Tech Manual

M20 Starpak

Multi-Functional Rotary Indexer

Serial No. 51667E

Operation&

Technical Manual

Ref. "51667E", Release 1.0, D.R.H. 19-11-98

BWI KP Aerofill 33-35 Clayton Road Hayes, Middlesex UB3 1RU England. Telephone: 0181-848 4501 Fax: 0181-561 3308 Telex: 935502 Aerfil GBarry Wehmiller International PLC. Registered in England. Number 490893. Registered Office: PO Box 95, Atlantic Street, Altrincham, Cheshire WA14 5EW

M20 STARPAK

MULTI-FUNCTIONAL ROTARY INDEXER

OPERATION

&TECHNICAL MANUAL

Contents

Chapter 1 - General Information............................ 2

1. Introduction................................................... 32. General Description...................................... 4

3. Machine Specifications................................. 54. Safety............................................................ 65. Installation..................................................... 76. General Maintenance.................................... 97. Operation...................................................... 128. Changeparts & Changeover Procedure........ 18

Chapter 2 - Common Equipment........................... 22

1. Machine Base Unit........................................ 232. Machine Guard Assembly............................. 24

3. Index Mechanism.......................................... 264. Conveyor Queue Sensor Assemblies........... 30

Chapter 3 - Machine Tooling.................................. 31

3.1. Preliminary Equipment.................................. 333.2. Liquid Product Fillers..................................... 373.3. Valve Crimping.............................................. 633.4. Liquid Propellent Fillers................................. 93

Chapter 4 - Spare Parts & Service......................... 128

1. Spare Parts................................................... 1292. Service.......................................................... 141

CHAPTER 1

GENERAL INFORMATION

Contents

1. Introduction................................................... 3

2. General Description...................................... 4

3. Machine Specifications................................. 5

4. Safety............................................................ 6

5. Installation..................................................... 7

6. General Maintenance.................................... 9

7. Operation...................................................... 12

8. Changeparts & Changeover Procedure........ 18

Chapter 1General Information

SECTION 1INTRODUCTION

This manual has been written for the guidance of users of BWI KP Aerofill M20 Starpak rotary indexer. Before the machine is installed and put into service, it is recommended that all relevant staff read this manual thoroughly to familiarise themselves with the operations and procedures required to run and maintain this machine in a safe efficient manner.BWI KP Aerofill operate a process of continual development of our range of machinery, therefore it is possible that minor differences may occur between the descriptions in this manual and the actual machine delivered. If the information required does not appear in this manual, or if you require technical assistance or spare parts, please contact your agent, or...

BWI KP Aerofill,33-35 Clayton Road,Hayes, Middlesex,UB3 1RUEngland.

Telephone: 0181-848 4501 (International: 0044 181 848 4501)Fax: 0181-561 3308 (International: 0044 181 561 3308)

Chapter 1 General Information

SECTION 2GENERAL DESCRIPTION

The BWI KP Aerofill M20 Starpak is an all pneumatic multi-functional rotary indexing machine, capable of processing a wide range of aerosol containers at speeds of up to 55 units per minute, subject to can size and fill volumes.

Empty containers on the infeed conveyor form a queue at the entrance to the machine, and are guided into a starwheel assembly by an infeed guide rail arrangement. Once in the starwheel pockets, the containers are indexed round under each of the machine's working heads in turn. These are explained further in the sections within Chapter 3 - Machine Tooling.

Once the container has been processed by each of the heads, it is indexed back onto the conveyor through an outfeed guide rail assembly, and is transported away to the next process.


SECTION 3MACHINE SPECIFICATION

3.1 MACHINE OUTPUT

Up to 55 c.p.m.

3.2 CONTAINER SIZE RANGE

Cans: Dia. 35-80mm / Height 50-320mmValves: 1" tinplate / aluminium cup, diptubes 0-325mm

3.3 PNEUMATIC REQUIREMENT

Supply: 8 bar (120 psi) Connection: 1" BSP femaleConsumption: Dependent on Application

3.4 PROPELLENT REQUIREMENT

Supply: 8 bar (120 psi)

Connection: 1" BSP femaleConsumption: Dependent on Application

3.5 LUBRICATION

General Purpose: Shell "Alvania" or Rocol "MTS 1000" greaseAir Service Unit: Shell "Tellus 22"Crimper: Molykote "165LT"

3.6 DIMENSIONS

Length: 911mmWidth: 705mmHeight : 1730mm


SECTION 4SAFETY

4.1 CLOTHINGw It is strongly recommended that eye protection and suitable protective clothing is worn whilst operating and maintaining the machine. Be sure that any loose clothing, cuffs and / or long hair is made safe.

4.2 MACHINE ISOLATION

w Always ensure that the machine is turned OFF, and is isolated from the pneumatic mains before any work is carried out. Where isolation is required, the following warning will appear in the descriptive sections of this manual:

! WARNING!

ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS SUPPLY BEFORE PROCEEDING.

w Some maintenance and set-up operations, however, may require the supplies to be turned ON. If this is the case, it is essential that these operations are only performed by

authorised, trained personnel in strict accordance with procedures given. Where this is required, the following warning will appear in the descriptive sections of this manual:

! WARNING!

THE FOLLOWING PROCEDURE REQUIRES THE MACHINE TO BE LIVE, AND SHOULD THEREFORE ONLY BE CARRIED OUT BY TRAINED PERSONNEL.

w These warnings and procedures are given in the interests of operator safety and good working practices, and as such they should be noted and followed.

FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY AND / OR DAMAGE TO THE MACHINE.

4.3 CRIMPERS

w The crimp unit's internal seals will bed-in after a period of use. The reduced friction between the seals and cylinder bores may allow the head to drop unexpectedly after the air supply is cut. This is normal and does not indicate any malfunction, but does call for vigilance on behalf of operators and service personnel.

DO NOT PUT YOUR HANDS UNDER THE CRIMP HEAD IF IT REMAINS IN THE UP POSITION WHEN THE PNEUMATIC SUPPLY IS CUT.

4.4 GENERAL

w This machine has been designed in accordance with the European Community legislation affecting the sale and construction of process and packaging machinery, and as such incorporates many features for the safety of it's operators. However, a degree of responsibility still rests with the operator to adopt and follow safe working practices.

BWI KP Aerofill can accept no liability for damage to the machine and / or personal injury arising from any incident where any safety features have been tampered with or disconnected.


SECTION 5INSTALLATION

5.1 SITE REQUIREMENTS

5.1.1 Pneumatic Supply

w The machine needs a pneumatic supply of at least 8 bar (120 psi). It is important to ensure that the air supply is clean and dry, and has sufficient flow available.

5.2 TRANSPORTATION

w During the installation procedure the machine will have to be positioned correctly in order to connect it to the adjoining equipment. This is best done using a fork lift truck.

w It is highly important that the machine is only lifted by positioning the forks under the base of the machine between the feet of the base unit.

THE MACHINE IS NOT DESIGNED TO BE LIFTED IN ANY OTHER WAY. ANY ATTEMPT TO LIFT THE MACHINE OTHER THAN AS STATED WILL ALMOST CERTAINLY CAUSE DAMAGE TO THE MACHINE.

5.4 INSTALLATION PROCEDURE

w In some cases the machine will be installed by BWI KP Aerofill service engineers. However, should the machine be supplied for the user to install, or if it has been moved to an alternate production site, then the following should be observed:

(i) Unpack the machine: w Remove all packing materials and ties, and check for transit damage. If any is found, contact your agent and / or BWI KP Aerofill immediately.

(ii) Position the machine: w Position the machine according to the layout plan, and level the machine by adjusting the support feet on the base unit.

(iii) Connect the conveyors: w Connect the machine conveyor to the infeed and outfeed conveyors. (See conveyor manual), and assemble any loose items.

(iv) Connect the air supply: w Connect the 8 bar (120 psi) mains air supply to the 3/4" BSP female fitting on the air service unit. This is located on the infeed end of the machine base unit under the infeed conveyor.

continued...

(v) Check Air Service Unit: w Check the oil level in the air lubricator of the air service unit and top up as required. Also drain off any fluid present in the moisture filter.

(vi) Run in machine: w

w

Finally, referring to Section 7 - Operation, start the machine and allow it to run for around one hour, as a running in period.

After this period a thorough inspection of the machine should be made to ensure that the machine is still set correctly and all assemblies are secure.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........


