 Recipe management ........................................................................................................... 4-44
4.9.6 Load recipe ......................................................................................................................... 4-44
4.9.7 Saving a recipe .................................................................................................................... 4-44
4.9.8 Saving recipe data to a USB stick/Loading recipe data from a USB stick ......................... 4-45
4.9.9 Portion weight, calibre, stuffing horn diameter ................................................................... 4-45
4.9.10 Basic selection screen of the Supervisor, part 1 menu level ............................................... 4-46
4.9.11 Basic selection screen of the Supervisor, part 2 menu level ............................................... 4-46
4.9.12 Poly-clip System Deutschland address screen ................................................................... 4-47
4.9.13 Rotation angles for machine functions ................................................................................ 4-47
4.9.14 Screen configuration for the Operator menu level .............................................................. 4-48
4.9.15 Inputs/Outputs, page 1 ....................................................................................................... 4-49
4.9.16 Inputs/Outputs, page 2 ....................................................................................................... 4-49
4.9.17 Inputs/Outputs, page 3 ....................................................................................................... 4-50
4.9.18 Inputs/Outputs, page 4 ....................................................................................................... 4-50

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4.9.19 Calibre .................................................................................................................................4-51
4.9.20 Safety module addresses ....................................................................................................4-51
4.9.21 EtherCAT bus, part 1 ...........................................................................................................4-52
4.9.22 EtherCAT bus, part 2 ...........................................................................................................4-52
4.9.23 Simulator .............................................................................................................................4-53
4.9.24 WS Food ..............................................................................................................................4-53
4.9.25 Film counter .........................................................................................................................4-54
4.9.26 HDP speed/ramp profile, page 1 .........................................................................................4-54
4.9.27 HDP speed/ramp profile, page 2 .........................................................................................4-55
4.9.28 Setting the date/time ...........................................................................................................4-55
4.9.29 Calibrating the touchpanel ..................................................................................................4-56
4.9.30 Call up wiring diagrams .......................................................................................................4-56

4.10 List of possible error messages ..................................................................4-57

5 Start-up and shutdown .......................................................................5-1

5.1 Note ..............................................................................................................5-1
5.2 Start-up check list ........................................................................................5-1
5.3 Adjusting the height of the discharge plate at the product outlet ................5-4
5.4 Filling the clip magazine ...............................................................................5-5
5.4.1 Bringing the machine into the clip loading position ..............................................................5-5
5.4.2 Filling the clip magazine ........................................................................................................5-6
5.4.3 Setting the braking force on the clip magazine .....................................................................5-6
5.4.4 Inserting the clip stick ............................................................................................................5-7

5.5 Changing the die ..........................................................................................5-7

5.6 Changing the punch .....................................................................................5-9
5.6.1 Checking the clearance .......................................................................................................5-12
5.6.2 Setting the clearance ...........................................................................................................5-13

5.7 Setting the separator hole ..........................................................................5-13

5.8 Clip pressure ..............................................................................................5-14
5.8.1 Checking the clip pressure ..................................................................................................5-14
5.8.2 Setting the clip pressure ......................................................................................................5-15

5.9 Inserting the film .........................................................................................5-17

5.9.1 Producing the film tube .......................................................................................................5-19
5.9.2 Testing the film travel ..........................................................................................................5-19
5.9.3 Readjusting the film roll .......................................................................................................5-20
5.9.3.1 Adjusting the deflection roller ..............................................................................................5-20
5.9.3.2 Adjusting the guide pulley ...................................................................................................5-20

5.10 Using the filling system with a different calibre ..........................................5-21

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5.11 Splice detection .......................................................................................... 5-24
5.11.1 Reading process (static) ...................................................................................................... 5-24

5.12 Spray system (optional) .............................................................................. 5-25

5.13 Shutting down the machine for a long period ............................................ 5-28
5.14 Tool change scenarios ............................................................................... 5-30

6 Product testing .................................................................................... 6-1

6.1 Note .............................................................................................................. 6-1
6.2 Preparing for product testing ....................................................................... 6-1
6.3 Product testing before start of production ................................................... 6-1
6.3.1 Testing the film travel ............................................................................................................ 6-1
6.3.2 Testing the seal seam ........................................................................................................... 6-2

6.4 After completion of product testing .............................................................. 6-2

7 Troubleshooting .................................................................................. 7-1

7.1 Note .............................................................................................................. 7-1
7.1.1 Preparing the machine for fault rectification ......................................................................... 7-1
7.1.2 After completing the work ..................................................................................................... 7-1

7.2 List of possible faults and problems ............................................................ 7-2

8 Cleaning and maintenance ................................................................. 8-1

8.1 General points .............................................................................................. 8-1
8.1.1 Working with process materials ............................................................................................ 8-1
8.1.2 Selecting process materials .................................................................................................. 8-1
8.1.3 Disposal of process materials ............................................................................................... 8-1

8.2 Shutting the machine down .......................................................................... 8-2

8.3 Preparing the machine for cleaning .............................................................. 8-4
8.4 Cleaning the sealing area ............................................................................. 8-6
8.5 Cleaning the sealing area ............................................................................. 8-7
8.5.1 Non food-processing machines: Cleaning the sealing area ............................................... 8-10
8.5.1.1 Non food-processing machines: After the cleaning work ................................................... 8-10
8.5.2 Food-processing machines: Cleaning the sealing area ...................................................... 8-12
8.5.2.1 Food-processing machines: After the cleaning work .......................................................... 8-14

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9 Maintenance .........................................................................................9-1
9.1 Note ..............................................................................................................9-1
9.2 Shutting down the machine before maintenance work ................................9-2
9.3 After completing the work ............................................................................9-3
9.4 Lubricating grease ........................................................................................9-3
9.4.1 Grease specification ..............................................................................................................9-3

9.5 Lubrication plan ............................................................................................9-4

9.5.1 Lubrication point 1: Cam roller of upper clip lever ...............................................................9-5
9.5.2 Lubrication point 2: Clip transport shaft ................................................................................9-5
9.5.3 Lubrication point 3: Cam roller of lower clip lever .................................................................9-5
9.5.4 Lubrication point 4: Clip lever shaft .......................................................................................9-6
9.5.5 Lubrication point 5: Separator cam roller ..............................................................................9-6
9.5.6 Lubrication point 6: Clip transport shaft ................................................................................9-7
9.5.7 Lubrication point 7: Right separator bearing .........................................................................9-7
9.5.8 Lubrication point 8: Separator guide tube .............................................................................9-7
9.5.9 Lubrication point 9: Spreading guide bolts ...........................................................................9-8
9.5.10 Lubrication point 10: Cylindrical axle ....................................................................................9-8
9.5.11 Lubrication point 11: Left separator bearing .........................................................................9-9

9.6 Lubrication points to be lubricated annually ................................................9-9

9.6.1 Lubrication point 12 annually: Sealing station counter support ............................................9-9
9.6.2 Lubrication point 13 annually: Clip head swing unit ............................................................9-10

9.7 Changing the air filter .................................................................................9-11

9.8 Replacing the Teflon strips on the seal pipe ..............................................9-14
9.9 Changing the knife ......................................................................................9-16
9.10 Converting the clip transport (spacing) ......................................................9-24
9.11 Converting the spreading ...........................................................................9-33

10 Transporting the machine .................................................................10-1

10.1 Disconnecting the power supply ................................................................10-1
10.2 Secure the front doors and the clip head ...................................................10-3
10.3 Pushing the machine ..................................................................................10-4
10.4 Loading and unloading the machine ..........................................................10-5
10.5 Transport by ship, plane or lorry ................................................................10-6
10.6 After transport ............................................................................................10-6

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11 Technical data .................................................................................. 11-1
11.1 Dimensions and weight .............................................................................. 11-1
11.2 Pneumatic connection ................................................................................ 11-1
11.3 Electrical connection .................................................................................. 11-1
11.4 Volume at the work station LpA ................................................................. 11-4
11.5 Film length, film width and film tube diameter ........................................... 11-4
11.5.1 Film roll dimensions ............................................................................................................. 11-4
11.5.2 Film surface width ............................................................................................................... 11-4

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1 Safety Instructions 1.1.1 Warning symbols on the machine

1.1 Introductory comments The following table shows the warning symbols on the
machine and explains what they mean.
This Poly-clip machine has been built in accordance
with the state of the art and the accident prevention Warning Meaning / Location
regulations in force. symbol
However, this machine may
• present danger to the lives of the user or others, Warning of dangerous electrical
• or adversely affect the working of the machine and voltages
other property of the user, if the machine Location 1: Protective cover on
• is operated or maintained by untrained control cabinet
persons Pull out the mains plug before
• and/or is used improperly or used for opening the enclosure!
purposes other than intended. Location 2: Protective cover on
transformer (optional)
• Note
Every person charged with start-up, operation, care, Warning of temperatures
maintenance and repair of this machine must first read up to 250 °C
and understand the Operating Manual, in particular Location: Sealing bar
the Safety Instructions.
Furthermore, the general regulations on safety and
Warning of risk of crushing
accident prevention in force must be observed.
Location: Film drive (optional)

Warning of catching and

entanglement of e.g. hair or clothes
Location: Protective cover on fan in
control cabinet

Hot surface warning (surface

temperatures of over 100 °C)
Location: Motors for the film drive

• Warning symbols on the machine refer to potential

danger points and must be observed without fail.
• Warning symbols must not be removed from the
machine.
• Damaged and illegible warning symbols must be
replaced without delay.

Safety Instructions
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 Poly-clip System GmbH & Co. KG TSCA 65 D
1.1.2 Warnings in manuals Example of a warning:

In the instructions, you will find warnings before steps

associated with risks. WARNING: Risk of injury when lifting
Below is a description of how a warning is constructed heavy film rolls
and what it means. You risk injury or crushing if you lift film rolls that
1.1.2.1 Warning sign weigh over 25 kg without lifting aids.
The warning sign is shown below. Warnings with this • Film rolls with a weight of over 25 kg may only be
sign warn against risk of injury or even death. Always moved onto the expansion shaft using a lifting
follow these instructions to avoid dangers. device.
• Wear safety shoes.

1.1.2.2 Danger levels

In each case, the warning sign in conjunction with a
signal word indicates a specific level of danger:

Warning sign Meaning Probabilit

and signal y
word
DANGER Failure to avoid the Given
danger will result in death immediate
or serious injury ly before
(irreversible).

WARNING Failure to avoid the Possibly

danger may result in
death or serious injury
(irreversible).

CAUTION Failure to avoid the Possibly

danger may result in
moderate or minor injury
(reversible) and possibly
damage to property.
ATTENTION Failure to avoid the Possibly
danger may result in
damage to property.

Safety Instructions
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1.2 Use of this machine 1.2.1.2 With reservation: Processing easily
flammable materials
1.2.1 Correct use The material to be processed comes into contact with
hot components. The film tube being stuffed with the
The TSCA is intended for sealing film from a roll to
material remains hot after sealing. Hence, please note
produce a ready-to-be-stuffed film tube in various
the following:
calibre sizes, closing the stuffed film tube, and
• No easily flammable or highly flammable materials
separating portion and straight sausages.
may be processed.
The machine can be used to process pasty
• The flash point of the material to be processed
substances.
must be high enough for the material not to catch
The machine is for commercial use only and is not
fire at the temperatures reached on the machine.
intended for private use.
During operation, all covers, doors, hoods and
If easily flammable materials are to be processed, the
shutters must be closed.
machine operating company must conduct an
analysis in line with due diligence based on the nature
1.2.1.1 With reservation: Processing and characteristics of these substances and any
potentially explosive materials potential dangers that may result therefrom in order to
The machine is not suitable for processing potentially clarify whether the materials can be processed using
explosive materials. If an operating company wants to this machine. In doing so, all legal and other
use this machine to process such materials, it must safety-related regulations and requirements, in
conduct an analysis in line with due diligence based particular, must be taken into account and relevant
on the nature and characteristics of these substances experts and test institutes must also be consulted
and any potential dangers that may result therefrom in where appropriate. The responsibility, especially for
order to clarify whether the materials can indeed be processing easily flammable materials, lies with the
processed using this machine. In doing so, all legal machine operating company. The manufacturer and
and other safety-related regulations and supplier may be contacted in this respect should it be
requirements, in particular, must be taken into of assistance in terms of machine design
account and relevant experts and test institutes must considerations. In this case, the manufacturer and
also be consulted where appropriate. The supplier must be provided with all necessary
responsibility, especially for processing potentially information and findings, recipes, processing
explosive materials, lies with the operating company procedures and experiences.
using the machine. The manufacturer and supplier
may be contacted in this respect should it be of The machines that feed the TSCA with material must
assistance in terms of machine design considerations. also be checked for their suitability. If any of these
In this case, the manufacturer and supplier must be machines is not suitable for processing easily
provided with all necessary information and findings, flammable materials, then the material must not be
recipes, processing procedures and experiences. processed.
The machines that feed the TSCA with material must
also be checked for their suitability. If any of these
machines is not suitable for processing potentially
explosive materials, then no potentially explosive
materials may be processed with the TSCA.

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1.2.2 Improper use 1.2.3 Modifications and alterations
This machine must not be operated unless the a For safety reasons, unauthorised modifications or
complete filling system, product outlet and smallest alterations to the machine and the attachment or
appropriate spray guard are fitted. installation of additional equipment or other
A complete filling system comprises the following: variants not sold by Poly-clip System are not
• Stuffing horn permitted. Welding and cutting work on the frame is
• Inner brake also prohibited; this work must only be carried out
• Possibly, inner ring (not required for every stuffing by Poly-clip System.
horn/calibre) b Protective devices prevent anyone reaching into
• Seal pipe the danger points during operation of the machine
• Forming shoulder and must not be removed, modified or bypassed.
c The safety of the machine may be impaired by clips
and spare parts which do not meet the standards
specified by Poly-clip System and which have not
been supplied by Poly-clip System.
Therefore, only original Poly-clip System clips may
2 3 be used with the machine and only original
Poly-clip System spare parts may be attached or
installed.

The EC declaration of conformity (CE) will lose its

4 5 validity and the safety guarantee for this machine will
expire in case of unauthorised modifications or
1 alterations (a and b), use of non-original Poly-clip
Fig. 1-1 Complete filling system System clips (c) and attachment and installation of
1 Stuffing horn non-original Poly-clip System spare parts (c).
2 Inner brake
3 Possibly, inner ring
4 Seal pipe
5 Forming shoulder

The machine must not be started up without its

panels on.
The machine is not suitable for wet operation.
The machine is not suitable for use in potentially
explosive atmospheres.
It is not permissible for more than one person to work
at the machine at the same time because this would
circumvent the safety measure of two-hand operation
for example.
If the TSCA itself or any of the machines that feed the
TSCA with material is not suitable for processing
potentially explosive materials, then no potentially
explosive materials may be processed.
If the TSCA itself or any of the machines that feed the
TSCA with material is not suitable for processing
easily flammable materials, then no easily flammable
materials may be processed.
No easily flammable or highly flammable materials
may be processed.

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1.3 Personnel selection and 1.3.3 Maintenance staff
qualification In addition, the maintenance staff must also meet the
following requirements:
Any person to carry out work on this machine must
• Thorough knowledge in the fields of mechanical
meet the following requirements:
engineering, electrical engineering and pneumatics
• Minimum age: 18 years; persons between 14 and
• Thorough knowledge of the design and operation of
18 years of age may only work under the
the machine
supervision of a person trained on the machine
• Trained on the machine by employees of Poly-clip
• Personally suitable and sufficiently qualified for the
System or by employees of service organisations
respective activity
appointed by Poly-clip System
• Appointed by the operating company to carry out
• Familiar with this Operating Manual, especially the
the respective activity
Safety Instructions
• Trained in handling the machine
• Work on mechanical and pneumatic equipment
• Familiar with the machine’s safety devices and how
may only be carried out by people with qualification
they work
as an industrial mechanic or mechatronics engineer
• Familiar with this Operating Manual, especially the
or at least an equivalent qualification
Safety Instructions and the sections that are
• Work on electrical equipment may only be carried
relevant to the activity
out by people with qualification as an electrician or
• Familiar with the basic regulations on occupational
a higher qualification
safety and accident prevention

1.3.1 Operators
In addition, the operators must also meet the following
requirements:
• Regularly trained on the machine by the operating
company (at least every six months)
• Training content: Functional processes of the
machine, operating procedures, hazards and
cleaning procedures (exposure time, application,
temperatures), safety precautions
• Training must be carried out directly at the machine
in accordance with this Operating Manual.
• During training, the danger points and all possible
dangerous situations which may occur during
operation of the machine must be explained to the
staff directly at the machine.

1.3.2 Cleaning staff

In addition, the cleaning staff must also meet the
following requirements:
• Regularly trained on the machine by the operating
company (at least every six months)
• Training content: Hazards of cleaning and cleaning
procedures (exposure time, application,
temperatures, points that it is critical to clean),
safety precautions
• Training must be carried out directly at the machine
in accordance with this Operating Manual.

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1.4 Personal protective equipment 1.5 Protective devices
required • The protective devices fitted are intended for
You must read the safety data sheets for the standing operation.
consumables used on the machine; these safety data • With the safety switches used, there is no incentive
sheets can be obtained from the suppliers of the to bypass the safety equipment (according to the
consumables. The safety data sheets contain methods for determining and eliminating the
additional notes regarding the required personal possibility of bypassing, DIN EN ISO 14119). The
protective equipment. For your safety, always use the safety switches are not easy to manipulate.
required personal protective equipment.
1.5.1 Danger points secured by a protective
• Safety shoes device:
Safety shoes must be worn during installation and
set-up of the machine, when loading heavy film rolls A Product outlet by a protective grating.
and during dismantling and transport of the machine. B Separator area by a protective shutter
on the front side.
• Hearing protection
Hearing protection must be worn where noise levels in
the work place are 85 dB(A) or higher. If the daily noise
exposure level LEX,8h exceeds 80 dB(A), measures
must be taken to reduce the noise. Suitable measures
include, for example, soundproofing or the use of
appropriate personal protective equipment (ear plugs
or noise protection headphones).

• Protective gloves A
When working on the spray system (optional), observe
the spray manufacturer’s instructions and wear
chemical-resistant protective gloves if necessary.

Depending on what product is being packed,

chemical-resistant protective gloves and possibly
also heat-resistant protective gloves may be required.
Observe the safety data sheet for the product!

Cut-resistant protective gloves must be worn when

changing the knife.
B
• If applicable, cold protection clothing
The staff's clothing must be appropriate for the
ambient temperature at the place of installation
(see section 3.2).

• Personal padlock with key Fig. 1-2 A Protective grating

To prevent the machine being switched back on while B Protective shutter
work is being carried out. You must carry the key for
the padlock on your person. 1.5.2 Work sequences protected by a
protective device:
A Raising the protective grating at the sausage outlet
B Raising the protective shutter at the front
C Swinging the sausage outlet to the side. (Fig. 1-3)
D Swinging the clip head to the side. (Fig. 1-4)
E Opening the left side panel. (Fig. 1-5)

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C
Fig. 1-3 C Product outlet, swung to the side

Fig. 1-4 D Clip head, swung to the side

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1.5.3 Emergency Stop pushbutton
When the Emergency Stop pushbutton (F, Fig. 1-6) is
pressed, the TSCA and the HDP hydraulic dosing
pump (if installed) are switched off immediately.
Automatic mode is exited.
Sealing bar heating is switched off.
An error message is displayed on the TSCA control
panel.

F
Fig. 1-6 F Emergency Stop pushbutton

1.5.4 Production only with sealing bar

locked
You will be prompted to lock the sealing bar; the
machine will only start production if the sealing bar is
locked. (Fig. 1-7)
E

Fig. 1-5 E Left side panel on the clip head,

opened
Fig. 1-7 1 Sealing bar locked

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1.5.5 Covers 1.5.5.3 Right side panel on the clip head
1.5.5.1 Protective covers on the control The right side panel on the clip head (1) prevents
cabinet/supply/spray system anyone reaching into an area that contains moving
parts such as the motor shaft.
The protective cover over the control cabinet (1) and (Fig. 1-9)
the protective cover on the supply (2) prevent anyone
reaching into an area that contains live parts.
The protective covers on the spray system (3) prevent
anyone coming into contact with the spray. (Fig. 1-8)

1
Fig. 1-9 1 Right side panel on the clip head
2
3
Fig. 1-8 1 Protective cover on the control cabinet
2 Protective cover on the supply
3 Protective covers on the spray system

1.5.5.2 Protective cover on the transformer

A protective cover over the transformer (optional)
prevents anyone reaching into an area that contains
live parts.

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1.5.5.4 Spray guard and inner ring • If no inner ring is required for the stuffing horn/
calibre, the gap between the spray guard (1) and
There is a risk of body parts, especially fingers, being the stuffing horn (2) must not exceed 8 mm.
crushed or severed in the closing and separator area. (Fig. 1-11)
The following components are screwed on in order to
prevent anyone reaching into the closing and
separator area from the sealing area: 1
• A spray guard (1, Fig. 1-10)
• Possibly, an inner ring (2, Fig. 1-10). The inner ring
is not required for every stuffing horn/calibre.
The spray guard and inner ring are not monitored. 2
They only offer protection under certain
circumstances. The operating company must ensure 8mm
that the machine is only operated if the following
prerequisites are met:
• The smallest appropriate spray guard (1) must be
fitted. When changing the stuffing horn or calibre,
you must check whether a different spray guard
needs to be fitted.
• If an inner ring (2) is required for the stuffing horn/
calibre, it must be fitted correctly. If the inner ring
was removed, e.g. during cleaning, it must be
Fig. 1-11 1 Spray guard (coloured)
re-fitted in the right place on the stuffing horn. The
2 Stuffing horn
gap between the spray guard (1) and the inner ring
(2) must not exceed 8 mm. (Fig. 1-10)
1.5.6 What happens if one of the protective
devices A to F is triggered?
1
In the following cases, an electrical circuit is
interrupted, the machine stops immediately and is no
2 longer operational:
• Protective grating at product outlet is raised
• Protective shutter is raised
8mm • Product outlet is swung to the side
• Clip head is swung to the side
• Left side panel is opened
• Emergency Stop pushbutton is pressed
A message is displayed on the control panel.

Fig. 1-10 1 Spray guard (coloured)

2 Inner ring

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1.5.7 All protective devices must be
checked!
1
• Before each start-up of the machine!
• Before any work is started on the machine!
• After all set-up, cleaning, care, maintenance and
repair work on the machine!
• Check they are present and working properly!

1.5.8 How are the protective devices

checked?
Prerequisite: The machine is operational.
For the test, you have to trigger the protective devices
one after the other.

Protective grating
1.) Raise the protective grating at the product outlet. 2
Result: Automatic mode is exited.
The TSCA is stopped.
Error message 03012 is displayed.
2.) Close the protective grating at the product outlet.
Result: The error message disappears.
The machine is operational again.

Product outlet
1.) Press the button and swing the product outlet to
the side.
Result: Automatic mode is exited.
The TSCA is stopped.
Error message 03012 is displayed.
2.) Swing the product outlet into the working
position.
Result: The error message disappears. C
The machine is operational again.
Fig. 1-12 C Product outlet, swung to the side

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Clip head Protective shutter/left side panel on the clip head
1.) Raise the protective shutter. 1.) Raise the protective shutter.
Result: Automatic mode is exited. Result: Automatic mode is exited.
The TSCA is stopped. The TSCA is stopped.
Error message 03012 is displayed. Error message 03012 is displayed.
2.) Unlock the clip head. 2.) Push the latch (1, Fig. 1-14) down.
3.) Swing the clip head to the side. 3.) Open the left side panel.
Result: Error message 03022 is displayed. Result: Error message 03052 is displayed.
4.) Swing the clip head into the working position. 4.) Close the side panel and lock it by pressing the
5.) Lock the clip head. latch (1, Fig. 1-14) up.
6.) Close the protective shutter. 5.) Close the protective shutter.
Result: The error messages disappear. Result: The error messages disappear.
The machine is operational again. The machine is operational again.

Fig. 1-14 1 Latch, here locked

Fig. 1-13 Unlock the clip head and

swing it to the side

Fig. 1-15 Opening the left side panel

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Emergency Stop pushbutton 1.6.3 Cleaning the machine
1.) Press the Emergency Stop pushbutton.
• The machine must be cleaned after every use. If
Result: Automatic mode is exited. product-carrying parts of the machine are not
The TSCA is stopped. The HDP hydraulic dosing cleaned promptly after switch-off, the product may
pump (if installed) is stopped. harden depending on what product was used. This
Error message 03002 is displayed. may result in production downtime.
2.) Pull the Emergency Stop pushbutton back out. • The machine must be cleaned in accordance with
The error message disappears. the local hygiene and accident prevention
The machine is operational again. regulations in force.
• When using cleaning devices, the device
• If the result of any of the checks differs from that manufacturer’s safety instructions must be
described here, the machine must be shut down observed.
immediately and the maintenance staff called. • Never exceed the cleaning agent dosages specified
• The machine may only be operated if all protective by the manufacturer as overdosing leads to
devices are installed and working properly. destruction of synthetic parts and heavy corrosion
of various metallic components.
• When selecting cleaning agents, the current local
1.6 Set-up, care, cleaning, hygiene regulations must be observed.
maintenance and repair work on
the machine
1.6.1 Who may carry out this work?
• Set-up work on production changeover:
Operators.
• Care and cleaning work:
Cleaning staff.
• Maintenance and repair work:
Maintenance staff.
• Work on the electrical equipment:
Qualified electrician or a trained person under the
guidance and supervision of a qualified electrician.

1.6.2 What must be observed and done

before this work commences?
Set-up, care, cleaning, maintenance and repair work
must only be carried out when the machine has
stopped.
How to shut the machine down before commencing
the respective work is described in the following
chapters.

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1.6.4 Work on the electrical equipment 1.6.4.2 Frequency converters and servo
controllers
Any unauthorised personnel that carrying out work on
When the frequency converters and servo controllers
the electrical equipment is at risk of electrocution.
are connected to the mains voltage, the components
Work on the electrical equipment of the machine must
of the power unit as well as certain components of the
only be carried out by a qualified electrician, or by a
control unit are connected to the electricity grid.
trained person under the guidance and supervision of
Hence touching these components can be fatal!
a qualified electrician, in accordance with the
• Frequency converters and servo controllers may
electrical regulations.
only be completely removed in accordance with the
A qualified electrician is someone who can assess the
safety instructions and applicable safety
work assigned and identify potential risks based on
regulations. No individual parts may be attached to
his/her technical (electrical) training, his/her
or removed from the frequency converters or servo
knowledge and experience as well as his/her
controllers and no repairs may be carried out.
knowledge of the relevant standards and regulations.
• The frequency converters and servo controllers still
carry a residual voltage after they have been
Before starting work:
switched off. The length of time it takes for these
- isolate,
components to discharge can be found in the
- secure against re-connection, for example by means
operating manuals for the components. Touching
of a lock on the main switch
the components before this period has expired can
- ensure that no voltage is present,
result in serious injury or death.
- earth and short-circuit,
- cover or bar access to neighbouring live parts!
1.6.5 Working with process materials
1.6.4.1 Machine connection
• The machine may only be connected to electricity When working with oil, grease, cleaning agents and
grids with a protective earthing (PE) system. other chemical substances, observe the
• The machine must not be operated without a manufacturers’ safety and dosage information as well
fault-current circuit breaker. Only universal as the general regulations in force.
current-sensitive earth-leakage circuit breakers Residues of oil, grease, cleaning agents and other
type B according to IEC 60755 may be used. chemical substances must be collected in
• The regulations of the local energy supplier and the accordance with the legal provisions for recycling or
applicable safety regulations must be observed disposal.
when connecting the machine. Local authority regulations pertaining to sewage
• It is essential to check for a protective earthing disposal apply.
function prior to start-up.
• Prior to start-up, it is essential to check that the
mains voltage matches the supply voltage specified
on the machine type plate.
• An adequately fused socket (not included in the
scope of supply) must be available on-site in the
vicinity of the machine.

