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Sacmi PMV 224, Maintenance And Operation Manual

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176.12

.A03

Revision 01 Date 14.11.2001

GENERAL INFORMATION

1

1.5

WARRANTY

SACMI shall be held responsible only for the machine as it was configured at the time of delivery.
Any operations that alter the configuration of the machine or operating cycle must be carried out by SACMI personnel
or duly authorized by SACMI’S Engineering Dept.
SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.

E0004

 ATTENTION!

The machine operator or maintenance staff are not responsible for carrying out operations under warranty, special
maintenance 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

SUPPLEMENTS

Information regarding the electric and electronic components of the machine are given in three handbooks provided
under separate cover and entitled:
- USE OF THE MICROPROCESSOR CONTROL SYSTEM (Instructions B manual)
- DESCRIPTION OF THE ELECTRONIC CARDS
- LIST OF DEVICES

These handbooks are supplied with this manual.

Summary of Contents for PMV 224

Page 1: ... TECHNIQUE TECHNISCHE DOKUMENTATION DOCUMENTACION TECNICA DOCUMENTAÇAO TÉCNICA D O C U M E N TA Z I O N E T E C N I C A MAINTENANCE AND OPERATIONS MANUAL 176 12 A03_01 MACHINE FOR FORMING LINERS INSIDE PLASTIC CAPS PMV 224 PMV 238 ENGLISH ...

Page 2: ...TABLE OF CONTENTS 176 12 A03 0 2 Revision 01 Date 14 11 2001 ...

Page 3: ...UAL MACHINE FOR FORMING LINERS INSIDE PLASTIC CAPS PMV 224 PMV 238 MANUFACTURER SACMI IMOLA Via Selice Provinciale 17 A 40026 IMOLA Bologna ITALIA PUBLISHED ON 30 10 2000 REVISION 01 14 11 2001 VERSIONS PMV 224 00 000 001 PMV 224A PMV 238 00 002 003 PMV 238A SERIAL NUMBER YEAR OF MANUFACTURE ...

Page 4: ...TABLE OF CONTENTS 176 12 A03 0 4 Revision 01 Date 14 11 2001 ...

Page 5: ...NSFER UNIT 2 6 2 1 1 6 QUALITY CONTROL UNIT 2 6 2 1 1 7 DISCHARGE UNIT 2 7 2 1 1 8 EXIT CONVEYOR BELT 2 7 2 1 1 9 DRIVE UNIT MANUAL OPERATION 2 8 2 1 1 10 PNEUMATIC SYSTEM 2 9 2 1 1 11 COOLING SYSTEM 2 9 2 1 1 12 ELECTRICAL SYSTEM CONTROL PANEL 2 9 2 1 1 13 TOOLS 2 9 2 1 2 INTENDED PROHIBITED USE AND MISUSE OF THE MACHINE 2 10 2 2 OVERALL DIMENSIONS 2 11 2 3 MACHINE SPECIFICATIONS 2 13 2 3 1 TECHN...

Page 6: ...S 3 2 3 2 SAFETY RULES FOR HANDLING 3 3 3 2 1 LIFTING PROCEDURES 3 3 3 2 2 HANDLING PROCEDURES 3 3 3 2 3 PLACING THE LOAD 3 3 3 3 INSTALLATION 3 4 3 3 1 GENERAL RULES 3 4 3 4 OPERATOR TRAINING 3 5 3 4 1 END USER 3 5 3 4 2 OPERATORS 3 5 3 4 3 MAINTENANCE STAFF 3 5 3 5 SAFETY PRECAUTIONS FOR OPERATING ADJUSTING AND SERVICING THE MACHINE 3 6 3 5 1 GENERAL SAFETY RULES 3 6 3 5 2 GUIDELINES FOR OPERATI...

Page 7: ...0 4 3 1 4 AUXILIARY CIRCUIT COOLING TANK COOLING TANK AND PLUNGER HEATER 4 10 4 3 2 CONNECTING THE PNEUMATIC SYSTEM 4 11 4 3 2 1 PNEUMATIC UNIT 4 11 4 3 2 2 PLASTIC COMPOUND FEEDER 4 11 4 3 2 3 EXTRUDER HEAD PLUNGER 4 11 4 3 3 CONNECTIONS TO THE VACUUM SYSTEM 4 12 4 3 3 1 PLASTIC COMPOUND FEEDER 4 12 4 3 3 2 VACUUM PUMP 4 12 4 3 3 3 WASTE AND BURR SUCTION SYSTEM 4 13 4 3 4 INSTALLING THE PROXIMITY...

Page 8: ...R FOR DOUBLE LINERS 7 21 7 5 5 ADJUSTING THE QUALITY CONTROL UNIT 7 23 7 5 6 SENSITIVITY LEVEL ADJUSTMENT 7 25 7 5 7 ADJUSTING THE DEFECTIVE PRODUCT CONTROL DEVICES 7 25 7 6 DISCHARGE CONVEYOR BELT ADJUSTMENT 7 26 8 MAINTENANCE 8 1 8 1 SCHEDULED MAINTENANCE 8 2 8 1 1 SCHEDULED MAINTENANCE CHART 8 2 8 1 2 SCHEDULED MAINTENANCE 8 6 8 1 2 1 REMOVING AND CLEANING THE EXTRUDER AUGER AND FILTER 8 6 8 1 ...

Page 9: ... Always keep 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 MANUAL The lay out of this manual allows it to be easily consulted as all the information and instructions provided are grouped together and divided into chapters and paragraphs The user ...

Page 10: ...04 ATTENTION The machine operator or maintenance staff are not responsible for carrying out operations under warranty special maintenance 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 SUPPLEMENTS Information regarding the electric and electronic components of t...

Page 11: ...eneral hazard Danger of being burnt by hot surfaces Danger of getting your hands crushed Danger of electrocution Risk of serious injury Risk of entanglement in moving parts Danger of falling Keep a safe distance away WARNING SYMBOLS Never perform maintenance or lubrication operations on moving parts E0004 E0002 E0003 E0007 E0011 E0010 E0017 E0015 E0001 ...

