Instruction manual MULTIVAC Language: Englisch ‘This instruction manual belongs to a the machine ‘See documentation for spare parts catalogue Manufacturer of the Service address: machine: MULTIVAC, ‘Sepp Haggenmiller GmbH & Co. KG 10-8787 Wolfertschwenden wwe, rmultiveecom Tel: (08334) 601 - 0 Fax: (08834) 601 - 199 Email: muwo@muttivac.de ‘This documentation may only be copied or passed on to third parties completely or parly it MULTIVAG has expres- aly given te approvalmuULivAc 01 Important information Note Note Documentation for the machines used Dear Customer, This documentation was carefully prepared based on the information available to us. Because of the age of the machine or because of modifications undertak- en by the customer himself, we cannot guarantee that this documentation corresponds in every way to the current version of the machine. We hope that you can still make good use of this documentation. MULTIVAC ‘Sepp Haggenmiller GmbH & Co. KG ‘Abt. Technische Dokumentation D-87787 Wolfertschwenden Tel. +49/(0) 83 34/ 601 - 0 Fax +49(0) 83 34/ 601 - 195 Betriebsanieitung hinweisaltedoku_10s0GB02.fm 14,09:2000 1A 9Contents MULTIVAC 10 2 We y 12 13 2 49 152 16 47 Important information Safety Transport, storage, installation, start-up/shut-down Switching on/off, input, displays Films, web transport, removal of film trim; pack transport Die lifting system Film forming Product infeed Evacuation, gas flushing, sealing ... Printing, labelling, embossing Cutting, punching, sliting ... Settings Trouble-shooting Diagrams, information for trained personnel Cleaning, maintenance Disposal, miscellaneous<< mucrivac Chapter 01Workplace noise level in dB (A) Without vacuum trim removal unit with vacuum trim removal unit Equipment leery to without vacuum pump, without blower Machine —> with GD Noise level L. for new Multivac FFS packaging machines Please read the other side of this, Page as well ‘Symbols and abbreviations © ® = Workplaces WZA = Die conte distance G = Blower co Noise mutfler TA = Vacuum trim removal unit VP = Vacuum pump in dB (A) per workplace ®@ 0 @ without GD with vacuum pump oF blower with GD without GO with ‘vacuum pump without vacuum pump, without blower with GD without BD with vacuum pump andlor blower without GD ‘The figures in the table relate to machine equipment with cross cutting unit(s), e.g. punches). MULTIVAC Muttivac Sepp Haggenmiller KG * Bahnhotst.4 Tol. (08334) 601-0 + Fax (08334) 601 199 0-87787 WollertschwendenExplanatory notes 1 Meaning of the noise level figures ‘The table on the other side of this page lists the warkpla- ‘ce noise level L in dB for individual types of machine with. different equipment, Please refer to this table when you require the noise level for your particular machine. External and ambient noise has been eliminated from these figures. Ifthe machine is installed in @ room that echoes, the actu «al noise level the personnel is subjected to may be higher. The figures relate to new or overhauled machines with ‘optimum settings at the time-of delivery. Higher levels may develop when the machine is in operation because of wear and tear or changad settings. Partculatly close attention should be paid to machine maintenance and sotting, 60 that noise levels are kept as low as possible. 2 Determination of the noise levels 2.1 Basis DIN 45 698, section 1 and section 28, date 11.80 Accuracy category applied: 2 2.2 Machine installation Solid floor, machine not attached 2.3 Machine condition New or overhauled machine. Automatic operation, with Packaging material 2.4 Measurement Equipment: Procise sound level meter, DIN 45 633 IEC 651, Category t Assessment Frequency assessment A, lke the human ear, ‘sound pressure in dB Dynamic characteristic: Show" ‘The measuring instrument is held pointing at the machine at points 1 and 2 (see ilustration on the front) Reading: ‘The maximum reached during the machine cycle 2.5 Corrections The true sound pressure L (=true workplace noise level) is calculated by correcting the measured sound pressure Las follows Le UK: ke Ky Extemal noise level, Ke Ambient value External noise level Ky 1 Ky = 10 (1 - ——— ) tort at AL = Reading (machine + external noise) minus Reading for external noise (machine switched off) ‘Ambient value Kz Ke = 10 (1 + —Multivac FFS packaging machines Application and function Page 1 ott (01 Important information R530, M855, R 5200 Application (Proper use) Production of packa- ging from reels of film, Particularly for food products and sterile ‘medical equipment. Forming, filling and sealing are carried out fon the machine. Function Evacuation, , {925 flushing, Loading of seating the product / sy / Forming of the fim Separation of the packsNumber of pages enclosed Dear customer! : Mutivac has put a great dea of efor and care into developing and (08334) 601-199 bulting your machine. Wo havo given top pry 10 making sure that you or your staff can operate the machine in safety, i.@. without being or by post: ‘exposed to any danger. Hygiono and relabity are further factors that arp very important 10 us. Mitac does not just comply witha tho a- test standards and legislation; we have also exploited the Years of ox porience we have had in bulding thousands of machines with advan- Muttivac ‘c0d technology for numerous diffrent applications - with benefits you Sepp Haggenmiller KG ony. Service oul you tke oto us your exparvnces and! suggestions? Moltivac would bo grtoll you de. Ploase copy this form and sond it D - 87787 Wolfertschwenden to Mulivae after you have filed iti. f you would prefer to present your roquosts tothe local Mutivac sorvco roam, please lool ree to do 20. — Report to the Multivac factory about experience with the machine Requests, suggestions. Please include drawings as wel Important: Please draw attention here to any changes that have been made to the machine: Address Completed by (name, date) TAL 90 sone FAK NO. Mutiivac machine, mode! ... Sera no. Muttivac would like to thank you for your assistance. We will contact you when we have reviewed the information you have given us. co Witlbe fitedinty MULTIVAC - | Kopiean = Q TRB am QVT am © Vertretung am ‘apna 21.08.1008 i TRB-Nr. ‘ute. NeGraphical symbols for MULTIVAC Packaging machines I Edition July 1992"Engish Copytightby Muttvec Sepp Haggenmiller KG « D-87787 Wolfertschwenden Tel: (08334) 601-0 Fax: (08334) 601- 199 + Telex: 5.45.65 i i \Graphical symbols Die, chamber closed icuation Gas flushing Heating, general . Pro-haating (Example: 1 cycle, bottom) Fim heat Plug Positorm system Contact vacuum gauge, pressure switch Gas tank, gas intake Throttle Ventilation Exhausting Evacuation package Evacuation chamber Sealing Steam, steam gonorator Package shrinking Warning! Attention! Dar High voltage. Bangor! Impulso Pause Separator, gonoral Water Water intake Water outlet Cleaning Ol lubrication Film real Top web narrow ‘Top web wide Unwine Wind Film monitor Film joint monitor Loading detector, product control . Flim bra Brake, general Loader, filler eo = Loading ow, lifting 71 Clutch 72 Electric motor 73 Advance 74 Slow movement 75 Fast movement 78 Delay 77 Conveyor bolt 7B lafeed conveyor 79 lntermadiate conveyor 80 Discharge conveyor 81 Cross-cutting 82 Paper/zig-2ag cutting 83 Package/cutting support 84 Cross cutting suppor, ‘85 Punch 186 Shape cutting a7 88 Knife shatt 89 Squeezing knife ‘90 Longitudinal cuting, gonoral {81 Perforation 92 Punching, sitting 39 Trim romoval ‘94 Vacuum pump, compressor 95 Blowor ‘98 Cooling 97 Ejector, id insertion 98 99 100 101 Embossing 102 Pring 108 Prag inde, laxographie prirtor 104 Ribbon advance shot 4105 Fibbon advance long 10? Label 38 Optical Signal Aiomatc operation Singla cycle Hat eporation Foot operation 118 Door 119 Acoustic signal 118 Gaooaty, cyt te saci, cycles per minuto 420 Adjustment continuously (Cockwise increasing) 121 122 Main switch 123 Control 1 108 405 1 1 11 44 1 1 smergency stop solely doves 199 Decrease value 134 Program stan 185 End of program 436 Function selection 137 Leating backward 188 Loating forward 139 Data input 440 Data rocall 4141 Movement in direction of the arrow 442 Movement towards tre operator eet 143 Movament off the operator 144 Direction of airgas flow 145, 148 Negated function 147 Podtoning the cursor 149 Back to menue 150 -End of input, bidet (caberator10) 09 hav co co faa Hoo A|¥ |®| Ch eh) >| O a2, MULTIVAC BLEL LAL ed 7a wt 2& g 8 2B J a at P ae 8), bf) bo.) >). 8 JF 8 8 |e 271 as =i, 13.6.5 .2 au) ook i it AD) a 4 aX n=) at P|. ! 00 |S <1), ef |, 4),03/,.© _O & Z =O BiLom i a1<< mucrivac Chapter 02(aah snpoitp 2.09105 In an emergency 1. Press the emergency stop button! (ee 2. Turn the main switch f OFF! fp 3. Shut off the compressed air and gas supply ost Write in the name of the person who is responsible (2.9 or first aid) Telephone number and where the person is 4. Call for help! Leave one page in the instruction manual (chapter 02). Take another one (from the pocket at the back of the instruction manual), make it waterproof and put it somewhere close to the machine!(potas 2.03 005 In an emergency 1. Press the emergency stop button! (ee 2. Turn the main switch OFF! 3. Shut off the compressed air and gas supply 4. Call for help! ‘Write in the name of the person who is responsible (2.9. for first aid) Telephone number and where the person is Leave one page in the instruction manual (chapter 02), Take another one (from the pocket at the back of the instruction manual), make it waterproof and put it somewhere close to the machine!Why this Book ... Mutivac, one ofthe leadersin form, fil, seal packaging, is aso thelea- derin product safety avareness, We have prepardthisoperator'ssafety ‘book to warn you of possible safety hazards involved in operating Multi- vac machines and te possible consequences offalure to observe good safety practices. This book tells you how to avoid and lessen or eliminate the chances for injury to yoursetf and others working around the Mutvac. Please read thisbook, follow the safety guidelines that offers and practice good sa- fety habits. ‘We are concered for your safety. Every Multivac machine is designed with your safety in mind, Your safety andthe safety habits we hope you will develop, ae the primary reasons we have published this book.@ Areas where extreme caution should be exercised Man and machine... Each Mutivac is built wih safety guards and systems designed to help protect you from injury. Like any machine, however, a Mutvac can te potentially hazardous to you if misused or operated carelessly. Muitvacs operate ecient, performing the same sequence of events over and over. Used correctly, a Mutvac is safe to operate—but the Mutivac cannot thnk! It can hurt you if you are careless, especialy if you bypass or dott use the buitin safety guards and systems, Human error and carelessness can cause accidents... and needless pain and suffering Every Multivac form-fll-seal machine is equipped with al least one emergency stop switch as well as @ main power oftfon switch, Everyone who uses or works on. or around a Multivac should know the location of al manually operated switches and how to use them. This applies especially to the emergency stop switches. The Multivac’s safety features are designed to protect you, Use—don't abuse—them, The infeed, forming, sealing, cross cuttin, and longitudinal cuting are areas where extreme caution should be exercised.@ Die safety... 1, ‘The forming and sealing dies have botiom parts which are normally hidden from view. These parts move upward with ‘remendous force to close wih the visible stationary top parts This force is sufciento crush and amputae fingers or hands placed between the two die parts. ‘The forming and sealing cies rely on heated metal parts to form and seal the packages. The heated metal parts can cause severe bums that may leave permanent scars. The closing areas ofthe dies are equipped with saety quads 1o keep your fngers and hands from accidertaly entering the dies and causing painful injury or amputation. Before clesring a jam, turn off the main power switch ‘and turn the Multivac’s main ait supply regulator to zero, Remember, there are heated parts inside the dies which cool slowly. Wear protective gloves or allow Ye hour cooling time. 2. Do not remove the die guards or stick your fingers under the guards while the Multivae is tumed on.Die lifting system. . . ‘The bottom parts ofthe sealing and forming dies ae on ras wich move to create the necessary up-down action. These moving parts have mary Contact points which can cause severe cuts, broken bones and amputations. ‘The upper parts of the dies have guards for your protection. The ras ‘are shielded from contact bythe infeed, intermecate and discharge pans as well as the sie frame of the Muitvac, 1. Never reach inside the Multvac from the ends or from undemeath without first turning off the electrical power and reducing air pressure to zero via the Multivae’s main air pressure regulator. 2. Turn off the electric power and reduce the air pressure to zer0 via the Multivae’s main air pressure regulator before removing the infeed, intermediate or discharge pans. 3 Removing dies from the rail can cause the ral to lift and drop. Keep your hands away from the area to prevent injury. Be careful when liting tooling. Some tooling may require additional help.@ Heated surfaces and die parts... Heat is used in such processes as sealing, forming and printing. Buin heating plete surfaces are extremely hot a high as 165°C (about 350°F)! Even though the Multvac’s heating surfaces are located in limited access areas, they ae stil potently very dangerous. Be careful—these surfaces are extremely hot and they cool very slowly. 1. Tum the main electrical switch off and allow a cooling period before touching any heated surface, These surfaces can be handled with extreme caution without @ cooling period, if protective gloves are worn, Remember, you're working with temperatures nearly double that of boiling water! 2. The upper dies have a heeting plate under the die head. Before removing the heads, turn off the main electrical switch, water supply, and turn the Multvec's main air supply regulator to zero Even when dle parts have been removed from the Muitivac, they retain great heat for long periods of time—be carefull 3@ Infeed system... ‘The web feed system pulls the lower film through the infeed roller system into the chain clips... through the forming Umit, loading area... sealing unit and cutting unit ‘The film is supplied on a roll which unwinds as itis pulled into the machine. Loose clothing and jewelry can also be pulled into the machine, pling you right along wit them. ‘The result could be severely pinched fingers from the roles, deep cuts from the web grippers—or worse. 1. Do not wear loose clothing and other items or jewelry around the Multivae, f caught, they can pull ou into the Multivac and cause serious injuries, All Multivac formfillseal machines have atleast one emergency stop switch, 2. If loose items ‘all into the Multivac, push the emergency stop switch, turn off the main power switch, and turn the Multivac’s main air supply regulator to zero before reaching into any guarded areas.@ Gears... “Muitvacs have moving mechanical parts such as gears, levers, rlatng shafts and roles, pivoting arms, etc. which connect together or make contact during machine operation, ‘These pars are located under the loading surfaces and inside the main control cabinet ofthe machine. ‘Serious injury could result rom contact with these parts it you are careless. Fingers or hands caught between the Contact points will be crushed or amputated. 1. Release the “control on/off" illuminated push button located on the front control panel, turn off the ‘main on-off switch, and turn the Multivac's main air supply regulator to zero before changing or adjusting the gears 2, Adjustments and gear changes should be performed only by qualified personnel. When changing gears, never attempt to mesh the gears by jogging the system under power. if the teeth do not mesh together, with main power of, rotate the change gear cone tooth at a time on the spine shatt, checking for proper alignment each time, There will always be ‘some point where the step gear and the change gear will mesh propery.© High voltage ... ‘The Multivacruns on 220 or 380 (415) volt AC electrical po- wer. That is enough voltage to cause injury or death ifyou contact exposed wires or terminals. Because ofthe danger, extreme caution should be exercised when working on the ‘Mutivac’s electrical systems. The Muttvac's electrical circuits are guarded only when all cabinet doors are closed, al electrical pars are properly in- stalled, and all control knobs, buttons, et. are in good re- pa. 1. Always. keep the control panel door closed end latched except when performing maintenance. 2, If you have to open @ control panel door, remove a die, or do any work in the area ofthe Multivac's elec- ‘tical system, TURN OFF THE ELECTRICAL POWER LEADING TO THE MULTIVAC. The electrical swit on the machine does not shut off power to the machine. 3. Electrical repairs should be made only by qualified electricians.@ Cross cut knife... The cross cut knife cuts across the ful with of the fim with great speed and force, then returns to its original starting position before completing its oyole. Tis knife blade is razor sharp and it is powerful enough to severely cut or amputate your fingers or hands. ‘The cross cut knife assembly has a safety guard to keep your fingers ‘and hands from making accidental contact with the cuting blade when the assembly is properly mounted on the machine. An unmounted or improperly mounted cross cut assembly must be considered un- safe to touch unless its air hoses are disconnected from the machine! Do not reach under this guard or the knife assembly Without fist turning off the machine power and disconnecting all the operating sir hoses to the oross cut knife. Be careful—an exposed knife blade is potentially very dangerous even when the knife is disconnected from the machine 1. Tum off the main electrical power and disconnect the hoses before adjusting or removing the knife assembly, When the hoses are connected, the knife can still cycle with severing force and speed even with the machine turned off 2. Always loosen the star knob and remove the knife essembly by ‘grasping the top side only. 3, Remember, this knife is extremely sharp! Even after it has been removed, its still potentially very dangerous. Be careful not to touch the cutting edges of the blade!© Punch unit Some Muttvacs have @ two-part unit used to punch hanger holes and ‘make round comers on finished packages. A bottom partis forced by ‘great pressure into a stationary upper part o squeeze and separate the firm, Large, powerful ar cylinders and strong mechanical linkage power the punch units. Fingers or hands placed between the two parts while the Tachine is running will be broken, crushed or amputated. ‘The punch assembly has a safety guard to keep fingers and hands from accidentally entering the punch unit 4. Always keep the safety guards in place while the Multivac machine is turned on. They are there to protect you. 2. Tum off the main power switch and disconnect the compressed air lines before removing guards to inspector repair the punch Unit. Always remove the upper part of the assembly when inspec- ting or performing maintenance on the punch. 3 Never reach between the upper and lower punch parts. Punch units can easily crush or amputate fingers and hands. 1@ Rotary knives... ‘These razor-sharp, round knives spin at very high speeds (1360 rpm) to cut and separate the packages lengthwise. On some model, these rotate Continuously, while on others they rotate intermittently. Rotary knives are extremely sharp, and will cut you tothe bone i handled imeroperly—even when they are idle on the Mulvac or setting on a shelf Muitvac rotary knives are guarded to prevent accidental contact while they are mounted on the machine 1. Do not reach under the safety guards while the Muttivac is running, Never run the Multivac with the guards off or any of the safety switches bypassed, 2. Tum off the main electrical switch before inspecting the knife assembly. The knives may continue to rotate for a while after the Multivac has been tumed off, Meke sure they have COMPLETELY STOPPED before removing the guards. 3. Shield the rotary knife assembly when placing it on a table, bench, etc. These knives are extremely sharp and will cut deeply whether they are on the machine or off!@ Shutting off the Multivacs electrical power . . . 4. Turn off the »control or/ot«iluminated push button lo- cated on the Multvac’s front panel and turn the Mult- vac's main on/off switch counter clodenise tothe »O oF (off) position to shut off the internal operating voltage 2. The electrical supply connected to the Muttivae's main nfott switchis 220 or 380 (415) vols. This onvof switch does not remove the power from the Multvac. Toshutthe power off, TURN OFF THE MAIN ELECTRICAL SWVITCH AT THEBUILDING'S SERVICE DISCONNECT SWITCH or AT THE BREAKER AND LOCK OUT THE CONTROL. 13© Shutting off the Multivac’s air supply . . . 1. The compressed air supplied tothe Muttvac should have an ini ne shutoff valve lacated within easy reach ofthe machine opera- tor. itis not, please draw this to your supervisor's attention, The supply lines were neither speciied nor installed by MULTIVAC en- Gineers. They are your company’s responsiblity. The at supply ‘connects directly 0a fiterrequtator. Reducing ar pressure ro va the regulator wil disable the Mulivac’s pneumatics. (Note ‘on some machines, shutting the main power switch off will deac- tivate the air dump valve solenoid which will instantaneously bleed all compressed air from the machine and in turn ender the pneumatic systems inoperative. I'you do not hear the audible air dump action, assume thatthe machine's pneumatia systems are active.) 2, Devices such as crass cut knives, ross cut punches, shape cut ters, hole punches, tear sit punches, and crass cut supports may be disabled a their quick disconnect. Most devices have two ho- ses; all hoses must be disconnected, 3, Clearly mark all work area power switches and shut-off val- ves-know thei locations-and know how to use them. 4In closing ... Your safety is important - to you, your employer, family and friends, and Multivac! ‘The cartoon character in this book had many problems, all of ‘which could have been avoided if he had followed the safety rules. ‘You, too, can avoid injury by practicing good safety habits. {tis important that you know your Multivac and be familiar with how it works. Therefore MULTIVAC provides training on each ma- chine when it is installed. Additional training is also available at MULTIVAC’S training ses- ‘sions in Wolfertschwenden or at their agents. Only you can operate the Multivac safely! Do not take the Multi- ‘vac's operations for granted-always be safety-minded. Multivacs are designed with your safety in mind, but they cannot think, You ‘mustalways think and practice safety-you have too much to loseifItisimportant thateach company practices: good safety, as well as each individual. We encourage copies of this booklet to be gi- ven to all maintenance and operating per- sonnel. Please keep one copy on fil and hhave each individual who reads it sign the nex page ofthe file copy. Additional copies ofthe safety booklet are avaiable atno cost by writing or clin MULTIVAC or thei r= presentatives. Also we would like to recommend our 17 minute animated »MULTIVAG Safety Vi- ‘deo« to be used as part of your in-plant sa~ fety program. | have read and understand the safety rules for the MULTIVAC packaging machine, & me Date MULTIVAC Mutivac - Sepp Haggenmille: KG - 0-87787 Wollerischwerden - Germany ‘Phone (08338) 601-0 Telex 54595 » Toloiax (0894) 601199.Press the "EMERGENCY STOP" button when there is danger Before doing any work in the danger area - Turn the main switch to "0" and lock it in this position - Shut off the compressed air supply and take action to make sure it will not be turned on again All repairs - especially those involving the electrical system of the machine - should only be carried out by experts In the operator's own interests, the safety equipement must be used and maintained properly. Alterations to and interference with the safety equipment are strictly prohibited! Every employee must be acquainted with the safety equipment on the machine. Newly recruited employees require this training as well.nis cnmnpennneercty aiop : STOR EMERGE E Sic te Every machine is equipped with et least one emergency stop switch. EMERGENCY STOP © Press this button when there is danger! All dangerous movements stop immediately. The dies open. © Eliminate the danger © Release the emergency stop switch by turning it © Important note: the electricity supply to the machine is not cut off when the emergency stop button is pressed.Every machine is equipped with a main switch. Additional equipment may have a main switch of its own. MAIN SWITCH © Before doing any work in the danger area: Turn the main switch to "0" The main switch turns the electricity supply on and off © Lock the main switch so that it cannot be switched'on again by anyone else ® When work needs to be done on the main_switch: Switch off the electricity supply to the machineoy pp coer mura DAT: R 4 SSED ALR inne PRESSED (A iy Every machine has at least one pressure regulation valve where the compressed air enters the machine. The pressure regulation valve may be located outside or inside the large and/or small control cabinet. PRESSURE REGULATION VALVE © Before doing any work in the danger area: Shut off the compressed air supply to the machine - Note the set pressure level or mark it on the manometer 7 ~ Turn the hand wheel counter-clockwise until the indicator on the manometer points to "0" e Make sure the air supply remains off by putting out a sign with the warning that the machine is being worked onWe had your safety in mind when we designed the machine! Guards at all the dangerous points and an appropriate monitoring system eliminate the danger of injury, provided that the following safety instructions are followed. Danger areas 1 FILM INFEED 2 FORMING STATION 3 SEALING STATION 4 CROSS CUTTING UNIT 5 LONGITUDINAL CUTTING UNIT 6 CONTROL CABINET 7 GEARBOX 8 DIE LIFTING UNIT 9 ADDITIONAL EQUIPMENTee Ee FILM INFEED Rotary motion - danger of injury Please note! - Do not wear any loose clothing - Do not wear any jewelry - Use suitable lifting equipment to move heavy reels into placeDANGERUAE FORMING STATION AN ‘Closing movement - danger of crushing Before doing any work in the danger area: Turn main switch to "0" and lock it © Shut off the compressed air supply. Make sure it will not be turned on again Please note! - Never reach into the die when the machine is on - Never put the protective fingers out of action or remove themFORMING STATION (continued) Cutting knives - danger of injury Hot heating plate - danger of burning Before doing any work in the danger area: © Turn main switch to "0" and lock it © Shut off compressed air supply. Make sure it will not be turned on again. Please note! “- Wear protective gloves - Hold the die top by its edges and put it in a safe place. The die top stays hot for about 40 minutes or even longer - Use suitable lifting equipment and obtain the help of another person when handling heavy dies ~- When the die bottom is taken out, die actuation rails may get caught and fall down, Keep your hands from the areaDANGER’ AREAS SEALING STATION aL Closing movement - danger of crushing Before doing any work in the danger area: © Turn main switch to "0" and lock it Shut off compressed air supply. Make sure it will not be turned on again. Please note! - Never reach into the die when the machine is on - Use suitable 1ifting equipment and obtain the help of another person when handling heavy dies - When the die bottom is taken out, die actuating rails may get caught and fall down. Keep your hands away from this area.pA yao iu DA -ER A (eS tice ses Gin En SEALING STATION (continued) Hot sealing plate - danger of burning Hot die bottom - danger of burning Before doing any work in the danger area: * Turn main switch to "O" and lock it © Shut off compressed air supply. Make sure it will not be turned on again. Please note! - Wear protective gloves - Hold the die top by its edges and put it in a safe place. The die remains hot for about 40 minutes or even longer - Keep the die in a suitable placeER ASI EAS ARE mano 5 CROSS CUTTING UNIT Sharp knife - danger of injury Before doing any work in the danger area: © Turn main switch to "0" and lock it © Shut off compressed air supply. Make sure it will not be turned on again. Please note! - Take hold of the cross cutting unit from above; do not reach into the knife area - Put the cross cutting unit in a suitable place. The cutting knife is dangerous even when it is not moving ~ Only test run the cross cutting unit when it is installed on the machine - Leave cross cut units on the machine even after they have been switched off.bear DF a NOE CROSS CUTTING UNIT (continuea) Cutting knife - danger of amputation| Before doing any work in the danger area: © Turn main switch to "0" and lock it Remove the hose connections from the punch or shut off the compressed air supply. Make sure it will not be turned on again. Please note! - Never reach under the punch top. Take hold of the top by its sides; high cutting pressure! - Put the punch top in a suitable plac the knife can be dangerous - Use suitable lifting equipment or obtain the help of another person when removing and re-installing cross cutting units GWE eS s ew big eae 2 SSSwan ae LONGITUDINAL CUTTING UNIT Sharp, high-speed knives - danger of injury Before doing any work in the danger area: Turn main switch to “O" and lock it Please note! - Hold the knife shaft right at its end.to remove it ~ Longitudinal cutting unit should always be put in the storage tray delivered with it. The knife shaft can be dangerous even when it is being stored ~ Be extremely careful when changing the knives!pee a iD DAI .