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1.7 Residual dangers 1.7.2 Trip hazard
Due to the intended use of the machine, despite the Cables and air hoses between the TSCA and other
fullest possible integration of safety into the machines must be laid in a way that avoids trip
state-of-the-art design and construction of the hazards.
machine, not all danger points can be secured such
that no accidents at all happen. The danger points, the
types of danger they pose and the protective 1.7.3 Risk of injury through tools left
measures that must be taken to prevent these attached
dangers are described in this chapter.
Tools or implements left attached to the machine
Failing to take these protective measures can lead to
present a serious risk of injury. In particular,
life-threatening injuries. It is therefore essential that
implements attached to the main axle may become
you read and observe this chapter carefully!
dangerous projectiles when the machine is operated.
• Always make sure that all tools and implements
1.7.1 Machine damage due to closing have been removed upon completion of assembly
and maintenance work.
protective shutter B incorrectly
• Make sure that the machine is not misused as a
Closing protective shutter B incorrectly will damage “storage place” for various tools.
the machine.
Before closing the protective shutter, unhook
the latch (1). (Fig. 1-16)

Fig. 1-17 1 Main axle

Fig. 1-16 1 Protective shutter

1 Latch

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1.7.4 Electrical hazards When using the afore-mentioned Teflon strips, please
note that their use and replacement depends heavily
Any unauthorised personnel that carrying out work on on the use and operation of the machine. We
the electrical equipment is at risk of electrocution. recommend you check the condition and wear of the
Work on the electrical equipment of the machine must Teflon strips upon every production start, every film
only be carried out by a qualified electrician, or by a change and every operator changeover - and possibly
trained person under the guidance and supervision of more often than that if you are using highly abrasive
a qualified electrician, in accordance with the films - and that you replace the Teflon strips as and
electrical regulations. when necessary. If any of the adhesive strips have
detached edges or damaged surfaces, they must be
Damaged cables present a risk of electrocution! When replaced immediately. The Teflon strip and the
moving machines, e.g. during cleaning, take care not adhesive must be completely removed from the seal
to run over cables. Damaged cables must be replaced pipe, leaving no residue. The entire seal pipe must be
immediately. completely free of adhesive residue. For details on
how to replace the Teflon adhesive strips,
see section 9.8.
1.7.5 Product contamination
As a manufacturer of machines and consumables that 1.7.6 Contact with the product being
are also used in the food industry in particular, we
make every effort to design the parts and materials
packed
that come into contact with foodstuffs in such a way Depending on what product is being packed, contact
that they meet the food law requirements. We meet with it may be hazardous to health. Observe the safety
the food law requirements in existence for this data sheet for the product!
purpose, i.e. the parts we use that come into contact If necessary, wear chemical-resistant protective
with the product have been issued with the necessary gloves or wear heat-resistant protective gloves if the
food safety certificates. product is extremely hot.
Please note that such safety certificates are not
required for parts that do not come into contact with
the product. However, should you nevertheless 1.7.7 Risk of injury due to heavy film rolls
require certificates for such parts in individual cases,
for example due to your own internal business You risk injury or crushing if you lift film rolls that weigh
requirements, then these certificates must be over 25 kg without lifting aids.
requested and issued separately. If such certificates • Film rolls with a weight of over 25 kg may only be
have not yet been issued and are therefore not moved onto the expansion shaft using a lifting
available, then they must be ordered against a fee. We device.
are happy to help you do this. • Wear safety shoes.
The Teflon strips used in our machines (article
number 5389: 60x0.15) do not come into contact with
the products being processed. This also applies to the
adhesive used to fix these strips. Only the inner
surface of the films comes into contact with the
product, not the Teflon strips as transport carriers of
these films nor the adhesive. The Teflon strips we use
and recommend have been issued with food safety
certificates.

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1.7.8 Risk of crushing when closing the 1.7.9 Risk of crushing when swinging the
front door clip head into the working position
There may be a risk of crushing when the front door is There are several places around the clip head where
closed. Open and close the front door carefully, and fingers could get crushed as the clip head is swung
make sure only one person at a time works in the area into the working position. Only one person at a time
around the front door. may work in the vicinity of the clip head and must do
For smaller people, there is a closing aid to help them so carefully.
close the upper front door. The closing aid is part of
the tool kit.

2
Fig. 1-18 1 Front door
2 Closing aid

Fig. 1-19 Clip head

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1.7.10 Risk of crushing when swinging the 1.7.12 Draw-in risk on the fan in the control
product outlet into the working cabinet
position
There is a risk of catching and entanglement of e.g.
There are several places around the product outlet hair or clothes on the fan in the control cabinet.
where fingers could get crushed as the product outlet • Do not reach in behind the protective cover
is swung into the working position. Only one person at (1, Fig. 1-21) on the fan!
a time may work in the vicinity of the product outlet • Keep a safe distance from the protective cover.
and must do so carefully.

1
Fig. 1-21 Protective cover

Fig. 1-20
1.7.13 Setting the dosing speed
1.7.11 Cuts when changing the knife
The dosing speed must be set at a speed that allows
When changing the knife, you could cut yourself on the operator to remove the finished portions from the
the sharp blade of the knife. TSCA without becoming stressed.

• Concentrate and perform this work carefully. Do

not touch the blade of the knife. 1.7.14 Transporting the TSCA
• Wear cut-resistant protective gloves.
For details, see section 1.7.30.

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1.7.15 Closing and separator area 1.7.17 Product outlet side
At this point the separator plates gather the film tube Here, the closing and separator area danger point is
to a smaller diameter and the content is squeezed out covered by the product outlet with the protective
of the resulting tail. grating.
Then the closing mechanism places the clips around If the sausage outlet is swung to the side or the
the tail. protective grating is raised, the machine is stopped.
The machine performs these operations with such
great force and speed that you risk body parts, • Never reach in under the protective grating (1,
especially fingers, being crushed or severed should Fig. 1-22) without first raising the protective grating.
you reach into this area while the machine is There is a high risk of injury here.
operating.
The closing and separator area danger point is
therefore covered during machine operation:
1
a) At the product inlet side by the stuffing horn with
inner brake and inner ring (the inner ring is not
required for every stuffing horn/calibre) and by the
smallest appropriate spray guard
b) At the front by protective device B, the protective
shutter. (Fig. 1-2)
c) At the product outlet side by protective device A,
the protective grating. (Fig. 1-2)
• The machine must be stopped before reaching into
it. To do this, raise the protective grating at the
product outlet. Fig. 1-22 1 Protective grating

• If extra-long portions are being produced, the cover

1.7.16 Film inlet side on the product outlet (1, Fig. 1-23) must be
unscrewed.
Here, the closing and separator area danger point is • Never reach into the product outlet opening
covered by the stuffing horn with inner brake and inner (1, Fig. 1-23) without first raising the
ring (the inner ring is not required for every stuffing protective grating. There is a high risk of injury
horn/calibre) and by the smallest appropriate here.
spray guard. (Fig. 1-10) • The cover must always be fitted unless
• Hence the machine must not be operated unless extra-long portions are being produced.
the complete filling system and smallest
appropriate spray guard are fitted.

Fig. 1-23 1 Cover

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1.7.18 Automatic mode 1.7.22 Sealing bar poses burn hazard
The product outlet side is partly closed by the With the heating switched on, in normal operation, the
emerging clip-pak®. However, the inside diameter of sealing bar reaches temperatures in excess of 180 °C.
the product outlet is larger than the emerging The sealing bar is protected by a safety guard at the
clip-pak®. front. However, during continuous operation, this
• Nonetheless, the operator must not reach into the guard can also get hot.
danger zone during operation. Touching this guard may result in burns. Do not touch
the sealing bar!

1.7.19 Stuffing process

The separating and closing cycle step is initiated by
the clip pulse of the HDP dosing pump or the
customer’s dosing system.
After each completed stuffing process, the clipping
machine cycle step takes place.
1
• Never reach into danger zones without stopping the
machine first.

1.7.20 Stuffing process in automatic mode

If, during automatic operation, the HDP dosing pump/
FP drum press or the stuffer becomes empty during
the stuffing process and cannot stuff another
complete portion, the TSCA remains in “Automatic
On” mode.
Once the stuffing time selected on the HDP dosing
pump/FP drum press or the stuffer has expired, the Fig. 1-24 1 Sealing bar with safety guard
equipment gives the clipping machine the clip signal
even though the portion is not fully stuffed.
The clipping machine cycle step is carried out.

• Note
Once the HDP dosing pump/FP drum press or the
stuffer is empty, the clipping machine should be
switched to “Automatic Off” or the emergency stop
button should be pressed for safety reasons.

1.7.21 Switching from Automatic On to

Automatic Off
This does not interrupt the work cycle that has already
started. After the stuffing process, the clipping
machine’s cycle step is initiated by the clip pulse and
is executed.
The clip pulse also causes the clipping machine to
switch to Automatic Off.
Once the work cycle that has already started is
completed, no more work cycles are carried out.
• Never reach into danger zones without stopping the
machine first.

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1.7.23 Risk of crushing when swinging the 1.7.24 Risk of crushing at the sealing station
sealing bar up/down
There is a risk of crushing at various points of the
When the sealing bar is swung up or swung back sealing station:
down, there is a risk of crushing at various points,
see Fig. 1-25/Fig. 1-26. There is a risk of crushing between sealing bar
(1, Fig. 1-27) and the counter support (2, Fig. 1-27).
• Make sure you have a firm footing, the sealing bar Never reach in between sealing bar and counter
is heavy! support!
• When you swing the sealing bar up, make sure it
engages securely.
• Do not reach into the danger zones.
• Only one person at a time to work on the sealing
bar. 1
2

Fig. 1-27 1 Sealing bar

2 Counter support

There is a risk of crushing between the sealing bar

(1, Fig. 1-28) and the seal pipe (2, Fig. 1-28). Never
reach in between the sealing bar and the seal pipe!

1
1 2
Fig. 1-25 1 Example of a crush point

Fig. 1-28 1 Sealing bar

2 Seal pipe

Fig. 1-26 Sealing bar swung up

1 Examples of crush points

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1.7.25 Risk of crushing at the film drive
There is a risk of crushing between the film drive
(1, Fig. 1-29) and the seal pipe (2, Fig. 1-29). Never
reach in between the film drive (optional) and the seal
pipe; the film drive moves abruptly towards the seal
pipe when a portion is discharged!

1
5

3
6
4
1 Fig. 1-30 3 Motor
4 Base plate
Fig. 1-29 1 Film drive
5 Carriage
2 Seal pipe
6 Stop
There are other crush risks when the film drive moves
back away from the seal pipe: 1.7.26 Risk of burns on the motors for the
• Risk of crushing between the motor (3) and
film drive
the base plate (4)
• Risk of crushing between the carriage (5) and Surface temperatures on the motors (3, Fig. 1-30) can
the stop (6). exceed 100 °C.
Never reach into this these danger points! (Fig. 1-30) • Never touch the motors!

Safety Instructions
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1.7.27 Tension core 1.7.30 Moving the machine
The tension core’s bellows may rupture or burst if air 1.7.30.1 Measures before transport
is admitted into them without a roll having been • The main power supply to the machine must be
pushed onto the tension core. This may present a risk disconnected, even for moving it short distances.
of injury by the compressed air escaping or rubber • The front doors and clip head must be secured
parts being blown off. before transport. For details, see chapter 10 about
moving the machine.
1
1.7.30.2 Pushing the machine
The machine is very heavy. If it starts to move in an
uncontrolled manner, there is a high risk of injury from
crushing.
• At least two people are required to move the
machine in a controlled manner on a level surface.
• The machine can only be moved in a controlled
manner on level surfaces and requires additional
securing on slopes. Caution is also required for
movement over thresholds and joints.
• The narrow side of the machine at the product
outlet is a suitable place for pushing it. (Fig. 1-32)

Fig. 1-31 1 Tension core

1.7.28 Contact with the spray from the spray

system (optional)
Depending on what spray is being used, contact with
it may be hazardous to health.
• Observe the manufacturer’s instructions.
• Wear chemical-resistant protective gloves if
necessary.

1.7.29 Fire in the control cabinet

What to do in the event of fire:
• To prevent the fire spreading to other areas, do not
open the control cabinet door.
• Pull out the mains plug.
• Do not attempt to extinguish with water – risk of
serious injury through electric shock. Only use
carbon dioxide fire extinguishers.

Fig. 1-32 Pushing the machine

• Do not move the machine jerkily.
• Wear safety shoes.
• Once the machine is in its final location, extend the
feet to prevent it from slipping.

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1.7.30.3 Loading and unloading the machine 1.7.31 Removal of transport packaging
Danger to life under suspended loads and in the
loading area! - Remove all parts attached for transport purposes
• Never stand under suspended loads or in the and all packaging before start-up.
loading area. - Closing straps are stretched tight and will spring off
• The machine may only be lifted using a forklift truck. when cut. Incorrect handling may result in injury.
The forklift truck must have a sufficient load - All machine parts or equipment removed for
capacity. transport purposes must be properly refitted in
• Only lift the machine as high as is required and only accordance with their intended use before the
move it slowly. machine is started up.

1.7.30.4 Transport by ship, plane or lorry 1.8 Disposal of packaging material

• For transport, the machine must be bolted to a
pallet to prevent it from tipping over. The machine Packaging material must be collected in accordance
must be secured against slipping using the feet and with the legal provisions for recycling or disposal.
tension straps. Packaging must be disposed of in accordance with
• Use suitable means to protect the machine from local legislative requirements.
moisture (film, desiccant bag).
• Make sure the means of transport offers a sufficient
load capacity. 1.9 Disposing of electrical/electronic
• Secure the load on the means of transport to
prevent it sliding or falling off.
components of the machine
Electrical/electronic components of the machine must
1.7.30.5 After transport be disposed of in accordance with local laws and
After transporting the machine, immediately secure it regulations; in the EU, the Waste from Electric and
with the feet (2) to prevent it slipping. The machine Electronic Equipment Directive applies.
may only be operated with the feet extended.
The castors (1) are only intended for moving the
machine. (Fig. 1-33) 1.10 Troubleshooting/test operation
Troubleshooting/test operation may only be carried
out by people who meet the requirements set out in
sections 1.3 and 1.3.3.

1
2

Fig. 1-33 1 Castor

2 Foot

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2 Machine description

2.1 Applications
The TSCA transfer-sealing/automatic clipping machine, a unit comprising a transfer/sealing and automatic
double clipping machine, processes all conventional films in a simple or layered form as well as composite films.
The TSCA seals flat film from a roll to produce a ready-to-be stuffed film tube, which is then stuffed and closed
in the integrated clip module.

5
4
7 6 2
3

Fig. 2-1 Drawing of the production process

1 Film roll
2 Product inlet
3 Stuffing horn
4 Forming shoulder
5 Sealing bar
6 Film drive (optional)
7 Clip module

Machine description
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2.2 Sealing 2.5 Inner brake
To seal the film, a hot sealing bar is lowered The speed at which the film is pulled off the stuffing
intermittently and pressed against the overlapping film horn is braked with the inner brake. The resulting
seam. dynamic pressure determines the firmness and calibre
If a film drive (optional) is installed, the film drive only of the portion.
operates during dosing and helps to transport the film.
Once the sealing procedure is complete, the sealing
bar is raised and the length of film tube required for
portioning in the clip module is pulled out.
The parameter settings for temperature, contact
pressure and sealing time required for the sealing bar
vary depending on the film type.

2.3 Closing and clipping process in

the clip module
The finished film tube, the start of which is closed with
a clip, is pulled into the clip module by the product
mass.
Once the portion has been pressed out, the
pre-separator (optional) moves into the stuffed film
tube.
Next, separator tools press against the stuffed tube
and a separating and spreading procedure is Fig. 2-2 Inner brake
performed.
Two clips are placed around the resulting film tube tail 2.6 Seal seam cooling: Compressed
in a single work step, thereby closing the end of one
portion and the start of the next portion. air cooling
The portions are automatically separated using a
knife. The seal seam needs to be cooled to prevent the film
sticking during gathering.
At normal speeds, compressed air cooling is used.
2.4 RFID system
The RFID system helps the operator fit the machine 2.7 Overspreading
with the clips and die. It prevents the machine being
damaged through operator error. Overspreading allows loose filling for expanding
The system provides contactless identification of the products, i.e. for products that expand during further
clips inserted and the die fitted. This information is processing. The spreading path must be set manually.
transmitted to the machine control system and
checked.
If different clip reels have been inserted or if clip and
die do not match, an error message is displayed on
the touch panel. The RFID system also has sensors
that check whether clips are present.
Once the clips run out, an error message is sent to the
touch panel.

Machine description
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2.8 Optional equipment 2.8.6 Sealing bar guard (optional)

2.8.1 Spray system (optional) The sealing bar guard is suitable for particularly rigid
films. This option extends the service life of the sealing
The spray system lubricates the film, making it easier bar. The guard makes sure the coating on the sealing
to process the film. bar is not worn away by the film.

2.8.2 Inkjet printer (optional)

When using the inkjet printer, the text is entered via a
display.
It is possible to connect a PC and print graphic
elements.
The inkjet printer is also suitable for wet operation. 1
2.8.3 Hot stamping printer (optional)
With the hot stamping printer, the print image is
created by mechanically setting numbers and letters.
Printing is achieved by using heat to fuse the hot
stamping foil with the film.

2.8.4 Print mark control (optional) Fig. 2-3 1 Sealing bar guard

Here, marks printed onto the film are used as control 2.8.7 Brush film guide (optional)
signals.
An optical sensor detects the marks and control The brush film guide is suitable for rigid films.
where the printer prints the film. This option extends the service life of the sealing bar.
The guard makes sure the coating on the sealing bar
2.8.5 Clip mark control (optional) is not worn away by the film.

Here, marks printed onto the film are used as control 2.8.8 HDP 30, HDP 40 or HDP 50 dosing
signals. pump (optional)
An optical sensor detects the marks and controls the
clip pulse. The HDP hydraulic dosing pump is used for
If there is no clip mark control, the clip pulse is volumetric dosing of viscous pastes. The HDPs offer
controlled by the customer’s dosing system or the different pump capacities.
HDP hydraulic dosing pump. Potentially explosive materials must not be processed
when an HDP dosing pump is connected.

2.8.9 Upper front door position prompt

(optional)
With this option, the control system will prompt you to
check the position of the upper front door. Production
cannot be started unless the upper front door is
closed.

Machine description
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2.8.10 Machine height adjustment (optional)
With machine height adjustment, the height of the
machine can be increased by either 12 cm or 22.5 cm.

2.8.11 Splice detection (optional)

A contrast scanner scans the film during machine
operation to detect splices. To remove the splice, the
machine is automatically stopped and remains in
“Automatic On” mode.

2.8.12 Film drive (optional)

The film drive helps to transport the film during dosing.

2.8.13 Special voltage transformer (optional)

The standard version of the machine is 400 Volt. Any
other version (200 to 600 Volt) is special voltage and
requires the optional special voltage transformer.

2.8.14 Filling system (optional)

Filling systems from 18 to 65 mm diameter are
available.

Machine description
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3 Installation of the machine 3.2 Machine location
3.1 Note The machine is not suitable for use in potentially
explosive atmospheres.
• Installation and set-up work must only be carried
out by people who meet the requirements set out in Minimum requirements:
sections 1.3 and 1.3.3. • Firm and level floor (less than 3 % slope) of
• The Operating Manual, especially the Safety sufficient weight-bearing capacity
Instructions, and the local accident prevention • Sufficient illumination (at least 500 lux),
regulations in force must be observed for all work.
• Pneumatic and electrical connection
• Safety shoes must be worn during transport,
• Water connection for cleaning
assembly and installation of the machine.
• Space for safe operation and daily machine
• Staff clothing must be appropriate for the ambient
maintenance
temperature in the place of installation. If
applicable, wear cold protection clothing. • Space required: Actual footprint of the machine
plus at least 800 mm on either side
• Depending on what product is being packed,
• Work area for the operator: At least 1.5 m2 and
chemical-resistant protective gloves and possibly
1 m deep. The work area must be free from clutter
also heat-resistant protective gloves may be
and intersecting traffic routes.
required. Observe the safety data sheet for the
product! • Ambient temperature at the place of installation:
• Work on the electrical equipment of the machine between 0 °C and +40 °C.
must only be carried out by a qualified electrician,
or by a trained person under the guidance and When choosing the location for the machine, please
supervision of a qualified electrician, in accordance observe the local accident prevention and sewage
with the electrical regulations. regulations.
• It is not permissible for more than one person to 3.3 Removing the packaging
work at the machine at the same time because this
would circumvent the safety measure of two-hand
operation for example.
CAUTION: Closing straps present risk of
injury
Closing straps are stretched tight and will spring off
when cut. There is a risk of injury.
• Cut carefully.

1.) Open transport packaging.

2.) Collect packaging material in accordance with
the local legal provisions for recycling or disposal.

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3.4 Moving machine to location
Two people are required to move the machine.
WARNING: Instability
There is a risk of crushing if the machine is not
WARNING: Machine is very heavy secured with the feet to prevent it from slipping.
• Once the machine is in its final location, it must be
As it is very heavy, the machine is difficult to control secured with the feet immediately to prevent it
once in motion. slipping.
• At least two people are required to move the
machine in a controlled manner on a level surface. 3.) Once the machine is in its final location, it must be
The machine can only be moved in a controlled secured with the feet immediately to prevent it
manner on level surfaces and requires additional slipping. To do this, loosen the nut (1, Fig. 3-2),
securing on slopes. wind the respective foot down until it has solid
• Caution is also required for movement over contact with the floor, then re-tighten the nut.
thresholds and joints.
• Do not move the machine jerkily.
• Wear safety shoes.

1.) Check the clip head is locked and the front doors 1
are secured.
2.) With the feet retracted, the machine can be
wheeled to its location on its castors. Move the
machine as a two-person operation. The narrow
side of the machine at the product outlet is a
2
suitable place for pushing it. (Fig. 3-1) 3
Fig. 3-2 1 Nut
2 Foot
3 Castor

4.) Remove the device used to secure the front

doors (1) during transport. (Fig. 3-3)

Fig. 3-1 Pushing the machine

Fig. 3-3 1 Transport safety device

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5.) Unlock the clip head. (Fig. 3-4)

Fig. 3-4 1 Unlocked

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3.5 Setting up the filling system
3.5.1 Unbolting the sealing bar and
swinging it up 1

Fig. 3-7 1 Sealing bar, swung up

3.5.2 Positioning the filling system

1
Fig. 3-5 Unbolting the sealing bar WARNING: Product contamination
1 Bolt
If a Teflon strip detaches from the seal pipe, the
adhesive from the Teflon strip could contaminate the
product.
• Check the condition and wear of the Teflon strips
upon every production start, every film change and
every operator changeover - and possibly more
often than that if you are using highly abrasive
films.
• If any of the adhesive strips have detached edges
or damaged surfaces, they must be replaced
immediately.
• Any Teflon strips that need replacing, as well as
their adhesive, must be completely removed from
the seal pipe, leaving no residue. The entire seal
pipe must be completely free of adhesive residue.

- Check the condition of the Teflon strips on the seal

pipe. Replace the Teflon strips if necessary.
See section 9.8.

Fig. 3-6 Swinging the sealing bar up

Fig. 3-8 Filling system

Installation of the machine

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1
Fig. 3-9 Fastening device for the filling system
1 Fixing plates
2 Quick lock, unlocked

Fig. 3-10 1 Filling system in position

2 Quick lock, locked

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3.5.3 Without HDP dosing pump 4.) Inner ring fitted: Check the gap between the spray
connected: Positioning the stuffing guard (1) and the inner ring (2). The gap must not
exceed 8 mm. (Fig. 3-12)
horn

1.) Push the stuffing horn (1) as far as it will go into

the funnel-shaped holder on the TSCA. (Fig. 3-11)
1
2
8mm

Fig. 3-12 1 Spray guard (coloured)

2 Inner ring
3 Inner brake

1
5.) No inner ring fitted: Check the gap between the
spray guard (1) and the stuffing horn (2). The gap
must not exceed 8 mm. (Fig. 3-13)

Fig. 3-11 1 Stuffing horn

1
DANGER: Crushing and amputation in
the closing and separator area
Without the smallest appropriate spray guard and/or 2
inner ring on the stuffing horn, the closing and
separator area would be accessible. Here, there is a 8mm
risk of crushing or amputation, especially of fingers.
• The smallest appropriate spray guard must be
fitted.
• If an inner ring is required for the stuffing horn/
calibre, it must be fitted in the right place on the 3
stuffing horn. The gap between the spray guard
and the inner ring must not exceed 8 mm.
• If no inner ring is required for the stuffing horn/
calibre, the gap between the spray guard and the Fig. 3-13 1 Spray guard (coloured)
stuffing horn must not exceed 8 mm. 2 Stuffing horn
3 Inner brake
2.) If an inner ring is required for the stuffing horn/
calibre: Fit the inner ring (2) in the right place on
6.) Fit the inner brake (3) onto the stuffing horn.
the stuffing horn. (Fig. 3-12).
3.) Fit the smallest appropriate spray guard (1).
(Fig. 3-12)

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3.5.4 With HDP dosing pump connected:
Positioning the stuffing horn 1
1.) Swing the clip head to the side.
2.) Unscrew the stuffing horn holder (1) from the
stuffing horn.

1
Fig. 3-14 1 Stuffing horn holder

3.) Push the stuffing horn (1) through the closing and
separator area of the TSCA and into the filling
system. (Fig. 3-15)

2
Fig. 3-16 1 Safety door
1 2 Bolt

5.) Push the adapter (1) onto the stuffing horn holder
(2). (Fig. 3-17)
6.) Screw the stuffing horn holder (2) onto the
stuffing horn.

3 1

Fig. 3-15 1 Stuffing horn

WARNING: Risk of crushing when 2

opening/closing the safety doors
There may be a risk of crushing when opening and
closing the safety doors on the dosing pump. Fig. 3-17 Interior of HDP dosing pump
• Safety doors that have been pushed up must be 1 Adapter (coloured)
secured with the respective bolt. When doing so, 2 Stuffing horn holder
make sure the respective bolt engages properly. 3 Funnel-shaped holder on the HDP
• Only one person at a time may work in the vicinity
of the safety doors.

4.) Push up the safety door (1) on the HDP dosing

pump and secure at the top using the bolt (2).
Check that the bolt has engaged properly.
(Fig. 3-16)

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10.) No inner ring fitted: Check the gap between the
spray guard (1) and the stuffing horn (2). The gap
DANGER: Crushing and amputation in must not exceed 8 mm. (Fig. 3-19)
the closing and separator area
Without the smallest appropriate spray guard and/or
inner ring on the stuffing horn, the closing and 1
separator area would be accessible. Here, there is a
risk of crushing or amputation, especially of fingers.
• The smallest appropriate spray guard must be
fitted. 2
• If an inner ring is required for the stuffing horn/
calibre, it must be fitted in the right place on the 8mm
stuffing horn. The gap between the spray guard
and the inner ring must not exceed 8 mm.
• If no inner ring is required for the stuffing horn/
calibre, the gap between the spray guard and the
stuffing horn must not exceed 8 mm. 3
7.) If an inner ring is required for the stuffing horn/
calibre: Fit the inner ring (2) in the right place on
the stuffing horn. (Fig. 3-18). Fig. 3-19 1 Spray guard (coloured)
8.) Fit the smallest appropriate spray guard (1). 2 Stuffing horn
(Fig. 3-18) 3 Inner brake
9.) Inner ring fitted: Check the gap between the spray
guard (1) and the inner ring (2). The gap must not
11.) Fit the inner brake (3) onto the stuffing horn.
exceed 8 mm. (Fig. 3-18)

1
2
8mm

Fig. 3-18 Closing and separator area of the TSCA

1 Spray guard (coloured)
2 Inner ring
3 Inner brake

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3.6 Connecting the stuffer/HDP 3.6.2 Connecting the TSCA with the stuffer
hydraulic dosing pump 1.) Screw the coupling sleeve into the dosing system
connection.
• Note
2.) Screw the connecting nut onto the coupling
The machine may only be operated with the feet sleeve.
extended.
Once the product inlet height is set correctly, the
connecting nut can be tightened easily.
3.6.1 Adjusting the product inlet height
The height can be changed at each foot by turning the
spindle (1).

2
1
2 SW46

1 SW24

Fig. 3-21 1 Connecting nut

2 Coupling sleeve

Fig. 3-20 1 Spindle

2 Lock nut

1.) Loosen the lock nut (2).

