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TABLE OF CONTENTS

002AZ001A

Page

ADJUSTMENTS ........................................................................................................................................ 7 - 1
7.1

PLASTICIZATION UNIT .......................................................................................................... 7 - 1

7.1.1

EXTRUDER ............................................................................................................................. 7 - 1

7.1.2

METERING PUMP .................................................................................................................. 7 - 1

7.1.3

FEED TUBE .............................................................................................................................7 - 2

7.1.4

BY-PASS SYSTEM ................................................................................................................. 7 - 2

7.2

INSERTION DRUM ................................................................................................................. 7 - 3

7.2.1

ADJUSTING THE PRECHARGE OF THE DRUM’S CONNECTING ROD ............................ 7 - 3

7.2.2

ADJUSTING THE CUTTER .................................................................................................... 7 - 4

7.2.3

ADJUSTING THE PELLET INSERTION STAGE ................................................................... 7 - 6

7.3

FORMING UNIT ...................................................................................................................... 7 - 7

7.3.1

PRODUCT REMOVAL ADJUSTMENT ................................................................................... 7 - 9

7.3.2

ADJUSTING THE QUALITY CONTROL UNIT ..................................................................... 7 - 10

7.4

PNEUMATIC SYSTEM ......................................................................................................... 7 - 12

7.5

HYDRAULIC SYSTEM .......................................................................................................... 7 - 12

7.5.1

ADJUSTING THE OIL FLOW UNDER LOW PRESSURE ................................................... 7 - 12

7.5.2

ADJUSTING THE FORMING STAGE (HIGH PRESSURE) ................................................. 7 - 12

7.5.3

ADJUSTING THE ACTUATOR DOWNSTROKE ................................................................. 7 - 12

7.6

COOLING SYSTEM .............................................................................................................. 7 - 14

7.7

INSTALLING AND REMOVING THE TOOLING .................................................................. 7 - 14

7.8

ADJUSTING THE EXIT CHANNEL ...................................................................................... 7 - 16

7.9

REPLACING THE INDUCTIVE SENSORS .......................................................................... 7 - 18

7.10

RESETTING THE ENCODERS ............................................................................................ 7 - 19

MAINTENANCE ........................................................................................................................................ 8 - 1
8.1

SCHEDULED MAINTENANCE ............................................................................................... 8 - 2

8.1.1

SCHEDULED MAINTENANCE CHART ................................................................................. 8 - 2

8.1.2

PERIODIC MAINTENANCE OPERATIONS ........................................................................... 8 - 8

8.1.2.1

Drive unit ..................................................................................................................................8 - 8

8.1.2.1.1

Checking the condition of the drive belts .................................................................................8 - 8

8.1.2.1.2

Tensioning the forming unit transmission belts ........................................................................8 - 8

8.1.2.1.3

Replacing the forming unit transmission belts ........................................................................ 8 - 8

8.1.2.1.4

Tensioning the insertion unit transmission belt ........................................................................8 - 8

8.1.2.1.5

Replacing the insertion unit transmission belt ........................................................................ 8 - 9

8.1.2.1.6

Checking the oil level in the forming unit’s geared motor ........................................................8 - 9

8.1.2.1.7

Changing the oil in the forming unit’s geared motor ............................................................... 8 - 9

8.1.2.2

50 kg/h Extruder .................................................................................................................... 8 - 11

8.1.2.2.1

Overhauling the extruder auger ............................................................................................ 8 - 11

8.1.2.2.2

Checking the oil level in the extruder geared motor and topping up .................................... 8 - 12

8.1.2.2.3

Changing the oil in the extruder geared motor ..................................................................... 8 - 12

8.1.2.2.4

Cleaning the nozzle ............................................................................................................... 8 - 12

8.1.2.2.5

Checking and setting pressure transducers BP1 and BP2 ................................................... 8 - 14

8.1.2.3

100 kg/h Extruder .................................................................................................................. 8 - 16

8.1.2.3.1

Overhauling the extruder auger ............................................................................................ 8 - 17

8.1.2.3.2

Checking the oil level in the extruder geared motor and topping up .................................... 8 - 18

8.1.2.3.3

Changing the oil in the extruder geared motor ..................................................................... 8 - 18

8.1.2.3.4

Cleaning the polymer metering pump ................................................................................... 8 - 18

8.1.2.3.5

Replacing/overhauling the polymer metering pump ............................................................. 8 - 18

8.1.2.3.6

Lubricating the universal joint ............................................................................................... 8 - 19

8.1.2.3.7

Cleaning the nozzle ............................................................................................................... 8 - 19

8.1.2.3.8

Checking and setting pressure transducers BP1 and BP2 ................................................... 8 - 19

8.1.2.3.9

Checking the condition and tensioning the extruder drive belt ............................................. 8 - 21

8.1.2.3.10 Tensioning the extruder drive belt ......................................................................................... 8 - 21
8.1.2.3.11 Replacing the extruder drive belt .......................................................................................... 8 - 21
8.1.2.4

150-200 kg/h Extruder ........................................................................................................... 8 - 22

8.1.2.4.1

Overhauling the extruder auger ............................................................................................ 8 - 23

8.1.2.4.2

Checking the oil level in the polymer metering pump geared motor and topping up ........... 8 - 24

Summary of Contents for CCM001

Page 1: ...NTATION DOCUMENTATION TECHNIQUE TECHNISCHE 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 USER S MANUAL 002AZ001A ROTARY HYDRAULIC COMPRESSIO...