~CONTROL CABINET High voltage - life in danger Before doing any work in the danger area: e Turn main switch to "0" and lock it « Shut off compressed air supply. Make sure it will not be turned on again. Please note! - Work in the control cabinet should only be carried out by trained electricians - When work needs to be done on the main switch, turn off the electricity supply to the machine. GEAR BOX Dangerous movements - danger of injury Before opening gearbox: e Turn main switch to "0" and lock it Shut off compressed air supply. Make sure it will not be turned on again. Please note! - Do not turn the machine on to move the gear wheelsDIE LIFTING UNIT Dangerous movement - danger of crushing This danger area is inside the machine. Particular care should be taken when dies have been removed or support plats have been taken off in the loading area: © Turn main switch to "0" and lock it @ Shut off compressed air supply. Make sure it will not be turned on again. Please note! When the machine is switched on - Do not reach between the die actuating rails or connecting rods - Do not reach into the machine from belowDANGER) AREAS ADDITIONAL EQUIPMENT Additional equipment includes all the equipment that has not been covered in the previous sections, e.g. printing units, filling units, heat embossing units etc. The following instructions are of a general nature. Their purpose is to emphasize the need for care. Hot parts - danger of burning Dangerous movement - danger of crushing High voltage - life in danger when working in a danger area: _@ Turn main switch to "0" and lock it @ Wear protective gloves ® Work involving the electrical system should only be done by appropriately trained staff Please note - Follow the safety instructions given in the instruction manual for the additional equipment concerned - Additional equipment from other manufacturers sometimes has an electricity supply system of its own. This needs to be turned off separately! - Follow the instructions on the proper handling of printing inksna UUM TECHNICAL DETAILS ¢ Magnetic switches The magnetic switch (1A) is located in the side of the machine while the magnet (1B) is in the side of the guards. When a guard is raised, the magnetic switch turns the machine off. © Protective fingers (2) Plastic fingers fixed to a shaft at one end and loose at the other are located in such a way thet they let the formed lower web through but make it impossible to reach into the dic. © Photocells (3) (depending on the equipment included on the machine) Consist of a transmitter and a receiver. If the light beam is interrupted, the die move- ment stops immediately. If the interruption lasts more than 3 seconds, the machine turns off. Please note! - Always put the guard in the right place. They are not interchangeable - Put guards on quickly, as otherwise a fault will be signalled - Repair or replace faulty guards immediately MULTIVACMAINTENANCE Clean the guards with warm water and washing-up liquid Remove guards with integrated photo- cells carefully and make sure they cannot fall over Check that the photocells are plugged in properly Clean the photocells reqularly, particularly when liquid or powdery products are being packaged<< mucrivac Chapter 03Installation, connection Pago 1 of 9 Contents O Safety © Points to note during installation Electrical connections © Compressed air connections © Vacuum connections © Cooling water connections O Gas connection Safety A Danger of injury M855, R 7000, R 5200, RT 5200, R 80 When assembling machine parts, use suitable lifting equipment or obtain the assistance of another person Follow the transport instructions Electrical connections should only be made by trained electricians and the relevant regulations must be observed, Do not reach into the control cabinet When fitting the dies and additional equipment follow the safety instructions in the description, Iastruction mara 29.07.1997 fufstoionaluypen 10.0602 Ig MULTIVACInstallation, connection Page 2 of 9 Points to note during installation - The machine does not need any foundations and does not have to be attached to the floor etc. - Align the machine horizontally in machine and cross direction using a spirit level. yucca ‘The machine can be damaged if it is not aligned properly. Minor unevenness in the floor can be levelled out by adjusting the feet (see the arrows in Ml 4): = Undo the lock nut ~ Adjust the foot + Tighten the lock nut - Make sure there is easy access to the control cabinets. + The machine dimensions and the location of the connections can be found in the dia- grams at the end of the section. - Follow the instructions in the relevant description when fitting the dies and additio- nal equipment. [ — w — ee vw w M4) Alignment of the machine Inetrction manual 2907.1907 faufstolonalutypen 100GB02 Ig MULTIVACInstallation, connection Page 3 of 9 Electrical connections Mains connection High voltage Life in danger Important instructions + All work should be carried out by trained electricians. - Observe the relevant regulations and directives. + Connected load figures can be found on the nameplate. ~ Connect the mains cable in accordance with the information given on the terminals, making sure the electrical wiring diagrams are observed. Cross-section of the mains cable ‘Nominai current’ A[ 36A | SOA | 63A | 80A Cross-section mm?| 6 | 10 | 16 | 25 Phase control ‘One of the two types of phase sequence relay illustrated on the right is fitted in the machine + Tum the main switch to 1 ~ Press the illuminated pushbutton HEATING; it will ight up On the phase sequence relay: The light-emitting diode (red) goes on: Phase sequence correct The light-emitting diode (red) does not go on: Change 2 phases of the mains cable on the terminal strip or check the fuse. M.2 Electrical connection, nameplate M3 Phase sequence relais * These figures include the connection of an external vacuum pump. Tho contactor (22)K1 reveals whother an extemal vacuum pump is activated by the machine, Instruction menuat 29.07.1987 futstolenalutypon_ 1006802 Ig MULTIVACinstallation, connection Page 4 of 9 Control connection for vacuum pump ~ Connection terminals’ are provided in the control cabinet for the operation of an external vacuum pump; follow the electrical wiring diagram, {f there is @ built-in Roots pump, make sure that it only starts when a signal has been teceived from the backing pump or the central vacuum system; follow the electrical wiring diagram. Important note! Note the connected load data on the pump. nameplate. * Only with the appropriate equipment It this is not the case, connect the pump separately. Connection of additional equipment - Additional equipment, such as infeed and discharge conveyors, printing units, can be connected on connection terminals provided for this purpose in the control cabinet; see the electrical wiring diagram. > Hexternal equipment, such as a filing unit, is ‘supposed to be synchronised, MULTIVAC or its agent should be consulted. etre Note the connected load data on the Nameplate of the additional equipment. —— Cena} y) 1M, 4 Location of the PG control connection terminals M..5 Location of the MC control connection terminals, Instrsction manual 2907.1997 eulstellenalutypen 100802 MULTIVACInstallation, connection Page 5 of 9 Compressed air connections Installation Lay a compressed air line of 3/4” to 1". Make Sure you incorporate a compressed air shut-off valve in the compressed aire line. Blow the line ‘out thouroghly before putting it into operation. The standard compressed air connection is located on the contro! cabinet at the infeed end of the machine. Depending on the machine equipment, there may be a further connection on the main control cabinet (see Ill. 6). Setting Compressed air in the supply line: min. 7 bar max. 10 bar Operating air pressure: 6 bar Setting on the pressure regulation valve: ~ Turning clockwise: Air pressure is increase - Turning counter-clockwise: Air pressure is reduced Important notes: - Lay a compressed air line of 3/4" to 1". Blow it out thoroughly before starting operation. = Apressure monitor is set in such a way when the machine is supplied that the machine stops when the pressure drops below 45 bar. A fault message appears on the diagnostics system. - Acompressed air shut-off valve (see arrow in 7) shuts the compressed air supply off completely, when the main switch is tumed 100. This does not apply to: Control valves for evacuation |W, 6 Compressed air connection 7 Compressed air setting Characteristics of the compressed air ~ Filter element 25 microns (to be fitted by the customer) = Moisture content max 7 g/m 3, Recommendation: if there are temperatures of 3°C and higher in the compressed air network, the compressor should be followed by a refrigeration drier. In the case of temperatures below 3°C, the compressor should be followed by an adsorption drier. Compressed air consumption ‘The compressed air consumption depends on the machine equipment and the operating speed (cycles per minute). An exact calculation ‘can be made at the factory on request. Instruction manual 29.07.1987 aufstetenalutypen_10.0G802 Ig MULTIVACInstallation, connection Page 6 of 9 Vacuum connections for external vacuum pumps There are machine configurations which form with a vacuum or evacuate the pack and do not have a built-in vacuum pump In such cases there may be one or more vacuum connections. General instructions: - Use only the special hose supplied with the machine as the vacuum line. - Wherever possible, avoid sharp curves, comers and long supply lines. Every change in ditection teads to a reduction in evacuation efficiency. - Read the instruction manual supplied by the pump manufacturer before starting operation Evacuation with a Roots pump A Roots pump must not be operated without a backing pump. Arrange the machine control ‘system in such a way that the Roots pump cannot start without the backing pump being switched on. The connection line between the Roots pump and the backing pump should be 2", Location of the connections The external vacuum connections are always near the places marked with an arrow in Il. 8. Consult the connection diagram about this as well. x * 11.8 Vacuum connections Evacuation via a central vacuum system In such cases there are two connections for evacuation on the sealing die, Note the distinction between APPROXIMATE/PRECISE vacuum (see the chapter entitled “Pack evacuation and gas flushing - connection to a central vacuum system’). WL Vacuum connections with a central vacuum system Instruction manual 2907.1997 ‘ulstelonalutypen_10.0G802 ig MULTIVACInstallation, connection Page 7 of 9 Cooling water connections Location The standard cooling water connection is on the main control cabinet (see Ill. 10). There may be an additional connection on the pneumatics contro! cabinet in the film infeed ae area (see the following connection diagram) K A low = outflow 1.10 Cooling water inflow and oultiow Setting Do not change the settings of the pressure Wawrorcsuio in ine sugay monitor and the flow monitor! min 1.5 bar max 4,5 bar fee emer Condensation may form if the cooling water flow 7 : volume is too high. The die top should be so So RO ‘warm that it can still be touched, can be fitted, according to the machine equipment. Pressure A pressure monitor is fitted directly after the water shut-off valve (see Ill, 11/top, number 1). {t is set so that the machine stops when the pressure drops below the minimum level. Flow ‘The water flow volume is set at the factory (see 71 IN. 14/top, number 2): <| { + flow volume is increased ! = flow volume is reduced \ | A flow monitor is fitted at the end of the water ; | circuit (see Ill. 1 / bottom) | ! Itis set so that the machine stops when the flow ees te volume is less than 2 min. 17. Water prossure and water flow control. Mason s0o0ere MULTIVACInstallation, connection Pago 8 of 9 © Cooling water requirement © Shutting off the cooling water 180 - 250 hour of cooling water at 15°C are = Turn the main switch to 0. required ‘A magnetic valve shuts the water supply off Instructions - When installing new lines, use a nominal width of 1/2". Blow them out thoroughly @ Requirements on the cooling water Sees catiag peek + Max. inflow temperature 15°C. A recooling unit should be used if the inflow - Water outflow should be downwards to temperature is higher. make sure that water left in the system does not flow back. Filter element 50 microns + If water costs are high, recooling in a self- contained circuit may be more economic. = pHlevel 7...7,5 This also reduces calcium déposits. MULTIVAC or its agent can submit proposals = Content of: about this on request. Iron (Fe) and manganese (Mn) < 0,1 mg/l Calcium (Ca) 22 ... 50 mg/ Magnesium (Mg) 13.... 30 mg/l Free chlorine (Ci) <0,1 mgt The water supply authorities responsible can provide information about water composition. Sisorommaper0ace0 MULTIVACInstallation, connection Page 9 of 9 Gas connection This section can be disregarded in the case of machines that do not have a gas flushing unit. @ Location The standard gas connection (1) is on the main control cabinet (see the following connection diagrams in III, 12 and 13). © Setting Set the gas pressure on the precise gas regulation valve (2) on the gas bottle: min. 6 bar max. 9 bar * ifthe machine is equipped accordingly. ‘Soe section 11 “Pack evacuation and gas flushing - gas mixing unit” for instructions on setting the gas mixing unit, IIL12 Gas connection* 10.13. Gas connection with gas mixing unit Instruction marwal 907.1997 ‘austofenalutypon_10.06802 ig MULTIVACInstallation, start-up 03 Transport, storage, installation, start-up/shut-down Contents O Safety O instaniation © Electrical connections © Compressed alr connections © Cooling water connections © Vacuum connections © Gas connections (© Final checks © Layout plan, connection diagram Safety Danger that the machine may topple over! Danger of injury! Page 1 of 19 R530 When assembling machine parts, use suitable liting equipment or obtain the assistance of another person Follow the transport instructions Electrical connections should only be made by trained electricians and the relevant regulations must be observed When fitting the dies and additional equipment follow the safety instructions in the description. ‘GB cautstallenInstallation, start-up 03 Transport, storage, installation, star-upishut-down Installation We recommend that you request the help of a ‘Multivac service technician when installing/starting up a machine Unpacking, preparation Remove the outer packaging tlm, wooden case) board, Remove all transport safety devices Remove accessory equipment supplied with the machine IL 1 Machine secured on square wooden supports and Lbars Undo all attachment screws (1) Remove the transverse (2) and longitudinal (3) wooden supports Page 2 of 19 ~ Use a fork-lit truck to lift the machine slowly by the L-bars (7) until the crossbeam (4) is accessible Undo the lock nuts (5) I. 2 Machine foot ‘Screw all the feet (6) out the same distance Place the machine on the floor carefully ‘Screw out any feet that are not touching the floor Properly Remove the L-bars (7) and spacing plates (8) Remove the crossbeam (4) Attachment scrows Transverse wooden supports Longitudinal wooden supports Crossbeam Lock nut Foot Lebars ‘Spacing plates eVounones Fnswion manual “fo0a03 ULT GB sufstellen . rIVACinstallation, start-up 03 Transpon, storage, instalation, star-up/shut-down Assembling the packaging machine ‘These instructions only need to be followed it the machine was delivered in paris. 1 this is not the case, miss out this section and continue with the “Alignment” section. Page 3 of 19 Make sure there are wooden supports between the extension and the forks Lift the extension carefully with a forklift truck Follow the instructions. In the "Safety" section! u Attachment of the extension “Extension” means the extensions at the discharge end of the machine, ‘The instructions in this section can be disregarded if the machine does not have an extension. 1.3 Extensions with wooden supports eau The extension must not be allowed to Ile on the forks - there Is a danger that It might be dented. Depends on the machine configuration Il 4 Extension with wooden support Position the extension at the discharge end of the machine. Danger that it may topple over! Put ‘a wooden support underneath it” Align the extension with the machine Fitting allgnment sections Fit alignment sections (9) at the connection points. Carefully join the parts of the machine together MN. 5 oining the machine togather fasion anual 38081088 emanate. MU LTIMAG ce sisonninstallation, start-up Page 4 of 19 03 Transport, storage, instalation, siar-upyshut-down, = Insert and tighten screws (10) directly below the = Plug all the plugs (14) in the distribution cabinet ‘connection points I. 8 Machine with distribution cabinet | 1M. 6 Connection points | = Attach the metal bracket (12) with screws (11) = Remove the wooden support” neue = Align the machine in accordance with the . {nstructions given later in this manual Never pull on the cables to remove the plugs. Do not use force when connecting plug-in : : : Connect hoses correctly by referring to their Connections. markings - Connect the compressed air hoses for the cutting units = if there is a vacuum pump for forming, connect the cable in the terminal box of the pump. reac: 13 L ° Check the direction of pump rotation betore switching on the machine = Connect the drive motor cable in the main q control cabinet (see electrical wiring diagram) ML 7 Oil container for automatic chain lubrication = Connect the cables of the cutting units, the vacuum trim removal unit, the edge trim rewind unit etc. in the main contro! cabinet (see electrical wiring diagram) + Connect the hoses for automatic chain lubrication (13) to the distributor in the main control cabinet * Depends on the machine configuration "paver manual ae 119.08.1983"..- pupeaigop 6B_aufsiéiion.Installation, start-up 03 Transport, storage, instalation, star-upishut-down Fitting the rotary shaft encoder d[Pe M8 Fitting the rotary shatt oncoder = Attach the rotary shait encoder with screws (15); do not tighten them = Put the toothed belt (16) on = Tighten the toothed belt and the screws (instructions on this can be found in chapter 05 entitled "Advance drive - tightening the toothed belt") = Fit the cables in the holders provided for this purpose and secure them with a plastic clip if necessary rodeos ‘The cables must not touch the toothed belt Page 5 of 19 Fitting the magnetic reed switch strips at the discharge end = Undo the screws (see arrow) at the discharge ‘end of the machine and remove them with the covers (16) M. 10 Fitting the magnetic reed switch sires - Make sure that all the socket head screws (17) have been undone - Always insert the pointed end of the magnetic reed switch strip (18) with the cable outlet first = Note where the guide groove (19) is. it must always face the inside of the machine. 