SECTION 6GENERAL MAINTENANCE

w Details of maintenance requirements can be found in the later sections of this manual covering the machine tooling.

w The following are guidelines for basic machine maintenance. It is important that the machine is regularly cleaned and lubricated. The recommended lubricants to be used are given in Section 3.3.

w Keep a record of any abnormal occurrences, noises, or vibration during operation. Also, keep a record of any stoppages and / or incidents. This information could be useful in diagnosing any problems that might occur.

w The instructions given throughout this manual are based on the machine performing a single eight hour operating shift per day. If the machine is being operated for longer periods, then the stated maintenance intervals should be adjusted accordingly.

w BWI KP AEROFILL CAN ACCEPT NO LIABILITY FOR ANY MACHINE PROBLEMS ARISING FROM FAILURE TO FOLLOW THESE INSTRUCTIONS.

6.1 MAINTENANCE PROCEDURES

! WARNING!


6.1.1 Daily

(i) Clean the machine regularly, preferablyafter each shift:

w If solvent cleaners are used, ensure that they are of a high flashpoint nature, and that they are not corrosive to machine components. For cleaning the machine's plastic components and guard panels, use a damp cloth with a mild detergent. Make sure that no rags or other cleaning materials are left on or in the machine.

(ii) Regularly check the air service unit: w The moisture filter section of the A.S.U. is fitted with a level sensor linked to an automatic dump valve. This will automatically drain the filter bowl when the water reaches a certain level. Top up the air lubricators if required, and drain off any fluid present in the moisture filters.

(iii) Lubricate the index mechanism as statedlater in this manual.

continued...

6.1.2 Weekly

w As daily, plus...

(i) Inspect the machines pipework andfittings:

w Check that all pipework, cables and fittings are secure and, in the case of pneumatic pipes, leak free. Any pipework or cables that are damaged should either be repaired if practicable, or preferably replaced.

(ii) Check that the guard and generalstructure of the machine are soundand in good working order:

w Check that the guard structure is sound and that all panels are securely in place.

The safety guard of the machine is designed so that it is not possible to open the access doors while the machine is running and, vice-versa, that the machine cannot be started with any of the doors open. If either of these conditions can be breached then there is a defect with the guard security system and the machine should not be operated until a satisfactory repair has been made.

(iii) Check all working heads: w Check that the working heads are all functioning correctly, as described in the later sections of this manual.

(iv) Inspect the index mechanism: w Inspect the index mechanism as stated later in this manual.

6.1.3 Monthly

w As weekly, plus...

(i) Perform a thorough inspection of the machine:

w Thoroughly inspect the machine, including all previous points, noting and rectifying any defects found.

(ii) Run the machine and listen for anynoise or uneven running:

w

w

While the machine is running, watch each of the machines main assemblies in turn to determine whether they are operating smoothly.

Similarly, listen for any unusual knocking, graunching or whining which could indicate impending component failure.

continued...

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........


SECTION 7OPERATION

7.1 MACHINE CONTROLS & THEIR FUNCTION

7.1.1 General Machine Controls

w The machine control console is mounted on the front of the machine base unit. The controls and their function are described below.

(i) The "START" button: w Press this green button to start the machine.

(ii) The "STOP / EM ERGENCY STOP " button:

w

w

Press to stop the machine in both normal use and emergency situations. It is designed to lock down on activation, and is released by twisting the button.

Note that this button will not stop the machine instantly, but will allow the machine to complete current cycle. It is required that all working heads complete their cycle and return to their rest positions for reasons of safety.

(iii) The " RESET" or "TABLE RELEASE" button:

w Press to reset the machine and working heads after a machine fault condition or emergency stop. This button will only function if all guard doors are closed, and the emergency stop button has been pressed then released. This prevents a reset while the machine is cycling.

(iv) The "SINGLE INDEX" key switch: w This key operated switch allows the machine to operated in individual single index cycles. For use only by authorised personnel during setting procedures.

(v) The "SPEED ADJUSTMENT" knob: w This large red hand wheel operates a variable flow restrictor used to increase or decrease the forward stroke speed of the index mechanism. Turn clockwise to decrease the operating speed, or anti-clockwise to increase.

(vi) The " PNEUMATIC PRESSURE INDICATOR ":

w This dial gauge displays the air pressure in the pneumatic circuit. Additional gauges may be fitted showing the different pressures in the operating cylinders of the crimper unit, depending on specification.

(v) The "EMERGENCY STOP" button: w Press to stop the machine instantly.

continued...

7.1.2 Working Head Controls

Also located on the console are a series of toggle switches which are used to individually select the required working heads. Note that the crimper / sensor is permanently engaged.

(i) The "PRODUCT FILLER 1" selectorswitch:

w Flick up to select the corresponding product filler, or down to de-select.

(ii) The "PRODUCT FILLER 2" selectorswitch:


(iii) The "PRODUCT FILLER 3" selectorswitch:


(iv) The "PRODUCT FILLER 4" selectorswitch:


(v) The " VALVE INSERTER / SENSOR " switch:

w Flick up to select the valve inserter / sensor head, or down to de-select.

(vi) The " GASSER 3" selector switch: w Flick up to select the corresponding propellent filler, or down to de-select.

ƒ Note that the crimper is permanently engaged.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

7.2 PRE-OPERATIONAL REQUIREMENTS

w Before the machine is run, ensure that the following requirements are achieved:

(i) Close all guard doors: w Check all guard doors are securely closed.

(ii) Turn on the pneumatic supply: w Turn the handle on the air service unit through 90° so that it is in line with the unit. Check that pressure gauge reads 8 bar (120 psi). Check the oil level in the air lubricator and top up if required. Drain off any fluid present in the moisture filter.

(iii) Check and engage the product supply: w Check that the required product supply is connected, then open the shut-off valve(s) by turning the handle on each valve through 90° so that it is in line with the pipework.

(iv) Check and engage the propellent supply: w Check that the required propellent supply is connected, then open the shut-off valve(s) by turning the handle on each valve through 90° so that it is in line with the pipework.

(v) Engage the required working heads: w Select the required working heads using the head selector switches.

(vi) Check " EMERGENCY STOP " buttons: w Check that all "EMERGENCY STOP" buttons are released. These are designed to lock down when pressed, and are released by twisting the button clockwise.

(vii) Check for obstructions: w Look around the machine and check that nothing is out of place, or causing an obstruction.

(viii) Start the conveyors: w Press the relevant "START" buttons on the line control panel (if applicable) to start the infeed and outfeed conveyors.

(ix) Check maximum queue switch: w Check that the maximum queue sensor on the outfeed side of the machine has not been activated.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

7.3 OPERATION PROCEDURE

7.3.1 To Run The Machine

(i) Press the "START" button: w Providing all the requirements of 7.2 - Pre- Operation Requirements are met, the machine will start cycling.

(ii) Press the "STOP / E/STOP " button when required:

w When required press the "STOP" button to decelerate and stop the machine.

w If the machine should stall, refer to 7.4 - Machine Stoppages During Operation.

7.3.2 Emergencies

! If an emergency situation arises:

(i) Press the " EMERGENCY STOP " button IMMEDIATELY :

w Pressing the "EMERGENCY STOP" button will stop the machine instantly.

(ii) Call your line technician: w IF THE NATURE OF THE EMERGENCY THREATENS YOURSELF OR OTHERS AROUND YOU, FOLLOW YOUR COMPANY'S OWN EMERGENCY PROCEDURES IMMEDIATELY.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...7.4 MACHINE STOPPAGES DURING OPERATION

w There are several conditions that may arise during normal operation which may cause the machine to stall. The following lists these conditions and the required action to restore operational status.

7.4.1 Minimum Can Queue

A closely formed queue of containers is required at the infeed to the machine to ensure consistent feed into the starwheel and continuous running of the machine. A sensor assembly is fitted to the infeed conveyor of the machine to maintain this, operating on the principle that when a sufficient queue of containers has formed, the sensor will register that containers are present and allow the machine to run. If the queue falls below the required minimum, the sensor will not register and the machine will stop.

If the machine fails to start, or stops during production:

(i) Check container supply: w Check that there is no problem with either the conveyors or the machine up-stream from the leak detector. A container may have fallen and / or jammed in the conveyors, or the up-stream machine, or the up-stream machine may have stopped for a separate reason. Either way, the Starpak will be starved of containers.

(ii) Rectify any problems found. w If no problems found, simply wait until the queue length builds back past the sensor and the machine will automatically re-start.

7.4.2 Maximum Can Queue

w If there is a problem with the down-stream machine and it stops, the queue of containers waiting to enter that machine will start to queue back towards the Starpak. If un-checked this queue could extend right into the Starpak causing the machine to lock-up, resulting in extensive damage. To prevent this and to ensure continuous running of the machine, a sensor assembly is fitted to the outfeed conveyor, operating on the principle that if a queue of containers from the down-stream machine reaches this point, the sensor will register that containers are present and stop the machine until the down-stream machine is operational and has caught up with the Starpak.