2.) Turn the spindle (1) until the required height is
obtained and the foot has solid contact with the
floor.

lower: turn clockwise

higher: turn anti-clockwise

3.) Retighten the lock nut (2).

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3.6.3 Connecting the TSCA and the HDP
hydraulic dosing pump
4
WARNING: Risk of crushing when
opening/closing the safety doors
There may be a risk of crushing when opening and
closing the safety doors on the dosing pump.
• Safety doors that have been pushed up must be
secured with the respective bolt. When doing so,
make sure the respective bolt engages properly.
• Only one person at a time may work in the vicinity
of the safety doors.
5
1.) Push up the safety door (1) on the HDP dosing
pump and secure at the top using the bolt (2).
Check that the bolt has engaged properly. Fig. 3-23 Interior of HDP dosing pump
(Fig. 3-22) 4 Adapter (coloured)
5 Stuffing horn holder

1 2.) Connect the TSCA and HDP with the connecting

piece (6). Mount the connecting piece (6) using
the quick-action clamps (7). (Fig. 3-24)

2 3
Fig. 3-22 1 Safety door
2 Bolt
3 Handle

7
6
7
Fig. 3-24 6 Connecting piece
7 Quick-action clamps

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• It is essential to check for a protective earthing
function prior to start-up.
WARNING: Risk of crushing when • Prior to start-up, it is essential to check that the
opening/closing the safety doors mains voltage matches the supply voltage specified
There may be a risk of crushing when opening and on the machine type plate.
closing the safety doors on the dosing pump. • An adequately fused socket (not included in the
• To close the safety doors, first grip the respective scope of supply) must be available on-site in the
safety door by the handle, and only then pull out vicinity of the machine.
the bolt. • Cables between the TSCA and other machines
• Only one person at a time may work in the vicinity must be laid in a way that avoids trip hazards.
of the safety doors.
• When the frequency converters and servo
controllers are connected to the mains voltage, the
3.) Close the safety door (1). To do so, first grip the components of the power unit as well as certain
respective safety door by the handle (3), and only components of the control unit are connected to
then pull out the bolt (2). (Fig. 3-22) the electricity grid. Hence touching these
components can be fatal!
• Frequency converters and servo controllers may
3.7 Mains connection only be completely removed in accordance with
the safety instructions and applicable safety
regulations. No individual parts may be attached
DANGER: Live parts to or removed from the frequency converters or
servo controllers and no repairs may be carried
Improper work on electrical equipment incurs a risk out.
of electrocution. • The frequency converters and servo controllers
Work on the electrical equipment of the machine still carry a residual voltage after they have been
must only be carried out by a qualified electrician, or switched off. The length of time it takes for these
by a trained person under the supervision of a components to discharge can be found in the
qualified electrician, in accordance with the electrical operating manuals for the components. Touching
regulations. the components before this period has expired
can result in serious injury or death.
• The machine may only be connected to electricity
grids with a protective earthing (PE) system.
• The machine must not be operated without a
fault-current circuit breaker. Only universal
current-sensitive earth-leakage circuit breakers
type B according to IEC 60755 may be used.
• The regulations of the local energy supplier and the
applicable safety regulations must be observed
when connecting the machine.

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3.7.1 Establishing the main connection
- Fit a suitable plug onto the five-core connecting
cable (4) at the back of the machine. (Fig. 3-25)

1
3

4
5
1 2 4 6
Fig. 3-25

1 For details, see Fig. 3-26 Fig. 3-26

2 Compressed air supply connection
3 Main switch
4 Five-core connecting cable No. Use: Marking
1 Connection for dosing system 751X1
from another supplier
2 Connection for rotary encoder 756X1
and printer
3 HDP connection or connection for 761X1
special functions
4 HDP EtherCAT connection 746X1
5 Ethernet connection 746X4
6 Ethernet connection 746X7

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3.8 Setting the operating pressure
1 1.) Open the protective cover (1). (Fig. 3-28)

2
5
1
4
7
6 Fig. 3-28 1 Protective cover

2.) Connect the compressed air hose to the supply

connection (1). (Fig. 3-29)
8
9
10 11

Fig. 3-27

No. Use: Marking

1 Seal seam cooling air regulator
2 Seal pressure pressure regulator 2
3 Seal pressure pressure gauge 1
4 Film drive pressure regulator
(optional)
5 Film drive pressure gauge
(optional)
6 Clip mark control connection 675X1
7 Sealing bar heating connection 151X1
8 Print mark control connection 675X5 Fig. 3-29 1 Compressed air supply connection
9 Configuration plug connection Option 716X1 2 Air release valve
10 Splice detector connection 677X1
3.) Switch on the customer’s compressed air supply.
11 USB connection USB
4.) Switch on the compressed air at the machine.
To do this, push the air release valve (2) in the
direction of flow, see arrow. (Fig. 3-29)

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5.) Read the air pressure off the pressure gauge (1).
Permissible operating pressure: 5 to 7 bar
(Fig. 3-30)
6.) To adjust the operating pressure, open the
1
shutter covering the pressure reducer (2).
(Fig. 3-30)

2
1
3

4
Fig. 3-31 Pressure reducer with air filter

1 Air pressure: Adjusting screw

2 Pressure gauge
3 Container with air filter
2 4 Condensate drain, fully automatic

Fig. 3-30 1 Operating pressure pressure gauge

2 Pressure reducer with air filter

7.) Lift the adjusting screw (1) and rotate until an

operating pressure of 5 to 7 bar is displayed on
the pressure gauge (2). (Fig. 3-31)
8.) Push the adjusting screw (1) back down.
(Fig. 3-31)

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3.9 Setting the distance between the
discharge plate and the separator

ATTENTION: Machine damage due to the

discharge plate colliding with the separator
If the gap between the discharge plate and the
separator is too small, they will collide during
operation. 1
• Calculate the required distance when the
separator is in the outermost spreading position.

1.) Raise protective grating A.

2.) Raise protective shutter B.
Fig. 3-33 1 Plate

4.) Swing the clip head (1) to the side. (Fig. 3-34)

B
1
Fig. 3-34 1 Clip head, swung to the side

Fig. 3-32 A: Protective grating

B: Protective shutter

3.) Remove the plate (1). (Fig. 3-33)

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5.) Open the locks (1) using the control cabinet key.
(Fig. 3-35)
6.) Open the right side panel (2) on the clip head.

2 20 mm

1
1 Fig. 3-37 1 Discharge plate
2 Separator

9.) To alter the distance, loosen the screw (3), move

the discharge plate (1), then retighten the
screw (3). (Fig. 3-38)

Fig. 3-35 1 Locks

2 Right side panel
1
7.) Put an open-end spanner (46 mm) on the motor
shaft (1). (Fig. 3-36)

1
Fig. 3-38 1 Discharge plate
3 Screw

Fig. 3-36 1 Motor shaft

8.) Turn the machine over using the open-end

spanner until the separator (2) is in the outermost
spreading position. Minimum distance between
the discharge plate (1) and the separator (2):
20 mm. (Fig. 3-37)

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10.) Reinsert the plate (1). (Fig. 3-39)

Fig. 3-39 1 Plate

11.) Close the right side panel (2) on the clip head.
(Fig. 3-35)
12.) Lock the locks (1). (Fig. 3-35)

CAUTION: Risk of crushing when

swinging the clip head into the working
position
There are several places around the clip head where
fingers could get crushed as the clip head is swung
into the working position.
• Before swinging the clip head in, make sure
nobody is in the swing area.
• Only one person at a time may work in the vicinity
of the clip head.

13.) Check that nobody is in the swing area of the clip

head, then swing the clip head into the working
position.
14.) Remove all tools from the vicinity of the machine.
15.) Close protective grating A.
16.) Close protective shutter B.

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Installation of the machine

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4 Indicators and controls 6 “T” button: Sealing manual
When this button is pressed, a complete sealing
4.1 Control panel procedure is performed.
7 Stuffer manual
First function: When this button is pressed, the
stuffer receives a stuffing signal until the button is
released.
Second function: Clip signal display
1 8 Two-hand button (two-hand operation)
First function: Place first clip:
The two-hand button and the “First Clip” button (3)
must be pressed simultaneously within 0.5 seconds.
Second function: Jog mode

2 3 4 5 6 7
Fig. 4-1 Control panel

1 Touch panel
Fig. 4-2 8 Two-hand button
2 Emergency Stop pushbutton
3 “First Clip” button (two-hand operation) Jog mode:
First function: Place first clip: With open safety circuit, the machine cycle step can
The “first clip” button and the two-hand button (8) be operated forwards or backwards in jog mode.
must be pressed and held simultaneously within Forwards: Simultaneously press the two-hand
0.5 seconds. This button combination also brings button (8) and the Jog mode forwards button on
the machine into the home position. the display:
Second function: Jog mode forwards (only with
open safety circuit)
To do this, press the “First Clip” button and the
two-hand button (8) simultaneously.
Third function: Acknowledge messages.
To do this, press the “First Clip” button.
4 Automatic On button Backwards: Simultaneously press the two-hand
button (8) and the Jog mode backwards button on
First function: Start automatic mode
the display:
Second function: Jog mode backwards (only with
open safety circuit)
To do this, press the Automatic On button and the
two-hand button (8) simultaneously.
Third function: Indicator light, green
5 Automatic Off button
• The machine will stop immediately if one of the
First function: Automatic Off buttons is released.
Second function: Indicator light, red
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4.1.1 Sealing station and film transport
adjustment controls

1
3

2
5 Fig. 4-4 Ball valve for cooling air for seal seam
(infinitely variable), here: transverse to
the direction of flow (off)

4 • Ball valve transverse to the direction of flow:

7 Cooling air for seal seam off
• Ball valve in the direction of flow:
Cooling air for seal seam on
6

8
9
10 11

Fig. 4-3

No. Use: Marking

1 Seal seam cooling air regulator
2 Seal pressure pressure regulator
3 Seal pressure pressure gauge
4 Film drive pressure regulator
(optional)
5 Film drive pressure gauge
(optional)
6 Clip mark control connection 675X1
7 Sealing bar heating connection 151X1
8 Print mark control connection 675X5
9 Configuration plug connection Option
716X1
10 Splice detector connection 677X1
11 USB connection USB

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4.2 Main switch, air release valve and 4.3 Pressure gauge and pressure
compressed air supply reducer with filter
connection The pressure gauge and pressure reducer are behind
The main switch, the air release valve and the a shutter:
compressed air supply connection are behind a
cover (1). (Fig. 4-5)

Fig. 4-5 1 Cover

1

2 3
1 2

Fig. 4-6 1 Compressed air supply connection Fig. 4-7 1 Operating pressure pressure gauge
2 Air release valve 2 Pressure reducer with air filter
3 Main switch
4 Five-core connecting cable

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4.4 Easy-Touch display 4.5 Program structure and
Once the machine is switched on, the integrated
passwords
program menu is activated and the following screen The program is divided into 2 menu levels for different
shown, for example, is displayed: user activities.
1 Operator menu level (grey, password 1111)
2 Supervisor menu level (blue, password 7419)

4.5.1 Changing the menu level

- In the basic selection screen, press the Key icon
selection button (see 1, Fig. 4-8).
The password input and icon selection screen
for the currently active menu level will be
displayed (see Fig. 4-9).
- Press the password input field (see 1, Fig. 4-9).
The keyboard for entering the password will be
displayed (see Fig. 4-10).

1
Fig. 4-8 Basic selection screen of the Operator
menu level 1
1 Key icon selection button
If the menu screen is not touched for 10 minutes, the
Operator menu level will be logged on.

- The icons and number fields displayed in a menu

screen serve as visual selection, input, display or
function buttons.
- To select or execute a function, touch the
corresponding icon button.

Fig. 4-9 Password input and icon selection

screen (here: Operator menu level)
1 Password input field

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4.6 Basic selection screens of the
Operator and Supervisor menu
levels
The basic selection screen consists of 4 areas
(see 1-4, Fig. 4-11).
1 4.6.1 Design of the basic selection screens
2
3 1

Fig. 4-10 1 Quit without saving

2 Clear input
3 Save and quit keyboard 2
- Enter the password for the desired menu level (for
passwords, see section 4.5).
The corresponding basic selection screen
appears.

Fig. 4-11 Basic selection screen of the Operator

menu level
1 Display: Current message
2 Icon selection buttons for selecting the
appropriate menu screens for setting the
functional parameters of the machine and
additional (optional) equipment
•Only the icon selection buttons for the additional
equipment installed and functional parameters
configured in the Supervisor menu level to be
visible in the Operator menu level will be
displayed!
•For meanings of icon selection buttons,
see 4.6.5
3 Menu bar, see section 4.6.6
4 Manual function buttons: Manual machine
functions (see section 4.6.9)
5 Scroll to basic selection screen, part 2

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4.6.2 Operating modes/Operating status 4.6.3 Navigation using the quick-selection
display buttons
The quick-selection buttons allow you to switch
directly between the settings screens for the stuffer
coupling, the speed, the length stop, the separator
hole/the clip pressure and the clip mark.

Icon Meaning / Function

1 2 3 4 - Quick-selection button to go to the
Fig. 4-12 Clip module operating mode display stuffer coupling screen
(see section 4.8.3)
1 Display: Current machine rotation angle
2 Display: Clipping process mode set (here: - Quick-selection button to go to the
Spreading) speed screen
3 Display: Portions per minute (see section 4.8.4)
4 Display: Portion runtime in ms - Quick-selection button to go to the
length stop screen
(see section 4.8.5)
- Only visible if the length stop option
is activated.
- Quick-selection button to go to the
separator hole, clip pressure,
spreading screen
1 2 3 4 (see section 4.8.9)
Fig. 4-13 TSA area operating mode display - Quick-selection button to go to the
clip mark screen (see section 4.8.6)
1 Actual value display: Film speed (measured at the
- Only visible if the clip mark option is
film counter)
activated.
2 Actual value display: Portion length
- Quick-selection button to go to the
3 Actual value display: Sealing bar temperature filling device (see section 4.8.8)
4 Actual value display: Film drive speed - Only visible if the filling device option
Only available if the option is installed. is activated.
- Quick-selection button to go to the
HDP screen (see section 4.8.7)
- Only visible if the HDP option is
activated.

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4.6.4 Navigation in the basic selection 4.6.4.1 The following icons may appear
screens and the screens for functional together with functional parameters
parameters •Cam On:
Switch on at this rotation angle position
•Rectangular buttons are always for
switching between screens and will
•Cam Off:
take you to further settings (see icon
Switch off at this rotation angle position
selection buttons 4.6.5).

•Round buttons are always assigned •Displays and input fields marked with a
with machine functions rotation angle icon always relate to
(see section 4.6.9). position settings.

•Switch-on delay:
Time by which switch-on is delayed

•Switch-off delay:
Time by which switch-off should be
delayed

•Time On:
How long something is switched on

•Time Off:
How long something is switched off

•Displays and input fields marked with a

stopwatch always relate to time settings.

•Displays and input fields marked with a

counter always relate to counter
settings.

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4.6.5 Meaning and function of icon Icon Meaning / Function
selection buttons
• Note
Which icon selection buttons you can see depends on Spray system (optional)
the respective machine configuration and the optional
equipment installed as well as whether the icon
selection buttons were set in the Supervisor menu
level to be visible in the Operator menu level or not.

- Film drive (optional)

Icon Meaning / Function

- Recipe
- Discharge tray (optional)

- Stuffer coupling
Selection of the type of
Stuffer-TSCA signal
exchange - RFID

- Knife counter
- Operating mode upon film
end - Product counter

- Clip size
- Sealing bar - Die size
- Stuffing horn
- Calibre
- Portion weight

- Sealing bar heating

- Printer

- HDP (optional)
- TSA drives

- Filling device
- Browse through basic
selection screens, forwards

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Icon Meaning / Function 4.6.6 Menu bar

The menu bar (see Fig. 4-14) is displayed in each

- Browse through basic screen.
selection screens,
backwards

1 2 3 4 5

Fig. 4-14 Menu bar, top: Operator menu level

Menu bar, bottom: Supervisor menu level
1 Home button: Press to go to the basic selection
screen of whichever menu level you are logged
into
2 Back button
Function 1: Scroll to last selected screen
Function 2: If, for example, one of the operating
modes Recipe management, Tool change or
Manual lubricationwas previously selected and
not ended, then the Back button will take you to
the operating mode that is still active rather than
the last screen
3 Operating Manual: Jumps to the relevant place in
the Operating Manual
4 Key
icon selection button Function 1: Press to go to
the password input and icon selection screen
Function 2: Display of the menu level currently
logged on
5 Message icon and icon selection button: Error
message display

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4.6.7 Password input and icon selection 4.6.8 Current messages
screen in the Operator menu level
1

1 3

4 5 6 7
2 3 4 5 6
8

9
8 Fig. 4-16 Current messages in the
Fig. 4-15 Password input and Operator menu level
icon selection screen in the 1 Display: Current message
Operator menu level 2 Blue: Currently selected message
1 Password input field 3 Older messages
2 Icon selection button: Language selection 4 Show details regarding currently selected
3 Icon selection button: Display service information message
4 Icon selection button: Lubricate TSCA 5 Scroll up
Takes you to Fig. 4-24 6 Acknowledge messages that are no longer
5 Icon selection button: Clean screen pending
6 Icon selection button: Lubricate HDP 7 Scroll down
Takes you to Fig. 4-27 8 Menu bar, see section 4.6.6
7 Menu bar, see section 4.6.6 9 Manual function buttons: Manual machine
8 Manual function buttons: Manual machine functions (see section 4.6.9)
functions (see section 4.6.9)

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4.6.9 Manual function buttons Icon Meaning / Function

The manual function buttons are assigned with

manual machine functions. Configuration of the
manual function buttons depends on the machine - Button lit green: Function is
configuration and is carried out by Poly-clip Service switched on
technicians in accordance with your specifications.
Up to 4 rows can be assigned with manual function
buttons. An overview of the icons and functions of the
manual function buttons can be found in section
4.6.9.2. - Button is greyed out and lit green:
Function is switched on and
blocked for operation

1 2
Fig. 4-17 Example:
Manual function buttons, row 1
1 Switch to next row of function buttons
2 Manual function buttons

4.6.9.1 Statuses of the function buttons

Icon Meaning / Function

- Function is switched off

- Button is greyed out: Function is

switched off and blocked for
operation

- Button flashing green: The

function has been switched on.
The function is preparing the
operation. As soon as the button
stops flashing green and is lit, the
function is switched on.

- Button is greyed out and flashing

green: Function is switched on
and blocked for operation

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4.6.9.2 Overview: Manual function buttons 4.6.10 Tool change screen
The screen can only be called up if the machine is in
Icon Meaning / Function the home position. Tool change is a separate
operating mode. The machine cannot be used for
production while this operating mode is active.

- Switch to next row of function

buttons

- Sealing bar heating On/Off

Button framed in green: Heating
is on and target temperature has
5 6 7
been reached
Button flashing green: Warming
1
up

- Spray system, manual (optional)

4
2 8
3
- Call up the
“Tool change” 9
screen (only possible in home
position)

Fig. 4-18 Tool change screen

- Read in RFID data
Machine is in home position
1 Display: Current machine rotation angle
2 Display: Clip stick left and right
3 Display: Die
4 Press the button to move the machine into the
- Jog mode forwards (only with home position;
open safety circuit) If the button is lit up green, the machine is already
in the home position.
5 Press the button to move the machine into the
clip loading position. You will be taken
to Fig. 4-19.
- Jog mode backwards (only with 6 Press the button to move the machine into the die
open safety circuit) change position. You will be taken to Fig. 4-20.
7 Press the button to move the machine into the
punch change position. You will be taken
to Fig. 4-21.
8 Press button to read the RFID data
9 Exit screen

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Fig. 4-19 Tool change screen Fig. 4-21 Tool change screen
Machine is in clip loading position Machine is in punch change position

Fig. 4-20 Tool change screen

Machine is in die change position

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4.7 Settings in the password input 4.7.2 Display service information
screen
4.7.1 Set language

1
1 2 3
A 2
34
4
5
6

6 7 B
5

8
7
Fig. 4-23 Service information
1 Display: Serial number
Fig. 4-22 Language settings
2 Software version of safety modules
A Language set in the machine control system,
language of error messages 3 Display: Name of PLC software
1 Language selection field: Display of the currently 4 Display: Version date of PLC software
active language in German 5 Display: Name of visualisation software
2 Language selection field: Display of the currently 6 Display: Version date of visualisation software
active language in English 7 Icon selection button for Display service
3 Language selection field: Display of the currently information:
active language in the respective local language If the icon selection button is grey, you are
4 Drop-down menu: Press to open the list of already in this screen
available languages
B Language of Operating Manual
5 Language selection field: Display of the currently
active language in German
6 Language selection field: Display of the currently
active language in English
7 Language selection field: Display of the currently
active language in the respective local language
8 Icon selection button for language selection:
If the icon selection button is grey, you are
already in the language selection screen

Indicators and controls

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4.7.3 Lubricate TSCA 4.7.3.1 Meaning of icons

Icon Meaning / Function

1 5 - According to day counter

- According to product
counter (clips placed)
2 6
- According to day counter
3 7 and according to product
counter (whichever is the
earliest)
4 8

9
Fig. 4-24 Lubricate TSCA
1 Display: When the number of clips displayed here
(here: 90000 clips) have been placed, a message
appears. If the message is pressed, the image
sequence for manual lubrication appears.
2 Display: Number of clips already placed (here:
36 pcs)
3 Lubrication interval according to product counter
(clips placed). For meanings of icons,
see section 4.7.3.1.
4 Button for calling up the image sequence for
manual lubrication. See section 4.7.3.2.
5 Display: When the time period displayed here
(here: 365 days) has elapsed, a message
appears. If the message is pressed, the image
sequence for manual lubrication appears.
6 Display: Time already elapsed (here: 5 days)
7 Lubrication intervals according to day counter.
For meanings of icons, see section 4.7.3.1.
8 Button for calling up the image sequence for
manual lubrication. See section 4.7.3.2.
9 Icon selection button for Lubricate TSCA:
If the icon selection button is grey, you are
already in the lubrication screen
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4.7.3.2 Button for calling up the image 4.7.4 Clean screen
sequence for manual lubrication

The image below shows one of the lubrication points:

3 2
1

Fig. 4-26 Clean screen screen

Fig. 4-25
1 Progress bar
1 Lubrication point
When the Clean screen icon button is pressed, the
2 Call up next lubrication point screen is locked for a specific period of time and can
3 Pressing this button confirms that all lubrication be cleaned. The progress bar indicates how long the
have been lubricated. screen has been/will remain locked for. While the
Clean screen screen is active, the First Clip and
Automatic On buttons are locked.
ATTENTION: Machine damage due to inadequate • Note
lubrication If you want to end screen locking, release the
Inadequate lubrication will damage the machine. Emergency Stop pushbutton (by pulling it). You may
need to press the Emergency Stop button first and
• In the image sequence for manual lubrication, then release it.
always call up and lubricate one lubrication point
after the other using button 2! (Fig. 4-25)
• Only press button 3 when all lubrication points
have been lubricated.

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4.7.5 Lubricate HDP 4.7.5.1 Meaning of icons

Icon Meaning / Function

1 5 - According to day counter

- According to product
2 6 counter (strokes performed)

- According to day counter

3 7 and according to product
counter (whichever is the
earliest)
4 8

9
Fig. 4-27 Lubricate HDP
1 Display: When the number of strokes displayed
here (here: 90000 strokes) has been performed, a
message appears. If the message is pressed, the
image sequence for manual lubrication appears.
2 Display: Number of strokes already performed
(here: 1 stroke)
3 Lubrication interval according to product counter
(strokes performed). For meanings of icons,
see section 4.7.5.1.
4 Button for calling up the image sequence for
manual lubrication. See Section 4.7.3.2
5 Display: When the time period displayed here
(here: 30 days) has elapsed, a message appears.
If the message is pressed, the image sequence
for manual lubrication appears.
6 Display: Time already elapsed (here: 1 day)
7 Lubrication intervals according to day counter.
For meanings of icons, see section 4.7.5.1.
8 Button for calling up the image sequence for
manual lubrication. See Section 4.7.3.2
9 Icon selection button for Lubricate HDP:
If the icon selection button is grey, you are
already in the lubrication screen

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4.8 Parameter settings in the • Note
Operator menu level The machine always stores the last used function
parameter settings. If, for example, a recipe was
4.8.1 Load recipe loaded and then later on, individual function
parameters for it were changed it, the machine stores
these latest function parameter settings. If the
1 2 machine is then switched off and on again, these last
used function parameter settings will be in the
machine control system. The last loaded recipe and
the last used function parameter settings may
therefore differ!

4.8.2 View recipe data

3
2
4
5 1
6 7

3
Fig. 4-28 Recipe management
1 Display: Name of the last loaded recipe
• Note
The name of the last loaded recipe is also always
shown in the basic selection screen on the left.
2 Close recipe management
If recipe management is not closed using this
button, the back arrow will keep taking you back Fig. 4-29 Recipe management: Recipe data
to recipe management and no values can be set.
1 Buttons for browsing up and down in order to
3 Recipe selection select a recipe
4 Buttons for browsing up and down in order to 2 Close recipe management
select a recipe
3 View recipe data in the selected recipe:
5 Load the recipe selected in position 3 If the icon selection button is grey, you are
6 Recipe management screen: already in this screen
If the icon selection button is grey, you are
already in this screen
7 View recipe data in the selected recipe (takes you
to Fig. 4-29)

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4.8.3 Stuffer coupling 4.8.3.1 Clipping process control

Icon Meaning

Clipping machine controls stuffer

1 2 Length stop

3
Clip mark
4

5 6 HDP controls clipping machine

Filling device controls clipping

machine

Fig. 4-30 Change values (+)

Change values (-)
1 Target value input field: Machine rotation angle
position at which the stuffer should start
2 Display: Clipping process control (here: Clipping
machine controls stuffer)
3 Switch button: Change clipping process mode
(for available clipping process modes, see table
in section 4.8.3.1)
4 Target value input field: Stuffer delay
5 Target value input field: Clip pulse delay
6 Target value input field: Spreading

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4.8.4 Speed 4.8.5 Length stop (optional)

1 2 1
2

Fig. 4-31 Change values (+) Fig. 4-32 Change values (+)
Change values (-) Change values (-)
1 Speed limit display 1 Actual value display: Portion length in mm
The maximum machine speed depends on 2 Target value input field: Portion length in mm
various factors, such as the type of clip used and (after XXXX mm, the clipping process is triggered/
the overspreading set, and is dynamic. the clip pulse is sent)
Green bar: Machine speed is up to 70% of the
maximum speed
Orange bar: Machine speed is between 70% and
90% of the maximum speed
Red bar: Machine speed is between 90% and
100% of the maximum speed
2 Target value input field: Machine rotation angle
position at which the knife should cut
Adjustment range: Factory setting

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4.8.6 Clip mark (optional) 4.8.7 HDP (optional)

1 3
2 1
4

Fig. 4-33 Change values (+) Fig. 4-34 Change values (+)
Change values (-) Change values (-)
1 Actual value display: film pulled off in mm 1 Target value input field: Number of strokes after
2 Target value input field: Blocks evaluation of clip which the clip pulse is sent
mark for the set length (mm).
This prevents, for example, a logo that is the
same colour as the clip mark from triggering the
clip pulse.
3 Target value input field: Distance between clip
marks (portion length in mm)
4 Target value input field: Overrun in mm after clip
mark is detected (stuffer overrun)

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4.8.8 Filling device (optional) 4.8.9 Separator hole, clip pressure,
spreading

1 2
1
4
3
5
6 7

Fig. 4-35 Change values (+)

Change values (-) Fig. 4-36 Change values (+)
1 Target value input field: Number of strokes after Change values (-)
which the clip pulse is sent 1 Target value input field: Clip pressure
2 Target value input field: Separator hole
3 Target value input field: Spreading
4 Overspreading (optional)
On, green/Off, red
5 Press the button to test the overspreading.
Only available if the option is installed and
switched on.
6 Target value input field: Switch on overspreading
at this rotation angle position
7 Target value input field: Switch off overspreading
at this rotation angle position

Note: If values in the input fields of this screen are

changed, a message screen appears. The operator
should check the settings in the screen and
acknowledge them if they are correct.
See section 4.8.10.