7 M11 Magnetic reed switch stripInstallation, start-up 03 Transpor, storage, installation, start-up/shut-down + Insert and attach the magnetic reed switch strips - Fit the covers (16) back on and tighten the screw loosely; do not tighten them behind them + Insert the cable in the main contro! cabinet = Connect the magnetic reed switch strip in the main control cabinet (see electrical wiring diagram) | ] 410 mm 4M $3. Connection terminals in the main control cabinot M12 Sotting the magnotic reed switch stip + Position the magnetic reed switch strips accurately and aitach them securely, The distance from the end of the panel to the ‘magnetic reed switch strip must be 10 mm Due) If the magnetic reed switch strips are not positioned correctly, faults are reported; the ‘machine will not run, eee MULT PUA ce austenInstallation, start-up 03 Transport, storage, installation, Instaltation of the film transport chain = Remove the chain guard (20) ~ Undo the clamping screw (21) = Move the sprocket wheel towards the centre of the machine by turning the tensioning screw (22) to the left Page 7 of 19 + Pull the chain tight until the ends of the chain touch Note: ‘Make sure the ends of the chain touch M14 Installation of the fim transport chain = Insert the chain into the chain guide rails on both sides and pull it towards the drive + The ends of the chain (23) must be easily ac- cessible __ lil. 16 Assembly of the film transport chain ~ Fit the chain link and the connecting link (24) together (red marking) + Clamp the locking wire (25) in position + Fitthe chain clamp (26) - Put onthe spring (27) + Tighten the chain in accordance with the ‘description in chapter 15Installation, start-up Pago 8 of 19 03 Transpon, storage, installation, star-uprshutdawn, Attachment of the discharge conveyor Instructions on this can be found in the description of the discharge conveyor in chapter 05: Checking, fitting of guards, panels etc. = Check the oil level of the pumps, central lubrication system and maintenance units + Secure bars (28) at the connection points. ~ Fit the side panelling (28) ~ Putin the support tray and the discharge plate .17 Fiiting the side paneling ~ Fit the die guards oe AULT IMAC ceaseInstallation, start-up 03 Transport, storage, installation, start-up/shut-down, Alignment + The machine does not need any foundations and ‘does not have to be attached to the floor etc. ~ Make sure there is easy access to the control cabinets Not ‘Always align the machine with a spirit level machine spirit level if one is available + Align the machine horizontally in mact cross direction using a spirit level (IN. 18) = Undo the fock nut + Adpst the toot + Tighten the fock nut cue The machine can be damaged If It Is not aligned properly. Page 9 of 19 ® WU. 18 Alignment of the machine Tinsbieion mafual 19.081092 7 plpeaten.Installation, start-up Page 10 of 19 03 Transport, storage, instalation, start-up/shut-down, Electrical connections Mains connection High voltage - Life in danger ¥ Important instructions + All work should be catried out by trained electriclans ~ Observe the relevant regulations and directives ~ Connected load figures can be found on the nameplate + Connect the mains cable in accordance with the information given on the terminals, making sure the electrical wiring diagrams are observed 1M. 19 Electrical connection Tolerance of the mains voltage + 10% - Cross-section of the mains cable | M20 Nameplate Neninalcovon™A | 25h 26h 60m | 8A | BOA | [cornet | «[etolw| x {MN ULTIMA essenInstallation, start-up 03 Transport, storage, instalation, star-upshut-down Phase control + Turn the main switch to | + Press the illuminated pushbutton HEATING; it wil ight up (On the phase sequence relay’ ‘The light-emitting diode (red) goes on: Phase sequence correct The light-emitting diode (red) does not go on: Change 2 phases of the mains cable on the terminal strip or check the fuse ‘The light-emitting diode (green) does not go on: Check the thermocouple on the drive motor and/or the mains cable e-——l e@) 0 FERRE Ul 24 Phase sequence relay Page 11 of 19 Control connection for vacuum pump - Connection terminals" are provided in the control cabinet for the operation of an external vacuum pump; follow the electrical wiring diagram Read the instruction manual provided by the Pump manutacturer before starting to operate the pump. The machine control system is designed in such a way that the Roots pump only starts when a signal has been received from the backing pump or the central vacuum system; follow the electrical wiring diagram. ecb I, 22 Location of the connection terminals Connection of additional equipment ~ Additional equipment, such as infeed and discharge conveyors, printing units, are connected on connection terminals provided for this purpose in the contro! cabinet; see the electrical wiring diagram and Mil. 22 - If external equipment, such as a filling unit, is supposed to be synchronised, MULTIVAC or its ‘agent should be consulted. * Only with the appropriate equipment. It thisis not the case, connect the pump separately [See MULTIVAC GB, aulstellenInstallation, start-up Page 12 of 19 63 Transport, storage, installation, start-up/shut-down Compressed air connections Compressed alr in the supply line min 8 bar max 10 bar Compressed alr consumption ‘The compressed air consumption depends on the machine equipment and the operating speed (cycles per minute). A calculation can be made at the factory on request. Characteristics of the compressed alr + Filter element 25 microns (to be fitted by the customer) - Moisture content max 1 g/m? Recommendation: It there are temperatures of 3°C and higher in the 1M, 23 Maintenance unit compressed air network, the compressor should be followed by a refrigeration drier. in the case of temperatures below 3°C, the compressor should be followed by an adsorption drier. Installation Lay a compressed air line of 3/4" to 1°. Blow it out thoroughly before starting operation. The standard compressed air connection is in the ‘main contro! cabinet. Depending on the machine equipment, there may bbe a further connection in the control cabinet at the infeed end of the machine (see Il. 23) TnstrUétion Mandal) Ee MULTIVAE |Installation, start-up 03 Transpon, storage, installation, stan-up/shut-down Setting Operating alr pressure: max 7 bar Setting on the pressure regulation valve (30): - Tuming clockwise: pressure is increased - Tuming counter-clockwise: Air pressure is reduced Notes ‘A pressure monitor is set in such a way when the machine is supplied that the machine stops when the pressure drops below § bar. The main valve (32) shuts the compressed air supply off completely, when the main switch is tumed to 0. This does not apply th particular to: = Control valves for evacuation and forming = Equipment for blowing out the water circuit A tault message appears on the display Amount of oll Setting the amount of oil on the tubricator (31): = Turning clockwise: Amount of otis increased ~ Turning counter-clockwis ‘Amount of ois reduced ‘Approximate figure: about ¥ drip/S min. Page 13 of 19 Vacuum connections for external vacuum pumps There are machine configurations which are designed for an external vacuum supply system. in such cases there may be one or more vacuum ‘connections. Gu Among other things, the shelf life of food packs depends on the maximum final vacuum level (and the nominal capacity) of the pump. Select sultable pumps. General instructions ~ Use only the special hose supplied with the machine as the vacuum line. = Where possible, avoid sharp curves, comers and tong supply tines. Every change in direction leads to a reduction in evacuation efficiency. = Read the instruction manual supplied by the ump manufacturer before starting operation Basic principles Extemal vacuum pumps should be located as close as possible to the machine. The vacuum hose should be no longer than 40 mat the most. oo MULTIVACInstallation, start-up 03 Transport, storage, installation, start-up/shut-down Location of the connection ‘The external vacuum connections are always near the places marked with an arrow in Ill. 24. Consult the connection diagram about this as well. Forming station Sealing station IM, 28 Vacuum connections Evacuation with a Roots pump ‘A Roots pump must not be operated without a backing pump. The machine control system is designed in such a way that the Roots pump cannot start without the backing pump being switched on. ‘The connection line between the Roots pump and the backing pump is 1 1/2 or 2", depending on the size of the backing pump. Page 14 of 19 Evacuation via a central vacuum system Jn such cases there are two connections for evacuation on the sealing die. Note the distinction between APPROXIMATEIPRECISE vacuum (seo ‘chapter 09), M25 Vacuum connections with a central vacuum sysiom A = Precise vacuum B= Approximate vacuum Instruction manival £1910g,1993." pipearasp. MULTIVAE © comoInstallation, start-up 03 Transport, storage, instalation, star-upishut-down Cooling water connections Requirements on the cooling water = Max. inflow temperature 15°C. + Filter element 50 microns + pHlevel 7... 7.5 + Content of: Iron (Fe) and manganese (Mn) < 0,1 mg Calcium (Ca) 22 ... 50 mg/l Magnesium (Mg) 13... 30 mg/l Free chlorine (Cl) < 0,1 mg/l ‘The water supply authorities responsible can provide information about water composition. Cooling water requirement 180 - 300 Uhour of cooling water at 15°C are required, depending on die size and the builtin vacuum pumps. Notes ~ When installing new lines, use a nominal width of 1/2". Blow them out thoroughly betore starting ‘operation. = Water outflow should be downwards to make sure that water left in the system does not flow back. - It water costs are high, recooling in a set- contained circuit may be more economic. This also reduces calcium deposits. Page 18 of 19 4, 26 Cooling water intiow and outtiow It processed (demineralized) water is to be used in ‘a water circuit, the pH level needs to be checked regularly. \W the pH level is in the alkaline range (ie. higher than 7.5), itis necessary to add e.g. powdered citric acid to prevent the formation ot aluminium hydroxide Al(OH)* ‘This would lead to deposits and - if the worst came to the worst - to blockage of the water lines. ‘The optimum pH tevel setting is between 6 and 7. Please consult MULTIVAC or its agent about installation of a recooting circuit. Setting Water pressure in the supply line: min 1,5 bar max 4.5 barInstallation, start-up 03 Transport, storage, installation, start-up/shut-down Flow The water flow volume is set at the factory based on a water inflow temperature of 10°C (see I. 27) Correction: + flow volume is Increased + flow volume is reduced Note: Condensation may form if the cooling water flow volume is too high. The die top should be so warm that it can still be touched, A tlow monitor is fitted in the outflow system (see 1, 28) I is set so that the machine stops when the flow volume is less than 2 min. Do not change the setting of the flow monitor! ‘Shutting off the cooling water + Turn the main switch to 0 A diaphragm valve shuts the water supply off. Page 16 of 19 1,27 Regulation of water flow |, 28 Water flow monitor GBiautstollén,Installation, start-up 03 Transport, storage, installation, stat-up/shut-down Gas connections This section can be disregarded in the case of ‘machines that do not have a gas flushing unit. Information on the Kind/mixing ratio of the gas Fequired can be obtained from your gas supplier or Via the Muttivac organisation. Location The standard gas connection (34) is on the main control cabinet. DANGER OF SUFFOCATION DANGER OF EXPLOSION Page 17 of 19 Sey MW, 29 Gas connection Observe the safety regulations Input pressure must not exceed 7 bar Ventilate rooms well, avoid gas accumulation ‘Shut off the gas supply when machine ‘operation stops Not ‘The gases do not smell! + When using oxygen: + Do not smoke + Make sure there is no oil and grease on parts such as fittings, valves and hoses through which gas tlows + Move flammable objects out of the room Insirudtion manual f 191081998, peste, _MULTIVACInstallation, start-up 03 Transport, storage, installation, start-up/shut-down Setting Set the gas pressure on the precise gas regulation valve on the gas bottle (33): ~ max. 7 bar ‘On the precise gas regulation vaive (35) in the main control cabinet: + Setting depends on the product and pack size. It there is a gas mixing unit (36), read the description of i in chapter 09. Page 18 of 19 1. 30 Precise gas regulation valve/gas connection 3336 Wl. 31 Gas connection with gas mixing unitInstallation, start-up Page 19 of 19 03 Transpon, storage, installation, start-up/shut-down Final checks When all the preparations have been completed, ccheck the following points again: + is compressed air available and is the compressor switched on? + Is cooling water available and is the shut-off valve open? - is a water outflow facility (unpressurized) available? - 1s gas available" and is the shut-off valve open? Oil level check + Vacuum pump = Maintenance unit + Automatic chain lubrication system* Grease level check + Automatic grease tubrication for the lifting unit* Itthe packaging machine was delivered in parts + Check the phase control in the main contro! cabinet + Check the direction of rotation of the vacuum pumps* * Depends on the machine configuration Instruction manual: 5! ‘GB.aulstellen muctiwacTransport instructions : 04 Transport without packaging Page itera Safety © Observe the safety regulations Lifting of loads © Note the weight information provided ch the Extremely dangerous packaging or in the shipping documents. ‘© Note where the centre of gravity is, danger that the load may topple over Transport without packaging Check the following points before transporting: - Have all the supply connections been - Have the cross cutting units on the discharge disconnected? extension been removed? - Are all the control cabinet doors closed? - Is suitable transporting equipment (crane or forklift truck) available? - Have all loose and moving parts been secu- red in place so that they do not fall off? - Is there enough space for the load along its transport route? ~ Have the reels of film been removed? - Has the cooling water been emptied? Be ca- reful in the case of temperatures below 0°C. - Keep a particularly close eye on projecting parts like the film unwind system and drive motor. ~ Never lift a machine by the discharge exten- ‘sionTransport instructions Transport without packaging 04 Page 2 of 3 Machine with closed sides: ~ Estimate the centre of gravity of the machi- ne. It may not be in the middle of the machi- ne. - When using a fork-llft truck, approach the machine from the control cabinet side. Posi- tion the forks of the forklift truck as far apart as possible. - When using a crane, put the ropes around the feet of the machine as shown in the illu- stration. Machine with open sides: eee + Only transport the machine after L-bars have been fitted. + Be particularly careful about projecting parts like the film unwind system, the edge trim re- moval unit or the drive motor. - Never lift a machine by the discharge exten- sion! 2 Liting a machine with a crane How a machine should not be fitted and transported TU A Co rgonarvens OR Gee e ersporanesTransport instructions Transport without packaging 04 Pago 3 of 3 Preparations for transport + Prepare an L-bar with dimensions of at least 120 x 120 x 12 (length depends on the ma- chine) for each side; Make a slit for each foot (see I.4) - Fit the bars: + Screw down the lock nut (6) Insert the L-bars (3) - Fit spacing plates (4) and washers (5) - Tighten the lock nut (6) In the case of machines with side openings of More than 1000 mm, two support beams have to be fitted (see Ill.4). Transport + Estimate the centre of gravity of the machi- ne. It may not be in the middle of the machi- ne, ~ When using a fork-lift truck, approach the machine from the control cabinet side. Posi- tion the forks of the fork-lift truck as far apart as possible. 1UL4 Fiting transport bars.<< mucrivac Chapter 04Operating controls Control panel 1 Main switch 2 Ammeter for heating current SEALING* 3 Ammeter for heating current FORMING* 4 Contact vacuum gauge/Vacuum gauge digital 5 Luminous key CONTROL HEATING ON/OFF 6 Luminous key PUNCH, ACROSS CUTTER, 7 Thermostat 8 Potentiometer with control lamp for VACUUM 9 Potentiometer with control lamp GAS FLUSHING ** 10 Luminous key PHOTOCELL ON/OFF 12 Luminous key ADVANCE * only on machinas with appropriate equipment ‘0 function on machines without evacuation 10.03.1994 Ig/g6p 13. Potentiometer with control lamp for SEALING 14 Potentiometer with control lamp CAPACITY (PAUSE) 15 Luminous key GAS ** 16 Diagnosis indication 17 Luminous key I, START 18 Luminous key AUTOMATIC. 19 Key EMERGENCY STOP 20 Advance control unit 21 Luminous key 0, STOP 22 Luminous key SECURITY circuit 23 Control for printing unit * 24 Potentiometer with control lamp FILM HEATING 25 Potentiometer with control lamp FORMING. 26 Cycle selector switch VACUUM STATIONPotentiometer chassis within switch cabinet The switch cabinet also houses:2 potentiometers: 30 across cutting time _ 32 time between program end and die opening 1 Each of these potentiometers is set in our works and should not be readjusted except in urgent cases.12 Turning the machine on The MULTIVAC PC is equipped with a pressure guard resp. safety switch for the following conditions: Dies mounted, Guards put on, Pressurized air and cooling water available, Switch cabinet door closed. In the electrical wiring monitoring of all these functions is provided. The machine can only be operated on condition that the entire security circuit is in order, If there are failures, look up the diagnis indication. Proceed in the order described now, when turning the machine on: (The cited positions refer to the illustration under 1.1): + Main switch on - Operate luminous key pos. § “Control/heating ON/OFF”. - Operate luminous key pos. 22 "Security circuit". If it is in order,(see above) the luminous key lights up. - Operate luminous key pos. 18 “Automatic ON/OFF". The machine is ready now for automatic operation. The luminous key lights up. - Operate luminous key pos. 17 "I. start". The machine starts the automatic operation with "Die closing”. The preshaped tumblers can be leaded or filled with merchandise on condition that the dies have been perfectly heated up.If only a single working cycle ("single cycle") is wanted, turn the machine on as describes be- fore, till including “operate luminous key pos. 22 security circuit". Luminous key pos. 18 "Au- tomatic ON/OFF" must not be operated. Operate luminous key pos. 17 "I, start * ‘The working cycle starts with the closing of the dies. The cycle ends - normally after the dies have opened and after an advance movement. The last packs that have been sealed and the last pockets that have been formed are trans- ported out of the dies. The end of the cycle can be changed if necessary: The dies open and there is no advance movement. The packs that have been sea- led last and the pockets that have been formed last remain in the dies. When this change is made, a trained electrician? is required’ to carry out a minor modification to the wiring of the control unit. If only the advance is wanted, e.g. to thread a film in, proceed as follows: Tarn on as described above till including luminous key <"Security circuit". Luminous key pos. 18 "Automatic ON/OFF” must not be operated. - Operate luminous key pos. 12 "Advance" ‘The machine now performs an advance motion (1 cut-off length). After you depress and re- operate the key, the machine performs another advance motion (1 cut-off length). Rexatarting after a failure in the security circuit Tf the security circuit is interrupted by a failure anywhere, e.g. @ switch cabinet door has been opened, the groen luminous key “security circuit” pos. 22 goes out, and the machine stops. ‘Remove the cause. You can read the cause of the failure on the diagnosis indicating instru- ment, pos. 16, in the form of a number. * Note for the electrician: See the wiring diagrams (Chapter 14) for details This change can be made from machine no. 2285 onwards (October 1995).1.3 tural i - ‘The positions cited here after, refer to the illustration under 1.1. If the machine program shall be interrupted but for a short time, Pxess the luminous key pos, 2. The cycle ends - normally after the dies have opened and after an advance movement. The last packs that have been sealed and the last pockets that have been formed are trans- ported out of the dies. The end of the cycle can be changed if necessary: The dies open and there is no advance movement, The packs that have been sea~ led last and the pockets that have been formed last remain in the dies. When this change is made, a trained electrician* is required to carry out a minor modification to the wiring of the control unit. Turning the machine off after the operation has been performed Main switch to "o" (The lamp goes out). Emexgency stop The emergency stop switch (mushroom-head key with yellow collar) is meant to turn the machine off in the event of danger. Never operate the emergency stop key if there is no danger. Operating the emexsency stop key — The machine run is instantly stopped. The dies are opened. After the cause for the danger has been done with, release the emergency stop key by turning anti- clockwise. Start the machine as described under 1.2. CAUTION: If the emergency stop key has been operated during an advance, the machine first will perform the rest of this advance * Note for the electrician: See the wiring diagrams (Chapter 14) for details. This change cen be made from machine no. 2285 onwards (October 1995).1.5 Adjusting the machine functions With regard to the ensuing description, it is taken for granted that + the respective dies have been mounted (compare section 2) + that lower and upper film have been run in ~ that the stroke of the die has been adjusted properly. Working speed The working speed of the machine depends on the required time for program performance. So the setting of times for the individual functions influences the maximum attainable number of cycles per minute. Adjusting the potentiometer "Output" Dependent on the position of this potentiometer, an interval time is added to each machine cycle, whereby the cycle time is increased. Adjust small values for long interval times that result in slow working speed. Adjust high values for short interval times that result in high working speed. Minimum and maximum values of the working speed are dependent on the adjustment of the other functions.Forming The forming of the film is done in the closed (forming) die (also compare section 2.1.1). First of all the lower film is clamped by top and bottom die. The Film is pushed against the heating plate and heated up with a pressurized air or vacuum - as the construction of the die may be -. Next the heated-up film is pushed into the cooled die by means of pressure air or/and a plug or/and pulled into the die by means of vacuum. The forming procedure depends on the properties of the film and the package format. The settings as described hereafter, are inter-dependent. Only their reasonable joint action results in first-rate forming. Adjusting the heating temperature Set the temperature with the thermostat for "Forming" (pos. 7). Experience shows the values lie between 100° and 180° C, depending on the kind of lower film used. Do not set the temperature higher than necessary, certainly not higher than 200° C. The heating plate has reached the adjusted temperature when the control lamp on the thermostat goes out. Adjusting the heating time Adjust the heating time with the potentiometer “Film heating. "7 As the evacuation time exceeds the heating time, normally the time set for evacuation will do for "Film heating". If there is gas-flushing of the packages, the gas-flushing time adds to the heating time.Adjusting the forming time Adjust the forming time with the potentimeter for “Forming, sealing" (13). Adjust the potentiometer in a way that perfect forming of the packages ensues. Normally this time is sufficient for excellent sealing. Evacuation, gas-flushing and sealing The following three functions are performed within the sealing die as described hereafter: = evacuation - gas-flushing of the product - sealing of upper with lower film Make sure that machine and die have been equipped to match the respective functions; if e.g. you wish to produce a SKIN package, your die must be of the bottom heated type. For medical packages, there is no evacuating nor gas-flushing. Turn the potentiometer + “evacuation” (8) clockwise. You can see on vacuum gauge (4) if your setting was right. Setting the potentiometer higher means higher vacuum > * ecetsee , if your machine is equipped with vacuum contact gauge, read the following page:Modes of operation for evacuation and gas flushing with machines equipped with contact vacuum gauge and potentiometer Function of contact vacuum gauge: Evacuation resp. gas flushing is determined when the preset pressure is reached. Function of potentiometer: Evacuation resp. gas flushing is determined when the preset time has elapsed. Combination of the two: The entire cycle composes of the two periods: - Begin of process until preset pressure is reached (contact vacuum gauge) - Reaching of preset pressure until preset time has elapsed (potentiometer) The optimal mode should be found by trials due to the application. Guidelines are given in the table below. VEREAdjustments for Die (Standard) e Heating temperature e - Adjustment on the thermostat - Standard value 60..170°C as per the type of film (Polystyrene and PVC approx. 140°C) has been reached when the control lamp goes out. - Finding the optimum heating tempera- ture: adjust the upper standard value, run test packages, reduce the heating temperature by steps. @ Heating time - Adjust on the potentiometer (depending on the film thickness) : e During the heating time the control 7 lamp beside the potentiometer is on. = Avoid long heating times and go back ~ to values ensuring good forming. @ Heating pressure - Adjustment on pressure reducing valve (not applicable for "heating with vacuum") . Standard value 1..3 bar - do not adjust higher! : @ Forming time > Adjustment on the potentiometer e During the forming time the control t lamp on the potentiometer is on, the forming time is dependent on the film properties. = Avoid long forming times and go back till the forming is just good. @ = Forming pressure - Adjustment on pressure reducing valve (Standard value 3..5 bar Do not adjust pressures higher than necessary and go back to a point where the forming is just good.16562 1.5.2.1 Evacuation* The following is an explanation of different evacuation systems. You only need to read the section which corresponds to your machine model. But first we need to explain the difference betwoon a "narrow upper web" and a "wide upper web." With reference to evacuation, we differentiate between 2 "narrow" and a "wide" upper web: - 4n upper web is considered "narrow" when it is considerably narrower than the lower web. Gen- erally it is a difference of about 15 um. A aarrow upper web is not clamped by the sealing die {on the outsides. The package(s) ie (are) evacuated through the open sides (see illustration). = An upper web is considered "wide" when it is as wide or almost as wide es the lower web. Gen- erally it is a difference of about 5 mm, & wide upper web is clamped completely by the sealing die. The package(s) is (are) evacuated through slits made in the lower web. "Narrow" upper wed "Wider uppes”aed The vacuum pump can be built into the machine (with closed sides only) or set up outside the machine. An additional backing pump is necessary for the HL (high performance) model. More detailed instruc- tions for backing pumps we supply can be found in Section 8 of this instruction manual. ~ * Disregard this section iz you are not evacuating your packages!1.5.2.2 Standard equipment e With this model you can use "wide" and "nerrow" upper webs. It is prerequisite, though, that you have an appropriate die available. The evacuation system is portrayed in the two illustrations below. Lae "Narrow" upper web "Wide" upper web Evacuation of die top and Evacuation of die top package through valve I thorough valve I and die and die bottom through vottom and package through valve II. valve II. The evacuation time, in both-systems, is set with potentiometers "vacuum " and*/ or with the vacuum gauge on the control e panel. Select using selector switch 4. See hereafter. After the dies have been closed, evacuation sets in. It continues till e.g. the time set on the potentiometer, has elapsed. Perishable products need high vacuum. It is attained if the actual value indicator of the vacuum gauge (3) moves ; |. 7 further. 82) @ ith products containing liquids (sauces, soups, juices) it may happen that too much liquid is fS =a = | COC | (lol) I lela drawn off. In such cases, throttle the suction with the adjestmant (1). Indicator (2) will show you how e efficient you have throttled. Q. | Standard evacuation system: the vacuum is only set with the potentiometer"Vacuum station" cycle selector switch On the control panel of your machine there is a 12-level cycle selector switch, with which you can choose the eva- cuation system which is re- quired for producing your special package. Of course, your machine bas to be equipped for the parti- cular system you choose, for example: If the package is to be gas flushed - selector switch levels 5 and 6 - the machine has to. be equipped with gas flushing equipment, that is, the dies has to be equipped for it. Selector switch settings and their fumotions: Function Position saiten Poventionster Ca Test function 1 | Evacuation with potentioneter + Sigie Evacuation with potentioneter sod otentioneter Evacuation with Contact vacuum gnu Stesershrinking eysten for fresh aot inking systea jeuation vith contact vacuua gauge and porentioneter Evacuation with potentioneter Gas-flushing with potentionst Evacuation with contact vacuum gauge and potentiometer Gascflushing with contact vacuum gauge and potentione ter olalalauln1.5.3.1 Gas flushing the packages* Some products require a special inert gas atmosphere in the package. Depending upon the equipment on your machine, you can gas flush through jets (with narrow upper web**) or through gas flushing pins. You will need an appropri- ately designed die for each system. Similarly, if your machine is equipped appropriately, you can gas flush using the VBS gas flushing system (see Section 1.5.3.3). Gas flushing with jets This simplified illustration shows how the inert gas is fed into the packages. After having been drawn from the gas cylinder, the gas pressure is reduced to about 0.1 ... 