INSTRUCTIONS MANUAL 221wiki.energoplast.co.rs/images/2/25/Manual_TVC_A.pdf · 2020. 6. 11. ·...

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INSTRUCTIONS MANUAL

221.02.A04MACHINE FOR BENDING SAFETY BANDS FOR PLASTIC CAPS

TVC 003

Revision 00 Date 11.09.1998

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TABLE OF CONTENTS

221.02.A04 Revision 00 Date 11.09.1998

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221.02.A04TABLE OF CONTENTS


MANUFACTURER

SACMI IMOLAVia Selice Provinciale, 17/A

40026 IMOLA (Bologna) - ITALIA

PUBLISHED ON

September 11, 1998

REVISION NO.

00

VERSIONS

TVC 003.00.001 - TVC003A

SERIAL NUMBER

YEAR OF MANUFACTURE

INSTRUCTIONS MANUAL

BENDING MACHINE FOR SAFETY BANDS FOR PLASTIC CAPS

TVC 003

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TABLE OF CONTENTS

221.02.A04 Revision 00 Date 11.09.1998

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221.02.A04TABLE OF CONTENTS


Page1 GENERAL INFORMATION ............................................................................................................ ............1 - 1

1.1 INTRODUCTION ........................................................................................................................ 1 - 11.2 WHERE TO KEEP THE MANUAL ............................................................................................. 1 - 11.3 HOW TO USE THE MANUAL .................................................................................................... 1 - 11.4 USERS OF THE MANUAL......................................................................................................... 1 - 11.5 WARRANTY ............................................................................................................................... 1 - 21.6 ENCLOSURES........................................................................................................................... 1 - 21.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL ...1 - 21.8 MACHINE IDENTIFICATION PLATE.......................................................................................... 1 - 3

2 MAIN FEATURES ......................................................................................................................................2 - 12.1 MACHINE DESCRIPTION ......................................................................................................... 2 - 12.1.1 MAIN DEVICES...........................................................................................................................2 - 22.1.1.1 CAP FEED CHANNEL ............................................................................................................... 2 - 22.1.1.2 WORK UNIT ............................................................................................................................... 2 - 32.1.1.3 TOOLING ....................................................................................................................................2 - 42.1.1.4 EXIT CHANNEL ......................................................................................................................... 2 - 52.1.1.5 CONVEYING CHANNEL.............................................................................................................2 - 52.1.1.6 LOWER STRUCTURE ............................................................................................................... 2 - 62.1.1.7 DRIVE UNIT ............................................................................................................................... 2 - 62.1.1.8 PNEUMATIC SYSTEM ...............................................................................................................2 - 72.1.1.9 ELECTRICAL CABINET............................................................................................................. 2 - 72.1.1.10 SAFETY DEVICES INSTALLED ................................................................................................. 2 - 72.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ................................................. 2 - 82.2 OVERALL DIMENSIONS ........................................................................................................... 2 - 92.3 TECHNICAL DATA .................................................................................................................. 2 - 102.3.1 SPECIFICATIONS ................................................................................................................... 2 - 102.3.2 ALLOWABLE FLUCTUATION OF THE VARIABLES .............................................................. 2 - 112.3.3 RATING PLATE ....................................................................................................................... 2 - 112.3.4 OPERATIONAL CHARACTERISTICS ..................................................................................... 2 - 122.3.5 NOISE EMISSION LEVELS ..................................................................................................... 2 - 132.3.5.1 ACOUSTIC RADIATION PRESSURE LEVEL (ISO/DIS 11202) ............................................. 2 - 132.3.5.2 ACOUSTIC POWER LEVEL (ISO 3746) ................................................................................. 2 - 142.3.6 LUBRICANT SPECIFICATIONS .............................................................................................. 2 - 142.4 DIAGRAMS .............................................................................................................................. 2 - 152.4.1 PNEUMATIC SYSTEM DIAGRAM .......................................................................................... 2 - 15

3 SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 13.1 SAFETY DEVICES INSTALLED ................................................................................................. 3 - 13.2 GENERAL RULES ......................................................................................................................3 - 33.3 SAFETY RULES FOR HANDLING .............................................................................................3 - 43.4 OPERATOR TRAINING ............................................................................................................. 3 - 53.5 SAFETY RULES FOR OPERATION AND MAINTENANCE ..................................................... 3 - 63.5.1 HAZARDS PRESENT IN THE MECHANICAL SYSTEM............................................................3 - 73.5.2 HAZARDS PRESENT IN THE ELECTRIC SYSTEM ................................................................. 3 - 83.5.3 HAZARDS PRESENT IN THE HEAT SYSTEM.......................................................................... 3 - 93.5.4 SAFETY RULES FOR MAINTENANCE OPERATIONS............................................................ 3 - 93.6 MAKING THE MACHINE INOPERATIVE WHEN NO LONGER USED .....................................3 - 9

4 INSTALLATION ................................................................................................................... ..................... 4 - 14.1 SHIPPING AND HANDLING ...................................................................................................... 4 - 14.2 POSITIONING .............................................................................................................................4 - 34.3 CONNECTIONS AND HOOK UPS .............................................................................................4 - 54.3.1 CONNECTING THE MACHINE TO THE COMPRESSED AIR MAINS..................................... 4 - 54.3.2 CONNECTING THE ELECTRIC CABLES ................................................................................. 4 - 6

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TABLE OF CONTENTS

221.02.A04 Revision 00 Date 11.09.1998

Page5 MACHINE START-UP ............................................................................................................................... 5 - 1

5.1 INTRODUCTION ........................................................................................................................ 5 - 15.2 PRELIMINARY CHECKS ........................................................................................................... 5 - 15.3 DAILY START-UP ...................................................................................................................... 5 - 2

6 OPERATING INSTRUCTIONS ................................................................................................................. 6 - 16.1 CONTROL DEVICES ................................................................................................................. 6 - 16.1.1 ELECTRICAL CABINET ............................................................................................................. 6 - 26.2 OPERATION IN MANUAL MODE ...............................................................................................6 - 46.3 OPERATION IN AUTOMATIC MODE ........................................................................................6 - 4

7 ADJUSTMENTS .................................................................................................................... .................... 7 - 17.1 CAP FEED CHANNEL ............................................................................................................... 7 - 17.1.1 ADJUSTING THE AIR PRESSURE IN THE PNEUMATIC CYLINDER .....................................7 - 17.1.2 REPLACING THE FEED CHANNEL TO HANDLE A NEW PRODUCT SIZE ............................7 - 37.2 ADJUSTING THE CAP STRIPPER RODS .................................................................................7 - 47.3 ADJUSTING THE HEIGHT OF THE TOOLS ............................................................................ 7 - 57.4 REPLACING THE CAP TRANSFER TURN-TABLE ...................................................................7 - 67.5 EXIT CHANNEL ......................................................................................................................... 7 - 77.5.1 ADJUSTING THE CHANNEL JAMMING CONTROL DEVICE ................................................. 7 - 77.5.2 REPLACING THE CAP EXIT CHANNEL TO HANDLE A NEW PRODUCT SIZE .....................7 - 87.6 CONVEYANCE CHANNEL ........................................................................................................ 7 - 97.7 PNEUMATIC SYSTEM ...............................................................................................................7 - 9

8 MAINTENANCE .................................................................................................................... .................... 8 - 18.1 GENERAL INFORMATION AND PRECAUTIONS REGARDING SAFETY .............................. 8 - 18.2 SCHEDULED MAINTENANCE .................................................................................................. 8 - 28.2.1 CLEANING THE TOOLS.............................................................................................................8 - 28.2.2 LUBRICATION ........................................................................................................................... 8 - 28.2.3 CLEANING THE ELECTRIC PARTS ..........................................................................................8 - 28.3 SPECIAL MAINTENANCE OPERATIONS .................................................................................8 - 48.4 TROUBLESHOOTING THE MACHINE ......................................................................................8 - 48.4.1 TROUBLESHOOTING GUIDE .................................................................................................. 8 - 4

9 DISMANTLING THE MACHINE........................................................................................................ ........ 9 - 1

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221.02.A04GENERAL INFORMATION 1


1 GENERAL INFORMATION

1.1 INTRODUCTION

E0004PWARNING!