Page 12: ... 11 2001 GENERAL INFORMATION 1 T2450 FIGURE 1 8 LOCATION OF THE MACHINE IDENTIFICATION PLATE E0005 E0006 ALERT SYMBOLS Heavy duty work gloves must be worn The point indicated must be effectively earthed 1 8 MACHINE IDENTIFICATION PLATE ...

Page 13: ...l system and the resulting product is checked for quality The main parts of the machine are indicated in the illustration below The machine can be equipped with a vision system for inspecting the top crown skirt liner and bottom decoration of the caps Detailed instructions regarding the vision system are found in the relevant manual 1 Extruder 2 Drive unit 3 Insertion drum 4 1st transfer drum 5 Fo...

Page 14: ... backwards and forwards to allow for expansion of the plasticization unit When the mounting bolts which secure it to the machine base are removed the unit and extruder can be moved sideways making it easier to carry out maintenance The extrusion head 8 and nozzle 9 that the molten material flows out from as well as the bypass valve 10 used to discharge the material through an auxiliary outlet port...

Page 15: ...pellets The cutter holds the pellets brings them down to the caps and puts them in This vertical movement is performed thanks to the cams provided The size and shape of the cutters is closely related to the type of the plastic material used This is normally determined during machine commissioning After the cutter has nearly come into contact with the bottom of the cap the pellet is pushed against ...

Page 16: ...s from the insertion to the forming drum To do this the caps are held in place between the transfer wheels adjustable and external guides When in the section that leads to the forming unit the caps are held in place from the top by a cover 3 2 2 1 0 7 1 Wheel 2 Guide 3 Cover T0632 FIGURE 2 1 1 3 1ST TRANSFER UNIT ...

Page 17: ...ains the spindles that hold the caps 1 The latter move vertically The caps are placed on the lower spindles 1 by the transfer turntable While the forming drum rotates the lower spindles are raised by a cam 3 bringing the hot pellet against the forming plungers 2 thereby forming the liners The profile of the liner depends on the shape of the forming tools installed FIGURE 2 1 1 4 FORMING UNIT 1 Low...

Page 18: ...ated in cylindrical bores equally spaced apart around the periphery of the body 2 Sensors 3 are secured to the bottom of the spindles while the spindles are attached to a cam 4 on the top The cam moves the spindles up and down While the unit rotates the sensors are moved down and come into contact with the caps checking them for any defects A mechanical and vacuum operated system is employed for t...

Page 19: ...rries them in an orderly manner to the area where they enter the next machine in line Solenoid valve YV4 sees that any defective products are ejected into the relative conveyor 1 Sample caps can be obtained through the conveyor 2 by pressing the relative button on the belt to activate solenoid valve YV11 The air operated diverter 3 allows the flow of outgoing caps to be directed as required with t...

Page 20: ...tor coupled with a worm reduction unit 1 An inverter is used to control the unit A slip clutch 2 mounted on the output shaft of the geared motor 1 disengages the reduction gear if the machine stops abruptly NOTE The slip clutch is set during machine inspection Further adjustments are not required A spindle is mounted at the back of the electric motor 3 The handwheel 4 can be fitted on it to operat...

Page 21: ...the following parts Extruder Forming unit The system includes a chiller optional which supplies liquid at a low temperature to the temperature control tanks The latter deliver the cooling fluid at the correct flow rates and at a controlled temperature specifically suited for each point of use 2 1 1 12 Electrical system control panel All information regarding the control panel is given in chapter 6...

Page 22: ...l automatic To enable the desired mode of operation use the relevant selector switch located on the control panel UNINTENDED AND PROHIBITED OPERATIONS No other tasks except those specified by the Manufacturer are to be performed For this reason the Manufacturer shall not be held responsible for the consequences deriving from the failure to observe the instructions contained herein MISUSE The manuf...

Page 23: ...1 2001 MAIN FEATURES 2 2 2 OVERALL DIMENSIONS FIGURE 2 2 A PMV 224 OVERALL DIMENSIONS WITH CABINET ON RIGHT HAND SIDE AND 20 KG H EXTRUDER 1940 1200 150 800 2020 1220 1000 2750 785 415 001 900 520 500 60 438 1330 1945 20 50 1023 2073 T2428 ...

Page 24: ... 11 2001 2 MAIN FEATURES FIGURE 2 2 B PMV 224 PMV 238 OVERALL DIMENSIONS WITH CABINET ON RIGHT HAND SIDE AND 40 KG H EXTRUDER 1023 250 50 20 50 1000 2750 785 500 1220 520 415 001 2020 800 1200 60 150 438 900 1940 173 2073 1915 1330 T2427 ...

Page 25: ... 5 0 5 POWER Heat to be dissipated 1 kcal h 25 000 25 000 25 000 Power requirements 50Hz kVA 51 62 62 Power requirements 60Hz kVA 57 70 70 Average power absorbed 50Hz kW 12 14 14 COOLANT Water 60 60 60 Propylene glycol 40 40 40 Flow rate l min 60 70 60 70 60 70 Pressure MPa 0 25 0 3 0 25 0 3 0 25 0 3 TOTAL WEIGHT 2 kg 4700 5200 5200 1 At a room temperature of 28 C and temperature of coolant at 0 C...

Page 26: ...LLOWABLE FLUCTUATION OF THE VARIABLES ELECTRIC Voltage 10 Frequency 2 PNEUMATIC Flow rate 15 Minimum pressure 0 5 MPa Maximum pressure 1 MPa COOLANT Flow rate 10 Pressure 20 10 FIGURE 2 3 3 LOCATION OF THE RATING PLATE 2 3 3 RATING PLATE E0012 V N Com Hz Cod In A T2506 ...

Page 27: ...must fall within the values given in the figure TYPE OF PLASTIC COMPOUNDS The machine can handle the following thermoplastic compounds POLYETHYLENE ETHYL VINYL ACETATE PVC free The machine needs to be set up in different ways according to the specific material in use Sometimes special parts are required FIGURE 2 3 4 PRODUCT SPECIFICATIONS The values in the figure are given for reference purposes o...

