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➟

Please copy this

information from the

CapStar

serial plate.

Cap Feeder

ANSI/Metric Installation
& Maintenance Manual

Refer all servicing to

qualified personnel.

This manual is intended

for use by qualified

mechanics and electricians

who install or service the

CapStar Cap Feeder

Inventory Number (Check One):

❑

FCCPSTLDSA

❑

FCCPSTRDSA

❑

FCCPSTLASM

❑

FCCPSTRASM

Cap

Star

15395 John Marshall Highway

Haymarket, VA 20169

Phone: (703) 753-8888

Toll Free: (800) 368-3582

Fax: (703) 753-7485

http://www.hoppmann.com

Inventory/Serial Number:

Содержание Cap Star FCCPSTLASM

Страница 1: ...ied mechanics and electricians who install or service the CapStar Cap Feeder Inventory Number Check One FCCPSTLDSA FCCPSTRDSA FCCPSTLASM FCCPSTRASM Cap Star First Edition Publication Version All Rights Reserved Copyright 2002 by Hoppmann Corporation 15395 John Marshall Highway Haymarket VA 20169 Phone 703 753 8888 Toll Free 800 368 3582 Fax 703 753 7485 http www hoppmann com Inventory Serial Numbe...

Страница 2: ...nditions The exclamation point caution symbol denotes possible personal injury and or damage to the equipment Thelightningboltcautionsymboldenotespossiblepersonalinjury and or damage to the equipment from electrical hazards Before You Start Tools You Will Need The CapStar Cap Feeders are offered in both ANSI and metric versions For maximum compatibility ANSI units are classified as soft ANSI const...

Страница 3: ...he CapStar Cap Feeder is Already Set Up 13 Unpacking and Inspection 14 Physical Setup 15 Setup 15 Initial Settings 17 Making Tooling Adjustments 19 Motor Speed Reducer Idler Assembly 22 Electrical Wiring Figures 14 Figure 3 1 Adjusting the Height 17 Figure 3 2 Secondary Hopper Location 18 Figure 3 3 CapStar Tooling 19 Figure 3 4 Height Adjustment 19 Figure 3 5 CapStar Speed Reducer 20 Figure 3 6 D...

Страница 4: ...veyor Belt Installation and Replacement 28 Elevator Belt Installation and Replacement Figures 26 Figure 4 1 Conveyor Belt Replacement Exploded View Replacement Parts 29 Notice to Hoppmann Corporation Customers 31 Warranty 32 Scheduled Preventive Maintenance Log Figures 29 Figure 5 1 Serial Plate Layouts 5 Chapter Page Table of Contents Continued 4 ...

Страница 5: ... of cap sizes and shapes at a cap delivery speed of 40 to 600 parts per minute Changeover from one cap style to another takes less than fiveminutesandisstraightforward Nospecialtrainingisneeded Figure 1 1 CapStar Cap Feeder Right Hand Unit Polypropylene Elevator Belt Electrical Cabinet Primary Hopper Singulation Wiper Horizontal Conveyor Feed Belt Hand Crank Leveling Feet Casters Pulley Take Up Se...

Страница 6: ...will be described in Chapter 3 The CapStar Cap Feeder is bolted onto an adjustable center stand using two support arms The support arms ride on friction guides that are used to raise and lower the unit when the hand crank is turned The vertical movement combined with the caster wheels allow the unit to be positioned exactly where it is needed Caps are loaded into the primary hopper bin see Figure ...

Страница 7: ...ensor theairstreamblowingdowncreates a back pressure The sensor reads the back pressure and if the cap is misoriented triggers a reject airjet to blow the cap down the return chute Correctly oriented caps are allowed to pass the airjet and positive pressure sensor and continue down the conveyor Chapter 1 Description and Specifications Figure 1 2 CapStar Head Polypropylene Elevator Belt Electrical ...

Страница 8: ...stallation Maintenance Manual 8 See Chapter 3 Installation Start up for the setup details Figure 1 3 CapStar Tooling Height Qualifier Air Prox Conveyor Tooling Support Wall Orientation Qualifier Wiper Singulation Wiper ...