1.0 bar. A solenoid valve opens and closes the gas supply at the correct time. The gas passes into the package through a gas flushing pipe with a jet. The gas is metered by the flow period or by a contact vacuum gauge (see Section 1.5.3.3). Preparation: Mount the correct die. In- sert the gas flushing tray in the open die (see illus- tration) and connect up the hose to the quick disconnect on the control box. Then con- nect the gas cylinder to the inert gas connection on the machine using a hose line. Please refer here to the Dimmensions and Connections Diagram in Section 6.1.5.3.1 (Cont'd) * Please refer to this section only if your machine is equipped for gas flushing. ** For narrow upper web, please refer to Section 1.5.2.1. Settings: First set the selector switch in the control panel on the correct setting. Set the gas pressure on about 0.1... 1.0 bar. High pressure —~ high flow speed Low pressure —® low flow speed Set the gas flushing period on the "as" CF potentionstor on the control panel @: Your best setting will depsnd upon the volume of the package and the speed at. which the gas flows. in. The sane is true here: tart with low settings and increase them until a good package is produced in the me] shortest time possible. Oooo Check your packages from time to time for tightness and good gas flushing. Please note: Inert gas sometimes cools the sealing plate down a little at the place where it flows in. If you find that this leads to poor sealed seams being produced, please try the following: = Reduce the inert gas intake pressure; increase the gas flushing period (if the required capacity of the machine will allow it); - Increase the sealing temperature slightiy. Turn the machine off and cut off the gas cylinder. When you turn the machine on again, you only need to open the gas cylinder and press the gas button. You do not need to reset the gas pressure and gas flush- ing period.1.5.3.2 Gas flushing with gas pins . This gas flushing system can only be used with a wide* upper web. A gas flushing pin which is built into the die bottom pushes through an opening in the edge of the mold when the die closes (see illustration). The film is held by the die around the entire edge of the package. Gas flows from the gas cylinder through a pressure- regulating valve to a solenoid valve. The latter opens and closes the supply line at the right time. From there gas flows through the gas flushing pin into the package. Preparation Mount only a die which is equipped for this gas flushing system. Connect the gas line to the die bottom. Also connect the gas cylinder to the inert gas connection on the machine. Please refer here to the Dimensions and Connections Diagram in Section 6. Settings: When making the settings, please proceed as previously instructed in Section 1.5.3.1, Settings. Note: If you are using a VBS system for gas flushing, please refer also to Section 1.5.3.3. * For wide upper web: Please read Section 1.5.2.1.1.5.3.3 Gas flushing products with different volumes VBS (Volume-controlled) gas flushing)* This gas flushing system is used when the size of the products being packaged varies considerably, and the packages still need to be gas flushed uniformely. With this system you can gas flush with pins or jets. Uniformly gas flushed Packages are produced by hav- ing the contact vacuum gauge stop the gas flushing process when the pressure set on it is reached. A "gas" solenoid valve (2) cuts off the gas supply. In order to ensure fast and more uniform gas flow, there is a pressure compensation tank (3) be- . fore the solenoid vaive. Preparatiot Mount a sealing die designed for this kind of gas flushing. Connect up the inert gas line from the machine to the die. A hose line with a quick disconnect runs from the gas valve under the sealing die. The inert gas cylinder should be connected to the inert gas intake on the machine. Refer to the Dimensions and Connections Diagram in Section 6. * This is possible only if the machine is equipped for it.1.5.4.1 Sealing In the sealing die, the upper web, for medical packaging a paper upper web, is sealed to the lower web after evacuation or gas flushing or after the dies close on a machine equipped for medical packaging. We differentiate between two kinds of sealing: Sealing the package with a seal around the entire package (contour or outline sealing) A heated sealing plate is designed so that it has ridges which match the contours of the packages. The Y6 solenoid valve activates and compressed air flows into a diaphragm which presses the sealing plate downwards. The webs of film are pressed together and heated up where the ridges are, and the webs are sealed together. After the sealing period is over, the valve activates again and the sealing plate rises. Setting the sealing temperature There is a thermostat ¥ on the control panel which is used for setting the sealing temperature you need. The correct setting depends upon the properties of the film. We regommend a temperature of 120° ~ 160°C. Be sure to start from low settings when setting the temperature. Caution! Too high a sealing temperature will make your Seals milky white and defective.1.5.4.1 (Cont'd) Setting the sealing period Set the sealing period on the "sealing"} potentiometer on the control panel. Make a few test packages to determine your best setting. Please remember that a longer sealing period’ does not improve the quality of your seal, but rather it may reduce the capacity of your machine. Only a good combination of your sealing temperature, Sealing period and sealing pressure will result in a good seal. Setting the sealing pressure There is a pressure- regulating valve on the "sealing" — solenoid valve (¥6)on which the sealing pressure is set. We recommend a pressure of 2-6 bar, depending upon the gauge of the film. You can tell if the sealing pressure is too high if you can see the seal in relief or if the surface structure of the sealing gasket is visible on the package seal.1.5.4.2 Sealing packages with total surface sealing (Skin) A heated, flat sealing plate is pushed down by a diaphragm when the Y6 solenoid valve activates. The upper web is heated up. At the same time the lower web (package pocket) is heated up in the die bottom. Two processes can be used to get the film to cling to the product: 1. The evacuation process stops in the die bottom but continiues in the die top. The warm film clings to the product due to the difference in the pressure. ISU 2. The evacuation process stops in the die top and bottom. Then the die bottom is ventilated and the atmospheric pressure presses the lower web of film around the product. When the upper and lower webs touch each other, they are sealed together. Please make sure here that the selector switch is set correctly; refer to Section 1.5.2.6. Be sure to only use suitable films. Setting the sealing temperature There are two thermostats on the control panel on which you can set the a temperature for thesdie top ¥ and the die bottom X . The correct setting depénds on the properties of the film. Generally the temperature for, the dig top should be 120° - 160° C,and fT the die bottom 50° When making the settings, be sure to start with low settings. Caution! The product touches the heating plate in the die top. So set the sealing temperature only as high as absolutely necessary.1.5.4.2 1.5.4.3 (Cont'd) Setting the sealing period See Section 1.5.4.1. Setting the sealing pressure See Section 1.5.4.1. Checking the sealed seam Please remember that the shelf life of the packaged product depends very deci- sively upon the quality of the sealed'seam. Therefore, you should check the , strength and tightness’ of the sealed seam at regular intervals. A very practical help in doing so is the bellow hand pump with needle which you will find in the toll box supplied with your machine. Use it to blow up a package (see illustration) and then put it under water. If bub- bles come out of the pack- age then there is a defect, such as too low a sealing temperature or a defective sealing gasket.Ventilation shortly after the sealing process starts, ventilation starts, that is the pressure outside and’ inside the sealing die is balanced so that it can open at the end of the sealing process. This is an automatic process which requires no settings. Capacity (Cycles per minute) It is set on the "capacity" potentiometer on the control panel. Depending upon the setting on the potentiometer, a pause period is added to each cycle of the machine, increasing the cycle period. The last part of the process, ventilation of the sealing die, takes place during the pause period. Some machines are equipped with special units, such as fillers, special cutting units, cartoners, etc., which require a long cycle period. In such cases it may not be possible to make use of the full capacity of the machine. :<< mucrivac Chapter 05Films 05 Films, wab transport, ramovat of film trim; pack transport Contents O Film as a packaging material O Film structure © Quality requirements © Determination of the sealable layer O Storage of the flim reels © Transport of the tlm reels ‘O Welght, metres on a reel (© Checking the interval between register marks © Appendices: + Instructions for register-printed packaging materials + Web width tolerances on Multivac rollstock machines Film as a packaging material There is a wide range of films available that have many different properties. A decision on which film 's the right choice for a specitic application is dependent on consideration of numerous factors, such as the product concemed, forming depth, Puncture resistance, sealing properties, temperature resistance, water vapour, oxygen and other gas barriers and pack presentation. Expert advice can be provided by film producers or by the Multivac Application Service Department. Page 1 of 10 All machines Note: Films of the same kind supplied by different producers can have processing properties that vary ‘considerably. It is therefore recommended that you keep at least half a reel in stock of a film that processes well for reference purposes ‘inetFilms 05 Films, web transport, removal of film tim; pack transport Film structure ‘A distinction is made between: - Monofiims = Muttlayer films, Monofilms. Monofilms consist of a single layer and form the Packaging material directly. ‘A monofilm cannot meet all the requirements that have to be satisfied in the extensive range of applications needed nowadays. Example: PE = Polyethylene PP = Polypropylene PS = Polystyrene PVG = Polyvinyl chloride Note: More details about films can be found in “Properties ‘and production of packaging films", that can be obtained directly from) MULTIVAC or from MULTIVAC'S agents, Page 2 of 10 Multilayer films A muttiayer film consists of two or more individual layers. Almost any combination of advantageous properties can be made by producing a multilayer film from a careful selection of different individual layers. ‘Standard muttilayer films generally consist of a substrate film and a sealing layer., Example: PAPE PE70um PE = polyethylene eomme™ . (sealing layer, water —, vapour bartior) PA 30 PA-= polyamide (substrato film) This multilayer film is written as follows: PAPE 30/70 PA = Polyamide HV = Tielayer EVOH = Gas barrier HV = Tielayer PE = Polyethylene pr This mutilayer fim is writen as follows: PA/EVOH/PE 30/70 M1 Muttlayer fms “AMULTIVAC cece |Films 05 Films, web transport, removal of film tim; pack transport Quality requirements Tolerance limits and quality requirements should be settled with the film supplier in advance in order to guarantee smooth production operations and ‘consistent pack quality. Requirements: + No swollen materials + No telescoping + Nooval reels xX = No projecting cores @ When film reels arrive from storage they should also, be checked to see if they meet these requirements. Page 3 of 10 + As few splices as possible ~ Core diameter corres- ponding to the film unwind system on the machine - Web widin corres- ponding to the die drawing andthe Muttivac standard, See the appended Multivac standard. tor tolerance information. Register mark tolerance (only when register-printed film is = being processed) See the appendix. 2 M2 Film reels Note: ‘Observe the local waste disposal regulations when disposing of reels of film that are damaged or cannot be used for some other reason (see chapter 16) Determination of the sealable layer ‘The sealing layer (in most cases PE / polyethylene) is generally on the inside of the film. It is identitied in different ways according to the film producer's preferences. It It Is not Identified, here are two examples: Rub both inside layers or both outside layers of strips of film together. The frictional resistance of the PE layer (soft layer) is higher. 4f you look at the film against the light, the sealing layer has a milky, matt appearance. In contrast to this, the outside is smooth / transparent. Nall tost: ‘The same test can be made using your fingernail ‘The soft layer (PE layer) can be roughened easily with a fingernail and also has a milky appearance when held up against the light. Fineiudioe wana? j'18101:1995Films 05 Fiims, web transport, removal of film trim; pack transport Storage of the film reels Wrong: = Indirect sunlight ~ De = Damp room that is rot clean + Concrete or stone tloor = Uneven surfaces + Longitudinal stacking of reels Pago 4 of 10 Right: - Onflat surfaces Always on their ends i = - OnsheNves | i I, 4 Right ways to store film reels = Store film reels in the packaging room for at Jeast 24 hours before processing starts = Do not remove the protective fim until the reel of film is required. Wrap reels in protective fim again whenprocessing of them is interrupted - Keep the information suppiled with the reel until al the film has been usedFilms (05 Films, web transport, removal of film tim; pack transport Transport of the film reels Do not remove the protective film when you are transporting film reels, Film reels can be transported = with a Rollboy, which is available from Muttivac and Muttivac’s agents With a lifting cart or a forklift truck Fork-lft truck 1.5 Possible means of transport Page 5 of 10 Weight Dimensions and weight The table on the right indicates the minumum and maximum weights of a reel in relation to the reel diameter. The figures are based on: + Reel width of 420 mm = Density of 0.9 (PP) and 1.4 (PVC) g/cm® - Core diameter of 3" = 76 mm resp. 6" = 152 mm Other rool widths: Welght (G) in kilograms, G = Weight according to Reel with (em) the table x 420 mm Reel diameters ‘Weight in kilogram (mm) Core diameter e 300 18-28 350 28-43 400 __ 39-60 450 51-80 66-102 q | ev-126_ | 98-153 620 417-181 700 437-213 750 158-246 800 [187-291 181-282 850 212-329 | 206-320 _ 300 236-370 | 232-360 950 265-412 | 259-403 1000 204-458 | 288-448 Tab.t MULTIVAC.Films Page 6 of 10 05 Films, web transport, removal of fm trim; pack transport Metres on a reel, depending on the material thickness and the reel diameter Tolerance levels: about - 10% Reel diameter 300 (mm) (rom) 400 (mm) 450 (mm) ‘Core diameter e x e a e s e Film thickness in um Number of metres 50 1269 | 949 | 1779 | 1459 | 2360 | 2048 [5036 | 2716 60 1057 | 791 | 1483 | 1216 | 1974 | 1707 | 2530 | 2263 70 ‘906 | 678 | 1271 | 1042 | 1692 | 1463 | 2168 | 1940 i 7ea_| 593 | 1112 | 912 | 1480 | 1280 | 1897 | 1697 {705 ~se7_| 988 | 11 | 1316 | 1138 | 1687 | 1509 _| | 634 | 474_ | 890_| 730 | itea | 1026 | 1516 | 1358 s77_| 431 | goa | 663 | 1076 | 931 | 1380 | 1234 120 sea_| 395 | 741 | 608 | 987 | 053 | 1265 | 1132 130 4ga_| 365 | 624 | 561 | 911 | 7ee | 1168 | 1045 140 453 | 399 | 695 | sex | eae | 702 | 1084 | 970 150 42a | aie | 593 | 486 | 7e9 | 683_| 1012 | 905 160 306 [297 | 556 | 456 | 740 | 640 | 949 | 649 | 170 s7a_| 279 | 523 | 429 | 97 | 602 | a93 | 799 180 352 | 264 | 494 | 405 | 658 | seo | 843 | 754 190. 3a4_| 250 | 468 | 3e¢_| 623 | 39 | 709 | 715 ~__ 200 3i7_| 237 | 445 | 365 | 92 | S12 | 759 | 679 25 «|= ez | 211 | 305 | 324 | 526 | 455 | 675 | 604 250 254 | 190 | 356 | 292 | 47a | 410 | 607 | 543 275 zai | 173 | 323 | 265 | 431 | 372 | 552 | 494 300 2i1_| 168 | 297 | 243 | 395 | 341 | 506 | 453 325 195 | 146 | 274 | 225 | 364 | 315 | 467 | 418 350 181 | 136 | 254 | 208 | 338 | 293 | 434 | 368 375 163 | 127 | 237 | 195 | 316 | 273 [| 405 | 362 __ 400 159 | 119 | 222 | 182 | 206 | 256 | 379 | 339 [a5 149 112 | 209 | 172 | 279 | 241 | 367 | 320 450 | 1a1_| 105 [198 | 162 | 263 | 228 [a7 | 302 475 134 | 100 | 187 | 154 | 249 | 216 | 320 | 286 500 ye7_| 95 | 178 | 146 | 237 | 205 | 304 | 272 525 tar | 90 | 169 | 199 | 226 | 195 | 289 | 259 550 115 | 96 | 162 | 193 | 215 | 186 | 276 | 247 575 140 83, 155 | 127 | 206 | 178 | 264 | 256 600 106 79 148 | 122 197, 171 253 226 700 91 68 127 | 104 169. 146 247 194 800 73 so | i | ot | 148 | 128 | 190 | 170 a) 70 | 53 sot | 132 | 14 [169 | 151 1000 6 47 ao 73 | ne [02 | 52 [136 MULTIVACFilms Page 7 of 10 05 Films, web transport, removal of film trim; pack transport Reel diameter 500 (mm) ‘550 (mm) (600 (mm) 650 (mm) Core diameter! 3" | 6" r e x e Ed e Flim thickness in wm ‘Number of metres 50. s7e2_| 3462 [ 4606 |_4206 | 5509 | 5190 | 6491 | 6171 60 3151_| 2685 | 3899 | 9572 | 4501 | 4325 | 5403 | 5143, 70 701 | 2473 | 3290 | 3062 | 3935 | 9707 | 4636 | 4408 80 2364_| 2164 | 2879 | 2679 | 3443 | 3243 | 4057 | 9857 30 ator | 1923 | 2sse | 2381 | 3061 | 2883 | 3606 | 3428 100 __|-te91 | 1731 [2303 | 2143 | 2755 | 2505 3086 410 17i9_| 1574 | 2004 | 1948 | 2504 | 2359 | 29 2805 120 1576 | 1442 | i919 | 1786 | 2206 | 2162 | 2705 | 2571 130 1455 | 1331 | 172 | 1649 | 2119 | 1996 | 2497 | 2974 140 1351_| 1236 | 1645 | 1531 | 1968 | 1853 | 2918 | 2204 150 1261 | 1154 | 1535 | 1429 | 1836 [1730 | 2164 | 2057 160 1182 | 1082 | 4438 [1340 [1720 | 1622 | 2028 | i928 170 sit2_| 1018 | 1385 | 1261 [1620 | 1526 | 1903 | 1815 180 1050 | 962 | 1280 [1191 | 1530 | 1442 | 1803 [1714 490 995 | it | r2t2 [1128 | 1450 | 1366 | 1708 | 1624 200 ~ | 945] 805 [1152 | 1072 | 1377 _[vea7_[ 1623 | 1543 225) e4o_| 769 | 1024 | 953 | 1224 | 1153 | 1442 | 1371 250 | 756 | e92 | oor | e567 | 1102 | 1038 | 1298 | 1234 275 ess_| 629 | e38_| 779 | 1002 | ose | 1180 | 1122 300 630 | 577 | 768 | 714 | s18 | 865 | 1082 | 1029 325 582 oo | 659 | 43 | 798 | 999 | 949 350 540, esa_| e12_| 77 | 741 | 927 | 862 ‘375 504 ei4_| 572 | 735 | e92 | 865 | 823 400 473 s76_| 536 | 689 | 649 | 811 | 771 425 445 saz_| 504 | 648 | 611 | 76s | 726 450 __|_420 512 | 476 | 612 | 577 | 721 | 686 __4a75 398 a5 | 451 | 5e0 | 546 | 683 | 650 500 378 461 | 429 | 551 [sig | 649 | 617 525 360 asg_| 408 | 525 | aoa | 618 | S88 550) 344) aig {390 | 501 | 472 | 590_| 561 575 329) 4o1_{| 373 | 479 [451 | 564 | 537 600) 315) 3e4_ [357 | 459 [asa [sai [514 700 270 329 | 306 | 394 | 371 | 46a | 4at 800 236 zes_| 268 | 344 | 32a | 406 | 306 900 | 210 | 192 | 256] 238 | 306 | 288 | 361 | 349 1000 seo_| 173 [230 [214 [275 [259 | 325 | 309 "muLTIvAcFilms Pago 8 of 10 (05 Films, web transport, removal ol film trim; pack transport Reel diameter 700 (ram) 750 (mm) 800 (mm) 850 (mm) Gore diameter] 3" | 6” = 6 es] 6 z e Film thickness in yum Number of metres 50 7s51_| 7231 | 8690 | 8370 | 9907 | 9587 | 11203 | 10883 60 e2e3 | 6026 | 7242 | 6975 | 8256 | 7989 | 9336 | 9069 [ 70 | “5304 [5165 | 6207 | 5970 | 7076 | esse | g002 | 7774 80 a7sg_| 4520 | 5431 | 5231 | 6192 | 5992 | 7002 | 6802 90 ai95_| 4017 | 4828 | 4650 | 5504 | 5326 | 6224 | 6046 100 a77e_| sere | 4345 | 4105 | 4954 | 4794 | seo1 | 5441 110 3432 [3287 | 3950 | 9805 | 4503 | 495e | 5092 | 4947 4120 si46_| 3013 | 3621 | 3437 | 4128. | 3995 | 4668 | 4595 130 2004 | 27e1 | 3342 | az19 | 3810 | 3687 | 4309 | 4186 140 2697 | 2583 | 3104 | 2989 | 3538 | 3424 | 4001 | 3887 150 2517 | 2410 | 2897 | 2790 | 3302 | 3196 | 3734 | 3628 | 160 | 2360 | 2260 | 2716 | 2616 | 3096 3401 170 zear | 2127 | 2556 | 2462 | 2014 3201 [1480 ‘| 2008 [2009 | 2414 | 2325 | 2752 3023 190 1987_| 1903 | 2287 | 2203 | 2607 2864 | 200 1eee_| 1808 | 2172 | 2092 | 2477 2724 225, 1676_| 1607 | 1931 | 1860 | 2202 2418 250 1510 | 1446 [1798 [1674 | 1981 217 275 1373 | 1315 |_1580_| 1522 | 1801 1979 300 1253 | 1205 | 14ae [1395 | 1651 1814 325 sie2_[ 111g [1937 | 1288 [i524 | 1674 350 1079 | 1093 | 1241 | 1196 | 1415 1555 375 1007 | 964 | 1159 | 4116 | 1321 1451 400) 44 [904 [1086 | 1036 | 1238 1360 425 ses esi | 1022 | 965 | 1166 1280 450 39 | 803 | 966 | 930 | 1101 1209 475 795 | 761_| 915 | se | 1043 1146 500 755 | 723 | seo | 837 | 991 1088 __s2 [719 [a9 | ses | 797 | aa | 1036 ees | 657_| 790 ~_ 901 989 657 | 629 | 756 861 946 600 29 | 603_| 724 | 697 | e26 907 700 539 | 547 | 621 | 598. | 708 77 ‘800 a72_| 452 | 543 | 523 | 619 680 ‘900 420 | 402 | 483 | 465 | 550 605. 1000 37a [362 [434 [418 | 495 544 uation n 18.01.1985Films 05 Films, web transport, removal of film trim; pack transport Page 9 of 10 Reel diameter 200 (mom) 950 (mm) 1000 (mm) Core diameter] 3" [6 3 S x & Film thickness in pm ‘Number of metres 50 12577 | 12257 | 14030 [13710 | 15561 | 15241 60 [1041 | toa1a | t162 | 11425 | 12968 | 12701 7 8984 | 8755 | 10021 | 9793 | 11115 | 10887 | 80 7s61_| 7661 | 8769 | e569 | 9726 | 9526 90 | e987 _| e810 | 7794 | 7617 | 8645 | e467 100 zea | 6129 | 7015 | 6ass | 77e1 | 7621 110) s7i7_| 5571 _| 6377 | 6232 | 7073 | 6928 120 s240_| 5107 | 5846 | 5713 | 6484 | 6951 130 4837_| 4714 | 5396 | 5273 | 5985 | 5862 140 4492 | 4378 | soit | 4896 | 5558 | 5443 150 4192 | ~4086_|4677_|_4570_| 5187 | 5080 160 3930 | _3830_| 4384 170, 3699 | 3605 | 4126 160 3494 | 3405 | 3897 190 3310 | 3226 | 3692 200 3144 | 3064 | 2507 225) | 2795 [e724 | 3118 : 250 806 275 2551 ce 300) 2338 325 2188 Bee 350 2004 375 1871 400, 1754 425 1651 450 1559 475, 147 500 1403 525 1336 550 1275 575 1220 600 1169 700 1002 800 877 00 779 1000 701 MULTIVAE =ei eases Films 05 Films, web transport, ramoval of film trim; pack transport Checking the interval between register marks Before you use register-printed films, check whether the printing is within the tolerance limits specified by Muttivac (see the appended Muttivac standard “instructions for _register-printed packaging materials"). Film producers have this standard and it is also available from Multivac on request. Example Non-oriented PAPE film ‘Cut-off length 220 mm Note: Tighten the fm Choice: measurement over 6 repeat lengths Setting = (repeat length x 6) Reading (figure measured) Permissible total deviation AU = Sano >. Permissible total deviation AU = Reading - setting y 199 9 « Page 10 of 10 Mt there are deviations outside the specified tolerances, itis questionable whether the film can be used. In such cases please make immediate contact with the film supplier. 0,2 %bis - 0,7 % 1M. 6 Printed film = 220 mm x 6 = 1320 mm 1314 mm 1314 - 1320 TES ¥ 100% = - 0.45% = 0,45 % is therefore within the specified tolerance limitsWerknorm-Nr. MULTIVAC Instructions 87787 Wolfertschwenden for register-printed packaging materials 71.100.101 1 Application area ‘These instructions specify repeat length tolerance limits The packaging material supplier is responsible for {or the printing of packaging materals for automatic printing quailty. He allocates bis packaging material to Multivac thermoforming packaging machines. ‘one of the categories outined below wilh regard to its The applicable tolerance depends on the properties of Stetch properties. the packaging material and its processing on the automatic packaging machine. ‘These instructions apply to: © Upper and lower web © Automatic Multivac thermoforming packaging ‘machines (all models) = The packaging materials listed below can epresent the substrate web of a material ‘on the following conditions: combination that dotermines the stretch + Machine in proper operating condition Propeiea of ste comnenatcn- : i + In the case of multilayer combinations the Machine equipment, 29. tolerance of packaging materials with similar + suitable fim dischargor (unwind system, properties applies, See ee re tee ere + The film width tolerance can be found in the suitable advance drive Multvac company standard 71,100.40 + register mark control with fim brake = The maximum reel weight depends on the kind + Special equipment, 0.g. deflection shoulder, foil ren ane een eae ick change dovice (adhesive device) may re- Quire adjustment of pressure tolerances, |W anything is unclear, please consult Muitvac or the Muttvac agent. ‘sa Ung dt he rate Zs wee eis nach i u LE] 2 explanations of terms used i j Register printing Print moti that is repeated atthe same intervals Repeat length a Fequited distance between wo consecutive print motifs, see page 3 il. 1.4 ‘The repeat length ais the same as the cut-of length AZI in the printing specification’. Repeat length Relative total difference U and absolute individual ditterence 4 a tolerance Relative total Reading - Setting a difference Aus came 100% ‘The reading Is an average figure calculated as follows: measurement of 3 or more repeat lengths on the film, but over at least 1 meter. The figure moasured has to be divi ded by the number of repeats measured, Absolute individual difference aa Ae (mm) Ditference between two consecutive repeats in mm * The printing specification gives detailed instructions for the printing 37626 2608.1097 | 2/00e | Ersater _71.100:200 Datum | 06.02.1996 Ny 54253, ‘05.02.1906 | top __| Eretz cure: Gez___| Holzemiipp Index [ AnderungsNes | Daum | Name | Sprache: GB Gepr. BRO eNeS 8 Toe 97eta rsrage ach incre Zang wd eit ech ros sgangie grat nna Zumctarcange eps ‘creda nda ater is Pace vata BeEeeTeS 0 Tose” MULTIVAC Instructions wenn 87787 Wolfertschwenden | _ for register-printed packaging materials |_71-100.101 fait 2 von: 3 3 Tolerances with register mark control witha film brake (Packaging material is stretched in the machine) 3.1 Packaging materials that do not stretch Relative total cifference AU: Oto -0,15% such as paper, Tyek board) Absolute individual difference aa ‘max.1 mm Pvc aluminium strip eto. 3.2 Packaging materials that stretch a small Relative total ifferenco AU: 70,1% to -0,5% amount ‘such as collulose film Absolute individual ctference & a: max. 1,5 mm biaxially oriented polyester ‘multilayer aluminium combinations ‘monoaxially oriented polyamide biavially oriented polyamide bianally oriented poylpropylene etc. 3.3 Packaging materials that stretch a large Relative total difference AU: +02% to -0,7% amount ‘such as non-oriented PAPE te. ‘Absolute individual diference & a max. 2mm 3.4 Packaging materials that stretch an Thistle total atloranee 703% to -09% extremely large amount Seren eee Absolute individual difference A a mex. 2mm. 4 Tolerances with register mark control with advance correction (advance drive is controlled by register marks) © This kind of register mark control is only possible on machines with MC Drive and - to a limited extent « Mulldrive advance drive, © Only possible with packaging materials that do not stretch or oniy stretch a small amount @ Relative total cifference AU, t 0.1% } Absolute individual difference aa: max. 0,6 mm © Please note: Fluctuations of AU > 0,05 % make it necessary to carry out extensive adjustment work on the machine and ‘may under no circumstances occur within a reel tis essential that agreements reached with the user/Multivac about the kind of register mark control that should be used. ¢ 57626 26.08.1997 | as/g0e [reat _71.400200 Daum | 08.02.1998 we 253 05.02.1996 | opp | Ereeutauet: Ge Hoteenitipp Trex | Andorunge-Nr: | Datum | Name | Sprache: GB GoprMULTIVAC 87787 Woltertschwenden Instructions for register-printed packaging materials Werknorm-Nr. 71.100.101 fz A u iH eI i uf i | 5 Register mark 5.1 Contrast The colour of the register mark should contrast stiongly with its surroundings. 