If the machine fails to start, or stops during production:

(i) Check down-stream machine& conveyors:

w Check that there is no problem with either the conveyors or the machine down-stream from the Starpak. A container may have fallen and / or jammed in the conveyors, or the down-stream machine, or the down-stream machine may have stopped for a separate reason. Either way, containers will queue back towards the Starpak.

(ii) Rectify any problems found. w If no problems found, simply wait until the queue length decreases and the machine will automatically re-start.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........


SECTION 8CHANGEPARTS & CHANGEOVER PROCEDURE

w The following is a list of operations that may be required to configure the machine to suit a different diameter and / or height of can, and valve type, from that which the machine is currently set for.

! WARNING!

UNLESS OTHERWISE STATED, ALWAYS ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS SUPPLY BEFORE PROCEEDING WITH ANY SETTING OR CHANGEOVER OPERATIONS.

i IMPORTANT:

It is essential that all changeparts fitted are the correct size for the container to be processed. For ease of recognition, all changeparts are marked with the diameter of the can they are designed for.

8.1 INFEED & OUTFEED FLIGHT RAILS

w If the can diameter has changed, the appropriate infeed and outfeed flight rail changeparts will need to be fitted as follows:

(i) Remove the existing infeed flightrailassembly:

w Unscrew the two locking thimbles on the top of the lower flight rail blade, and lift the assembly clear.

(ii) Position the replacement infeed flightrailassembly:

w Position the appropriate replacement flight rail assembly on the location dowels, and secure with the locking thimbles.

(iii) Repeat steps (i) and (ii) for the outfeed flightrail assembly.

8.2 INFEED & OUTFEED GUIDE RAILS

w If the can diameter has changed, the infeed and outfeed guide rails will need to be adjusted as follows:

(i) Slacken the guide rail: w Slacken the two lock nuts on the guide rail adjustment screws.

(ii) Position a sample container: w If the diameter of the container to be processed is greater than the current setting, back off the two lock nuts and slide the rail out sufficiently for a sample container to be positioned in the infeed.

(iii) Adjust the guide rail position: w Adjust the guide rail position to give 2-3mm clearance either side of the container, then secure with the adjuster and lock nuts, ensuring that the rail is parallel.

continued...

(iv) Repeat steps (i) to (iii) for the outfeedguide rail.

8.3 CENTRE STARWHEEL

w If the can diameter has changed, the appropriate centre starwheel changeparts will need to be fitted as follows:

(i) Remove the existing starwheel assembly: w Unscrew the four locknuts on the top of the lower starwheel, and lift the starwheel assembly off the location dowels.

(ii) Fit the replacement starwheel assembly: w Position the appropriate replacement starwheel assembly on the location dowels, and secure with the locking thimbles.

8.4 OUTER FLIGHT RAIL

w If the can diameter has changed, the appropriate outer flight rail changepart will need to be fitted as follows:

(i) Remove the existing outer flightrailassembly:

w Unscrew the four locking thimbles on the top of the lower flight rail blade, and lift the assembly clear.

(ii) Fit the replacement outer flightrailassembly:

w Position the appropriate replacement flight rail assembly on the location dowels, and secure with the locking thimbles.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

8.5 PRODUCT NOZZLE HEIGHT

If the can height has changed, the height setting of the product nozzle will need to be adjusted. Refer to Chapter 3.1, Section 2.2.1 - Nozzle Height Adjustment for the correct procedure.

8.6 PRODUCT CHANGE

If a change in product type is required, the product rams will need to be flushed through and primed accordingly. Refer to Chapter 3.1, Section 1.2.2 - Nozzle Height Adjustment for the correct procedure.

8.7 PRODUCT FILL VOLUME

If a change in product fill volume is required, the product rams will need to be adjusted accordingly. Refer to Chapter 3.1, Section 1.2.1 - Fill Volume Adjustment for the correct procedure.

8.8 VALVE SENSOR HEIGHT

If the can height has changed, the height setting of the valve inserter will need to be adjusted. Refer to Chapter 3.2, Sections 2.2.1 - Height Adjustment & 2.2.2 - Valve Sensing Probe Height Adjustment for the correct procedure.

8.9 CRIMPER HEIGHT

If the can height has changed, the operating height of the crimpers will need to be adjusted. Refer to Chapter 3.3, Section 1.2.1 - Height Adjustment for the correct procedure.

8.10 CRIMP DIAMETER & DEPTH

If the valve type has changed, the crimp diameter will need to be checked and, if necessary, adjusted. Refer to Chapter 3.3, Section 1.2.2 - Crimp Diameter and Depth Adjustment for the correct procedure.

8.11 PROPELLENT NOZZLE CHANGEOVER

If a different aerosol valve is to be used, the nozzle adaptor assembly will most likely need to be changed to suit. Refer to Chapter 4.2, Section 4.2.1 - Nozzle Changeover for the correct procedure.

THIS IS ESSENTIAL FOR SAFE, EFFICIENT FILLING.

8.12 PROPELLENT NOZZLE HEIGHT

If the can height has changed, the height setting of the propellent nozzle will need to be adjusted. Refer to Chapter 3.2, Section 4.2.2 - Nozzle Height Adjustment for the correct procedure.

8.14 PROPELLENT CHANGE

If a change in propellent type is required, the propellent ram will need to be flushed through and primed accordingly. Refer to Chapter 3.4, Section 1.2.2 - Nozzle Height Adjustment for the correct procedure.

continued...8.15 PROPELLENT FILL VOLUME

If a change in propellent fill volume is required, the propellent ram will need to be adjusted accordingly. Refer to Chapter 3.4, Section 1.2.1 - Fill Volume Adjustment for the correct procedure.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

CHAPTER 2

COMMON EQUIPMENT

Contents

1. Machine Base Unit........................................ 23

2. Machine Guard Assembly............................. 24

3. Index Mechanism.......................................... 26

4. Conveyor Queue Sensor Assemblies........... 30

Chapter 2Common Equipment

SECTION 1MACHINE BASE UNIT

1.1 GENERAL DESCRIPTION

1.2

SETTING AND ADJUSTMENT

w The base assembly requires no specific setting or adjustment.

1.3 MAINTENANCE

The machine stands on a base frame constructed steel angle section and houses the index and conveyor drive mechanisms mounted on the underside of the machine baseplate, and the pneumatic control valves for the working heads. The base frame is clad with stainless steel panelling, and is fitted with adjustable feet to compensate for uneven flooring. The base unit also carries the machine control panel, mounted on the rear face of the unit.

! WARNING!


1.3.1 Daily

(i) Clean the base unit exterior: w Machine cleanliness is highly important. A build up of dirt or debris may impair the efficiency of equipment housed in the machine base. This could cause an unsafe operating condition within the machine, and as such the base assembly and cover plate should be cleaned in accordance with Chapter 1, Section 6.1.

1.3.2 Weekly

w As daily, plus...

(i) Inspect the base unit: w Check that the general structure of the base is sound, and that all pipework and fittings are secure and, in the case of pneumatic pipes, leak free. Pipes that are damaged should either be repaired if practicable, or preferably replaced.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........


SECTION 2MACHINE GUARD ASSEMBLY

The machine is fitted with a safety guard, mounted off the baseplate. This is of stainless steel box-section tube construction, with either laminated glass or "Makrolon" panelling. The access doors of the guard are equipped with automatic door bolts to prevent access into the machine while it is in motion.

Additionally, the infeed and outfeed to the machine are guarded by tunnels mounted on the side of the main guard structure around the conveyors to prevent access to the machines moving mechanisms whilst the machine is operating.

These features are incorporated for the safety of the machine's operators in accordance with the European Community legislation affecting the sale and construction of process and packaging machinery.

BWI KP Aerofill can accept no liability for damage to the machine and / or personal injury arising from any incident where these safety features have been tampered with or disconnected.

2.2 SETTING AND ADJUSTMENT

w The guard assembly requires no specific setting or adjustment.

2.3 MAINTENANCE

! WARNING!


2.3.1 Daily

(i) Clean the machine guard: w Cleanliness is highly important. A build up of dirt on the guard panelling will impair visibility into the machine. This could hide an unsafe operating condition within the machine, and as such the guard assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1.

2.3.2 Weekly

(i) Inspect the machine guard: w Check that the guard structure is sound and that all panels are securely in place.