Page 2: ...002AZ001A 0 2 TABLE OF CONTENTS...

Page 3: ...F CONTENTS 002AZ001A USER S MANUAL ROTARY HYDRAULIC COMPRESSION PRESS CCM 001 MANUFACTURER SACMI IMOLA Via Selice Provinciale 17 A 40026 IMOLA Bologna ITALIA PUBLISHED ON 25 10 2001 VERSIONS CCM001000...

Page 4: ...002AZ001A 0 4 TABLE OF CONTENTS...

Page 5: ...3 Insertion drum unit 2 11 2 1 1 4 Forming unit 2 14 2 1 1 5 Exit channel 2 17 2 1 1 6 Pneumatic system 2 17 2 1 1 7 Hydraulic system 2 17 2 1 1 8 Cooling system 2 17 2 1 1 9 Electric system control b...

Page 6: ...ION 4 1 4 1 SHIPPING AND HANDLING 4 1 4 2 POSITIONING 4 4 4 3 CONNECTIONS AND HOOK UPS 4 5 4 3 1 CONNECTING THE EXTRUDER TO THE PRESS 4 5 4 3 2 HYDRAULIC CONNECTION FROM THE POWER UNIT TO THE PRESS 4...

Page 7: ...nit transmission belt 8 8 8 1 2 1 5 Replacing the insertion unit transmission belt 8 9 8 1 2 1 6 Checking the oil level in the forming unit s geared motor 8 9 8 1 2 1 7 Changing the oil in the forming...

Page 8: ...5 18 Tensioning belt B 8 34 8 1 2 5 19 Replacing the toothed belt B 8 35 8 1 2 5 20 Lubricating the gears 8 35 8 1 2 6 Forming unit 8 36 8 1 2 6 1 Cleaning 8 37 8 1 2 6 2 Overhauling the actuator valv...

Page 9: ...lant 8 47 8 1 2 11 3 Cleaning the filters 8 47 8 1 2 11 4 Changing the coolant 8 47 8 1 2 12 Safety devices 8 48 8 1 2 12 1 Checking the efficiency of the safety devices 8 48 8 1 2 13 Air injection de...

Page 10: ...002AZ001A 0 10 TABLE OF CONTENTS...

Page 11: ...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 12: ...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 SUPPLEMENTS Informa...

Page 13: ...P Risk of explosion E0015 Keep a safe distance away WARNING SYMBOLS E0001 Never perform maintenance or lubrication operations on moving parts E0034D O2 Do not use oxygen to recharge the accumulators A...

Page 14: ...002AZ001A 1 4 1 GENERAL INFORMATION T2525 1 8 MACHINE IDENTIFICATION PLATE...

Page 15: ...serted inside the dies A hydraulic system is employed to close the dies at a pressure that can be regulatedwhiletheproductioncycleisbeingperformed Thetimerequiredforcoolingdownisstrictlyrelatedtothesp...

Page 16: ...re 2 1 OVERALL VIEW 1 7 14 6 4 13 11 3 2 1 Extruder 2 Metering pump 3 Feed tube 4 By pass system 5 Drive unit 6 Insertion drum 7 Forming unit 8 Pneumatic system 9 Hydraulic system 10 Cooling system 11...

Page 17: ...lled The unit includes an extruder 1 metering pump 2 a heated feed tube 3 and a by pass system 4 In order to compensate for any thermal expansion and to allow maintenance to be carried out the unit is...

Page 18: ...1 and is pushed in the cylinder 2 by the auger 3 through the four thermal conditioning zones The auger is driven by a geared motor 4 The zones are supplied with heating elements and electric cooling...

Page 19: ...002AZ001A 2 5 MACHINE FEATURES 2 Figure 2 1 1 1 B 100 kg h EXTRUDER 1 Hopper 2 Cylinder 3 Auger 4 Extruder gearbox T1544 2 1 3 4...

Page 20: ...002AZ001A 2 6 2 MACHINE FEATURES T1702 Figure 2 1 1 1 C 150 200 kg h EXTRUDER 1 Hopper 2 Cylinder 3 Auger 4 Hydraulic motor 5 Motor pump unit 6 Tank 1 3 4 2 6 5...

Page 21: ...geared motor M8 towards a delivery flange 7 The latter then sends the material to the feed tube The pressures of the suction and delivery lines of the material is controlled by transducers BP1 and BP...

Page 22: ...ure by heating elements EH8 The temperature is measured by thermocouple BT8 In some cases the feed tube can be supplied with a mixer which sees that the characteristics and temperature of the molten m...

Page 23: ...n unit or discharge the material into the waste container The melt is fed through a flange 1 and can either be carried to a nozzle 3 where it is extruded or to the discharge outlet 4 depending on the...

Page 24: ...ransmits motion to the entire machine This unit includes a epicyclic geared motor M9 mounted on the vertical axis a handwheel 2 to carry out operations in manual mode a cogged belt 3 that drives the f...

Page 25: ...e pivot point is controlled by a pneumatic cylinder 11 The pivot unit includes a connecting rod 13 that holds up the insertion unit The wheel 31 that receives motion from the drive shaft through wheel...

Page 26: ...rum pivot point 10 Support unit 11 Pneumatic cylinder 13 Connecting rod 14 Tensioner 15 Toothed belt 16 Stripper wheel 19 Air duct for pellet insertion 20 Air duct for pellet ejection 21 Insertion dru...