Indicators and controls

4-22 EN/09-2017
 Poly-clip System GmbH & Co. KG TSCA 65 D
4.8.10 06500 Check clip transport/Separator 5 Target value input field: Separator hole
hole/Clip height/Spreading message This value is either entered by the operator or
loaded from the recipe.
screen

ATTENTION: Machine damage due to

incompatible settings
If the clip, die, punch, spreading and discharge plate
1 4 are not coordinated with one another, the machine
may get damaged!
3 • Do not acknowledge settings until you have
ensured that the settings are compatible with one
2 5 another.

6 6 Actual value display: Distance between separator

10 7 and discharge plate
8 7 Question mark: Indicates there may be a
difference between the target and the actual
value. The operator must check the settings and
11 9 then acknowledge by pressing the question mark
button. Once it has been pressed, the question
mark button changes to a green tick.
8 Actual value display: Spreading
9 Target value input field: Spreading
10 Actual value display: Die width
11 Target value input field: Die width
Fig. 4-37 06500 Check clip transport/Separator
hole/Clip height/Spreading message
screen
Change values (+)
Change values (-)

Icon Meaning

Operator requirement: The operator

must check the settings.

If the actual value matches the target

value, the question mark automatically
changes into a green tick.

1 Actual value display: Clip pressure

2 Target value input field: Clip pressure
This value is either entered by the operator or
loaded from the recipe.
3 Tick: Indicates there is no difference between the
target and the actual value.
4 Actual value display: Separator hole

Indicators and controls

EN/09-2017 4-23
 Poly-clip System GmbH & Co. KG TSCA 65 D
4.8.11 Knife, film end
Operating modes upon film end
Icon Meaning
- When the film end is
detected, the portion is
still stuffed to the end
and the clip is placed.
- When the film end is
1 2 3 detected, the portion is
not stuffed to the end
and instead the clip is
placed immediately.
- When the film end is
detected, the machine
stops immediately and
no clip is placed.

4
5

Fig. 4-38 Change values (+)

Change values (-)
1 Target value input field: Knife counter
Number of portions after which the knife cuts
(used for producing sausage chains)
2 Target value input field: Cutting process counter;
Number of cutting processes after which the
machine should switch to Automatic Off
3 Actual value display: cutting processes already
performed; Press button to reset counter to 0
4 Film end: Operating mode upon film end
5 Switch button: Change operating mode upon film
end

Indicators and controls

4-24 EN/09-2017
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4.8.12 Sealing bar 4.8.13 Sealing bar heating

1 1
2 3
2 3

Fig. 4-39 Change values (+) Fig. 4-40 Change values (+)
Change values (-) Change values (-)
1 Target value input field: Rotation angle position at 1 Actual value display: Heating temperature in
which the sealing bar should begin to be lowered degrees Celsius
2 Target value input field: Period of time for moving 2 Target value input field: Heating temperature in
counter support up degrees Celsius
3 Target value input field: Sealing time 3 Input field: Permissible deviation from the target
value in degrees Celsius

Indicators and controls

EN/09-2017 4-25
 Poly-clip System GmbH & Co. KG TSCA 65 D
4.8.14 HDP 4.8.14.1 HDP 30
Pressing the icon selection button shown below takes
to you to the HDP screens. The screens you are taken
to look different depending on the type of HDP
installed.
See section 4.8.14.1 for HDP 30 and section 4.8.14.2
for HDP 40 and HDP 50.
1

Fig. 4-41 HDP icon selection button

2
Various operating status parameters are displayed at
the top of the HDP screens:
3 4
5 6

1 2 3 4
Fig. 4-42
1 Actual value display: Film speed (measured at the
film counter) Fig. 4-43 HDP 30, page 1
2 Actual value display: Portion length Change values (+)
3 Actual value display: Sealing bar temperature Change values (-)
4 Actual value display: Film drive speed 1 For meanings of displays, see section 4.8.14
Only available if the option is installed. 2 Target value input field: Dosing cylinder early start
in ms, before the rotary cylinder has reached the
working position
3 Target value input field: Delay in ms before the
dosing cylinder indicates “Level full”
4 Target value input field: Delay in ms before the
dosing cylinder indicates “Level empty”
5 Icon selection button:
If the icon selection button is grey, you are
already in this screen
6 Icon selection buttons:
Open other pages of the screen

Indicators and controls

4-26 EN/09-2017
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Important note regarding input fields 6 and 7:
If specific times are entered in input fields 6 and 7, the
filling device must work against any pressure that may
be generated. If the filling device is not suitable for
this, the value in input fields 6 and 7 must be left at 0,
1 otherwise the filling device will be damaged.

6 Target value input field: Filling device early start in

2 4 ms
Value 0: No early start. The filling device will not
3 5 be started until the rotary cylinder has reached
the home position.
6 7 Value other than 0: The filling device is started
before the rotary cylinder has reached the
working position.
7 Target value input field: Filling device overrun
8 time in ms
Value 0: No overrun time. The filling device stops
9 10 when the dosing cylinder indicates “Level full”.
10 Value other than 0: The filling device continues to
run even though the dosing cylinder has indicated
“Level full”.
8 Target value input field: HAG hydraulic unit
overrun time after Automatic Off in ms;
Only available if an HAG hydraulic unit from
Poly-clip System is installed.
9 Icon selection button:
Fig. 4-44 HDP 30, page 3: with filling device If the icon selection button is grey, you are
Change values (+) already in this screen
Change values (-)
10 Icon selection buttons:
1 For meanings of displays, see section 4.8.14 Open other pages of the screen
2 Size of dosing cylinder used: here, 250-700 ml
3 Switch button: Select a different size for the
dosing cylinder
4 Type of dosing: here, filling device fills dosing
cylinder
5 Switch button: Select a different type of dosing

Indicators and controls

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 Poly-clip System GmbH & Co. KG TSCA 65 D

1 1

2 4
3 5
2 3

6 4 5
7 8 7
8 7

Fig. 4-45 HDP 30, page 3: with FP drum press Fig. 4-46 HDP 30, page 4
Change values (+) 1 For meanings of displays, see section 4.8.14
Change values (-)
2 Move dosing cylinder manually towards working
1 For meanings of displays, see section 4.8.14 position. The movement stops when the button is
2 Size of dosing cylinder used: here, 250-700 ml released.
3 Switch button: Select a different size for the 3 Move dosing cylinder manually towards the home
dosing cylinder position. The movement stops when the button is
4 Type of dosing: here, FP drum press fills dosing released.
cylinder 4 Move rotary cylinder manually towards working
5 Switch button: Select a different type of dosing position. The movement stops when the button is
released.
6 Target value input field: HAG hydraulic unit
overrun time after Automatic Off in ms; 5 Move rotary cylinder manually towards home
Only available if an HAG hydraulic unit from position. The movement stops when the button is
Poly-clip System is installed. released.
7 Icon selection button: 6 Icon selection button:
If the icon selection button is grey, you are If the icon selection button is grey, you are
already in this screen already in this screen
8 Icon selection buttons: 7 Icon selection buttons:
Open other pages of the screen Open other pages of the screen

Indicators and controls

4-28 EN/09-2017
 Poly-clip System GmbH & Co. KG TSCA 65 D

2 3

4 5

6
8 8 7

Fig. 4-47 HDP 30, page 5

1 For meanings of displays, see section 4.8.14
Points 2 to 6 are actual value displays:
2 Period of time: Move rotary cylinder from working
position into home position
3 Period of time: Move rotary cylinder from home
position into working position
4 Period of time: Move dosing cylinder from
working position into home position
5 Period of time: Move dosing cylinder from home
position into working position
6 Period of time: Period of time until the dosing
cylinder indicates “Level full”
7 Icon selection button:
If the icon selection button is grey, you are
already in this screen
8 Icon selection buttons:
Open other pages of the screen

Indicators and controls

EN/09-2017 4-29
 Poly-clip System GmbH & Co. KG TSCA 65 D
4.8.14.2 HDP 40 and HDP 50 9 Icon selection buttons:
Open other pages of the screen

1
1
2 3
2 3

4 5
4 6
5
8
6 7 7
8 9 9
10
10

Fig. 4-48 HDP 40/50, page 1

Change values (+) Fig. 4-49 HDP 40/50, page 2
Change values (-) Change values (+)
1 For meanings of displays, see section 4.8.14 Change values (-)
Note regarding fields 2 and 3: 1 For meanings of displays, see section 4.8.14
If the values in fields 2 and 3 are changed, the dosing 2 Target value input field: Maximum permissible
volume is electrically adjusted once the machine is in deviation between ACTUAL film length value and
automatic mode. TARGET film length value in mm (film break
2 Target value input field: 5Portion dosing volume control)
in ml 3 Target value input field: Portion calibre in mm.
3 Target value input field: Dosing volume correction The calibre must be entered precisely for the “film
value to achieve a precise portion weight; Only break control” to work.
available if scales (optional) are installed. 4 Actual value display: film pulled off in mm
4 Target value input field: HDP speed in % 5 Target value input field: Blocks evaluation of clip
5 Target value input field: Dosing cylinder early start mark for the set length (mm). This prevents, for
in ms, before the rotary cylinder has reached the example, a logo that is the same colour as the clip
working position mark from triggering the clip pulse.
6 Target value input field: Delay in ms before the 6 Target value input field: Distance between clip
dosing cylinder indicates “Level full” marks (portion length in mm)
7 Target value input field: Delay in ms before the 7 Target value input field: Overrun in mm after clip
dosing cylinder indicates “Level empty” mark is detected (stuffer overrun)
8 Icon selection button: 8 Switch clip mark (optional) on/off depending on
If the icon selection button is grey, you are receipt
already in this screen On, green/Off, red

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4-30 EN/09-2017
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9 Icon selection button: Important note regarding input fields 6 and 7:
If the icon selection button is grey, you are If specific times are entered in input fields 6 and 7, the
already in this screen filling device must work against any pressure that may
10 Icon selection buttons: be generated. If the filling device is not suitable for
Open other pages of the screen this, the value in input fields 6 and 7 must be left at 0,
otherwise the filling device will be damaged.

6 Target value input field: Filling device early start in

ms
Value 0: No early start. The filling device will not
be started until the rotary cylinder has reached
1 the home position.
Value other than 0: The filling device is started
before the rotary cylinder has reached the
2 4 working position.

3 5 7 Target value input field: Filling device overrun

time in ms
6 7 Value 0: No overrun time. The filling device stops
when the dosing cylinder indicates “Level full”.
Value other than 0: The filling device continues to
run even though the dosing cylinder has indicated
8 “Level full”.
8 Target value input field: HAG hydraulic unit
9 10
overrun time after Automatic Off in ms;
10 Only available if an HAG hydraulic unit from
Poly-clip System is installed.
9 Icon selection button:
If the icon selection button is grey, you are
already in this screen
10 Icon selection buttons:
Open other pages of the screen

Fig. 4-50 HDP 40/50, page 3: with filling device

Change values (+)
Change values (-)
1 For meanings of displays, see section 4.8.14
2 Size of dosing cylinder used: here, 250-700 ml
3 Switch button: Select a different size for the
dosing cylinder
4 Type of dosing: here, filling device fills dosing
cylinder
5 Switch button: Select a different type of dosing

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EN/09-2017 4-31
 Poly-clip System GmbH & Co. KG TSCA 65 D

2 4
3 5

6
7 8
8

Fig. 4-51 HDP 40/50, page 3: with FP drum press

Change values (+)
Change values (-)
1 For meanings of displays, see section 4.8.14
2 Size of dosing cylinder used: here, 250-700 ml
3 Switch button: Select a different size for the
dosing cylinder
4 Type of dosing: here, FP drum press fills dosing
cylinder
5 Switch button: Select a different type of dosing
6 Target value input field: HAG hydraulic unit
overrun time after Automatic Off in ms;
Only available if an HAG hydraulic unit from
Poly-clip System is installed.
7 Icon selection button:
If the icon selection button is grey, you are
already in this screen
8 Icon selection buttons:
Open other pages of the screen

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4-32 EN/09-2017
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6 Actual value displays:
• Dosing cylinder actual position (here 359.9)
• Axis referenced (green)/not referenced (grey);
here the axis is not referenced
7 Move dosing cylinder manually towards working
1 position. The movement stops when the button is
released.
3 4 5 8 Move dosing cylinder manually towards the home
2 position. The movement stops when the button is
released.
9 Actual value displays (only with HDP 50 installed):
6 7 8 • Rotary cylinder actual position (here 359.6)
• Axis referenced (green)/not referenced (grey);
here the axis is not referenced
10 11 10 Move rotary cylinder manually towards working
9 position. The movement stops when the button is
released.
13 13
11 Move rotary cylinder manually towards home
position. The movement stops when the button is
released.
12 12 Icon selection button:
If the icon selection button is grey, you are
already in this screen
13 Icon selection buttons:
Open other pages of the screen
Fig. 4-52 HDP 40/50, page 4
1 For meanings of displays, see section 4.8.14
2 Actual value displays:
• Dosing volume adjustment actual position
(here 3.0)
• Axis referenced (green)/not referenced (grey);
here the axis is referenced
3 Move dosing volume adjustment down manually.
The movement stops when the button is
released.
4 Move dosing volume adjustment up manually.
The movement stops when the button is
released.
5 Press the button to release the brake. The dosing
volume adjustment can now be adjusted
manually at the HDP.

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 Poly-clip System GmbH & Co. KG TSCA 65 D
4.8.15 Spray system (oil sprayers)

2 3
1
4 5
4
2 5
6
8 3 6
7

Fig. 4-53 HDP 40/50, page 5

1 For meanings of displays, see section 4.8.14
Fig. 4-54 Spray system (oil sprayers)
Points 2 to 6 are actual value displays: Change values (+)
2 Period of time: Move rotary cylinder from working Change values (-)
position into home position 1 Target value input field: Duration oil sprayers are
3 Period of time: Move rotary cylinder from home switch on for in ms
position into working position 2 Target value input field: Number of machine
4 Period of time: Move dosing cylinder from cycles between 2 spray pulses (in the setting
working position into home position shown, oil is sprayed after every portion)
5 Period of time: Move dosing cylinder from home 3 Target value input field: Machine rotation angle at
position into working position which the oil sprayer additional equipment should
6 Period of time: Period of time until the dosing be switched on
cylinder indicates “Level full” 4 Pre-separator (optional)
7 Icon selection button: On, green/Off, red
If the icon selection button is grey, you are 5 Press the button to test the pre-separator.
already in this screen Only available if the option is installed and
8 Icon selection buttons: switched on.
Open other pages of the screen 6 Target value input field:
Meaning of field with pre-separator switched off:
Clip pulse delay
Meaning of field with pre-separator switched on:
Period of time for which the pre-separator
remains closed.

Indicators and controls

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4.8.16 Discharge tray (optional) 4.8.17 Read RFID data and transfer it into the
recipe

1 2

1 2

3 4

4 3

Fig. 4-55 Change values (+)

Change values (-) Fig. 4-56 “RFID data match” screen
1 Target value input field for machine rotation 1 Actual value display: Read RFID data
angle: Tilt discharge tray
2 Target value display: RFID data stored in the
2 Target value input field for machine rotation recipe
angle: Return discharge tray
3 Press button to read the RFID data
3 Target value input field: Period of time to tilt the
discharge tray 4 Die width
4 Press the button for tilting the discharge tray: the
discharge tray is tilted and then moves back into The read RFID data (1) should match with the RFID
the home position data of the recipe (2). (Fig. 4-56)
If this is not the case, the icon screen will look
different, see Fig. 4-57.

Indicators and controls

EN/09-2017 4-35
 Poly-clip System GmbH & Co. KG TSCA 65 D

1 2

3
4
5
Fig. 4-58 Password input screen, Supervisor menu
level
- Press button 1 (Fig. 4-58). You will be taken to the
basic selection screen of the Operator menu level,
6 but will remain logged in with the rights of the
Supervisor menu level.
Fig. 4-57 “RFID data do not match” screen - Call up the RFID data screen again. You will be taken
1 Actual value display: Read RFID data to Fig. 4-59.
2 Target value display: RFID data stored in the - Press button 6 (Fig. 4-59). The read RFID data will be
recipe transferred into the recipe.
3 Press button to read the RFID data
4 Die width
5 Press the button to acknowledge the message
6 Key icon selection button

To transfer the read RFID data into the recipe, you

have to call up the icon screen again in the Operator
menu level with the rights of the Supervisor menu
level. Proceed as follows:

- Press the Key icon selection button (see 6,

Fig. 4-57).
- Enter the password for Supervisor menu level.

Indicators and controls

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1 6 2

3
4
7 5

Fig. 4-60 Details regarding the read RFID data

Fig. 4-59 “RFID data do not match” screen, logged

in with “Supervisor” rights
1 Actual value display: Read RFID data
2 Target value display: RFID data stored in the
recipe
3 Press button to read the RFID data
4 Die width
5 Press the button to acknowledge the message.
6 Press the button to transfer the read RFID data
into the recipe.
7 Call up details regarding the read RFID data.
Takes you to Fig. 4-60.

Indicators and controls

EN/09-2017 4-37
 Poly-clip System GmbH & Co. KG TSCA 65 D
4.8.18 Product counters 4.8.19 Portion weight, calibre, stuffing horn
diameter

1
3
1
2 4 3
2
4
5 6 5

Fig. 4-61
1 Reset the portion counter to zero Fig. 4-62
2 Portion counter 1 Clip size of the last loaded recipe or entered value
3 Reset the chain counter to zero 2 Die type of the last loaded recipe or entered value
4 Chain counter 3 Stuffing horn diameter
5 Counter for all executed clip cycles 4 Portion weight
6 Portions per minute 5 Calibre

Indicators and controls

4-38 EN/09-2017
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4.8.20 Printer (optional) 2 Switch button: Switch between printer settings
3 Actual value display: Amount of film in mm that
has been pulled off since the print mark was
detected
4 Target value input field: Delay between detection
of print mark and print pulse (1st print field)
5 Target value input field: Delay between detection
of print mark and print pulse (2nd print field, for
especially long portions)
If the second print field is not being used, enter
1 the value 0.
3 2 6 Target value input field: Distance between print
marks
4 7 7 Length of the print pulse of the TSCA to the
printer in ms

5 6

Fig. 4-63 Change values (+)

Change values (-)

1 Display: Selected printer setting

Available printer settings

Icon Meaning / Function

- Printer Off

- Printer On

- Random printing

- Print mark

Indicators and controls

EN/09-2017 4-39
 Poly-clip System GmbH & Co. KG TSCA 65 D
4.8.21 TSA drives 4.8.22 Drive overview, part 1

1 2 3
4

Fig. 4-65 Drive overview

Settings for the respective drive

Fig. 4-64 Drive selection

1 Master axis
2 Film drive left
3 Film drive right
4 Close window

Indicators and controls

4-40 EN/09-2017
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4.8.23 Film drive (optional) 4.9 Supervisor menu level
4.9.1 Password entry and icon selection
screen

2
1
3 4
2 4
5 3

5 6 7 8 9

Fig. 4-66 Film drive

1 For meanings of displays, see section 4.6.2 Fig. 4-67 Password entry and icon selection mask
2 Switch film drive (optional) on/off in the Supervisor menu level
On, green/Off, red 1 Password input field
3 Target value input field: Period of time in ms until 2 Press to go to the basic selection screen of the
the film drive has reached the working position; Operator menu level (You remain logged in with
During this time, no film is pulled off. the rights of the Supervisor menu level)
4 Target value input field: Target length of film 3 Press to go to the basic selection screen of the
pulled off in mm until the film drive moves apart Supervisor menu level
again 4 Press to go to the basic selection screen of the
5 Target value input field: Speed at which the film is Operator menu level (You are then no longer
pulled off, in m/min logged in with the rights of the Supervisor menu
Note: With manual sealing using button “T”, the level)
movement sequence of the film drive is different than 5 Icon selection button: Language selection
in automatic mode and the value entered in field 4 is Takes you to Fig. 4-22
not used. 6 Icon selection button: Display service information
Takes you to Fig. 4-68
7 Icon selection button: Lubricate TSCA
Takes you to Fig. 4-24
8 Icon selection button: Clean screen
Takes you to Fig. 4-26
9 Icon selection button: Lubricate HDP
Takes you to Fig. 4-27

Indicators and controls

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 Poly-clip System GmbH & Co. KG TSCA 65 D
4.9.2 Display service information 8 Icon selection button for Display service
information:
If the icon selection button is grey, you are
already in this screen

4.9.3 Current messages

1 1

2 2
34
5
76 3

4 5 6 7 8

Fig. 4-69 Current messages in the Supervisor

menu level
1 Display: Current message
2 Blue: Currently selected message
3 Older messages
4 Show details regarding currently selected
message
5 Scroll up
6 Acknowledge messages that are no longer
pending
7 Scroll down
Fig. 4-68 Service information 8 Call up message history
1 Display: Serial number Takes you to Fig. 4-70.
2 Software version of safety modules
3 Display: Name of PLC software
4 Display: Version date of PLC software
5 Display: Name of visualisation software
6 Display: Version date of visualisation software
7 Display: Version of visualisation software

Indicators and controls

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4.9.4 Message history

1
2
6b

6a

3 4 5 6 7

Fig. 4-70 Message history

1 Display: Current message
2 Blue: Currently selected message
3 Scroll one page to the left
4 Jump one page up in the messages
5 Jump one page down in the messages
6 Scroll one page to the right
6a Scroll one page to the right/left
6b Scroll one page up/down
7 Scroll to Export message history screen

Indicators and controls

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 Poly-clip System GmbH & Co. KG TSCA 65 D
4.9.5 Recipe management 4.9.6 Load recipe
1.) Using the selection buttons (4, 5, Fig. 4-71),
select the desired recipe.
1 2 2.) Press Load recipe (6, Fig. 4-71):

Result: The selected recipe is now located in the

4 machine memory.

3 4.9.7 Saving a recipe

5 1.) Using the selection buttons (4, 5, Fig. 4-71),
select a saving location. Remember, all
8 6 parameters present in the saving location will be
overwritten when you save!
9 10 7 2.) Press Recipe name (1, Fig. 4-71).
11 Result: The keyboard appears.
3.) Enter the recipe name and confirm.
4.) Press Save recipe (7, Fig. 4-71):

Fig. 4-71 Recipe management

1 Display of the last loaded recipe/Input of new
The recipe has been saved in the selected
recipe name
saving location. All parameters present in this
2 Close recipe management saving location have been overwritten.
3 Recipe number: Pressing the recipe number
makes the keyboard appear and you can then
enter the desired recipe number
4 Recipe selection
5 Buttons for browsing up and down in order to
select a recipe
6 Load the recipe selected in position 4
7 Save the parameters set as a new recipe in the
selected saving location
ATTENTION: All parameters present in this
saving location will be overwritten!
8 Load the recipe selected in position 4
9 Recipe management screen:
If the icon selection button is grey, you are
already in this screen
10 View recipe data in the selected recipe,
see Fig. 4-29.
11 Scroll to USB screen,
see Fig. 4-72.

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4.9.8 Saving recipe data to a USB stick/ 4.9.9 Portion weight, calibre, stuffing horn
Loading recipe data from a USB stick diameter

1
1
3
2 2
4
5

3 6 7
7
4
5

Fig. 4-73
6 1 Clip size of the last loaded recipe or entered value
2 Die type of the last loaded recipe or entered value
Fig. 4-72 USB
3 Stuffing horn diameter
1 Close recipe management
4 Portion weight
2 Transfer recipes onto a USB stick
5 Calibre
3 Import recipes from a USB stick
6 If the icon selection button
4 Recipe management screen is grey, you are already in this screen
5 View recipe data in the selected recipe 7 Press to go to the Calibre screen, see Fig. 4-85.
6 USB
screen If the icon selection button is grey, you are
already in this screen
7 Progress bar

Indicators and controls

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4.9.10Basic selection screen of the 4.9.11 Basic selection screen of the
Supervisor, part 1 menu level Supervisor, part 2 menu level

1 2 3 9 10

11
4
8
5 12 14
7 6 13

Fig. 4-74
1 Press to go to the display of the address screen Fig. 4-75
of 9 Press to go to the WS Food screen
Poly-clip System Deutschland (see Fig. 4-76) (section 4.9.24)
2 Pressing this button takes you to the Set rotation 10 Press to go to the Film counter screen
angle for machine functions and additional (section 4.9.25)
equipment 11 Press to go to the HDP speed/ramp profile screen
screen (see Fig. 4-77) (section 4.9.26)
3 Pressing this key takes you to the Interface 12 Press to go to the Set date/time screen
configuration for the Operator menu level (section 4.9.28)
interface (see section 4.9.14)
13 Press to go to the Calibrate touchpanel screen
4 Press to go to the Inputs/Outputs screen (from (section 4.9.29)
section 4.9.15)
14 Press to go to the Call up wiring diagrams screen
5 Press to go to the Calibre screen (section 4.9.19) (section 4.9.30)
6 Press to go to the Addresses of safety
components screen (section 4.9.20)
7 Press to go to the EtherCAT bus screen (from
section 4.9.21)
8 Press to go to the Simulator screen
(section 4.9.23)

Indicators and controls

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4.9.12Poly-clip System Deutschland 4.9.13 Rotation angles for machine functions
address screen

2 3

Fig. 4-77 Rotation angle for machine functions

Change values (+)
Change values (-)
1 Display of the current machine rotation angle
2 Under the green light, the rotation angles for
3 switch-on are displayed and adjusted
3 Under the red light, the rotation angles for
switch-off are displayed and adjusted

Fig. 4-76
1 Poly-clip System Deutschland address
2 Press to go to the address of the national/local
contact partner (see 3)
3 Address of the national/local contact partner

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 Poly-clip System GmbH & Co. KG TSCA 65 D
4.9.14 Screen configuration for the Operator
menu level
1.) In the basic selection screen of the Supervisor
menu level, press the Screen configuration icon
selection button:

The Screen configuration for the Operator menu

level, part 1 screen appears (see Fig. 4-78).
2
1 2

Fig. 4-79 Selection

1 Quit
2 Scroll up/down
The assignment of the icon selection button is
changed.
• Note
If the other parts of the basic selection screen should
not be visible in the Operator menu level, you can
simply switch the arrow buttons to invisible.
If the other parts of the basic selection screen should
remain visible in the Operator menu level, you must
not switch the arrow buttons to invisible!

Fig. 4-78 Screen configuration for the Operator

menu level1Call up screen
configuration, part 2
2 Call up screen configuration, part 3
2.) To change the assignment of an icon selection
button, touch the icon selection button.
A range (Fig. 4-79) of available assignments will
appear.
3.) Touch the desired icon.

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4.9.15 Inputs/Outputs, page 1
In case of error, you may be asked by the Poly-Clip
Hotline to call up one of the following screens
(Fig. 4-80 and Fig. 4-82 to Fig. 4-84).

Fig. 4-81 Module errors

1
4.9.16 Inputs/Outputs, page 2

4
3 2

Fig. 4-80 Inputs/Outputs, page 1

1 Equipment identification of the module
2 Temperature of the module in °C
(temperature display only for safety modules)
3 Status of the module
(Green box means: signal present at the input or
output.)
4 Safety modules (always marked yellow)
5 View Inputs/Outputs, see page 1:
If the icon selection button is grey, you are
Fig. 4-82 Inputs/Outputs, page 2
already in this screen
• Note
Module errors are indicated by a flashing lightning
arrow (Fig. 4-81).