The safety guard is designed so that it is not possible to open the access doors while the machine is running and, vice-versa, that the machine cannot be started with any of the doors open. If either of these conditions can be breached then there is a defect with the guard security system and the machine should not be operated until a satisfactory repair has been made.

continued...NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........


SECTION 3INDEX MECHANISM

Ref. Dwg. No. Z418-03-00


The index mechanism is mounted centrally under the machine base plate, and provides the controlled rotary indexing motion of the starwheel assembly above.

The mechanism is constructed around a central shaft, which runs in a pair of needle bearings carried in a bearing housing, which is mounted on a sub-plate suspended from the base plate. At the bottom of this shaft is the index hub assembly, which is basically a pair of discs carrying 12, 16 or 20 vertical dowel pins (depending on machine type i.e. M20 = 20 pins, etc.) to provide the equivalent number of index positions per starwheel revolution.

Rotary motion is provided by an air/oil cylinder which is fitted with a two-armed, hinged lever assembly. The whole mechanism is mounted on a sub-plate bolted to the underside of the machine base plate. When the forward stroke of the cylinder is initiated, the hinged lever assembly moves forward, engaging the front arm with the nearest dowel pin, so causing the hub to rotate. As the forward stroke nears it's completion, the side arm is brought into position to act as a stop, which halts the rotation of the hub.

At the end of the cylinder's forward stroke, a striker plate activates a pilot valve which initiates the return stroke, withdrawing the hinged lever assembly. As the lever assembly is withdrawn, it pivots against spring pressure to disengage from the dowel pins, with the spring returning the lever to it's rest position. To provide some resistance for the air cylinder to work against, and to prevent the hub rotating backwards during the return stroke of the index mechanism, an adjustable friction brake assembly is fitted to act on the disc on the lower surface of the hub. On completion of the return stroke, another striker plate activates a second pilot valve to signal the start of the next forward stroke.

In order to produce a smooth action from the indexing mechanism, the cylinder used to provide the indexing motion is hydraulically powered on it's forward stroke, and pneumatically powered on the return stroke. The incompressible nature of the hydraulic oil eliminates the jerking that can arise with all-pneumatic cylinders under load. The hydraulic pressure is supplied by an air / oil dash-pot mounted on the machine base plate, and is basically an oil reservoir piped to the cylinder through the index forward stroke control valve (on the control panel). When the forward stroke of the air cylinder is initiated, the pneumatic circuit applies air at mains supply pressure to the reservoir, forcing the oil through the pipework and activating the cylinder. On completion of the forward stroke the air to the reservoir is cut, and the pneumatic return stroke of the cylinder returns the oil to the reservoir.

continued...

3.2SETTING & ADJUSTMENT

! WARNING!


3.2.1 Index Stroke Speed

w A speed valve on the machine control panel regulates the forward stroke of the indexing cylinder. The pneumatic circuit of the machine is so arranged that the starwheel will index forward as soon as the heads have retracted clear of the cans. However, the next filling cycle will not commence until all the metering rams have fully returned. Therefore, the forward indexing speed of the machine should be tuned so that the index stroke ends at the same time as the filling rams complete their return stroke. This will give maximum output with minimum wear.

3.2.2 Return Stroke Speed

A pre-set air flow restrictor is mounted inside the machine base and should not be tampered with. A faster return stroke will make machine operation noisy, accelerate wear, and will produce no gain in output, possibly even upsetting the pneumatic sequences.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

3.3 MAINTENANCE

! WARNING!


3.3.1 Weekly

(i) Clean the index mechanism: w Machine cleanliness is highly important. A build up of dirt or debris on the index mechanism may impair the efficiency of the assembly. This could cause an unsafe operating condition within the machine, and as such the index assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1, then fully re- lubricated as stated below.

(ii) Inspect the index mechanism: w Ensure that the general structure is sound and that all fasteners are secure.

w Check that all pipework and fittings are secure and leak free.

w Check the dowel pins in the hub assembly for signs of wear, and ensure that they rotate freely in their bearings.

w Check the main shaft for slop around the keyways and/or irregular movement about the needle bearings.

(iii) Lubricate the index mechanism: w Grease the mechanism through the grease nipples on the control panel.

w Grease the shaft bearings through the grease nipple at the top of the main shaft.

w With the indexing mechanism in it's rest position, i.e. fully retracted, and the air supply to the machine turned off, check the oil level in the air/oil dashpot and, if required, top up to the mark on the dip stick.

continued...

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........


SECTION 4CONVEYOR QUEUE SENSOR ASSEMBLIES

w Ref. ass'y. No. 452-21-0c


4.1.1 Minimum Can Queue

A closely formed queue of containers is required at the infeed to the machine to ensure consistent feed into the starwheel. A sensor assembly is fitted to the infeed conveyor of the machine to maintain this, operating on the principle that when a sufficient queue of containers has formed, the containers will pivot the sensor arm and hold it back, tripping the valve. This registers that containers are present and allow the machine to run. If the queue falls below the required minimum, the arm will not be activated and the machine will stop.To prevent the machine starting when the first container activates the assembly on it's way to the machine, a flow restrictor is fitted to the valve, set so that it takes a short time for the pressure to build up to activate the receiving valve in the machine. This acts as a time delay to give the containers enough time to reach the machine and form a static queue before the machine starts. The machine will only run while the sensor arm is held back by a queue, not when tripped by individual containers.

4.1.2 Maximum Can Queue

4.2 SETTING AND ADJUSTMENT

If there is a problem with the down-stream machine and it stops, the queue of containers waiting to enter that machine will start to queue back towards the Starpak. If un-checked this queue could extend right into the Starpak causing the machine to lock-up, resulting in extensive damage. To prevent this a sensor assembly is fitted to the outfeed conveyor, operating on the principle that if a queue of containers from the down-stream machine reaches this point, a special flightrail section will allow them will bunch up and activate the sensor arm. This will stop the Starpak until the down-stream machine is operational and has caught up.

The assemblies are pre-set prior to despatch, and should not need to be adjusted.

continued...

4.3 MAINTENANCE

! WARNING!


4.3.1 Daily

(i) Clean the assembly: w Cleanliness is highly important. as a build up for dirt or debris may impair the ability of the sensors to detect the container queue. As such the sensor assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1.

4.3.2 Weekly

w As weekly, plus...

(iii) Inspect the assembly: w The assembly should be inspected regularly to ensure that all fittings and pipework are secure and leak free, and that they are correctly set for the current application.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

CHAPTER 3

MACHINE TOOLING

Contents

3.1. Preliminary Equipment............................... 33

1. Can Cleaner.................................................. 34

3.2. Liquid Product Fillers................................. 37

1. 250ml Product Ram...................................... 38

2. 1/2" Streamflow Nozzle..................................57

3.3. Valve Crimping............................................ 63

1. Tandem Crimper & Double ActingVacuum Crimp Head..................................... 64

3.4. Liquid Propellent Fillers............................. 93

1. 90ml Propellent Ram.................................... 94

2. Nozzle Air Cylinder........................................ 110

3. Propellent Nozzle Body................................. 115

4. Nozzle Adaptor.............................................. 121

CHAPTER 3.1

PRELIMINARY EQUIPMENT

Contents

1. Can Cleaner.................................................. 34

Chapter 3.1Preliminary Equipment

SECTION 3CAN CLEANER

w Ref. Dwg. No’s. X420-33-00 / 0V


w Sequence of OperationThe can cleaner assembly is a simple device to pneumatically blast dust and dirt particles from containers before they are filled. The assembly consists of a double-acting air cylinder, with a hollow piston rod, mounted vertically on the machine head plate, with a probe tube mounted on the end of the cylinder rod. The probe runs down through a shroud mounted on the underside of the head mounting bracket. The shroud acts as a collector for the dust and dirt expelled from the containers, being connected to an external vacuum pump through a port in its side.

First, a container is indexed into position under the head by the index mechanism. Once in position, a pneumatic signal activates the probe air cylinder and the probe is lowered into the container. Once fully extended, a timed air blast is delivered through the probe to agitate any dust and dirt which is then sucked out through the shroud by the vacuum pump. The air cylinder then retracts the probe and the container is indexed away to the next process.

3.2 SETTING & ADJUSTMENT

! WARNING!


3.2.1 Height Adjustment

w If there is a change in container height, the height setting of the can cleaner will need adjusting as follows:

(i) Slacken the locking handle on the side of the head mounting bracket.

(ii) Position an empty sample container under the head:

w Place an empty sample container in the starwheel pocket under the nozzle to be set.

w If the height of the new container is greater than the current container, turn the handwheel at the top of the support assembly clockwise to raise the nozzle sufficiently to allow a sample container to be positioned.

