6.8. Tooling wiring and connecting
Section 7- Pneumatic drawing
Section 8- Tooling insertion check list
Section 9- TS-30 technical data
1-1
1. Setting Up the machine
1.1. Floor print
The TS-30 must be positioning to assure proper accessibility for maintenance and
operation. Before choosing the site for the machine, please consider that you will
also need room for packaged and non-package products apart from the space
needed for the machine itself.
1.2. Leveling
To assure the proper operating of the TS-30, use a level and adjust its feet. Don’t
forget to lock the foot in position using the locknut after the leveling is
completed. If the TS-30 is equipped with optional wheel, just push the wheel
lock.
1.3. Vacuum pump setup
Before starting to work, check the oil level through the view glass on the pump,
to see if there is a sufficient quantity of oil in the pump. Never use oil other than
recommended by the manufacturer. Never exceed maximum quantity of oil
indicated, when adding or changing oil.
1-2
1.4. Connections
1.4.1. Electric connections
Electrical connection must be set according to the Id plate of the TS-30
and the electrical schematic drawing found in section 6.1. Electrical
connections must be made by qualified personnel. This person must make
sure that the electrical entries correspond to the proper voltage and
amperage of the machine. An important step in connecting the machine is
to make sure that the pump turns in its correct rotation. Warning : The
pump should not rotate more than 3 to 4 seconds in the wrong
rotation or it may cause serious damage. The proper rotation is
indicated by an arrow on the pump motor.
1.4.2. Pneumatic connections
Used ½’’NPT inner diameter pneumatic pipe. See section 9 for pneumatic
specification of the TS-30. See section 7 for localization of pneumatics
parts.
2-1
2. Operation
2.1. Operating Procedures
2.1.1. General description
The TS-30, Sipromac vacuum tray sealer has been designed to package a
wide variety of fresh, frozen or processed product that will be sold in a
clean, safe, appe al in g "ca se re ady" container. S ip r om ac tray seali n g M. A.P
(modified-atmosphere-packaging) machines will provide a controlled
oxygen level ensuring freshness for a longer period of time.
The simplified operation sequence is: first the operat or sets the tray on the
bottom chamber. Next, the operator push the drawer under the cover (the
upper chamber) and the optional film rewinder is automatically activated.
When the drawer re achs the correct position, the chamber is push against
the cover and the vacuum is made inside the chamber, followed by
injection of the neutral gas. Then the tray is pushed against an electric
element equipped with a knife to cut off and seal the film. Afterwards, the
chamber will open. The operator pulls back the drawer and take out the
tray and the excess film if the TS-30 is not equipped with a film rewinder.
2.1.2. Sealing Station
2.1.2.1. Chamber
2.1.2.2. Film rewinder
The chamber is divided in 2 parts: the upper chamber and the lower
chamber. A lid gasket allows for a vacuum in the chamber when
both parts come together. It is the lower chamber part that joins the
upper one by the mouvement of the cylinder. Then comes the
vacuum phase in the chamber and the addition of a substitute gas
until atmospheric pressure is reached.
All the tooling is located inside the chamber: the die plate is
located in the lower section and the knifes and heating elements
used to seal the film are in the upper section. The upper cylinder
pressures the h eating element in a way to seal the film on the tray.
A number of spring loaded film support keep the film tight by
maintaining a light pressure during the complete cycle.
A brake-motor leads the rewinder to provide the movement of the
film. The distance of film will move is controlled either by photocell indexer that can read the printed part of the film or by a
mecanical wheel made to each specifications of the trays. The
tightening cones prevent film rippling. Adjustement screws control
the pressure on top of the film for better film tension.
2-2
cover
+
-
+
-
Always respect initial wire way
+
-
red
wht
+
-
red
wht
gnd
tooling
red
wht
red
wht
82
82
82
79
79
79
80
80
80
80
80
80
cable ties black
( Tie wrap )
4''
# 057-0305
wire hi temp TEW / 2
AWG
16
# 030-0530
copper tubing
# 105-601
or 105-600
(according movement piece)
Always respect initial wire way
W 003
!
area parts in
movement
loop obligatory
for go & comes
movement
Z5
82 ( Z6)
80 ( Com)
79 ( Z5)
gnd
Z6
Z6
Z5
W 5 & 6
2.2. Tooling insertion
Here is the procedure to change a tooling or remove it for maintenance: (See
Section 8)-Tooling Insertion Check List to make sure all the steps are respected.