Carefully read the entire Maintenance & Operations Manual before working on the machine and/or handling thepacking containers.This manual contains important information for safeguarding the operators, the maintenance staff as well as themachine itself.SACMI reserves the right to make changes to the machine and the manual without giving prior notice.This manual and related drawings are the property of SACMI, therefore they cannot be reproduced in any form. Failureto observe this, will entitle SACMI to take legal action.Additional copies of this manual can be obtained by contacting SACMI’s After Sales Service Dept.

1.2 HOW TO KEEP THE MANUAL

E0004PWARNING!

This manual must always accompany the machine even when it is resold. The manual should always be close at handso that the operator and maintenance staff are able to consult it rapidly at any time.

1.3 HOW TO USE THE MANUAL

The layout of this manual allows it to be easily consulted as all the information and instructions provided are groupedtogether in chapters and paragraphs. The user has to simply refer to the table of contents. The information providedwith Alert, Warning or Danger symbols must be read carefully. The notes pertinent to the operator’s safety or healthare given inside a block and are also pointed out by Alert, Warning and/or Danger symbols. Moreover, they are writtenin italics as shown below.

E0004PWARNING!

The SAFETY PRECAUTIONS chapter must be read carefully as it contains important information and safetywarnings.

1.4 USERS OF THE MANUAL

In this manual, the personnel that work around the machine are divided as follows:- Operator: this is the person responsible for supervising and operating the machine.- Routine maintenance staffFor a more detailed description, see the paragraph dealing with OPERATOR TRAINING in the SAFETY PRECAUTIONSchapter.

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221.02.A04 Revision 00 Date 11.09.1998

1.5 WARRANTYSACMI 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 personnelor duly authorized by SACMI’S Engineering Dept.SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.

E0004PATTENTION!

The machine operator or maintenance staff are not responsible for carrying out operations under warranty, specialmaintenance and repairs. These operations are to be performed only by the manufacturers specially trainedtechnicians. For this reason, these types of operations are not dealt with in this manual.

1.6 ENCLOSURESInformation regarding the electric and electronic components of the machine are given in three handbooks providedunder separate cover and are entitled:- USE OF THE MICROPROCESSOR CONTROL SYSTEM (Instructions B manual)- LIST OF DEVICES, SETTING THE OPERATING DATA AND NOTES REGARDING USE

These handbooks are supplied with this manual.

1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THEMANUAL

WARNING SYMBOLS

E0004PGeneral hazard

E0002PDanger of being burnt on hot surfaces (when plastic caps are handled)

E0003PDanger of hands being crushed

E0007PHigh tension, danger of being electrocuted

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221.02.A04GENERAL INFORMATION 1


TIPOTYPE

MATRICOLA No.SE R I A L N U M B E R

ANNOYE A R

V I A S E L I C E P R O V I N C I A L E 1 7 / A I M O L A - I T A L I A

E0020

ALERT SYMBOLS

E0005OHeavy duty work gloves must be worn (when plastic caps are handled)

E0006OMachine must be connected to an effectively grounded power point

ADDITIONAL SYMBOLS

E0009CA list of the tools needed to carry out maintenance is provided

1.8 MACHINE IDENTIFICATION PLATE

T1355

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221.02.A04 Revision 00 Date 11.09.1998

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221.02.A04MAIN FEATURES 2


2 MAIN FEATURES

2.1 MACHINE DESCRIPTION

The TVC003 is a rotary upright machine designed to bend the safety band applied around plastic caps. It includes atool holding unit fitted with two sets of punches (top ones turn while the bottom ones translate) that bend the band asrequired. A channel is used to feed the caps to this unit. Once the operations have been completed, the caps are sentto an exit channel and discharged from the machine.A microprocessor based system is used to operate the control cabinet. This system provides all required informationin real time.The machine can be divided into the parts indicated in the figures below:

Fig. 2.1 - OVERALL VIEW

1 - Base2 - Drive unit3 - Work unit4 - Spindle5 - Tooling6 - Cap feed channel7 - Exit channel8 - Pneumatic system9 - Electric cables

10 - Electrical cabinet

T1356

7

92

3

4

6

5

1

8

10

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2 MAIN FEATURES

221.02.A04 Revision 00 Date 11.09.1998

2.1.1 MAIN DEVICES

2.1.1.1 Cap feed channel(See figure 2.1.1.1)

The caps enter the machine (directed) through the feed channel (1) fixed to the base. It is possible to inspect a sectionof the channel by opening the door (2). To open the door, turn the knob (3).Blowers (18 and 19), both of which are adjustable, are installed on the door. The function of the blowers is to feed capswithout interrupting the flow of incoming products.A fiber optic photocell (6) placed on a mount is attached to the feed channel. This photocell detects when the minimumcap level is reached. The pneumatic cylinder (4) controls the cap flow. In fact, this cylinder holds the caps back, whennecessary, thereby preventing them from flowing. This happens when the fiber optic photocell (6), located at the feedchannel inlet, is free (no caps) or when the photocell located in the exit channel is activated (channel full).

Fig. 2.1.1.1 - CAP FEED CHANNEL

2

6 1

4

19

3

18

T1357

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2.1.1.2 Work unit(See figure 2.1.1.2)

The work unit picks up the caps from the feed channel and places them on the support (1) through the turntable (2).The latter sees that the caps are moved around the axis of the unit. Thanks to the upper fixed cam (3), the uppermovable assembly fitted with a spring loaded pin (4) moves down. These devices provide a reference for the caps onthe lower movable assembly (5). The latter is operated by the fixed cam (6). The upper and lower movable assembliesare timed and move up thereby bringing the cap to the tool (7). The particular shape of the latter allows the band tobe shaped as required. The assembly (5), along with the pin (4), then move down releasing the caps that have alreadybeen bent from the tools so that they can be let out through the discharge channel.

Figure 2.1.1.2 - WORK UNIT

3

2

8

6

5

1

7

4

T1358

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2 MAIN FEATURES

221.02.A04 Revision 00 Date 11.09.1998

2.1.1.3 Tooling

The fixed and movable tools are used to produce caps that meet the customer’s individual requirements. A data sheetis provided with each group of tools. This sheet gives all the information the user needs to know to interchange thevarious parts that need to be replaced.

2 - 5



2.1.1.4 Exit channel(See figure 2.1.1.4)

The caps leave the exit channel in an orderly manner and are directed as required.This unit includes a plate (1) which acts as a mount for the various parts that make up the unit.The inspection door (2), located in the end section, can be opened by turning the knob (3).The blowers (5) are used to remove the caps from the channel.A mount for the fiber optic photocell (6) is attached to the exit channel. The function of this photocell is to detect whenthe maximum level has been reached in order to interrupt the cap flow in the feed channel, when required.

Cap control deviceThe cap control device detects any caps that have remained in the zone (12). This is accomplished through the lever(11). In fact, the lever moves thereby inactivating a proximity sensor (17) which stops the machine.

2.1.1.5 Conveying channel

The conveying channel sends the caps either to a downstream machine or a diverter with cap counter for filling theboxes, depending on the configuration of the production line employed.

Fig. 2.1.1.4 - EXIT CHANNEL

1

11

5

2

6

3

5

3

17

12

11

T1359

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2 MAIN FEATURES

221.02.A04 Revision 00 Date 11.09.1998

2.1.1.6 Lower structure

The lower structure consists of a base which is joined to the upper plate by four load-bearing corner sections. Feetthat can be adjusted in height are used to sustain the frame. The structure is enveloped with safety panels.

2.1.1.7 Drive unit

The drive unit consists of a motor-worm reduction unit whose driving end is keyed directly to the work unit shaft. Acontrol is provided for manual operation. The latter is inactivated by a safety switch which acts directly on the inputshaft of the gearbox.

Figure 2.1.1.7 - DRIVE UNIT

T1376

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2.1.1.8 Pneumatic system

The pneumatic system includes a control unit, located in the machine base, that contains the air preparation elements(filters and pressure regulators), control devices for the pneumatic actuators (blower solenoid valve and solenoid valvewhich operates the pneumatic cylinder that regulates cap flow in the feed channel) as well as the blower manifold.