(iii) Adjust the head height setting: w With the sample container in place, turn the adjustment wheel anticlockwise to lower the nozzle, and set the height to give 2-3mm clearance between the top of the can bead and the lowest point of the nozzle spout.

(iv) Tighten the locking handle to clamp the assembly in position, then remove the sample container.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

3.3MAINTENANCE

! WARNING!


1.3.1 Weekly

(i) Clean the exterior of the assembly: w Cleanliness is highly important. A build up of dirt or debris may impair the efficiency of the assembly, and as such the assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1. Make sure that no rags or tools are left on or in the machine.

(ii) Inspect the assembly: w The assembly will require periodic visual inspection. Attention should be paid to the following:

w Inspect the air cylinder to identify any possible leaking of seals.

w All pipework should be regularly checked for leaks

w Check that all fittings and unions are secure.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

CHAPTER 3.2

LIQUID PRODUCT FILLERS

Contents

1. 250ml Product Ram...................................... 38

2. 1/2" Streamflow Nozzle..................................57

Chapter 3.2Liquid Product Fillers

SECTION 1250ml PRODUCT RAM

w Ref. Dwg. No's. Y167-74-MEB, X175-53-0MA & 175-55-0P

The machine is equipped with a 250ml product ram assembly, mounted on the side of the machine, to measure and dispense a set volume of up to 250ml of product to the product filling nozzle. Each product ram assembly consists of a 21/8" air cylinder (Y167-74-MEB), a 250ml metering ram (X175-53-0MA), and a bottom cap and master valve assembly (W175-55-0P).

The air cylinder is the large diameter cylindrical unit forming the upper half of the ram assembly, and provides stroke adjustment and pneumatic power for the metering ram assembly mounted below. The metering ram receives it’s product supply from an external source, and delivers a pre-set dose of product into the aerosol container through the bottom cap and then the filling nozzle. The bottom cap contains the master valve assembly, which is basically a non-return valve to prevent product being sucked back into the ram during the return stroke.

The air cylinder contains an upper piston and a lower piston. The upper piston is mounted on the hollow helical screw shaft at the top of the assembly, and provides fill volume adjustment by means of the thimble mounted on the top of the screw, with the piston acting as a stroke back-stop for the lower piston.

The lower piston is connected to a rod that runs down into the metering ram. At the lower end of this piston rod, inside the metering ram, there is a third piston assembly. The product continually feeds into the metering ram from an external supply through the inlet port in its upper flange.

The lower piston is constructed using a ported floating piston which slides open when retracted to allow the product above it in the metering ram to flow through the piston, priming the ram, then when the piston rod is extended by the downstroke of the air cylinder,

w Sequence of Operation

First a container is positioned under the product nozzle. A pneumatic signal then initiates the downstroke of the ram air cylinder lower piston, and consequently the metering ram piston. The metering ram piston head closes, forcing the product out of the metering ram and through the pipework to the filling nozzle, through which the product is discharged into the container. As the air cylinder piston nears the end of it’s downstroke, the underside of the piston strikes a pilot valve assembly which switches the pneumatic signal to the underside of the lower piston to return the piston to it’s rest position. This action retracts the metering ram piston, which slides open to allow the product above to pass through to prime the ram, resetting the whole assembly for the next cycle.

continued...1.2 SETTING & ADJUSTMENT

1.2.1 Fill Volume Adjustment

! WARNING!

THE FOLLOWING PROCEDURE REQUIRES THE MACHINE TO BE LIVE, AND SHOULD THEREFORE ONLY BE CARRIED OUT BY AUTHORISED TRAINED PERSONNEL.

w The product ram assembly is adjustable to provide fill volumes of up to 250ml. The upper outer sleeve of the assembly provides this adjustment as described below.

i NOTE:

There is a scale mounted vertically on the side of the ram air cylinder, running up under the sleeve. This is a calibrated scale in increments of 2ml to provide a simple visual reference for setting the propellent fill volume.

(i) Cut air supply to the ram air cylinder: w The air supply to the ram air cylinder must first be cut by operating the sliding dump valve located on the pipework next to the pump housing. This dumps the air on the air cylinder lower piston.

(ii) Adjust the fill volume setting as required: w

w

w

To increase the fill volume, turn the sleeve anti-clockwise. This raises the upper piston in the air cylinder, allowing the lower piston a longer stroke, giving a higher fill volume.

To decrease the fill volume, turn the sleeve clockwise. This lowers the upper piston in the air cylinder, limiting the lower piston to a shorter stroke, giving a lower fill volume.

Set the sleeve so that its bottom edge

(iii) Re-engage the air supply to the ram air cylinder:

w Slide the dump valve back to it's original position to re-engage the air supply to the ram air cylinder.

(iv) Perform a single fill cycle: w

w

Refer to Chapter 1, Section 7 - Operation, and perform a single fill cycle on a sample container.

Ensure all working heads other than the product ram being set are de-selected.

(v) Check that the actual volume deliveredis correct:

w If for any reason there is a discrepency between the set volume and the actual volume delivered, repeat steps (ii) or (iii) and (iv) and (v) to trim the unit to the required setting.

continued...1.2.2 Product Change

w If the product type is to be changed, the filling heads must first be flushed through to remove all traces of the previous product type, as follows.

! WARNING!


(i) Turn on the air supply: w Engage the pneumatic mains supply as if for normal operation.

(ii) Disconnect the external product supply: w Shut off the external product supply to the heads, then close the inlet shut-off valves and disconnect the supply.

(iii) Connect the required flushing agent: w Connect a suitable supply of the required flushing agent to the inlet. Note that the system is designed to operate with a gravity fed supply.

(iv) Place empty containers in the starwheel: w Place a sufficient number of empty, un-valved containers in the infeed conveyor and starwheel pockets leading up to the product heads, to allow the heads to perform 5-6 cycles each.

(v) Run the machine for 5 - 6 cycles on each product ram:

w

w

Referring to Chapter 1, Section 7 - Operation, engage the selector switches of the product heads to be flushed, then run the machine for 5 - 6 cycles, or until the discharge from the nozzles is clean.


(vi) Disconnect the flushing agent supply: w When flushing is complete close the inlet valves and disconnect the flushing agent supply.

(vii) Connect the required product supply: w Connect the required product supply and open the shut-off valves.

(viii) Repeat steps (iv) and (v): w Repeat steps (iv) and (v) to prime the product rams with the new product type.

(ix) Isolate the machine: w De-select the product fillers and isolate the machine.

continued...

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

1.3MAINTENANCE

! WARNING!


1.3.1 Weekly

(i) Clean the exterior of the productram(s):

w Cleanliness is highly important. A build up of dirt or debris may impair the efficiency of the product ram assembly. This could cause an unsafe operating condition within the machine, and as such the assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1.

(ii) Inspect the product ram(s): w

w

w

The product rams should be inspected, paying attention to the following:

All pipework should be regularly checked for leaks, and check that all fittings and unions are secure.

Inspect all structural joints to identify any possible leaking of seals, particularly the gland seal where the lower piston rod enters the metering ram. Should product be found escaping from this point, simply tighten the gland nut with the spanner

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

1.4 SEAL REPLACEMENT

~ Seal Replacement Intervals: 6 months

The reciprocating action of the piston assemblies will eventually cause the piston seals to wear. This would cause a drop in efficiency in the unit as the air used to power the unit will leak past the seals and cause inconsistencies in the air pressure, and variations in fill volume will occur due to propellent bleeding past the ram piston. Also, the 'O' rings will become compressed over a period of time which could cause air / propellent leaks.

Spares Required:

w K167-74MEB 2 1 / 8" Product Air Cylinder

Spares Kit No.

Ass'y. Description ComponentPart No.

Component Description Qty.

K167-74-ME 21/8" Product Air Cylinder - - -- - W167-01-12 Gland Seal 3- - W167-20-01 Buffer 1- - V592-06-15 Valve Op. Lever 1

- - 940-25-05 'O' Ring 1- - 940-25-09 'O' Ring 1- - 940-25-19 'O' Ring 1- - 940-25-66 'O' Ring 1- - 940-33-10 P.T.F.E. 'O' Ring 1- - 940-34-61 Seal 1- - 940-34-84 Oil Seal 1- - 940-46-050 Spring 1- - 940-70-22 'O' Ring 1- - 943-40-95 3 Way Valve Cam Op. 1

w K175-53-0MA 250ml Product Ram

Spares Kit No.



