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Ulma SMART Series Training Manual

Tray sealer
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SMART
TRAINING MANUAL
VER. 0.2
06-06-2005
Smart Technical Manual
Page 1 of 75

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Summary of Contents for Ulma SMART Series

  • Page 1 SMART TRAINING MANUAL VER. 0.2 06-06-2005 Smart Technical Manual Page 1 of 75...
  • Page 2 INDEX 1. Overview 2. Operation a. Components b. Screens 3. Cycles: a. Sealing and Cutting b. Feeding the film c. Vacuuming and Gas 4. Subgroups: a. Mould b. Electrical Cabinet c. Vacuum Pump d. Various Settings. 5. Options a. Printed Film b.
  • Page 3 1. Overview The thermosealing or tray sealing machine is used to seal preformed trays (of plastic material, usually expanded polystyrene and rigid plastics) This machine will seal layer of film matching the quality of the tray, and will go through a vacuuming and gas injection cycle.
  • Page 4 The Smart machine is divided into two machine models, SMART 400 AND SMART 500, with S-400 being the smaller range and S-500 is the larger one. The big difference is the sealing surface of the machine. Otherwise they are very similar on the exterior. These machines can operate with more than one mould, although they require a somewhat time-consuming process.

  • Page 5: Machine Dimensions

    MACHINE DIMENSIONS Smart Technical Manual Page 5 of 75...
  • Page 6 2. Operation Product loading and unloading is made manually for this machine. If the machine is properly connected to the grid, (380 VAC, three-phase plus neutral and ground, have the correct air supply, (6 bar and 350 l/min), gas is connected and at the correct output pressure (between 2-5 bar) If the film is properly unwinded, the guards are closed.
  • Page 7 Smart Grafcet. TURN ON MACHINE Guards OK Emergency buttons OK Thermals OK Machine off press ON/OFF ON/OFF button (reset) Machine ready product 2 RUN + drawer out + temp.OK + chamb.In buttons FORMERS CYCLE Drawer inserted Drawer detected inside Vacuuming up and down Vacuuming finished Gas down –...
  • Page 8 a. COMPONENTS 1. Control Panel 10. Mould 2. Emergency Stop Button 11. Vacuum installation 3. General Switch 12. Excess border collector 4. Tractor System 13. Vacuum pump 5. Electrical and Pneumatic Cabinet 14. Mould guide 6. Air inlet 15. Reel holder 7.
  • Page 9 b. SCREENS Communication between the machine and the operator is made through the display screen Smart 1 – Temperature Controller 2.- Display 3 – Emergency Stop (STOP) 4 - ON/OFF Button ESA VT50 Screen The messages that appear on screen are: Smart Technical Manual Page 9 of 75...