2.1.1.9 Electrical cabinet

The electrical cabinet includes both a power section and a control section.The power section includes all the equipment required for the electric actuators (contactors, relays, etc..) as well asthe parts for processing the signals transmitted by the controls mounted on the machine or from the keyboard(microprocessor based control system, motor drives, etc..).The control section allows the user to operate the machine and monitor functioning. The machine can be run in eithermanual or automatic mode. A programmable logic controller is used. The following operations can be carried out fromthe keyboard:

- Setting the work-cycle- Setting or modifying the operating parameters- Displaying the operating data

2.1.1.10 Safety devices installed

The machine is equipped with mechanical and electric safety devices that ensure safe machine operation and use.In addition, the machine is provided with fixed and movable guards fitted with interlocks or mechanical shutdowndevices.A detailed description of the devices is given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.

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2 MAIN FEATURES

221.02.A04 Revision 00 Date 11.09.1998

2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE

INTENDED USE OF THE MACHINEThe machine is specially designed and constructed to produce products that have the characteristics indicated in thespecifications.

The machine operates safely if:- it is used under the conditions and within the limits prescribed and indicated in this paragraph- maintenance is performed at the intervals indicated in chapter 8 - MAINTENANCE- it is used properly by following the directions given in chapter 6 - OPERATING INSTRUCTIONS.

E0004PWARNING!

If the machine is remote controlled, suitable signs must be put up while the machine is running.

The machine can be run only in the following two modes:- manual- automaticUse the mode selector on the control panel to select the desired mode of operation

UNINTENDED AND PROHIBITED OPERATIONSNo other operations can be carried out unless expressly authorized by the manufacturer. The manufacturer shall notbe held responsible for injury to personnel or damage to the machine caused by failure to observe these warnings.

MISUSE OR ERRONEOUS USEThe manufacturer shall not be held responsible for any damage, injury or other consequences deriving from incorrector erroneous use of the machine.

The most common causes of incorrect machine operation are:- inadequate training of the operating personnel- fatigue, tiredness (especially during the night shift) or distraction- negligence due to superficiality or incorrect habits.

Remember that machine supervision and operation can be carried out only by expert competent personnel who havebeen well trained and able to:- use the machine under normal operating conditions- know what to do in an emergency

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2.2 OVERALL DIMENSIONS

The dimensions of the machine and electrical cabinet (the distance they have to be away from each other is given inchapter 4 - INSTALLATION) are indicated in the figure below:

C

1

AD

B

742

350

600

800

497

1712

1270

+25 -5

2030

380

50

1300

2400

4000

E

300

100

860

2100

2515

2

E

600

986

800

T1884

Figure 2.2 - OVERALL DIMENSIONS

1 Machine2 Electrical cabinetA Cap entryB Cap exit

C Compressed air inletD Work zoneE Electrical hook-up

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2 MAIN FEATURES

221.02.A04 Revision 00 Date 11.09.1998

2.3 TECHNICAL DATA

2.3.1 SPECIFICATIONS

Speed/1' (per 28 mm ROP) up to 800Diameter mm from 25 to 52Height mm from 12 to 30Power requirements (50 Hz) kW 1.5Absorbed power (50 Hz) kW 1.2Electric motor power output (50 Hz) kW 1.5Auxiliary voltage 110 VAG - 24 VDCAir consumption (pressure 0.5 MPa) dm3/1' 300Air pressure MPa 0.5Operating temperature °C 5 - 40Humidity (no condensate) % 30 - 95Machine weight see chapter 4 INSTALLATIONCabinet connecting cable RST + Earth 380V-50Hz: four-pole, copper mm2 4 x 4Hose to compressed air mains, inside diameter mm 13

(*) With different voltages and frequencies or when material other than copper is used the cable has to be adequatelysized by a qualified electrician.

For further information regarding the lubricants used, see paragraph 2.3.6 - LUBRICANT SPECIFICATIONS.

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2.3.2 ALLOWABLE FLUCTUATION OF THE VARIABLES

ELECTRICVoltage ±10%Frequency ±2%

PNEUMATIcFlow rate ±15%Minimum pressure MPa 0,5Maximum pressure MPa 1

COOLANTFlow rate ±10%Pressure +20% - 10%

2.3.3 RATING PLATE

The figure below illustrates the rating plate on which the customer’s individual operating data (voltage-frequency-auxiliary circuits) is given. The plate is attached to the electrical cabinet door.

Figure 2.3.3 - LOCATION OF THE RATING PLATE

V

N° Com.

Hz

Cod.

In A

E0012

T1984

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2 MAIN FEATURES

221.02.A04 Revision 00 Date 11.09.1998

2.3.4 OPERATIONAL CHARACTERISTICS

TYPE OF PRODUCTThe machine can handle thermoplastic caps whose dimensions have been previously agreed upon with SACMI’sEngineering Dept (See example in figure 2.3.4).

E0004P IMPORTANT!

The machine has to be set-up in different ways depending on the type of cap being handled. For this reason, specialparts need to be used. Refer to the “data sheet” provided by Sacmi.

PRODUCTION CAPACITYThis is strictly related to the type of cap being handled and its dimensions.The maximum production output is given in paragraph 2.3.1 - SPECIFICATIONS.

Figure 2.3.4 - PRODUCT CHARACTERISTICS

The dimensions given in the figure are for reference purposes only and are not binding in any way.

PLASTIC CAPS

30

12

ø 52

ø 25

T1890

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2.3.5 NOISE EMISSION LEVELS

2.3.5.1 Acoustic radiation pressure level (ISO/DIS 11202)

Test conditions- Operating conditions: machine running with load.- Type of operation: bending of safety band for plastic caps- Operating cycle: cap feed and bending- Test environment: factory with reflecting flooring.

Instruments employedClass 1 instruments (IEC 804)

Values measured

LbA

LpA

LpC peak

P1 61,7 91,5 104,0

P2 63,0 94,5 111,0

P1 - Control position, measured at a height of 1.55 m from the floorP2 - Noisiest position of the ideal machine perimeter, traced a meter away from itLbA - Background noise level.LpA - Acoustic pressure emitted, corrected, weighted A, average valueL

pC peak- Maximum volume of the instant acoustic radiation pressure weighted C.

Figure 2.3.5.1 - NOISE EMISSION LEVELSA Reference surfacesB Surfaces from which measurements were taken

1400

1000

1000

3400

1000

1000

5900

TVC

ATV

BTA

7900

A

B

P2

T1362

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2 MAIN FEATURES

221.02.A04 Revision 00 Date 11.09.1998

2.3.5.2 Acoustic power level (ISO 3746)

Test conditions- Operating conditions: run with load.- Type of operation: bending of safety band for plastic caps- Operating cycle: cap feed and bending- Test environment: factory with reflecting flooring.

Instruments employedClass 1 instruments (IEC 804)

Results

LpA

= Surface acoustic radiation pressure in dB weighted A. 92.0 dBAL

wA = Acoustic power level in dB weighted A. 111 dBA

2.3.6 LUBRICANT SPECIFICATIONS

POINT OF USE OIL

A Geared motor 23°E - 50°C ISO 3498CC 320 (320 cSt. - 40°C)

B General lubrication 11,5°E - 50°C ISO 3498CB 150 (150 cSt .- 40°C)

GREASE

C Work unit: Dropping point: 180 °C- Stripper rod Penetration: 265 - 295 dmm

- Shaft bearings ISO 3498 - XM2

- Cams

- Rollers

- Ball bushings

When selecting the lubricants see the charts given in the LUBRICATION DATA SHEET.

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2.4 DIAGRAMS

2.4.1 PNEUMATIC SYSTEM DIAGRAM

Figure 2.4.1 - PNEUMATIC SYSTEM DIAGRAM

PA Air preparationAZ ActuatorsSO Blowers

1 Filter2 Pressure regulator3 Flow divider4 Solenoid valve manifold8 Blower flow divider9 Pressure regulator10 Quick coupling15 Cap stop

A Blowers, Feed channelB Blowers, Feed channelC Blowers, Feed channelD Blowers, Feed channelE Blowers, Exit channelF Blowers, Exit channelX Line, Cylinder openY Line, Cylinder closed

SP1 Pressure switchYV3 Solenoid valve, Incoming cap stoppageYV9 Solenoid valve, Blowers

T1363

PA AZ

SO

FA B C D E

8

YV9

4

YV3 9

1

2

3

10

SP1

XY Y Y Y

X

15

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2 MAIN FEATURES

221.02.A04 Revision 00 Date 11.09.1998

221.02.A04

3 - 1

SAFETY EQUIPMENT AND PRECAUTIONS 3


3 SAFETY EQUIPMENT AND PRECAUTIONS

3.1 SAFETY DEVICES INSTALLED

The machine is provided with mechanical and electric safety devices which ensure all around protection for theoperator and machine (see figure 3.1).