Page 27: ...nit disk 23 Cutter 23A Insertion nozzle 23B Body 23C Cutter 23D Screw 24 Distributor 25 Pulley 26 Wheel drive mechanism 26A Shaft 26B Sleeve 26C Toothed wheel 26D Toothed wheel 26E Toothed wheel 26F T...

Page 28: ...is mounted on the upper drum body 13 The relative rod 14 that drives the devices used for stripping the product is found inside each cartridge A fork 15 whose task is to act on the stripper is keyed t...

Page 29: ...002AZ001A 2 15 MACHINE FEATURES 2 T2493 Figure 2 1 1 4 A FORMING DRUM 5 13 12 17 15 9 8 2 7 11 4 3 10 18 14 A A 1 25 6 19...

Page 30: ...002AZ001A 2 16 2 MACHINE FEATURES T2529 Figure 2 1 1 4 B TOOL WITH CENTRAL DRIVE 5 25 12 13 19 15 9 2 8 7 10 11 4 1 3 14 18 A 6 17 21 A...

Page 31: ...a long service life An oil flow control unit mounted on the machine that is fitted with two flow rate control valves provided with a graduated scale In addition a pressure control valve for the actua...

Page 32: ...mode selector on the control panel to select the desired mode of operation UNINTENDED AND PROHIBITED OPERATIONS The machine must be used only for the tasks it was expressly designed for unless otherw...

Page 33: ...001A 2 19 MACHINE FEATURES 2 2 2 OVERALL DIMENSIONS Figure 2 2 A OVERALL DIMENSIONS WITH 50 kg h EXTRUDER 1350 2200 2100 800 990 200 1680 365 520 1400 Y T2569 3140 1000 VOLT Y 440 415 380 5480 480 220...

Page 34: ...002AZ001A 2 20 2 MACHINE FEATURES Figure 2 2 B OVERALL DIMENSIONS WITH 100 kg h EXTRUDER 2200 1350 1650 450 400 300 1815 3245 T2496 Y VOLT Y 440 415 380 5670 480 220 6070...

Page 35: ...002AZ001A 2 21 MACHINE FEATURES 2 Figure 2 2 C OVERALL DIMENSIONS WITH 150 kg h EXTRUDER 1720 1380 2200 300 3510 3520 450 1430 905 T2511 5680...

Page 36: ...002AZ001A 2 22 2 MACHINE FEATURES Figure 2 2 D OVERALL DIMENSIONS WITH 200 kg h EXTRUDER 2230 1380 1780 800 450 1430 540 3510 T2495 4045 5680...

Page 37: ...l 10 10 10 10 Syneco FTR S protective fluid 4 4 4 4 Temperature 10 C 10 C 10 C 10 C Pressure MPa 0 3 0 3 0 3 0 3 Flow rate l 1 90 115 145 168 Average consumption 10 C l 1 75 95 120 140 PRODUCT Type of...

Page 38: ...each machine on which the processing parameters for the selected material are given In addition this data can be stored and called up whenever the material handled is changed E0004P ATTENTION If mate...

Page 39: ...the floor P2 Noisiest position of the ideal machine perimeter measured at a distance of 1 meter from the surface of the machinery LbA Background noise level LpA Continuous A weighted sound pressure l...

Page 40: ...mp C Diametro Diameter mm Tranciante Cutter holder Tipo Type Larghezza Width mm Altezza coltello mm Giostra dosatrice Insertion unit Coltello Cutter Tipo Type Fase meccanica mm Soffio inserim Insertio...

Page 41: ...ressure regulator Air injection in dies 10 Shut off valve and pressure gauge 11 Accumulator 12 Die injection valve SP1 Pressure switch Mains pressure SP7 Pressure switch Machine air supply YV1 2 Solen...

Page 42: ...002AZ001A 2 28 2 MACHINE FEATURES Figure 2 4 1 A AIR SUPPLY SYSTEM DRAWING T2567 11 SP1 PA SP7 YV17 1 2 3 10 YV33 YV4 YV3 4 5 YV6 YV25 26 YV22 YV23 YV9 9 12 YV1 2 EV...

Page 43: ...002AZ001A 2 29 MACHINE FEATURES 2 T2516 T2512 Figure 2 4 1 B LAYOUT OF ELEMENTS IN THE AIR SUPPLY SYSTEM YV9 YV22 YV1 2 YV23 YV6 YV25 26 9 SP7 SP1 YV17 YV3 1 YV33 YV4 12 2 10...

Page 44: ...rcuit 8 Non return valve High pressure circuit 9 Pressure gauge Low pressure 10 Pressure gauge High pressure 11 Accumulator High pressure 12 Accumulator Low pressure 13 Control valve High pressure 24...

Page 45: ...002AZ001A 2 31 MACHINE FEATURES 2 Figure 2 4 2 A HYDRAULIC SYSTEM DIAGRAM A B T R B A C 23 22 21 16 18 17 15 YV30 19 20 10 11 SP6 12 9 YV21 8 6 YV27 7 13 M1 3 2 1 4 SP4 5 M4 1 14 BT10 SL2 T T2576...

Page 46: ...2 32 2 MACHINE FEATURES T2498 T2523 T2520 T2522 Figure 2 4 2 B LAYOUT OF ELEMENTS IN HYDRAULIC SYSTEM A B B A 21 16 23 22 14 11 12 M1 19 20 15 17 18 YV30 SL2 12 11 SP6 YV27 6 13 9 10 M4 M1 BT10 5 YV2...

Page 47: ...ent Extruder and hydraulic power unit temperature control circuit M18 Pump motor Lower tools temperature control M19 Pump motor Upper tools temperature control M20 Pump motor Extruder and hydraulic po...

Page 48: ...EATURES Figure 2 4 3 A LAYOUT OF ELEMENTS IN COOLING SYSTEM T2568 A T T E 15 14 T B 13 D C US UI YV20 BT20 SP20 16 YV19 SP19 BT19 16 YV18 SP18 BT18 16 17 R M R M R M SP3F YV29 YV28 SP2F 8 8 9 10 YV5 Y...

Page 49: ...CHINE FEATURES 2 T2522 T2500 Figure 2 4 3 B LAYOUT OF ELEMENTS IN COOLING SYSTEM 11 YV7 12 6 8 8 YV29 YV28 SP2F SP3F T1574 9 10 T1590 YV5 E B D C C T2510 EH19 YV19 YV20 EH20 EH18 YV18 16 BT20 BT18 BT1...

Page 50: ...002AZ001A 2 36 2 MACHINE FEATURES...

Page 51: ...sible for any injury to personnel or damage to the machine resulting from failure to observe these precautions or use the safety devices provided 3 1 2 SAFETY DEVICES INSTALLED 3 1 2 1 Shutdown device...

Page 52: ...utton on the control panel to release it Emergency stop button on the switchboard control panel It is installed on the switchboard control panel in the position shown in the figure Operation manual Ef...

Page 53: ...ntal plane whatever the type of equipment being used To facilitate the lifting and handling operations use bars levers and ramps from a safe distance Never use your hands The person in charge must hav...

Page 54: ...ng the machine must always be kept free of obstacles clean dry and well lit The lighting in the areas around the machine and in particular in the work zone should be efficient and have a level of illu...

Page 55: ...safety accident prevention specific for the type of product handled by the machine in force in the country where the machine is installed Operator tasks The operator is only authorised use the contro...

Page 56: ...aff should perform is to reset the circuit breakers E0017 When working on the machine never climb up on any part other than the service floor or ladders The machine guards and enclosing barriers are n...

Page 57: ...or make checks when the machine is shut down under emergency conditions E0004P WARNING When the extruder needs to be serviced or repaired after reaching its operating temperature always use adequate g...

Page 58: ...ollow the instructions given in Chapter 8 in the CHECKING THE ACCUMULATOR PRE CHARGE paragraph Use suitable safety devices Thoroughly clean the entire machine especially the working parts and if neces...

Page 59: ...cturer shall not be held responsible for any property damage or personal injury resulting from failure to observe current safety precautions regarding lifting and handling materials inside the factory...

Page 60: ...002AZ001A 4 2 4 INSTALLATION Figure 4 1 A DIMENSIONS AND WEIGHTS kg 4600 1650 1700 2050 1 11 13 L 1000 14 L 2400 12 T1548 6 4 8 15 16 10 9 19 L 1500 L 1800 kg 450 3 17 kg 320 18 kg 520...

Page 61: ...bes and accessories 13 Slings for lifting press 14 Slings for lifting electrical cabinet 15 Extruder feeder 16 Feed hopper 17 Temperature regulator 18 Chiller 19 Extruder lift slings 2 1 T2530 1800 13...

Page 62: ...4 2 Position the press 1 Put the extruder tracks 6 in place Place the extruder 2 on the tracks Install the extruder connecting tube 4 making sure the coupling flange is clean Tighten the nuts and bol...

Page 63: ...gure 4 3 1 Connect the extruder tube 1 to the flange 2 of the press by using the screws 3 Make sure the mating surfaces are clean Tighten with a torque wrench Refit the tube 1 cover 4 E0004P WARNING B...

Page 64: ...bes with different diameters are used to connect the hydraulic power unit to the press 1 3 4 1 2 Connect the tubes on the hydraulic power unit 1 and press 2 in the order given starting from the bigges...

Page 65: ...d on the hydraulic power unit 2 using a pair of tubes 1 diameter Connect the distribution block 5 to the extruder 3 with the related delivery and return tubes D Figure 4 3 3 HOOKING UP THE COOLANT SYS...

Page 66: ...truder Connect the plastic compound feeder to the pneumatic diverter control unit with the relative hose in the point marked C in the figure The hose must have an inside diameter of 6 mm E0004P WARNIN...

Page 67: ...P TUBO SCAT S TUBO SCAT P ESTR SCAT S ESTR M10 M21 M9 M4 M1 M8 M2 6 1 Electric cabinet 2 Press base 3 Hydraulic power unit 4 Temperature regulator 5 Keyboard 6 Extruder BQ1 Encoder BQ2 Thickness trans...

Page 68: ...Connection to the supply mains The electrical cabinet has to be connected to the supply mains Use a suitably sized four pole cable as indicated in the SPECIFICATIONS paragraph The three wires R S T ar...

Page 69: ...ow to adjust the auxiliary equipment accessories and safety devices and guards employed and trial runs are carried out to check the adjustments made 5 2 PRELIMINARY CHECKS CONDITIONS machine hooked up...

Page 70: ...ic power unit by pressing key 8 Activate the high pressure circuit with key 10 All the actuators will move up except for those found near the control cams for the hydraulic valves Make sure the pressu...

Page 71: ...ing down the hydraulic power unit correspond to those set for the related instruments Wait until the oil has reached the set temperature Wait until the temperature in the various zones of the extruder...

Page 72: ...NDITIONS Machine on and at the correct temperature Guards closed Turn the mode selector on the control panel to AUT Start the automatic cycle by using key 1 5 6 SUBSEQUENT START UPS Perform only the o...

Page 73: ...d Work cycle setting Setting or changing the operating parameters even during the production cycle Display of messages and operating parameters Storage and retrieval of the desired operating parameter...

Page 74: ...002AZ001A 6 2 6 OPERATING INSTRUCTIONS Figure 6 1 CONTROL KEYBOARD C E F G H D A B 24 4 5 6 7 12 13 14 15 19 23 22 21 20 30 30 31 29 26 25 25 27 0 1 2 3 8 9 10 11 18 17 16 T2517...

Page 75: ...SETUP MAN Low pressure on off 28 11 MAN Hydraulic power unit stop 12 SETUP MAN Extruder by pass stop 13 SETUP MAN Insertion drum in on off 28 14 MAN Insertion drum out on off 28 15 MAN Low pressure sw...

Page 76: ...er unit by using key 8 Start the high pressure circuit by using key 10 E0004P WARNING The actuators move slowly up due to the low flow rate of the hydraulic fluid but exert the forming force once they...

Page 77: ...ed out by the machine during an automatic cycle are shown in the flow chart below 1 Cycle start key is pressed 2 Start of plasticization Start of rotation Actuators start 3 Drum speeds up to reach req...

Page 78: ...M to be inserted PRODUCT REMOVAL The formed product PS is removed from the stripper ring ES and placed on the stripper wheel SE which carries it to the exit channel CONTROL STAGES 29 START OF FORMING...

Page 79: ...Punch SE Stripper wheel Figure 6 4 B PRODUCTION CYCLE A Valve down oil at high pressure B Valve in first position upwards oil at low pressure C Valve in second position upwards oil at high pressure GI...

Page 80: ...1 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 GS GI A B C C C C A T1598 B B A 30 17 C C C C C C C C C C C A A A C C C C C C C C C C C C 16 15 14 13 12 11 10 2...

Page 81: ...ly cause is the product is jammed between the tools DIAGRAM 1 actuator is detected up 2 stoppage with forming drum motor brake insertion drum inactivated by pass opening hydraulic power drained 3 plas...

Page 82: ...or secured to the base detects any incomplete forming strokes If this sensor is activated by the measurement rod the machine performs the emergency cycle illustrated in the flow chart below DIAGRAMMA...

Page 83: ...trated in the flow chart below DIAGRAM 1 double product detected 2 pellet insertion in die in question stopped product ejected 4 feed restarted next detection die empty 3 next detection double product...

Page 84: ...the emergency cycle illustrated in the flow chart below DIAGRAM 1 heavy light product detected 2 counter for empty heavy light product per run is activated start of delay time for stoppage due to def...

Page 85: ...ted in the flow chart below DIAGRAM 1 incorrect position detected 2 error counter per run activated counter control 32 3 start of delay time for stoppage due to defective product yellow warning light...

Page 86: ...ERATING INSTRUCTIONS 6 6 PRODUCT SAMPLING Press key 34 see figure 2 1 1 3 to obtain samples consisting of several finished caps The conveyor is used for this purpose As a result the quality of the pro...

Page 87: ...e never set the extruder motor to a speed higher than the speed used for the metering pump This may cause over pressure in the pump suction line consequently shutting down the machine 7 1 2 METERING P...

Page 88: ...TTENTION Refer to the Instructions B manual for the control system for information on how to set the parameters 7 1 4 BY PASS SYSTEM Adjusting the operating parameters The parameters that can be set a...

Page 89: ...the upper eccentric pin 11 or 16 located at the end of the connecting rod 9 Push the insertion drum inside the forming drum by hand As a result the pin 11 will be under the back plate 12 Place the mag...

Page 90: ...turn the drums clockwise until one of the 4 cutters 23B is in the middle of the nozzle orifice Loosen the two screws 23D M3x8 mm that secure the cutter blade Place a strip whose thickness is as indic...

Page 91: ...6D 26C 26A 29 26F 26E 26B 21 X mm T2577 13 Connecting rod 16 Stripper wheel 21 Insertion drum 23 Cutter 23A Insertion nozzle 23B Casing 23C Cutter 23D Screw 24 Rotary distributor 26 Wheel drive mechan...

Page 92: ...he drums clockwise until the encoder reads 0 Remove the guard that protects the belt found under the insertion drum s connecting rod Place a 6 mm socket head wrench in the fitting at the bottom of the...

Page 93: ...n parameters are strictly related to the type of material handled as well as other variables Therefore observe the values given on the Data sheet Adjusting the stripper wheel Conditions Mode selector...

Page 94: ...002AZ001A 7 8 7 ADJUSTMENTS T2493 Figure 7 3 FORMING DRUM 5 13 12 17 15 9 8 2 7 11 4 3 10 18 14 A A 1 25 6 19...

Page 95: ...e strippers are mechanically controlled by cams The position of the cams is given on the Data sheet E0004P WARNING Changingthepositionofthestrippercamsamongthemselvesandinrelationtotheactuatorpilotcam...

Page 96: ...nd the reference surface 3 adjust the height of the reference surface 3 tighten the ring nuts 1 close the safety guards and turn the mode key selector to MAN start the hydraulic power unit with the re...

Page 97: ...s parameters on the CCM page of the control display This allows the dimension field within which the product is considered acceptable to be defined The system is able to detect 0 25 mm thickness varia...

Page 98: ...theoretical position and the low pressure oil flow has to be decreased On the other hand if is indicated the actuators are lower than the theoretical position therefore the low pressure oil flow needs...

Page 99: ...re 7 5 PRODUCT REMOVAL ADJUSTMENT 20 Inductive sensors 21 Measurement rod 22 Low pressure adjustment valve 23 High pressure flow control 24 Low pressure flow control 25 High pressure valve 26 Actuator...

Page 100: ...et for the upper and lower tools affect the quality characteristics and dimensions of the caps See the Data sheet for further information 7 7 INSTALLING AND REMOVING THE TOOLING The tooling to be used...

Page 101: ...002AZ001A 7 15 ADJUSTMENTS 7 T1597 Figure 7 7 TOOLING 2 Coolant manifold 4 Nuts 5 Flange 6 Tool cartridge 7 Anti rotation pin 8 Stripper 9 Ring nut 10 Die 11 Support plate 5 6 2 7 8 4 9 10 11...

Page 102: ...plate 17 if necessary Fully tighten the screws 14 Fully tighten the screw 12 Adjusting timing in relation to the stripper wheel Conditions Mode selector turned to set up Adjustments Loosen the screw 1...

Page 103: ...14 Figure 7 8 ADJUSTING THE EXIT CHANNEL 1 Beltwithcompartments 9 Hole for wrench 11 Cam 12 Screw 14 Screw 16 Product 17 Back plate 18 Screw 19 Paddle 20 Wheel compartment 21 Nut 22 Adjuster A B 14 12...

Page 104: ...r to read properly If inductive proximity sensors SQ7 SQ23 SQ21 SQ22 or SQ24 are replaced mark the position of the relative mounts on the base so that they can be put back in the same spot when replac...

Page 105: ...ith the handwheel for manual operations until inductive proximity sensors SQ1 and SQ11 are both activated both of them must be activated Zero set the encoder key turned to set up Turn the unit counter...

Page 106: ...002AZ001A 7 20 7 ADJUSTMENTS...

Page 107: ...ivided as follows routine maintenance to be carried out by the customer s maintenance staff special maintenance to be carried out by the manufacturer s technicians or customer s workers who have been...

Page 108: ...r e d u r t x e n i l i O 2 2 2 1 8 l e v e l k c e h C 5 y r a s s e c e n f i l i o d d A A 0 1 3 2 2 1 8 e g n a h C A 0 5 e l z z o N 4 2 2 1 8 e l z z o n n a e l C 0 1 r e l p u o c e l z z o n...

Page 109: ...j l a s r e v i n U 6 3 2 1 8 e t a c i f i r b u L 0 1 2 P B 1 P B s r e c u d s n a r t e r u s s e r P 8 3 2 1 8 y r a s s e c e n f i t e s d n a k c e h C 3 5 4 h p a r g a r a p S N O I T A C I...

Page 110: ...s s e r P 0 1 3 2 1 8 0 1 4 2 1 8 y r a s s e c e n f i t e s d n a k c e h C 3 5 4 d n a 8 P S h c t i w s e r u s s e r P 8 V Y e v l a v f e i l e r e r u s s e r p 1 1 3 2 1 8 1 1 4 2 1 8 y r a s...

Page 111: ...e s n I y e l l u p 8 1 5 2 1 8 9 1 5 2 1 8 t h g i t f i e e s d n a n o i t i d n o c k c e h C 5 5 1 5 2 1 8 6 1 5 2 1 8 d e r i u q e r f i e c a l p e R 0 2 1 M U R D G N I M R O F t i n u g n i...

Page 112: ...1 8 g n i l p u o c e l b i x e l f r e t l i f l i o e g n a h C F 0 8 2 0 0 3 e v l a v e r u s s e r p b P 9 9 2 1 8 n a e l C 5 1 e v l a v e r u s s e r p h P 0 1 9 2 1 8 n a e l C 5 1 e v l a v...

Page 113: ...f i e c a l p e R 0 4 2 T L E B R O Y E V N O C T I X E T C U D O R P t l e B 1 4 1 2 1 8 2 4 1 2 1 8 t h g i t f i e e s d n a n o i t i d n o c k c e h C 5 3 4 1 2 1 8 y r a s s e c e n f i e c a l...

Page 114: ...he nut 6 Loosen the screw 7 As soon as possible pull the belt 5 off the pulley 8 Loosen the screws 1 Loosen the nut 2 Loosen the screw 3 until the belt 4 can be removed Change the belt 4 Tighten the s...

Page 115: ...ghtening the nuts 11 Fully tighten the screws 10 Install the mount with sensor by tightening the screw 12 Make sure the sensor is activated Time the forming unit insertion unit exit wheel and exit cha...

Page 116: ...002AZ001A 8 10 8 MAINTENANCE 17 18 19 20 16 A A T2513 Figure 8 1 2 1 DRIVE UNIT T2528 12 11 10 6 5 8 7 9 4 1 3 2 13 14 15 21 22...

Page 117: ...and nozzle as soon as possible Remove the filter 1 Take off the cover 6 found on the back of the extruder near the screw axis Put in the fixture 7 While turning it push the screw 8 forwards until it p...

Page 118: ...e caps 31 back on 8 1 2 2 3 Changing the oil in the extruder geared motor Take off caps 31 and 32 wait until all the oil has flown out of the geared motor or thrust block and then put the cap 32 back...

Page 119: ...002AZ001A 8 13 MAINTENANCE 8 T2575 Figure 8 1 2 2 50 kg h EXTRUDER 6 31 33 32 7 8 1 3 17 5...

Page 120: ...ive cables connected BP1 inlet pressure cable XJ98 BP2 outlet pressure cable XJ99 C First of all adjust transducer BP1 D Call up the DATA page on the display E Adjust trimmer N until the display reads...

Page 121: ...002AZ001A 8 15 MAINTENANCE 8 T2580 Figure 8 1 2 2 5 CHECKING AND SETTING PRESSURE TRANSDUCERS BP1 AND BP2 SYSTEM SYSTEM...

Page 122: ...002AZ001A 8 16 8 MAINTENANCE 8 1 2 3 100 kg h Extruder Figure 8 1 2 3 100 kg h EXTRUDER T2535 A A T2532 11 12 1 3 9 6 15 13 17 18 19 20 10 14 23 29 28 30 2 4 7 5 8 16 BT6 8 BT7 21 22...

Page 123: ...ove the heating elements 8 by loosening the mounting screw found under the volumetric pump Loosen the quick connect coupler and take out thermocouples BT6 and BT7 Loosen the screw 9 to loosen the heat...

Page 124: ...il level in the extruder geared motor and topping up Make sure the oil level shown by the gauge 28 is correct If it is not top up as follows Take off the cap 29 Add oil until the correct level 28 is r...

Page 125: ...verhauled or new pump by carrying out the operations in reverse order 8 1 2 3 6 Lubricating the universal joint Take off the cover 21 Clean the universal joint and surrounding areas removing any extru...

Page 126: ...layed should be 80 of the nominal pressure value of the transducer for 0 350 bar transducers the value should be 280 bar If this value is not displayed set trimmer B located on the bottom of the trans...

Page 127: ...the extruder drive belt Loosen the screws 19 with the covers and panels removed Use the screws 20 to move the motor to tension the drive belt Fully tighten the screws 19 Put the covers back in place 8...

Page 128: ...002AZ001A 8 22 8 MAINTENANCE 8 1 2 4 150 200 kg h Extruder Figure 8 1 2 4 150 200 kg h EXTRUDER T2534 12 11 21 22 16 15 17 23 9 3 6 10 4 14 15 20 13 24 T2535 8 29 30 2 7 5 8 28 BT6 BT7 25 26 27...

Page 129: ...g the mounting screw found under the volumetric pump 5 Loosen the quick connect coupler and take out thermocouples BT6 and BT7 Loosen the screw 9 to loosen the heating element Remove the two screws 7...

Page 130: ...0 Remove the plate for the fixture used to remove the auger Tighten the three screws used to secure the plate Install the hydraulic motor 21 Connect the hydraulic lines Turn on the machine with the ma...

Page 131: ...e the thermocouple 15 mounted on the nozzle body Take off the covers that protect the connecting tube 14 Loosen the screws 13 Move the extruder to the end of the guides with the connecting tube attach...

Page 132: ...sducer is installed E0004P ATTENTION The transducers have to be set while the polymer meter pump station is at the operating temperature B Make sure the transducer probes are properly installed and re...

Page 133: ...002AZ001A 8 27 MAINTENANCE 8 Figure 8 1 2 4 10 CHECKING AND SETTING PRESSURE TRANSDUCERS BP1 AND BP2 T2580 SYSTEM SYSTEM...

Page 134: ...switch SP8 to a value higher than the 200 bar indicated on the knob s graduated scale Run the extruder motor at 20 of it speed Adjust pressure relief valve YV8 until the pressure gauge reads 200 bar...

Page 135: ...002AZ001A 8 29 MAINTENANCE 8 8 1 2 5 Insertion drum Figure 8 1 2 5 A INSERTION DRUM T2548 7 8 6 9 D 5 12 10 11 E 4 A 1 2 3 B C 22 41 T2574 F 15 28 27 21 24 25 35 23 H 14 19 16 20 17 18 13 G 26 29...

Page 136: ...002AZ001A 8 30 8 MAINTENANCE Figure 8 1 2 5 B INSERTION DRUM T2552 SURFACE TO BE ADAPTED T2551 40 42 43 4 CORRECT POSITION POSITION WITH BELT SLACKENED...

Page 137: ...he screws 13 and 16 and ring nut 17 Pull out the insertion drum lifting the entire unit up from the cutter holder Loosen the screw 18 at the worktable Take out the cutter holder Loosen the screws 23 a...

Page 138: ...n the ADJUSTING THE CUTTER and ADJUSTING THE PELLET INSERTION STAGE paragraphs in chapter 7 8 1 2 5 9 Checking the precharge of the drum s connecting rod Make sure the connecting rod is charged 0 25 m...

Page 139: ...utter holder Loosen the screws 18 at the worktable Take out the cutter holder Remove the snap ring 19 Remove the wheel G at a worktable with vice Remove the snap ring 20 Take out the shaft 21 at a wor...