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 Poly-clip System GmbH & Co. KG TSCA 65 D
4.9.17 Inputs/Outputs, page 3 4.9.18 Inputs/Outputs, page 4

2 3

1
4

Fig. 4-83 Inputs/Outputs, page 3; with film drive Fig. 4-84 Inputs/Outputs, page 4
(optional)
1 Frequency converter, clip module
2 Frequency converter, film drive left (optional)
3 Frequency converter, film drive right (optional)
4 RFID

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4.9.19 Calibre 4.9.20 Safety module addresses

1
2 7 1
3 8
2
4 9
5 10
6 11

Fig. 4-85 Calibre Fig. 4-86 Safety module addresses, here, with
1 Target value input field: Calibre HDP (optional)
2 Actual value display: Position during the opening 1 Target address
process of the separator from which the 2 Actual address
separator is open wide enough for the calibre The safety module address status is displayed.
entered to fit through the separator hole Discrepancies between target and actual status will
3 Actual value display: The separator travels render the safety system non-operational.
through the area between positions 2 and 4 at the
speed set in the time [ms] shown here
4 Actual value display: Position during the closing
process of the separator from which the
separator is closed far enough for the calibre to
no longer fit through the separator hole
5 Actual value display: Portions per minute TSCA
6 Actual value display: Speed
7 Target value input field: Machine rotation angle
position at which the stuffer should start
8 Actual value display: Time required by the stuffer
to stuff the calibre entered in position 1
9 Actual value display: Stuffer ends stuffing
10 Actual value display: Portions per minute of the
stuffer (measured on the TSCA)
11 Target value input field: Speed

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4.9.21EtherCAT bus, part 1 4.9.22 EtherCAT bus, part 2

Fig. 4-87 EtherCAT bus connection of bus Fig. 4-88 EtherCAT bus connection of bus
components, part 1: here, with film drive components, part 2
(optional)

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4.9.23 Simulator 4.9.24 WS Food

1 2
3
2 3 4

Fig. 4-89 Change values (+) Fig. 4-90 Change values (+)
Change values (-) Change values (-)
1 Simulator On, green/Off, red 1 Switch WS Food on/off
2 Set stuffing time* On, green/Off, red (here: switched on)
3 Set stuffing pause* 2 WS Food version
* These settings are only displayed when the 3 Customer IP address
simulator is switched on. 4 Port number

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 Poly-clip System GmbH & Co. KG TSCA 65 D
4.9.25 Film counter 4.9.26 HDP speed/ramp profile, page 1

1
2
2
1 2.1 2.2 2.3

3
3.1 3.2 3.3

4 5

Fig. 4-91 Change values (+) Fig. 4-92 HDP speed/ramp profile, page 1
Change values (-) Change values (+)
Change values (-)
“Slip” denotes the deviation from the preset speed. 1 For meanings of displays, see section 4.8.14
2 Speed profile: Move dosing cylinder from home
1 Actual value display: Current slip in mm
position into working position
2 Target value input field: Maximum permissible
Fields 2.1 to 2.3 are actual value input fields:
slip in mm
2.1: Ramp acceleration in %
2.2: Speed in %
2.3: Ramp deceleration in %
3 Speed profile: Move dosing cylinder from working
position into home position
Fields 3.1 to 3.3 are actual value input fields:
3.1: Ramp acceleration in %
3.2: Speed in %
3.3: Ramp deceleration in %
4 Icon selection button:
If the icon selection button is grey, you are
already in this screen
5 Icon selection buttons:
Open other pages of the screen

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4.9.27 HDP speed/ramp profile, page 2 4.9.28Setting the date/time

1
1 2
2
2.1 2.2 2.3
5 4
3
3
3.1 3.2 3.3
4
5

Fig. 4-94 Set date/time screen

Fig. 4-93 HDP speed/ramp profile, page 2
1 Display: Date
Change values (+)
Change values (-) 2 Display: Time
1 For meanings of displays, see section 4.8.14 3 Input field: Date
2 Speed profile: Move rotary cylinder from home 4 Input field: Time
position into working position 5 Load the data entered in positions 3 and 4 into
Fields 2.1 to 2.3 are actual value input fields: the operating system
2.1: Ramp acceleration in %
2.2: Speed in %
2.3: Ramp deceleration in %
3 Speed profile: Move rotary cylinder from working
position into home position
Fields 3.1 to 3.3 are actual value input fields:
3.1: Ramp acceleration in %
3.2: Speed in %
3.3: Ramp deceleration in %
4 Icon selection button:
If the icon selection button is grey, you are
already in this screen
5 Icon selection buttons:
Open other pages of the screen

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 Poly-clip System GmbH & Co. KG TSCA 65 D
4.9.29Calibrating the touchpanel 4.9.30 Call up wiring diagrams

2 3
1
1 4
2

Fig. 4-95 Calibrate touchpanel screen Fig. 4-96 Call up wiring diagrams
1 Start the Calibrate touchpanel function
2 Save and re-start the operating system 1 Call up German wiring diagram TSCA 65 D
2 Call up German wiring diagram HDP
3 Call up English wiring diagram TSCA 65 D
4 Call up English wiring diagram HDP

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4.10 List of possible error messages 04618 Lubrication interval 1
04619 Lubrication interval 2
00001 Reading RFID 04621 Recipe management active
00104 RFID device clip head 04622 Factory settings management active
00105 RFID device die 04623 Data management active
00106 Timeout RFID device clip head 04639 File access error
00107 Timeout RFID device die 04641 Loading recipe
00201 RFID unidentified die 04642 Saving recipe
00202 RFID clip reel missing 04643 Saving all recipes
00203 RFID right and left clips different! 04644 Importing recipes from USB
00204 RFID Clip and die do not match! 04645 Exporting recipes to USB
00208 RFID clip does not match input 04651 Loading factory setting
00210 RFID die does not match input 04652 Saving factory setting
00211 RFID die missing 04653 Exporting factory setting to USB
00219 RFID settings do not match! 04660 Automatically loading factory setting
00221 Fault RFID parameter access 04661 Machine type?
00300 Clip / die changed 04662 CONFIGURATION MODE
03001 Fault emergency stop 04663 CODING SYSTEM CHANGE ACTIVE
03002 Emergency stop 04664 OPERATION COUNTER
03011 Fault safety guard 04931 No home position
03012 Safety guard 04932 Drive blocked
03021 Fault safety swing out 04933 Fault inverter main drive
03022 Safety swing out 04934 Drive overspeed / direction
03051 Fault safety cover left 04935 Writing parameters in inverter main
03052 Safety cover left drive
03101 Fault 2-hand jog forwards 04936 Fault clip drive temperature brake
03102 Fault 2-hand jog backwards resistor
03201 Fault feedback safety 04944 Writing parameters
03202 Fault feedback emergency stop 4951 Group error encoder
03203 Fault feedback clip drive 04960 Group error WS-food server
03300 Safety CPU stop 6500 Check clip transport / separator hole /
03301 Wrong version safety PLC clip pressure / spreading
03311 Fault restore version safety PLC 6837 Clip / spreading drive alignment active
03312 Fault back up version safety PLC 50200 Fault incremental encoder interface
4020 Fault compressed air 50201 Fault temperature module
04022 Shut AC power down! 50202 Fault analog input module
04031 Starting controller, please wait! 50220 Fault feedback drive group 1
04052 Timeout 2-hand button 50251 Timeout manual sealing button
04053 Timeout stuffer active 50252 Timeout manual stuffer button
04054 Timeout clip signal 50310 Fault timeout sensor clip mark
04058 Timeout 1st clip button 50311 Fault sensor clip mark no mark
04059 Timeout automatic on button detected
04060 Timeout automatic off button 50315 Target value product counter reached
04111 Warning refill clips 50405 Sealing bar not locked
04112 No clip --> automatic off 50410 Fault dancing roller film end
04141 Warning oil level (refill container) 50411 Fault dancing roller upper limit
04142 Fault oil container empty position
04175 ! ! ! SIMULATOR ACTIVE ! ! ! 50460 Fault heating motor protection
4512 Clipping load limit! Check setting! triggered
4513 Main drive load limit! Check setting! 50461 Fault heating temperature too low
4520 Clip drive torque limit maximum 50462 Fault heating temperature too high
4521 Clip drive torque limit minimum 50470 Film slip too high!
04601 I/O test active 50475 Fault film break
04602 Tool change active 50480 Film splice detected
04617 Cleaning display 50485 Fault film length longer than seal bar
length
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 Poly-clip System GmbH & Co. KG TSCA 65 D
50490 Printer not ready
50491 Fault timeout printer
50492 Fault timeout sensor print mark
50493 Fault sensor print mark no mark
detected
50510 Fault sealing compartment cover open
51521 HDP fault safety front door
51522 HDP safety front door
51531 HDP fault safety door right
51532 HDP safety door right
51572 HDP fault output safety
51580 HDP fault dosing cylinder power
amplifier not ok
51582 HDP fault rotary cylinder power
amplifier not ok
51590 HDP fault hydraulic pressure < 30 bar
51620 HDP lubrication interval 1
51621 HDP lubrication interval 2
51650 HDP 201M1
51651 HDP warning fill quantity adjustment
brake open
51660 HDP 211T1
51661 HDP referencing dosing cylinder
51665 HDP 651K8
51670 HDP 215T1
51671 HDP referencing rotary cylinder
51675 HDP 653K8
51700 HAG not ready
51701 HAG fault oil level too low
51702 HAG fault drive overload
51703 HAG fault fan overload
51704 HAG fault oil temperature too high (idle
mode)
51710 HAG warning oil filter blocked
51720 Checkweigher not ready
52000 Fault film drive left 106M1
52010 Fault film drive right 111M1
80000 System stop
80003 Free space < 30%, deleting alarm
history older than 30 days
02100...02200 Check EtherCAT address
02801...02820 Low voltage module
02901 / 02902 Fault module
04011...04015 Error fuse

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5 Start-up and shutdown 5.2 Start-up check list
5.1 Note This check list is provided purely for information and
assistance. Always observe the Safety Instructions for
• Only trained and authorised staff may operate this the activities and the action-related warnings in the
machine. The machine may only be operated by relevant chapters.
trained people aged 18 years or over, or by people
aged 14 years or over under the supervision of 1.) Switch on the compressed air supply.
someone trained on the machine. 2.) Set the operating pressure.
• The Operating Manual, in particular the Safety 3.) Press the Emergency Stop pushbutton.
Instructions chapter, and the local accident
4.) Switch on the main switch.
prevention regulations in force must be observed.
5.) Switch on sealing bar heating.
• It is not permissible for more than one person to
work at the machine at the same time because this A message screen appears:
would circumvent the safety measure of two-hand
operation for example.
• This machine must not be operated without filling
system with inner brake, product outlet or
appropriate spray guard for the stuffing horn.
• The machine must not be started up without its
panels on.
• The machine may only be operated with the feet
extended.
• Staff clothing must be appropriate for the ambient
temperature in the place of installation. If 1
applicable, wear cold protection clothing.
• Hearing protection must be worn where noise
levels in the work place are 85 dB(A) or higher.
• When working on the spray system (optional),
observe the spray manufacturer’s instructions and
wear chemical-resistant protective gloves if
necessary.
• Depending on what product is being packed,
chemical-resistant protective gloves and possibly
also heat-resistant protective gloves may be
required. Observe the safety data sheet for the
product! Fig. 5-1 Example of a message screen
• Safety shoes must be worn when loading heavy 1 Question mark: Indicates a difference
rolls of film. between the target and the actual
value.

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 Poly-clip System GmbH & Co. KG TSCA 65 D
ATTENTION: Machine damage due to
incompatible settings CAUTION: Hot sealing bar
If the clip, die, punch, spreading and discharge plate
The sealing bar can get very hot. You could burn
are not coordinated with one another, the machine
yourself if you touch the sealing bar.
may get damaged!
• Do not touch the sealing bar.
• Do not acknowledge settings until you have
ensured that the settings are compatible with one
another.
CAUTION: Risk of crushing when
6.) Do not acknowledge settings in the message swinging the sealing bar up/down
screen until you have ensured that the settings When the sealing bar is swung up or swung back
are compatible with one another. At position 1, down, there is a risk of crushing at various points.
you must, e.g., check that the separator does not • Make sure you have a firm footing, the sealing bar
hit the discharge plate when in its outermost is heavy!
spreading position. To acknowledge, press the • When you swing the sealing bar up, make sure it
question mark button (1). Once it has been engages securely.
pressed, the button changes to a green tick. • Do not reach into the danger zones.
(Fig. 5-1) • Perform the work as a one-man operation.
7.) Check the safety devices.
8.) Put cut-resistant protective gloves on. 14.) Without touching the sealing bar itself, unbolt the
9.) Install the appropriate die, punch and spreading sealing bar, swing it up and make sure it engages
for the clip. securely.
10.) Select the correct clip size for the product, fill the
clip magazine and insert the clip sticks into the
clip channel. WARNING: Product contamination
11.) Select the hydraulic dosing pump or stuffer
program. If a Teflon strip detaches from the seal pipe, the
adhesive from the Teflon strip could contaminate the
12.) Set the production parameters (e.g. clip pressure)
product.
on the control panel display or select the relevant
recipe. • Check the condition and wear of the Teflon strips
upon every production start, every film change and
13.) Set the distance between the discharge plate and every operator changeover - and possibly more
the separator. See section 3.9. often than that if you are using highly abrasive
films.
• If any of the adhesive strips have detached edges
or damaged surfaces, they must be replaced
immediately.
• Any Teflon strips that need replacing, as well as
their adhesive, must be completely removed from
the seal pipe, leaving no residue. The entire seal
pipe must be completely free of adhesive residue.

15.) Check the condition of the Teflon strips on the

seal pipe. Replace the Teflon strips if necessary.
See section 9.8.

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5-2 EN/05-2017
 Poly-clip System GmbH & Co. KG TSCA 65 D
16.) Position the filling system (see section 3.5.2/
section 5.10).
17.) Position the stuffing horn. See section 3.5.3 or CAUTION: Hot sealing bar
section 3.5.4.
The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar.
DANGER: Crushing and amputation in • Do not touch the sealing bar.
the closing and separator area
Without the smallest appropriate spray guard and/or
inner ring on the stuffing horn, the closing and CAUTION: Risk of crushing when
separator area would be accessible. Here, there is a swinging the sealing bar up/down
risk of crushing or amputation, especially of fingers. When the sealing bar is swung up or swung back
• The smallest appropriate spray guard must be down, there is a risk of crushing at various points.
fitted. • Make sure you have a firm footing, the sealing bar
• If an inner ring is required for the stuffing horn/ is heavy!
calibre, it must be fitted in the right place on the • Do not reach into the danger zones.
stuffing horn. The gap between the spray guard • Perform the work as a one-man operation.
and the inner ring must not exceed 8 mm.
• If no inner ring is required for the stuffing horn/ 22.) Without touching the sealing bar itself, swing the
calibre, the gap between the spray guard and the sealing bar back down and lock it.
stuffing horn must not exceed 8 mm. 23.) Set up the printer (optional).
24.) Release the Emergency Stop pushbutton.
18.) Fit the inner ring (not required for every stuffing
25.) Switch on sealing bar heating.
horn/calibre), smallest appropriate spray guard
and inner brake. 26.) Raise protective grating A.
19.) Check the gap between the spray guard and the 27.) Swing the clip head to the side.
inner ring or between the spray guard and the 28.) Produce the film tube. See section 5.9.1.
stuffing horn; it must not exceed 8 mm. See 29.) Test the film travel. Readjust the film roll if
section 3.5.3 or section 3.5.4. necessary. See Section 5.9.2 et. seq.
20.) Adjust the height of the discharge plate at the 30.) Check the seal seam. Correct the sealing
product outlet. See section 5.3. parameters if necessary.

CAUTION: Injuries through bursting

bellows in tension core CAUTION: Risk of crushing when
swinging the clip head into the working
The bellows can burst if compressed air is supplied position
when there is no film roll on the tension core.
There are several places around the clip head where
• Only supply compressed air to the air release valve fingers could get crushed as the clip head is swung
if there is a film roll on the tension core. into the working position.
• Before swinging the clip head in, make sure
21.) Insert film (see paragraph 5.9). nobody is in the swing area.
• Only one person at a time may work in the vicinity
of the clip head.

31.) Check that nobody is in the swing area of the clip

head, then swing the clip head into the working
position.

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 Poly-clip System GmbH & Co. KG TSCA 65 D
32.) Close protective grating A. 5.3 Adjusting the height of the
33.) Press the “First Clip” button and the two-hand discharge plate at the product
button simultaneously to place the first clip.
outlet
34.) Stuff the film tube with product in manual mode.
35.) Remove the start of the tube that has been cut 1.) Raise protective grating A.
off. 2.) Raise protective shutter B.
36.) Press the Automatic On button.
37.) Push the Automatic Off button after 3-4
clip-paks® have been produced.
38.) Check the clip-pak® for firmness of filling, check
that there is no product in the tail and check that
the clip is tight.
39.) If necessary, adjust the settings on the HDP
dosing pump or the TSCA.
A
40.) If the product is OK, press the Automatic On
button and begin production.

Fig. 5-2 A: Protective grating

B: Protective shutter

3.) Remove the plate (1). (Fig. 5-3)

Fig. 5-3 1 Plate

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 Poly-clip System GmbH & Co. KG TSCA 65 D
The discharge plate (2) is now visible. (Fig. 5-4) 5.4 Filling the clip magazine
5.4.1 Bringing the machine into the clip
loading position

2
ATTENTION: Machine damage
If the machine is not moved to the tool change
positions in the correct order and tool change is not
performed in the correct order, the machine could be
damaged.
• Observe the correct order: Clip change, die
change, punch change.
• Observe the order of activities specified in the
table “Tool change scenarios” in section 5.14.
Fig. 5-4 2 Discharge plate

4.) Release the clamping lever (3) by turning it

anti-clockwise. (Fig. 5-5)
5.) Set the height of the discharge plate on the
wheel (4):
• higher: turn anti-clockwise
• lower: turn clockwise

1.) With the safety circuit closed, bring the machine

into the home position. To do so, press the “First
Clip” button and the two-hand button
simultaneously within 0.5 seconds.
2.) Press the “Clip loading position/Change
positions” button (Fig. 5-6).

Fig. 5-6
3
Result: The Tool change screen (Fig. 5-7) appears.
4
Fig. 5-5 3 Clamping lever
4 Wheel

6.) Lock the clamping lever (3) by turning it

clockwise.
7.) Reinsert the plate (1). (Fig. 5-3)
8.) Close protective grating A.
9.) Close protective shutter B.

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 Poly-clip System GmbH & Co. KG TSCA 65 D
5.4.2 Filling the clip magazine
• Prerequisite:
The machine has been brought into the clip loading
position in accordance with section 5.4.1.

1.) Select the correct clip size for the product.

2.) Push the clip reels (1, Fig. 5-9) onto the magazine
spindles until you hear the clip reels click into
place.
1
5.4.3 Setting the braking force on the clip
magazine
The spindle brake must be set such that the clip stick
can be easily uncoiled without deformation.
1.) Control the braking force by turning the knurled
nut (2):
• Higher braking force: turn clockwise
• Lower braking force: turn anti-clockwise

Fig. 5-7 Tool change screen, machine in home

position
1 Clip loading position button
1
3.) With the safety circuit closed, press button 1 to
move the machine into the clip loading position.
(Fig. 5-7)
Result: The machine automatically moves to the
2
selected machine position.

Fig. 5-9 1 Clip reel

2 Knurled nut
3 Clip channel

Fig. 5-8 Tool change screen, machine in clip

loading position

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5.4.4 Inserting the clip stick 6.) With the safety circuit closed, press button 4.
(Fig. 5-10)
Prerequisite: The machine has been brought into the
7.) Check whether both clips are inserted in the die.
clip loading position in accordance with section 5.4.1.
If necessary, pull the clip stick out and repeat the
process.
8.) Press button 6 to exit the screen. (Fig. 5-10)
Result: The machine moves into the home position
and the RFID system reads the data in again.

5.5 Changing the die

Prerequisite: The clip sticks must have been pulled
4 out of the clip channel. This can only be done in the
clip loading position. See section 5.4.1.

ATTENTION: Machine damage

If the machine is not moved to the tool change
positions in the correct order and tool change is not
6 performed in the correct order, the machine could be
damaged.
• Observe the correct order: Clip change, die
change, punch change.
• Observe the order of activities specified in the
table “Tool change scenarios” in section 5.14.

Fig. 5-10 Tool change screen, machine in clip

loading position
4 Home position button
6 Exit screen

1.) Swing the sausage outlet to the side.

2.) Cut and remove the plastic protection on the clip
reel.
3.) Bend the start of both clip sticks without 1.) With the safety circuit closed, bring the machine
snapping them off. into the home position. To do so, press the “First
4.) Insert both clip sticks simultaneously into the clip Clip” button and the two-hand button
channels (3) until you can feel some resistance. simultaneously within 0.5 seconds.
(Fig. 5-9) 2.) Press the “Clip loading position/Change
positions” button (Fig. 5-11).

CAUTION: Risk of crushing when

swinging the product outlet into the
working position
There are several places around the product outlet
where fingers could get crushed as the product outlet
is swung into the working position. Fig. 5-11
• Work carefully.
• Only one person at a time may work in the area of Result: The Tool change screen (Fig. 5-12) appears.
the product outlet.

5.) Swing the product outlet back into the working

position.

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 Poly-clip System GmbH & Co. KG TSCA 65 D

Fig. 5-12 Tool change screen, machine in home Fig. 5-13 Tool change screen, machine in die
position change position
2 Die change position button 4 Home position button
6 Exit screen
3.) With the safety circuit closed, press button 2 to
move the machine into the die change position. 4.) Raise protective shutter B. (Fig. 5-2)
(Fig. 5-12) 5.) Swing the sausage outlet to the side.
Result: The machine automatically moves to the 6.) Unscrew the fixing screw (2) and exchange the
selected machine position. die (1). (Fig. 5-14)

2 1
Fig. 5-14 1 Die
2 Fixing screw

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7.) Close protective shutter B. 5.6 Changing the punch

CAUTION: Risk of crushing when ATTENTION: Machine damage

swinging the product outlet into the If the machine is not moved to the tool change
working position positions in the correct order and tool change is not
There are several places around the product outlet performed in the correct order, the machine could be
where fingers could get crushed as the product outlet damaged.
is swung into the working position. • Observe the correct order: Clip change, die
• Work carefully. change, punch change.
• Only one person at a time may work in the area of • Observe the order of activities specified in the
the product outlet. table “Tool change scenarios” in section 5.14.

8.) Swing the product outlet back into the working

position.
9.) Insert the clip sticks back into the clip channel.
See section 5.4.4.
10.) Press button 6 to exit the screen. (Fig. 5-13)
Result: The machine moves into the home position
and the RFID system reads the data in again.

1.) With the safety circuit closed, bring the machine

into the home position. To do so, press the “First
Clip” button and the two-hand button
simultaneously within 0.5 seconds.
2.) Press the “Clip loading position/Change
positions” button (Fig. 5-15).

Fig. 5-15

Result: The Tool change screen (Fig. 5-16) appears.

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 Poly-clip System GmbH & Co. KG TSCA 65 D

Fig. 5-16 Tool change screen, machine in home Fig. 5-17 Tool change screen, machine in punch
position change position
3 Punch change position button 4 Home position button
6 Exit screen
3.) With the safety circuit closed, press button 3 to
move the machine into the punch change 4.) Raise protective shutter B. (Fig. 5-2)
position. (Fig. 5-16) 5.) Swing the sausage outlet to the side.
Result: The machine automatically moves to the
selected machine position.
CAUTION: Sharp-edged punch and
sharp knife
You could cut yourself.
• Wear cut-resistant protective gloves!
• Work carefully and do not touch the blade of the
knife or the edges of the punch.

6.) Put cut-resistant protective gloves on.

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7.) Remove the screws (1). (Fig. 5-18)

1
1

2 2
Fig. 5-19 1 Stop
2 Punch

9.) Tighten the screws (1). (Fig. 5-18)

10.) Close protective shutter B.

Fig. 5-18 1 Screws

2 Punch CAUTION: Risk of crushing when
swinging the product outlet into the
8.) Exchange the punch. In doing so, remember the working position
punch (2) sit flush with the stop (1). (Fig. 5-19) There are several places around the product outlet
where fingers could get crushed as the product outlet
is swung into the working position.
• Work carefully.
• Only one person at a time may work in the area of
the product outlet.

11.) Swing the product outlet back into the working

position.
12.) Press button 6 to exit the screen. (Fig. 5-17)
Result: The machine moves into the home position
and
the RFID system reads the data in again.

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5.6.1 Checking the clearance
Note: This activity may only be carried out by people
who meet the requirements set out in sections 1.3 and
1.3.3.

1.) Raise protective shutter B. 1

2.) Swing the clip head to the side.
3.) Open the locks (1) using the control cabinet key.
(Fig. 5-20)
4.) Open the right side panel (2) on the clip head.

Fig. 5-21 1 Motor shaft

6.) Slowly turn the machine over using open-end

spanner and check the clearance. Permissible
clearance range: 0.1 to 0.3 mm. (Fig. 5-22)
7.) If necessary, reset the clearance.
2 See section 5.6.2.
8.) Close the right side panel (2) on the clip head.
(Fig. 5-20)
9.) Lock the locks (1). (Fig. 5-20)
1 10.) Remove all tools from the vicinity of the machine.
11.) Close protective shutter B.

CAUTION: Risk of crushing when

swinging the clip head into the working
position
Fig. 5-20 1 Locks
2 Right side panel There are several places around the clip head where
fingers could get crushed as the clip head is swung
5.) Put an open-end spanner (46 mm) on the motor into the working position.
shaft (1). (Fig. 5-21) • Before swinging the clip head in, make sure
nobody is in the swing area.
• Only one person at a time may work in the vicinity
of the clip head.

12.) Check that nobody is in the swing area of the clip

head, then swing the clip head into the working
position.

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5.6.2 Setting the clearance 5.7 Setting the separator hole
Note: This activity may only be carried out by people 1.) Swing the clip head to the side.
who meet the requirements set out in sections 1.3 and
1.3.3.

2
0. 1
-0
.3
mm
1
2

Fig. 5-23 Clip head swung to the side

1 Adjusting wheel
2 Securing lever

2.) Loosen the securing lever (2).

3 3.) Turn the adjusting wheel (1) and adjust the
number value for the required separator hole
underneath the securing lever so it can be easily
4 read.
Bigger separator hole
Fig. 5-22 1 Punch
2 Die Set higher number value.
3 Upper adjusting screw Smaller separator hole
4 Lower adjusting screw

Smaller clearance Set smaller number value.

1.) Turn upper adjusting screw (3) anti-clockwise and
release. 4.) Tighten the securing lever (2).
2.) Turn lower adjusting screw (4) clock-wise to the
stop.
Larger clearance CAUTION: Risk of crushing when
swinging the clip head into the working
1.) Turn lower adjusting screw (4) anti-clockwise and position
release.
There are several places around the clip head where
2.) Turn upper adjusting screw (3) clockwise to the fingers could get crushed as the clip head is swung
stop. into the working position.
• Before swinging the clip head in, make sure
nobody is in the swing area.
• Only one person at a time may work in the vicinity
of the clip head.

5.) Check that nobody is in the swing area of the clip

head, then swing the clip head into the working
position.

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5.8 Clip pressure
Cutting and deforming the clips requires different
forces depending on the clip and film type. The clip
pressure must be set accordingly.

5.8.1 Checking the clip pressure

1.) Swing the clip head (1) to the side. (Fig. 5-24)

Fig. 5-25 1 Locks

2 Right side panel

4.) Put an open-end spanner (46 mm) on the motor

1 shaft (1). (Fig. 5-26)

Fig. 5-24 1 Clip head, swung to the side

2.) Open the locks (1) using the control cabinet key.
(Fig. 5-25)
3.) Open the right side panel (2) on the clip head. 1

Fig. 5-26 1 Motor shaft

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5.) Turn the machine over using the open-end 5.8.2 Setting the clip pressure
spanner to perform a test close on the clip.
1.) Raise protective shutter B. (Fig. 5-27)

Force required Meaning

Requires too Clip pressure set too high
much force, clip
is not closed
Requires barely Clip pressure set too low
any force
Requires a lot of Clip pressure set correctly
force

6.) Remove the closed clip from the die.

7.) Close the right side panel (2) on the clip head.
(Fig. 5-25)
8.) Lock the locks (1). (Fig. 5-25)
9.) Remove all tools from the vicinity of the machine.

CAUTION: Risk of crushing when B

swinging the clip head into the working
position
There are several places around the clip head where
fingers could get crushed as the clip head is swung
into the working position.
• Before swinging the clip head in, make sure Fig. 5-27 Protective shutter B
nobody is in the swing area.
• Only one person at a time may work in the vicinity 2.) Push the latch (1) down. (Fig. 5-28)
of the clip head.

10.) Check that nobody is in the swing area of the clip

head, then swing the clip head into the working
position.