2.2.1. Chamber setup
Each tooling contains 2 sub-assemblies:
-the die plate witch is located in the lower chamber,
-the upper tooling witch is located in the upper chamber.
2.2.1.1. Die Plate installation
Take out all the hex socket head bolts (4) using "allen key ¼"
provided with tooling. Remove the die plate from the chamber.
Inverse these steps to put the tooling back. Die plates are d esigned
to avoid installation on the wrong side.
2-3
2.2.1.2. Upper tooling insertion
2.2.2. Setup
2.3. Film insertion
The film must follow the path as shown in section 5. Using the m anual feeding
button make the rewinder turn until film 's lock faces up the tube. Make the film
pass over the roll and fix the lock on it. To fix the lock properly make the
rewinder turn one rotation using manual feeding button. The tightening cones
must be located in a way to stretch the film. Locate those on the edge of the film
cutout. Two wheels allow the centering of the roll with the chamber. An
ajustable roller and two handles keep the film tight and smooth on the roll even
when it is almost empty. Look carefull y at section 5 and follow the instructions
regarding the circuit of the film to have the glue on the film toward the tray.
Also, the film must be inside the eye indexer. To remove the used spool roll from
the rewinder, use the special flat tool and pull gently on the lock, then, turn it t o
loosen the film and take the spool out.
Unscrew the nuts (4) of the upper tooling with Allen key 3/16.
Rotate the tooling to the right like opening a door.
Disconnect the 3 connectors.
Inverse the previous steps to put upper tooling back. Make sure all
wires are in their respective connector.The upper tooling has the
same design particularities as the die plate to insure the installation
in the proper position. Put the film back
(See section 2.3)
If there's a ch ange i n the tray model, you may change the encoder wheel if
it is necessary, in cases where die plate had been changed.
2-4
2.4. Digital control setting
2.4.1. Basic
Model TS-30 programming is made by the keyboard of the MC
programmable controller. There are 2 modes available on the MC-40:
Program Mode & Function Mode. The MC-40 can store up to 20 programs
with different parameters corresponding to various conditions of use. The
program Mode allows changing in t he current program and also changing
the parameters related to that program. The function Mode set the
parameters of the TS-30 and is valid for all the programs
Use "Power" key to power ON/OFF the vacuum tray sealer. When the unit
is on, the identification of the last executed program is displayed on the
LCD screen.
Use the "ESC" key to change from the program menu to the function menu
and from the fonction menu to the program menu.
In function menu, use "S ELECT" key to select a function and "ENTER"
key to accede and modify the selection.
In program menu, use "S ELECT" key to select a pro gram and "ENTER"
key to accede and modify the selection.
In programs submenu, use "ENTER" key to pass over the parameters and
go to the followin g one; the parameters blink t o point out the acquisition
mode. A return to program menu is performed aut omatically following the
last parameter acquisition.
In program submenu, use "ESC" key to get back to the program menu.
Strike any k ey to clear the error message which may be displayed on the
LCD screen.
There is a emergency stop button on your MC-40 keyboard used for
emergency power cut off.
Password on request ( contact your dealer )
2.4.2. Function menu
2-5
2.4.2.1. F1- Create a program
SELECTPxx+1 NO NAME
Pxx+2 NO NAMESELECT
SELECTPxx+... NO NA ME
SELECT
*you may select the
program that you
had created only.
To select a program creat ed
ESC
F1 CREATE A PROGRAM
SELECT
F2 DELETE A PROGRAM
F3 REWIND OPT IO N
SELECT
ESC
Press enter to create
a program
1
-acces this function with enter
2
-
choose the program with select
3
-confirm delete with enter
choose with select
.
rewind enable
.
rewind desable
To create a program and rewind option
F4 REWIND INPUT
SELECT
choose with select
.
encoder
.
photocell
To modify a program created
ON/OFF
VACUUM:xx.x %
Pxx NO NAME
VACUUM PLUS:xx S
SEAL TIME: xx S
ENTER
Enter a value
Enter a value
The program name flash,
you may create a name
for Pxx.
Displayed if gas flush is
enable, see diagnostic
menu. Enter a value.
ENTER
ENTER
ENTER
ENTER
ENTER
GAZ PLUS: x.x S
When executing the "create a program" function, the program
submenu is acceded, starting with the identification. The initial
identification "Pxx NO NAME" is given to the program and all
parameters are established to zero; the program number is allocated
automatically.
For a selected program, set the identification, using the numeric
keyboard characte rs chart; pressing numeric key until the character
you wish is selected (4 times for the numeric value). Use
"ENTER" key to validate the character and to validate the
characters strin g at the end (the new char acters string is blinki ng).
In a middle of an acquisition, use "ESC" key to come backwards
and erase one or several characters.
2-6
Example:
key ENTER to validate the characters string
EXAMPLE 1 (9 characters)
keys 2, 2, ENTER -> E
keys 8, 8, 8, ENTER -> X
keys 1, ENTER -> A
keys 5, ENTER -> M
keys 6, ENTER -> P
keys 4, 4, 4, ENTER -> L
keys 2, 2, ENTER -> E
keys 9, 9, 9, ENTER -> space
keys 1, 1, 1, 1, ENTER -> 1
After you entered the program's name, you may enter different
parameters speci fic to the program. You will find the meaning of
the parameters in section 2.4.3.
2.4.2.2. F2- Delete a program
When executing the "delete a program" function, the programs
menu is acceded and the number of the first program in memory
blink to point out the deletion mode. Use "SELECT" key to select a
program and "ENTER" key to accede and confirm deletion of the
selection. Use "ES C" key to unconfirm a deletion and to leave the
function. When leaving the function, the number of the actual
program on the LCD screen will cease to blink.
2.4.2.3. F3 -Rewind Option
This is an option on your Tray Sealer , it has to be enabled if you
have the automatic rewinder.
2-7
2.4.2.4. F4- Rewind input
Example:
It's possible to change the input which controls the film's
rewinding. The two possibilities are: ENCODER or PHOTOCELL
choosen by “SELECT” key and “ENTER” key.
When you s elect ENCODER, the film's unwinding will stop when
the flat of the wheel faces the sensor.
If PHOTOCELL is elected you should see a black mark on the film
(±10mm2). This mark tells you where the film's unwinding stops.
2.4.3. Program menu
You can switch from Function Mode to Program Mode by using the E SC
key. You press SELECT key to see all the different programs. It is also
possible to modify the parameters of a program in MODE PROGRAM by
picking up the program you wish with “ENTER” key. Here are the
different parameters regarding each program.
2.4.3.1. Name
Set the program identification by using the numeric keyboard chart,
until the desired caracter is reach then press enter for the next
selection until the complete name is displayed.
2.4.3.2. Vacuum (0 - 99.5%)
Percentage of vacuum to reach i n t he cham ber con sidering "99.5%"
of vacuum almost total. To save cycle time, always use the
minimum vacuum necessary to obtain the correct oxygen level in
the tray.
For a selected program set the vacuum level, starting with the
values; the decimal point is automatically inserted following the
second digit entry and the validation is automatically performed
keys 9, 0, 0 or 9, 0, ENTER or 9, 0, 1 or keys 9, 0, 2 or 9, 0, 3 or 9, 0, 4 -> 90.0 %
keys 9, 7, 5 or 9, 7, 6 or 9, 7, 7 keys 9, 7, 8 or 9, 7, 9 -> 97.5 %
keys 0, 0, 0 or 0,ENTER -> 0.0 %
2-8
following the third digit entry (The new vacuum level blink). The
Example:
keys 1, 5
15 secs
vacuum level is truncated to the nearest lower half value. In the
middle of an acquisition, use "ENTER" key to validate the vacuum
level and "ESC" key to come backward and start over with a new
acquisition (the old vacuum level blink). Set the vacuum level to
zero to bypass the pressure transducer and proceed only using the
vacuum plus time.
2.4.3.3. Vacuum plus (0 – 99 secs)
This value means the time that vacuum will be maintained in the
chamber when we reach the instructions programmed in Vacuum.
During this delay the pump is still vacuuming.
For a selected program set the vacuum plus time, in seconds; the
validation is automatically performed following the second digit
entry (the new vacuum plus time blink). In a middle of an
acquisition, use "ENTER" key to validate the vacuum plus time
and "ESC" key to come backward and start over with a new
acquisition (the old vacuum plus time blink).
keys 0, 1 or 1, ENTER
-> 1 sec
->
2.4.3.4. Gas plus (0.0-5.0 sec)
Value of time for positive pressure of the neutral gas in the
chamber before sealing. It’s an extra pressure regarding to
atmospheric pressure.
If the film appears to bulge out on the top of the sealed tray you
must reduce the value of the Gas Plus. If the opp osite happens and
the film bulges in, increase the value of the Gas Plus.
2.4.3.5. Seal time (0 – 99 secs)
Running time value for the trays to be in contact with the h eating
element. Depend on film and tray material.
For a selected program set the sealing time, starting with the
seconds. Use "ENTER" key to validate the sealing time and "ESC"
key to come backward and start over with a new acquisition (the
old sealing time blink).
2-9
Example:
keys 0, 1 or 1, ENTER -> 1 sec
2.4.3.6. Plate temperature (0 – 160 °C)
Heating element temperature. Depend on film and tray material.
N.B: the machine shuts off by itself if the temperature goes higher
than 175 °C.
2.4.4. Operation sequence
Here is a description of a complete sequence to illustrate the function of
each parameter.
2.4.4.1. Vacuum cycle
As soon as the switch indicates the chamber is below the cover,
the cylinder is operated and at the same time the vacuum valve
opens if there is any value other than 0% programmed in
VACUUM. The screen will let you know th e state of the vacuum
evolution. When we get the programmed value in VACUUM, the
cycle goes automatically to VACUUM PLUS cycle which
maintains the valve opened for the delay programmed. The vacuum
valve shuts automatically at the end of the cycle. The gas c ycle c an
now start.
2.4.4.2. Gas cycle
Gas valve opens automatically to reach an over pressure of gas in
the chamber corresponding to the time of GAS PLUS. Gas valve
then shuts and a d elay of 1 second allows time for stabilization in
the chamber before the sealing.
2.4.4.3. Seal cycle
Valve for the bellows is operating during the delay programmed in
SEAL TIME. Sealing is now completed. There is a .5 second delay
before going back at the atmospheric pressure. The atmosphere
control valve operates fo r a minimum of 1 sec and if the vacuum is
below 1% the chamber lock i s released and then the lower chamber
will go down.
2-10
2.4.5. System monitor
DIAGNOSTIC MENU
SELECT
SYSTEM MONITOR
ENTER
SOFTWARE: XX.XX
WORK HRS: 00000
CYCLE: 0000000
SELECT
SELECT
SELECT
Shows the total number of
hours done by the machine.
Shows the total number
of cycles done by the
machine
Shows the MC-40
software version.
To access the system monitor, power up the vacuum packaging machine
while keeping the "ESC" key pushed. Use "SELECT" key to select the
system monitor function and "ENTER" key to access and visualize the
monitored parameters. Use "SELECT" key to change over from the software
revision, the amount of working hours done and the amount of complete
cycles performed since first initialization.
A password can be added. For this, please contact your supplier.
3-1
3. Trouble shooting
3.1. Failure during a packaging cycle
3.1.1. "VACUUM ERROR" message is displayed on LCD
No pressure variation is picked up by the PCB transducer during the
vacuum sequence within a preset period of time.
-> Check vacuum lines for potential leaks or kinks.
3.1.2. "GAS FLUSH ERROR" message is displayed on LCD
No pressure variation is picked up by the PCB transducer during the gas
sequence within a preset period of time.
-> Check gas flush and vacuum lines for potential leaks or kinks.
3.1.3. "CHAMBER ATM ERROR" message is displayed on LCD
No pressure variation is picked up by the PCB transducer during the
atmosphere sequence within a preset period of time.
-> Check vacuum lines for potential leaks or kicks.
3.1.4. "COVER DOWN ERROR"
The cover switch is defective or needs adjustment , it will happen during
the vacuum cycle if that switch lost the signal .