Page 140: ...tall the exit conveyor belt and secure it in place with nut 7 Check and time the stripper wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph in chapter 7 8 1 2 5 17 Disassembling...

Page 141: ...the pulleys Tighten screws 40 that secure the tensioner and tighten the nut 4 Install the wheel D and tighten with ring nut 5 Install the safety guard by tightening the screws 3 Install the connectin...

Page 142: ...002AZ001A 8 36 8 MAINTENANCE 8 1 2 6 Forming unit Figure 8 1 2 6 FORMING UNIT T2537 1 4 2 T2553 14 15 13 12 11 6 10 5 8 7 9 3...

Page 143: ...parts back in place Install part 2 being careful not to cut the gaskets Install part 1 by tightening the screws 3 8 1 2 6 3 Greasing the roller Grease the valve roller with grease fittings 4 Use the...

Page 144: ...s in reverse order to put the parts back in place E0004P ATTENTION Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself 8 1 2 6 6 Replacing the lower fl...

Page 145: ...the nut 10 and take out the spacer Loosen the pin 12 Take out the fork 11 and stripper 13 at the same time Raise the rod and grease the cylindrical surface that has just been exposed Push the rod insi...

Page 146: ...002AZ001A 8 40 8 MAINTENANCE 10 9 4 3 8 T2538 1 2 20 19 T2539 17 18 13 15 12 11 14 16 8 1 2 7 Cams Figure 8 1 2 7 CAMS...

Page 147: ...um manually until the part of the drum without any rods corresponds to the stripper cam Loosen the screws 10 Replace the cam 4 Position the cam as indicated on the Data sheet Fully tighten the screws...

Page 148: ...ributor 8 1 2 8 1 Replacing the gaskets Contact SACMI S CUSTOMER SERVICE DEPARTMENT when carrying out this operation 8 1 2 9 Hydraulic system Figure 8 1 2 9 A HYDRAULIC SYSTEM T2542 2 6 14 13 20 23 19...

Page 149: ...002AZ001A 8 43 MAINTENANCE 8 Figure 8 1 2 9 B HYDRAULIC SYSTEM T2565 T2543 39 40 41 42 38 T2555 33 37 31 32 36 35 34 36...

Page 150: ...nce this has been done tighten the clamp 13 Loosen the cartridge type filter 6 and replace it with a new one Carry out the operations in reverse order to put the parts back in place 8 1 2 9 5 Checking...

Page 151: ...with a rag 8 1 2 9 13 Checking the accumulator precharge Make sure there is no pressure in the hydraulic circuit Unscrew the cap found on the side where the inflation valve 38 is installed Unscrew the...

Page 152: ...w 4 found under the filter 1 to let out any extraneous matter for example water created by the condensate 8 1 2 10 2 Cleaning and replacing the silencers Unscrew the silencers 3 and or silencer 2 Blow...

Page 153: ...se the valve 4 Remove the thermocouple 5 Loosen the filter 3 and place a container on the underlying parts to protect them from the fluid that may flow out Remove the filter cartridge and blow air to...

Page 154: ...r manual mode open one of the two protective panels 1 E0004P WARNING The machine must not be running Make sure the GUARDS OPEN fault message appears on the control panel display Close the panels Carry...

Page 155: ...22 when it is not activated by cams 1 and 2 8 1 2 13 2 Replacing the valves Loosen the screws 21 when the valve is not activated to be carried out on the side opposite the operator Detach the air hose...

Page 156: ...paragraph in chapter 7 8 1 2 14 3 Replacing the belt Loosen the nut 29 Loosen the screws that secure the guard 31 and take off the guard Loosen the screw 30 until the belt can be removed from the pull...

Page 157: ...ing point 200 C Worked penetration DIN 51804 300 dmm Dynamic toughness 7000 mPas G Density at 20 C 0 92 Dropping point DIN ISO 2176 250 C Worked penetration DIN ISO 2137 310 340 dmm Dynamic toughness...

Page 158: ...8 1 16 1 96 4 89 6 30 8 73 14 74 22 49 34 36 43 25 60 43 73 16 100 9 V 613 1006 1412 2613 3460 4179 6042 8328 11377 13998 17830 22238 26000 FINE THREAD SCREWS DIAMETER mm 8 10 12 14 16 18 20 22 24 THR...

Page 159: ...he Instructions B manual for information on how to locate and clear the trouble If safety devices come into action reset the machine as described in chapter 6 OPERATING INSTRUCTIONS However the follow...

Page 160: ...essure flow rate Actuator gasket worn Coupling gasket worn Rpm of polymer metering pump incorrectly set too high Insertion drum transmission worn Incorrect reject threshold The related hydraulic valve...

Page 161: ...e Hydraulic accumulator precharge decreased Thermostatic valve incorrectly set Coolant temperature incorrect Thehydraulicvalveusedtomovethe actuators up is stuck in the open position Plastic compound...

Page 162: ...002AZ001A 8 56 8 MAINTENANCE...

Page 163: ...sure from the accumulators by using the tester inflator provided Follow the instructions given in Chapter 8 in the CHECKING THE ACCUMULATOR PRE CHARGE paragraph Thoroughly clean the machine paying par...

Page 164: ...002AZ001A 9 2 9 DECOMMISSIONING...

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Sacmi CCM001, User Manual

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