Fig. 5-28 1 Latch

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3.) Open the left side panel on the clip head. 5.) Remove all tools from the vicinity of the machine.
(Fig. 5-29) 6.) Open the left side panel on the clip head.
(Fig. 5-31)

Fig. 5-29
Fig. 5-31
4.) Set the clip pressure. (Fig. 5-30):
7.) Push the latch (1) up. (Fig. 5-32)
- Release the brake (4) by turning it clockwise. If
necessary, use the stuffing horn key to do this.
- Turn the setting wheel (1). The number value (2) next
to the marker (3) is the clip pressure that has been
set.
- Lock the brake (4) by turning it anti-clockwise. If
necessary, use the stuffing horn key to do this.

1
1
2
Fig. 5-32 1 Latch

4 8.) Close protective shutter B.

3
Fig. 5-30 1 Setting wheel
2 Number value (clip pressure set)
3 Marking
4 Brake

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5.9 Inserting the film
WARNING: Product contamination

WARNING: Risk of injury when lifting If a Teflon strip detaches from the seal pipe, the
heavy film rolls adhesive from the Teflon strip could contaminate the
You risk injury or crushing if you lift film rolls that product.
weigh over 25 kg without lifting aids. • Check the condition and wear of the Teflon strips
• Film rolls with a weight of over 25 kg may only be upon every production start, every film change and
moved onto the expansion shaft using a lifting every operator changeover - and possibly more
device. often than that if you are using highly abrasive
• Wear safety shoes. films.
• If any of the adhesive strips have detached edges
The film roll is placed onto a tension core with built-in or damaged surfaces, they must be replaced
bellows to clamp the roll. immediately.
The air supply/release valve is on the front of the • Any Teflon strips that need replacing, as well as
tension core (Fig. 5-33). their adhesive, must be completely removed from
the seal pipe, leaving no residue. The entire seal
1 pipe must be completely free of adhesive residue.

1.) Check the condition of the Teflon strips on the

seal pipe. Replace the Teflon strips if necessary.
See section 9.8.
2.) Operate the air release valve with the
compressed air gun until the tension core has
released enough air for the film roll to be
pushed on.
3.) Swing the stop bracket (1, Fig. 5-34) in (to align
the film roll to the centre of the inlet).

Fig. 5-33 1 Air supply/release valve

1

Fig. 5-34 1 Stop bracket

4.) Push the new film roll onto the tension core up to
the stop.

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CAUTION: Injuries through bursting

1 2 3
bellows in tension core
The bellows can burst if compressed air is supplied
when there is no film roll on the tension core.
Only supply compressed air to the air release valve if
there is a film roll on the tension core.

5.) Using the compressed air gun, feed compressed

air in at the air release valve until enough pressure
builds up between the tension core and the film
roll to hold the film roll in place.
6.) Swing the stop bracket back.
7.) Guide the film over the guide pulleys as shown in
Fig. 5-35. Fig. 5-36 1 Feeler wheel of the film end switch
2 Film counter
3 Rubberised guide pulley

8.) Feed the film up behind the guide tube on the

sealing unit and push the edge facing you into the
insertion opening on the forming shoulder
(Fig. 5-37).
9.) Pull the film out of the forming shoulder.

Fig. 5-35 Film feed

• The film roll unwinding direction can be changed if

need be as per the dashed line (Fig. 5-35). This may
be necessary when using printed film that has been
coiled with the print facing in.
• Make sure the feeler wheel of the film end switch is
resting on the film (see 1, Fig. 5-36).
• Make sure the magnetic tape at the rear end of the
rubberised guide pulley (3, Fig. 5-36) is not dirty. If
1
the tape is dirty, the film counter (2,Fig. 5-36) will Fig. 5-37 1 Forming shoulder
not work.

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5.9.1 Producing the film tube 7.) Film tubes must be produced by hand until the
film tube protrudes beyond the closing point in
1.) Swing the clip head to the side. the clip module and the first clip can be placed.

CAUTION: Hot sealing bar CAUTION: Risk of crushing when

swinging the clip head into the working
The sealing bar can get very hot. You could burn position
yourself if you touch the sealing bar. There are several places around the clip head where
Allow the sealing bar to cool down before you start fingers could get crushed as the clip head is swung
work. into the working position.
• Before swinging the clip head in, make sure
2.) Unbolt the sealing bar and swing it up nobody is in the swing area.
(see section 3.5.1). • Only one person at a time may work in the vicinity
3.) Pull the film to the end of the sealing bar. The film of the clip head.
edges must overlap.
4.) Swing the sealing bar down and lock it. 8.) Check that nobody is in the swing area of the clip
head, then swing the clip head into the working
position.
CAUTION: Risk of crushing 9.) Manually trigger first clipping procedure.

There is a risk of crushing:

- between sealing bar and seal pipe, 5.9.2 Testing the film travel
- between seal pipe and counter support,
The film should not stray to the left or right. Readjust
- between seal pipe and film drive (optional).
the film roll if necessary, see section 5.9.3.
The correct film travel can be adjusted on the film roll
Do not reach in between the sealing bar and the seal (Fig. 5-39).
pipe!
Do not reach in between sealing bar and counter
support!
• Note
Do not reach in between the seal pipe and the film The film roll is adjusted by turning the tension shaft
drive (optional)! with a socket wrench; this must only be done when
the machine has stopped.
5.) Manually trigger the lubrication process. To do
this, press the “T” button (1, Fig. 5-38) on the
control panel.

Fig. 5-39

1
Fig. 5-38 1 “T” button (manual sealing)

6.) Check the seal seam on the completed piece of

tubing. Correct the settings if necessary.

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The film must overlap when it leaves the forming 5.9.3 Readjusting the film roll
shoulder.
The top edge of the film must be fed into the flat slot The film should enter the forming shoulder with as little
on the forming shoulder (Fig. 5-40, Fig. 5-41). friction as possible between the two.

5.9.3.1 Adjusting the deflection roller

1.) Release both clamping levers (1, Fig. 5-42).

1
Fig. 5-40

1
Fig. 5-42 1 Clamping levers

2.) Adjust the deflection roller as required.

3.) Tighten the clamping levers.

5.9.3.2 Adjusting the guide pulley

Fig. 5-41 1.) Release both clamping levers (1, Fig. 5-43).

Fig. 5-43 1 Clamping levers

2.) Adjust the guide pulley as required.

3.) Tighten the clamping levers.

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5.10 Using the filling system with a
different calibre
Prerequisites:
• The machine must be switched on.
• Compressed air must be present.

1.) Press the Emergency Stop pushbutton.

CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar. 1
• Do not touch the sealing bar.
Fig. 5-45 Unbolting the sealing bar
1 Bolt
CAUTION: Risk of crushing when
swinging the sealing bar up/down
When the sealing bar is swung up or swung back
down, there is a risk of crushing at various points.
• Make sure you have a firm footing, the sealing bar 1
is heavy!
• When you swing the sealing bar up, make sure it
engages securely.
• Do not reach into the danger zones.
• Perform the work as a one-man operation.
1

Fig. 5-46 1 Sealing bar, swung up

DANGER: Contact with the product

being packed
Depending on what product is being packed, contact
with it may be hazardous to health.
Fig. 5-44 1 Sealing bar
• Observe the safety data sheet for the product!
2.) Without touching the sealing bar itself, unbolt the • If necessary, wear chemical-resistant protective
sealing bar, swing it up and make sure it engages gloves or wear heat-resistant protective gloves if
securely. the product is extremely hot.

3.) Remove the stuffing horn.

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4.) Unlock the quick lock (1) and remove the filling
system.

2
1

Fig. 5-48 1 Quick lock, locked

2 Filling system, in position

Fig. 5-47 Fastening device for the filling system

1 Quick lock, unlocked DANGER: Contact with the product
being packed
Depending on what product is being packed, contact
with it may be hazardous to health.
WARNING: Product contamination • Observe the safety data sheet for the product!
If a Teflon strip detaches from the seal pipe, the • If necessary, wear chemical-resistant protective
adhesive from the Teflon strip could contaminate the gloves or wear heat-resistant protective gloves if
product. the product is extremely hot.
• Check the condition and wear of the Teflon strips
upon every production start, every film change and 7.) Insert the stuffing horn. Do not forget to fit the
every operator changeover - and possibly more smallest appropriate spray guard, the inner brake
often than that if you are using highly abrasive and, if needed, the inner ring. See sections 3.5.3
films. and 3.5.4.
• If any of the adhesive strips have detached edges
or damaged surfaces, they must be replaced
immediately.
• Any Teflon strips that need replacing, as well as
their adhesive, must be completely removed from
the seal pipe, leaving no residue. The entire seal
pipe must be completely free of adhesive residue.

5.) Check the condition of the Teflon strips on the

seal pipe. Replace the Teflon strips if necessary.
See section 9.8.
6.) Insert a different filling system and lock the quick
lock (1).

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8.) Set the height of the counter support (3) so that is
pushes the seal pipe (2) up slightly (max. 0.1 mm).
To do this, release the locking mechanism (5) and
adjust the height using the adjusting nut (4).

2 1
Fig. 5-50 1 “T” button (manual sealing)

3 10.) Once the counter support is set correctly, click

the locking mechanism (5, Fig. 5-49) into place.

CAUTION: Hot sealing bar

4 The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar.
5 • Do not touch the sealing bar.

Fig. 5-49 1 Sealing bar

2 Seal pipe CAUTION: Risk of crushing when
3 Counter support swinging the sealing bar up/down
4 Adjusting nut
5 Locking mechanism When the sealing bar is swung up or swung back
down, there is a risk of crushing at various points.
• Make sure you have a firm footing, the sealing bar
is heavy!
CAUTION: Risk of crushing • Do not reach into the danger zones.
• Perform the work as a one-man operation.
There is a risk of crushing between the seal pipe and
counter support and between the sealing bar and 11.) Without touching the sealing bar itself, swing the
seal pipe. sealing bar back down and lock it.
Do not reach in between sealing bar and counter
support!
Do not reach in between the sealing bar and the seal
pipe!

9.) Check the position of the counter support during

operation. To do this, place a piece of paper
between the seal pipe and the counter support.
Press the “T” button (1, Fig. 5-50) on the control
panel and pull on the paper. It should not be
possible to pull the paper out.

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12.) Adjust the height of the sealing bar so there is a
gap of approximately 5 to 7 mm between it and
the sealing tube. To do this, release the locking
mechanism (2) and adjust the height using the
adjusting nut (1).

1
3

Fig. 5-51 1 Adjusting nut 2 1

2 Locking mechanism Fig. 5-52 1 Film
2 Reading process trigger button
3 Contrast scanner
CAUTION: Risk of crushing
5.11.1 Reading process (static)
There is a risk of crushing between the seal pipe and 1.) Place the film in the light spot of the contrast
counter support and between the sealing bar and scanner, then press and hold the trigger button
seal pipe. (2, Fig. 5-52) for more than 1 s.
Do not reach in between sealing bar and counter
support! The transmission light and the function display flash
Do not reach in between the sealing bar and the seal slowly.
pipe!
2.) Continue to transport the film until the splice is
13.) Check the position of the sealing bar during captured in the light spot of the contrast scanner.
operation. To do this, press the “T” button Then press and hold the trigger button
(1, Fig. 5-50) on the control panel. The seal pipe (2, Fig. 5-52) for more than 1 s.
should not move up or down. • If the transmission light and the function display
14.) Once the sealing bar is set correctly, click the go out, the reading process was successful.
locking mechanism (2, Fig. 5-51) into place. • If the transmission light and the function display
flash quickly, the reading process has failed
because there was insufficient contrast between
5.11 Splice detection the film and the splice.

A contrast scanner scans the film during machine

operation to detect splices. To remove the splice, the
machine is automatically stopped and remains in
“Automatic Off” mode.

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5.12 Spray system (optional)
1 2
WARNING: Incorrect use of spray is
dangerous
Depending on what spray is being used, contact with
it may be hazardous to health.
• Observe the manufacturer’s instructions.
• Wear chemical-resistant protective gloves if
necessary.

The spray system lubricates the film.

The 2.5 l spray canister is placed in the machine,
see Fig. 5-53.

Fig. 5-54 1 Atomisation pressure regulator;

Standard setting 1.8 bar
2 Spray system pressure gauge

The 10 l spray canister is placed in front of the

machine. In this case, the spray hose and the fill level
cable must be fed through holes in the bottom of the
machine and connected, see Fig. 5-55.

1
Fig. 5-53 1 Spray canister

Fig. 5-55

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To access the non-return valve, liquid valve and spray
nozzles, proceed as follows:
1.) Push the Emergency-Stop button.
2.) Switch the main switch off.

CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar.
• Do not touch the sealing bar.

CAUTION: Risk of crushing when

swinging the sealing bar up/down
When the sealing bar is swung up or swung back
down, there is a risk of crushing at various points.
1 2
• Make sure you have a firm footing, the sealing bar
is heavy!
• When you swing the sealing bar up, make sure it
engages securely.
• Do not reach into the danger zones. 3
• Perform the work as a one-man operation.

3.) Without touching the sealing bar itself, unbolt the

sealing bar, swing it up and make sure it engages
securely.
4.) Disconnect the compressed air supply.
5.) Raise protective shutter B.
6.) Swing the clip head to the side.

Fig. 5-57 Spray system, side view

1 Non-return valve
2 Liquid valve
3 Non-return valve connection direction

The blue hoses carry compressed air and the white

hoses carry the spray.

Fig. 5-56 Clip head, swung to the side

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• To increase the liquid volume:
Loosen the threaded pin (1, Fig. 5-59) and turn the
inner nozzle (2) anti-clockwise, then re-tighten the
threaded pin.
• To reduce the liquid volume:
Loose the threaded pin (1, Fig. 5-59) and turn the
inner nozzle (2) clockwise, then re-tighten the
threaded pin.

The spray duration and other parameters for the spray

system are set on the control panel display.
See Fig. 4-54.

1 1
Fig. 5-58 Spray system, front view
1 Spray nozzles

The liquid volume is set at the spray nozzles:

Fig. 5-59 Spray nozzle

1 Threaded pin
2 Inner nozzle with sealing ring

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5.13 Shutting down the machine for a 3.) Without touching the sealing bar itself, remove
the film from the seal pipe on the TSCA.
long period
1.) Disconnect the main power supply. To do this,
switch the main switch (2, Fig. 5-62) to the Off CAUTION: Hot sealing bar
position.
The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar.
CAUTION: Hot sealing bar • Do not touch the sealing bar.

The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar. CAUTION: Risk of crushing when
• Do not touch the sealing bar. swinging the sealing bar up/down
When the sealing bar is swung up or swung back
down, there is a risk of crushing at various points.
CAUTION: Risk of crushing when • Make sure you have a firm footing, the sealing bar
swinging the sealing bar up/down is heavy!
When the sealing bar is swung up or swung back • Do not reach into the danger zones.
down, there is a risk of crushing at various points. • Perform the work as a one-man operation.
• Make sure you have a firm footing, the sealing bar
is heavy! 4.) Without touching the sealing bar itself, swing the
• When you swing the sealing bar up, make sure it sealing bar back down and lock it. (Fig. 5-61)
engages securely.
• Do not reach into the danger zones.
• Perform the work as a one-man operation.

2.) Without touching the sealing bar itself, unbolt the 1

sealing bar, swing it up and make sure it engages
securely. See section 3.5.1.

1
Fig. 5-61 1 Sealing bar locked

Fig. 5-60 1 Sealing bar, swung up

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5.) Disconnect the main compressed air supply. To
do this, move the air release valve (1, Fig. 5-62)
against the direction of flow (see arrow). ATTENTION: Production downtime if cleaning
delayed

1 2 If product-carrying parts of the machine are not

cleaned promptly after switch-off, the product may
harden depending on what product was used. This
may result in production downtime.
• Clean product-carrying parts of the machine
promptly after switching off.

10.) Clean the machine as described in chapter 8.

11.) If the machine needs to be moved: Unscrew the
control cables to other machines.

Fig. 5-62 1 Air release valve

2 Main switch

6.) Remove the compressed air hose.

7.) Pull out the mains plug.
8.) Disconnect the product feed at the stuffer/
customer’s dosing system.

DANGER: Contact with the product

being packed
Depending on what product is being packed, contact
with it may be hazardous to health.
• Observe the safety data sheet for the product!
• If necessary, wear chemical-resistant protective
gloves or wear heat-resistant protective gloves if
the product is extremely hot.

9.) Disconnect the TSCA from the stuffer or

customer’s dosing system.

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5.14 Tool change scenarios
The following table is merely a checklist. Always observe the Safety Instructions and the action-related warnings
in the relevant chapters.

ATTENTION: Machine damage

If the machine is not moved to the tool change positions in the correct order and tool change is not performed
in the correct order, the machine could be damaged.
• Observe the correct order: Clip change, die change, punch change.
• Observe the order of activities specified in the table “Tool change scenarios” in section 5.14.

Tool change scenarios

Procedure/scenario Staff responsible Sequence of activities
Clip reels are empty Operators 1.) Bring the machine into the clip loading position
(button 1, Fig. 5-63).
2.) Remove the empty clip reels.
3.) Place new clip reels onto the magazine spindles
and insert clips.
4.) Bring the machine into the home position
(button 4, Fig. 5-63).
Die is defective Operators 1.) Bring the machine into the clip loading position
(button 1, Fig. 5-63).
2.) Pull the clip sticks out of the clip channel.
3.) Bring the machine into the die change position
(button 2, Fig. 5-63).
4.) Exchange the die.
5.) Bring the machine into the clip loading position
(button 1, Fig. 5-63)
6.) Insert clips.
7.) Bring the machine into the home position
(button 4, Fig. 5-63).
Punch is defective Operators 1.) Bring the machine into the punch change position
(button 3, Fig. 5-63).
2.) Change the punch.
3.) Bring the machine into the home position
(button 4, Fig. 5-63).

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The clip transport (spacing) Maintenance staff 1.) Bring the machine into the clip loading position
needs converting, but the (button 1, Fig. 5-63).
spreading must remain the 2.) Pull the clip sticks out of the clip channel and
same remove the clip reels.
3.) Bring the machine into the die change position
(button 2, Fig. 5-63).
4.) Remove the die.
5.) Bring the machine into the punch change position
(button 3, Fig. 5-63).
6.) Remove the punch.
7.) Convert the clip transport (spacing).
See section 9.10.
• Remove the clip guide plate.
• Remove the transport finger (unit comprising
transport holder and transport lever).
• Fit a different transport holder in the transport
lever. Fit the transport finger (unit comprising
transport holder and transport lever).
• Fit the clip guide plate.
8.) Bring the machine into the die change position
(button 2, Fig. 5-63).
9.) Insert the appropriate die for the spacing.
10.) Bring the machine into the punch change position
(button 3, Fig. 5-63).
11.) Insert the appropriate punch for the spacing.
12.) Bring the machine into the clip loading position
(button 1, Fig. 5-63).
13.) Insert the appropriate clips for the spacing.
14.) Bring the machine into the home position
(button 4, Fig. 5-63).

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The spreading needs to be Maintenance staff 1.) Bring the machine into the clip loading position
converted (button 1, Fig. 5-63).
2.) Pull the clip sticks out of the clip channel.
3.) Bring the machine into the die change position
(button 2, Fig. 5-63).
4.) Remove the die.
5.) Bring the machine into the punch change position
(button 3, Fig. 5-63).
6.) Remove the punch.
7.) Convert the spreading. See section 9.11.
• Remove the clip guide plate.
• Remove the transport finger (unit comprising
transport holder and transport lever).
• Manually convert the spreading.
• Fit a different transport holder in the transport
lever. Fit the transport finger (unit comprising
transport holder and transport lever).
• Fit a different clip guide plate.
8.) Bring the machine into the die change position
(button 2, Fig. 5-63).
9.) Insert a different die.
10.) Bring the machine into the punch change position
(button 3, Fig. 5-63).
11.) Insert a different punch.
12.) Test the clearance.
13.) Bring the machine into the clip loading position
(button 1, Fig. 5-63).
14.) Insert clips.
15.) Bring the machine into the home position
(button 4, Fig. 5-63).

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The clip transport (spacing) Maintenance staff 1.) Bring the machine into the clip loading position
and the spreading need (button 1, Fig. 5-63).
converting 2.) Pull the clip sticks out of the clip channel and
remove the clip reels.
3.) Bring the machine into the die change position
(button 2, Fig. 5-63).
4.) Remove the die.
5.) Bring the machine into the punch change position
(button 3, Fig. 5-63).
6.) Remove the punch.
7.) Remove the clip guide plate.
8.) Remove the transport finger (unit comprising
transport holder and transport lever).
9.) Manually convert the spreading.
10.) Fit a different transport holder in the transport
lever. Fit the transport finger (unit comprising
transport holder and transport lever).
11.) Fit a different clip guide plate.
12.) Bring the machine into the die change position
(button 2, Fig. 5-63).
13.) Insert the appropriate die for the spacing.
14.) Bring the machine into the punch change position
(button 3, Fig. 5-63).
15.) Insert the appropriate punch for the spacing.
16.) Test the clearance.
17.) Bring the machine into the clip loading position
(button 1, Fig. 5-63).
18.) Insert the appropriate clips for the spacing.
19.) Bring the machine into the home position
(button 4, Fig. 5-63).

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1 3
4

Fig. 5-63 Tool change screen, machine in home

position
1 Clip loading position button
2 Die change position button
3 Punch change position button
4 Home position button
6 Exit screen

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6 Product testing 6.3.1 Testing the film travel

6.1 Note The film should not stray to the left or right. Readjust
the film roll if necessary.
• The work described in this chapter may only be The correct film travel can be adjusted on the film roll
carried out by trained experts. (Fig. 6-1).
• Hearing protection must be worn where noise
levels in the work place are 85 dB(A) or higher. • Note
• Staff clothing must be appropriate for the ambient The film roll is adjusted by turning the tension shaft
temperature in the place of installation. with a socket wrench; this must only be done when
• It is not permissible for more than one person to the machine has stopped.
work at the machine at the same time because this
would circumvent the safety measure of two-hand
operation for example.
• The Safety Instructions in chapter 1 and the
applicable local accident prevention regulations
must be observed when carrying out this work.

6.2 Preparing for product testing

Before product testing starts, the clip head must be Fig. 6-1
swung to the side.
The film must overlap when it leaves the forming
shoulder.
6.3 Product testing before start of The top edge of the film must be fed into the flat slot
on the forming shoulder (Fig. 6-2, Fig. 6-3).
production

CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar.
• Do not touch the sealing bar. Fig. 6-2

CAUTION: Risk of crushing

There is a risk of crushing:

- between sealing bar and seal pipe,
- between seal pipe and counter support,
- between seal pipe and film drive (optional).

Do not reach in between the sealing bar and the seal

pipe!
Do not reach in between sealing bar and counter
support!
Do not reach in between the seal pipe and the film
drive (optional)!

Fig. 6-3

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6.3.2 Testing the seal seam
Test the strength of the seal seam by means of a rip
test:
1.) To do this, insert both index fingers into the tube
and pull outwards (Fig. 6-4).
2.) If the welding seam rips, the welding parameters
need to be corrected.

Fig. 6-4

Visually check the seal seam:

• The film must be cleanly sealed through, but must
not melt away.
• There must not be any holes in the film.

If necessary, the sealing parameters must be

corrected.

6.4 After completion of product

testing

CAUTION: Risk of crushing when

swinging the clip head into the working
position
There are several places around the clip head where
fingers could get crushed as the clip head is swung
into the working position.
• Before swinging the clip head in, make sure
nobody is in the swing area.
• Only one person at a time may work in the vicinity
of the clip head.

1.) Check that nobody is in the swing area of the clip

head, then swing the clip head into the working
position.
2.) Check all protective devices are complete, fitted
correctly and functioning properly.
3.) Remove all tools from the vicinity of the machine.

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7 Troubleshooting
7.1 Note
• Maintenance and repair work must only be carried out by trained, specialist staff.
• Work on the electrical equipment of the machine must only be carried out by a qualified electrician, or by a
trained person under the guidance and supervision of a qualified electrician, in accordance with the electrical
regulations.
• Safety shoes must be worn during installation and set-up of the machine, when loading heavy film rolls and
during dismantling and transport of the machine.
• Hearing protection must be worn where noise levels in the work place are 85 dB(A) or higher.
• Cut-resistant protective gloves must be worn when changing the knife.
• Depending on what product is being packed, chemical-resistant protective gloves and possibly also
heat-resistant protective gloves may be required. Observe the safety data sheet for the product!
• When working on the spray system, observe the spray manufacturer’s instructions and wear
chemical-resistant protective gloves if necessary.
• The staff's clothing must be appropriate for the ambient temperature at the place of installation
(see section 3.2).
• The mandatory protective equipment is required for electricians.
• It is not permissible for more than one person to work at the machine at the same time because this would
circumvent the safety measure of two-hand operation for example.
• Maintenance and repair work must be carried out when the machine has stopped.
• The Safety Instructions in chapter 1 and the applicable local accident prevention regulations must be
observed when carrying out this work.

7.1.1 Preparing the machine for fault rectification

How to shut the machine down before commencing the respective work is described in the following chapters.

7.1.2 After completing the work

Check all protective devices are complete, fitted correctly and functioning properly. See section 1.5.

Troubleshooting
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7.2 List of possible faults and problems

Fault Cause / Fault Remedy

1 Film rips a) Splice a) Re-insert film

b) Film edge damaged b) Check the film roll for damage at the
edges, exchange if necessary
2 Sealing bar does not a) No compressed air a) Open compressed air supply
lower into sealing b) Compressed air too low b) Change air pressure setting
position
3 TSCA stops a) Film ripped a) Eliminate the cause and feed new
operation film in
b) End of film b) Fit a different film roll
c) Pressure set too low c) Increase compressed air setting
d) Clip module has stopped the machine d) Read error message and eliminate
cause
e) Automatic clip monitoring has e) Insert new clip roll, start RFID reading
switched the machine off process
f) Protective device opened f) Check cause and close protective
device
4 Incorrect film travel Film keeps moving up or down when a) Re-insert film
exiting forming shoulder, film sticks to b) Fit a different film roll
seal pipe, film incorrectly inserted
5 Seal seam only a) The sealing bar is not set correctly a) Check sealing bar setting
partially closed or
closed with creases
6 Missing clip a) Clip stick stretched a) Reduce clip reel braking force
b) Clip does not sit correctly in die rack b) Check clip transport
c) Clip in the die c) Remove clip
d) Die/punch damaged d) Replace die/punch
7 Clip too loose Clip pressure too low Set clip pressure higher

8 Clip too tight Clip pressure too high Set clip pressure lower

9 Clip closed unevenly a) Die plate damaged a) Replace die

b) Punch damaged b) Replace punch
c) Clearance set incorrectly c) Change clearance setting
10 Damaged film tube a) Clip pressure set incorrectly a) Correct the setting
b) Knife cuts too soon b) Change cutting time
c) Inner brake set too tight c) Change inner brake force
d) Separator damaged d) Polish damaged areas or replace the
separator
e) Spray nozzles (optional spray system) e) Check spray system
set incorrectly
11 The knife does not a) Knife is blunt a) Sharpen/replace the knife
cut b) Knife cuts too late b) Correct the setting
c) Knife is too short c) Exchange the knife
12 The machine won’t a) The safety circuit is broken a) Check the safety equipment
run

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Fault Cause / Fault Remedy

13 Ideal shape - symmetrical closure: None

- the wires are in position, of equal length
and free of burrs

14 Clip legs flattened to a) Clip pressure too high a) Reduce clip pressure
the left and (or) right b) Clip too big b) Use a smaller clip

15 The clip is the right The die is too big for the clip Change the die
size, but is not tight
enough

16 The clip legs are The clearance between the punch / die is Correct the clearance
different lengths incorrect

17 The film tube is not a) The clip is too big a) Use the correct clip size
securely closed b) The clip pressure is too low b) Correct the clip pressure

18 The film tube is a) The clip is too small a) Use a bigger clip
protruding from the b) The separator hole is too big b) Set the separator hole smaller
clip c) The separator is not pulling the film c) Adjust the joint rods until the
tube far enough over the die base separator hole sits 2/3 under the die
base
d) Knife cuts too soon d) Correct the knife cutting time

Troubleshooting
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Fault Cause / Fault Remedy

19 The clip sits Clip transport is set incorrectly Bring feed chain on chain wheel of clip
deformed in the die transport forward by one or two teeth

20 Burr on the cutting a) The clearance is too large a) Set clearance to 0.1 to 0.3 mm
edge (depending on the clip)
b) The cutting edges on the punch are b) Replace punch
damaged

21 The clip is badly The separator hole is offset to the side of Centre the die base to the separator
deformed, the film the die hole
tube is damaged

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8 Cleaning and maintenance 8.1.1 Working with process materials

8.1 General points When working with oil, grease, cleaning agents and
other chemical substances, observe the
• The machine must be cleaned after every use. If manufacturer’s safety and dosage information and
product-carrying parts of the machine are not instructions for use as well as the general regulations
cleaned promptly after switch-off, the product may in force. Never exceed the cleaning agent dosages
harden depending on what product was used. This specified by the manufacturer as too much leads to
may result in production downtime. the destruction of synthetic parts and heavy corrosion
• The machine must be cleaned in accordance with of various metallic components!
the local hygiene and accident prevention 8.1.2 Selecting process materials
regulations in force.
• All cleaning and maintenance work must only be Do not use chlorine-based cleaning and maintenance
carried out when the machine is stopped. products!
• The Operating Manual, in particular the Safety Only use food-safe lubricants in accordance with
Instructions chapter, and the general accident USDA-H1 or NSF ISO 21469!
prevention regulations in force must be observed. When selecting cleaning agents, the current local
• Cleaning and maintenance work may only be hygiene regulations must be observed.
carried out by people who meet the requirements
set out in sections 1.3 and 1.3.2. 8.1.3 Disposal of process materials
• Depending on what product is being packed, Residues of oil, grease, cleaning agents and other
chemical-resistant protective gloves and possibly chemical substances must be collected in
also heat-resistant protective gloves may be accordance with the legal provisions for recycling or
required. Observe the safety data sheet for the disposal.
product! Local authority regulations pertaining to sewage
• Safety shoes must be worn during installation and disposal apply.
dismantling of the machine.
• Wear protective goggles when cleaning the TSCA
with a high-pressure washer!
• Hearing protection must be worn where noise
levels in the work place are 85 dB(A) or higher.
• Staff clothing must be appropriate for the ambient
temperature in the place of installation. If
applicable, wear cold protection clothing!
• It is not permissible for more than one person to
work at the machine at the same time because this
would circumvent the safety measure of two-hand
operation for example.