  • Page 10: Display In Menu Mode

    DISPLAY IN RUN MODE This displays the status of the machine (stopped, running cycles, or even for alarms). To go to this display mode: Shift Hold down and press Note: After turning on, the machine enters this mode automatically. DISPLAY IN MENU MODE This is the display mode in which the machine operating parameters are modified (product number, etc.).
  • Page 11 Once already in the submenu, to go to the next screen hold down and press Shift and to go to go back to the previous screen hold down and press Shift Modifying the value of a parameter: To modify the parameter for a screen already on display: 1.
  • Page 12 RUN mode Said mode is made up of the following displays: • “ULMA PACKAGING SMART”. Begins when machine is connected, and exits when it moves to the MENU or RUN mode. • “Máquina apagada” (Machine Off; ON/OFF button). All of the machine’s devices (air, resistances…) are disconnected, to connect press the ON/OFF...
  • Page 13 SCREENS IN MENU MODE: This operation mode allows access to the modification screens for the parameters and activations that govern the system's operation. Press to enter into MENU mode. Shift Said mode is made up of the following displays: PARAMETERS •...
  • Page 14 • “Consigna de vacío” (Vacuum Default). Default amount of vacuum to be made inside package. This default is only considered if the vacuum and gas mode in the activations submenu is connected to a vacuum gauge. Smart Technical Manual Page 14 of 75...
  • Page 15 ACTIVATIONS • “Production” (Production). Activating the production control that will stop the machine once the number of packages that was set through the production menu is complete. • “Vacío” (Vacuuming). (Optional) Activating vacuuming of packages. • “Gas”. (Optional) Activating gas injection of packages. •...
  • Page 16 PRODUCTION • “Número de producto” (Product Number). A total of 100 products may be stored, which are associated with parameters, activations, etc. • “Número envases/ciclo” (Package/Cycle Number). Number of packages made by the machine in each cycle. Parameter used to count packages during controlled production.
  • Page 17 MANUAL • “Cajón inferior” (Lower Drawer). The lower drawer is pushed all the way in, and remains in that position until this parameter is activated again, therefore returning to its initial position. • “Campana superior” (Top Cover). While the drawer is inside, the top cover will lower to the intermediate position, and it stays in that position until this parameter is activated again, returning to its initial position.
  • Page 18 Version until middle of 2003 SMART SCREENS DIAGRAM MOULD PRESSURE PARAMETERS ACTIVATIONS PRODUCTION MANUAL MODE 983 mbar ACTIVATE PRODUCTION 00 CYCLES/MINUTE MANUAL LOWER DRAWER 0:NO 1:YES NO LOAD 0:NO 1:YES SEALING TIME 01.0 S ACTIVATE VACUUMING 00 CYCLES/MINUTE MANUAL TOP CHAMBER 0:NO 1:YES WITH LOAD 0:NO 1:YES...
  • Page 19 Version from mid 2003 SMART SCREENS DIAGRAM Shift + F5 ULMA PACKAGING SMART Shift + F4 Shift + F3 Shift + F3 Shift + F3 Shift + F3 MOULD PRESSURE PARAMETERS ACTIVATIONS MANUAL MODE PRODUCTION 983 mbar ACTIVATE PRODUCTION 00 CYCLES/MINUTE...
  • Page 20 Shift + F3 Shift + F3 Shift + F3 Shift + F3 GAS COMPEN. TIME ACTIVATE PHOTOCELL PACKAGES TO MAKE MANUAL VENTILATION 00.0 S 0:NO 1:YES 0:NO 1:YES Shift + F3 Shift + F3 Shift + F3 VENTILATION TIME ACTIVATE ENCODER PACKAGES PENDING 00 0 S 0:NO 1:YES...
  • Page 21 Shift + F3 ADVANCE W/ PHOTOCELL 250 mm Shift + F3 GAS DEFAULT 150 mbar Shift + F3 VACUUM DEFAULT 050 mbar Manual tecnico Smart Página 21 de 75...
  • Page 22 HIDDEN SCREENS. The hidden screens are exclusively for the use of the Ulma technician, the client should not have access to these since it could modify the factory settings In addition to the normal screens, there are a series of hidden screens with the use of two passwords, to configure the machine.
  • Page 23 Version until middle of 2003 DIAGRAM OF HIDDEN SCREENS FOR SMART SETTINGS MENU CONTINUOUS RUN 0:NO 1:YES ENABLE SETTLER ADVANCE PULSES 0000 0:NO 1:YES 1:RESET Extract drawer 0000 Vacuuming alarm 0000 ENABLE ENCODER? TOTAL PRODUCTION 0:NO 1:YES 00003746 Emer. Er. 0000 Gas Alarm 0000...
  • Page 24 Version until middle of 2003 DIAGRAM OF HIDDEN SCREENS Shift +F5 FOR SMART ULMA PACKAGING SMART Shift + F1) & (Shift + Help) PASSWORD 0000 0943 1111 CONTINUOUS RUN? SETTINGS MENU 0:NO 1:YES Shift + F3 Shift + F3 ADVANCE PULSES 0000...
  • Page 25 3. CYCLES a. Sealing and Cutting The sealing cycle of a machine can simply be sealing and cutting, or sealing and cutting using vacuuming and gas. (The most usual.) The sequence is: 1. With the machine connected, the film unwinded, the temperature controller at the correct temperature and the vacuum pump operating.
  • Page 26 b. Feeding the film. The film roll is placed in the reel holder and can be printed or transparent. It is unwinded by passing it through the brake beam that controls the movement of the film, through a series of rollers, under the chamber and at the end it is passed through the group of group of take-up rollers and the excess border collector.
  • Page 27 FILM LID There are many versions of reel holders and brakes. Version 01 Brake shoe version 01 Smart Technical Manual Page 27 of 75...
  • Page 28 Version 02 Brake shoe version 02. Smart Technical Manual Page 28 of 75...
  • Page 29 Version 03,(current) Brake shoe for version 03, currently (02-23-05). The film is fed with a gear motor that rotates a rubber roller and another metal roller that adds pressure on the first, the film passes through both of these and is collected by a border collector.
  • Page 30 film feeding gear motor, with the transmission belt to the border collector. Counting encoder for film advance. SQ1. Smart Technical Manual Page 30 of 75...
  • Page 31 Film traction roller. Smart Technical Manual Page 31 of 75...
  • Page 32 c. Vacuuming and Gas. The Smart tray sealing machine normally has the vacuum + gas option. This option is a group of valves and conduits to air vacuum inside the closed mould and then add gas to fill this vacuum. The systems are separate although they have a few similar points.
  • Page 33 Gas Valve Top gas valve and top ventilation valve System prior to 03-23-05, with the vacuum meter in the bottom vacuum block and the drawer ventilation valve. Smart Technical Manual Page 33 of 75...
  • Page 34 4. Subgroups. a. Mould. The mould for a Smart sealing machine is made up of: • Chamber • Frame • Blocks CHAMBER BLOCKS FRAME The mould is a subgroup that is specifically prepared for a tray model, which is unique and exclusive for same, (and this tray model can be made in various depths) The mould can be prepared in different ways according to the specifications of the tray and film to be used by the client.
  • Page 35 The mould is the place on the machine where the systems are found that hold the tray, seal and cut the film and will contain the vacuuming and gas injection (if required for the cycle.). If during production the tray model varies, the mould must be replaced on the machine. Each tray model or type has a matching unique and different mould.
  • Page 36 Frame for expanded polystyrene tray Frame with silicone joint for a rigid plastic tray. Smart Technical Manual Page 36 of 75...
  • Page 37 BLOCKS: The function of the blocks is to support the base of the tray, as well as to fill the cavity of the drawer, to facilitate the vacuuming-gas process. The blocks are made of plastic material and are calculated according to the different tray heights to be sealed. There is normally a blocks reference table attached according to the tray heights.
  • Page 38 CHAMBER: The chamber is the most complex part of the mould. It contains the sealing and cutting systems, as well as the stampers to avoid that the film to be sealed moves during the sealing process. • Sealing Plates • Blades •...
  • Page 39 Counter- rotation Sealing plate fastening screws System holding plate Film stamper Sealing plate fastening screws Stamper spring System holding plate Blade spring System holder plate guides Sealing plate Thermocouple Resistance fitted pin Connection Block Sealing plate hole Resistance Smart Technical Manual Page 39 of 75...
  • Page 40 Sealing plate Counter- rotation Separator support plate hole Systems holding plate Cutting blade Blade fastening screw Sealing plate tie Stamper Internal stamper joint System holder plate guide 220V Connection Block Thermocouple connectin block Sealing plate cabling Systems holding plate stopper Sealing blade Stamper Smart Technical Manual...
  • Page 41 Chamber Joint Chamber cover Vacuum intake Power supply hole Systems holding plate guide hole Spring housing Vacuum intake 220V hose + thermocouple Systems holding plate guides Chamber spring Chamber Smart Technical Manual Page 41 of 75...
  • Page 42 b. Electrical Cabinet The electrical cabinet is found on the top of the Smart sealing machine. Inside the cabinet there are two different parts, these are the electrical components part (top) and the pneumatic components (bottom) Power Supply Frequency Changer Main Switch Vacuum pump thermal and contact switch...
  • Page 43 EV Group. Large cylinder Up (YV4) and EV Air Inlet Down(YV5). Drawer Out YV3 and In YV2 YV9 Ejector Smart Technical Manual Page 43 of 75...
  • Page 44 c. Vacuum pump. The vacuum pump is always located at the bottom of the machine and can be two kinds, normal (grey, for gases with % Oxygen less than 20%) or special (red, for gases with % Oxygen over 20%) The pump is connected to the vacuum + gas group through a reinforced clear tube and all joints are sealed with normal silicone to avoid leaks.
  • Page 45 d. Various Settings. The Smart machine has a series of settings common to the 400 and 500 models. 1. Adjusting sealing and cutting cylinder. 2. Adjusting drawer insertion cylinder. 3. Adjusting collector outlet cones. 4. Adjusting reel holder. 5. Adjusting vacuuming + gas 6.
  • Page 46 If the distance is over or under that length, it is adjusted in the thread of the cylinder rod, and then it is fastened with the locknut. 20 mm distance between the drawer and chamber. Screw plunger and locknut. To adjust the first stop of the cylinder at the bottom we use the distance between the top plate and the chamber as reference (spring measurement, approx.
  • Page 47 over the guide columns, therefore, the reference height (70 mm) is taken differently (Drawing or plan to indicate this is pending). If we take the distance between the plates, we get an approximate measurement of 82 mm. Distance with no compression (69- When the chamber closes this distance 70mm) should be 4mm or less...
  • Page 48 2. Adjusting drawer insertion cylinder. Vacuum conduit Gas conduits Frame positionning pins The drawer is the group of parts that are in charge of moving the trays below the chamber and film for sealing and cutting. The drawer will be placed on the frame, using two positioning pins as reference.
  • Page 49 has two conditions, one is SQ4 and the other is SQ6, which is a detector located on an L-shaped support that will detect that the drawer is IN) The drawer requires a very good adjustment, since if the stopping position of the drawer IN is not exact, the blades will be damaged on the first cycle.
  • Page 50 Ball joint and thread of long cylinder Adjusting the drawer’s position according to the chamber is made at the thread of the long cylinder piston. Smart Technical Manual Page 50 of 75...
  • Page 51 Gas Tubes (blue) Guide rods. Tray ejection cylinder. Guide Rods Drawer movement cylinder Vacuum tube Smart Technical Manual Page 51 of 75...
  • Page 52 Flow Regulator SQ5 Detector SQ4 Detector Smart Technical Manual Page 52 of 75...
  • Page 53 80 mm height Drawer. 120 mm height Drawer. 3. Adjusting collector outlet cones. Each time the film width is changed, it is important to adjust these cones to control the correct film tension. Border collector at center of cone Smart Technical Manual Page 53 of 75...
  • Page 54 4. Adjusting reel holder. To change the reel, turn the knob to open and close the cones using the inside of the shaft. To remove the cone on the side, simply turn it a little until the screw enters the passing hole.
  • Page 55 first parameters we basically control the residual percentage of oxygen inside the tray. With the combination of the rest of the parameters, we basically control the swelling of the tray (Taking into account the value of the vacuuming and the gas). The parameter that is most complicated to control is opening the ventilation through valve.
  • Page 56 5.- Separator plate fastening screws 6.- Loosen the fastening screws for the sealing plate and place them sideways to have access to the connection box. 6.- Sealing plate fastening Connection Box screw At this point we have access to all of the components to be changed. When the desired part is changed, we have to follow all of the steps in reverse order.
  • Page 57 8. Adjusting printed film In Chapter 5.a (Option, printed film) the entire procedure is described in detail. 9. Operating safeties and start buttons 10. Controller inputs and outputs 11. Normal film feed and LID Smart Technical Manual Page 57 of 75...
  • Page 58 12. Parameters for temperature controller Settings Menu CTION ISPLAY Temperature default Access settings menu in-t for more than 3 seconds Select type of input 2 in-t (Thermocouple type J, - 100.850ºC) Move to next screen Select degrees centigrade, C Move to next screen SL-H Highest default limit, 300ºC SL-H...
  • Page 59 Alarm CTION ISPLAY Temperature default Access operation level Activate run Move to next screen AL1H Highest alarm limit AL1H Move to next screen AL1L Lowest alarm limit AL1L Exit operation level Temperature default Self-Tuning CTION ISPLAY Temperature default Access self-tuning menu for less than 1 second Activate self-tuning...
  • Page 60 Protections Menu (Limit user access to certain screens) CTION ISPLAY Temperature default Access protections menu oAPt for more than 1 second Select protection mode 2 oAPt Move to next screen iCPt Select protection mode 2 iCPt Move to next screen YtPt Select protection OFF YtPt...
  • Page 61 Move to next screen AL 1n Select On/OFF to exit Alarm 1 AL 1n Move to next screen AL H 1 Alarm Hysterisis 1 AL H 1 Exit advanced functions in-t More than 3 seconds Exit settings Temperature default More than 3 seconds In the protections Menu change Protection Mode to “2”...
  • Page 62 13. Frequency changer parameters TSM03000 SMART PARAMETERS FOR FREQUENCY CHANGER (U1) (U1) INVERTER PARAMETERS Nombre Valor Name Value Contraseña Password Selección de modo de parada Stop type selection Selección de referencia de frecuencia Frecuency reference selection Selección de prohibir marcha inversa Reverse mode selection Selección de función de tecla STOP/RESET STOP/RESET buttons function selection...
  • Page 63 5. Options a. Printed Film Correcting printed film consists of using a cover film that is printed according to client requirements, which will match the design of the trays in the frame. The printed film reel should have repetitive marks and at an equal distance that will serve to control the film advancement.
  • Page 64 The eye-mark detector is fibre optics. The amplifier is in the electrical cabinet and has a series of LEDs and a display that shows the status of same. Smart Technical Manual Page 64 of 75...
  • Page 65 In normal operation when the eye-mark is not being detected, the amplifier has the LEDs red indicator light OFF, the six green-red LEDs ON, and the display will show a value equal to the fibre optics reading at that moment. (between 4095 and 3000) When the eye-mark is detected, the LED red indicator light is ON, and the LED green- orange lights go OFF, and the value of the display will change to a lower value, between (1500 and 650 more or less.
  • Page 66 Eye-mark Printed Film. Smart Technical Manual Page 66 of 75...
  • Page 67 b. Skin Skin is an option that can be offered by the Smart machine. This package type makes it different from the normal vacuuming + gas sealing. It is only made through vacuuming and the final aspect is that the film is adhered to the product. (Like when packaging with thermo-sealing vacuuming with stretch film).
  • Page 68 Skin Mould: Intermediate Fixed Sealing Plate Stamper The Skin mould, is different than the standard mould where the sealing plate is fixed (it is fixed tot he chamber) and has no separator plate. It also has an intermediate stamper which is the one that really seals the film at the edge of the tray (overlap), this intermediate stamper has a T-shaped silicone joint to stamp the tray and is moved with springs.
  • Page 69 Vacuuming group. The vacuum group is specific for this application, it has two air-piloted electrovalves more than the standard group. Vacuum cutting EV vacuuming Bottom ventilation EV Fast-slow ventilation EV Bottom vacuuming On the bottom drawer vacuuming section there are two electrovalves: one for vacuuming and the other for normal ventilation.
  • Page 70 This stroke is for lowering the intermediate stamper. This parameter is the vacuum time used to create a good vacuum in the mould, it is quite critical and also serves for the film to begin heating up. This time is used to ventilate the drawer, but it is not used for Skin. The extraction time is the time where the drawer cylinder is activated to facilitate tray removal.
  • Page 71 This time is used to preheat the film before top vacuuming. This time is used to vacuum a little more in the chamber and therefore force the film to move closer to the sealing plate. In this screen we will only use ventilation 2 for Skin, this will be the time used to ventilate the chamber right after cutting, so that the hot film “sticks”...
  • Page 72 Select 1 value to enable the Skin function on the machine. Vacuuming must also be selected in 1. Gas however must be disabled, 0 value. The vacuuming + gas selection must be according to times. 0 Value Smart Technical Manual Page 72 of 75...
  • Page 73 The Skin operating mode must be first enabled. We access the setting using Shift + F1 + Help. After entering the password, we look for the screen Select 1 on the screen and exit to the normal menu. Smart Technical Manual Page 73 of 75...
  • Page 74 c. Liquid Settling Tank The liquid settling tank is placed between the vacuum pump and the group of vacuuming + gas valves. Its function is to retain the possible liquids or sauces that fall inside the drawer during the sealing process and to avoid the vacuum pump from becoming blocked.
  • Page 75 d. Drum In some cases a gas reserve may be needed before the gas circuit, to speed up production or because the cavity to be filled (tray) is large. In these cases a drum is installed next to the vacuum pump, for this purpose. Gas Drum Smart Technical Manual Page 75 of 75...

This manual is also suitable for:

Smart 400Smart 500