Shutdown devices

These devices detect and indicate malfunctioning and prevent the machine from being run or actually stop it.

Fault signaling

Whenever a fault is present, a red flashing light located over the electrical cabinet comes on to inform the operator.The trouble that shut the machine down appears on the display of the control keyboard. Refer to the INSTRUCTIONSB manual for a full description of the fault messages.

Safety devices for the operator

The machine is equipped with mobile safety guards that are interlocked with electric devices. In addition, fixedmechanical barriers are also installed that prevent accidental access to moving parts of the machine as well asdangerous parts that are live or very hot.

Emergency stop buttons

Emergency stop buttons (see figure 3.1) are provided on:- the machine base- the control panelOperation: manualAction: machine immediately stoppedReset: manual

221.02.A04

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SAFETY EQUIPMENT AND PRECAUTIONS3


Figure 3.1 - SAFETY DEVICES INSTALLED

HL Machine state indication lightsSB1B Remote emergency stop buttonSB100 Emergency stop button on control panelSQ33 Limit switch, Manual operation handwheel engagedSQ100 Limit switch for movable guards: the machine stops

when the guards are opened

1 Panels (on the four sides) attached with screws(1/4 of a turn)

3 Pneumatic control unit cabinet5 Pressure switch, No air pressure7 Proximity sensor, Caps not removed9 Safety chain (manually installed)

T1377

1

9

3

5

SQ100

1

SB1B

SQ33

7

SQ 100

HL

SB100

221.02.A04

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3.2 GENERAL RULES

E0004 WARNING!

INSTALLATIONInstall the machine by following the instructions provided by the Manufacturer and observing the safety regulationsin force in your country.It is extremely important that the machine is properly connected to adequate earth electrodes. SACMI shall not be heldresponsible for any damage to the machine or injury to personnel resulting from improper installation.

SAFETY DEVICES & GUARDSThe machine comes equipped with electrical and/or mechanical safety devices which safeguard the machine and theoperator. The safety devices and guards provided MUST NOT be removed or inactivated under any circumstances.SACMI shall not be liable for any damage or injury if the machine operator fails to observe these precautions.

CHECKS, REPAIRS & MAINTENANCEDo not perform any checks, repairs or maintenance operations on moving parts. Use clearly visible signs to warn allpersonnel of possible danger. Before carrying out these operations, disconnect the electricity supply by using the mainswitch. The main switch is to be padlocked in the “power off” position so that the machine cannot be started upaccidentally.To ensure overall machine efficiency and trouble-free operation, it is essential that the directions supplied by SACMIare followed and that the required maintenance is carried out.It is advisable to periodically check all of the safety devices for proper functioning and the insulation of the electricalcables. The latter must be replaced if damaged.

LIVE ELECTRICAL PARTSIt is severely forbidden to work on or near live electrical parts.The electrical cabinet doors must be kept locked and warning signs signaling potential danger must be placed on themBefore opening the electrical cabinets or switchboards, disconnect the electricity supply with the main switch.

QUALIFIED PERSONNELThe assembling, disassembling and servicing of the machine must be performed by qualified personnel. Whencarrying out these operations, always use adequate equipment and follow the instructions provided.

MACHINE NOT IN USEIf the machine is not going to be used for a long period of time, it is to be made inoperative by disconnecting the powercable from the mains and applying all the required safety devices.

221.02.A04

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3.3 SAFETY RULES FOR HANDLING

E0004 WARNING!

SLINGING THE LOADSTo safely and correctly lift and handle the machine always:- use equipment which best suits the characteristics and has an adequate lift capacity;- cover all sharp edges;- make sure the safety device for the lift hook works properly;Before lifting:- make sure all personnel is safely away and that no one can enter the area where the machine is being moved- make sure the load is stable- make sure there is no material which may fall when the parts are lifted- work vertically in order to avoid banging the parts.

HOISTINGTo facilitate the lifting and handling operations use bars, levers and ramps. Never use your hands. The person in chargemust:- know the path to be followed and be able to clearly see it- give information to the crane operator from a position where he/she can be clearly see- stop immediately is dangerous conditions arise

PLACEMENTBefore placing the machine make sure the floor is perfectly level and is able to support the weight of the machine.Do not place the loads near factory exits, fire fighting equipment, passage areas, control panelsand power lines.The machine must be placed so that it is stable and the slings can be easily removed. Do not place worn containersor those with protruding material on top of it.Do not stack material at a dangerous height.

221.02.A04

3 - 5



3.4 OPERATOR TRAINING

E0004 WARNING!

THE COMPANYThe company using this equipment must see that the machine operators:- match the requirements listed below- read and understand the manual in its entirety- are adequately instructed and trained on how to safely carry out their tasks- are specifically instructed and receive adequate training on how to operate the machine correctly.

THE OPERATORThe operators must at least:- understand the technology employed and have specific experience in operating this type of machine- be well educated and able to read and fully understand the contents of this manual as well as properly interpret thedrawings provided- have a good technological background (in the electric, mechanical and pneumatic fields) so that they are able to safelycarry out the operations they are responsible for as specified in the manual- know all the safety rules and standards

- general (hygiene 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.

THE MAINTENANCE STAFFThe maintenance staff must be selected using the same criteria.In addition, they must be trained in specific technological areas and be specialized (mechanical, electric, pneumatic)so that they can carry out the operations they are responsible for (as specified in the manual) in complete safety.

Tasks the operator and maintenance staff are and are not responsible forThe operations for running and maintaining the machine the personnel is responsible for (operation, routinemaintenance, special maintenance) are subdivided in the various parts of this manual.It is fundamental that the members of the staff carry out only the tasks in the areas they are specifically responsiblefor (mechanical, electric, pneumatic).

Operator tasksThe operator is strictly forbidden to access the electric equipment installed inside the electric cabinet and remove theguards that prevent access to the live electric parts of the machine components, for example:- motor terminal blocks- terminal blocks of the solenoid valves and servo controlled valves- terminal blocks of the junction boxes- pressure switchesThe operator is authorized to use only the controls and instruments mounted on the machine control panel.

E0004 WARNING!

The operator or person running the machine must not work on the electric equipment under any circumstances. Inaddition, the routine maintenance man must not modify the wiring and electric connections.

221.02.A04

3 - 6



3.5 SAFETY RULES FOR OPERATION AND MAINTENANCE

The object of this chapter is to inform the operators and maintenance staff:- about some potentially hazardous and/or dangerous situations that may be encountered while operating orperforming maintenance on the machine- about the safety measures and devices employed and how to use them correctly- about any additional risks- on the measures to be taken (general and specific precautions to eliminate potentially harmful situations).Detailed information is given in this chapter. Your attention is called to the instructions in this manual, at the pointswhere the situations are encountered.

E0004 WARNING!

Some of the illustrations provided show the machine, or parts of it, without the safety guards or with the guardsremoved. This is done exclusively in order to better comprehend the machine. The machine must never be runwithout the guards or with the guards inactivated.Along with matching the requirements previously stated, the operator and maintenance staff must attend a trainingcourse and get on-the-job experience before being authorized to run the machine. The purpose of this is not onlyto instruct him/her on how to run the machine and carry out maintenance under normal operating conditions but also:- to teach them the safety precautions to be followed at all times and use of the various devices- how to recognize, control and remedy machine malfunctioning and the hazardous situations described in thismanual, above all those dealt with in this chapter.

Potential hazards are mainly encountered in the mechanical, heat and electric systems of this machine. Wherepossible, the potentially dangerous areas have been neutralized:- directly, using solutions specifically designed- indirectly, employing barriers, guards and safety devices

E0004 WARNING!

It is strictly forbidden to operate the machine if the barriers, safety guards and devices have been removed, changedor tampered with in any way. This must never be done.Before performing any type of operation on the machine, always consult the manual for information on how tocorrectly carry out the procedures. In addition, the manual contains important information concerning safety. Whenin doubt, contact Sacmi’s Customer Service Department.