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8.2 Shutting the machine down 3.) Without touching the sealing bar itself, remove
the film from the seal pipe on the TSCA.
1.) Disconnect the main power supply. To do this,
switch the main switch (2, Fig. 8-3) to the Off
position.
CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn
CAUTION: Hot sealing bar yourself if you touch the sealing bar.
• Do not touch the sealing bar.
The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar.
• Do not touch the sealing bar. CAUTION: Risk of crushing when
swinging the sealing bar up/down
When the sealing bar is swung up or swung back
CAUTION: Risk of crushing when
down, there is a risk of crushing at various points.
swinging the sealing bar up/down
• Make sure you have a firm footing, the sealing bar
When the sealing bar is swung up or swung back is heavy!
down, there is a risk of crushing at various points. • Do not reach into the danger zones.
• Make sure you have a firm footing, the sealing bar • Perform the work as a one-man operation.
is heavy!
• When you swing the sealing bar up, make sure it 4.) Without touching the sealing bar itself, swing the
engages securely. sealing bar back down and lock it. (Fig. 8-2)
• Do not reach into the danger zones.
• Perform the work as a one-man operation.

2.) Without touching the sealing bar itself, unbolt the

sealing bar, swing it up and make sure it engages 1
securely. See section 3.5.1.

Fig. 8-2 1 Sealing bar locked

1

Fig. 8-1 1 Sealing bar, swung up

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5.) Disconnect the main compressed air supply. To
do this, move the air release valve (1, Fig. 8-3)
against the direction of flow (see arrow).

1 2

Fig. 8-3 1 Air release valve

2 Main switch

6.) Remove the compressed air hose.

7.) Pull out the mains plug.

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8.3 Preparing the machine for
cleaning
The activities described in this section must be carried
out by the operators at the end of production.

DANGER: Contact with the product

being packed
Depending on what product is being packed, contact
with it may be hazardous to health.
• Observe the safety data sheet for the product! 1
• If necessary, wear chemical-resistant protective
gloves or wear heat-resistant protective gloves if
the product is extremely hot.
Fig. 8-5 1 Plug
1.) Disconnect the product feed at the stuffer/
customer’s dosing system. 6.) Swing the clip head to the side.
2.) Disconnect the TSCA from the stuffer or 7.) Pull the stuffing horn (1) out through the closing
customer’s dosing system. and separator area. (Fig. 8-6)
3.) If an HDP dosing pump is installed, remove and
dismantle the dosing set for cleaning. Also 2
remove the connecting piece between the dosing
set and the stuffing horn as well as the oil pan for
cleaning. See operating manual for HDP dosing
1
pump.
4.) Unscrew the stuffing horn holder (1) from the
stuffing horn.
3

1
Fig. 8-4 1 Stuffing horn holder

5.) If no HDP dosing pump is connected, seal off the

funnel-shaped holder (1) with the plug. (Fig. 8-5) Fig. 8-6 1 Stuffing horn
2 Inner ring
3 Inner brake

8.) Unscrew and remove the inner brake (3) and the
inner ring (2), if there is one, from the stuffing
horn. (Fig. 8-6)
9.) Set the stuffing horn, inner brake and inner ring, if
there is one, aside for cleaning.

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10.) Pre-clean the stuffing horn with the stuffing horn
cleaner (1).
(Fig. 8-7)

Fig. 8-7 1 Stuffing horn cleaner

11.) Raise protective shutter B.

12.) Raise protective grating A.

CAUTION: Risk of crushing when closing

the front doors
There may be a risk of crushing when the front doors
are closed.
• Open and close the front doors carefully.
• Only one person at a time may work in the vicinity
of the front doors.

13.) Close both front doors (1, Fig. 8-8).

Fig. 8-8 1 Front doors

14.) Close all switch boxes on the machine.

15.) Cover electrical parts to protect them from
moisture.

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8.4 Cleaning the sealing area 2.) Clean off any dust. Use a cleaning cloth and
stainless steel cleaner to do this.
3.) It is particularly important to check the film guide
pulleys are dust-free otherwise dust will get onto
DANGER: Risk of crushing/electrocution the inside of the film and contaminate the product
if cleaning the machine whilst in that is being packed.
operation
If you clean the machine while it is operating, you are
at risk of serious injury through crushing or CAUTION: Risk of crushing when closing
electrocution. the front doors
All cleaning and maintenance work must only be There may be a risk of crushing when the front doors
carried out when the machine has stopped. are closed.
• Open and close the front doors carefully!
• Only one person at a time may work in the vicinity
WARNING: Incorrect use of cleaning of the front doors.
agents is dangerous
Your health is at risk if you use the cleaning agents 4.) Close both front doors.
incorrectly.
Read and observe the manufacturer’s specifications
for the cleaning agent.

CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar. In addition, the
sealing bar could get scratched.
• Do not touch the sealing bar.

ATTENTION: Destruction of transparent plastics

Scouring pads scratch transparent plastics
(Plexiglas). The material is then no longer transparent.
Scouring pads must not be used on transparent
plastics (Plexiglas).

ATTENTION: Wet cleaning causes damage

In the sealing area, electrical parts, etc., may be
damaged if they come into contact with water.
• Do not use a high-pressure washer; instead use a
cleaning cloth and stainless steel cleaner.
• Close the front doors before cleaning the rest of
the machine.

1.) To do this, open both front doors.

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8.5 Cleaning the sealing area

DANGER: Risk of crushing/electrocution

if cleaning the machine whilst in
operation
If you clean the machine while it is operating, you are
at risk of serious injury through crushing or
electrocution.
All cleaning and maintenance work must only be
carried out when the machine has stopped.

DANGER: Contact with the product

being packed
Depending on what product is being packed, contact
with it may be hazardous to health.
• Observe the safety data sheet for the product!
• If necessary, wear chemical-resistant protective
gloves or wear heat-resistant protective gloves if
the product is extremely hot.
Fig. 8-9

ATTENTION: Production downtime if cleaning 4.) Remove the plate (1) at the product outlet and set
delayed aside for cleaning. (Fig. 8-10)

If product-carrying parts of the machine are not

cleaned promptly after switch-off, the product may
harden depending on what product was used. This
may result in production downtime.
• Clean product-carrying parts of the machine
promptly after switching off.

1.) Swing the clip head to the side.

2.) Raise protective grating A. 1
3.) Raise protective shutter B.

Fig. 8-10 1 Plate

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5.) Remove the tray (1) and set aside for cleaning. To
do this, flip the latch (2) down. Push the tray (1) to
the left and pull towards you to remove.
(Fig. 8-11)

1
1 Fig. 8-12 1 Lubricant pan

7.) Re-insert the lubricant pan. (Fig. 8-13)

2

1
Fig. 8-11 1 Tray
2 Latch

6.) Remove the lubricant pan (1). (Fig. 8-12) Clean

the lubricant pan with a cleaning cloth and Fig. 8-13
stainless steel cleaner.

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10.) The motor shaft (1) is now accessible. To access
all dirty areas, move the machine into different
positions by moving the motor shaft (1) .
(Fig. 8-16)

Fig. 8-14
Fig. 8-16 1 Motor shaft
8.) Open the locks (1) using the control cabinet key.
(Fig. 8-15)
9.) Open the right side panel (2) on the clip head.

Fig. 8-15 1 Locks

2 Right side panel

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8.5.1 Non food-processing machines:
Cleaning the sealing area

DANGER: Risk of crushing/electrocution

if cleaning the machine whilst in
operation
If you clean the machine while it is operating, you are
at risk of serious injury through crushing or
electrocution.
All cleaning and maintenance work must only be
carried out when the machine has stopped.

Fig. 8-17 Substructure of clip head

DANGER: Contact with the product
being packed 8.5.1.1 Non food-processing machines:
Depending on what product is being packed, contact After the cleaning work
with it may be hazardous to health.
• Observe the safety data sheet for the product! 1.) Apply a protective layer to the machine and the
• If necessary, wear chemical-resistant protective parts removed for cleaning. For example:
gloves or wear heat-resistant protective gloves if • Oil the separator, especially the polished parts,
the product is extremely hot. with food-grade oil.
• Grease all moving parts with food-grade grease.

WARNING: Incorrect use of cleaning

agents is dangerous DANGER: Crushing and amputation in
Your health is at risk if you use the cleaning agents the closing and separator area
incorrectly. Without the smallest appropriate spray guard and/or
Read and observe the manufacturer’s specifications inner ring on the stuffing horn, the closing and
for the cleaning agent. separator area would be accessible. Here, there is a
risk of crushing or amputation, especially of fingers.
1.) Clean the machine and all parts removed for • The smallest appropriate spray guard must be
cleaning. Clean the machines that do not process fitted.
food with a cleaning cloth, plastic spatula and • If an inner ring is required for the stuffing horn/
solvent. calibre, it must be fitted in the right place on the
2.) Perform a visual check for cleanliness on the stuffing horn. The gap between the spray guard
machines and all parts removed for cleaning, and the inner ring must not exceed 8 mm.
particularly: • If no inner ring is required for the stuffing horn/
• Separator area. To access all dirty areas, move calibre, the gap between the spray guard and the
the machine into different positions by moving stuffing horn must not exceed 8 mm.
the motor shaft (1). (Fig. 8-16)
• Stuffing horn, stuffing horn holder, inner brake 2.) Position the stuffing horn. Fit the inner brake and
and inner ring, if there is one the inner ring, if there is one, on the stuffing horn.
• If an HDP dosing pump is installed, the individual See Sections 3.5.3 and 3.5.4.
parts of the dosing set, the connecting piece 3.) If an HDP dosing pump is installed, refit the
between the dosing set and the stuffing horn and dosing set, the connecting piece to the stuffing
the oil pan. See operating manual for HDP dosing horn and the oil pan. See operating manual for
pump. HDP dosing pump.
• Substructure of the clip head, see Fig. 8-17. 4.) Close the right side panel (2) on the clip head.
(Fig. 8-15)
5.) Lock the locks (1). (Fig. 8-15)

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CAUTION: Risk of crushing when

swinging the clip head into the working
position
There are several places around the clip head where
fingers could get crushed as the clip head is swung
into the working position.
• Before swinging the clip head in, make sure
nobody is in the swing area.
• Only one person at a time may work in the vicinity
of the clip head.

6.) Check that nobody is in the swing area of the clip

head, then swing the clip head into the working
position.
7.) Reinsert the tray (1) at the product outlet. To do
this, insert the tray (1) into the opening and push 1
it to the right. Hook the latch (2) and flip it up.

2
Fig. 8-18 1 Tray
2 Latch

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8.) Reinsert the plate (1) at the product outlet. 8.5.2 Food-processing machines: Cleaning
(Fig. 8-19) the sealing area

DANGER: Risk of crushing/electrocution

if cleaning the machine whilst in
operation
If you clean the machine while it is operating, you are
at risk of serious injury through crushing or
electrocution.
1 All cleaning and maintenance work must only be
carried out when the machine has stopped.

DANGER: Contact with the product

being packed
Depending on what product is being packed, contact
Fig. 8-19 1 Plate with it may be hazardous to health.
• Observe the safety data sheet for the product!
9.) Close protective shutter B. • If necessary, wear chemical-resistant protective
10.) Close protective grating A. gloves or wear heat-resistant protective gloves if
the product is extremely hot.

CAUTION: Risk of crushing when

swinging the product outlet into the DANGER: Eye damage due to hot water
working position and dirt particles
There are several places around the product outlet When cleaning the machine with a high-pressure
where fingers could get crushed as the product outlet washer , hot water under pressure and dirt particles
is swung into the working position. can cause serious eye injuries.
• Work carefully. • Follow the operating instructions for the
• Only one person at a time may work in the area of high-pressure washer!
the product outlet. • Wear protective goggles when cleaning with a
high-pressure washer.
11.) Close all shutters and panels.
12.) Re-connect TSCA to stuffer or customer’s dosing
system. WARNING: Incorrect use of cleaning
agents is dangerous
13.) Before longer periods of non-operation, for
example weekends, spray the machine with a fine Your health is at risk if you use the cleaning agents
coat of anti-corrosion oil. incorrectly.
14.) Check all protective devices are complete, fitted Read and observe the manufacturer’s specifications
correctly and functioning properly. for the cleaning agent.
See section 1.5.
15.) Remove all cleaning materials and tools from the
vicinity of the machine. ATTENTION: Cleaning difficulties
When the cleaning water is hotter than 55 °C, protein
solidifies and makes cleaning more difficult.
The cleaning water should be max. 55 °C.

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ATTENTION: Damage to electrical parts
Electrical parts may be damaged if they come into
contact with water.
• Cover electrical parts before cleaning
commences.
• When cleaning the machine with a high-pressure
washer, never expose electrical parts to direct
steam jets.
• Close front doors before cleaning.

ATTENTION: Damage caused by incorrect use of

a high-pressure washer
The sealing area must never be cleaned with a Fig. 8-20 Substructure of clip head
high-pressure washer.
Small parts in the clip module may be destroyed if 4.) Lather the machine systematically from top to
you hold the cleaning nozzle too close to the machine bottom (for the required lather time).
when cleaning it with the high-pressure washer or if 5.) After lathering, carefully rinse the machine and all
you set the pressure too high on the high-pressure parts removed for cleaning systematically with
washer. approx. 55 °C hot water from top to bottom,
• Never use a high-pressure washer to clean the removing all cleaning agent residues.
sealing area. 6.) Perform a visual check for cleanliness on the
• Only clean the clip module with the high-pressure machines and all parts removed for cleaning,
washer set at 80 bar maximum. particularly:
• Keep the cleaning nozzle at least 1 m away from • Separator area. To check all areas, move the
the machine surface. machine into different positions by moving the
• Do not use a dirtblaster. motor shaft (1) . (Fig. 8-16)
• Stuffing horn, stuffing horn holder, inner brake
1.) Remove coarse dirt from the machine and the and inner ring, if there is one
parts that have been removed for cleaning. • If an HDP dosing pump is installed, the individual
2.) Rinse the machine carefully with warm water parts of the dosing set, the connecting piece
max. 55 °C. between the dosing set and the stuffing horn and
the oil pan. See operating manual for HDP dosing
3.) Perform a visual check for cleanliness on the
pump.
machines and all parts removed for cleaning,
particularly: • Substructure of clip head
• Separator area. To access all dirty areas, move 7.) Disinfect the machine and all parts removed for
the machine into different positions by moving cleaning.
the motor shaft (1) . (Fig. 8-16) 8.) After disinfecting, carefully rinse the machine and
• Stuffing horn, stuffing horn holder, inner brake all parts removed for cleaning with drinking water.
and inner ring, if there is one
• If an HDP dosing pump is installed, the individual
parts of the dosing set, the connecting piece
between the dosing set and the stuffing horn and
the oil pan. See operating manual for HDP dosing
pump.
• Substructure of the clip head, see Fig. 8-20.

Cleaning and maintenance

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8.5.2.1 Food-processing machines: After
the cleaning work
CAUTION: Risk of crushing when
1.) Dry the machine and all parts removed for swinging the clip head into the working
cleaning with compressed air. position
2.) Apply a protective layer to the machine and the There are several places around the clip head where
parts removed for cleaning. For example: fingers could get crushed as the clip head is swung
into the working position.
• Oil the separator, especially the polished parts,
with food-grade oil. • Before swinging the clip head in, make sure
nobody is in the swing area.
• Grease all moving parts with food-grade grease.
• Only one person at a time may work in the vicinity
3.) After the clip head has been cleaned, lubrication
of the clip head.
points 1 to 11 must be lubricated
(see section 9.5).
8.) Check that nobody is in the swing area of the clip
head, then swing the clip head into the working
DANGER: Crushing and amputation in position.
the closing and separator area 9.) Reinsert the tray (1) at the product outlet. To do
Without the smallest appropriate spray guard and/or this, insert the tray (1) into the opening and push
inner ring on the stuffing horn, the closing and it to the right. Hook the latch (2) and flip it up.
separator area would be accessible. Here, there is a (Fig. 8-21)
risk of crushing or amputation, especially of fingers.
• The smallest appropriate spray guard must be
fitted.
• If an inner ring is required for the stuffing horn/
calibre, it must be fitted in the right place on the
stuffing horn. The gap between the spray guard
and the inner ring must not exceed 8 mm.
• If no inner ring is required for the stuffing horn/
calibre, the gap between the spray guard and the
stuffing horn must not exceed 8 mm.

4.) Position the stuffing horn. Fit the inner brake and
the inner ring, if there is one, on the stuffing horn.
See Sections 3.5.3 and 3.5.4.
5.) If an HDP dosing pump is installed, refit the
dosing set, the connecting piece to the stuffing
horn and the oil pan. See operating manual for
HDP dosing pump.
6.) Close the right side panel (2) on the clip head.
(Fig. 8-15)
7.) Lock the locks (1). (Fig. 8-15)

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Fig. 8-22 1 Plate

1 11.) Close protective shutter B.
12.) Close protective grating A.
13.) If water has got into the sealing area despite the
front doors being closed, open the front doors
and dry the area.

CAUTION: Risk of crushing when

swinging the product outlet into the
working position
There are several places around the product outlet
where fingers could get crushed as the product outlet
is swung into the working position.
• Work carefully.
• Only one person at a time may work in the area of
the product outlet.
2
14.) Close all shutters and panels.
Fig. 8-21 1 Tray
15.) Re-connect TSCA to stuffer or customer’s dosing
2 Latch
system.
10.) Reinsert the plate (1) at the product outlet. 16.) Before longer periods of non-operation, for
(Fig. 8-19) example weekends, spray the machine with a fine
coat of anti-corrosion oil.
17.) Check all protective devices are complete, fitted
correctly and functioning properly.
See section 1.5.
18.) Remove all cleaning materials and tools from the
vicinity of the machine.

Cleaning and maintenance

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Cleaning and maintenance

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9 Maintenance
9.1 Note
• Certain maintenance work may only be carried out by people who meet the requirements set out in
sections 1.3 and 1.3.3. There is a corresponding note for this work.
• Work on the electrical equipment of the machine must only be carried out by a qualified electrician, or by a
trained person under the guidance and supervision of a qualified electrician, in accordance with the electrical
regulations.
• The Operating Manual, in particular the Safety Instructions chapter, and the local accident prevention
regulations in force must be observed.
• It is not permissible for more than one person to work at the machine at the same time because this would
circumvent the safety measure of two-hand operation for example.
• Maintenance work must always be carried out when the machine has stopped.
• Safety shoes must be worn during installation and set-up of the machine, when loading heavy film rolls and
during dismantling and transport of the machine.
• Hearing protection must be worn where noise levels in the work place are 85 dB(A) or higher.
• Cut-resistant protective gloves must be worn when changing the knife.
• Depending on what product is being packed, chemical-resistant protective gloves and possibly also
heat-resistant protective gloves may be required. Observe the safety data sheet for the product!
• When working on the spray system, observe the spray manufacturer’s instructions and wear
chemical-resistant protective gloves if necessary.
• The staff's clothing must be appropriate for the ambient temperature at the place of installation
(see section 3.2).

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9.2 Shutting down the machine before maintenance work
Before certain maintenance work is performed, the machine must be shut down. This will be explicitly pointed
out in the description of the maintenance work concerned.

1.) Disconnect the main power supply. To do this, switch the main switch (2, Fig. 9-2) to the Off position and
secure with a lock to prevent it from being switched back on. Carry the key on your person.

CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn yourself if you touch the sealing bar.
• Do not touch the sealing bar.
• Allow the sealing bar to cool down before you start any further work.

CAUTION: Risk of crushing when swinging the sealing bar up/down

When the sealing bar is swung up or swung back down, there is a risk of crushing at
various points.
• Make sure you have a firm footing, the sealing bar is heavy!
• When you swing the sealing bar up, make sure it engages securely.
• Do not reach into the danger zones.
• Perform the work as a one-man operation.

2.) Without touching the sealing bar itself, unbolt the sealing bar, swing it up and make sure it engages
securely. See section 3.5.1.

Fig. 9-1 1 Sealing bar swung up

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3.) Disconnect the main compressed air supply. To do this, move the air release valve (1, Fig. 9-2) against the
direction of flow (see arrow).

1 2

Fig. 9-2 1 Air release valve

2 Main switch

4.) Remove the compressed air hose.

5.) Before working on the electrical equipment, pull out the mains plug.

9.3 After completing the work

Check all protective devices are complete, fitted correctly and functioning properly. See section 1.5.

9.4 Lubricating grease

The Poly-clip grease cartridge delivered with the machine contains special lubricating grease that satisfies
European food regulations, meets the requirements of the FDA guidelines of Section 21 CFR 178.3570 and is
approved in accordance with USDA-H1. It provides a high level of corrosion protection, is not washed out
during cleaning of the machine and can be used in a wide service temperature range. Grease for the manual
lubrication points (grease gun) is available under article number 33269 (400 g).
Using different grease may result in a lack of lubrication and cause consequential damage, e.g. if the grease
used does not have the required viscosity.
Poly-clip System GmbH & Co. KG accepts no liability for damage caused by using a different grease or any
consequential damage thereof.

9.4.1 Grease specification

• Synthetic hydrocarbon oil (base oil) with aluminium complex soap (thickener)
• Approved according to USDA H1 or certified according to NSF ISO 21469
• Service temperature range -45 °C to 120 °C
• Density: 0.92 g/cm3 [20°C]
• Consistency: up to NLGI grade 2.

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9.5 Lubrication plan

Fig. 9-3 Lubrication after every 90,000 closed clips (factory setting)

Lubrication point 1: Cam roller of upper clip lever

Lubrication point 2: Clip transport shaft
Lubrication point 3: Cam roller of lower clip lever
Lubrication point 4: Clip lever shaft
Lubrication point 5: Separator cam roller
Lubrication point 6: Clip transport shaft
Lubrication point 7: Right separator bearing
Lubrication point 8: Separator guide tube
Lubrication point 9: Spreading guide bolts
Lubrication point 10: Cylindrical axle
Lubrication point 11: Left separator bearing
There are also the following lubrication points, although these are not shown in the lubrication plan:
Lubrication point 12: Sealing station counter support
Lubrication point 13: Clip head swing unit

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9.5.1 Lubrication point 1: Cam roller of upper clip lever

Fig. 9-4 Lubrication point 1

9.5.2 Lubrication point 2: Clip transport shaft

Fig. 9-5 Lubrication point 2

9.5.3 Lubrication point 3: Cam roller of lower clip lever

Fig. 9-6 Lubrication point 3

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9.5.4 Lubrication point 4: Clip lever shaft

Fig. 9-7 Lubrication point 4

9.5.5 Lubrication point 5: Separator cam roller

Fig. 9-8 Lubrication point 5

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9.5.6 Lubrication point 6: Clip transport shaft

Fig. 9-9 Lubrication point 6

9.5.7 Lubrication point 7: Right separator bearing

Fig. 9-10 Lubrication point 7

9.5.8 Lubrication point 8: Separator guide tube

Fig. 9-11 Lubrication point 8

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9.5.9 Lubrication point 9: Spreading guide bolts
With overspreading, the lubrication point is omitted and the bar must be greased from the outside.

Fig. 9-12 Lubrication point 9

9.5.10 Lubrication point 10: Cylindrical axle

With overspreading, the lubrication point is omitted and the bar must be greased from the outside.

10

Fig. 9-13 Lubrication point 10

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9.5.11 Lubrication point 11: Left separator bearing

11

Fig. 9-14 Lubrication point 11

9.6 Lubrication points to be lubricated annually

9.6.1 Lubrication point 12 annually: Sealing station counter support
Lubrication cannot take place until the stop piece has been removed.

Fig. 9-15 Lubrication point 12

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9.6.2 Lubrication point 13 annually: Clip head swing unit

13

Fig. 9-16 Lubrication point 13

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9.7 Changing the air filter
If the flow is too low, even though the operating pressure has not changed, the air filter should be replaced.

CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn yourself if you touch the sealing bar.
• Do not touch the sealing bar.
• Allow the sealing bar to cool down before you start any further work.

CAUTION: Risk of crushing when swinging the sealing bar up/down

When the sealing bar is swung up or swung back down, there is a risk of crushing at various
points.
• Make sure you have a firm footing, the sealing bar is heavy!
• When you swing the sealing bar up, make sure it engages securely.
• Do not reach into the danger zones.
• Perform the work as a one-man operation.

1.) Without touching the sealing bar itself, unbolt the sealing bar, swing it up and make sure it engages
securely.

Fig. 9-17 1 Sealing bar swung up

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2.) Disconnect the main compressed air supply. To do this, move the air release valve (1) against the direction
of flow (see arrow). (Fig. 9-18)

Fig. 9-18 1 Air release valve

2 Pressure gauge

3.) Check that the pressure gauge is displaying 0 bar (2, Fig. 9-18).
4.) Open the shutter (1). (Fig. 9-19)

1
Fig. 9-19 1 Shutter (here, coloured)
2 Pressure reducer with air filter

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5.) Remove the container (1) by turning it clockwise. (Fig. 9-20)

1 1
3

2
Fig. 9-20 1 Container
2 Filter plate
3 Air filter

6.) Remove the filter plate (2) by turning it clockwise. (Fig. 9-20)
7.) Remove the used air filter (3).
8.) Put a new air filter (3) on the filter plate (2).
9.) Fit the filter plate (2) by turning it anti-clockwise, but only hand-tighten it.
10.) Fit the container (1) by turning it anti-clockwise, 2.5 Nm torque.
11.) Close the shutter (1). (Fig. 9-19)
12.) Reconnect the compressed air supply.

CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn yourself if you touch the sealing bar.
• Do not touch the sealing bar.

CAUTION: Risk of crushing when swinging the sealing bar up/down

When the sealing bar is swung up or swung back down, there is a risk of crushing at
various points.
• Make sure you have a firm footing, the sealing bar is heavy!
• Do not reach into the danger zones.
• Perform the work as a one-man operation.