5.2 Location, size The register masks must be printed on both edges of the film. See illustrations 1... 4 or the printing specification for details about the location and size of the register mark. Scanning by a unit on the packaging machine: + Upper web: from the non-sealing side Lower wob: from the sealing side When opaque films are involved, the register marks ‘must be printed on the scanning side (l. 7). MWAEAZLS300 1row I. 2: AZL > 300 rye |=, 5.3 Distance between rows - Maximum distance between register marks 300 mm When cut-otf lengths > 300 mm: Print an additional mark (il. 2) Mutt-row dies: Distance between rows PM 22 100 mm: 1 row of register marks per row of packs (Il. 3) Distance between rows PM 2 < 100 mm: ‘row of register marks por rapeat length a ut-of length AZL (I. 4) 5.4 Register mark in the area of the print motif ‘The register mark must be preceded by an Unprinted area at least 60 mm long (ll. 6, note rave ray 9mm | | FaU= FEU + 1mm | FBU' is the width to be given to the film o manufacturer when ordering. nominal top web width .2 Tolerance for machines fitted with new" chain top wob wth with tolerance specifcation FBO isthe width to be gven to tho fim narceciner eae K1/2" (2.2) or K5V8" (2:9) Only to be used if the film is run exclusively on i machines fed with chain. u Semirigi im net] Flexible sims Semen =reu + 3m ui Fou=Feu +2 FaU'= FEU +3 mm iW 2. How to determine the type of chain Semi-tgid film PP ae |a machine by examining the rou =FBu $+ 3mm i grippers Ae a u Extended tolerances applicable only with th "new" chain K5/8" (2.3) for all types of film 3 i | — 4 Fou=Fau +4 mm 2. Yor 22 “new! 23°nen" ripper f vipper eee Rie Re If high transversal tension is expected: Distinguishing features of ew" chain: = Height of gripper a 2 Clip guide (A) This tolerance gives an extra satety edge against 1 Enlongated hole in clip (B) the film being pulled out of the grippers, ‘Access to chain: either af the bottom web infeed or, after removal of the tray, in the loading area, In case of doubt, please contact Multivac or their Top web width tolerances agents, 159508 18.11.1007, Ereate fr 08.09.1987 sae 21.09.1987 Ersett duh: Schulz/gop Tnderangs-nr | _ Datum Sprache: GBUnwind system - upper web F12 Page 1 of 3 05 Films, wab transport, omoval of film trim; pack transport M 860 E, F Contents © Application O Parts (O Method of operation ~ © Sotting the actuating cam on the switch Fee roller valve ations O Maintenance: © Trouble-shooting Application ‘The purpose of the unwind system is to unwind the upper web in cases where a small amount of web tension will not cause problems. {tis mainly suitable for: = Films with random printing Unprinted and register-printed films that only stretch minimally + Films with sealing that is not sensitive Parts Mandre! Brake segment Guide tame Guide disco ‘Swing arm Star knob t0 correct fim alignment Locking scrow ‘Spring for swing arm Switch toler vaive eevanaene TS teoroeUnwind system - upper web F12 05 Films, wob transport, removal offi pack transport Method of operation The mandrel (1) is in a fixed position. The reel of film rolls on the mandrel and is braked inside the reel core by the pneumatically actuated brake segment (2). ‘The lateral position of the film reel is determined by the guide frame (3) and the guide discs (4). When the advance is actuated, the film that is required is pulled off the loop of film. Threading the upper web M. 3Tbreading the upper web Conditions that have to be tulle: ‘Main switch has been turned on ~ The swing arm (5) is in its lower position and the brake segment (2) has been released - Determine which side of the film is the sealable side. This side has to face downwards In the sealing die ~ Push the reel of film onto the mandrel (1) + Fitthe guide trame (3) ~ Set the guide discs {4) to the appropriate web width Page 2 of 3 ‘At the same time, a switch roller valve (9) is actuated, which releases the brake segment. Under the infivence of iis own weight the swing arm moves ‘back into its original position and the brake is, actuated. This has the effect of pulling a loop of film off the reel; depending on the setting of the actuating cam, tension is applied to the web. Danger of amputation! Do not reach Into the die + Thread the film in accordance with the web feeding diagram (11) and stick it to the lower wed with strips of adhesive tape. if the upper web is register-printed, make sure that the print motif is positioned correctly on the pocket (see “Register mark controf} - “Press the ADVANCE pushbutton. The upper web moves into the sealing station, where it is sealed to the lower web. - Check whether the web is entering the sealing die symmetrically. If this is not the case, adjust the guide trame (3) accordingly by turing the star knob (6) + Tighten the locking screw (7) (MULTIVAC *Unwind system - upper web F412 05 Films, web transport, removal of film trim; pack transport Setting the actuating cam on the ‘switch roller valve ‘The actuating cam has been set at the factory and does not normally need to be adjusted. However, if wrinkles start to form, set the tension of the web by adjusting the actuating cam. Conditions that have to be fullilled + Main switch has been turned OFF + The swing arm (6) isin ts home position No reel of film has been loaded Undo the hexagonal socket-head screw (13) = Adjust the actuating cam clockwise only in the area of position 8 The tension of the web will be reduced + Adjust the actuating cam counter-ctockwise ‘only in the area of position B ‘The tension of.the web will be Increased ‘When the unwinding system is in operation, the ‘actuating cam moves between the braked position (8) and the unbraked position (A). Maintenance Atter 8 operating hours = Remove any contamination from the infeed roller - Check the alignment of the web while the unwinding system is in operation Page 3 of 3 IIL Switch roller valve / upper wob A Unbraked position B Braked position © Home position Trouble-shooting Web too loose or too tight ~ Sel the actuating cam on the switch roller valve Web Is not entering the gripper chains symmetrically + The mandrel is no tonger parallel + The film is wound poorly on the reel or the reel Is not the correct shapeUnwind system - lower web : F12 Page 1 of 3 05 Fiims, wab transport, removal of film tim; pack Wanspot M860 E, F Contents © Application O Parts =n O Method of operation f fae O Threading the upper web O Setting the actuating cam on the switch roller valve O Maintenance M. 4 Location O Trouble-shooting Application The purpose of the unwind system is to unwind the lower web in cases where a small amount of web tension will not cause problems. Parts Mandrat Brake segment Guide trame Guide disc ‘Swing arm ‘Star knob to correct tim alignment Locking screw ‘Spring for swing am Switch roller valve waVannen~ POR eigenUnwind system - lower web F12 05 Films, web transport, removal of flm trim; pack transport Method of operation The mandtel (1) is in a fixed position. The reel of filen rolls on the mandrel! and is braked inside the reel core by the pneumatically actuated brake segment (2) The lateral position of the film ree! is determined by the guide frame (3) and the guide discs (4). When the advance is actuated, the film that is required is pulled off the loop of film. Page 2 of 3 ‘At the same time, a switch roller valve (9) is actuated, which releases the brake segment. Under the infivence of its own weight the swing arm moves back into its original position and the brake is actuated. This has the effect of pulling a loop of film off the «eel; depending on the setting of the actuating cam, tension is applied to the web. Threading the lower web (utyecaisce Do not feed the lower web into the hot sealing die without the upper web. It you do, the lower web will stick to the sealing plate. M3 Threading the tower web Conditions that have to be fulfilled: - Main switch has been tuned on ~The swing arm (5) is in its lower position and the brake segment (2) has been released + Determine which side of the film is the sealable. side. This side has to face upwards in the die - Push the reel of film onto the mandrel (1) + Fit the quide trame (3) ~ Set the guide discs (4) to the appropriate web width Danger of amputation! Do not reach Into the die une - Thvead the film in accordance with the web feeding diagram (11) and insert it in the open ripper chains on the infaed roller (10) ~ Press the ADVANCE pushbutton a number of limes. Check whether the web is taken hold of symmetrically by the gripper chains. I this is not the case, adjust the guide frame (3) accordingly by turning the star knob (6) Tighten the focking screw (7)Unwind system - lower web F12 Page 3 of 3 05 Films, web transport, removal of film trim; pack transport, Setting the actuating cam on the switch roller valve The actuating cam has been set at the factory and does not normally need to be adjusted. However, if wrinkles stan to form, set the tension of the web by adjusting the actuating cam. Conditions that have to be fulfilled ~ Main switch has been tumed OFF ~The swing arm (5) isin ts home position ~ No reelof film has been loaded Undo the hexagonal socket-head screw (13) ~ Adjust the actuating cam clockwise only in the area of position B The tension of the web will be increased ~ Adjust the actuating cam counter.clockwlse only in the area of position B ‘The tension of the web will be reduced ‘When the unwinding system is in operation, the ‘actuating cam moves between the braked position (@) and the unbraked position (A) Maintenance After 8 operating hours Remove any contamination trom the infeed roller ~ Check the alignment of the web while the unwinding system is in operation 13 | 5 M4 Switch roller valve / upper wob A Unbraked position 8 Braked position © Home position Trouble-shooting Web too loose or too tight + Set the actuating cam on the switch roller valve Web is not entering the gripper chains symmetrically ‘The mandrel is no longer parallet The film is wound poorly on the reel or the reel is not the correct shapeAdvance Controi The advance control is installed in the control panel of the machine. It has the following operating controls: (1) Advance setting button s (2) Braking path setting button Vv (3) Digital display (4) Setting dials General The advance length can be set with an accuracy of 1/10 mm, To make it mechanically possible to achieve this high accuracy, the speed of the advance is automatically reduced to the lower speed set. Two figures therefore have to be set so that the packaging operation can be carried out: - Advance length (pack length) ~ The point for switching from fast to slow advance. Setting the Advance Here we will use an example to illustrate how to set the advance: - Advance length (pack length): 150 mm - The machine has been turned on and is ready for operation. 1. Set the setting dials (4) to 1500 The additional fourth digit is the setting for 1/10 mm, i.e, the number after the decimal point. 2. Press the advance setting button (1) briefly with a thin object (pencil). The advance length is now stored. The machine will not function properly if the advance setting button is pressed too long! Important note:Starting the machine - First cycle The counter (digital display 3) will start to count down from 1500, 4.@., 1499...1498...1497.-... 2.0.20... 02+++- +0000. The counter does not stop at 0000, but rather it counts down the advance actually Carried out. So it continues to count down: 1499, 1498 and stops at, for example, 1472. This counter overrun is caused by the mechanical braking path of the drive. In this example, the advance path is 2.8 mm (1500 -1472 = 2.8 mm) too long. - Second cycle To compensate for the deviation (2.8mm), in the first cycle, the counter does not return to 1500 for the second cycle, but rather it starts with 1472. This process is repeated with each of the following cycles so that the advance path required is almost exactly right as of the second cycle. Example: Cut-off length = 150 mm 1 sa 606 we |Please observe the following point: - Every time the counter counts down past zero - when the machine is being run manually or is running automatically - the number displayed on the setting dials will be stored again and then determines the length of the following advance. - If the cut-off length needs to be changed, set the new cut-off length on the setting dials (4) and press the advance button (1) briefly. Tha new number will appear on the digital display, and the new cut-off length will be carried out with the next advance movement. Important note: New settings should only be made when the machine is idling. ~ It is possible that the transport chain may stretch when the machine has been running for a lengthy period of time. This has the effect of increasing the advance as well. You can determine the actual advance by marking the transport chain and the side of the machine. The difference between the actual and theoretical advance then has to be deducted from the figure set on the setting diais (4). In the case of our example, the situation would be follows: Theoretical advance: 150 mm Actual advance : 155 mm Stretching of the transport chain: about 3% This would mean that the setting of the setting dials (4) now ought to be 1450. ~ The advance setting is stored.in the counter. The counter has an integrated battery to make sure that this setting is not deleted when the machine is switched off. This battery provides the electronics power supply for up to 2 weeks after the machine has stopped running. If the energy capacity has been used up for any reason, the battery has to be re-charged for at least 16 hours. Charging is carried out whenever the machine is turned on (main switch) and the "control" pushbutton is pressed. Storage of the advance setting can only be guaranteed again after this recharging operation has been completed.Setting the Point for Switching to the reduced Advance Speed At the factory this switching point is set 65 mm before the end of an advance movement and usually does not need to be increased (see Diagram 1). If, however, you discover that the seal is not properly aligned with the package, i.e., the package is off- center toward the discharge end of the machine, the distance between the switching point and the end of the advance movement (S1-S2) will need to be lengthened. The reason for this is that the mechanical braking path X gets longer, the greater the switching speed v is. The braking path should in general be 2 - 3 mm. If the braking path is longer than 3 mm, the distance between the switching point and the end of the advance movement will need to be lengthened. The following three diagrams illustrate this clearly: Diagram 1: : ie Switching point Sis located v 65 mm before switthing point 8). The speed V, is reduced to V. Ff 2 at s.. Diagram 2 If, for some reason, for example, due to heavy product, the reduced speed V, is not reached within the 765 mn, y Vj > V, and, therefore, the brakifg path X, will be longer : than x, . i ' Therefore increase the distance 8-8): - Set the number 0750 on the setting dials - Press the pushbutton V (2) briefly.Diagram 3: After the distance between and § has been lengthened, the m&chine will again achieve the reduced advance speed V, before the end of advance; braking path X, will be achieved again. V, = High speed of advance V, = Reduced speed of advance 8, = Switching point S, = Theoretical zero/counter = 0000 X, = Mechanical braking path/counter display X, = Lengthened mechanical braking path/counter displaySetting the cut-off length on the advance control The advance control (see illustration below) is used for setting the length of the advance (cut-off Length). Because precise switching is ‘required, the advance speed has to be reduced before the machine brakes. This point is also set on the advance control. The control has the following functions: (1) Advance setting button in control box (2) Band pushbutton ve —— length of the reduced advance speed (3) Digital display (4) setting for cut-off and re-. duced advance speed Function of the Advance Setting Button (1) This pushbutton always has to be pressed when... a) the machine has:been turned on again. The cut-off length (advance) shown on the setting dial (4) is automatically stored when the machine is ‘turned on, and it determines the next advance. b) the cut-off length-(advance) has -been reset of the setting dial (4). ‘The new setting is then stored i and determines the.next advance. The advance pushbutton (1) does not have to be pressed when... i a) the advance is activated manually ( €4 pushbutton). Each time the €3 pushbutton is pressed, the counter automatically aSsumes the number set on the setting dial (4). b) the machine is running on "automatic". The counter automatically assumes the number set on the setting dial (4) each time it has count downto 0000. c) the advance is controlled by a register mark and photoelectric scanning head when a printed top web is being run. The counter automatically assumes the number set on the setting dial (4) each time the advance startsSetting the cut-off length The cut-off length can be set with an accuracy of 1/10 mm. . Example: . The cut-off is 332.0 mm. The setting on (4) would therefore be 3220. The last digit is the number after the comma! “Phe"Gut-ofF"length is stored by pressing the adva setting puabbutton (1). The advance starts: _——~ The counter begins to count down from 332.0: 331.9, 331.8, 331.7 down to 0000, The countdown can be fol- lowed on the display (3). ce! When the counter reaches 0, it is automatically reset on its reference number (for example, 3320) and starts its countdown again: 3320... 3319... 3318 and so on until the advance stops (gor example, at 3284). The difference between this last number and the 3320 will be automatically corrected with the next cycle’s advance. i‘ Example: Cut-off: 332 Bisplay 3320 The counter counts from 3320, 3319 to 0000 and then again from 3320, 3319 to 3284. The difference: 3320 - 3284 = 3.6 mm too much advance: Example: Cut-off length: 3320 Counter display ' pw 6000 as Advance “a Advance Counter display 3 Advance2, Setting the point for switching to the reduced advance speed At the factory the switching point is set for 55. mm before the "end of advance” and usually does not need to be changed (see Diagram 1). If you shoilld find that the advance is visibly longer than the pre-set value, e.g. the reduced advance speed when checking the welding seam, is too short (see Diagram 2). You can increase the above-mentioned length by: - setting 65 mm, i.e., 0650, on (4) and then = pressing the range button V (2). This stores the new switching point, that is, with the next cycle, the drive motor will switch to the slower speed 65 mm before the “end of advance” (see Diagram 3). vi V1 = High advance speed V2 = Reduced advance speed S1 = Switching point S2 = Theoretical O-point/counter 0000 X1 = Mechanical braking path _X2 = Extended mechanical braking pathIf you are running a printed upper web, the selector switch being in position €2 (look at the switchbox of the machine) the register mark will control the turn-off of the machine. This, however, would only then be safeguarded if the printed Jength of the register mark < the advance pre-set on the machine advance contro} unit. Now as the printed length cannot be changed, the value to be preset on the advance control unit should be chosen slightly bigger to safeguard the desired turn-off by means of the selenium cell: After the end of the advance, the counter displays the difference between the effected advance length and the counter setting e.g. counter setting 3350 actual advance length 332,4 after the advance, counter displays 2,6. During the following "die opening” signal, the counter is re-set, i.e. it returns to ready position (3350). a L Eye spot distance- z.@, cNomirial size “@ “ye spi Z 232 - Lane Counter display [3359 690 [?ff26 320 Advance as aie rr CAUTION: If you should change over to running without printed upper web, be sure to readjust the exact cut-off length on the advance control unit! .Poy 6 4 2.4 Setting the Cut-off Length’ on the Advance Control wo different functions are set on the advance control: - the cut-off length (advance) - the length of the advance's braking path. Operating Control (1) Advance setting button s* (2) Braking path setting button v¥ (3) Digital display (4) Setting dials 2.4.1 General The cut-off length can be set with an accuracy of 1/10 mm. To make it mechanically possible to achieve this high accuracy, the speed of the advance is auto- matically reduced to the lower speed set at the end of the advance movement. The braking path is set at the factory to correspond to the speed switching point and generally does not need to be changed. If, for some reason, it does need to be reset, please refer to the instructions in Section 2.4.3. 2.4.2 Setting the Cut-off Length Here we will use an example to illustrate the function and operation of the advance control: - cut-off length: 200 mm; - the machine has been turned on and is ready for operation; [~ ‘2 First an optional value has been set on the setting dials (4) 4 Setting the cut-off length on the setting dials (4) of the advance control unit: 2000. The last digit is the number after the decimal point (1/10 mm). Attention: For technical control reasons sétting 0600, \ must _never be selected. fe Press the advance setting button (1) only for “a *moment: 1 Cut-Gf length is now stored. ‘The number 2000 will now appear on the digital display (3). sec® Starting the Machine - First Cycle The counter (digital display (3)) will start to count down from 2000, i.e., 1999, 1998,.1997 down to 0000. The counter does not stop at 0000, but rather it counts down the advance actually carried out. So it continues to count down: 1999, 1998 and stops at, for example, 1972. This counter overrun is caused by the mechanical braking path of the drive. In this example, the advance path is 2.8 mm (2000 ~ 1972 = 2.8) too long. - Second Cycle To compensate for the deviation (2.8),in the first cycle, “the counter does not return to 2000 for the second cycle, but rather it starts with 1972. This process is repeated with each of the fol- lowing cycles so that the advance path required is almost exactly right as of the second cycle. Example Cut-off Length = 200 mm Counter display * 3000 ooo 1972 Advance i | * 5 Counter display 2. Advance Counter display 3 Advance | 51 = Speed reversal S2 = Theoretical zero. creat fee-2Please observe the following points Every time the counter counts down past zero - when the machine is being run manually or is running automatically - the number displayed on the setting dials will be stored again and thus determines the length of the following advance. If the cut-off length needs to be changed, set the new cut-off length on the setting dials (4) and press the advance button (1) for a moment. The new number will appear on the digital display, and the new cut-off length will be carried out with the next advance movement. :s/te-% is off-center toward the discharge end of the ma~ Setting the Point for Switching to the Reduced Advance speed At the factory ‘this switching point is set on 55 mm before the end of an advance movement and usually does not need to be increased (see Diagram). If, however, you discover that the seal is not properly aligned with the package, i.e., the package chine, the distance between ‘the switching point and the end of the advance movement (S;~ Sz) will need to be lengthened.. © The reason for this is that the mechanical braking path X gets longer, the greater the switch- ing speed Va is. The following three diagrams illustrate this clearly: Diagram Switchiag point S; is located . 55 mmbefore switching point S2. The speed V, is reduced to V, at S,. Diagram 2 If, for some reason, for example, due to heavy product, the reduced speed V, is not reached within the iM 55 mm, V,> V, and, therefore, the braking path X, will be longer than ‘Therefor Le Speed BE cad oF cdvanes Vy © Speed of advance Wy = Reduced speed af advance Increase the distance S, - S 5 + suteehing pote T Set the number 0650 on the set- 1% ~ Tworetical sero/couter 0000 K; © Mechanical Braking path ting dials: X, * Langthesed nechanieat braking path = Press the pushbutton v (2). 