Page 28: ...t environment factory with reflecting flooring Instruments employed Class 1 instruments IEC 804 Values measured A Points measurements are taken from B Reference points C PMV D ATV 60 C P1 P2 FIGURE 2 3 5 NOISE LEVELS A D B P1 Control post measured 1 55 m from the floor P2 Noisiest position of the ideal machine perimeter traced a meter from it LbA Background noise level LpA Acoustic pressure emitte...

Page 29: ... operation plastic liner formation for plastic caps Operating cycle material feed and cap formation Test environment factory with reflecting flooring Instruments employed Class 1 instruments IEC 804 Results LpA LwA dB A dB A PM 224 86 5 107 PM 238 85 7 106 0 LpA Surface acoustic radiation pressure in dB weighted A LwA Acoustic power level in dB weighted A ...

Page 30: ...lve Extruder YV8 Solenoid valve Vortex YV9 Solenoid valve Blower manifold YV10 Solenoid valve Blower for ejecting defective pellets YV12 Solenoid valve Air blown to pick up sample caps YV16 Solenoid valve Compound cutter if provided YV18 Solenoid valve Cylinder used to check for overturned caps if provided YV30 Solenoid valve Air blown for ejecting defective caps YV101 Solenoid valve Air blown for...

Page 31: ...Chiller 2M Delivery manifold Cooling lines 2R Return manifold Cooling lines 3 Cooling tank Plunger fluid heater 4 Cooling tank Auxiliary circuit fluid 5M Delivery manifold Auxiliary circuit 5R Return manifold Auxiliary circuit 6 Plastic compound cutter 7 Area for loading plastic compound into extruder 8 Forming cam 9 Forming drum ...

Page 32: ...ines 3 Cooling tank Plunger fluid heater 4 Cooling tank Auxiliary circuit fluid 5M Delivery manifold Auxiliary circuit 5R Return manifold Auxiliary circuit 6 Plastic compound cutter 7 Area for loading plastic compound into extruder 8 Forming cam 9 Forming drum FIGURE 2 4 2 B LAYOUT OF COOLING SYSTEM T2446 1 7 5M 5R 4 6 2M 2R 3 8 7 9 ...

Page 33: ...SYSTEM LAYOUT 1 Pump 2 Manifold 3 Vacuum switch 4 Vacuum meter 5 Rotary distributor GIOSTRA DI SCELTA TRASPORTO TAPPI GIOSTRA DI SCELTA CONTROLLO TAPPI GIOSTRA FORMATRICE ASPIRAZIONE ARIA NELLO STAMPO 1 2 3 4 2 5 1 2 3 4 2 5 B B A A QUALITY CONTROL UNIT CAP CONVEYANCE QUALITY CONTROL UNIT CAP CONTROL ...

Page 34: ...2 22 176 12 A03 Revision 01 Date 14 11 2001 2 MAIN FEATURES ...

Page 35: ... be held responsible 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 devices The shutdown devices signal any malfunctioning and stop the machine or prevent it from being started up 3 1 2 2 Indicating a shutdown Each time a fault arises causing the machine to s...

Page 36: ...ary electric system and solenoid valve control system is cut off Reset from control panel turn the button to release it Emergency stop button on the control panel This is located on the control panel in the position indicated in the illustration Operation manual Action the drive system and machine motors except those for the vacuum and suction pumps required to transport the product stop immediate...

Page 37: ...perfectly horizontal 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 have a clear view of where the machine is to be moved give instructions to the crane operator from a position where he she can be clearly seen stop the operation immediately if dangerous ...

Page 38: ...e area surrounding 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 illumination not less than 300 lux The customer must make sure that fire fighting equipment is provided in the area where the machine is installed and that there is a system for protection...

Page 39: ... and on the job 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 controls and instruments provided on the machine s control panel 3 4 3 MAINTENANCE STAFF The maintenance staff must be selected according to the same criteria as that indicated for the operat...

Page 40: ...this member of staff 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 not designed to bear the weight of a person If climbed on they may collapse causing injury to personnel and damage to the machine E0004P It may be necessary to temporarily remove or di...

Page 41: ...tions to avoid being burnt use gloves tongs etc HOT MATERIAL LEAVING THE EXTRUDER RISK OF BEING BURNT Either wait until the material has cooled down or be sure to take the proper safety precautions use pick up tools gloves etc 3 6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED E0004P WARNING 3 6 1 GENERAL When the machine is no longer to be used make it inoperative by shutting off the electricity a...

Page 42: ...3 8 176 12 A03 Revision 01 Date 14 11 2001 SAFETY EQUIPMENT AND PRECAUTIONS 3 ...

Page 43: ...E IS SUBDIVIDED FOR SHIPMENT The machine is divided into various blocks to meet shipping and installation requirements FIGURE 4 1 1 HOW THE MACHINE IS SUBDIVIDED FOR SHIPMENT 1 Drum base 2 Extruder base 3 Plastic compound hopper 4 Plastic compound feeder 5 Mobile control panel 6 Electrical cabinet 4 3 2 5 6 1 T2477 ...

Page 44: ...ly It is highly important that all the parts are weighed when they reach the end user to check that they match the weights indicated here exactly FIGURE 4 1 2 A WEIGHTS AND DIMENSIONS 1800 1300 1220 kg 2800 1 Drum base 2 Extruder base kg 1500 T0340 T2478 1050 1900 1800 4 Plastic compound feeder kg16 3 Plastic compound hopper T0345 650 kg 16 6 Electrical cabinet kg 700 650 800 1200 2000 T0346 T0349...

Page 45: ...50 x 350 x 350 8 Crate with tools supplied with machine 550 x 350 x 350 9 Crate with electric cables 7 Crate with spare parts supplied with machine 550 x 350 x 350 10 Crate containing the machine base barrier guards T0351 900 1550 1200 T0350 FIGURE 4 1 2 B WEIGHTS AND DIMENSIONS 12 Floor trunking electrical wiring kg 200 ...

Page 46: ...y precautions E0004P WARNING All lifting and handling operations are to be carried out by authorised and trained personnel only All persons should stay well clear of suspended loads and the range of action of the lifting system while the machine is being moved Carefully follow the instructions given in Chapter 3 SAFETY EQUIPMENT AND PRECAUTIONS E0004P WARNING The manufacturer shall not be held res...

Page 47: ...ath the levelling screws Place the base on the blocks and make sure it is in the exact position indicated in the layout provided Place the base plates B beneath the base near the levelling screws A Turn the screws A until their ends enter the holes in the plate B Remove the wooden blocks Level the base by working at points P Place a spirit level L as shown in the figure Once the correct level has ...

Page 48: ...der assembly 2 and keep it up while assembling Insert and slightly tighten the screws C in the upper and lower sections Fit the plates D beneath the base 2 near the levelling screws Check the level of the base 2 by placing a spirit level at a suitable point on the main surface Adjust as required Check that the base rests perfectly at all points S by using a thickness gauge Fully tighten the screws...

Page 49: ...pper 8 over the extruder flange 2 Secure it with the screws A Install the plastic compound feeder 9 over the hopper 8 Secure it with the screws B NOTE The plastic compound feeder is an optional extra 1 T2439 FIGURE 4 2 3 B PLASTIC COMPOUND FEEDER AND HOPPER T0372 2 A B 4 FIGURE 4 2 3 A PLASTIC COMPOUND FEEDER AND HOPPER 2 3 4 3 ...

Page 50: ...he safety guards as instructed in the drawing found in the crate Make the electrical connections assuring the safety devices work efficiently E0004P WARNING Never run the machine without the safety guards and devices installed The machine cannot be run if the guards are installed but the limit switches are disconnected from the electricity supply Never tamper with the connection of the limit switc...

Page 51: ...e tank A lead to the extruder base and must be connected to the delivery and return manifolds M R respectively 4 3 1 2 Hoses for joining the chiller to the manifolds M R The delivery and return hoses 3M 3R respectively which run from the chiller have to be connected to the delivery and return manifolds M R respectively as shown in the diagram NOTE These connections are to be made by the customer 2...

Page 52: ... are found beneath the drum base Connect the hoses together by referring to the identification numbers stamped on them 4 3 1 4 Auxiliary circuit cooling tank cooling tank and plunger heater Fill the tanks to the level indicated B by pouring the cooling fluid in through the filler provided A NOTE The specifications of the cooling fluid are detailed in chapter 2 MAIN FEATURES The cooling tank for th...

Page 53: ...Connect a hose with internal diameter as indicated in the specifications paragraph running from the compressed air mains supply to the fitting A 4 3 2 2 Plastic compound feeder Use the hose B 6 8 mm dia to connect the plastic compound feeder if provided to the point shown in the figure 4 3 2 3 Extruder head plunger Connectthehose E 10 12mmdia runningfromsolenoid valve YV6 in the pneumatic unit to ...

Page 54: ...O THE VACUUM SYSTEM 4 3 3 1 Plastic compound feeder Connect the suction hose A to the plastic compound feeder if provided as indicated in the diagram 4 3 3 2 Vacuum pump Join the connection hose to the vacuum pump at the point B shown in the diagram Repeat the operation for the second pump T0636 B B FIGURE 4 3 3 2 VACUUM PUMP ...

Page 55: ... burr suction system Connectthehoses C D E F tothefilterunitatthepoints indicated in the diagram Connect the other ends of the hoses C D E F to the machine as shown in the diagram FIGURE 4 3 3 3 B WASTE BURR SUCTION T2454 T2453 FIGURE 4 3 3 3 A WASTE BURR SUCTION C D F E D E F ...

Page 56: ...E PROXIMITY SENSORS T0402 4 3 4 INSTALLING THE PROXIMITY SENSORS The sensors are removed after the machine has been inspected in order to prevent them from being damaged during shipment Therefore they must be installed as indicated in the diagram after the machine has been assembled SQ5 ...

Page 57: ... place for shipment Some cables are removed and placed in a container while others are disconnected from the cabinet and wound up The cables are arranged as indicated in the tables and located as illustrated in the diagrams A B disconnected at one end and wound up C completely removed and placed inside a container T0614 B C A D D B FIGURE 4 3 5 1 A ARRANGEMENT OF THE CABLES FOR SHIPMENT ...

Page 58: ...ectrical cabinet Cables B and C are to be laid in the wireways E0004P WARNING First connect the power cables see relevant table These cables are stiffer and more difficult to handle and more space is therefore required If possible the power cables must be grouped together and separated from those leading to the programmable logic array Connect the cables to the machine and inside the electrical ca...

Page 59: ... XJ8 Power section cable Machine base XJ9A Power cable conduit Extruder XJ9B Power cable conduit Extruder XJ11 Sample pick up control box cable XJ13 Solenoid valve control box cable Pneumatic system XJ16 Interface signal cable Upstream machine XJ19 Auxiliary control panel cable XJ30 Interface power cable Upstream machine XJ31 Machine control panel cable T2410 XJ5 XJ2 XJ2T XJ13 XJ6 XJ1 XJ1A XJ8 XJ3...

Page 60: ...injury 4 3 5 3 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 are to be joined to the main switch terminals Connect the earth wire to the terminal marked PE located inside the electrical cabinet E0004P WARNING As there are a number of electronic con...

Page 61: ...to service as this is a good way to become familiar with how the machine works when adjustments are made to the auxiliary equipment accessories guards and safety devices and when test runs are carried out to make sure the adjustments have been made correctly 5 2 PRELIMINARY CHECKS CONDITIONS Make sure the machine is connected to the mains electricity and air supplies PROCEDURE Set the extruder noz...

Page 62: ...s reached the set value Start up the extruder and wait until the material loaded in the hopper flows towards the by pass outlet Stop the extruder CLEANING THE EXTRUDER NOZZLE Discharge all the material from the extruder by pressing keys 17 and 28 simultaneously and several times Remove the plastic compound coming out of the extruder nozzle until the material coming out is clean Sequence of operati...

Page 63: ...d and at the correct operating temperature The guards should be closed Turn the mode selector on the control panel to the AUT position Start the automatic work cycle by pressing key 1 at the same time as key 28 5 6 SUBSEQUENT START UP PROCEDURES Perform the operations described in the paragraph OPERATIONS TO BE PERFORMED BEFORE STARTING THE PRODUCTION CYCLE ...

Page 64: ...5 4 5 START UP 176 12 A03 Revision 01 Date 14 11 2001 ...

Page 65: ...cessor based programmable logic controller is provided The following operations can be performed by using the controls on the keyboard the work cycle can be set the operating data can be entered or changed even when the work cycle is in progress messages and settings can be displayed the operating data for the selected work cycle can be stored and retrieved self diagnosis maintenance checks E0004 ...

Page 66: ... number of days delay Press Disable key 12 to inactivate the pre heater immediately or to cancel a request for pre heating 2 The plunger temperature control if provided is always activated at the same time as the extruder heating system The LEDs built into keys 9 and 13 indicate whether the plunger heating control is on or off 3 With the mode selector turned to the MAN position the position of the...

Page 67: ...eder start 28 10 MAN Plastic compound feeder stop 10 MAN Vacuum pump start 28 11 MAN Vacuum pump stop 11 MAN Extruder heater stop 2 12 Extruder pre heater inactivation if provided 1 12 Cap feeder start 28 14 MAN Cap feeder stop 14 MAN Suction device start 28 15 MAN Suction device stop 15 MAN Cooling pumps start 28 16 MAN Cooling pumps stop 16 MAN Extruder nozzle cleaning 28 17 MAN FDP start if pro...

Page 68: ... RESET buttons are exactly the same as for those located on the machine control keyboard The STOP button which is always enabled regardless of the position of selector switch SA1 stops the automatic cycle if in progress and or stops the drum motor if rotating The START button which is only enabled if selectorSA1 is in the position to enable the auxiliary control panel performs the following functi...

Page 69: ...astic compound extruder 5 First transfer unit 6 Forming unit the liners are formed inside the caps 7 Second transfer unit and cap cooling 8 Quality control unit caps checked with a pneumatic mechanical system 9 Discharge unit 10 Exit channel and cap counter 1st Rej Caps rejected because defects detected by vision system if installed 2nd Rej Caps rejected because of defects detected by pneumo mecha...

Page 70: ...6 6 176 12 A03 Revision 01 Date 14 11 2001 6 OPERATING INSTRUCTIONS ...

Page 71: ...er page of the electronic control system These parameters include the following Temperature in the heated areas Extruder motor speed available only for operations in manual mode Coolant temperature The values for these parameters are given on the Data sheet E0004P ATTENTION Consult the Instructions B manual that deals with the control system for information on how to set the parameters ...

Page 72: ...g burnt The hole F in the nozzle must be centered with the cutters G To adjust proceed as follows Loosen the four screws A Loosen the two screws B Loosen the clamp nuts H Move the extruder backwards or forwards by loosening or tightening the screws C as necessary Fully tighten all the screws in reverse order Once all the screws have been tightened make sure the hole has stayed in the correct posit...

Page 73: ...recautions to avoid being burnt To adjust the position of the extruder nozzle proceed as directed below Use the handwheel to run the machine until the cutter G is brought over the extruder nozzle hole N Place the comparator R on the block which holds the roller M Loosen the screws B D on the ring nut I Loosen the screw O and completely lower the runner P Turn the ring nut I until the extruder nozz...

Page 74: ...necessary safety precautions to avoid being burnt NOTE The cutting clearance Q should range from 0 02 to 0 05 mm The cutter G when close to the nozzle N rests on the runner P which acts as a reference for the height of the cutter To adjust or change the cutter clearance Q proceed as directed below Place the comparator R on the roller holder M Loosen the screw O and lower the runner P until the cut...

Page 75: ... the comparator A on the side of the insertion drum C Bring the comparator A to one end 1 of the nozzle F By using the handwheel turn the drum C until the comparator A reaches the opposite end 2 of the nozzle F There should be a difference in level along the plane where the measurements are taken i e E must be between 0 0 and 0 03 mm The lowest part should be at the point where the cutter moves do...

Page 76: ...ents and speed of the fans according to the set points entered The temperatures in the five process areas depend on the type of plastic compound being handled Use the keyboard to open the extruder settings page and enter the desired values for the set points for the temperatures in the five zones The display shows the actual temperatures at the same time The temperatures for safety temperature con...

Page 77: ... determined in order for the machine to operate properly Normally these parameters are determined during machine commissioning as the type of plastic compound used the weight of the pellets and the varnish applied are extremely important factors capable of affecting the whole process If it is necessary to change the heights P and T perform the operations described below FIGURE 7 2 CUTTER T2444 T C...

Page 78: ...hecomparatorsgivethesamereadings Since the spindles 5 are attached to the cam 1 they are raised or lowered to the same degree as indicated by the instrument To measure the correct distance between the cutter and the bottom of the cap use the lower surface of the transfer wheels as a reference However they are 6 mm higher as shown in figure 7 2 FIGURE 7 2 1 POSITION OF THE COMPARATORS 4 4 4 1 3 2 5...

Page 79: ...he spacers 5 to raise or lower the cam 4 along with the center plunger on the spindle as required each spacer is 0 5 mm thick Reassemble The center plunger on the spindle can thus be moved closer or further away setting P figure 7 2 so that the correct pressure can be applied on the pellet against the bottom of the cap 1 Screw 2 Screw 3 Block 4 Cam 5 Spacers T0425 4 3 1 2 5 FIGURE 7 2 2 PLUNGER HE...

Page 80: ...ENTS 7 Revision 01 Date 14 11 2001 7 2 3 ADJUSTING THE AIR SUPPLY The air pressure must be 3 5 bar The pressure can be adjusted by using the pressure control 1 located in the pneumatic unit T0428 FIGURE 7 2 3 PNEUMATIC UNIT 1 ...

Page 81: ... this off set is 1 5 mm The exact setting is determined during machine inspection To adjust proceed as directed below Use the handwheel to turn the drum until one of the screws 2 is brought in line with one of the holes 1 Fit the wrench 4 into the hole 1 and loosen the screw 2 Repeat for the other five screws 2 Make sure that before loosening the last screw 2 the cam 3 is in line with the hole 1 w...

Page 82: ...tters must be placed at the corresponding number To adjust proceed as directed below Loosen and remove the screw A from the side opposite the rod Turn the flange B moving the pointer to the desired number Fully tighten the screws A Generally speaking the movement C indicated in the figure along with the other work parameters are determined during machine testing as the type of plastic compound use...

Page 83: ...p and guides 2 can be modified by loosening the three fixing screws and moving one in relation to the other The height of the cover 3 can be adjusted It should be 0 7 0 8 mm from the top of the cap These adjustments are made during machine testing as they are strictly related to the dimensions of the cap T0632 2 2 1 0 7 1 Turn table 2 Guide 3 Cover 3 FIGURE 7 3 1ST TRANSFER TURN TABLE ...

Page 84: ...9 provided Use the wrench 10 to loosen the plunger 2 by a few turns Raisethelowerspindle 1 asshowninthefigure byusingalever 8 andablock 7 bothsuppliedwiththemachine Place a shim 6 between the roller 4 and the cam 3 the size of the shim should be equal to A see diagram With the aid of the wrench 10 screw the forming plunger 2 until the end of the spindle 2 comes into contact with the end of the low...

Page 85: ...igure If the stripper has to be adjusted loosen the two screws that secure it and move it until it comes into contact with the shim 2 Fully tighten the screws and repeat the operations for all the remaining strippers The height of the shim 2 is determined during machine testing as it is strictly related to the height of the cap If the shim supplied with the machine is not available keep in mind th...

Page 86: ...of plastic compound being used Normally the coolant temperature is determined during machine commissioning To change the temperature alter the set point from the control keyboard as directed in the INSTRUCTIONS B Manual 5 6 3 4 2 1 5 6 1 2 4 T0631 FORMING WITHOUT CAP FORMING WITH CAP 1 Lower plunger 2 Shim 3 Cap 4 Stripper 5 Spring 6 Mobile bush FIGURE 7 4 2 B PMV 238 STRIPPER HEIGHT ADJUSTMENT 0 ...

Page 87: ... check the sensor that monitors thickness and the vacuum system settings The central sensor may or may not be installed depending on the type of liner to be checked A complete set of sample caps is required for some adjustment procedures These should have the number of the forming punch stamped on the liner The sample caps should be produced with the sensing spindles removed from the machine to pr...

Page 88: ...heck the liner to see whether the internal 1 or the external part 2 is in contact The liner should touch both the central sensor 1 and the external part 2 to an equal extent To obtain this condition loosen or tighten the central sensor 1 as required Set the comparator 10 mounted on the central sensor 1 to zero Screw in the sensor until the comparator reads a movement of 0 05 to 0 06 mm Observe mea...

Page 89: ...s rest on as indicated in the diagram Position three comparators 1 on the cam 4 at 120 as illustrated in the diagram Reset the comparators Loosen the screws 2 Tighten or loosen the grub screws 3 in order to raise or lower the cam 4 All the comparators should indicate the same degree of movement Tighten the screws 2 FIGURE 7 5 2 ADJUSTING THE HEIGHT OF THE SENSING SPINDLES 1 T2509 T0437 3 2 4 5 Pos...

Page 90: ...own in the illustration Each sensing spindle should be adjusted by using sample caps which are stamped with the number of the forming plunger that the spindle controls during the production stage Reset the comparator 1 with the cap placed under the sensor Check that the roller 5 rests on the cam 6 Loosen the screw 3 Turn the cam 4 until the comparator indicates an upwards movement of approx 0 1 mm...

Page 91: ...indle in question near the flat section of the spring loaded block 1 Check that the sensor 3 is activated Set the sensor 3 so that it is 3 mm away from the fixed back plate 2 Use the control keyboard to open the Liner thickness window on the Machine drive system data page see Instructions manual B A number ranging from 34 to 38 will appear Place a 2 mm shim under the roller 4 so that a 5 mm cleara...

Page 92: ...1 Date 14 11 2001 FIGURE 7 5 4 ADJUSTING THE SENSOR FOR DOUBLE LINERS P5 T0619 T0443 T0444 1 Spring loaded block 2 Fixed back plate 3 Sensor 4 Spindle roller P2 Trimmer P5 Trimmer AP53 MODULE TRIMMER LED 24V 15V EJECT P2 3 2 1 4 FLAT SECTION ...

Page 93: ...eads zero mVolts Connect wires 753 and 754 to the terminal block Adjust trimmer P1 found on module AP51 until zero off set is given for the vacuum level in the control chamber data item on the Data page After the adjustments have been performed and it is certain that defect free liners will be produced run the machine Set the vacuum to 40 cm Hg by using the control 4 found on the quality control u...

Page 94: ...01 Date 14 11 2001 FIGURE 7 5 5 ADJUSTING THE QUALITY CONTROL UNIT OUT P1 P2 TRIMMER 1 Junction box 2 Trimmer 3 Transducer cover 4 Control P1 Trimmer P2 Trimmer P6 Trimmer TP2 P6 TPø 3 2 T0619 T0445 T0446 A 4 15V MODULE AP51 LED TP1 1 T0434 ...

Page 95: ...TIVE PRODUCT CONTROL DEVICES This adjustment is required to locate the best point to trigger the ejection valve and therefore eject defective caps Go to page C machine data page 2 from the control keyboard see the Instructions B manual Use the Delay time for starting the pellet blower data item to adjust the delay time for activating the solenoid valve Use the Length of blower operation for ejecti...

Page 96: ...CONVEYOR BELT ADJUSTMENT The air operated diverter changes its position after a pre set number of caps has been counted this normally corresponds to the number of caps contained in a box To change this value use the keyboard controls as directed in the INSTRUCTIONS B manual ...

Page 97: ...gress sign to the electrical cabinet press the emergency stop buttons on the machine in Always keep in mind the main hazards that can arise and remember the safety instructions given in chapter 3 SAFETY EQUIPMENT AND PRECAUTIONS The maintenance operations are divided into routine maintenance to be performed by the customer s maintenance staff special maintenance to be performed by the manufacturer...

Page 98: ... L B 0 1 s r e l l o r e l d n i p s m o t t o B 2 1 e t a c i r b u L B 0 1 s g n i r a e b t f a h S 3 1 e t a c i r b u L D g 0 5 g 0 5 5 s m a c e l d n i p S 4 1 e t a c i r b u L B g 2 g 2 1 s l e e h w d o r r e p p i r t S A 4 1 e t a c i r b u l d n a k c e h C B 0 0 4 s e h s u b e l i b o m r e p p i r t S B 4 1 e t a c i r b u l d n a k c e h C B 0 0 2 T I N U L O R T N O C Y T I L A U...

Page 99: ...E T S A W r e t l i F 4 2 n a e l C 5 r e w o l B 5 2 r e t l i f n a e l C 5 P M U P M U U C A V s r e t l i F n a e l C 5 s e n a V e c a l p e r y r a s s e c e n f i d n a k c e h C 0 2 R E T A E H N O I T C U D N I s r o t c u d n I 8 2 n a e l C 5 s r e v o C 9 2 e c a l p e R 0 1 S D R A U G s e c i v e d y t e f a S y c n e i c i f f e r o f k c e h C I T N A C I F I R B U L I E D E H C I ...

Page 100: ...8 4 176 12 A03 Revision 01 Date 14 11 2001 8 MAINTENANCE FIGURE 8 1 1 A PARTS TO BE SERVICED T2458 15 21 22 1 16 17 13 24 18 25 ...

Page 101: ...8 5 176 12 A03 Revision 01 Date 14 11 2001 MAINTENANCE 8 FIGURE 8 1 1 B PARTS TO BE SERVICED 11 14 A T0385 T2508 T0386 5 3 2 T0645 4 7 9 6 12 14 14 B ...

Page 102: ... the extruder To do this turn the main switch on the motor control cabinet to off and lock it in its open position with a pad lock Remove the pad lock key Remove the extruder from its base and turn it so that the extrusion die and auger can be easily removed Remove the guards in front of the extruder Loosen the screws 1 and 7 and turn the ring nut 2 so that the nozzle 3 is approx 1 mm lower than t...

Page 103: ...ormed when the extruder has reached its operating temperature When it is cold it is impossible to remove the parts because of the hardened plastic Proceed as follows Shut off the electricity supply and remove the cables from the terminal block 9 These cables are for the electric heating elements in the extruder head 10 Remove the screws 11 12 so that the cylinder 13 can be taken out Remove the nut...

Page 104: ... the operation can be facilitated by using your hands Cleaning the auger and filter Thoroughly clean the auger with hand tools removing any resin present If the surface of the auger is dark and opaque polish it with a brush and abrasive paste As an alternative the auger can be soaked in a normal paintdiluentfor8 10hourstocleanit Forthispurpose a tube capable of holding the auger should be used A p...

Page 105: ...shim is approx 0 5 mm thick and there are normally five of them installed If all the shims have already been removed it is necessary to install a new cutter along with five shims Refit the cutter 1 and turn it with the aid of the tool X to center the cut part with the sleeve 2 Reinstall and lock the assembly in place with the ring nut 4 Place the sleeve 2 on the fixture Y as shown in the diagram T...

Page 106: ... placed on a magnetic surface or in a vice Grind the cutters by removing the minimum amount of material necessary so that cutting can be performed properly The result should be that value A is the same for all the cutters and value B should be within the values indicated in the diagram Remove the cutter 1 from the fixture and put it back into place on the assembly 3 B 0 2 1 5 T2505 T0460 T2435 FIG...

Page 107: ...ion can be removed Insert a spacer in the slot that guides the lower plungers to hold them up during the operation The spacer should be put between the bottom of the slot and the pin bearing 3 Take out the spacer holding up the lower plunger that is to be removed Take out the pin 3 with bearing of the lower plunger to be removed Take out the pin 4 and bearing while holding up the lower plunger The...

Page 108: ...ring pin for lifting plunger 5 Return cam 6 Cam section 7 Stripper cam 8 Slots for removing lower plungers 9 Stripper rod 10 Guide 2nd transfer turn table 11 Guide 1st transfer turn table 12 2nd transfer turn table 8 6 5 4 7 9 3 2 1 T1112 10 12 11 FIGURE 8 1 2 3 REMOVING THE LOWER PLUNGER FROM THE FORMING DRUM ...

Page 109: ... 6 Loosen the jaw 4 At this point the components are loose and can be disassembled To install proceed in the reverse order making sure that the cavity in the central plunger 5 coincides with the reference pin 7 NOTE The screw 6 must be tightened with a torque wrench set as indicated in the chart below Machine Thread diameter of the plunger fixing screws Tightening torque PMV224 M12x1 3 5 daNm PMV2...

Page 110: ...is compressed by approx 1 mm Loosen the screw 6 Loosen the bolt 4 on the fixture until the spring is completely released Remove the lower plunger from the fixture Disassemble the lower plunger To re assemble the plunger perform the same operations in reverse order It is important that the screw 6 is tightened with a torque wrench set as indicated in the chart below Machine Tightening torque PMV224...

Page 111: ...ity index ISO 3448 320 Kinematic viscosity ASTM D 445 320 cSt at 40 C GREASE B Dropping point 200 C Worked penetration 300 dmm DIN 51804 Dynamic toughness mPas 7000 C NLGI 1 DIN 51818 Dropping point ISO 2176 145 C Penetration ISO 2137 310 340 dmm D Dropping point 180 C Worked penetration 220 250 dmm DIN 51804 In order to choose the correct lubricants refer to the LUBRICANT SHEET supplied separatel...

Page 112: ...eed to be removed in order to lubricate the gears Lubricate while running the machine with the handwheel Use extreme caution as there is a risk of getting caught in moving parts and being very seriously injured Always put the side guards back into place after each lubricating operation Never operate the machine with the guards removed ...

Page 113: ...8 15800 10K MS 0 49 0 96 1 64 4 07 5 25 7 28 12 28 18 74 28 63 36 04 50 36 60 97 85 3 V 511 839 1177 2178 2884 3483 5035 6940 9481 11665 14900 18532 21740 12K MS 0 58 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 PITCH mm 1 00 1 00 1 50 1 50 1 50 1 50...

Page 114: ...use the forming drum as a reference Proceed in both directions up to the insertion drum and the exit wheel T2434 TIMING 8 2 1 5 TIMING 8 2 1 4 TIMING 8 2 1 3 TIMING 8 2 1 1 TIMING 8 2 1 2 FIGURE 8 2 1 TIMING THE DRUMS 1 Insertion drum 2 1st transfer turn table 3 Forming unit 4 2nd transfer turn table 5 Quality control unit 6 Discharge unit 7 Centering ring 8 Fixture 9 Screw 10 Screw 11 Toothed whe...

Page 115: ...d in relation to the tool 8 This may not happen for two reasons a The two halves of the turntable s wheel are not properly set During machine testing the two wheels are set secured in place with screws 14 and drilled so that they can be correctly positioned with a special fixture without having to remove the sensing spindle b The 1st transfer turntable is not timed with the forming unit In case a ...

Page 116: ...ring 7 is brought to the point where the caps are passed from the turn table to the insertion drum 1 grippers The insertion drum s gripper must perfectly coincide with the centering ring in the point mentioned above If it does not happen loosen the bolts 9 which hold the gear wheel 11 in place turn the insertion drum assembly which is integral with the turn table until the correct position is reac...

Page 117: ...un the second turn table until the space which holds the centering ring is brought to the point where the caps are passed from the turn table to the quality control unit The tool 13 must perfectly coincide with the centering ring 7 in the point mentioned above If it does not happen loosen the bolts 10 which hold the gear wheel 12 in place turn the quality control unit until the correct position is...

Page 118: ...g 7 in the point mentioned above This may not happen for two reasons a The two halves of the discharge unit s wheel are not properly set During machine testing the two wheels are set secured in place with screws 18 and drilled so that they can be correctly positioned with a special fixture without having to remove the sensing spindle b The discharge unit is not timed with the quality control unit ...

Page 119: ...arameters S1 S2 S3 S4 and S5 for the referencevaluesrefertothedata sheet provided by SACMI See the INSTRUCTIONS B Manual Replace the cutters or nozzle for the reference values refer to the data sheet provided by SACMI SeetheADJUSTMENTSchapter Replace the damaged cutters or resharpen them SeetheMAINTENANCEchapter Correct the distance between the plunger when fully down and the bottom of the cap See...

Page 120: ...de surface A pellet is stuck in a cavity in the 1st transfer turn table Remove the pellet and clean the slide surface Remove the pellet 8 3 1 2 1st transfer turn table 8 3 1 3 Forming unit PROBLEM CAUSE REMEDY Height of the stripper incorrect Spring that keeps the stripper pressed against the cap broken Stripper bush jammed There are plastic or metal residues on the lower spindle surface Correct t...

Page 121: ...he cavities that hold the caps are dirty inside The distance between the sensor and the table the caps flow on is incorrect The distance between the outside lip and the central body of the sensor is incorrect skip if provided Shells deformed while the liners were being formed See the chapter that deals with the FORMING DRUM Air loss inside the sensing equipment as air leaks out through the fitting...

Page 122: ...n is incorrect The distance between the outside lip and the central body of the sensor is incorrect skip if provided Quality control unit incorrectly set Sensitivity of the quality control unit incorrectly set Set sensor AP53 that controls liner thickness as required See the INSTRUCTIONS B Manual Clean the cavities that house the caps Adjust the distance between the sensor and the table the caps f...

Page 123: ... forming plunger is excessive Channelsforexhaustingairfrom the forming equipment are clogged Thespringsofthelowerspindles give way Pellets are placed eccentrically in relation to the caps Increase the speed of the extruder auger by entering a higher value for parameter S22 from the microprocessor system keyboard See the INSTRUCTIONS B manual Increasethetemperatureset points for the extruder by usi...

Page 124: ... parameter S22 fromthemicroprocessorsystem keyboard See the INSTRUCTIONS B manual Center the pellets in relation to the caps SeetheADJUSTMENTSchapter Replace the defective rings of the forming equipment 8 3 2 4 Plastic compound runs over the edge of the liners outside the perimeter PROBLEM CAUSE REMEDY 1 Plasticcompoundrunsovertheedge of the liners Pellet is too heavy Pellets are placed eccentrica...

Page 125: ...h Failure on the part of one or more cutters to properly grasp causes double pellets to be formed See the chapter that deals with the INSERTION DRUM Decrease the speed of the extruder auger by entering a lower value for parameter S22 fromthemicroprocessorsystem keyboard See the INSTRUCTIONS B manual See the chapter that deals with the INSERTION DRUM ...

Page 126: ...8 30 176 12 A03 Revision 01 Date 14 11 2001 8 MAINTENANCE ...

Page 127: ... lines between the cooling unit and water mains and the factory drain line Thoroughly clean the machine paying particular attention to the moving parts Lubricate as a protective measure if necessary Close the doors of the electrical cabinet and machine to prevent the parts from being tampered with dust from building up etc Activate all the safety devices provided DECOMMISSIONING Remove the various...

Page 128: ...9 2 176 12 A03 Revision 01 Date 14 11 2001 9 DECOMMISSIONING ...

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