13.) Without touching the sealing bar itself, swing the sealing bar back down and lock it.

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9.8 Replacing the Teflon strips on the seal pipe

WARNING: Product contamination

If a Teflon strip detaches from the seal pipe, the adhesive from the Teflon strip could
contaminate the product.
• Check the condition and wear of the Teflon strips upon every production start,
every film change and every operator changeover - and possibly more often than
that if you are using highly abrasive films.
• If any of the adhesive strips have detached edges or damaged surfaces, they must
be replaced immediately.
• Any Teflon strips that need replacing, as well as their adhesive, must be
completely removed from the seal pipe, leaving no residue. The entire seal pipe
must be completely free of adhesive residue.

Fig. 9-21 One Teflon strip, operation without film drive

Fig. 9-22 Three Teflon strips, operation with film drive (optional)

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1.) Remove the Teflon strips from the seal pipe, ensuring no residue is left.
2.) Remove the adhesive from the seal pipe, ensuring no residue is left. The entire seal pipe must be completely
free of adhesive residue.
3.) Cut new Teflon adhesive strips to size. Round off the corners facing the product inlet to prevent premature
peeling of the adhesive tape.

Fig. 9-23 Teflon adhesive strips on the seal pipe

4.) Apply the new Teflon adhesive strips to the seal pipe, making sure the surface is smooth and crease-free.
Firmly press down the edges.
5.) If necessary, reduce any excess Teflon adhesive tape with a cut (see Fig. 9-24).

Fig. 9-24 Cut

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9.9 Changing the knife
Note: This activity may only be carried out by people who meet the requirements set out in sections 1.3 and
1.3.3.

1.) With the safety circuit closed, bring the machine into the home position. To do this, press the “First Clip”
button and the two-hand button simultaneously within 0.5 seconds.
2.) Raise protective shutter B.

CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn yourself if you touch the sealing bar.
• Do not touch the sealing bar.
• Allow the sealing bar to cool down before you start any further work.

CAUTION: Risk of crushing when swinging the sealing bar up/down

When the sealing bar is swung up or swung back down, there is a risk of crushing at
various points.
• Make sure you have a firm footing, the sealing bar is heavy!
• When you swing the sealing bar up, make sure it engages securely.
• Do not reach into the danger zones.
• Perform the work as a one-man operation.

3.) Without touching the sealing bar itself, unbolt the sealing bar, swing it up and make sure it engages
securely. See section 3.5.1.

Fig. 9-25 1 Sealing bar swung up

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4.) Disconnect the main compressed air supply. To do this, move the air release valve (1, Fig. 9-26) against the
direction of flow (see arrow).

Fig. 9-26 1 Air release valve

2 Pressure gauge

5.) Check that the pressure gauge is displaying 0 bar (2, Fig. 9-26).
6.) On the control panel, call up a screen that shows the current machine rotation angle (1). (Fig. 9-27)

Fig. 9-27 1 Current machine rotation angle

DANGER: Risk of body parts, especially fingers, being crushed

or severed
You are at risk of incurring injury by crushing and cutting in the closing and
separator area, even in jog mode.
• The machine must therefore only ever be operated by one person at a time!
• Do not reach into the danger zone.
• Always ensure you have a firm footing during jog mode!

7.) Press the First Clip button and the two-hand button simultaneously. Keep both buttons pressed until the
knife cylinder is accessible (machine rotation angle approx. 170°).

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CAUTION: Sharp-edged punch and sharp knife

You could cut yourself.

• Wear cut-resistant protective gloves!
• Work carefully and do not touch the blade of the knife or the edges of the
punch.

8.) Put cut-resistant protective gloves on.

9.) Remove the pneumatic hose (1).

1
3
2

Fig. 9-28 1 Pneumatic hose

2 Knife cylinder
3 Screws

CAUTION: Knife cylinder springs out

Under the knife cylinder, there is a knife holder held under pressure by a
compression spring. When the screws are loosened, the knife cylinder will
spring towards you.
• Hold the knife cylinder firmly as you unscrew the screws.
• Keep your face a safe distance from the danger point.

10.) Hold the knife cylinder (2) firmly and unscrew the screws (3, ). (Fig. 9-28)

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11.) Remove the knife cylinder. (Fig. 9-29)

Fig. 9-29

12.) Remove the knife holder. (Fig. 9-30)

13.) Remove the washer (1) and the compression spring (2). (Fig. 9-30)

1
2

Fig. 9-30 1 Washer

2 Compression spring

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14.) Disassemble the knife holder. (Fig. 9-31)

Fig. 9-31 1 Knife

15.) Exchange the knife (1) and reassemble the knife holder. (Fig. 9-31)
16.) Insert the washer (1). (Fig. 9-32)

Fig. 9-32 1 Washer

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17.) Slide the compression spring onto the knife holder. (Fig. 9-33)

Fig. 9-33

18.) Insert the knife holder into the cylinder sleeve. (Fig. 9-34)

Fig. 9-34

19.) Insert the knife cylinder. (Fig. 9-35)

Fig. 9-35

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CAUTION: Knife cylinder springs out

Under the knife cylinder, there is a knife holder held under pressure by a compression
spring. If you do not hold the knife cylinder really firmly during reassembly, it springs
towards you.
• Press the knife cylinder down and hold it firmly in place while you tighten the
screws.
• Keep your face a safe distance from the danger point.

20.) Press the knife cylinder down and hold it firmly in place while you tighten the screws (3). (Fig. 9-36)
21.) Connect the pneumatic hose (1). In doing so, align the hose connection (4) as shown, otherwise the hose
will tear during operation. (Fig. 9-36)

1
3
2
4

Fig. 9-36 1 Pneumatic hose

2 Knife cylinder
3 Screws
4 Hose connection

22.) Remove all tools from the vicinity of the machine.

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CAUTION: Hot sealing bar

The sealing bar can get very hot. You could burn yourself if you touch the sealing bar.
• Do not touch the sealing bar.

CAUTION: Risk of crushing when swinging the sealing bar up/down

When the sealing bar is swung up or swung back down, there is a risk of crushing at
various points.
• Make sure you have a firm footing, the sealing bar is heavy!
• Do not reach into the danger zones.
• Perform the work as a one-man operation.

23.) Without touching the sealing bar itself, swing the sealing bar back down and lock it. (Fig. 9-37)

Fig. 9-37 1 Sealing bar locked

24.) Reconnect the compressed air supply.

25.) Close protective shutter B.
26.) With the safety circuit closed, bring the machine into the home position. To do this, press the “First Clip”
button and the two-hand button simultaneously within 0.5 seconds.

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9.10 Converting the clip transport (spacing)
Note: This activity may only be carried out by people who meet the requirements set out in sections 1.3 and
1.3.3.

Prerequisite:
• The clip sticks must have been pulled out of the clip channel. This can only be done in the clip loading
position. See section 5.4.1.
• The clip reels must have been removed.
• The die and punch must have been removed. See sections 5.5 and 5.6.

1.) With the safety circuit closed, bring the machine into the home position. To do this, press the “First Clip”
button and the two-hand button simultaneously within 0.5 seconds.
2.) Press the “Clip loading position/Change positions” button (Fig. 9-38).

Fig. 9-38

Result: The Tool change screen (Fig. 9-39) appears.

1 2 3

Fig. 9-39 Tool change screen,machine in home position

1 Clip loading position button
2 Die change position button
3 Punch change position button
4 Home position button

3.) With the safety circuit closed, press button 3. (Fig. 9-39), The machine moves into the punch change
position (machine rotation angle 95°).

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4.) Raise protective shutter B.
5.) Swing the clip head to the side.
6.) Release the spring (1). To do this, press the spring out of the lower holder using a screwdriver.
(Fig. 9-40)

Fig. 9-40 1 Released spring

7.) Loosen the screws (1) on the clip guide plate. (Fig. 9-41)

Fig. 9-41 1 Screws

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8.) Pull the clip guide plate (1) down and out. (Fig. 9-42)

Fig. 9-42 1 Clip guide plate

9.) Unscrew the transport lever retainer (1) (left-hand thread). (Fig. 9-43)

Fig. 9-43 1 Retainer (coloured)

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10.) Unscrew the rear fixing screw of the transport holder. (Fig. 9-44)

Fig. 9-44

11.) Unscrew the lower fixing screw (1) of the transport holder. Remove the transport lever and transport holder.
(Fig. 9-45)

Fig. 9-45 1 Lower fixing screw

2 Transport holder
3 Transport lever

12.) Fit a different transport holder (2) into the transport lever (3) (Fig. 9-45).

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13.) Push the transport holder and transport lever unit onto the axle (1). (Fig. 9-46)

1
Fig. 9-46 1 Axle

14.) Screw in the lower fixing screw (1) of the transport holder, but do not fully tighten it yet.
(Fig. 9-47)

Fig. 9-47 1 Lower fixing screw

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15.) Screw in and tighten the rear fixing screw of the transport holder. (Fig. 9-48)

Fig. 9-48

16.) Tighten the lower fixing screw (1) of the transport holder. In doing so, make sure there is still a gap of 3 mm.
(Fig. 9-49)

3 mm

1
Fig. 9-49 1 Lower fixing screw

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17.) Insert the washer (1). (Fig. 9-50)

Fig. 9-50 1 Washer (here, coloured)

18.) Screw in the transport lever retainer (1). In doing so, make sure the grease nipple (2) is facing forwards.
(Fig. 9-51)

2
Fig. 9-51 1 Retainer
2 Grease nipple

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19.) Insert the clip guide plate from below. (Fig. 9-52)

Fig. 9-52 1 Screws

20.) Tighten the screws (1). (Fig. 9-52)

21.) Hook the spring (1) back on. (Fig. 9-53)

Fig. 9-53 1 Spring

2 Die

22.) With the safety circuit closed, bring the machine into the die change position. (2, Fig. 9-39)
23.) Insert the appropriate die (2) and tighten the screw. (Fig. 9-53)
24.) With the safety circuit closed, bring the machine into the punch change position. (3, Fig. 9-39)

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CAUTION: Sharp-edged punch and sharp knife

You could cut yourself.

• Wear cut-resistant protective gloves!
• Work carefully and do not touch the blade of the knife or the edges of the
punch.

25.) Put cut-resistant protective gloves on.

26.) Fit the appropriate punch for the spacing. See section 5.6.
27.) With the safety circuit closed, bring the machine into the clip loading position. (1, Fig. 9-39)
28.) Insert the appropriate clips for the spacing. See section 5.4.4.
29.) With the safety circuit closed, bring the machine into the home position. (4, Fig. 9-39)

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9.11 Converting the spreading
Note: This activity may only be carried out by people who meet the requirements set out in sections 1.3
and 1.3.3.

Prerequisite:
• The clip sticks must have been pulled out of the clip channel. This can only be done in the clip loading
position. See section 5.4.1.
• The die and punch must have been removed. See sections 5.5 and 5.6.

1.) With the safety circuit closed, bring the machine into the home position. To do this, press the “First Clip”
button and the two-hand button simultaneously within 0.5 seconds.
2.) Press the “Clip loading position/Change positions” button (Fig. 9-54).

Fig. 9-54

Result: The Tool change screen (Fig. 9-55) appears.

1 2 3

Fig. 9-55 Tool change screen,machine in home position

1 Clip loading position button
2 Die change position button
3 Punch change position button
4 Home position button

3.) With the safety circuit closed, press button 3. (Fig. 9-55), The machine moves into the punch change
position (machine rotation angle 95°).

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4.) Raise protective shutter B.
5.) Swing the clip head to the side.
6.) Release the spring (1). To do this, press the spring out of the lower holder using a screwdriver.
(Fig. 9-56)

Fig. 9-56 1 Released spring

7.) Loosen the screws (1) on the clip guide plate. (Fig. 9-57)

Fig. 9-57 1 Screws

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8.) Pull the clip guide plate (1) down and out. (Fig. 9-58)

Fig. 9-58 1 Clip guide plate

9.) Unscrew the transport lever retainer (1) (left-hand thread). (Fig. 9-59)

Fig. 9-59 1 Retainer (coloured)

Maintenance
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10.) Unscrew the rear fixing screw of the transport holder. (Fig. 9-60)

Fig. 9-60

11.) Unscrew the lower fixing screw (1) of the transport holder. Remove the transport lever and transport holder.
(Fig. 9-61)

Fig. 9-61 1 Lower fixing screw

2 Transport holder
3 Transport lever

Maintenance
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CAUTION: Sharp-edged punch and sharp knife

You could cut yourself.

• Wear cut-resistant protective gloves!
• Work carefully and do not touch the blade of the knife or the edges of the
punch.

12.) Put cut-resistant protective gloves on.

13.) Mask off the blade of the knife (1) with adhesive tape for the duration of the work. (Fig. 9-62)

Fig. 9-62 1 Knife blade (coloured)

14.) Swing the sausage outlet to the side.

15.) Open the left side panel on the clip head.

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16.) Open the locks (1) using the control cabinet key. (Fig. 9-63)
17.) Open the right side panel (2) on the clip head.

Fig. 9-63 1 Locks

2 Right side panel

18.) Unscrew the screw (1), counterholding underneath as you do. Remove the screw and the washer.
(Fig. 9-64)

Fig. 9-64 1 Screw

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19.) Use a screwdriver to spread the separator slightly. (Fig. 9-65)

Fig. 9-65 Spreading the separator

20.) Press the spreading lever in. (Fig. 9-66)

Fig. 9-66

Maintenance
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21.) Remove the bold (1) and the spreading lever (2). (Fig. 9-67)

Fig. 9-67 1 Bolt

2 Spreading lever

22.) Remove the plate (1). To do this, loosen the screws (2). (Fig. 9-68)

1 1
Fig. 9-68 1 Plate (coloured)
2 Screws

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23.) Remove the screws (1). (Fig. 9-69)
24.) Remove the flange (2) and the spring (3).

1 2 3
Fig. 9-69 1 Screws (coloured)
2 Flange
3 Spring

25.) Loosen the screw (1). (Fig. 9-70)

26.) Remove the nut (2) and the washer (3).

2
3

Fig. 9-70 1 Screw

2 Nut
3 Washer

Maintenance
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27.) Pull out the rod (1). (Fig. 9-71)

Fig. 9-71 1 Rod

28.) Move the separator to the left so that it no longer hangs in the side wall on the right. (Fig. 9-72)

Fig. 9-72

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29.) Take all the washers off the separator. (Fig. 9-73)

Fig. 9-73

30.) Push the correct number of washers of the correct thickness for the spreading onto the separator.
(Fig. 9-73) See table for details.

Spreading Number/thickness of washers

30 Washer 1.5 mm
26 Washer 1.5 mm
Washer 1.5 mm
18 Washer 1.5 mm
Washer 1.5 mm
Washer 0.5 mm

31.) Hang the separator back in the right side wall.

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32.) Insert the rod (1). Observe the groove (2). (Fig. 9-74)

2
Fig. 9-74 1 Rod
2 Groove (coloured)

33.) Pull up the washer (3) at the very bottom. (Fig. 9-75)
34.) Turn the nut (2) on the thread.
35.) Tighten the screw (1).

2
3

Fig. 9-75 1 Screw

2 Nut
3 Washer

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36.) Check if the screw has been tightened too much or too little. To do this, turn the machine over at the motor
shaft (1). (Fig. 9-76) It should not take much force to move it, but the separator must not wobble.

Fig. 9-76 1 Motor shaft

37.) Put spreading lever (2) in position. (Fig. 9-77)

38.) Push the bolt (1) into the hole that matches the desired spreading.

Fig. 9-77 1 Bolt

2 Spreading lever

Maintenance
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39.) Put the washer (2) underneath and tighten the screw (1). Counterhold underneath as you do. (Fig. 9-78)

2
Fig. 9-78 1 Screw
2 Washer

40.) Insert the spring (3) and flange (2). (Fig. 9-79)
41.) Tighten the screws (1).

2 3 1
Fig. 9-79 1 Screws (coloured)
2 Flange
3 Spring

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42.) Fit the plate (1). Tighten the screws (2) for it. (Fig. 9-80)

1 1
Fig. 9-80 1 Plate (coloured)
2 Screws

43.) Fit a different transport holder (2) into the transport lever (3) (Fig. 9-61).
44.) Push the transport holder and transport lever unit onto the axle (1). (Fig. 9-81)

1
Fig. 9-81 1 Axle

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45.) Screw in the lower fixing screw (1) of the transport holder, but do not fully tighten it yet. (Fig. 9-82)

Fig. 9-82 1 Lower fixing screw

46.) Screw in and tighten the rear fixing screw of the transport holder. (Fig. 9-83)

Fig. 9-83

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47.) Tighten the lower fixing screw (1) of the transport holder. In doing so, make sure there is still a gap of 3 mm.
(Fig. 9-84)

3 mm

1
Fig. 9-84 1 Lower fixing screw

48.) Insert the washer (1). (Fig. 9-85)

Fig. 9-85 1 Washer (here, coloured)

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49.) Screw in the transport lever retainer (1). In doing so, make sure the grease nipple (2) is facing forwards.
(Fig. 9-86)

2
Fig. 9-86 1 Retainer
2 Grease nipple

50.) Insert a different clip guide plate from below. (Fig. 9-87)

Fig. 9-87 1 Screws

51.) Tighten the screws (1). (Fig. 9-87)

52.) Hook the spring (1) back on. (Fig. 9-88)
53.) With the safety circuit closed, bring the machine into the die change position. (2, Fig. 9-55)

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54.) Insert a different die (2) and tighten the screw. (Fig. 9-88)

Fig. 9-88 1 Spring

2 Die

55.) With the safety circuit closed, bring the machine into the punch change position. (3, Fig. 9-55)

CAUTION: Sharp-edged punch and sharp knife

You could cut yourself.

• Wear cut-resistant protective gloves!
• Work carefully and do not touch the blade of the knife or the edges of the
punch.

56.) Put cut-resistant protective gloves on.

57.) Fit a different punch. See section 5.6.

Maintenance
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58.) Put an open-end spanner (46 mm) on the motor shaft (1). (Fig. 9-89)

Fig. 9-89 1 Motor shaft

59.) Slowly turn the machine over using open-end spanner and check the clearance. Permissible clearance
range: 0.1 to 0.3 mm. (Section 5.6.2, Fig. 5-22) If necessary, reset the clearance.
60.) Close the right side panel (2) on the clip head. (Fig. 9-90)
61.) Lock the locks (1). (Fig. 9-90)

Fig. 9-90 1 Locks

2 Right side panel

62.) Remove the adhesive tape from the knife blade.

63.) Open the left side panel on the clip head.
64.) With the safety circuit closed, bring the machine into the clip loading position. (1, Fig. 9-55)
65.) Insert clips. See section 5.4.4.
66.) With the safety circuit closed, bring the machine into the home position. (4, Fig. 9-55).

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10 Transporting the machine
• Before moving, you must check that the clip head
of the TSCA has been locked and the front doors of
the TSCA have been secured. The sealing bar on 1
the TSCA must be swung back down and locked.
• Safety shoes must be worn during machine
transport.
• The Operating Manual, especially the Safety
Instructions, and the local accident prevention
1
regulations in force must be observed for all work.
• Depending on what product is being packed,
chemical-resistant protective gloves and possibly
also heat-resistant protective gloves may be
required. Observe the safety data sheet for the
product!
Fig. 10-1 1 Sealing bar, swung up
10.1 Disconnecting the power supply
3.) Without touching the sealing bar itself, remove
The main power supply to the machine must be the film from the seal pipe on the TSCA.
disconnected, even for moving it short distances:
1.) Disconnect the main power supply. To do this,
switch the main switch (2, Fig. 10-3) to the Off CAUTION: Hot sealing bar
position.
The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar.
CAUTION: Hot sealing bar • Do not touch the sealing bar.

The sealing bar can get very hot. You could burn
yourself if you touch the sealing bar. CAUTION: Risk of crushing when
• Do not touch the sealing bar. swinging the sealing bar up/down
When the sealing bar is swung up or swung back
down, there is a risk of crushing at various points.
CAUTION: Risk of crushing when • Make sure you have a firm footing, the sealing bar
swinging the sealing bar up/down is heavy!
When the sealing bar is swung up or swung back • Do not reach into the danger zones.
down, there is a risk of crushing at various points. • Perform the work as a one-man operation.
• Make sure you have a firm footing, the sealing bar
is heavy! 4.) Without touching the sealing bar itself, swing the
• When you swing the sealing bar up, make sure it sealing bar back down and lock it. (Fig. 10-2)
engages securely.
• Do not reach into the danger zones.
• Perform the work as a one-man operation.

2.) Without touching the sealing bar itself, unbolt the

sealing bar, swing it up and make sure it engages
securely. See section 3.5.1.

Moving the machine

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DANGER: Contact with the product

being packed
1 Depending on what product is being packed, contact
with it may be hazardous to health.
• Observe the safety data sheet for the product!
• If necessary, wear chemical-resistant protective
gloves or wear heat-resistant protective gloves if
the product is extremely hot.

9.) Disconnect the TSCA from the stuffer or

Fig. 10-2 1 Sealing bar locked customer’s dosing system.

5.) Disconnect the main compressed air supply. To

do this, move the air release valve (1, Fig. 10-3) ATTENTION: Production downtime if cleaning
against the direction of flow (see arrow). delayed

If product-carrying parts of the machine are not

1 2 cleaned promptly after switch-off, the product may
harden depending on what product was used. This
may result in production downtime.
• Clean product-carrying parts of the machine
promptly after switching off.

10.) Clean the machine as described in chapter 8.

11.) Unscrew the control cable to the customer’s
dosing system or the stuffer.

Fig. 10-3 1 Air release valve

2 Main switch

6.) Remove the compressed air hose.

7.) Pull out the mains plug.
8.) Disconnect the product feed at the stuffer/
customer’s dosing system.

Moving the machine

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10.2 Secure the front doors and the
clip head
1.) To secure the front doors, the two door handles
must be securely fastened together (Fig. 10-4).

Fig. 10-4 1 Transport safety device

2.) The machine’s clip head must be locked to

secure it. (Fig. 10-5) 1

Fig. 10-5 1 Locked

Moving the machine

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10.3 Pushing the machine
1.) Check that the sealing bar on the TSCA has been
swung down and locked.
2.) Wind all the feet up. To to this, loosen the nut (1,
Fig. 10-6), wind the foot up, then re-tighten the
nut.

Fig. 10-6 1 Nut

WARNING: Risk of crushing if machine Fig. 10-7 Pushing the machine

movement becomes uncontrolled
As it is very heavy, the machine is difficult to control
once in motion. Risk of crushing!
• At least two people are required to move the
machine in a controlled manner on a level surface.
The machine can only be moved in a controlled
manner on level surfaces and requires additional
securing on slopes. Caution is also required for
movement over thresholds and joints.
• Do not move the machine jerkily.
• Wear safety shoes.
• Once the machine is in its final location, extend the
feet to prevent it from slipping.

Move the machine as a two-person operation. The

narrow side of the machine at the product outlet is a
suitable place for pushing it. (Fig. 10-7)

Moving the machine

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10.4 Loading and unloading the
machine

WARNING: Danger to life due to

suspended loads
Danger to life under suspended loads and in the
loading area!
• Never stand under suspended loads or in the
loading area.
• Make sure the forklift truck offers a sufficient load
capacity.

The machine may only be lifted using a forklift truck.

The forklift truck must have a sufficient load capacity.
1
For machine weight, see chapter 11.
- Pick up the machine in the middle of the long side.
- Only lift the machine as high as is required and only
move it slowly. Fig. 10-9 Centre of gravity of machine, side view

Fig. 10-8 Centre of gravity of machine, front view

Fig. 10-10 Centre of gravity of machine when

coupled with HDP dosing pump, front
view

Moving the machine

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10.6 After transport

WARNING: Instability

There is a risk of crushing if the machine is not

secured with the feet to prevent it from slipping.
1 • Once the machine is in its final location, it must be
secured with the feet immediately to prevent it
slipping.

After transporting the machine, immediately secure it

with the feet (2) to prevent it slipping. The machine
may only be operated with the feet extended.
The castors (1) are only intended for moving the
machine. (Fig. 10-12)

Fig. 10-11 Centre of gravity of machine when

coupled with HDP dosing pump, front
view

10.5 Transport by ship, plane or lorry 1

- For transport, the machine must be bolted to a pallet
2
to prevent it from tipping over. The machine must be
secured against slipping using the feet and tension
straps. Fig. 10-12 1 Castor
- Use suitable means to protect the machine from 2 Foot
moisture (film, desiccant bag).
- Make sure the means of transport offers a sufficient
load capacity.
- Secure the load on the means of transport to prevent
it sliding or falling off.

Means of transport Transport conditions

Ship Transport in a seawater
resistant container
Aeroplane Transport in a container
Lorry Transport on a pallet

Moving the machine

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11 Technical data 11.1 Dimensions and weight
• Note Width: 1465 - 2165 mm
The values listed here are for reference. The
authoritative ones are those on the machine’s type Depth: 1155 - 2445 mm
plate. Height: 1725 - 1925 mm
Weight excl. packaging: 790 kg
1 2 3
When TSCA 65 D coupled with HDP 30/40/50:
Width: 2000 - 2700 mm
Depth: 1155 - 2445 mm
Height: 2280 - 2480 mm
Weight excl. packaging: 1365 kg
4 5 6 7 8 9
10 11.2 Pneumatic connection

Fig. 11-1 Type plate Operating pressure: 0.5 - 0.7 MPa (5 - 7 bar)

1 Machine type Compressed air 2.5 standard litres/work

2 Serial number / Year of construction consumption: cycle
3 Weight [kg]
4 Power consumption [kW] The compressed air used must be pre-filtered and free
5 Frequency range [Hz] from condensation.
6 Number of phases
7 Voltage range [V] 11.3 Electrical connection
8 Fuse [A]
9 Compressed air range [bar]
10 Machine type Supply voltage: 200-230 VAC,
380-460 VAC, 50/60 Hz
Power consumption: 3.6 kW
Fuse: 16 A
TSCA 65 D control cable: TSCA / customer’s
dosing system

Technical data
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 Poly-clip System GmbH & Co. KG TSCA 65 D

Fig. 11-2 TSCA 65 D

Technical data
11-2 EN/05-2017
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Fig. 11-3 TSCA 65 D with HDP 30/40/50

Technical data
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11.4 Volume at the work station LpA 11.5 Film length, film width and film
A-rated sound pressure level emission LpA at the work tube diameter
stations allocated for the machine:
11.5.1 Film roll dimensions
Sound pressure level with seal seam LpA: 78 dB(A)
cooling and front doors closed
Sound pressure level with seal seam LpA: 80 dB(A)
cooling with front doors open

• This value was measured:

• according to EN 11201
• with clip M 09-175
• on aluminium composite film
• without stuffer material, with air sausage
• with knife switched on Fig. 11-4
• in operation with an HDP hydraulic pump
• with 20 cycles K Core diameter 76 mm (3")
The value comprises a measurement uncertainty R Roll diameter, maximum 450 mm
KpA of up to 2.5 dB. RB Roll width, maximum 221 mm
• For noise protection reasons, the machine should RB Roll width, minimum 63 mm
only be operated with the front doors closed. When
working with the front door open, the operator must
wear appropriate personal protective equipment K Core diameter 76 mm (3")
(ear plugs or noise protection headphones). R Roll diameter 450 mm
• If the daily noise exposure level LEX,8h exceeds Film length with film thickness of 85 μm 1700 m
80 dB(A), measures must be taken to reduce the
Film length with film thickness of 65 μm 2300 m
noise. Suitable measures include, for example,
soundproofing or the use of appropriate personal Film length with film thickness of 45 μm 3300 m
protective equipment (ear plugs or noise protection 11.5.2 Film surface width
headphones).
• The sound pressure level was measured with seal
seam cooling running at normal cooling rate.

Fig. 11-5 S = Seal seam

D = Film tube diameter (calibre)
Ü = Overlap

D Ü
18 - 38 6 mm
39 - 70 8 mm
71 - 120 10 mm

Calculating the film surface width FB:

D x b + Ü = FB
(b = 3.14)
Example: Diameter 40 x 3.14 + 8 = 133.6 mm FB
(rounded up to 134)

Technical data
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EN/04-2018
Poly-clip System GmbH & Co. KG TSCA 65 D

EN/04-2018