7 etna weet , ‘ 3 Diagram 3 After the distance between S, and S$, has been lengthened, the ma- chine will again achieve the re- 7 duced advance speed V, before the Heat end of advance; braking path X, will be achieved again.Vacuum trim removal unit (05 Flims, web transport, removal of film tim; pack transpon .. Contents O Pans O Contiguration / application © Method of operation © Notes O Switching the unit on O Maintenance Parts Base section with fan Container with fiter insert Hoses for the suction removal of odgo strip Suction removal of middle strip with perspex pipe (Cap for covering additional connection openings ax ene Vacuum trim removal unit - shown hore with 4 perspex pipe - for the suction removal of ‘edge and middie strip Pago 1 of 2 All machines Configuration / application Vacuum trim removal unit with an unperforated filter insert, suitable for the suction removal of edge strip ~ Strip width with rigid fim (about 600) = max. 11 mm + Strip width with flexible film = max. 20 mm. = Wider strips and thicker films can only be processed with an edge trim cutter Vacuum trim removal unit with a completely perforated filter insert, suitable for the suction removal of edge and middle strip as well as + Punch film waste (film punch, thumb hole punch) = In connection with a granulator, to remove the small pleces of tim Note: The vacuum trim removal unit is not suitable for the suction removal of trim in latice form, Vacuum trim removal unit with vaperforated fiter inser me EE M3 Vacuum trim removal unit with perforated filer insertVacuum trim removal unit 05 Films, web transport, removal of film trim; pack transport Method of operation ‘The film trim is sucked into the container (2) by the fan (1). Take the fiter insert out to remove the film trim, Option: level control facility ‘A fault message appears on the display when the container is full. The machine stops a specific time ater this, Page 2 of 2 Notes: - = Please make sure that the film waste Is disposed of properly, so that environmental impact is minimised. = Put a cap (5) on all the connections of the vacuum trim removal unit that are not being used. If this is not done, the vacuum trim removal Unit cannot be operated. = Do not stretch of kink the suction hoses ~ Avoid long suction hoses. Switching the unit on MC control The vacuum trim removal unit switches on automatically when the START, AUTOMATIC, ADVANCE pushbutton is pressed (see the chapter entitled “Switching on / off”). if the machine has been switched on but is not in production, the vacuum trim removal unit switches off automatically after about 2 minutes. PC control Vacuum trim, removal unit ON > Vacuum trim removal unit OFF are M4 Iluminated pushbutions for the vacuum trim removal unit PC control Maintenance + Empty the container for the film waste in good time. {f the container is too full, the suction capacity is reduced and fauits occur + Make regular checks to see if the suction hoses are connected properly or are damaged instiaon ganas | 08.09.1994. .-"! -pifpeaigop MULTIVAC ‘GB -trimmatisauger 4Discharge plate Geaea ERs seo ey | : { The machine may only be 1 + operated with a discharge y ! plate. Danger of injury! ZA 1 Star knob screws 2 Hexagon socket head cap screws 3 Discharge plate 4 Bolts Turn the MAIN SWITCH TO 0 before carrying out any work on the discharge plate. Setting the height of the discharge piate The height at which the discharge plate is set is determined by the depth of the pack ~ Remove the tunnel guara* ~ Undo the star knob screws (1) Important note: The discharge plate (3) may slip downwards! - Move the discharge plate (3) until the required position has been reached. ~ Tighten the star knob screws (1) gently - Undo the hexagon socket head cap screw of the bolt (4) on both sides* - Set the incline of the discharge plate by moving the bolts (4) - Tighten the hexagon socket head cap screw of the bolt (4) on both sides - Tighten the star knob screws (1) securely ~ Attach the tunnel guard again* SMELT 1205 389): e/pee/oon, siDischarge plate Changing the discharge plate When the number of tracks is changed, e.g. by changing the inserts in the die, the discharge plate also has to be changed. - Remove the tunnel guard* - Unscrew the upper star knob screws (1) completely Important note: The discharge plate (3) may slip downwards! = Undo the lower star knob screws (1) - Unscrew the hexagon socket head cap screws (2) with a key until the discharge plate (3) can be removed upwards. - Insert a new discharge plate (3) - Tighten the hexagon socket head cap screws securely on both sides with a key - Set the height as outlined above * Depends on the model $oL08:8 89. caver LU LTIMAG: HE ee tre: Beats<< mucrivac Chapter 06Dear customer, this chapter is reserved for optional equipment that is not (yet) installed on your machine (at present) MULTIVAG ‘Sepp Haggenmaller KG ‘Technical Documentation Department D-87787 Woltertschwenden Tel. (083 34) 601-0 Fax (0 83 34) 6 01 - 1.95 ‘GB_Hinweiskundo:<< mucrivac Chapter 07Section 24 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.3.4 2.3.2 Set of Dies Dies Change of dies What you need to know Forming die Sealing die Support and safety guards Setting the distance between dies and the die stroke Setting the distance between dies Setting the die stroke Film unwind system Longitudinal cutting Cross cuttingDies . With few exceptions, a forwing die and a sealing die are required for producing packages (please refer also to Section 1.1.1). The two dies together with their package-specific accessory parts, such as the infeed tray, support tray, etc., combine to forma "die format set." Each die consists of a die top and a die bottom. The die top is stationary*, mounted on the frame of the machine, while the die bottom is moved up and down by the die lifting systen, The following is a short explanation of the different types of dies and their special features. It is quite possible that we will discuss dies which are not used on your machine or which you have a special model of and is slightly different. For settings of the dies, please refer to Section 1.5. Forming dies In the forming die the package pocket is formed in the lower web. Usually a combination of compressed air, vacuum and a plug are used to form the film, The forming process is divided into two parts, @ith the exception of aluminum film forming): first the film is heated up and then it is actually formed. Forming dies can be equipped with changeable forming inserts ahd’ plugs or with one. permanent. shape. * Please refer bere to Section 2.3.2.1.1.1 Forming die Die top Die bottom Heating plate Limiting plate Spacer platés Gasket (FEZ ISSONSA) aus After the die closes, compressed air presses and/or vacuum pulls the film onto the heating plate (3); the film heats up. When this operation has finished, the forming process starts: Compressed air presses and/or vaguum pulls the heated film into the die mold. The film goes hard when it touches the cooled mold and retains its shape. : 2.1.1.2 Forming die with pre-heating 1 Die top 2 Die botton 3 Heating plate 4 Limiting plate 5 Spacer plates 6 Gasket The lower-web is heated-up and formed in two séparate operations on the machine. First oom pressed air presses the lower web onto the heating plate (3) which beats up the film. Now the die opens and an advance transports the heated piece of film forward one cycle. Then it is pressed by compressed air and/or pulled by vacuum info: the mold. ‘The film goes hard when it touches the cooled mold and retains its shape.2.1.1.3 Plug-assist forming die for rigid film Die top Die bottom Heating plate Limiting plate Spacer plates Gasket Plug Youruns Pirst the lower web is pressed against the heat- ing plate (3) by compressed air; the film is heat- ed up. Not until the next operation on the machine is the film formed by compressed air and the plug. Depending upon how the selector switch is set (Section 1.5.1.4), the film will be "pre-formea" by compressed air and thon, after a short delay, formed into it final shape by the plug - or vice versa. When the film touches the cooled mold of the die, it goes hard and retains its shape. 22: with ad@itional diaphraga 8 Diaphragm 9 Base plate For various reasons, it ia sometimes necessary to in- crease the closing force of the dies. In such a case, an additional diaphragm is fitted in the dio bottom. When the die has closed, compressed air is pumped into the diaphragm (or several diaphragms) and thus the closing force of the die bottom is increased. With type of die, the die gasket is usually omitted because the film acts es a seal.2.46164 2.1.1.5 Plug-assiet forming die for flexible film Die top Die bottom Heating plate Limiting plates Spacer plates Gasket Plug Handles for removing plugs Pneumatic cylinder for plug stroke 41 Plug lifting mechanism Soraueuns Pirst the film is pulled onto the heating plate (3) by vacuum; it is heated up. With the next cycle, the plug (7) - or several plugs - and simultaneous vacuum form the film. Plug-assistdies have a very low design. ‘The plugs can be easily removed by their handles (8). Plug-assist forming die with Acou-forming 1 Die top 2 Die bottom 3 Heating plate 7 Plug 8 Diaphragm 9 Base plate 2 Lifting mechanism The film is simultaneously palled by vacuum and pressed by compressed air onto the - heating plate (3) and heated up. The plug (7) has the same shape as the package. As the ‘plug atarts to move down, the film is stretched slightly by the vacuum. Then compressed air presses tho film andthe: vscuum pulls the film onto the. plug until it reaches its lowest position. The diaphragms (8) increase the closing force. In general the film between the die bottom and top in this case also acts as a gasket seal.2.1.2 Sealing dies In the sealing die, the package is evacuated* and then the lower and upper webs of film (coated paper and paperboard as well) are sealed together. 2.1.2.1 Sealing die 1 Die top 2 Die bottom 3 Sealing plate 5 Spacer plates 6 Gasket 8 Diaphragn After the die bas closed, evacuation begins. The air is pulled out of the package through connections in the die. If the machine is equipped for it, the package is then gas flushed. Gas flows into the package through separate connections in the die or through gas flushing jets. Now compressed air passes into the diaphragm (4) and presses the warm sealing plate onto the webs of film. They are sealed together and the die opens. o+_with additional heating The die bottom also bas a heating aystem which heats up the package pockets. The sealing plate is-flat and does not have any ridges; the spacer plates are wade of aluminum. 2 Heated die bottom 3 Plat sealing plate 4 Limiting plate *only on machines with evacuation system2.2 2.2.1 2.2.2 Changing dies What you need to know Before you take off the dies, actuate the drain valve. Press the pushbutton until com- pressed air flows out of the water drain. MAIN SWITCH OFF, Whenever you work on the machine, do not leave any ob- jects on the control box or near the dies. Vibrations of the machine during operation could cause them to fall into the dies and cause costly damage. Forming die Remove the support trays and alternately unscrew the screws on the die. Carefully remove the die top. Be careful not to damage the plug-in connector or get any water on it. Remove the compressed air hose line on the die bottom. Take the quick disconnects off the water connections. Take out the die bottom. Before you put the die away, check what kind of condition the silicone gasket and heating plate are in. Change the thermoforming depth in the new die by putting in aluminium spacer plates as well as thermoforming limiting plates or special inserts, as the case may be. Push the die bottom true-to-side onto the die rails until the locating pins fit into the correct boreholes. Connect up the cooling water lines. Connect up the com- pressed air line as shown below. Please be sure that the o-ring on the stationary body of the comprossed air connection is there and not damaged. To facilitate removal of the thermoforming limiting plates, use the suction cups included in the tool box. Connect the hose line (1) on the forming die bottom to the compressed air connection (2) ~ film heating. The compressed air for "film heating” passes through a duct from the body of the machine into the form- ing die top. Connect the water connections (3). After you have checked and are sure that all the o-rings are not damaged in any way, carefully put on the forming die top. Screw in the fastening screws alternately, but do not tighten them up yet because the distance between the dies must still be adjusted as explained further on.2.2.3 Sealing die Follow the instructions for the forming die corre- spondingly for the sealing die. Use the filler plates supplied. Be sure that the teflon coating on the seal- ing plate is clean and not damaged. Also check whether pieces of polyethylene have collected behind tue seal- ing plate, impairing its mobility. Never scrape the sealing plate with sharp-edged utensils. Check the silicone gasket on the sealing die bottom, too. Dies for skin packages (total surface sealed) Gaution: The die bottom is heated up to teuperatures of 80°C or more. Be sure to wear asbestos gloves when handling it. Do not use plastic filler plates in the skin sealing die bottom. nd do not forget to connect the elec— trical plug-in connector. It is approximately half- way between the forming and sealing dies. 2.2.4 Support trays and safety guards Put in the support trays and support rails and put on the safety guards. 2.2.5 Adjusting the discharge conveyor belt * Adjust the height of the discharge conveyor belt (1) to match the height of the product, using the hand- wheel (2), The clamping lever (3) should be tight. Check to make sure that the conveyor belt has been pulled all the way out in the direction shown by the arrow and that its hori- zontal position is correct. 2.3 Setting the distance between dies The distance between the dies must always be a multiple of the length of the pack- age. Only then will the package pockets be centered correct- ly in the sealing dis. * The discharge conveyor belt is a special accessory.2.3 2.3.1 Setting the distance between dies and the die stroke Setting the distance between dies ‘the distance between dies is always | | an integral multiple of the cut- || off length. Please make. sure when placing the forming die that the ‘locating mark on the die top aligns with the mark on the machine. frame. Then the die- distance will be correct. Additional dies which are supplied after the machine usually do not have a locating mark. If you use a die from another machine of the same model but with a dif- ferent length, you may not be able to use the locating uark on that die as your reference point. In such cases, we recommend making your own mark by mounting the dies and positioning them at the correct distance* from each other, Example: Cut-off length: 195 um, average distance between dies**: 1,400 mm. In this case, 7 whole cut-off lengths fit between the two dies. The correct distance between dies is therefore 7 x 195 um = 1,365 mu. Now loosen the screw locks. Set the correct distance between dies* by moving the forming die. Tighten up the screw locks. Make the locating mark on the form- ing die top at the point where the contact pin (mag- netic switch) lines up with the die top. Caution! Be sure to turn the main switch to 0 before loosening the screw locks on the die !ji gouiiye yorudeth ota yt writ _3e EOrb gyoutud vumecuth vet qo! oyovie of neti goood vonotard odT Bio-swo out go olgtviua Loxpotal as painzot oft tavom voy sed. .ddjael uxom gatiesol ont todd oxua od ,0i0 odd dtiu omgile qed sib ont ao ditengjam) miy tostaoo edt Yo sfbbia ao ,omoxt eutdoau oft ao (dotivo odt ao notversaulit odt ot qwode goovvus odf doa oved won [liv vol .tdgiz Bo. +20fb goyuted eoastath sooz109 eibpaticul Se modst etinor: oft vei dotiqqua ors dotdy aed fonoietban eth s cee woy I .iuem yaiveoos 9 oved tom ob yiicl “Lib 5 tis dud Lobo vaun ond Yo ontsoeu todtons dort piitaool odd onu of olde of don yen voy duukT~2 Too vee ceib edd 32 od eysulc nce aoib ot Yo avgbo oi tom wool worse oonedarb odd yataocem sok adsiog vorvroter os buas <0 biuow Intog oomorokos tossed A .eorb sesuded Iragivid odt to opbs Sros-stef odd ,oousvent vdt to doxiooq edt to wyhe dsci-siel vt of yottwaoos Orb gaiticot utd gordion ,énuodd ,f60i sauq uit 0% yd Burimcovob ot "avth mevwted eomegald cyesove" ody #* vo on OS€f eswEGe:: goo Fi .ooidect oft to mtadh os a0ib moovtod byron oometarh odd at tI .m @VOS ond to ofLbaia edt ai bovetmes ei oth gaiunod ont crofu sbovo od seo tf coidu aidtiu roto hoodt te qatewd os! a 2 uo, via od setdy adie Q(t wkce gi eS. 0 geivour) eifmg Gi fotantas oF 20 avty uted Te o7 vif ude guciuen. of vatuooloretevoo sLanet! ont beudedtos ror of $i ommul wusbute saidtunag cforms £0 us) oth vif wuld vondoe ut vaitniogte ou. sie “dy 23<< mucrivac Chapter 08Loading rules (08 Product infeed Pago 1 of 2 When the pack pocket has left the forming die, the product is filed. This can be done manually or automatically. : The following rules should be followed when carrying out loading operations: Product must not project out of the pack pocket ‘A product that projects above the film web may damage the sealing die and the cutting units. Not like this... & w bbut like this ! Adapt the size of the pocket of vacuum packs to the product being packaged Not tke this ... ww ww but like this ! All machines without a moving sealing die top Load products with sharp edges In the pack pocket in an appropriate way Load products with sharp edges ir the pack pocket ‘80 that the sharp edges either point at each other or ‘est against the film where the walls are stronger, Not like this ..: but like this 1 Adapt the shape of the pocket of vacuum packs to the product being packaged Not like this ... but like this ! ke: Loading rules .08 Product infeed Page 2 of 2 Keep the sealing area clean If product or liquids get in the sealing area this has an adverse effect on the shelf life of the product Particular care has to be taken with: = starchy and fibrous products, e.g. potatoes ~ films with a narrow temperature range, e.. polypropylene (PP) and multilayer alurinium- based materials Not like this ... but like this’! tes ty Hot, watery products ‘ It is not possible to reach any vacuum level you want with hot, watery products, see the -steam graph. Let products coo! off first. Where this is not possible, a special evacuation unit can be fitted. When hot products are being packaged, consideration also has to be given to the heat resistance limits of the packaging material ‘Steam graph te wo ° pat be © oi > oe 7 oo: 8 ba & a = a 100 90 ° ton © 10 20 30 40 50 60 70 80 90 100% Temperature. ————> Powdery products It static electricity builds up on the film, the product, may collect uncontrollably on the upper-web or in the sealing area. Solution: antistatic devices Pay attention to hygietie requirements ‘The machine is often switched on and off. by pressing the pushbuttons 0 and I. Traces of the Product, such as grease or blood, are transferred to the pushbutions from the operator's hands. Bacteria can be formed 01 the pushbuttons, which are transferred to the product via the operator's fingers when the machine is turned on and off again. Solutions: = Is particularly important to clean and disinfect the pushbutton controls regularly = Itis also possible to order the optional foot switch [struction manual <. : aoe bree MI ULTIVA<< mucrivac Chapter 09Absolute measuring vacuum gauge with digital display The vacuum gauge consists of the pressure transducer’ and a diplay unit. It measures the absolute pressure* in the chamber: The measuring inaccuracy in relation to the final vacuum (lowest possible pressure) is less than about 3 mbar. It therefore allows conclusions to be Grawn about the residual pressure in the pack, even at the low levels that are required by sensitive products to achieve long shelf lives. It can be used to prevent production of defective packs due to leaks in the vacuum system. The current pressure level is displayed digitally. Two independent pressure settings can also be made, one for the vacuum and the other for back-filling with inert gas. * Vacuum and pressure are interdependent. A reduction in the pressure level (mbar) means an increase in the vacuum level and vice-versa. Display unit Pressure transducer The display unit is on The pressure transducer is in the control panel the large control cabinet 1 Digital display 2 Pushbutton “Vacuum setting display" 2A Control lamp "Vacuum setting reached" It stays on as long as the actual pressure level is lower than the set level 3 Pushbutton "Gas pressure setting display" 3A Control lamp "Gas pressure setting reached” It stays on as long as the actual pressure level is lower than the set level 4 Adjustment screw "Vacuum sealing" 5 Adjustment screw “Gas pressure setting" a. 11.88 1z/pee/se (TU LT VACAbsolute measuring vacuum gauge with digital display Measurements shown on the digital display Chamber opened: If the chamber is open, this means that the pressure in the chamber is the same as the air pressure outside (e.g. 950mbar) and therefore fluctuates. Chamber closed: The absolute pressure in the chamber is measured and displayed now, irrespective of the air pressure outside. Setting the required vacuum level (This is only possible with selection of the appropriate program "Vacuum sealing station") - Stop the machine - Press pushbutton (2). The digital display (1) now shows the current vacuum setting. - Use a screwdriver to turn the vacuum setting adjustment screw (A) until the required setting is displayed. Please not. : If the sign "-" occurs left of the vacuum get value on the display, the appropriate adjustment screw has been turned to far counter- clockwise. Please correct: Otherwise the system is in a range not permissible. Extremely low final pressure levels Pressure levels of 3 mbar or less are meant here, i.e. levels that are necessary for sensitive products (e.g. fresh meat, fresh pasta products). In order to avoid the production of defective packs, the vacuum gauge can be used to monitor final pressure levels and stop the machine if necessary. The monitoring system takes action if the vacuum setting is not reached. - The evacuation operation is not completed; the machine stops. - "31" appears on the diagnostics display Possible causes: # - Leaks in the vacuum system - Sealing gasket is damaged or worn out - Water in the pump oi Pee bebe MMULTIVAGAbsolute measuring vacuum gauge with digital display Operation with vacuum monitoring - Determine the lowest possible final pressure level (see vacuum test) - Set the gauge about 2-3 mbar above this - Turn the "vacuum" potentiometer to the left until the stop is reached (in the case of MC control, enter vacuum time "0") Operation without vacuum monitoring - Set the gauge about 10-20 mbar above the lowest possible final pressure level. - Set the "Vacuum" potentiometer so that the required final pressure level is reached comfortably (in the case of MC control, enter the vacuum time - about 1-2 seconds) Setting the required gas pressure level (This is only possible with selection of the appropriate program "Vacuum station") - Press pushbutton (3) and at the same time use a screwdriver to turn adjustment screw (5) until the required setting is displayed. Gas pressure levels slightly above atmospheric pressure are possible (maximum absolute pressure about 1200 mbar). Please note: If the sign "-" occurs left of the gas pressure get value on the display, the appropriate adjustment screw has been turned to far counter clockwise. Please correct: Otherwise the system is in a range not permissible. Please note: The gas flushing operation does not end when the setting is xeached, but continues for a further period of time that is set on the "Gas flushing" potentiometer**. The final pressure level is therefore higher. If the potentiometer is turned to the left until the stop is reached, the final pressure level is almost exactly the same as the Setting. ** Enter the gas flushing time in the case of MC control. Seas is can a ee BADE lee SeesAbsolute measuring vacuum gauge with digital display Zero point correction When pressure measurement systems have been in operation for a lengthy period of time, the zero point may be displaced. Low pressure levels cannot be measured completely accurately any more. If sensitive products are being packaged and a long shelf life is required, it is recommended that the zero point is corrected every six months. A zero point correction always has to be made when the display unit or pressure gauge has been replaced. This correction is made by Multivac's service staff on request. Companies that have the appropriate equipment can also carry out the zero point correction themselves as outlined below: Equipment needed - Accurate control vacuum gauge with a 10/8 mm connection hose - Screwdriver Adjustment Should only be carried out by a trained electrician. Adjustment of the zero point should be made at the lowest possible pressure. - Connect the control vacuum gauge to the T (see illustration) ‘= Undo the screw on the front plate ~ Pull the gauge and the front plate forwards - Select "Vacuum test" as outlined below, but run the machine without product - When the final pressure level has been reached: compare the reading on the digital display (1) with the reading on the control vacuum gauge and if necessary use a screwdriver to make a correction by turning the "zero" trimmer. - Put the gauge back into place - Remove the hose connection on the control vacuum gauge, plug the T and tighten the cap nut securely.