221.02.A04

3 - 7



3.5.1 HAZARDS PRESENT IN THE MECHANICAL SYSTEM

NON LOADING BEARING STRUCTURES

E0004 WARNING!

The movable guards of the machine are not constructed to withstand the weight of a person. Do not climb on topof the surface created by the guards or rest against the peripheral structure.Failure to observe this precaution may cause serious damage to the machine, severe injury to personnel or evendeath.

HAZARDS THAT MAY BE ENCOUNTERED IN THE WORK AREAWhen in the area where the machine is installed as well as the surrounding area personnel risks slipping, tripping,falling, etc, both while operating the machine and carrying out maintenance. In designing the machine, a good amountof space has been left free around the machine where it is installed to reduce these risks.The walkways and areas surrounding the machine must always be:- free of obstacles (such as step stools, tools, containers, boxes of material)- clean and dry (immediately remove any drops of oil )- well lit

LIGHTINGIt is fundamental that the areas surrounding the machine and in particular the work zone are always well lit, especiallyat night. Replace any defective elements without delay. Minimum value 300 LUX.

RISKS FACED IN THE DRIVE SYSTEM

E0004 WARNING!

As the drive unit consists of moving parts the operators risk accidentally coming into contact with them and as aresult:- they risk getting their hands and/or limbs crushed, caught and dragged and cut off.

DURING OPERATIONThe moving parts of the drive unit housed in the base (gears and belts) which create hazardous conditions areprotected with guards and bolted boxes.

SAFETY GUARDS AND DEVICES

E0004 WARNING!

The safety guards and devices must never be removed while the machine is running. When carrying outmaintenance they may be removed taking the precautions indicated in the maintenance chapter. The parts removedmust be put back in place and firmly secured as soon as maintenance has been completed.

221.02.A04

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RISKS PRESENT IN THE PRODUCT HANDLING SYSTEM

E0004 WARNING!

The handling system exposes the operators to the following risks, as they may accidentally come into contact withmoving parts:- hands and/or limbs may be crushed, caught and dragged and cut off.

DURING OPERATIONThe product handling system inside the machine presents no risks for the operators as it is fully protected with movableinterlocked guards. The machine stops running if one of the guards is opened while it is operating.

DURING MAINTENANCEThe movable guards have to be opened, taking all the precautions indicated in the maintenance chapter. The movableguards must be closed as soon as maintenance has been completed.

ADDITIONAL RISKSPrecautions to be taken.- When turning the units in manual mode make sure your hands are out of the way of moving parts.- Always make sure that other persons (operators - maintenance men) do not have their hands near or in the area ofmoving parts or are inspecting parts that can be operated in manual mode.Failure to observe these precautions may cause your hands and/or limbs to be crushed, caught and dragged and evencut off.The risk of being crushed is indicated by signs placed inside the guards in the machine.

3.5.2 HAZARDS PRESENT IN THE ELECTRIC SYSTEM

ELECTRICAL CABINET: RISKS FACED FROM DIRECT CONTACT WITH LIVE PARTSThe electrical cabinet can be accessed while electricity is being supplied to the system.As dictated by the EN 60204-1 standard, it must be closed with lock and key and therefore can be accessed only witha key or tool. Only authorized personnel specifically trained to access live parts should be given the key or tool.

WHILE POWER IS BEING SUPPLIED TO THE ELECTRICAL CABINET THE SPECIALIZED ELECTRICIAN CANONLY RESET THE SAFETY DEVICES.

E0004 WARNING!

Whenever carrying out operations to replace a component either inside or outside the electrical cabinet, themaintenance man must shut off the plant by turning the main switch located on the control panel to its OFF/openposition and locking it with a padlock and key. The key must be removed in order to prevent accidental start-up.

FIRE FIGHTING EQUIPMENTThe following must be provided and installed by the customer in the area where the machine is installed:- a fire fighting system that complies with legislation in force in the country where the machine is installed.

221.02.A04

3 - 9



3.5.3 HAZARDS PRESENT IN THE HEAT SYSTEM

E0004 WARNING!

When carrying out maintenance always use adequate safety gear and devices to prevent being burnt (gloves,grippers, etc.).

ACCESS INSIDE THE MOVABLE GUARDSWhile the machine has stopped due to emergency the movable guards may have to be opened to clean the parts andmake the required checks.

HOT MOTORS, RISK OF BEING BURNTThe electric motors, while running, can reach temperatures that can cause slight burns. AVOID DIRECT CONTACTor take adequate precautions.

3.5.4 SAFETY RULES FOR MAINTENANCE OPERATIONS

The safety measures to be observed while carrying out maintenance are indicated in this chapter. The procedures andany additional precautions for each single operation are given in chapter 8 - Maintenance.Before carrying out maintenance, make sure the machine is in a safe condition. Once the maintenance operations havebeen completed, make sure the machine is able to run safely and in particular that the protection and safety deviceswork correctly.

E0004 WARNING!

Failure to observe these precautions may cause severe injury to personnel.

3.6 MAKING THE MACHINE INOPERATIVE WHEN NO LONGER USED

The operations given below need to be carried out when the machine is no longer used:- Turn off the machine’s power supply by using the factory’s main switch.- Unplug the power cable from the electrical cabinet’s terminal block.- Disconnect the cables that join the cabinet to the machine, detaching the connectors.- Disconnect the line between the factory’s compressed air mains and the control unit.- Disconnect the 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, ifnecessary.- Close the doors of the electrical cabinet and machine to prevent the parts from being tampered with, dust from buildingup, etc.- Activate all the safety devices provided.

When dismantling the machine see chapter 9 - DISMANTLING THE MACHINE.

221.02.A04

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4 - 1

221.02.A04INSTALLATION 4


4 INSTALLATIONAfter the machine has been delivered, make sure the environmental conditions (temperature, humidity, etc..) are asspecified and agreed upon at the time of purchase. This is important as the machines are always constructed accordingto the data provided.

4.1 SHIPPING AND HANDLING

MACHINE DIVISIONThe machine is divided into groups according to the shipping and installation requirements.

DIMENSIONS AND WEIGHTSThe weights and dimensions of the individual parts, according to the shipping requirements, are approximate thereforethey are given for reference purposes only.

SYSTEMS FOR LIFTING INDIVIDUAL PARTSThe best systems for lifting and handling the heaviest and largest parts as well as those that require special care andtools provided by Sacmi are shown in figure 4.1.As far as the machine body is concerned, the slings (shown in the figure) have to be attached to the four points (A)of the base. Proceed as follows: Insert the screw (1) in the washers (2), slings (3) and nut (4). Place the screw in thehole (A) and tighten. Only the nut (4) should be fully tightened so that the slings (3) are able to move freely.Before hoisting, make sure the slings are correctly positioned in points B.When lifting the smaller parts and packages, be extremely careful and use equipment with an adequate lift capacity.All safety rules and precautions must be observed at all times.Upon receiving the machine, handle the crates with care. Always use means that are able to sustain their weightwhenever moving the crates both inside and out. It is fundamental that the user weighs all the parts when they arriveon site to verify their exact weight.

LIFTING PRECAUTIONS- Use lift equipment whose range of action and capacity are adequate for the weight and dimensions to be sustained.- Protect the points where the slings come into contact with the machine with cardboard or rags.- Gradually move the load until it is perfectly stable.- Make sure no people or things are in the path to be followed while the load is being lifted.- Slowly lift and move the parts with extreme caution avoiding any kind of swaying, even the slightest.

WARNING!

The manufacturer shall not be held responsible for damage to things or injury to personnel caused by failure toheed the safety standards in force regarding lifting and handling material inside the user’s factory.

Lifting and handling can be carried out only by persons specially trained and authorized to perform theseoperations.Make sure there are no people near the lifted load and/or in the range of action of the lift equipment while themachine is being lifted and moved.

- Follow the lifting instructions given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.- When being moved, the load must remain perfectly horizontal regardless of the type of equipment used to carryout the operations.

E0004P

4 - 2

4 INSTALLATION

221.02.A04 Revision 00 Date 11.09.1998

Figure 4.1 - DIMENSIONS AND WEIGHTS OF THE CRATES

1 - Machine body2 - Electrical cabinet3 - Crate containing spare parts4 - Crate containing machine outfit5 - Crate containing parts 1-2-3-4

kg 570

A

B

1

5

kg 950 T1887

260

260 350

18001500

2200

1800

600 800

1

3

24

A B

T1379

kg 250

2

3 4

kg 25kg 50

T1887

986800

25152100

4 - 3



4.2 POSITIONING(References given in figure 4.2/A)

The various parts that make up the machine, whose specifications, weights, dimensions and hook up points havealready been dealt with, are to be placed and installed as shown in the figure. Carry out the operations in the ordergiven and carefully follow the directions given below.

E0004PWARNING!

Be very careful to install the cap feed channel (A) and exit channel (B) that conveys the caps to the next machinein the correct position.In addition, the work area around the machine should always be kept as indicated in the figure.

- Lift the machine body (see figure 4.1)- Place the machine body in the established position (see figure 4.2/A)- Remove the guards to access the feet (see figure 4.2/B)- Level the machine body by adjusting the feet, tightening or loosening them as required. Use a spirit level to check.Fully tighten the lock nuts of the feet.

E0004PWARNING!

Pay careful attention to the amount of space the cap feed and exit channels (A and B) are off the ground. The exactmeasurements are given in the figure.

- Lift the electrical cabinet (see figure 4.1)- Place the electrical cabinet in the required position. Follow the directions given in figure 4.2/A and make sure it is thecorrect distance away from the machine.

4 - 4

4 INSTALLATION

221.02.A04 Revision 00 Date 11.09.1998

Figure 4.2/A - POSITIONING THE PARTS

1 Machine2 Electrical cabinetA Cap feed channelB Cap exit channelC Compressed air inletD Work area

Figure 4.2/B - LEVELING THE MACHINE

T1153

T1886

800800

800

800

1270

2

A

B

D

1

C

4 - 5



4.3 CONNECTIONS AND HOOK UPS

E0004PWARNING!

The various systems are to be hooked up to the mains by specialized personnel instructed by SACMI.

4.3.1 CONNECTING THE MACHINE TO THE COMPRESSED AIR MAINS(References given in figure 4.3.1)

Use a hose to connect the air preparation unit, equipped with a fitting (A) located in the pneumatic control unit, to thecompressed air mains. The specifications of the hose are indicated in paragraph 2.3 TECHNICAL DATA.

Figure 4.3.1 - CONNECTING THE MACHINE TO THECOMPRESSED AIR MAINS

A Compressed air supply

T1366

T1888

A

4 - 6

4 INSTALLATION

221.02.A04 Revision 00 Date 11.09.1998

4.3.2 CONNECTING THE ELECTRIC CABLES(References given in figure 4.3.2)

E0004PWARNING!

Due to the presence of electronic converters inside the electrical cabinet, make sure the power supply circuitbreakers are of the B type, in compliance with CEI 64-8 specifications, Art. 532.2.1.4. In this way, the system isprotected against d.c. leakage currents.

E0004PWARNING!

After machine testing, the cables are disconnected from the electrical cabinet, rolled up and prepared for shipment.

- Unwind the electric cables- Plug the cables into the electrical cabinet as shown in the figure. The cables are marked with the symbols illustratedin the figure.The power cable has to run into the cabinet and be plugged into the terminal block in the points marked RST andconnected to earth. The rating plate and fixing screws for the earth connection are found in the lower base.

E0004PWARNING!

The power cable is not supplied with the machine. Its specifications and dimensions are given in paragraphSPECIFICATIONS.

E0004PWARNING!

The machine is to be earthed to the outside. For this reason, connect the earth line to the copper bar located insidethe main electrical cabinet. The connections are marked PE (EN60445).

Also join the connections on the machine marked (417-IEC-5019) to the external earth terminals.

E0004PWARNING!

Failure to ground the parts indicated may cause serious damage to the machine and severe injury to personnel.

4 - 7



Figure 4.3.2 - CONNECTING THE ELECTRIC CABLES

XJ1 Power lead connector, Power supply boxXJ2 Signal lead connector, Signal emitter boxXJ3 Power lead connector, M17 control (only w/cap counters)XJ5 Power lead connector, Heating elementXJ8 Signal lead connector, Heating element controlXJ10 Power lead connector, Motor M8 power supplyXJ14 Signal lead connector, Interface to next machine in lineXJ16 Signal lead connector, Interface to preceding machine in line

T1999

XJ1

XJ2

XJ14

XJ16

XJ10

XJ3

XJ5

XJ8

4 - 8

4 INSTALLATION

221.02.A04 Revision 00 Date 11.09.1998

5 - 1

221.02.A04MACHINE START-UP 5


5 MACHINE START-UP

5.1 INTRODUCTION

E0004PWARNING!

These operations can be carried out solely by the manufacturer’s specialized technicians who are responsible forstarting up the machine as specified in chapter 1 - GENERAL INFORMATION. If these operations are carried outby other persons, dangerous situations may be created that can cause serious injury to persons and/or damageto the machine.The control key references are given in chapter 6 - OPERATING INSTRUCTIONS.

First time machine start up is to be carried out by personnel specialized in both the mechanical and electric fields.The customer’s operator and maintenance staff have to be available and look on when the machine is started up (thisis useful to better understand machine operation, how to adjust the auxiliary equipment, accessories, and safetyguards and devices employed) and when the machine is tested to see that it has been properly adjusted.

5.2 PRELIMINARY CHECKS

CONDITIONSThe machine is factory tested prior to delivery therefore it simply has to be checked to see if it was damaged duringshipment or installation.

PROCEDURE(The control references are given in chapter 6 - OPERATING INSTRUCTIONS)

- Operate the machine in manual mode to make sure nothing obstructs the parts.- Open the feed channel door and put in one cap for each spindle.- Bend the cap bands corresponding to the spindles.- Check the results obtained.

If the dimensions need to be adjusted, see chapter 7 - ADJUSTMENTS.

- Supply power to the electrical cabinet by turning the main switch QS1 to on.- Turn on the compressed air supply and make sure an adequate pressure value is read on the gauge. The exact

value is given in paragraph 2.3 - TECHNICAL DATA.- Make sure the motors run in the right direction. If they do not, reverse two supply wires of the cabinet’s power cable

(figure 4.3.3), disconnect the conductors from terminals R and S and reverse them.

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5 MACHINE START-UP

221.02.A04 Revision 00 Date 11.09.1998

E0004PWARNING!

In the event of malfunctioning for which adjustments need to be made, stop the machine and carry out theoperations given in chapter 7 - ADJUSTMENTS.

5.3 DAILY START-UP

(The control references are given in chapter 6 - OPERATING INSTRUCTIONS)

- Join the machine to the compressed air mains.- Supply power to the machine by turning the main switch QS1 to on.

The machine can now be run in either manual or automatic mode.

- Turn selector SA100 to “manual” to operate the machine in manual mode.- The start (green ) and stop (red ) buttons are used for manual operation.- Turn selector SA100 to “automatic” to set the machine to run in automatic mode, in line with the next machine.- Selector SA6 enables the vibrator.- Press button SB101 to reset any faults and set the machine up for operation.- Press button SB30M to start the automatic cycle if the machine is set-up to run in “local” (selector SA30 turned to

“local”).- Press button SB30A to stop the automatic cycle if the machine is set-up to run in “local” (selector SA30 turned to

“local”).- Make sure no leds are on (red alarm). If they are, remedy the problem and reset the machine by pressing button

SB101.

6 - 1

221.02.A04OPERATING INSTRUCTIONS 6


6 OPERATING INSTRUCTIONS

E0004PWARNING!

Closely follow the directions given in this manual and operate in accordance with all safety standards.

6.1 CONTROL DEVICES(See figure 6.1)Some controls are located on the control panel while others are to be found on the machine.

Figure 6.1 - CONTROL DEVICES

1 Electrical cabinet3 Top indicator panel3 Control panel4 Machine5 Manual control with limit switch SQ33QS1 Main switchSB1B Remote emergency stop button

3

2

1

QS1T1368

SB1B

5

4

6 - 2


221.02.A04 Revision 00 Date 11.09.1998

6.1.1 ELECTRICAL CABINET(References given in figures 6.1 and 6.1.1)

The electrical cabinet (1) consists of a power section (5) that houses all the parts needed to operate the variouscomponents (contactors, relays, etc) and a logic section (2) that contains the devices for processing the signalstransmitted by the machine controls or from the keyboard.A control keyboard (4) is located in the logic section. This keyboard allows the operator to control and monitor machineoperation.A programmable logic controller and control keyboard (4) are used. This set-up allows the operator to set the work-cycle as required.Fault messages and the most important stages of the work-cycle are shown on the display (3).

E0004P WARNING!

Enable button SB31 has to be pressed whenever a run button is pressed.All the information regarding use of the control panel is given in the Instructions B manual, Use of themicroprocessor-based control system.

AP2 Temperature regulator, Tool heating (optional)AP3 Temperature regulator, Tool cooling (optional)

PC1 Counter, Caps producedPC2 Electronic counter, Caps rejected to FDP (only with FDP)

QS1 Main switch

SA1 Selector switch, Machine OFF-ONSA18 Selector switch, Tool heating OFF-ONSA30 Mode selector switch, LOCAL - OFF - REMOTESA40 Selector switch, Cap discharge control OFF - ONSA100 Mode selector switch, MANUAL - OFF - AUTOMATIC

SB6A Stop button, Motor M6 in manual modeSB6M Run button, Motor M6 in manual modeSB7 Start/Stop button, Motor M7 in manual modeSB8A Stop button, Motor M8 in manual modeSB8M Run button, Motor M8 in manual modeSB11 Start/stop button, Motor M11 in manual modeSB22 Start/stop button, Motor M22 in manual modeSB30A Stop button, Automatic cycle with machine in local modeSB30M Start button, Automatic cycle (enabled with machine in automatic and local mode, to be pressed together

with SB31)SB31 Pushbutton, Control panel enablingSB33A Stop button, Motor M33 in manual modeSB33M Run button, Motor M33 in manual modeSB100 Emergency stop button on electrical cabinetSB101 Reset button, ShutdownSB102 Reset button, PC1SB103 Pushbutton, Box change (only with cap counter; PC1 output)

6 - 3

221.02.A04OPERATING INSTRUCTIONS 6


Figure 6.1.1 - TOP INDICATION AND PUSHBUTTON PANEL

R

QS1

QS1 PC1 AP2 AP3

SB30A SB7 SB6A SB33A SB22 SB8A SB11 SA100 SA30 SB31

SB100

SB101 SB30M SB6M SB33M SB8M SA1 SA40

SB102 SB103 SA18

T1994

6 - 4


221.02.A04 Revision 00 Date 11.09.1998

6.2 OPERATION IN MANUAL MODE

If the machine is set to run in manual mode (selector switch SA100 turned to MAN), the motors can be run individuallyby pressing the relevant buttons located on the control panel.

6.3 OPERATION IN AUTOMATIC MODE

Turn selector switch SA100 to AUT to set the machine to run in automatic mode.

OPERATIONIf selector switch SA30 is turned to “local”, the automatic cycle is started by pressing button SB30M located on thecontrol panel. If the machine is set up for “remote” operation, the trigger for operation is provided by the next machine.The automatic cycle is started only if all the safety and operating conditions have been satisfied.The fault messages shown on the top display indicate the troubles that prevent the machine from running (see theInstructions B Manual).The machine starts the operations for processing the caps automatically in the following order:- The compressed air solenoid valve opens- Caps are fed- Cap conveyor starts running- Machine motor starts running

PRODUCTION CYCLEThe feed unit picks up the caps from the feed channel and places them on the work unit spindles. The latter bring thecaps to the tools which give them their final shape. The caps are then discharged into the exit channel and are sentto either the next machine or counter for filling the boxes.

HOW TO STOP THE MACHINEIf selector switch SA30 is turned to “local”, the automatic cycle is stopped by pressing button SB30A . On the other hand,if the machine is set for “remote” operation, the trigger for stopping the machine is provided by the next machine.

The following operations are carried out:- Cap feed at machine inlet is interrupted- The motors stop running after the last cap processed has been discharged from the machine.

7 - 1

221.02.A04ADJUSTMENTS 7


7 ADJUSTMENTS

The adjustments described below are to be made when deemed necessary by the operator to remedy malfunctioningor after maintenance has been carried out, parts replaced, etc.. Always carefully observe all safety rules andprecautions.

E0004PWARNING!

The operations can be carried out only after the machine has come to a full stop taking all the precautions describedin the introductory part of this manual. In particular, use extreme caution and wear heavy-duty work gloves whenworking near signs indicating hot parts - danger of being burnt.It is fundamental that the power to the machine is shut off before accessing the electrical cabinet, cable boxes andwherever there is a sign indicating danger of being electrocuted.

7.1 CAP FEED CHANNEL

7.1.1 ADJUSTING THE AIR PRESSURE IN THE PNEUMATIC CYLINDER(References given in figure 7.1.1)

E0004PWARNING!

This operation is carried out with the machine running, therefore take all the necessary precautions.

- Read the pressure given on the gauge (10) and check the solenoid valve (12) (YV3) used to stop incoming caps. Thevalue given in paragraph 2.3.1 - SPECIFICATIONS should be read.

- To adjust the pressure, if required, turn the knob (11) until the correct value is obtained.

7 - 2

7 ADJUSTMENTS

221.02.A04 Revision 00 Date 11.09.1998

Figure 7.1.1 - ADJUSTING THE AIR PRESSURE IN THE PNEUMATIC CYLINDER

1012

11

T1888

7 - 3



7.1.2 REPLACING THE FEED CHANNEL TO HANDLE A NEW PRODUCT SIZE

The feed channel consists of two units: the bend and the straight part that feeds the work unit. The product size handledcan be varied in the following ways:1) The caps differ from the ones previously handled only in height, which is increased (∆h+)2) The caps differ from the ones previously handled only in height, which is decreased (∆h-)3) The caps differ from the ones previously handled only in diameter, which is increased (∆Ø+)4) The caps differ from the ones previously handled only in diameter, which is decreased (∆Ø-)5) The caps differ from the ones previously handled in both height and diameter (∆Øh)The various options and how the parts need to be adjusted are summarized in the chart below:

Dimensions of caps that vary from the previous ones

WHAT TO DO

Bend Straight section

∆h+ Replace the rails (1) with higher ones Replace the rails (2) with higher ones, the guideand support

∆h- Replace the rails (1) with lower ones Replace the rails (2) with higher ones, the guide(3) and support

∆Ø+ Replace the rails (1), base (4) and cover (5) Replace the rails (2), base (6), cover (7), guide (3)and relative support

∆Ø- Replace the rails (1) with wider ones Replace the rails (2) with wider ones, guide (3)and relative support

∆Øh Replace the rails (1), base (4) and cover (5) Replace the rails (2), base (6), cover (7), guide (3)and relative support

Remove the parts to be replaced and install the new ones making sure they are perfectly aligned.

Figure 7.1.2 - REPLACING THE FEED CHANNEL TO HANDLE A NEW PRODUCT SIZE

7

3

5

6

2

41

T1357

7 - 4

7 ADJUSTMENTS

221.02.A04 Revision 00 Date 11.09.1998

01

7.2 ADJUSTING THE CAP STRIPPER RODS

The cap stripper rods are driven by the upper cam (1) which moves down, up and down synchronized with the lowercam and the upstroke. The rod has to press on the bottom of the cap. The pressure exerted is controlled by springpreloading as well as the height of the upper cam.The height of the upper cam is adjusted by loosening the screws (2) and adjusting the grub screws (3) to obtain axialmovement of the cam. Use three comparators (4) to check the adjustments made. The comparators should all readthe same value to maintain cam parallelism in relation to the conditions present prior to the adjustments.

Figure 7.2 - ADJUSTING THE CAP STRIPPER RODS

3

1

2

4

T1371

7 - 5



7.3 ADJUSTING THE HEIGHT OF THE TOOLS

The height of the tools is adjusted by tightening or loosening the punch (1), as required. The grub screw (2) preventsthe punch from coming loose and is to be tightened once the punch has been set as required. Adjustments have tobe made to obtain proper operation as if the tool is too low it will permanently deform the caps. On the other hand, ifit is too high, the safety band will not be properly formed.

Figure 7.3 - ADJUSTING THE HEIGHT OF THE TOOLS

1

2

T1375

T1374

2

1

7 - 6

7 ADJUSTMENTS

221.02.A04 Revision 00 Date 11.09.1998

7.4 REPLACING THE CAP TRANSFER TURN-TABLE

The transfer turn-table (2) has to be replaced when, for example, the diameter of the caps being handled is changedto a slight extent. Remove the screws, take off the two sections of the disk with cavities that make up the turn-tableand replace them.

NoteThe machine can be set-up to handle caps that differ in height and diameter only slightly (approximately ≥ 2 mm).If the caps that need to be processed differ greatly, the machine has to be fitted with different tools which are to bearranged for with SACMI’s Engineering Department. These tools are to be installed either by SACMI or speciallytrained personnel.

Figure 7.4 - REPLACING THE CAP TRANSFER TURN-TABLE

3

2

8

6

5

1

7

4

T1358

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7.5 EXIT CHANNEL(References given in figure 7.5)

7.5.1 ADJUSTING THE CHANNEL JAMMING CONTROL DEVICE

This device is able to detect when a cap is jammed in the channel. This is accomplished by means of a lever (8) which,when triggered, inactivates a proximity sensor (9) that stops the machine. The lever (8) has to be adjusted in relationto the sensor so that the sensor itself is constantly activated during normal operation.

Figure 7.5 - EXIT CHANNEL

T1378

8

9

3

7

2

6

4

15

7 - 8

7 ADJUSTMENTS

221.02.A04 Revision 00 Date 11.09.1998

7.5.2 REPLACING THE CAP EXIT CHANNEL TO HANDLE A NEW PRODUCT SIZE

The exit channel consists of two groups: the bend and the straight part that feeds the work unit. The product sizehandled can be varied in the following ways:1) The caps differ from the ones previously handled only in height, which is increased (∆h+)2) The caps differ from the ones previously handled only in height, which is decreased (∆h-)3) The caps differ from the ones previously handled only in diameter, which is increased (∆Ø+)4) The caps differ from the ones previously handled only in diameter, which is decreased (∆Ø-)5) The caps differ from the ones previously handled in both height and diameter (∆Øh)The various options and how the parts need to be adjusted are summarized in the chart below:

Dimensions of the caps that vary compared to the previous ones

WHAT TO DO

Bend Straight section

∆h+ Replace the rails (1) with higher ones Replace the rails (2) with higher ones, the guideand support

∆h- Replace the rails (1) with lower ones Replace the rails (2) with higher ones, the guide(3) and support

∆Ø+ Replace the rails (1), base (4) and cover (5) Replace the rails (2), base (6), cover (7), guide (3)and relative support

∆Ø- Replace the rails (1) with wider ones Replace the rails (2) with wider ones, guide (3)and relative support

∆Øh Replace the rails (1), base (4) and cover (5) Replace the rails (2), base (6), cover (7), guide (3)and relative support

Remove the parts to be replaced and install the new ones making sure they are perfectly aligned.

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7.6 CONVEYANCE CHANNEL

The conveyance channel does not need to be adjusted. The air flow rate of the blowers that advance the caps in thechannels can be set by adjusting the regulators located in the control unit.

E0004P IMPORTANT!Further information regarding the conveyance channel is available on request.

7.7 PNEUMATIC SYSTEM

The air flow rate of the blowers that advance the caps in the channels can be set by adjusting the regulators locatedin the control unit. Adjust the blowers as required.The required pressure is given in paragraph 2.3.1 - SPECIFICATIONS.

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7 ADJUSTMENTS

221.02.A04 Revision 00 Date 11.09.1998

8 - 1

221.02.A04MAINTENANCE 8


8 MAINTENANCE

8.1 GENERAL INFORMATION AND PRECAUTIONS REGARDING SAFETY

E0004PWARNING!

Only expert personnel who fully understand how the machine and plant in general operate can carry outmaintenance, as indicated in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.Take all the precautionary steps in order to prevent accidental machine start-up.- turn the main switch on the electrical cabinet to OFF- remove the safety key- put a “maintenance in progress” sign on the electrical cabinet- make sure the emergency stop buttons are pressedAlways keep in mind the potential risks and follow the safety rules given in chapter 3 - SAFETY EQUIPMENT ANDPRECAUTIONS.

Maintenance operations are subdivided as follows:- routine maintenance (to be carried out by the customer’s maintenance staff)- special maintenance (to be carried out by the manufacturer’s technicians or customer’s personnel who have beenspecially trained).

The following are some examples of routine maintenance:- mechanical jobs: lubricating and cleaning mechanical parts, replacing and tensioning the belts, replacing andcleaning the pneumatic valves

- electric jobs: replacing the fuses in the electrical cabinet.

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8 MAINTENANCE

221.02.A04 Revision 00 Date 11.09.1998

8.2 SCHEDULED MAINTENANCE

Carry out the operations at the intervals stated in chart 8.2.

8.2.1 CLEANING THE TOOLSThe fixed and movable tools have to be accurately cleaned at the intervals stated in the chart. Use the brass bristlebrush supplied with the machine and blow compressed air, if necessary.

E0004PWARNING!

Pay special attention when cleaning the tools.In particular, make sure no pieces of material are stuck between the tools.

8.2.2 LUBRICATIONLubrication is an extremely important operation. In fact, the parts need to be lubricated as indicated to prevent partsfrom breaking or wearing down.

8.2.3 CLEANING THE ELECTRIC PARTSThe electric parts (photocells, fiber optics, inductive sensors) need to be cleaned and operation (mechanical) of thelimit switches has to be checked to ensure proper machine operation.

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221.02.A04MAINTENANCE 8


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7500

1500

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8 MAINTENANCE

221.02.A04 Revision 00 Date 11.09.1998

8.3 SPECIAL MAINTENANCE OPERATIONS

Any special maintenance operations (therefore not given in the scheduled maintenance chart) can be carried out solelyby the manufacturer’s engineers or the customer’s personnel who have been specially trained. The operations mustbe carried out by carefully following the directions provided by the manufacturer.

8.4 TROUBLESHOOTING THE MACHINE

Whenever the machine shuts down, a red led on the control unit display comes on. Refer to the Instructions B manualfor information on how to locate and clear the trouble. If safety devices have been activated, reset the machine asdescribed in chapter 6 - OPERATING INSTRUCTIONS.

However, the following may cause malfunctioning:- faults during the work cycle- defects in the productThe troubles, causes and actions to be taken are described on the following page.

TROUBLE

Feed channel : caps jammed

Work unit : caps are not inserted

REMEDY

remove any deformed caps

clean the table the caps flow on

check the air mains pressure givenon the central gauge (valuesindicated in paragraph 2.3.1SPECIFICATIONS)

set the air flow rate of the blowers

check the air mains pressure

set the flow regulators

CAUSE

there are deformed caps in thechannel

the table the caps flow on in thefeed channel is dirty

insufficient compressed air

insufficient compressed airExit channel : caps jammed

8.4.1 TROUBLESHOOTING GUIDE

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221.02.A04DISMANTLING THE MACHINE 9


9 DISMANTLING THE MACHINE

MAKING THE MACHINE INOPERATIVE WHEN NO LONGER USEDThe operations given below need to be carried out when the machine is no longer used:- Turn off the machine’s power supply by using the factory’s main switch.- Unplug the power cable from the electrical cabinet’s terminal block.- Disconnect the cables that join the cabinet to the machine, detaching the connectors.- Disconnect the line between the factory’s compressed air mains and the control unit.- Thoroughly clean the machine paying particular attention to the moving parts. Lubricate as a protective measure, ifnecessary.

- Close the doors of the electrical cabinet and machine to prevent the parts from being tampered with, dust from buildingup, etc.

- Activate all the safety devices provided.

DISMANTLING THE MACHINERemove the various parts of the machine by carefully observing all current safety regulations as well as following thedirections given in chapter 4 - INSTALLATION in this manual. Special attention must be given to the procedures forlifting and handling the machine as well as the warnings and precautions given in paragraph 3.3 - SAFETY RULESFOR HANDLING.

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9 DISMANTLING THE MACHINE

221.02.A04 Revision 00 Date 11.09.1998

INSTRUCTIONS MANUAL 221wiki.energoplast.co.rs/images/2/25/Manual_TVC_A.pdf · 2020. 6. 11. ·...

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