Страница 9: ...rs Dimensional Specifications A Overall Height 65 81 1655 mm 2060 m B Load Height 35 51 908 mm 1314 mm C Discharge Height 46 62 1174 mm 1580 mm D Overall Length 60 1536 mm E Overall Width 54 1371 mm F Belt Width Horizontal 6 152 mm G Interfaced Conveyor Clearance 7 178 mm Performance Specifications Elevator Max Speed 37 feet min Conveyor Max Speed 43 feet min Table 1 1 CapStar Cap Feeder Specifica...

Страница 10: ...ce Manual 10 Figure 1 4 CapStar Cap Feeder Specifications Your direct supplier may have changed some of these specifications during tooling to better match your application s requirements CapStar Cap Feeder Specifications E F F A B C L C G ...

Страница 11: ...lothing Do not wear loose jewelry or neckties near the equipment Wear safety glasses or otherprotectiveeyewearwhenservicingoroperatingtheCapStar Never place hands or tools in the equipment when it is operating Avoid Pinch Points Exposed pinch points include the elevating belt at the bottom of the hopper and at the intersection of the horizontal belt At the horizontal belt where the cap sorter guid...

Страница 12: ...te Removepackingmaterials from sensors tooling and moving parts Make a visual check to be sure parts have not come loose during shipping If you find any concealed damage call the shipping carrier and your direct sup plier immediately Do not attempt to fix the problem yourself unless told to do so by your direct supplier Step 2 Record Serial Number of the CapStar If you have not already done so rec...

Страница 13: ...gages the wheel and the wheel brake tab protrudes above the larger locking tab To release the brake step on the small wheel brake tab or lift up on the larger locking tab Lowerthefeetuntiltheweightistransferredtothefeetandengage the locknuts A level should be placed on the horizontal continuous belt and the unit should be leveled The unit can be raised or lowered into position by turning the hand ...

Страница 14: ...ing the knob and setting the height 1 8 to 1 4 above the cap Step 2 Set the Angle Set the angle of the singulation wiper by loosing the hand knob and pivoting the wiper so that only one cap by diameter can pass the wiper The CapStar Cap Feeder is now setup to send a line of caps to the orientation qualifier Step 3 Orientation The orientation qualifier is set to allow one cap one cap diameter form ...

Страница 15: ...vent connecting to the wrong voltage Turn the main power switch on Rotate the switch clockwise to energize The EMERGENCY STOP switch should be pulled out and illuminated When the EMERGENCY STOP switch is pushed in the electrical power is cut off and the light is off If the motors do not start to run turn the speed controls up until the elevator belt starts to lift caps out of the hopper It is reco...

Страница 16: ...nts Product which is carried from the primary hopper by the elevator belt is metered into a secondary hopper see Figure 3 2 The secondary hopper assists with settling the parts before they enter the tooling area and horizontal conveyor Step 1 Adjust the Speed The speed at which the elevator is run shouldbesetsothattheproductinthesecondaryhoppermaintains a consistent level Parts leave the secondary...

Страница 17: ...e adjusted to allow only one single level of parts to pass in a single file line Step 4 Adjust Air Proximity Vertical and Horizontal Position When caps enter the second stage of tooling or the orientation qualifier area the air prox will qualify the part to a cavity up position The air prox is attached to the tooling support wall To adjust the wall loosen the hand knobs on the back side of the wal...

Страница 18: ...customersdownstream equipment Anyrejectedproduct entersthe return chute and is reintroduced into the system for recirculation Motor Speed Reducer Idler Assembly Speed Reducer No Lubrication Required The speed reducer used in the CapStar is lubricated for life with synthetic lubricant and requires no regular maintenance see Figure 3 5 Figure 3 5 CapStar Speed Reducer Reducer Idler Assembly Motor Mo...

Страница 19: ...C 118 KBIC 218 1 3 2 4 Notes Do not use this diagram if your CapStar has an AC motor or a different motor speed controller than shown Follow the suggested wiring drawing provided by your direct supplier Motor Controller Start Stop Options Option 1 Open P3 circuit of speed pot with a pilot duty switch circuit for stop Option 2 Interrupt line voltage To reverse motor rotation interchange leads A and...

Страница 20: ...ring Diagram Mounting IEC 63A Face Mounting 186 Watts Hoppmann Part Number MOTORMAC025 150 Watts Hoppmann Part Number MOTRM 20HP T6 T4 T5 T1 T2 T3 L1 L2 L3 T6 T4 T5 T1 T2 T3 L1 L2 L3 HIGH VOLTAGE LOW VOLTAGE 220V 50 HZ 380V 50 HZ FRAME SINGLE SPEED DFT 71 DFT 8fl Protection Level IP54 Protection Level Chapter 3 Installation Startup ...

Страница 21: ...ds are independent non synchronized The Main Power Switch provides power to the electrical box The EMERGENCY STOP cuts power to the controllers and the motors The Main Power Switch must be turned off before opening the electrical box Until the Main Power Switch is turned off the breaker s and the terminal strips are still powered up The Motor 1 M1 drives the vertical elevating belt The Motor 2 M2 ...

Страница 22: ...100 GND LOCKABLE DISCONNECT 1PBL START STOP CB1 15A RUN SIGNAL FROM CUSTOMER 1CR 103 102 A1 A2 101 PL1 R 101 NEU MOTORS RUN POWER ON 100 Chapter 3 Installation Startup Figure 3 8 CapStar Wiring Schematic CapStar Wiring Schematic ...

Страница 23: ...9 CapStar Wiring Schematic CapStar Wiring Schematic 101 NEU 2PT 314 317 318 P3 P2 P1 L1 L2 F F A A 310 311 312 313 1 5HP 2 MTR CONVEYOR DRIVE 125 1FU 2A 126 2FU 3A 1PT 304 307 308 P3 P2 P1 L1 L2 F F A A 302 303 1 4HP 1 MTR PREFEEDER DRIVE 1MC 2MC 33 34 MCR 104 ...

Страница 24: ...nents are securely fastened Inspect the unit for loose screws loose guides or covers and tighten as necessary Inspect the conveyor belts for wear or fraying Gently clean dust from the hopper Inspect for air leaks The orientation sensor bleeds air continuously This is normal Since bleeding air is makes noise feel around the air lines and the air line connectors for leaks General Cleaning Whennecess...

Страница 25: ...taining the electrical cords for both motors Step 3 Remove the Load Box Remove the 4 M8 screws that mount the load box Swing load box out of position and rest on tableorworkbench Loosenboltsandremovebothendcoversand the drive cover Step 4 Remove Drive Cover Remove the drive cover from the conveyor see Figure 4 1 Step 5 Remove Tooling Step 6 Remove Covers Loosen bolts and remove tail pulley cover S...

Страница 26: ...hrough the lower spools see Figure 4 1 Step14 ReinstallSlidePlate Reinstallslideplateoftheconveyor drive Step 15 Install Conveyor Mounting Clips Step 16 Tighten Idler Pulleys Do not overtighten the belt When tightening the takeup pulley apply the minimum tension necessary to take up slack and properly track the belt If you apply toomuchtensionyoucaneasilydestroythebeltordecreasethelife of the pull...

Страница 27: ... pin located on the underside return side of the elevator loosen both sides of the lower pulley takeup brackets With the chain loose remove the one pin Step2 InstallReplacementChain Installthenewchain reinsert pin and tighten the lower take up bracket refer to Figure 3 1 in the Installation Startup Chapter 3 of this manual for take up bracket location ...

Страница 28: ... spare parts and will assist us in making sure we have the correct parts for your tooled system See Figure 5 1 for the two types of serial plates that may be located on your system This information is necessary when ordering replacement parts or service Hoppmann Corporation s contact information is listed on the following page Model Number Date Serial Number 15395 John Marshall Highway Haymarket V...

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