<< mucrivac Chapter 10Dear customer, this chapter is reserved for optional equipment that is not (yet) installed on your machine (at present) MULTIVAG ‘Sepp Haggenmaller KG ‘Technical Documentation Department D-87787 Woltertschwenden Tel. (083 34) 601-0 Fax (0 83 34) 6 01 - 1.95 ‘GB_Hinweiskundo:<< mucrivac Chapter 11Cross cutting unit Film cross cutter QR 85 Contents © Application O Parts © Method of operation O Safety O Switching on/oft © Operation © Setting the QR 85 O Setting the blade © Changing the blade O Setting the time © Changing the chain O Tightening the chain © Maintenance O Additional equipment Parts Application The film cross cutter QR 85 separates the packs at right angles to the film web. It can be used for films with a total thickness of up to 350 microns. Blade Blade holder Housing ‘Sprocket wheel Pneumatic cylinder Clamping lever Guard Compressed ai supplyCross cutting unit Film cross cutter QR 85 Page 2 of 9 Method of operation A blade that cuts on one side is pulled through the web of film by a compressed air cylinder via a gear rack and a chain drive. At the end of a set time the blade returns to its original position. The path of movement of the blade is determined by a guide. Safety DANGER! Cross cutting knife. Do not reach under the cross cutter. Only remove the cross cutter when the main switch Is OFF and both the compressed alr hoses have been disconnected. The film cross cutter can be switched on and off separately on the control panel. The simple clamping device makes it possible to position the unit exactly at any place in the cutting area. * Before carrying out any* work: Turn the main switch to 0 and disconnect the quick disconnects. * When interupling the cutting operation, watch out for the projecting blade. © To feed in the film, only press (switch on) the illuminated pushbutton on the control panel when film fas reached the film discharge without congestion. * Put the film cross cutter on a suitable surface when taking it off the machine. Watch out for the projecting blade. Except when making settingsCross cutting unit Film cross cutter QR 85 Page 3 of 9 Switching on/off Follow the Instructions In the "Safety" sectlon ZL Press the CROSS CUTTING pushbutton, “E The ciode wit ight up. The cross cutting unit is activated. tt more than one cross cutting unit is installed, the units can be selected individually, depending on the program. Call up the FUNCTIONS ON/OFF display: © Funct.:Switch onvott 16.5 T/Min. Rogistor mark controt: Cutting 1 0 Cutting 2 oCutting 3 o- whe Input: Note: 0 = cutting unit is switched off When the pushbutton is pressed or number 1 is 1 = cutting unit is activated entered, the cross cutting unit is initially only activated. The cutting operation itself is only carried out during the machine cycle.Cross cutting unit Film cross cutter QR 85 Page 4 of 9 Setting the film cross cutter The correct position of the film cross cutter on the machine is marked by a fine when the test run is made at the factory. IL 3 Setting the fim cross cuttor The film cross cutter is set correctly if the edge of the housing facing the sealing die is on the marked line (see Ill. 3). Setting instructions: Follow the instructions In the “Safety” section + Undo the clamping lever (6) - Position the film cross cutter correctly - Tighten the clamping lever Notes: * Alter the machine has been in operation for a while, the film transport chain lengthens slightly. The position of the cutting line should therefore be checked regularly and the film cross cutter should be reset if necessary. © When connecting the compressed air supply, pay attention to the coloured marking (12) that distinguishes the forward and backward movement: The connection for the forward movement’ is marked with a coloured tape. ‘* When the machine has several film cross cutters that are operated altemately, pay attention to the coloured markings (12) for the different connections! * Forward movement » cutting operationCross cutting unit Film cross cutter QR 85 Page 5 of 9 Setting the blade The film cross cutter will only work properly if the reversing points for the forward and backward movement are set properly. The initial setting is made in the factory. After the unit has been in operation for some time, the position of the blade changes, e.9. due to lengthening of the chain, so that resetting is necessary (see Ill. 4): 3% uw 13 ee, 4 Setting the ravarsing points - Undo the clamping screws (14) - Tur the adjusting screw (13) clockwise: the Gistance to the edge will increase ‘Turn the adjusting screw counter-clockwise: the distance to the edge will decrease - Tighten the clamping screws (14) ive If the setting Is not accurate, the life of the blade can be reduced constderably; the blade may even break. Check the position of the blade regularly! Changing the blade Follow the instructions In the "Safety" section Remove the guard (9) - Remove the blade (2) from the sliding element (15) eeu The gulde roller (2.3) Is held loosely by a pin B12 ! iad = Undo the screw (2.1) "5 Chansingthe blade + Take out the blade (1), turn it round or fit a new one ~The blade has to engage both the projecti (2.2) - Secure the blade with the screw (2.1) - Insert the blade holder in the sliding element, watching the guide roller! Put the guard (9) back on againCross cutting unit Film cross cutter QR 85 Page 6 of 9 Setting the time The time from the beginning of the cutting operation to the beginning of the return movement can be set individually. The time set at the factory relates to the cutting system installed when the machine is delivered. [vee The time set must always be long enough to guarantee reliable completion of the return movement before the advance begins, Call up the TIME display (Example) 700: 0.00 06: 0.00 Z12:0.00 218: 0.00 224: 0.00 230: 0.00 236; 0.00 42: 0.00 M16, Example = Input new setting for time 38. (procede in steps) < check the signal on the Input board Depends on the machine configurationTrouble-shooting 19 Trouble shooting 42. Splice lower web* + see 41 45 Advance monitor - Switch the machine off and then switch it back on again (]_~ Shange the aigital advance counter Page 8 of 19 49. Heating monitor current/temperature* Temperature monitor: ~ Temperature not yet reached after switching the machine on; wait ~ Fuse has tripped. Try switching the @! fuse back on. If it trips again, the heating element has a fault (short circuit, ground contact). Current monitor: - Current monitor evaluation unit set incorrectly ~ Fuse has tripped (see temperature monitor) 51 Lack of oll, chain tubrication* = Refill the central lubrication system with oil Check tho signal on the input board Oil level switch dirty Depends on the machine configuration SeeTrouble-shooting 19 Trouble-shooting 54° Forming dle safety guard Incorrectly positioned, Magnetic reed switch (N.C. contact) faulty** + Forming die safety guard not in the correct position (| - See.4:it te diagnostics display 54 continues after the safety guard has been repositioned, the magnetic reed switch is faulty. If the magnetic reed switch is faulty: call the Multi- vac customer service department 55. Sealing die safety guard Incorrectly positioned, Magnetic reed switch (N.C. contact) faulty - Proceed as outlined under 54 56 Discharge right" safety guar Incorrect- ly positioned, Magnetic reed switch (N.C. contact) faulty + Tunnel guard not in the correct position + Proceed as outlined under 54 57 Discharge left* safety guard incorrect- ly positioned, Magnetic reed switch (N.C. contact) faulty + Tunnel guard not in the correct position + Proceed as outliried under 54 Page 9 of 19 58 Press “S" pushbutton/safety relay faulty [P| ~ Check safety rotays: Press the illuminated pushbutton SAFETY CIRCUIT and keep it pressed. Relays must open, 59. Interruption time of the photoelectric beam exceeded* Press ON pushbutton - Photoelectric beam interrupted If the green illuminated pushbutton SAFETY CIRCUIT blinks, press it. Start the machine by pressing illuminated pushbutton | Photoelectric beam dirty Photoelectric beam plug isconnected ~ Photoelectric beam plug faulty + Safety guard warped ~ Check the signal on the input board - Check the photoelectric beam relay Depends on the machine configuration S00 also the previous section entitled “Fauts on safely guards" FTrouble-shooting 13 Trouble-shocting Other faults This is a list of the faults that do not lead to a display. Summary @ Pack faults = Pockets not formed sufficiently or wrinkled = Pockets are damaged - Poor vacuum in the pack - Unsatisfactory gas flushing + Pack leaks/poor sealing ~ Faulty cutting - Cross cutting = Film punch - Paper cross cutting/serrating cutting + Film cross cutting unit + Longitudinal cutting - Roll-and-shear cutting - Squeezing knives - Rotary knife assembly = Shape cutting = Complete cutting - Circular and shape cutting © Advance drive ‘© Film is held poorly by the gripper chains ‘© Die bottom “sticks” when opened © Faults in the compressed air system © Faults in the water circuit © There is a noticeable noise when the machine is running Page 10 of 19 Pack faults Pockets not formed sufficiently or wrinkled - Heating time or forming time set too short - Forming pressure too low ~ Heating temperature too high or too low Plastic plates in the forming die. Use alu plates. + Muftler on the quick-exhaust valve of the forming die bottom is dirty + Air bubble caught between the film and the heating plate Film infeed not parallel Fitm tension too tow - Hose line to the forming die damaged + Water cooling inadequate. Set higher water flow. - Calcium deposits in the die Pockets are damaged + Thermoforming radius plates are missing; fit them + Thermoforming radius plates are damaged; smooth them off Poor vacuum in the pack Increase the setting of the vacuum gauge and/or the evacuation time (depends on the program) Fitter before the vacuum pump is blocked up; replace it + Sealing valve leaks, sealing plate’ presses downwardsTrouble-shooting 13 Trouble-shooting + Slits not cut correctly + Opening for siiting knives in the forming die top clogged up with film + Slitting knives in the forming die are worn out; replace them by new ones Unsatisfactory gas flushing* Gas flushing nozzle dirty Inorease the GAS switching point setting’* Increase the gas flushing time"* Gas input pressure too high Gas mixing unit set incorrectly Pack leaks/poor sealing ‘Check whether the pack has been damaged in the forming die, during transport or in the sealing die. Smooth off any projections ("tiash*) fon inserts in the forming die, on plates and bars. Before doing this, tum the main switch to 0 and lock it in this position! Film fed in incorrectiy; feed it in correctly (the sealing layers of the upper and lower web have to rest directly on top of each other) + Sealing temperature too high or too low = Sealing time too short - Air pressure too low for sealing. Pressure is set on the pressure regulation valve in the lower section of the control cabinet. - Sealing gasket in the die bottom is worn out. When ordering a new one, quote the ‘complete die number. + Diaphragm in the sealing die top faulty - Sealing plate worn out. Change it or have a new Teflon coating applied. - Ita row of packs is open on one side (outside): = Film is being fed in asymmetrically; set the film guides = Heating element faulty - Melted polyethylene behind the sealing plate. Clean it caretully. Poge 11 of 19 Faulty cutting Cross cutting The illuminated CROSS CUTTER ON/OFF Pushbutton has to be pressed Film punch M4 Film punch = Corner rounding blades in the punch top worn out ~ Silicone rubber in the punch top worn out - Nut for setting the punch is set incorrectly - Blade holder in the punch top displaced, loose - Compressed air hoses damaged Valves, lifting cylinder leaking, faulty ‘Depands on the machine configuration ‘Deponds on the programTrouble-shooting Pago 12 of 19 13 Trouble-shooting Paper cross cutting / serrating cutting ~ Blade blunt; change it - Diaphragm in the punch top faulty - Quick disconnect blocked - Mufller on the quick-exhaust valve is dirty = Lock nut on the lifting cylinder of the cutting support is loose Film cross cutting unit . + Compressed air hose disconnected or ; damaged IW. 5 Paper cross cutting/serrating cutting unit ~ Quick disconnect blocked ~ Lock nut on the lifting cylinder of the cutting support loose - Blade movement too short + Blade blunt; change it ~ Blade operation time too short ~ Chain sluggish - Gear rack sticks > Cylinder teaks - Silicone rubber on the cutting support worn out + Setting of the cutting length incorrect + Blade movement too long/noisy = Stop for gear rack incorrect M6 Film cross cutting unit ~ Chain loose. Tighten it with the eccentric screw. Reset the stop. - Gear rack does not éngage the pinion properly. Tighten the pressure screw somewhat. Longitudinal cutting Roll-and-shear cutting - Upper circular biades blunt; change them ~ Upper circular blades dispiaced or loose - Lower circular blades wom out W.7 Roll-and-shoar cutting unitTrouble-shooting 13 Trouble-shooting ‘Squeezing knives - Blades blunt; change them - Grooves in the counterpressure roller. Pressure applied is too high; set it at a lower level. Relocate the counterpressure roller taterally by fitting spacing rings. If the counterpressure roller is damaged badly, change it. Dae - When running the machine without film, move the blades away from the roller (Gisconnect the hose) Rotary knife assembly Blades biunt; change them Blade clamp loose Shape cutting ‘Complete cutting Call the Multivac customer service department Punch blunt; sharpen it Safety screw motor lever - lever assembly broken Circular and shape cutting unit - Blades blunt; change them + Cutting support is not positioned correctly ‘Springs on the film holder are broken Chain loose Page 13 of 19Trouble-shooting 13 Troubie-shooting ‘Advance drive + Cutoff length varies, is wrong + Chain stretched in places. + Connection incremental transmitter - motor is loose Film is held poorly by the gripper chains + Chain too loose. Grippers do not open. Tighten the chain, ~ Film brake has lost friction due to film dust. Clean it with spirits or soapy water. - Film tension set too low - Film reel guided poorly. Set the frame correctly. Die bottom “sticks” when opened (only vacuum-seal / forming die) The die can be heard to drop onto lifting rails. This is a sign of inadequate ventilation. Tum the machine off at once. Turn the main switch to 0 and lock it in this position. Position the die bottom on th ling rails again. Muffler on the main valve blocked; change it - Check the signal from the output board to the ventilation magnetic valve - Ventilation magnetic valve faulty; change it - Safety time (Z 01.07) too short Faults in the compressed alr system = Water in the forming die. Compressed air contains too much water. ‘Check the water separator/air drying unit. - Condensation emptying device does not work, Clean the water container and perhaps the drain valve, = Too much oil in the compressed air system. Set the oil mist lubricator (1 drip in 5 minutes). Page 14 of 19 Faults In the water circult ~ Water escapes at the side orn the dle: O-ring between the machine frame and the die top is missing or worn out + Lid gasket is damaged + Water hose in the machine is faulty Calcium deposits in the dies. Die top gets warm - Water flows when the machine has been switched off: - The water inlet valve does not close. Clean and remove calcium deposits. There Is noticeable nolse when the machine is running Forming aie whistles Round silicone cord in the forming die is ‘worn out replace it. Tun the main switch to 0 and lock it in this position, - Forming time and/or forming pressure are set too high - Heating pressure set too high Rubbing noises in the mechanical system Lubrication inadequate. Lubricate the dry points. ‘Turn the main switch to 0 and lock it in this position ~ Compressed air blows out = O-ring in the connection to the forming die is missing or damaged - Hose damaged Diaphragm in the quick-exhaust valve has hardenedTrouble-shooting 18 Trouble-shooting Power supply to the control unit O06 y IL 12 Power supply to the control unit Power supply to the control unit is provided by a three-phase transformer with a rectifier. 1-3 Each phase is protected by a fuse between the transformer and the rectifier 7 RedLED*on: —fuse blown + LED elight-emitiing diode Page 15 of 19 The three +24V outputs are protected by fuses (4), (5) and (6) 4 5 Fuse: Fuse: Fuse: Green LED on: safety circuit input modul switches, it PC control, power outputs fuses ok, output voltage availableTrouble-shooting 13 Trouble-shocting Control unit Page 16 of 19 — UW. 13 Control unit Handling the control boards ee + Tum the main switch to 0 before changing the control boards! + The control boards have MOS switching circuits. They can be destroyed it affected by electrostatic charging. + Put the palm of your hand on the machine housing before removing a board + To remove the card, pull out the plug and use a screwdriver to undo the two screws by turning them a quarter of a revolution to the left. Then pull the board out evenly using both hands. PC control Mains supply 40 CPU 11 Controt boards. - Always store/dispatch boards in protective antistatic covers.Trouble-shooting 19 Trouble-shooting Note the following when changing the boards: ~ Carry out coding (setting the rocker switches) as on the old board - There may be 4 or 5 rocker switches on the input and output boards, depending on board configuration: The Sth switch on the new boards has to be ‘on 0, while the other four have to be in the ‘same position as on the old board! - The CPU board has an EPROM* The EPROM from the old board has to be used for the new board ieee 1 {iL 14 Rocker switches EPROM = programmable component Pago 17 of 19, ~ When changing the EPROM, make sure that the Eprom is plugged straight into the socket again (noteh on the EPROM) - all the connections are plugged in the sockets correctly Note: The boards can be placed anywhere in the rack. Only the mains supply board and the CPU board have to be fitted in a specific location,Trouble-shooting 13 Trouble-shooting Mains supply board This board supplies voltage to the PC* control - Onloff switch: mains switch mains voltage Meaning of the LEDs: + 24V LED on: 24V mains voltage is available, 5V are produced internally + OnLEDon: Outputs of the output boards switched on - OM LED on: Outputs of the output boards switched off CPU board This board controls co-operation between the individual boards. It contains the specific program for the machine on a programmable component (EPROM). = On/off switch: switch for the outputs. ‘The switching position of the outputs can be seen on the mains supply board (on/off LED). Meaning of the LEDs: = Cycle LED on: internal fault + +5V LED on: ready for operation ~ Parity LED on: intemal fault Timing boards - Timing board Z 0 ( = Z 00) Contains the basic setting for machine times. Do not adjust these times. Meaning of the LEDs: - Red LED on: timing module has been activated - Green LED on: time is running - Timing boards Z 1, Z2(=Z01,Z 02) The times that depend on external factors, eg. the film used, are set on this board via meters on the control panel Page 18 of 19 A ony Sen Aus En ius 0 W. 15 Mains supply board ° mn W. 16 CPU board 17 Timing boards PC = Programmable Control CPU = Central Processing UnitTrouble-shooting 18 Trouble-shooting Input boards Interface between the machine (pushbuttons, proximity switches etc.) and the CPU. Only input signals larger than 16V are processed. Meaning of the LEDs: + LEDs on: input signal available ~The LEDs also go on when the input signal is, less than 16V. If in doubt, measure the voltage of the input signal. - Some signals are only available for a short time! Output boards They activate e.g. relays, valves with 24V. All the outputs have short-circuit protection. fa short-circuit occurs, eliminate the fault and reset the board by switching the switch on the mains supply board off and on. Meaning of the LEDs: - LED top right: on when a short-circuit occurs + Output LEDs on: output voltage available - Some signals are only available for a short time! Pago 19 of 19 Us = | U. I. 18a) Input board, 32-pin 19 Output board, S2pin I, 18) input board, 16-pin |_— Short circuit - LED fanaa cee SS | 22.08.1994 i lgipealooy 2 muLrivaAe<< mucrivac Chapter 14Key for identification numbers for pneumatic components 14 Diagrams, Information for trained personnel Page 1 of 3 Electropneumatic components e.g. magnetic valve Purely pneumatic components, e.g. vacuum valve ‘Sub-assembly Function Instrstion maida 2" SLES 28:08.1994.-=5." -:lgfpealgeps’ oo MULTIVAC All machine s with MC 92 control Ge paclidance Teer! ae -xample: o}siv|s| Magnetic vaive (no. 5) T CL forreel brake or = i 1 lifting unit, allocated é rey g to the basic machine gfe B Tid 1203 4 5 6 Example Pneumatically actuated C2] Te [ua [2] ere evkctianon CI for the seating station Feerel peer 1 AS Separator SD Muffler DG Pressure regulator SE Quick-exhaust valve DM Compressed air motor SK Quick disconnect DR On-way restrictor SM Hose diaphragm DS Throttle/regulator SP Storage container KH Ball valve. ‘VD Steam generator LF Air filter VP Vacuum pump ME Mechanically actuated valve WE Maintenance unit MK Manually actuated valve WV Aternate-pressure valve PN Pneumatically actuated valve (OR gate) PU Pump ZD_Two-pressure valve (AND gate) RS Check valve ZY CylinderKey for identification numbers for pneumatic components Page 2 of 3 14 Diagrams, Information for trained personnel ‘Sub-assembly Function 0 Basic machine Cooling water Main valve Reel brake, ting unit Chain cleaning, lubrication Register mark contro! oaens 1. Forming station Die fitting Heating Forming Plug Ventitation Upper web forming ito E Nourenao 2 Sealing station Die fitting Evacuation Vacuum supply Ventilation Gas fishing A Sealing Steam oaranso MU LTIVAG rine ininiction anal. 12.01.1994Key for identification numbers for pneumatic components Page 3 of 3 14 Diagrams, Information for trained personnel ‘Sub-assembly_ 3. Sealing station Printing, labelling, embossing 5 Product infeed, pack transport Funetion ousenso RaRrso Pre:post-sealing evacuation dito, ventilation dito, sealing Muttiprint Cross cutting unit, top titling ditto, bottom liting ditt, cuting Punching, siting Longitudinal cutting ‘Shape cutting, lifting ditto, cutting Filling station Pack lowering Leak check Loading check Transport Instniction manual Be 12.0171094 .”~- Igjpeavg6p. “MULTIVACAbbreviation in pneumatic and electric diagrams M 855 E 4.0.6 Standard Multiprint * ' Flexoprinter * Special equipment * Depending on machine construction Machine equipment incl. option SL pe aay bain whe tSiSieat neAbbreviation in pneumatic and electric diagrams M855 EB 4.0.6 PPP DDD DD DD DD DDD DDD oo we eee mecimo ewTARe 9/0 9/3 9/4 9/7 9/8 9/12 28 130 131 320 330 505 S/eee 10 320 Output valve switched Current supply 24v Photoce1l Thermostat forming die Thermostat top sealing die Thermostat bottom sealing die Power pack cru modul in panel PLC E 00 E01 E = modul for signal input A 00 A = modul with output 24V (geared valve) A OL Z = timemodul Z Ol + Z 02 Advance Counter Photoelectric beam forming die Photoelectric beam sealing die Thermostat embossing station Diagnose unit Counter central lubrication Thermo sensor heating top forming die Thermo sensor heating top sealing dic Thermo sensor heating bottom sealing die Thermo sensor motor drive Rotation impulse encoder (drive) Pressive sensor of contact vacuum gauge Thermosensor embossing station Heating top forming die Heating top sealing die Heating bottom sealing die Heating switch cabinet Heating embossing station Depending on machine constructionAbbreviation in pneumatic and electric diagrams M 855 E 4.0.6 FOL Circuit breaker heating switch cabinet Fil Overcurrent relais vacuum pump F3 Overcurrent relais motor longitudinal F4 Overcurrent relais trim exhaust F5/... Circuit breaker heating top forming die Pr? Circuit breaker heating top sealing die FB Circuit breaker heating bottom sealing die F 010 Circuit breakers motor Fil Overcurrent relais advance motor slow F O11 Circuit breaker vacuum pump F 12 Overcurrent relais advance motor fast F 012 Circuit breaker control F 013 Fuse 24v rectifier F 014 Fuse 24V safety circuit F 015 Fuse 24V control F 016 Fuse 24V valve F 320 Circuit breaker embossing station 1 Control lamp heating and control 4 Control lamp machine ON (I) 5 Control lamp register mark control 6 Control lamp cross cutting 7 Control lamp advane 8 Control lamp automatic~ 9 Control lamp safety circuit "Ss" K K H H H H H H 10 Control lamp synchronization auxiliary ON/OFF I Hl Control lamp folm heating (vacuum) H 12 Control lamp gas flushing time 12/1 Control lamp gas flushing ON H 13 Control lamp sealing and forming H13/1* Control lamp contact vacuum gauge ON #19 Control lamp control voltage 24V control panel H 20 Control lamp 24V valve H O22 Control lamp current supply 24V control H O22 Control lamp current supply 24V.safety circuit H O23 Control lamp current supply 24V rectifier (lights up if fuse blows) * Depending on machine constructionAbbreviation in pneumatic and electric diagrams M855 E 4.0.6 1 Contactor vacuum pump 3 Contactor longitudinal cutter 4 Contactor trim exhaust 5/... Contactor heating top forming die 7 Contactor heating top sealing die 8 Contactor heating bottom sealing die 10 Contactor release brake, cycling knife shaft a1 Contactor advance siow 12 Contactor advance fast 20 Contactor control 24V 23 Relay phase sequence, thermorelais 24/1 Relay safety circuit’ cross cutting 24/2 Relay safety circuit longitudinal cutting Relay safety circuit forming die 25/2 - Relay safety circuit sealing die 26 Relay water pressure / air pressure . 