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TMS 5001

THEY MUST NOT BE REMOVED OR DISMANTLED FOR ANY REASON: ANYONE WHO
DELIBERATELY DISABLES OR ALTERS THE SAFETY DEVICES WILL BE RESPONSIBLE
FOR ANY OF THE OPERATIONS THAT ARE CARRIED OUT AFTER SAID MODIFICATION.

3.3.1

RISK AREAS

Operating the machine during the normal production cycle does not present a risk to personnel as the

protective cabins prevent accidental access to moving parts.

If maintenance must be carried out on parts located inside the cabin, the various "

risk

” areas must be analysed,

which are classified by functional groups in the following table.

THE RISK AREAS ARE CONSIDERED TO BE THE PARTS OF THE MACHINE IN WHICH THERE

IS A RISK OF DEATH, SERIOUS INJURY OR ACCIDENT FOR THE OPERATOR OR PERSONNEL
IN GENERAL, IF THEY ARE EXPOSED DIRECTLY AFTER HAVING REMOVED OR DISABLED
THE SAFETY PROTECTIONS AND DEVICES.

3.3.2

GROUP

FUNCTIONAL GROUP

RISK AREA

DESCRIPTION

Press

Press Area

- Moving parts: risk of impact,

entrainment or crushing.

Transport

All the areas of displacement

- Moving parts: risk of impact,

entrainment or crushing.

- Risk of falls from the walkways.

Blow mould

Blow mould area

- Moving parts: risk of impact,

entrainment or crushing.

Nailing

Nailing area

- Moving parts: risk of impact,

entrainment or crushing.

Furnace

Lamp holder area.

- Risk of burns by direct contact

with the furnace containers.

Stretching/blowing

Press area blowing.

Mould area blowing.

- Parts of the blowing press and

moulds in motion: risk of

entrainment or crushing.

Loading

Upper platform loading area.

- Risk of falls from the upper

platform loading area.

Unloading

Bottle unloading area.

- Moving parts: risk of impact,

entrainment or crushing.

Electrical cabinet

Cabinet area.

- Current: risk of electric shock.

Boilers

Baseplate area.

- Compressed air: risk of explosion.

Leads

Press area

- Compressed air: risk of whiplash.

Preforms Elevator

Entrapment area

-Rotatory parts: risk of entrapment

Expulsion system

Entrapment area

-Moving parts: risk of entrapment

TO REDUCE OR ELIMINATE THE RISK OF AUDITION DISEASE OR BURN WHEN MANIPULATE
THE OVEN SEE THE SECTION 3.4.6

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Summary of Contents for TMS 5001

Page 1: ...TMS 5001 INSTRUCTIONS MANUAL OPERATION MANUAL ...

Page 2: ...CES 4 CUSTOMER PREMISES INSTALLATION INSTRUCTIONS 4 1 UNLOADING THE MACHINE 4 2 PLACING THE FEET ON THE MACHINE 4 3 PLACING THE LEAD IN CONVEYOR 4 4 PLACING THE PREFORM ELEVATOR 4 5 PLACING THE DISCHARGE HOPPER 5 OPERATION STAGES 5 1 STRETCHING BLOWING 5 2 IMPERVIOUS CYLINDER 5 3 PRESS 5 4 MOULD 5 5 BOTTLE MOULD BOTTOM PIECE 5 6 OVEN STRETCHING 5 7 OVEN 5 8 ...

Page 3: ...ERNAL SWITCHES 6 2 MANOEUVRES 6 3 SCREENS 6 4 ALARMS MALFUNCTION CAUSE SOLUTION 7 FORMAT CHANGE 7 1 PREVIOUS PROCEDURES 7 2 FORMAT CHANGE START UP 8 BLOWING ADJUSTMENTS 8 1 PARAMETERS OF THE HEAT FIXATION PROCESS 8 2 LIST OF SHAPING DEFECTS AND SOLUTIONS 9 MAINTENANCE 9 1 CHECKING THE BLOWING MACHINE 9 2 LUBRICATING THE BLOWING MACHINE 9 3 MECHANIC LINING UP ...

Page 4: ...characteristics of the Mould blowing machine and its components and also how to operate it Blowing adjustments This section explains the elements that must be adjusted and the parameters that must be set in order to produce superior quality containers Maintenance manual This section deals with the necessary maintenance works on the machine and its components and it also explains when and how to im...

Page 5: ...ld blowing machine on demand Technical Assistance Service Servicio Industrial de Electrónica SA C Llinars s n Polígono Industrial Monguit 08480 L AmetlladelVallés Spain Phone no 34 93 846 30 51 Fax no 34 93 849 22 11 E mail Jordi claramunt side es The document to apply for technical assistance or spare parts should include machine ID data which appear on its ID plate These data consist of informat...

Page 6: ...e and with a relative humidity below 70 The storage temperature must range between 5ºC and 50ºC OPERATING TEMPERATURE The Mould blowing machine must be preserved from atmospheric agents rain hail snow fog etc Warning in a corrosive atmosphere the maintenance methods and the frequency of the revisions must be scheduled accordingly so as to avoid the excessive wear of the components This machine has...

Page 7: ...nts When working near movable parts operators must make sure neither their clothes nor their hair is caught by them WARRANTY The warranty terms and conditions and its duration have been set out in the purchase agreement subscribed by the purchaser and SIDE SA COVERAGE It will cover all the broken parts or those presenting an excessive wear due to the amount of operating hours Once a component unde...

Page 8: ...t to present any claims against the Manufacturer Repair works implemented by technicians other than those appointed by the Manufacturer or without the Manufacturer s explicit authorisation will void the warranty The Manufacturer will only be liable for those issues concerning the Mould blowing machine described in this Manual and any subsequent claim for damage or for any harms caused by the flaws...

Page 9: ...r pressure bar 40 Air quality Dry cold oil free food processing quality LOW AIR PRESSURE Low air pressure bar 7 Necessary flow rate m3 h 50 Air quality Dry COOLING WATER Cooling water pressure bar 10 máx Cooling water temperature ºC 8 10 Cooling power Kcal h 16000 GENERAL DATA Workplace temperature ºC 15 45 Premises Indoors Relative humidity 25 70 Noise level 85 dB HEATING OVEN Total heating power...

Page 10: ...0 bars 4500 Pre blowing pressure adjustment Range bar 0 to 10 MIN MÁX BOTTEL DIMENSIONS Minimum volume 10 litres Maximum volume 30 litres Maximum volume 50 litres for XL Ask for further capacities MACHINE DATA Mechanical speed cycles hour 950 Maximum height preform elevator 3350 Weight Kg 9500 Mould weight Kg 258 Tool for mould colocation weight Kg 43 1 These may vary depending on the machine opti...

Page 11: ...r the safety of the blow moulding machine Make sure that the facilities that must be connected to the blow moulding machine meet the manufacturer specifications Make sure that the installation and maintenance staff be it your own or outsourced is specialised and has received specific training REQUIREMENTS OF THE INSTALLATON PREMISES The TMS 1002e blow moulding machine must be placed upon a flat so...

Page 12: ...arts risk of impact entrainment or crushing Transport All the areas of displacement Moving parts risk of impact entrainment or crushing Risk of falls from the walkways Blow mould Blow mould area Moving parts risk of impact entrainment or crushing Nailing Nailing area Moving parts risk of impact entrainment or crushing Furnace Lamp holder area Risk of burns by direct contact with the furnace contai...

Page 13: ...For the same reasons the furnace area also presents a residual risk of burns 4 The electrical cabinets are areas of residual risk because even when the cabinet doors are open and the safety devices are activated high voltage still passes through the terminals where the cabinet is connected to the external network if the operator touches these contacts they can die from electrocution 5 The pressure...

Page 14: ... THE COMPETENT INSTITUTIONS IF THE MACHINE DOOR LIMIT SWITCHES FAIL THE EMERGENCY STOP IS ACTIVATED REFERENCE DESCRIPTION PURPOSE 1 Anti intrusion screens Typical Panels of fixed screens on the machine frame Mechanical protection located in areas where there is a risk to people 2 Hinged doors Hinged doors and limit switches are activated when the door is closed 3 Discharge valves 40bar Discharge v...

Page 15: ...TOP THE MACHINE WHEN THERE IS NO DANGER PRESENT IS AGAINST THE SAFETY RULES AND CAN CAUSE DAMAGE TO THE MACHINE 3 4 4 ELECTRICAL CABINET SAFETY DEVICES 3 4 4 1 ELECTRICAL CABINET DOOR SAFETY DEVICES These safety devices interrupt the power supply to the entire machine in case of opening one of the master cabinet doors The cabinet has a limit switch and a hardware device that automatically trigger ...

Page 16: ...e alarm condition Fixed green turned on to signal the start of machine cycle 2 Indicator Light Machine alarm buzzer Machine cycle start buzzer 3 4 4 6 SECURITY KEYS SYSTEM To achieve a succesful security procedure to protect to the operator from any posible accident or injury when he needs to ge tinto the machine MUST FOLLOW THE NEXT PROTOCOL IT IS NECESSARY TO TURN OFF ONE OF THE TWO SECURITY KEY...

Page 17: ...RRENT THERE IS HIGH VOLTAGE IN THE AREAS MARKED AND THEREFORE RISK OF ELECTRICAL SHOCK INJURY OR DEATH THIS SIGN MAY INDICATE THE SUPPLY VOLTAGE VALUE MOVING MECHANISMS PARTS INDICATES THAT THERE IS A DANGER OF INJURY OR DEATH DUE TO THE PRESENCE OF MOVING MECHANISMS IF IT IS OPERATED WITHOUT SAFETY DEVICES AND PROTECTIVE ELEMENTS OR IF SUCH DEVICES ARE NOT EFFICIENT HIGH TEMPERATURE DANGER OR BUR...

Page 18: ...Page 17 of 106 TMS 5001 MACHINE ...

Page 19: ...Page 18 of 106 TMS 5001 TOOL FOR MOULD COLOCATION Block mould ...

Page 20: ...the capacity to provide the safest working conditions A crane gantry crane or fork lift truck must be used to move or unload the blower The blower has lifting points prepared for fixing hooks When fitting fasteners chains or strops they must be positioned so that the machine is always parallel to the ground when being raised Otherwise loads at the joints would exceed specifications which could cau...

Page 21: ...Page 20 of 106 TMS 5001 1 A B ...

Page 22: ...Page 21 of 106 TMS 5001 Mechanized Surface oven table Bubble precision level A Mechanized Surface press Bubble precision level B ...

Page 23: ...Page 22 of 106 TMS 5001 2 3 UP UP DOWN and LEVEL DOWN and CONTACT DOWN and CONTACT ...

Page 24: ... dismantle some of the components of the blow moulding machine This section explains how to reassemble the dismantled units 4 3 PLACING THE FEEDING HOPPER LEAD IN CONVEYOR This should comply with the following The retainer cylinder must be centred Frontal height fitting Levelled according to the base OUT OUT ...

Page 25: ...rotection frame in order to avoid obstacles such as cables and pipes on the floor that may hinder mobility around the machine Between the fixed facilities in the plant and the machine a flexible 500mm sleeve minimum length should be placed in order to facilitate alignment and avoid pipe rupture due to the vibrations It is advised to use safety fixing systems chains for high pressure flexible pipe ...

Page 26: ...2 IMPREVIOUS CYLINDER The impervious cylinder unit and the blowing nozzle seal the preform carrier during the blowing stage 5 3 PRES The blowing press opens and closes the blowing moulds producing simultaneously the necessary reaction to balance the pressure in the blowing moulds 5 4 MOULD The mould blowing unit and the stretching blowing unit form the containers The blowing moulds are placed betw...

Page 27: ...ty to provide the safest working conditions A crane gantry crane or fork lift truck must be used to move or unload the mould A crane must to support the mould weight see the technical data page 9 5 5 MOVEMENT OF THE BOTTLE MOULD BOTTOM PIECE The Bottle mould bottom piece unit combines with the movement of the press plates to form the bottom piece of the mould container 5 6 OVEN The Oven unit heats...

Page 28: ... heating phase 5 8 PREFORM HOLDERS The nozzle cooling unit consists of an air cooling tunnel through which the preform carriers pass once the container has been extracted 5 9 DELIVERY The delivery system consists of an integral system including different stages that range from picking the containers from the preform carrier units to placing them in a vacuum belt conveyor ...

Page 29: ... mould for the blowing stage 5 11 LOADING AND NAILING The loading and nailing unit consists of an integral system that places the preforms on the preform carriers and then fixes them to the nozzles 5 12 HOOPER AND FEEDER The hopper and feeder unit place the preforms in the right position and takes them to the loading and nailing unit OPTIONAL STANDARD ...

Page 30: ...Page 29 of 106 TMS 5001 5 13 PREFORM CARRIER The preform carriers move through the blow moulding machine conveyor circuit and it is there that the preforms are placed ...

Page 31: ...ower supply and the operating air intake When the pilot lights up it means that the power and the air inlet are enabled and the security features are activated 2 USB slot Export and import recipes and alarms 3 MANUAL or AUTOMATIC Selector that lets us choose between either manual or automatic features 4 EMERGENCY button which like the others installed around the machine stops all movement instantl...

Page 32: ...ve easy access to any point in the program The central area of the screen varies depending on the operating mode and function selected Many of the functions are restricted according to the level of access to the machine screens ATTENTION If you press on a particular function on a screen and it does not occur you do not have sufficient access to perform this function ...

Page 33: ...managing the recipe parameters of container format in progress On the setup area access to the program set up screen where we can configure the machine options and settings language preference change date and time and access to special and advanced features 5 Format name displays the name of current container format Clicking on this point we access the screen for editing the format name and descri...

Page 34: ...l conditions By pressing on the light we access the OK conditions for running the cycle Finally we have the Homing button that runs the Home function or function in which all mechanical pneumatic and electrical machine devices are reset to the correct starting position for running the machine cycle 4 Bottle production Start Stop button It only works when all conditions are met for preform blowing ...

Page 35: ... this module carries preforms or container holders It includes the servomotors that advance and restrain the holders the oven entry piston and the restraining systems at different points of the machine It also includes the preform guidance system optional Press Stretch module responsible for preparing the blowing process by opening and closing the blow press stretching motion floating bottom and c...

Page 36: ...e and ready to work Once these two operations have been completed the machine is ready to work in manual or automatic mode according to the position of the Manual Automatic selector on the keypad 6 3 3 OPERATE IN AUTOMATIC MODE With the Manual Automatic switch in the automatic position we press the preform holder carrier start up button Then we press the lamp ignition button and finally the prefor...

Page 37: ...larm occurring due to any severe cause for example emergency mushroom opening the machine doors Primary Alarms shut off dangerous power sources electric pneumatic and hydraulic Whenever a primary alarm is triggered the machine alarm sounds continuously Process Alarm This alarm occurs when the various machine cycles are running and they cannot continue because of an event for example waiting for a ...

Page 38: ...ss level to another for a specified time The basic access level U BAS requires no password and is the baseline for the production operator Advanced access level U ADV is designed for the machine operator or technician from this level we can modify the operating parameters of the machine or process This level is also required for using the machine in manual operating mode Finally there are two leve...

Page 39: ...d provide temporary passwords and provide information on specific features or functions FORMAT NAME We access this screen by clicking on the name of the format found in the header at the top of the screen This screen is used to define the format name of the bottle or container to be produced by the blower It should be a logical name and one that serves to identify the work format while offering th...

Page 40: ...he press stretching and blowing Load preform loading cycle Extraction containers and or bottles extraction cycle Oven cycle that controls the oven module Machine Basic machine data Preforms loaded into machine Number of preforms loaded into machine Production Bottles and or containers counter Total bottles loaded Total bottles blown Total bottles NOT blown rejected Partial N of bottles blown parti...

Page 41: ...ficiency dial percentage of blown bottles over bottles loaded Rejection dial percentage of bottles NOT blown over bottles loaded Parameters Bottles and or containers counter Total bottles loaded Total bottles blown Total bottles NOT blown rejected Partial bottles blown partial counter Machine Counters Time machine active total time machine is connected to mains Time machine cycle total number of m...

Page 42: ...es to run before the greasing cycle This value can be changed depending on the user level set Greasing Cycle Once the number of greasing cycles has been exceeded the grease pump is activated The system waits for the circuit pressure switch signal on each side If the signal does not appear a warning will be displayed on screen Once the pressure switch is activated a 10 second delay occurs and the g...

Page 43: ...hat is the doors are open Thermal cut out Alarm thermal magneto electric alarm located inside the control cabinet due to overconsumption or short circuit Inverters Alarm variable speed motors alarm Variable speed drives are electrical devices located inside the electrical cabinet Their function is to gradually vary the speed of the motors they control Like any electronic device they may trip inter...

Page 44: ...ic cylinder in charge of opening the path of the downspout so that the preform loading cycle can begin It also shows the state of the detectors that identify the end of the process Step by Step 2 indicates the state of the SV of the pneumatic cylinder in charge of allowing a preform to pass through from the downspout to the loading system It also shows the state of the detectors that identify the ...

Page 45: ...d of the process Parameters of the loader 1 2 Hopper Belt Speed The speed is introduced as a percentage of the maximum speed allowed by the variable speed drive to the minimum Ascent Speed Belt Vibrator time taken in seconds for the pneumatic vibrator installed in the base of the preform loading belt in chute 2 to move Elev speed Belt speed of the preform loading belt The speed is introduced as a ...

Page 46: ...lt The speed of the belt is controlled by a variable speed drive see parameter Ascent Speed Belt Position rollers activation of the motor for the roll that load all the preforms on the elevator Hopper levels indication from the level detection photoelectric cells in the preform hopper Ascent Pref Levels Low indication from the level detection photoelectric cells of the preform positioner Step by S...

Page 47: ...n the base of the preform loading belt in chute 2 to move Elev speed Belt speed of the preform loading belt The speed is introduced as a percentage of the maximum speed allowed by the variable speed drive to the minimum Preform Position Rollers Speed speed of the roll that loads all the preforms on the elevator ...

Page 48: ...t identify the end of the turning process Output Bottles Belt status of bottle detection photocell at the end of the output belt If the photocell is enabled during the scheduled time see Extractor Output Jam Time then preform loading is automatically disabled and a secondary alarm is generated In turn the output jam solenoid is activated for a while see Extractor parameters Sol Act Time and the sy...

Page 49: ... find the starting and final movement coordinates current coordinates and detection of the final movement through route limits of the servomotor not physical detectors Oven Clamps indication from the solenoid valve of the clamp s pneumatic cylinder in the heater area in charge of moving the preform from the heater to inside the press Press Clamps indication from the solenoid valve of the clamp s p...

Page 50: ...should take The line control system internally defines the adequate speed and necessary accelerations to comply with the specified time Advance Speed Oven maximum speed of the movements of the Heater line in the automatic cycle in mm s Max Cycle time maximum duration of a complete machine cycle If the machine for any reason should take longer than this specified time a process alarm is triggered S...

Page 51: ...ess 1 Press 2 and stretch Here we can find the starting and final movement coordinates current coordinates and detection of the final movement through route limits of the servomotor not physical detectors The position limits of Press 2 Line are the same as those for Press 1 Line Press Closed indicates the state of the security detector of Press 1 and Press 2 when they are closed These detectors ar...

Page 52: ...2 are the same as the values for Press 1 time taken in seconds for Press Lines 1 and 2 to open close The movement is defined by the starting and final progress coordinates and by using the time that this movement should take The line control system internally defines the adequate speed and accelerations to comply with the specified time Due to the need to synchronise the movements of Press 1 and 2...

Page 53: ...ction of the final movement through route limits of the servomotor not physical detectors and the intermediary signals that they use in the case of the stretching process such as starting positions for the pre blowing of preforms Pre Blow indicates the state of the low pressure pre blowing SVs for each blowing block Blown indicates the state of the high pressure blowing SV for each blowing block D...

Page 54: ...w value means that it has not been updated Blow Process Options Pre Blow activates deactivates the low pressure SVs It is used for testing Blown for the correct control of the blowing process the preforms are only blown if their temperatures read by the infrared cameras at the exit of the heater are between the minimum and maximum blowing temperatures see Heater screen This option deactivates this...

Page 55: ...ven Controls Oven Power on off status of ovens module power Ventilator indicates on off status of ovens module fans Water intake indicates the status of the inlet water solenoid for cooling the ovens and press Pre Heat pre heating status of the oven for each oven The oven is preheated when the temperature of the probes is lower than the pre heating temperature see oven control parameters Oven OK s...

Page 56: ...ply the compensation necessary to achieve and maintain the desired temperature Ventilator Speed Speed of the fan in each control module The parameter is a percentage relative of the maximum fan power regulated by speed adjuster Pref Neck Vent Speed Speed of the fan in each control neck The parameter is a percentage relative of the maximum fan power regulated by speed adjuster Oven Modulation perce...

Page 57: ...ond heater control screen where we are able to see a temperature graph of the heaters and the cameras We can also see a register of the evolution of the temperatures during the preform blowing process in an attached table Camera Temperature 1 Camera Temperature 2 Desired Temperature 1 Oven Temperature 1 Oven Temperature 2 ...

Page 58: ... value of the lamps is introduced as a percentage of the maximum power The numbering of the lamps is carried out in the following way the main lamp is number 1 counting upwards until we reach the least powerful lamp which is given the number of the total maximum amounts of lamps in the oven The graphical profile of each heater involved in the process is shown on the same screen On the TMS5001 XL a...

Page 59: ... of the machine From this screen we access the same screens as in automatic mode but adapted for manual mode tests and adjustments We can also run partial cycles of the various functions of the machine Loader Cycle Extractor Cycle Transport Cycle Press Cycle Press Cycle with Blowing Oven Cycle WARNING These functions can only be used in Advanced User access level because of the damage they may cau...

Page 60: ...n to be moved This cursor can move directly selecting the function on the touch screen or by using the and buttons on the screen Using the F1 and F2 buttons on the operator panel we can activate deactivate the selected function In the same screens we also find the necessary parameters to execute certain functions ...

Page 61: ...ave and loading the disc is always done from the current format workspace in use The screen is divided into four parts Save Current Format on Disk save the current work format with the current name to disk We can confirm or change the name and on pressing the button Save to Format to Disk it is copied Load Format from Disc from a drop down list we select the format to upload and click Load Format ...

Page 62: ... of the format to be saved Step 2 Press Save Format on Disc to save data Step 3 The control system asks us if we are sure that we want to save the current format because if it already exists it will be over written and therefore we will lose the one previously saved on the disk 2 3 1 ...

Page 63: ...he disk Select the desired format Step 2 Press Load Format from Disc to load the selected format Step 3 The control system asks us if we are sure we want to load the format selected in the work area because the process data with which we are working will be overwritten and therefore we will lose the current work data 3 ...

Page 64: ...f stored formats on the disk Select the format we want to delete Step 2 Press Delete Disc Format to delete the selected format Step 3 The control system asks us if we are certain that we want to delete the selected format from the disk Whatever happens we will not lose the current job data 1 2 3 ...

Page 65: ...example waiting for a detector of a given element within the cycle Whenever a Process Alarm is triggered the machine alarm sounds continuously Secondary Alarm Warning of an event for example Greasing Alarm This does not shut down the machine production cycle Whenever a Secondary Alarm is triggered the machine alarm sounds intermittently When the Alarm light on the screen is red it indicates a Prim...

Page 66: ... last 10 000 alarms is stored Functions E STOP indicates the status of emergency mushrooms Emergency Stop Doors indicates the status of the machine s safety doors Siren status of the acoustic signal that warns of an alarm state Pilot Reset indicates status of the signal lamp that indicates resetting of Reset alarms Alarm Pri Pro Sec Indicates the Primary Process Secondary alarm status Reg button t...

Page 67: ...eview the maintenance section of this manual Parameters 1 Number of hours worked since the last maintenance day 2 Number of hours scheduled for maintenance 3 Number of days worked and planned before the next service The maintenance warning can be activated in two cases The number of hours worked exceeds the number of hours scheduled The number of days since the last maintenance day is higher than ...

Page 68: ...ours worked since the last day maintenance work was done on the blowing machine 2 Number of hours scheduled for maintenance work on the blowing machine 3 Number of days worked since the last day maintenance work was done on the blowing machine Buttons Counter reset button Weekly Res Weekly hours worked counter reset Monthly Res Monthly hours worked counter reset Quarterly Res Quarterly hours worke...

Page 69: ...f spanners 7 2 FORMAT CHANGE START UP 1 Before starting to change the format make sure that you close the water inlet valve in the first place and then the water outlet valve 2 Follow the order explained in this manual in order to carry out the different tasks so as to prevent ruptures due to the interference between parts of different formats during the format change process ...

Page 70: ... 1 Remove the blast tubes from the bottom of the mould 2 Remove the fixing bolts from the bottom of the mould and remove the bottom of the mould 3 For maximum format moulds fitthe safety fixing flanges on the machine Then open the press to access the fastening screws ...

Page 71: ...itted for normal format moulds First you must open the press to loosen the fastening screws All but two on the front should be loosened Do the same for the other half 6 Close the mould removing the fixing flanges for the maximum format moulds or the 4 remaining screws for standard moulds Fit the mould joint flanges ...

Page 72: ...nd 60Nm for the M10 12 9 basefastening screws 7 2 2 LIFT ADJUSTMENT First adjust lift speed so that the preforms are correctly loaded into the machine In order to change the speed of the lift belt it is necessary to regulate the variator frequency adjusting it to heavier or lighter loads The variator is placed in the switchboard marked with the sign U2 To modify the speed turn the wheel marked on ...

Page 73: ...lers DEPENDING on the format intended 2 Place the two preforms on each end and adjust the position of the rollers so that the body of the preform passes through the two rollers and so that the preform wing prevents it from falling Depending on the dimensions of the preform wing leave more or less space between the roller and the preform X measure 3 Once the rollers have been adjusted tighten the b...

Page 74: ... the rails and the preform so that the latter may pass through them Depending on the size of the preform wing leave more or less room between the rails and the preform X measure Values advised never below 0 5mm 3 Once the rails of the lead in conveyor and the divider have been adjusted adjust the roofs that prevent the preforms from raising when they are coming down the lead in conveyor In order t...

Page 75: ... final value of the adjustment for future reference for format changes with the same preform neck take must be implemented 5 Once the whole unit has been adjusted put its protections back in place 7 2 5 CAMBIO DE FORMATO 1 To change the preform holder unit nozzles we must first detach the preform protectors To do so we unscrew the M6 screws x2 that hold them in place 2 Once we have extracted the g...

Page 76: ...ard We tighten the M6 screws x2 to 14 Nm 5 We repeat the process for the other nozzles When we want to change nozzles format with a diameter greater than 60 mm we must arrange the preform holder units in such a way that the preform holders are fitted in the transport every two places that is one occupied and the next empty 7 2 7 SETTING THE OVEN Before manipulating the ovens make sure the machine ...

Page 77: ...whether measure Y equals 25mm approximately This measure is also an approximate one and before modifying the position of the bulbs you are advised to define the thermal profile modifying their voltage parameters Still if you are working with very little or very big preforms you might have to bring the bulbs closer to the preforms or separate them instead 5 In order to modify the position of the bu...

Page 78: ...workbench and loosen the lateral fixing bolt of the bulb support Do the same thing with the other bulb support 8 Take the bulb with the hand by its two ends and move it towards the desired measure and then fix the lateral bolt 9 Depending on the type of bottle it might be necessary to move the bulb vertically ...

Page 79: ...01 10 In order to regulate it access the rear fixing bolt loosen it and move the bulb support vertically 7 2 8 FEEDER ADJUSTMENT 1 Loosen screws and adjust front guides 2 Regulate photocell and mirror to the desired height ...

Page 80: ...e has come into position go to the manual screen press close press mould to lower the bottom and keep pressed until the opening of the press reaches 5mm in order to calibrate the stretching correctly 3 Enter the manual screen then and choose from a range of stretching rods 4 Exit the manual screen and go to the main screen again press the stretching position right by the press 5 Place a preform up...

Page 81: ...ity problems If preforms from different dates and presses are used you might have to manipulate the mould blowing machine constantly in order to guarantee the integrity of the containers Effects of environmental conditions upon preforms The age and the humidity content of preforms affects container elaboration to a great extent The higher the humidity content in the preform the faster it will crys...

Page 82: ...e material down The pre blowing is a primary process parameter that makes it possible to control material distribution Electric stretching encoder position Each function of the blowing cycle starts by using encoder points that blow the valves The position o f each encoder point can be separately moved from the screen using times In general the pre blowing encoder point is placed in such a way that...

Page 83: ...isation of the container might demand a relocation of the encoder point If during the stretching calibration for the blowing process they are positioned too soon the openings of the bottle might be misaligned for the air is activated before the stretching rod reaches the lower part of the preform or fixes the base opening If during the stretching calibration they are positioned too late the bottle...

Page 84: ... the process Control preform quality 8 2 2 FORM DEFECTS CAUSE SOLUTIÓN Corrugation Rings towards the inside Lack of primary air during the blowing stage Check the presence of primary air and pressure Check primary electro valve feeding Longitudinal malformation of the container Dirty outlets in blowing cavity Clean air outlets Low preform temperature Increase preform temperature progressively Moul...

Page 85: ...pressure Increase primary air pressure Misalignment see also container perpendicularity High pressure too soon Delay primary air Shrink Control the different parts of the pneumatic facility of primary air Check the stretching rod speed Too much distance between the rod and the bottom Check distance between rod and bottom 3mm Stretching unit off axis Adjust stretching unit Uneven preform thickness ...

Page 86: ...eforms and or foreign bodies throughout the starter motor and after every subsequent stoppage as a result of a defect O O O O O 0 5 Visual control of the following parts of the machine in order to detect possible broken parts ascending conveyor belt preforms transport rails loading and unloading system oven etc and clean them of grease dust preforms and bottles O O O O O 1 Clean the excess grease ...

Page 87: ...ing or tightening the chain if necessary O O O O 0 5 Check if there is water in the air entrance filter of the pneumatic maintenance groups Clean if necessary and check the proper functioning of the dryer if it has one O O O O 0 5 Check the automatic greasing system level of lubrication grease of the pump O O O O 0 25 Check pipes and lubrication injectors of the press and the rest of the equipment...

Page 88: ...als and electric contacts in the control cabinet and in all of the parts of the machine O O 6 Check and if necessary replace or clean ventilation filters of the control cabinet and the functioning of ventilation or air conditioning O O 1 Clean the valves of the SBM machine and steering and if necessary replace them and any damaged parts O O 4 Parts of the air water radiator O O 1 Clean the transpo...

Page 89: ...lish with paste for stainless steel O 1 If the machine has an air recovery system installed change the gaskets of recovery O 2 Dismantle the air water exchanger and clean O 2 Change de bushings of the bottom holder O 2 Change de bushings of charge discharge machine O 3 ...

Page 90: ... a door The pump consists of different parts it is provided with a deposit to store the grease The deposit is on the upper part of the unit The pump has two alarms absence of lubrication pressure and low level of grease The former informs us that the circuit does not have enough pressure which means that we are not lubricating the movable parts correctly The latter informs us that the grease level...

Page 91: ... Colour Light yellow Structure Homogeneous oily Density DIN 51 757 at 20ºC g cm3 0 85 Drop melting point DIN ISO 2176 ºC 220 Penetration at 25ºC DIN ISO 2137 0 1mm From 400 to 430 Consistency Type NLGI DIN 51818 0 Usage temperature range ºC From 45 to 120 9 2 4 MANUAL LUBRICATION SYMBOL DESCRIPTION PERIOD A1 Lubrication with Klübersunth UH1 14 1600 grease Weekly and or after 80 production hours A2...

Page 92: ... with the booster dolly in the upper position so in manual mode put the booster dolly up and open the mold to keep the booster dolly up when air supply shut down The lubrification shown below has to be done with the booster dolly in the lower position so in manual mode put the booster dolly down ...

Page 93: ... bolts in all the connecting sockets Remove connecting sockets from the valve gear 2 Loosen fixing bolts in the valve unit using an Allen key 3 Turn the unit upside down Remove the valve of ring P1 from its base Fix the ring inserting the Seeger pliers in the lateral holes of the base Turn the ring from left to right and pull towards you Before manipulating the valve make sure the system voltage h...

Page 94: ...e Fix the ring inserting the Seeger pliers in the lateral holes of the base Turn the ring from left to right and pull towards you 5 Remove non return valves from operation valves P1 and P2 6 Remove retention ring of the relief valve 7 Remove retention ring of valve P2 ...

Page 95: ...ement of the removed parts with your hand 10 Remove valve P2 of the piston in the covered part Press the Allen key against the piston valve inside the unit Check the movement of the removed parts with your hand 11 Remove the relief valve of the piston in the covered part Press the Allen key against the piston valve inside the unit Check the movement of the removed parts with your hand ...

Page 96: ... default and they should not be lubricated again Otherwise apply a fine layer of grease with your hand Ref OE 0101 020 around the seal see arrows 16 Apply with your hand a fine layer of grease in the 0 rings Ref OE 0101 020 Insert the 0 rings in the covered area with your hand Make sure the 0 rings fit the rim of the hole see arrows 17 Insert valve P1 separating the piston from the carcase Tighten...

Page 97: ...he parts introduced by pressing the Allen key against the valve piston inside the unit 19 Insert the relief valve piston Tighten with your hand the parts introduced in the unit Check the movement of parts introduced by pressing the Allen key against the valve piston inside the unit 20 Insert the relief valve retaining ring 21 Insert the P2 valve retaining ring ...

Page 98: ...ring see arrow is damaged If the ring is damaged replace it 25 Apply a fine layer of grease Ref OE 0101 020 in the outer side of the 0 seat rings see arrow 26 Turn the unit upside down and insert the non return valves of function valves P1 and P2 The flat end must be oriented towards the ring seat which will be inserted next 27 Insert valve P1 in the ring seat Pick the ring by inserting the Seeger...

Page 99: ...eral holes Turn the ring from left to right and tighten it down into the unit 29 Insert the fixing bolts into the valve unit manually Tighten the bolts with a 25 Nm torque using an Allen key 30 Place the connector sockets for the valve gear Tighten the fixing bolts of all the connector sockets with an 60 Ncm torque ...

Page 100: ...ght be damaged as when the preforms cool down they may clamp the stretching rods and hinder the movement of the whole system An excessive stretching of the belts might result in belt tearing If the belt is not sufficiently stretched the cogs might be torn out The steps that must be followed to replace the stretching belt have been included next Below are the steps for replacing the stretch belt 1 ...

Page 101: ...ressively at 20Nm by cross clamping both clamps 6 Tighten stretching screws as shown in the picture until reaching the adequate tension Do not stretch excessively or leave the belt loose Holding the rod support on one end check whether the belt can move 10 15 mm with your hand on the central part 7 Tighten the M16 12 9 quality fastening nuts and screws x3 to 105Nm Screw M24 screw should be tighten...

Page 102: ...oint 2 in reverse 9 3 5 CYLINDER SEALING GASKET Below are the steps for removing the airtight cylinder to replace damaged parts or for cleaning and or inspection The elements in this blower assembly subject to wear are those subjected to movement of the cannula These are shown in the following figure in red and green Before manipulating the cylinder make sure the system voltage has been cut off an...

Page 103: ...y hoses of the two blowerunits Then dismantle their electrical connections 2 Push with your hand in the direction of the arrow so that the shaft moves downwards 3 Loosen the nozzle and remove it Then remove the screws and remove the cylinder ...

Page 104: ...ual close the mould 8 Actuate the cylinder using the screen check that the nylon cap does not jam it can rotate If it does further loosen the adjusting nut 9 Tighten the adjusting screw locknut until the nylon cap hits the cylinder and then tighten the jam nut 10 Now the impervious cylinder is adjusted To check whether it has been correctly adjusted place new preforms in again close the mould and ...

Page 105: ...ion of the belt manually To do so access the machine screen menu as follows i Manual ii Load iii Preform lift belt 100 iv ON Belt in operation 4 View the lower roller while it is working observe whether it is centred or if it moves See Figure 3 5 If the belt is not centred tighten the roller on the same side towards which the belt tends to move in order to move it in the opposite direction See Fig...

Page 106: ...Page 105 of 106 TMS 5001 H 10 30 ...

Page 107: ...Page 106 of 106 TMS 5001 if A B then A B A B A B ...

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