3.1.5. "HI LIMIT TEMP"
The machine will shut-off by itself if the temperature goes higher than
175°C
In case of failure in triac element or MC-40 board.
3-2
3.2. Insufficient vacuum in chamber
To find the leakage quickly, check for leaks with a precision vacuum meter,
going back step by step from the chamber to the pump.
Warning: Verify connections of measuring equipment before verifying machine.
Most frequent points of leakage: lid gasket, damaged vacuum hose or loose hose
clamps.
3.3. Faulty seal
3.3.1. Insufficient seal
-> Sealing pressure too low, bellows leaking or pressure bar jammed.
-> Silicone rubber uneven.
3.3.2. No seal
-> Faulty contact in sealing circuit or bad heating element.
-> Contactor does not work.
3.3.3. Seal does not stick
-> Seal area extremely contaminated by fat or meat juice.
-> Sealing temperature is too low.
Warning: Do not incr ease sealing ti me more than really necessa ry; higher
temperature will reduce working life of Teflon and silicone rubber.
3-3
3.3.4. Fault in the valve
Vacuum or air valve does not open.
-> Check whether there is voltage on the magnetic valves during their
period of operation. If there is no voltage a wire is broken or the PC board
is damaged.
Vacuum valve does not close.
Lid does not open at the end of the cycle; air enters, but th ere is still 20 40% vacuum in chamber.
3.4. Control board failure
The board software allows access to a "Diagnostics Menu". Only qualified
service technicians are authorized to access this menu by entering a security
password.
By access either the "D1 input test" feature or the "D2 output test" feature, a
trained technician will be able to quickly know the origin of the problem: pump,
sealing system, pneumatic problem, security switch problem, etc..
Keep in mind that in most cases trouble is due to a leakage, loose electrical
connection or evident damage to the main component: vacuum pump, valves,
electrical contactors, thermal overload, fuses holder or transformer.
For assistance do not hesitate to contact your local service technicians.
4-1
4. Maintenance
4.1. Regular maintenance
Routine controls to be made at regular intervals:
Check lid sealing for damage and hardened spots.
Check evacuation hose for damage (contraction of diameter or abrasions).
Check vacuum connections for tightness.
Check oil in pump (oil level in view glass; add if necessary. If the pump oil
changed color, replace it.)
Check vacuum in chamber with precision vacuumeter.
Check the dryer filter if crystal is not blue change the part.
4-2
4.2. Heating element replacement
-> Take apart the upper tooling (see section 2.2.1.)
-> Locate where the springs are located. (See Picture 4.1) . Each tooling has it’s
particular configuration, drawing in this manual are only there for example.
Unscrew the bolts (7/16"-14 or ¼”-20) that hold the defective heating plate.
-> Locate the defect heating element with a multimeter (resistivity = 0) than unplug
the heating element.
-> Remove the defect element and replace it by a new one, use special ceramic putty
and high temp red silicon to set the element on the heating plate as was used by
Sipromac.
Some tooling does not require ceramic putty.
-> Reassemble the heating plate.
4-3
4.3. Blade replacem ent
-> Take apart the heating plate (see section 4.2).
-> Unscrew bolts (1/4"-20 x 3/4") that hold the lower tool plate and take it apart. (see
Picture 4.2)
-> Unscrew screws (6-32 x 3/8") that hold the knife and change the knife.
-> Reassemble the lower tool plate.
4.1 - Heating element replacement
4-4
Picture 4.2 - Blade replacement
8-1
8. Tooling insertion check list
- Upper tooling insertion
- Film insertion and adjustment
- Mechanical indexer change
- Load appropriate program
9-1
9. TS-30 Technical data
9.1. Power consuption
Electric spec.: 208-220V / 3 ph / 60Hz
Vacuum pump BUSCH 40 m3/h, 208-220V / 3 ph / 60Hz
BUSCH 63 m3/h, 208-220V / 3 ph / 60Hz
Power consumption:
Electricity (208-220V / 3 ph / 60Hz) to be confirmed
:
TS-30 without Vacuum pump : approx. 4.6 kW
With vacuum pump BUSH 40 m3/h: approx. 6.1 kW
With vacuum pump BUSH 63 m3/h: approx. 6.8 kW
Disconnect switch require and not supply