27 Relay fast release break 28 Relay advance 39 Relay automatic 40 Relay die in downward position 130 Relay photocell at forming die 131 Relay photocell at sealing die 230 Relay synchronization 255 Relay for labelling unit 320 Contactor heating for hot embossing station 505 Relay central lubrication RAR AA RAR RAR AR AR AR RAR AR AR RR iS & a bl Mains supply L2 Mains supply L3 Mains supply M1 Motor vacuum pump M3 Motor longitudinal cutting M4 Motor trim exhaust M10 Motor advance M 10/1 Motor ventilator N Neutral wireAbbreviation in pneumatic and electric diagrams M 855 E 4.0.6 Amperemeter top foming die Amperemeter top sealing die Counter cycle Counter operation hour Indicator power (cycle per minute) m8 youwr PE Safety wire Qi Main switch R5 Potentiometer vacuum/film heating R6 Potentiometer gas-flushing R7 Potentiometer Sealing/forming Rill Potentiometer output interval R15 Potentiometer cross cutting R 16 Potentiometer sealing, ventilation R17 Potentiometer security time R18 Potentiometer diagnosis time 1 Key control and heating ON/OFF 5 Switch register mark control ON/OFF 6 Switch gas flushing ON/OFF i Key advance 8 Switch automatic ON/OFF 9 Key safety circuit s 8 s 8 s 8 s 10 Switch synchronization I S$ 10/1 Switch synchronization 11 sil Switch cross cutting ON/OFF s 13 Switch contact vacuum gauge ON/OFF S14 Key start (1) S 16 Key stop (0) S18 Switch NoT-STOP s 35 Guard water pressure S 36 Guard air pressure S37 Vacuum guage s 40 Limit switch die opened s 41 Limit sealing die closedAbbreviation in pneumatic and electric diagrams M 855 E 4.0.6 Ss 51/1 Ss 51/2 S12 Magnetic switch forming die s 52/1 : aa Magnetic switch sealing die 8 52/4 s 53/1 $ 83/3, Magnetic switch cutting unit $ 53/4 S 53/5* $ 24/2 Magnetic switch knife shaft 8 55 Safety switch cabinet door $132 Limit switch £i1m monitoring forming die $133 Limit switch film monitoring sealing die $ 210/72 Magnetic switch tunnel guard $505 Central lubrication (lubricator filling switch) ri. Transformator control 18/20V vl Motor slow u2 Motor fast * Depending on machine constructionAbbreviation in pneumatic and electric diagrams M 855 E 4.0.6 << we eae ue DE DE DE DE DE DE DE BE DC DS BE DE DE DE DE DE DS EB DE DED Be Oa Motor slow Motor fast Connection Motor slow Motor fast Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug Plug connection connection connection connection connection connection connection connection connection connection connection connection connection connection connection in diagram heating forming die preheating bottom forming die top sealing die bottom sealing die socket in cabinet door trim exhaust photocell top film switch panel operat. panel (power current) switch panel operat. panel (power current) switch panel operat.panel (low volt.current) vacuum gauge operating console (infeed side) diagnostic system multiprint counter Terminal strip switch penel (power current) Plug Plug Plug Plug Plug Plug Plug Plug connection connection connection connection connection connection connection connection switch panel - approach belt socket discharge. belt filling station loading supervision £il1 and empty package monitor socket gas mixer multiprint beam socket heating embossing stetionAbbreviation in pneumatic and electric diagrams M855 E 4.0.6 WEEE dH HS gH HE A Hd ag ng ad Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic Magnetic valve valve valve valve valve valve valve valve valve valve valve punch die-stroke film heating (pressure air) film forming (pressure air) embossing film break for register mark control sealing gas flushing evacuation top sealing die evacuation bottom sealing die water cross cutter shut off valve valve valve valve valve valve valve valve valve diaphragm in forming die shrinkage ventilation top sealing die loading station (filling station) forcing squeeze knive against residual film winder multiprint flexographic printer Central lubricationGiese Unterage dact ohne unsere Zustinmung weder verval igh nach Oritten2uginglch gemacht werden. Zuviderhandlungen verplichten 24 Schadenersat2 und find strabar. Alle Rechte vorbehaten, a aa eh a eres cece a ee L ame be sees tenes aon 1212 yon ya va 010s 185 eae zor go ta 31g zonovror suis * pee sation ee YY 380 ee, yee Ee oo— Sea a pete! meat A c 200.. —{— ee Funktionsdiagramm fetta = fan Pie reatatat se BERR ETA |S esse ee ———Diese Unteriage dart one unsere Zuttinaung weder verselitigt nach Oittenaugtaglch gemacht werden, “uviderhandlungen verpfchten 2u Schadanersat2 und ‘ind stratbar. Alle Rechte vorbehalten, aa — : ae. 3S Fj | fe #-----------4, S6 —f ies Beet a _— EE G »| — ¥ ve RT ae aie lime mene ——p—| O) 7 Po ™ ae G R ” a | a we a 3) oe r] E ve a — Oe. o 6™ —aa o al aan n arn wr ve i Qa G ¥e s : i —e et fel I+ a . ° Bd oG va tein ‘a es UV) sees, a t a7 2m QO M.- th ve ih aa : we ae a Tee ata! | lu O (iat ee « [3190 | Piller pears rane wo w/¥ Ga a a ee] [|] — Ff +] Funktiondiagramm Soon te IEEE : sopra van cnet Sant HEE mere | te rt assKey for identification numbers for electrical components Pago 1 of 3 14 Diagrams, information fr trained personnel R530, M 860, R (T) 5200 with MC 92 control 7 lolsly ol cae Electropneumatic components, 0 | | Y Example: .9. Magnetic valve 7 Magnetic vatve (no. 2) Z | fe for reel brake of titing unit é allocated to the basic = > machine = Poy ‘ ge 8 3 ee 8 | i | ‘A Unit, e.g. amplifier Q Power switch B_ Thermocouple, sensor, transmitter R_ Resistor © Capacitor S Switch, pushbutton E Heating, lighting T Transformer, transducer F Tripping device, fuse U_ DCIAC convertor, G. Generator, battery, power supply frequency convertor 4 H_— Horn, signal lamp V__ Transistor, thyristor, diode EeEo K Relay, contactor W Wire L. Coil, throttle X_ Plugin connection, terminal M_= Motor Y Magnetic vatve, brake P Measuring device: 2 RF. filter ‘Sub-assembly Function Insiietion maniial ” 62.03.1994. oe LULA i sohlissolmes2: so 3. 7 =Key for identification numbers for electrical components 14 Diagrams, information for trained personnel ‘Sub-assembly 0 Basic machine 1. Forming station 2 Sealing station | Function Cooling water, controt Air supply Film inteed Chain advance Rogister mark control aeons Die titting Heating Forming Pug Ventilation Upper web forming dito eanenso 0 Die titting 5 Sealing 4, Evacuation 6 Steam 2 Vacuum supply 7 3 Ventilation 8 Safety circuit + photoelectric beam 4 Gas flushing Insruetion manidal~ 02.08.1984 | igigp.» "> J ULTIVAC GB_el.schlisselmes2Key for identification numbers for electrical components Page 3 of 3 14 Diagrams, information for trained personnel ‘Sub-assembly 3. Sealing station 3. Printing, tabetting, embossing 4 Cutting, punching, | sitting 5 Product inteed, | pack transport Funetion 0. Pre-ipost-sealing, evacuation + dito, ventilation 2 ditto, sealing Muttiprint Ink -Jet ow Cross cutting, top litting ditto, bottom iting ditto, cutting Punching, siting Longitudinal cutting ‘Shape cutting, itting ait, cutting ourenso, Filling station Pack lowering Leak check Loading check Transport Remso Wisiiibe mana 72ST | 02.00.1994 ade 2 ‘ MULTIVACFunction diagram 114 Diagrams, information for trained personne} Forming die - standard R5200/ M860F MC 92 control ‘Operation cent x0 X1 x2 x3 | | Position Magnetic valve HEATINGTing Magnet valve Magnet valve FORMINGIAing Magenti valve FORMING compra Magnet valve FORMING vac, (2) Filing imo HEATING a = Actuated position (5) Fting ime FORMING = Not actuato potion (H)_HeaTINe (Die doeos (FORMING Branch OF unetion AND lnetion BRT ee MMIULTIVAC cosmo:Function diagram 114 Diagrams, information for trained personnel Forming die - pre-heating .5200/ M B60F ‘Operation’ — X0 Xt X2 x3, Function Main switch Hating ‘Saiey ‘Switching on Dio ing Magnetic vane Reaire ‘Magnet valve FORMINGHng ‘Wagnote vave FORUNGearpra Magnetic vane FORMING vac, TE) Filing time FORMING a =Actuated postion anc OR nein AND funtion (i) HEATING b= Not actuated positon : (i) FoR (Sal Die closed Gost ep MIULTIVACFunction diagram 14 Diagrams, information for trained personnel Forming die - pre-heating/plug R 5200/ M860F Program Plug - alr MC 92 control nm. 3 Operation \— XO Xt Xe x3 Function Main switch Heating ‘Safety Switching on | Die Ming pacer ‘Magnotic valve FORMINGHIing Tagnate vane FORMING compeae Magne vate FORMING vac agnotc vave PLUS EB) Filing sme FORMING ‘a= Actuated position Brareh Lor neon AN tuneion ® -Ptus- peta b= Not actuatod poston HEATING FORMING [Gil Cie dosed [ey pws ite | MMULTIVAC {88 ine mota sFunction diagram 14 Diagrams, information for trained personnol Forming die - pre-heating/plug R5200/ Ma60F Program Air - plug MC 92 control ro. 4 [Operation | XO Xt x2 Xa vac ear [Magnetic vane FORMINGITng Wagnote vaNe FORVING carera Magna valve FORNING vas, Magnetic vave PLUG ()_Ftng ee FORMING = Aetitod postion (H) Pts. pevav Hg ease arereh on tenon AND orton WeATING (FORMING (Gil Die coses iim Pw aura AMULTIVAC Be imecempninaFunction diagram 19Fams, information for trained personnel Forming die - pre-heating/ACCU F5200/Ma6oF ] Program Wah avi Weatng Salaty ‘Swiening of Bie ing Magratievave HEAT vacerprae Magri valve ‘REFORMING Tin awh MC 92 control nm 5 ‘Operation ca XOX KEK ot asin Wagraievane ‘DAPHR.DVDED [1] Fig time FORMING FORMING [@) PLuG- DeLay [iy] sare Te Brae 2X0 tnction PRE-FORMING = 2 = Actuated poston GH) Plus retuavetay >= Not actuate positon pases HEATING ra il Die coses 4 Instruction manual a MTR AA SE oppoalge = 'GB" iS /m8 posi s 09.08.1984." Zo1pealain CB Gnd ptals 3Function diagram 14 Diagrams, information for trained personnel Forming die - ALU R'5200/ M S60F Program MC 92 control 0. § § | Operation a XOXIx2x3 1 2 3 4 Magnets valve | 12V8 FORMINGYAting Magnet valve | _12V5 FORMING comer Magnoicvavo | _13¥1 PLUG. Filing time FORMING. = Actuatod postion Branch [OR uncon AND unetion (CH) Ptue- DeLay FORMING [al] Die dosed ‘gece MMULTIVAC | certsFunction diagram 14 Diagrams, information for trained personne! Evacuation...sealing Evacuation / vacuum sensor and time [Operation a XO Xt x2 x3 Function Main switch Heating ‘Satory Switching on G | | Position gz Dieting Magnotc valve Die botiomi/pack Wagneiie vate Die top ‘Magnetic vale entiation francd [)_ evacuation = Aewates 9 SCAN Not actuate positon LVENTATION-DELAY [] eeumsonser ED closed ‘All machine with MC 92 control Y ontunion Program AND unetion {ger eal “MULTIVACFunction diagram 14 Diagrams, information for trained personnel Evacuation...sealing Evacuation / time Function Main switch Heating Satery ‘Swaching on Die iting Magnetic vave_| _2i¥2 Die botiom/pack ‘Magnetic valve Dio top Niagnetc valve Ventiaton Magnote vaive Sealing [)evacuarion [sarc VENTUATION DELAY Mce2 [Operation _ | Xo x1 x2 x3 |] Position 2 a = Acunted postion Branch poston Edd Die closed ‘All machines with control Nw Program AND function vio MMULTIVACFunction diagram 14 Diagrams, information for trained personno! Forming die - standard ea no, ‘Operation ee x0 Xt X2 x3 | 2 Position Hating Saloty ‘Switching on 2 Die iting Magnetic valve HEATING acca | TORN l Actuated postion anes om tncion Avo uneon lot actutod positon Die dosed (HEATING [Z] FoRMINeFunction diagram 14 Diagrams, information for trained personne! Forming die - pre-heating M860E Program| 10. ‘Operation ~| Function-- -|Reterenca lrumbor XO Xt x2 x3 Main switch Heating Salety ‘Switching en Die Hing Magnetic valve HEATING Wagretc valve FORMING HEATING ‘a= Actuated position Branch [oR tuncton AND tuneton FORMING b= Not actuated postion (BE die closed<< mucrivac Chapter 15‘Tiglich = Tranaporcuecce ausblasen (Klemaare b¢fnen an dar Elnlautrolie). Kaccenfoheung ausblasen. + Lufcaruck, wasserdruck, Gasdruck pri einstellen. Mertungscinheit prilfen (evel. Kondenevaes = Wale und Senuelaplazce prifen. Versehmeteunges sb besten is wnrmen Zustand encfern Diatand bei eingebauter und externer Vatu punpe pruren. = Teenneiarichtongen gegen Torrosion echteren (hur tarefeale Sle od orrentonsschutzaictel vervenden) patty = Blow off transport chain (open grippers at the infeed roll) Blov off chaia guide, = Check and, if naceenary, readjust air pressure, wacer pressre, ges pressure. + Check mtinemance unit (if ne water). = Check heatieg and fn'wara condition. saeaiy, drain condensed ning plate. Renove dire preferably = Check off level at installed and excernal vacuum pump. Protact separation devices apainst corrosion. Use oy moneact@ ofTe and antincorrontve apes, resp ‘cuaque jour = Ghatae de cranaport Z souttler (pinces i ouvir prée tae d soulfter. (eau de condensation faire bchapper, oi nécesseize). = Plaque de chauttage ot de soudute # véritier, 11 et recoumaadé de lee nattoyer d chads = Miveny "tulle € virttier our te poape Z vide incorporie = UesTTser sevlement es husTes sans acide at des anttcorrasits, DProthger Tes dtaposttits de stparation contre corrosion. - Linpiar Las guies de traneporse ~ gaupraber preiin de aire, gas y aqua ai ot procino = coaprober vnidad de manteninieato (+i dejar salir agun condentade). = couprobar place de calefacctén y sellaje. 26 seoases fniner ensuciedades 3 estada eceaerio WocheneLich = Merkzeuge und deren Dichtungen prilfen. = SimtLiche Dicheungen an den SchraubverschiUenen, Ger Sehilucne prufen; Schliuche priten. + Sehlitenesser in Foraverkzeug prifen. = Die Messer der Trenaeiaricheungen peifen, ssf. sehirfen bev, aunvechaelas = Radiencancan an der Redieotafel auf ihre einvandtreie Funktion praten. = Sichernettaxreta priten: Schutseinrichtungen encternen, Maschine sul stenen Sleiben- Mie aebferen Schucreinricheunges viederholen. = Not-Stop-Eineicheung prifen! Bel Lavfender Masching Pilscaster dricken, Mesehine mul sofore stoppen. weeny = Check dies and the appropriate g = check all seals at the acres pluge of the Now check heseae = Check stiteing knife blades in the forming die. = checs, Sf necessary grind or exchange the knife Dl of "be cutting devices. = Check operating buttons on the control panel to ae if they work properly. = Check safety circuit; ranove aafary guards feast not run. REpeae vith several safety = check energency-atop unit: Press sushroos button while ‘achine runes Machine aust stop immediately. = Varltier tes coucenux de fente dane Uouriltage de forme. = Vorifier 1 Aapoateite de sipretion «¢ aU nécatsaire, a aiguiser ov dchanger. = Varitier si lee bouzone de commande du pupitre fenetionnent cane difaut. = Véritier 1e cireute de sécurité, center les dtapontetta de sécuried, In anchine dole sarctter. Mrlpleer avec plusieurs diaposicife de sdcuricé, + Areie dturgence i virifier: bouton chempignce & presser pendant que Ie machine set en marche Li'aacnine doit dvarracer iamédiatenest. season ~ comprobar hormas y junta = couprobar juntes y unionae de Lae conduccions > comprobar evel ‘de formato = couprobar cuchillas de los dispositivos de corte, si ee prectso afflarias y canbiaties. = comprobar #1 funeionanianto de Las teclas de nando = couprobar cireuito de seguridad elininendo dispositives de proceccién; 1a niquine tiene que queda perada, Repatir esto con max dispositives de proveceiéa. correspondiente + comprobar res) de 1a homme Mas pesforadoras (0 La niguine tiene que parat inoediatamente. Wartungspian M8SS E Maintenance schedule Plan de mantenimiento Plan d entretien muurivac Wo eeetkerte prifen, eg. Katte abchepannen (siehe Abschsite 3). = Fuskeion der Werkteug-Bubeylinder prifens BEE. Endlagendtspfung neu einstellen. = Funktion der Schalidiopfer und Schaeltent= 1Beewngevencile peilen. = MikronebelBter reinigen und neu auftGtle wooumty, Quarserty = Check tention of crasspore, chainy x snecensary (see section 3 )- ~ Check function of die ifeing cylinders; revedjuat slow dove at end of erevel LF necessary. = Check fonction of aufflers and quick exhaust vai = Check and.repleaiah micro mist ofter. enaion chain if soit, tous tee 3 opi = Verltier 1a eenaton de 14 chafoe de transport, tendre La chats eL ndcensaite (roi pea = Véritier 1e fonctionneneat des Wousttlage, fin de course dwiter at abceseaite. = Véritier 14 fonctionnement des Hilencieux ot des soupapes d"échappenent rapide. i erfonvcral = comprober In canstén de 1a cadena de transporte, preciso, tensar Ia cadena (ver patrafo 3). fuseionaaiente de] cilindro elevator de Fapular de guevo, ai ee praciso ta anoreiguacléa + comprober funciée de lot amortiguadeses 7 de 1 valuta de ventilactée rapide, = Ligpiar lubrieador de aire y relLoar BatbjUhetions jabeticn = Auntuuschen der Dichteleaence am den Poeunee aylindern der Werkzeugrtubeinricheang. + Dicheungssteze an den Yaupeventilen {Ur Forsen und Bvakuleren ausceuschen, = MadeLlager In Nerkzeughodeyeten susvecisein (ager vorher prifen) + Kinmern an der Traneporcherce ptten, Sehaghafte Klennarn austauschen = Sehieskoutake oder Relaishoncakte prifen (besenen). + Sichchontrole ia Schatescbrank (love Dette, Klesoen ust). very 6 sonthe, Yearly, = Exchange the veal elenence at che pneueatic cylinders of the aie Iifeling cevie > Exchange repate kice at che main valves for fetuing and evacust on, in die Litcing syscem = Check grippers st the eranaport chain. Exchange damages gripper. = Check aprockece at the film infect roller; if necessary, exchange ehes, = check visually contaces at relays and contactors = Viual controt in conceal cabinet (Looe wices, cerminals eee.) and file discharge ous les 6 anf 12 = Tchange dee lineata de joint sur tes vérine poeuneciques du dispositif de Levage de 'outtllage, = Tehange den jour da joints de vila sur Lee aupepes prlacipalen pour Formage at fvacuation. = tetenger lee roulenents i siguilles dese Le disposes de ievage de Vewtillane (Gouteawat "sitter avant): ~ Verifier 16s pinces des chaines de crensport, ichanger es pldcen défactuen = Verifier ou, af ater sur roulear d'ancrée at satire, ichenger lex rouee i chatoo tortie de fils, + Verifier visueltenene Las contects sor Les reli = Controle viavel dans L'armoire de commande (¢ils Soren de commexions eters) semosteat anus] > cambiar junces del cilindro neusatica, elevader de homat = cambiar los jueger de empaguetadaras para e1 formade yovacio situada eo Las vilvulas principelens = cambiar cojinere 40 agujas en el siacems de elevacion = comprotar pinzas en ia cadena Cembier lee pincer defects > feuprober pisones de rodillos de entrade y salide de taniea, ‘cambiar ai ee preciaa = conprobar contactos del rélevador y de toe rales ~ control visual dei cuadro electrice (cables flofo dommes, ete). Rraneporte. Wartungsplan M855 E Maintenance schedule Plan d' entretien muLtivac Plan de mantenimientoHauptschalter auf O! ca Interrupteur princip. sur O! Turn main switch OFF ! / Interruptor principal en O! mrrsowene.- Suen : ‘WUaRIFICATEUR DE HROUILLARD fexpfohtene Sie: huile recomandé: MICRO ~ "FOC LUBRICATOR OMRICADOR DE NEBLIBA ~ #ICRO Fecoonended ofa! scelten tecomendadon! scheme, anton 2 remplit al Bate uleati-aciasctha fone eft weed Fellesar seomalente Hascetiung: 1 Tropten ia} Minuten agjunts 1 drop in 3 ale. sourte dans. Lee [Sew Come Bomn gots én 9 anutos ‘CuALINE DE TRANSPORT CANEMA DE TRANGPORTE. Iuile recomandé: aceltes Tecomendedos: 4a graisver chaque mote aceltar neneulaneate ichets de film d elininer resore file ccrepe cl Fite sobre S eonsic oD woo BW rarer roo any ate rsuearaensesrt szvien cou : wer Leven sverax Sistem DE PALACAS DB ovIAKLEsTO ane recomandés aus era Seeocendndas! Wichent1ich achateren eser chaque seasine Hehrevecksett Fegreste weekly, ar senanalnente multi purpose grease vierteLjanrlich reinigen cover tove lea 3 mois rs cena ze Bt ergo [Sm Cen Benn] Schmierplan, Plan de graissage Blatt 9 Feuille Lubrication chart Plano de tubricacién Sheet HojoFoLTenquenscuverDumc PILN CROSS CUTTER DEVE DECOUPE TRANSVERSALE (CORTE TRANVERSAL DP’ L LAMTRA chatne d graiseer chaque ois celtar meneulasente fa cadena hulle recomand aceltes recouandados: EB] in FOUTENRESTWICKLER ‘TRIN wnmen Jthelich OLeUl tung exnevern exchange off annually ENROULOTR POUR DECHETES ENROLLADOR DE RESTO: PARA Uk LAMTHALA huile @ remplir tous tes ans Kenovar anualiente el Lubricante ‘eeptohiene Dla: tutte recomandée: Fecomended ols: aceiten recomadadon @ uae 9D wo Teles 100 r soptobiene Ble: huattes recomandé: TORE A vioE Fecomsended olla: scelten recemendadon: Ayutte chague jour aceite dtertanence [eee 100 energor xc100 EJ corene w100 ANTRIEBSKETTE cuaite p‘evmainenent sapfohlene Ole: wile recomendbe: DRIVE CHAIN CADENA DE" ACCTONAMTENTO Feboomended olis; — teatten'scmaar Sig, y vA monatlich dlen 4 groisser chaque mois fkeso esse 0 | BP MP 0 | Shell Te2Ius 100 | ‘ : Tubricete aonthly aceltar aenaulanente H za te M8SSE Schmierplan Plan de graissage Blatt ® Feuille Lubrication chart Plano de fubricacién Sheet Hoja3.2 3.2.1 Setting the trip cams The trip cams are set correctly before the machine leaves the factory. If, for some reason, it is necessary to adjust or reset the cams, please follow the instructions below. Caution! Be sure to set the main switch on "0" before you work on the machine! Presetting the cams There are 2 limit switches in the control box for controlling the automatic operation of the machine (see illustration). EE oe eee eee ee see i { | ! 1 1 The limit switches have the following functions: S40 Die opened S41 Die closed3.2.2 Setting the trip cams precisely Die down (opened) $40 This limit switch is mounted on an adjust~ able lever. If you want to increase the die stroke (measure A), then move the limit switch (handwheel) to the right side. To decrease the die stroke, turn the hand wheel to the left side. (clockwise) Die up (closed) $41 This limit switch is attached firmiy to the control box. The cam should then be adjusted so that when the die is closed completely, it just presses the limit Switch. At this point then, the cycle, i.e. evacuation heating, etc., is started.Checking the universal joints when starting up synchronized conveyor belt drives Please make sure that the cardan shafts have been protected with the necessary rubber covers. If they are not: - Grease the universal joints with acid-free grease (A) (This grease is provided if such shafts are retrofitted) - Pull the rubber covers (B) over the cardan shafts ~ Secure both ends of the rubber covers tightly with nylon (C) so that they do not slip.Cleaning Page 1 of 5 15 Cleaning, maintonance Contents O Safety © Important Instructions (© Preliminary work O Pretiminary cleaning © Main cleaning © Disintection © Removal of calcium deposits Important! Avoid damage by corrosion! © Cleaning agents and disinfectants, Note: Hang the enclosed, sealed cleaning plan up on the ‘machine where it can be seen easily. Safety Danger of chemical burns, danger of fire! Danger of amputation by the lifting unit! ‘When handiing cleaning agents: ‘Wear rubber gloves and safety goggles. Not A.chemical bun is not noticed immediately. No flames or uncovered lights when using disinfectants that contain alcohol. Do not smoke! Always make sure there is enough ventilation. Follow the safely instructions on the cleaning agents and disinfectants used. Ail aluminium-based machines Important instructions Important instructions - No water inthe machine - No cleaning agents that contain chlorine. Use cleaning agents with a pH level of 6 to 95 instead. - No disinfectants containing chlorine. Use disinfectants containing alcohol instead, - No high-pressure, steam-jet and foam cleaning equipment, no running water. Use a bucket, a brush and a cloth instead. - Do not allow any cleaning agents and disinfectants to come into contact with polycarbonate safety guards, if they contain the following chemicals: = Salmiacisal-ammoniac > Strong alkalis = Substances similar to glycol + Only use cleaning agents based on citric acid to remove calcium deposits MmuULT IVACCleaning 15 Cleaning, maintenance EE Page 2 of 5 Preliminary work = Main switch ON + Move film out of the machine + Remove film reels and store them in a different room Tum the main switch off + Close the control panel cover" = Check whether all he doors are closed + Cover dies and other sensitive parts (e.g. labellers) with film * Depends on the machine configuration Preliminary cleaning Remove the worst dirt etc.: remove all large ‘contaminants, e.g. pieces of meat, by hand. Wash ‘everything down by hand with warm water. rr ed No water must be allowed to get into the machine. ‘Water leads to the corrosion of bearings, titing units and cutting units, and causes expensive damage, ‘Only use a damp cloth or a brush when cleaning inside the machine. GB :romgundiagCleaning Page 3 of 5 15 Gloaning, maintanance beac area nero inaeieetniaeornnerag Wash the outside of the machine off with a bucket of warm water containing no cleaning | agents 2 : eB ~ Blow the whole of the machine off with © compressed air and et i ry : a Fit the safety guards, support bars etc, a back on the machine. : e . TRIS EERE RENN oR >t : rah athe covers ha had been put onthe Remove safety guards and clean them by hand ri Be eerste Proto S with warm water and a mild cleaning agent. ~ Take loading and support plates out and clean - them outside the machine, + Clean the outside of the machine with warm = water and a neutral cleaning agent. Read the | a ae information on the cleaning agent to determine . Corrosion prevention | the correct concentration and. instructions. for | e see page 4 using the cleaning agent. a E : ee | evutmeraeeenemtmemrerneneommaner!| iam inetoeion manwal 26.05.1994 5kCleaning 15 Cleaning, maintenance re Page 4 of 5 Disinfection (if necessary) After the machine has been cleaned, spray it wih an alcohol-based disinfectant Removal of calcium deposits Acidic cleaning agents can discolour the machine. Calcium deposits on the machine should therefore only be removed at lengthy intervals. Procedure: Femove the calcium deposits with a cleaning agent containing citric acid ‘Then wash the machine off thoroughly with warm water. Important! Avoid damage by corrosio Every time the machine has been cleaned or disinfected: - Blow the film chain off and oil it. To do this, activate the lubrication cycle": see the earlier section “Automatic lubrication and cleaning of the transport chain. - Spray the easily corroded parts of the cutting units or wipe them with an oil-:mpregnated cloth. = Disinfectants degrease metal. This can lead to the formation ot surtace rust. WW this occurs, polish the rust away and use a corrosion prevention agent to produce the grease film again. Only use corrosion prevention agents that are approved for food applications (e.g. white oil) for parts of the machine that ‘come into contact with the product * Depends on the machine configurationCleaning Page 5 of 5 15 Cleaning, maintenance Cleaning agents, disinfectants and corrosion prevention agents T Ener of your own Henkel Hygiene GmbH | Fink Hygienetechnik Lever Sutter Cleaning agent for the inside! ‘Special cleaning agent outside of the machine PO-topax10 for meat counters pH tevel 86 93 94 Cleaning agent for ; ‘Okoron “Schonreiniger” / oe Okoron MAG enue | Disinfectant P3 - alcodes Antisept SU 319, PH lovel 55 74 74 Corrosion prevention agent No cleaning agents and disinfectants that contain Sources of supply for cleaning agents, chlorine. ‘These agents attack the machine Please contact Multivac or your agent i you have (Only use cleaning agents with a pH level of 6 to 9.5. any questions about sources of supply.<< mucrivac Chapter 16Dear customer, this chapter is reserved for optional equipment that is not (yet) installed on your machine (at present) MULTIVAG ‘Sepp Haggenmaller KG ‘Technical Documentation Department D-87787 Woltertschwenden Tel. (083 34) 601-0 Fax (0 83 34) 6 01 - 1.95 ‘GB_Hinweiskundo: