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8 - 2

8

MAINTENANCE OPERATIONS

166.07

.A02

Revision 00  Date 18.10.1998

8.1

SCHEDULED MAINTENANCE

The machine does not require any particular type of maintenance.

CLEANING THE TOOLS
The fixed and movable tools must be cleaned at the intervals stated in the chart. Use the brass bristle brush provided
and jets of compressed air, if  required.
The tools need to be cleaned to remove any dust that may build up while the caps are being processed.

E0004P

WARNING!

Pay special attention to both the fixed and movable knurling tools. Make sure they are perfectly clean. Make sure
fragments of material are not wedged between the movable and fixed cutters.

LUBRICATION
Lubrication of the various parts  is extremely important. Accurate lubrication safeguards the machine against wear and
break down.

Summary of Contents for BTA 900

Page 1: ...CHNISCHE DOKUMENTATION DOCUMENTACION TECNICA DOCUMENTA AO T CNICA D O C U M E N TA Z I O N E T E C N I C A ENGLISH INSTRUCTIONS MANUAL 166 07 A02 KNURLING MACHINE FOR ALUMINUM CAPS CUTTING MACHINE FOR...

Page 2: ...0 2 TABLE OF CONTENTS 166 07 A02 Revision 00 Date 18 10 1998...

Page 3: ...ER SACMI IMOLA Via Selice Provinciale 17 A 40026 IMOLA Bologna ITALIA PUBLISHED ON 18 10 1998 REVISED 00 VERSIONS BTA 900 00 002 003 BTA900A SERIAL NUMBER YEAR OF MANUFACTURE INSTRUCTIONS MANUAL KNURL...

Page 4: ...0 4 TABLE OF CONTENTS 166 07 A02 Revision 00 Date 18 10 1998...

Page 5: ...S 2 23 2 4 1 PNEUMATIC SYSTEM DIAGRAM 2 23 2 4 2 COOLING SYSTEM DIAGRAM 2 24 2 4 3 VACUUM SYSTEM DIAGRAM 2 24 3 SAFETY EQUIPMENT AND PRECAUTIONS 3 1 3 1 SAFETY DEVICES INSTALLED 3 1 3 2 GENERAL 3 3 3...

Page 6: ...HE SPINDLES 7 14 7 5 2 ADJUSTING THE KNURLING STAGE FOR ALUMINUM CAPS 7 16 7 5 3 REPLACING THE SPINDLE PINION FOR SIZE CHANGE OVER 7 17 7 5 4 REPLACING THE MOVABLE TOOLS FOR SIZE CHANGE OVER 7 17 7 6...

Page 7: ...the manual near the machine where it can be easily consulted The manual must always be at hand so that the operator and maintenance staff are able to consult it rapidly at any time 1 3 HOW TO USE THE...

Page 8: ...e and repairs These operations are to be performed only by the manufacturers specially trained technicians For this reason these types of operations are not dealt with in this manual 1 6 ENCLOSURES In...

Page 9: ...C E P R O V I N C I A L E 1 7 A I M O L A I T A L I A E0020 ALERT SYMBOLS E0005O Heavy duty work gloves must be worn when plastic caps are handled E0006O Machine must be connected to an effectively gr...

Page 10: ...1 4 1 GENERAL INFORMATION 166 07 A02 Revision 00 Date 18 10 1998...

Page 11: ...of two coaxial drum assemblies placed opposite each other The infeed turn table supplies the caps to the spindles located on the work drum Thanks to the microprocessor based switchboard all the requir...

Page 12: ...nd prevent jamming A fiber optic photocell 6 is mounted on the infeed channel The purpose of this device is to detect when the level of caps in the channel reaches minimum The pneumatic cylinder 4 con...

Page 13: ...FIXED ALUMINIUM CAP INFEED CHANNEL 1 Cap infeed channel 2 Door 3 Knob 4 Pneumatic cylinder 6 Fiber optic photocell 7 Screw 8 Fiber optic mount 9 Fiber optic 14 Bracket 15 Nut 16 Insert 17 Grub screw...

Page 14: ...2 1 1 1 B FIXED INFEED CHANNEL FOR PLASTIC CAPS 1 Infeed channel 2 Door 3 Knob 4 Air cylinder 6 Fiber optic photocell 7 Screw 8 Fiber optic mount 9 Fiber optic 14 Bracket 15 Nut 16 Insert 18 Air blowe...

Page 15: ...ndles thanks to the rod 2 which follows the movement of the cam 5 by means of the rollers 8 The vacuum distributor 15 is found inside the cam 5 and is held against the body of the turn table 3 by the...

Page 16: ...0 1998 2 7 8 5 6 16 21 20 19 21 4 11 12 3 1 15 Figure 2 1 1 2 INFEED TURN TABLE 1 Turn table body 2 Feed rod 3 Wheel 4 Cavity 5 Cam 6 Guard 7 Guide tab 8 Rollers 11 Screw 12 Screw 15 Vacuum distributo...

Page 17: ...he body of the work drum 3 rotates The gear 4 secured to a sleeve acts as a fixed gear wheel which drives the spindles The distributor 6 is held against the ring 7 by the disk 8 through the spring uni...

Page 18: ...10 1998 T1142 Figure 2 1 1 3 WORK DRUM 1 Shaft 2 Mount 3 Drum body 4 Gear 6 Distributor 7 Ring 8 Disk 9 Spring unit 10 Nozzle 11 First flange bearing 15 Wedge 16 Screw 17 Section 18 Dowel 19 Spindle 1...

Page 19: ...idual part This is done to ensure correct exchange with the spare parts 2 1 1 5 Spindle see figure 2 1 1 5 The movable tools which are needed to produce the caps are mounted on the spindles The unit c...

Page 20: ...2 10 2 MAIN FEATURES 166 07 A02 Revision 00 Date 18 10 1998 T1143 Figure 2 1 1 5 SPINDLE 1 Bush 3 Shaft 4 Pinion 5 Nut 7 Wedge 8 Flange 9 Drum 11 Movable tools 7 9 T1140 3 1 4 5 8 11...

Page 21: ...er optic photocell 6 is fixed to the exit channel This photocell detects when the maximum level is reached stopping the flow of caps into the infeed channel as required Device that detects when caps a...

Page 22: ...98 Figure 2 1 1 6 EXIT CHANNEL 1 Plate 2 Inspection door 3 Knob 5 Air blower 6 Photocell 7 Screw 8 Fiber optic mount 9 Fiber optic 10 Spring 11 Lever 12 Spindle 17 Sensor 18 Disk 19 Nut 20 Screw 21 Mo...

Page 23: ...scribed below The geared motor 1 complete with a torque limiter 5 cogged pulley 3 and cogged belt 4 transmits motion to the drive shaft 2 The drive shaft 2 transmits motion to the work drum and the in...

Page 24: ...1 Geared motor 2 Drive shaft 3 Cogged pulley 4 Cogged belt 5 Torque limiter 6 Pinion 7 Pinion 8 Bush 9 Crank 10 Knob 11 Handwheel 12 Tensioner 13 Tensioner 14 Tensioner 15 Screw 16 Ring nut 17 Self l...

Page 25: ...e table which holds the caps down when they are transferred from the infeed turn table to the spindles and vice versa 2 1 1 13 Switchboard references given in chapter 6 USE OF THE MACHINE The switchbo...

Page 26: ...tic To select the required mode of operation use the mode selector on the control panel UNINTENDED AND PROHIBITED OPERATIONS The machine must be used only for the tasks it was expressly designed for u...

Page 27: ...installation between the two parts is given in chapter 4 INSTALLATION are given in the figure below Figure 2 2 OVERALL DIMENSIONS 1 Machine 2 Switchboard A Cap inlet B Cap outlet C Compressed air inl...

Page 28: ...mm2 Auxiliary voltage 110 VAG 24 VDC Air consumption 0 5 Mpa pressure 1500 Nl dm3 1 Air pressure Cylinder YV3 polypropylene caps 0 4 MPa Air pressure Cylinder YV3 polyethylene or aluminium caps 0 2 0...

Page 29: ...te 15 Minimum pressure 0 5 MPa Maximum pressure 1 MPa COOLANT Flow rate 10 Pressure 20 10 2 3 3 RATING PLATE The data regarding the machine voltage frequency auxiliary circuits is stamped on the plate...

Page 30: ...The machine needs to be set up differently for each cap size therefore special parts have to be used Refer to the data sheet provided by Sacmi PRODUCTION CAPACITY Depends primarily on the type of caps...

Page 31: ...uments employed Class 1 instruments IEC 804 Values measured LbA LpA LpC peak P1 59 7 90 0 104 5 P2 60 0 91 0 103 5 P1 Control position measured at a height of 1 55 m from the floor P2 Noisiest positio...

Page 32: ...e acoustic radiation pressure in dB weighted A 89 2 dBA LwA Acoustic power level in dB weighted A 108 dBA 2 3 6 LUBRICANT SPECIFICATIONS POINTS OF USE OIL A Geared motor 23 E 50 C ISO 3498 CO 320 320...

Page 33: ...feed blower B Hollow rod cleaning blowers C 2nd blower Infeed channel D 3rd blower Infeed channel E 4th blower Infeed channel F 5th blower Infeed channel G 1stblower Dischargechannelorlastblower in in...

Page 34: ...re 2 4 2 COOLING SYSTEM DIAGRAM YV4 Solenoid valve CUS Bearing mount Knurling drum P Water delivery line N Water drain line 2 4 3 VACUUM SYSTEM DIAGRAM Figure 2 4 3 VACUUM SYSTEM DIAGRAM 1 Pump 2 Mani...

Page 35: ...over the electric cabinet comes on to inform the operator The cause of the fault appears on the display of the control keyboard The meaning of the fault messages is given in the INSTRUCTIONS B Manual...

Page 36: ...de HL2 Warning light Machine ready to start in Automatic or Remote mode or overturned caps detected HL3 Flashing light Machine shutdown HL4 Warning light Machine Off SB1B Remote control emergency butt...

Page 37: ...ossible danger Before carrying out these operations disconnect the electricity supply by using the master switch The master switch is locked in the off position so that the machine cannot accidentally...

Page 38: ...arts HOISTING To facilitate the lifting and handling operations use bars levers and ramps Never use your hands The person in charge must know the path to be followed and be able to clearly see it give...

Page 39: ...aff must be selected using the same criteria In addition they must be trained in specific technological areas and be specialized mechanical electric pneumatic so that they can carry out the operations...

Page 40: ...ntenance staff must attend a training course and receive on the job instruction before working on the machine Along with receiving information on machine operation and maintenance under normal conditi...

Page 41: ...as surrounding the machine must always be free of obstacles such as step stools tools containers boxes of material clean and dry immediately remove any drops of oil well lit LIGHTING It is fundamental...

Page 42: ...arts that can be operated in manual mode Failure to observe these precautions may cause your hands and or limbs to be crushed caught and dragged and even cut off The risk of being crushed is indicated...

Page 43: ...on are given in the MAINTENANCE chapter chapter 8 Before carrying out maintenance make sure the machine is in a safe condition Once the maintenance operations have been completed make sure the machine...

Page 44: ...3 10 3 SAFETY EQUIPMENT AND PRECAUTIONS 166 07 A02 Revision 00 Date 18 10 1998...

Page 45: ...ng the smaller parts and packages be careful and use the most suitable equipment observing the safety precautions Use extreme caution when handling the crates both inside and out using equipment that...

Page 46: ...THE CRATES AND PACKAGING 1 Machine body 2 Switchboard 3 Packaging of spare parts supplied 4 Packaging of tools provided 5 Crate containing parts 1 2 3 4 T1182 1 2 5 Kg 600 Kg 250 Kg 1000 3 4 Kg 25 Kg...

Page 47: ...d the machine is always as shown in the figure Lift the machine body see figure 4 1 Place the machine body in the required position see figure 4 2 A Take off the guards to access the feet see figure 4...

Page 48: ...18 10 1998 Figure 4 2 A PLACING THE PARTS 1 Machine 2 Switchboard A Cap infeed channel B Cap exit channel C Cooling and compressed air inlet D Work area T1152 800 800 800 800 A B 928 5 136 5 A B C 2...

Page 49: ...ided by SACMI 4 3 1 CONNECTING THE MACHINE TO THE COMPRESSED AIR LINE references in figure 4 3 1 Connect the air preparation unit fitted with snap in coupling A located in the pneumatic control unit t...

Page 50: ...les References in figure 4 3 3 1 E0004P WARNING Afterthemachinehasbeentestedthecablesaresetupforshipment disconnectedfromtheswitchboardandwound up inside the machine Untie the rolls of electric cables...

Page 51: ...4 3 3 1 CONNECTING THE ELECTRIC CABLES XJ1 Cable Connection to power box XJ2 Cable Connection to signal box XJ5 Heater cable only for plastic cap cutter XJ10 Motor M8 power cable XJ14 Signal connector...

Page 52: ...3 3 Connection to the supply mains E0004P WARNING As there are a number of electronic converters inside the electrical cabinet make sure the ground fault circuit interrupters on the power supply are...

Page 53: ...heck the adjustments made 5 2 PRELIMINARY CHECKS CONDITIONS The machine has been factory tested when delivered therefore it only needs to be inspected for any damage that might have occurred during sh...

Page 54: ...e Turn selector switch SA100 to manual to run the machine in manual mode The green run button and the red stop button are used for manual operation Turn selector switch SA100 to automatic to run the m...

Page 55: ...ty precautions carefully observed 6 1 CONTROL DEVICES See figure 6 1 The machine controls are found on the switchboard and machine Figure 6 1 CONTROL DEVICES 1 Control panel 2 Manual operation with li...

Page 56: ...ndled AP2 Temperature control Tool heating optional AP3 Temperature control Tool cooling optional PC1 Electronic counter for exiting caps detected by SQ11 optional PC2 Electronic counter for caps reje...

Page 57: ...CHINE 6 Revision 00 Date 18 10 1998 Figure 6 1 1 TOP DISPLAY AND CONTROL PANEL T2021 SB100 SB101 SB30M SB6M SB33M SB8M SB102 SB103 SA18 SA1 SA40 SB30A SB7 SB6A SB33A SB22 SB8A SB11 SA100 SA30 SB31 M11...

Page 58: ...tructions B Manual The machine starts working the caps automatically carrying out the operations in the order given compressed air solenoid valves are opened start of cap infeed start of cap conveying...

Page 59: ...sted 7 1 CAP INFEED CHANNEL references in figures 7 1 A and 7 1 B REGULATING THE AIR PRESSURE IN THE PNEUMATIC CYLINDER E0004P WARNING This operation must be performed with the machine running therefo...

Page 60: ...ed channel 2 Door 3 Knob 4 Pneumatic cylinder 6 Fiber optic photocell 7 Screw 8 Fiber optic mount 9 Fiber optic 10 Pressure gauge 11 Knob 12 Cap stoppage solenoid valve YV3 14 Bracket 15 Nut 16 Insert...

Page 61: ...nsert 16 Place the Allen wrench provided in the grub screw 17 Turn the wrench to adjust the position of the insert 16 in relation to the cylinder therefore in relation to the caps inside the channel i...

Page 62: ...urn table away from the work drum REPLACING THE CAVITY Remove the screw 11 take out the cavity 4 and replace it repeat this operation for each cavity E0004P WARNING Take care not to damage the O rings...

Page 63: ...te 18 10 1998 2 7 8 5 6 16 21 20 19 21 4 11 12 3 1 15 Figure 7 2 INFEED TURN TABLE 1 Turn table body 2 Rod 3 Wheel 4 Cavity 5 Cam 6 Guard 7 Guide tab 8 Rollers 11 Screw 12 Screw 15 Distributor 16 Spri...

Page 64: ...t the spring assembly 9 Remove the counter grub screw and tighten the grub screw 14 1 4 of a turn at a time Put the counter grub screw back on REPLACING THE GEAR WHEEL DURING THE SIZE CHANGE OVER PROC...

Page 65: ...7 7 166 07 A02 ADJUSTMENTS 7 Revision 00 Date 18 10 1998 Figure 7 3 WORK DRUM 11 19 1 10 4 7 6 8 9 2 T1142 3 15 A 4 17 16 4 18 T1140 T1142 A 14 8 21 20...

Page 66: ...on to the die 2 Mount the die 2 on a tool holder 3 supplied with the machine Install the assembly on a suitable rotary table Turn the holder and the tools and read the value given on the comparator 4...

Page 67: ...he drum away by using the crank 3 Disassemble the wedge 4 by loosening the two relative screws Take out the wedge 4 by tightening the central grub screw 5 Remove the key 6 by loosening the relative sc...

Page 68: ...e 18 10 1998 Figure 7 4 2 1 DISASSEMBLING THE FIXED TOOLS FOR ALUMINUM CAPS 1 Screw 3 Crank 4 Wedge 5 Middle grub screw 9 Screw 10 Tool pack mount 11 Screw 12 Screw 13 Tool pack 14 Pin T1176 T1172 T11...

Page 69: ...8 Figure 7 4 2 2 DISASSEMBLING THE FIXED TOOLS FOR PLASTIC CAPS 1 Screw 3 Crank 4 Wedge 5 Middle grub screw 6 Key 7 Key 8 Union 9 Screw 10 Tool pack mount 11 Screw 12 Screw 13 Tool pack 14 Pin 1 T1168...

Page 70: ...tools from the shaft by using the puller 2 supplied with the machine and replace the part in question 7 4 2 3 DISASSEMBLING THE MOVABLE TOOLS FOR ALUMINUM CAPS T1180 1 2 7 4 2 4 DISASSEMBLING THE MOVA...

Page 71: ...166 07 A02 ADJUSTMENTS 7 Revision 00 Date 18 10 1998 7 5 SPINDLE ADJUSTMENT Figure 7 5 SPINDLE ADJUSTMENT 1 Bush 3 Shaft 4 Pinion 5 Nut 7 Wedge 8 Flange 9 Drum 11 Movable tools T1143 7 9 11 T1140 3 1...

Page 72: ...movable tools 11 and the fixed ones 12 by placing a thickness gauge 13 in the median zone of the tools VALUE TO BE CHECKED Aluminum caps 0 25 mm go 0 30 mm not go Plastic caps figure 7 5 1 A X 0 05 m...

Page 73: ...6 07 A02 ADJUSTMENTS 7 Revision 00 Date 18 10 1998 Figure 7 5 1 C ADJUSTING THE RADIAL POSITION OF THE SPINDLES 7 Wedge 8 Flange 11 Movable tools 12 Fixed tools 13 Thickness gauge 11 8 7 13 11 12 T116...

Page 74: ...the pusher 14 provided Slightly tighten the nut 5 without fully securing it Put in the tool 15 and block the pinion 4 with the screw 16 Turn the shaft by placing the wrench 17 on the front attachment...

Page 75: ...sensor 17 stopping the machine The lever 11 has to be adjusted radially in relation to the spindle 12 while the disk 18 needs to be adjusted axially ADJUSTING AXIALLY Loosen the nut 19 and move the di...

Page 76: ...0 1998 Figure 7 6 EXIT CHANNEL 1 Plate 2 Inspection door 3 Knob 5 Air blower 6 Photocell 7 Screw 8 Fiber optic mount 9 Fiber optic 10 Spring 11 Lever 12 Spindle 17 Sensor 18 Disk 19 Nut 20 Screw 21 Mo...

Page 77: ...th a system for tensioning the transmission belts ADJUSTING THE TORQUE LIMITER The function of the torque limiter is to ensure perfect coupling between the motor and the pinion If problems arise in th...

Page 78: ...2 Drive shaft 3 Cogged pulley 4 Cogged belt 5 Torque limiter 6 Pinion 7 Pinion 8 Bush 9 Crank 10 Knob 11 Handwheel 12 Tensioner 13 Tensioner 14 Tensioner 15 Screw 16 Ring nut 17 Self locking nut 18 N...

Page 79: ...tments are required 7 12 VACUUM SYSTEM No adjustments are required 7 13 ELECTRICAL CABINET A description of the equipment along with all the instructions for programming and using the electrical cabin...

Page 80: ...7 22 7 ADJUSTMENTS 166 07 A02 Revision 00 Date 18 10 1998...

Page 81: ...tons Always keep in mind the potential risks and follow the safety rules given in the SAFETY EQUIPMENT AND PRECAUTIONS chapter chapter 3 Maintenance operations are subdivided as follows routine mainte...

Page 82: ...ovided and jets of compressed air if required The tools need to be cleaned to remove any dust that may build up while the caps are being processed E0004P WARNING Pay special attention to both the fixe...

Page 83: ...NG CHANNEL SAFETY DEVICES VACUUM PUMP Filter Vanes OPERATION Change oil Lubricate Lubricate Tension Tension Tension Lubricate Lubricate Lubricate Clean Lubricate Lubricate Lubricate Replace seals Repl...

Page 84: ...tructions provided by the manufacturer 8 3 TROUBLESHOOTING A red LED on the control unit comes on to inform the operator whenever the machine stops The operator can simply locate the fault that caused...

Page 85: ...he distributor s spring assembly remove and clean the ejection nozzles make sure vacuum is present check the vacuum pump filter make sure the incoming caps are correctly directed adjust the distributo...

Page 86: ...paragraph 7 5 SPINDLE ADJUSTMENT see paragraph 7 5 SPINDLE ADJUSTMENT replace see paragraph 7 4 TOOL ADJUSTMENTS replace see paragraph 7 4 TOOL ADJUSTMENTS adjust or replace the tool see paragraph 7...

Page 87: ...essed air connection between the power unit and the mains Disconnect the cooling system from the water mains and factory drain line Thoroughly clean the entire machine especially the moving parts lubr...

Page 88: ...9 2 9 DISMANTLING 166 07 A02 Revision 00 Date 18 10 1998...

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