K175-53-0MA 250ml Product Ram - - -- - W168-09-02 Cup Seal 1- - W168-10-02 Back Seal 1- - 940-33-08 P.T.F.E. ‘O’ Ring 1- - 940-33-10 P.T.F.E. ‘O’ Ring 1- - 946-26-58 Ball Valve 1

continued...

K175-55-0P Product Master Valve

Spares Kit No.



K175-55-0P Product Master Valve - - -- - W002-23-02 Master Valve Seal 1- - W175-55-05 Master Valve Spring 1- - 940-33-08 P.T.F.E. ‘O’ Ring 1- - 940-33-10 P.T.F.E. ‘O’ Ring 1

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...1.4.1 Product Ram Removal

w To replace the seals and 'O' rings in the product ram assembly, the assembly will first need to be removed from the machine a follows:

! WARNING!


(i) Disconnect the product ram assembly: w Disconnect all pipework leading to and from the product ram assembly, and blank off all ports to prevent ingestion of any foreign matter.

(ii) Remove the product ram from themachine:

w Support the assembly, slacken and remove the mounting bolts, then carefully withdraw the ram assembly from is mounting.

! CAUTION!

THIS ASSEMBLY IS HEAVY! Have an assistant ready to support the assembly while the retaining bolts are being removed, and to help when removing the assembly from the machine.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...1.4.2 Bottom Cap (Ref. Dwg. No. Y169-18-0M)

~ Replacement Interval: 6 months

Spares Required:

Spares Kit No.



K175-55-0P Product Master Valve - - -- - W002-23-02 Master Valve Seal 1- - W175-55-05 Master Valve Spring 1- - 940-33-08 P.T.F.E. ‘O’ Ring 1

- - 940-33-10 P.T.F.E. ‘O’ Ring 1

(i) Remove the bottom cap assembly: w Slacken and remove the four cap head screws that secure the bottom cap assembly to the metering ram barrel, withdraw the assembly from the barrel, and remove the old 'O' ring.

(ii) Remove the master valve assembly: w Remove the three cap head screws that retain the master valve housing, extract the housing and valve assembly, then remove the old 'O' ring from the cap body.

w Withdraw the valve stem from the housing and discard the old spring.

(iii) Remove the old master valve seal: w Place the valve stem in a vice fitted with protective soft-jaws, unscrew the seal retaining nut, and remove the old master valve seal.

(iv) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(v) Fit the new seal and spring: w Fit the new seal (W002-23-02) to the valve stem and secure with the retaining nut.

w Fit the new spring (W002-22-07) to the valve stem and seat the stem in the valve housing.

(vi) Re-assemble the valve assembly: w Install the new 'O' ring (940-33-11) in the counterbore in the cap body, then fit the seal housing and valve assembly and secure with the three cap head screws.

continued... If the metering ram piston is to be serviced,

go to 1.4.5 now.

(vii) Re-fit the bottom cap assembly: w Re-fit the bottom cap assembly to the metering ram barrel, not forgetting the new 'O' ring (940-33-08), and secure with the four cap head screws.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...1.4.3 Air Cylinder Upper Piston (Ref. Dwg. No. Y167-74-ME)


Spares Required:

From Spares Kit



K167-74-ME 21/8" Product Air Cylinder - - -- - 940-25-66 'O' Ring 1

- - 940-34-84 Oil Seal 1

(i) Slide the adjustment thimble down toaccess the air cylinder top cap:

w Unscrew the four countersunk screws that retain the adjustment thimble, and slide the thimble sleeve down to expose the air cylinder top cap.

(ii) Remove the upper assembly and screw shaft to expose the upper piston:

w Unscrew the four tie rod nuts that retain the top cap of the assembly. Hold the cylinder barrel and carefully withdraw the upper assembly and screw-shaft. This will expose the upper piston assembly on the end of the piston rod.

(iii) Remove the upper piston head, anddiscard the old seals:

w Slacken and remove the piston retaining nut from the underside of the piston head, and slide the two piston halves off the screw-shaft.

w Remove the old lip seal and 'O' ring.


(v) Fit the new seals: w Carefully fit the new lip seal (940-34-84) and 'O' ring (940-25-66) to the upper piston half.

(vi) Re-assemble the piston assembly: w Re-assemble the piston assembly in the reverse order of step (iii) above.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...1.4.4 Air Cylinder Lower Piston (Ref. Dwg. No. Y167-74-ME)


Spares Required:

From Spares Kit:



K167-88ME 41/2" Air Cylinder - - -- - 940-25-08 'O' Ring 1- - 940-70-20 'O' Ring 1- - 992-11-19 Cup Washer 2

w With the air cylinder upper piston removed:

(i) Remove the cylinder barrel and sealing washer:

w Carefully pull the cylinder barrel from the pump housing to expose the lower piston assembly, and remove the sealing washer from the barrel location groove in the housing.

(ii) Refer to 1.4.5 steps (i) to (iii) and remove the metering ram barrel.

(iii) Remove the lower piston assemblyretaining nut:

w Insert a tommy bar in the hole at the bottom end of the lower piston rod, and remove the lower piston retaining nut.

(iv) Disassemble the lower piston assembly: w Remove each component of the lower piston assembly from the piston rod - i.e. the washer, buffer, piston body, and actuator plate.

w Discard the old seals.

(v) Clean the components: w Clean the other components using a high flashpoint solvent, ensuring that there is no foreign matter present where the new seals are to be fitted.

(vi) Re-assemble the piston assembly: w Re-assemble the piston assembly in the reverse order of step (iii) and (iv) above, fitting the new lip seals (940-34-84 x2).

(vii) Clean the pump housing as above.

(viii) Refit the cylinder barrel: w Fit the new 'O' ring (940-70-22) to the groove in the pump housing, then refit the cylinder barrel, taking care that the new 'O' ring is seated correctly.


go to 1.4.5 now.

(ix) Refer to 1.4.5 step (ix) and refit themetering ram barrel.

(x) Re-assemble the upper assembly: w Re-assemble the upper assembly in the reverse order of 1.4.3, steps (i) to (ii).

(xi) Refit the product ram to the machine: w Refit the product ram to the mounting plate in the reverse order of steps (i) to (iii) at the start of this chapter.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...1.4.5 250ml Ram Piston (Ref. Dwg. No. X175-53-0MA)


Spares Required:

From Spares Kit



K175-53-0MA 250ml Product Ram - - -- - W168-09-02 Cup Seal 1

- - W168-10-02 Back Seal 1- - 940-33-08 P.T.F.E. ‘O’ Ring 1- - 940-33-10 P.T.F.E. ‘O’ Ring 1

(i) Disconnect the metering ram barrel and bottom cap assembly:

w If not already done, disconnect all pipework leading to and from the metering ram barrel and bottom cap assembly, and blank off all ports to prevent ingestion of any foreign matter.

(ii) Remove the metering ram barrel: w Support the ram barrel and remove the four socket head screws that secure the barrel to the air cylinder pump housing, and carefully withdraw the ram barrel to expose the metering ram piston assembly.

(iii) Unscrew the piston assembly: w Insert a tommy bar in the hole in the tapered piston head, and another in the hole in the piston rod, and unscrew the piston assembly.

(iv) Remove the piston from the piston head: w Insert a tommy bar in the hole in the tapered piston head, remove the locknut inside the seal retaining nut, and remove the lower piston head assembly and back seal.

(v) Unscrew the seal retainer and discardthe old cup seal:

w Slacken and remove the cup seal retaining nut from the lower piston head, and remove the old cup seal.

(vi) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

If the pump housing assembly is to be serviced, go to 1.4.5 now.

continued...

(vii) Fit the new seals and re-assemble the piston assembly:

w Re-assemble the piston assembly in the reverse order of steps (iv) to (vi) above, fitting the new back seal and the new cup seal (W168-10-02 & W168-09-02).

(viii) Re-assemble the metering ram assembly: w Re-assemble the metering ram in the reverse order of steps (i) to (iii) above, fitting the new 'O' ring (940-33-10). When refitting the barrel, use the tapered lead at the top of the barrel to form the cup seal as shown on the drawing.

(ix) Re-fit the bottom cap: w Re-fit the bottom cap, not forgetting the new 'O' ring (940-33-08).

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...1.4.6 Pump Housing, Pilot Valve and Gland Housing (Ref. Dwg. No. Y167-88-ME)


Spares Required:

From Spares kit:



K167-88ME 41/2" Air Cylinder - - -- - W167-01-12 Gland Seal 3- - 940-25-05 'O' Ring 1- - 940-25-09 'O' Ring 1- - 940-33-10 P.T.F.E. 'O' Ring 1- - 940-34-61 Seal 1- - 940-34-86 Oil Seal 1

(i) Gain access to the gland housing: w Push the piston rod down through the pump housing to expose the gland housing.

(ii) Remove the gland housing from thepiston rod:

w Insert a tommy bar in the hole in the side of the gland housing, slacken the gland nut, then slide the gland housing down off the rod and set aside.

(iii) Remove the piston rod from the pump housing:

w Carefully withdraw the piston rod from the top of the pump housing.

(iv) Remove the cover plate in the top face of the pump housing:

w Remove the four countersunk screws that retain the central cover plate in the top face of the pump housing, and lift out the plate.

(v) Remove the valve operating pin anddiscard the old 'O' rings:

w Carefully lift out the valve operating pin complete with the seal holder and spring, and remove the old 'O' rings from the seal holder.


(vii) Re-assemble the operating pin assembly: w Re-assemble the operating pin assembly in the reverse order of steps (iv) and (v) above, fitting the new 'O' rings (940-25-05 & 940-25-09) to the seal holder.

(viii) Remove the external pilot valve assembly from the side of the pump housing.

continued...

(ix) Remove the seal retainer plate in thepump housing aperture and discard theold lip seal:

w Remove the four screws that hold the seal retainer plate in the top face of the pump housing aperture, remove the plate, and extract the lip seal that is now exposed.

(x) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(xi) Re-assemble the seal and valveassembly:

w Re-assemble the seal and valve assembly in the reverse order of steps (viii) and (ix) above, fitting the new lip seal (940-34-61) to the seal holder.

(xii) Remove the gland nut and lip seal, and the outer 'O' ring from the gland housing.

(xiii) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(xiv)

Re-assemble the gland housing assembly: w Re-assemble the gland housing assembly in the reverse order of step (xi) above, carefully fitting the new gland seals (W167-01-12 x3) and the new 'O' rings (940-25-19 & 940-33-10). Gently tighten the gland nut - this should be checked and adjusted as required once the unit is back on the machine.

(xv) Re-install the pump housing on the piston rod:

w Clean the piston rod as above and slide the lower end of the rod down through the gland housing, then slide the upper end of the rod up through the pump housing.

Refer back through the procedures and re-assemble the product ram assembly, and refit the assembly to the machine.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

1.5 FAULT FINDING

Fault Remedy

Metering ram fails to fill: „ Check propellent supply is available.

„ Check propellent ram inlet valve is open.

„ Check all air couplings are engaged.

„ Check air supply to ram air cylinder.

„ Check propellent nozzle opens.

„ Ensure gland seal nut is not too tight.

„ Check NCNF lever is not being actuated due to nozzle being set too high.

„ Check propellent piston head is not jammed.

„ Check air cylinder master valve assembly.

„ Ensure air cylinder piston seals are not leaking.

Fill volume not consistent: „ Check propellent supply.

„ Vent propellent metering ram.

„ Ensure air cylinder piston returns fast enough.

„ Check propellent nozzle closes at end of fill.

„ Check propellent piston slides freely.

„ Check propellent piston seals.

NOTES

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

Chapter 3.2Liquid Product Fillers

SECTION 21/2" STREAMFLOW PRODUCT NOZZLE

Ref. Dwg. No. X175-46-0D


SEQUENCE OF OPERATION:

This machine is equipped with ‘Streamflow’ product filling nozzles mounted on the height adjustable mounting plate. Each nozzle consists of a lower body section, a cylinder body and a cylinder barrel, which are screwed into each other, and house a spring loaded piston / spool assembly, with the spring being fitted to hold the spool closed when the pneumatic supply is shut off. The lower body section is also fitted with a product inlet tube, which is connected to the product supply pipework from the metering ram assembly.

When a container is indexed into position under the filling nozzle, pneumatic signal to the cylinder body forces the piston / spool upwards against the spring pressure to open the nozzle. Simultaneously, another signal activates the filling cycle of the product ram assembly. The product is then discharged into the container through the nozzle and connecting pipework. Once the product dose has been discharged, the signal to the cylinder body is cut and another is applied to the top of the barrel to force the spool down onto the seal, thus shutting off the nozzle to prevent any dripping. The nozzle is now ready to repeat the cycle.

continued...


! WARNING!


2.2.1 Nozzle Height Adjustment

w If there is a change in container height, the height setting of the nozzle will need adjusting as follows:

(i) Slacken the locking handle on the side of the nozzle mounting bracket.

(ii) Position a sample container under thehead:

w

w

Place an empty sample container in the starwheel pocket under the nozzle to be set.

If the height of the new container is greater than the current container, turn the handwheel at the top of the support assembly anti-clockwise to raise the nozzle sufficiently to allow a sample container to be positioned.

(iii) Adjust the head height setting: w With the sample container in place, turn the adjustment wheel clockwise to lower the nozzle, and set the height to give 4mm clearance between the top of the can bead and the lowest point of the nozzle spout.

(iv) Tighten the locking handle to clamp the assembly in position, then remove the sample container.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

2.3 MAINTENANCE

! WARNING!


2.3.1 Weekly

(i) Clean the exterior of the assembly: Cleanliness is highly important. A build up of dirt or congealed product may impair the efficiency of the shut-off mechanism in the nozzle. This could cause splashing and inconsistent fills, and as such the assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1.

(ii) Inspect the nozzle: The nozzle should be inspected, paying attention to the following:


Inspect the structural joints of the air cylinder to identify any possible leaking of seals.

Inspect the tip of the nozzle to ensure that the mechanism is shutting off correctly

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

2.4 SEAL REPLACEMENT PROCEDURE


The reciprocating action of the air cylinder piston will eventually cause the internal seals to wear and / or deform. This will reduce the efficiency of the unit as air will bleed past the seals and reduce the working pressure of the unit, and also product splashing and inconsistent fills may be experienced.

Parts Required:

Spares Kit No.



K175-46-0J 1/2" Streamflow Nozzle - - -- - W120-54-04 P.T.F.E. Seal 1

- - V120-54-08 Seal Washer 1- - 940-25-08 'O' Ring 1

940-25-66 'O' Ring 1940-34-46 Lip Seal 1940-34-81 Lip Seal 2

2.4.1 Nozzle Removal

! WARNING!


w The nozzle must first be removed from the machine, as follows:

(i) Disconnect all pipework: w Disconnect the pipework leading to and from the nozzle assembly, then blank off all ports using clean, dry, lint-free rag to prevent ingestion of any foreign matter.

(ii) Remove the nozzle assembly: w Remove the nozzle assembly by undoing the bracket clamp which holds it in place. The nozzle assembly should be supported until it can be lowered from the clamp. Note that the clamp bolts do not have to be removed for the assembly to be removed.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

2.4.2 Seal Replacement

With the assembly on a workbench:

(i) Gain access to the spool piston sub-assembly:

w

w

Unscrew the cylinder barrel from the cylinder body to reveal the spool piston sub-assembly.

Remove the return spring.

(ii) Disassemble the piston sub-assembly: w Unscrew the piston locknut, and remove the clamp washer, lip seals and retainer, and support washer.

(iii) Remove the old seals: w Remove the old lip seals from retainer, and the old 'O' ring from the cylinder body.

(iv) Remove the spool: w Unscrew cylinder body from the lower body section and extract the spool.

(v) Remove the old seals: w Remove the old 'O' ring from the cylinder body and the lip seal from the lower body.

(vi) Remove the lower clamp and the old seal: w Unscrew the three retaining screws from the lower clamp, and remove the clamp and the old PTFE seal.

(vii) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals and 'O' rings are to be fitted.

(viii) Re-assemble the product nozzle assembly fitting the new seals:

w Re-assemble the product nozzle assembly in reverse order of steps (i) to (ix) above, fitting the new PTFE seal (W120-54-04), seal washer (V120-54-08), the new lip seals (940-34-46 & 940-34-81 x2) and 'O' rings (940-25-08 & 940-25-66), taking care not to damage any of these.

(ix) Refit the nozzle assembly pipework in reverse order of steps as above.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

2.5 FAULT FINDING

Fault Remedy

Zero, low or inconsistent product fill: „ Check product supply.

„ Check pipework and connections.

„ Check spool operation.

„ Check seals are not leaking.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

CHAPTER 3.3

VALVE CRIMPING

Contents

1. Tandem Crimper & Double ActingVacuum Crimp Head..................................... 64

Chapter 3.2Valve Crimping

SECTION 1TANDEM CRIMPER & D/A VACUUM CRIMP HEAD

w Ref. Diagrams on following pages & Dwg. No's. Y404-62-0A & Y404-47-0E


w

The tandem crimper and double acting vacuum head assembly is a unit designed for drawing a vacuum in containers which have had valves inserted, then crimping the valve in place.

Each crimper unit consists of primary cylinder and a secondary cylinder. The primary cylinder is mounted on the crimper plate and forms the basis for the crimper assembly. Through the primary cylinder runs the hollow primary shaft, which carries the crimp head at it’s lower end, and is connected to the secondary cylinder at it’s top end. Mid-way down this shaft is a piston, which operates within the primary cylinder. The action of this piston lowers and raises the crimp head. The secondary shaft runs through the hollow primary shaft, and is attached to the crimp wedge of the head assembly at it’s lower end. At the top end, the secondary shaft is connected to a tandem piston assembly, consisting of the upper and lower secondary pistons, which reciprocates within the secondary cylinder to operate the crimp wedge. Another piston, the primary piston, is located within the lower bore of the secondary piston and slides on the primary shaft. This piston acts as a stop when the head is lowered, allowing the vacuum phase of the crimping process to be performed before the crimp head itself is lowered fully to crimp.

Sequence of operation:

1.1 Stage 1 - Crimper at rest

The crimp head, vacuum shroud and primary and secondary assemblies all held in their retracted positions. The vacuum pump constantly running.

1.1.1

Air applied to port 'C' to hold vacuumshroud retracted (up).

1.1.2

Air applied to port 'E' to hold up secondary cylinder.

1.1.3

Air applied to port 'B' to hold up primary shaft and crimp head.

w Port 'B' is indirectly powered by the air applied to port 'E' passing through the upper secondary cylinder and out of port 'E1', then through pipework from 'E1' to port 'B'.

1.2 Stage 2 - down stroke & vacuum

ƒ The vacuum shroud is extended, as are the internal stop piston, primary shaft and crimp head. Once these are extended, the vacuum phase is performed.

1.2.1

Air applied to port 'S' to extend the internal stop piston.

1.2.2

Air applied to 'H' to extend the vacuum shroud.

continued...

1.2.3

Air to port 'E' cut and applied to port 'A' to power down the primary shaft and crimp head.

w The air under the primary piston from Stage 1.1.3 exhausts through a flow restrictor on port 'B', through in the connecting pipework, back into port 'E1' then out of port 'E'. This air finally exhausts through a valve in the crimper circuit. The flow restrictor is incorporated to control the flow of the exhausting air, providing a means of controlling the speed of the downstroke.

w To enable the vacuum phase to take place, the primary shaft is prevented from descending fully by the internal stop piston contacting the top of the primary cylinder. This holds the crimp head clear of the aerosol valve, allowing the vacuum seal to contact the neck of the can. Once the seal makes contact the air in the can is evacuated around the valve and out through port 'F'.

1.3 Stage 3 - crimp

1.3.1

Vacuum phase times out.

1.3.2

Air to ports 'H' & 'S' cut, air to port 'A' maintained.

w With air removed from port 'H' the vacuum shroud, while still in contact with the can, is free to 'float'. When the air to port 'S' is cut, the air still applied to port 'A' powers the primary shaft and crimp head down to complete the downstroke, with the crimp head sliding down through the vacuum shroud. This brings the crimp head down on the aerosol valve, which locates in the can location ring in the crimp head, and presses down on the valve to compress the valve gasket. The air previously holding down the vacuum shroud and the

1.3.3

Pilot valve activated, air applied to ports'C', 'D' and 'D1'.

w At the end of the downstroke, an external pilot valve mounted on the secondary cylinder is activated. This signals air to be applied to port 'C' to retract the vacuum shroud, and to ports 'D' and 'D1' to power down the secondary shaft and crimp wedge to crimp the valve. The vacuum is maintained in the can by the crimp head pressing down on the valve. The air under the upper secondary piston passes out through port 'E' and exhausts through the circuit.

1.3.4

Air applied to port 'G' signals end of crimp. w Some of the air applied to port 'D' in 1.3.3 is allowed to escape through the bleed hole in the secondary cylinder top cap, under the crimp diameter adjustment nut. When the secondary shaft completes its downstroke, the buffer on the underside of the adjustment nut seals the bleed hole, causing a pulse of air to pass through port 'G'. This pulse activates a valve to signal that the crimp is complete and initiates the crimper return stroke.

1.4 Stage 4 - return stroke

1.4.1

Air to ports 'D' & 'D1' cut, air applied toport 'E' to retract secondary shaftassembly.

w Air is first applied to port 'E' to retract the secondary shaft and crimp wedge, consequently allowing the crimp jaws to close. This has to be first movement of the return stroke since if the crimp head is retracted while the jaws are still open, the jaws will pick up the can.

1.4.2

Air applied to port 'B' to retract primaryshaft and crimp head.

w Port 'B' is indirectly powered by the air applied to port 'E' in 1.4.1 passing through the upper secondary cylinder and out of port 'E1', then through a flow restrictor in the pipework connecting 'E1' to port 'B'. The flow restrictor is incorporated to ensure that the primary cylinder takes longer to pressurise than the secondary cylinder. This results in a delay between the two cylinders operating, preventing the can from being picked up as 1.4.1. The air above the tandem secondary pistons exhausts through ports 'D' and 'D1', then

w The crimper is now ready to repeat the cycle.

Tandem Crimper

Guide to Main Assemblies & Pneumatic Ports

5

7

9

1

2

3

4

6

8

'D''G'

'D1''E''E1'

'S'

'A'

'B'

'C'

'H'

'F'

1.

2.

Crimp Diameter Adjustment Nut

Secondary Cylinder

3. Secondary Shaft & Tandem

Piston Assembly

4. Internal Stop Piston

5. Primary Shaft

6. Primary Cylinder

7. Primary Piston

8. Crimp Head

9. Vacuum Shroud

'E'

'E1'

'B'

'C'

Stage 1

Crimper at Rest

'E'

'E1'

'S'

'A'

'B'

'C'

'H'

'F'

Stage 2

& Vacuum

Downstroke

Stage 3

Crimp

'H'

'D''G'

'D1' 'E''E1'

'S'

'A'

'B'

'C'

Stage 4

Return Stroke

'D'

'A'

'E'

'E1'

'B'

'C'

Ref. "51667E",


w Valves of different types and specifications may possess varying crimp properties by nature of differing materials, dimensions etc. Consequently, if an alternate valve is to be processed the crimper may need to be adjusted using the following procedures to achieve the valve manufacturers’ recommended crimp dimensions. Note that the crimp head must be in it’s down position, and also that the crimp diameter should be set before the crimp depth.


w If the overall container height has changed, the height setting of the crimper will need to be adjusted as follows.

! WARNING!

PARTS OF THE FOLLOWING PROCEDURE REQUIRES THE MACHINE TO BE LIVE, AND SHOULD ONLY BE CARRIED OUT BY TRAINED PERSONNEL.

(i) Gain access to the crimper: w Open the guard door to gain access to the crimper unit and height adjustment column.

(ii) Pull the crimp head down: w With the pneumatic supply turned OFF, it will be possible to manually pull the crimp head down to it's lower position. The crimp head may slide down under it's own weight when the pneumatic supply is cut. If not, grasp the crimp head and gently pull downward until a pronounced stop is felt.

! WARNING!

The crimp unit's internal seals will bed in after a period of use, and as a consequence the head may drop unexpectedly after the air supply is cut. This does not indicate any malfunction, but does call for vigilance on behalf of operators and service personnel.

ƒ If the crimp head should remain in the UP position when the air is cut:

w DO NOT put your hands under the crimp head;

w DO NOT use any tools or excessive force to lower the head;

(iii) Release the mounting bracket: w Slacken the locking handle on the side of the column mounting bracket to allow the height to be adjusted.

(iv) Position a sample container with valve: w If the overall height of the container to be processed is greater than that which the machine is currently set for, turn the handwheel at the top of the support assembly clockwise to raise the crimper sufficiently to allow a sample container, complete with a seated valve, to be placed in the starwheel pocket under the crimper.

continued...

(v) Adjust the crimper height setting: w With the sample container in position, turn the handle anti-clockwise to lower the crimper until the can location ring in the crimp head touches the lip of the sample valve.

w Lower the head by a further two turns of the handle to ensure that the valve gasket is sufficiently compressed when the crimp process takes place, and to prevent the crimper bottoming-out in operation.

(vi) Remove the sample container / valve: w Manually lift the crimp head sufficiently to remove the sample container / valve, then lower the head back to the down position.

(vii) Secure the mounting bracket: w Tighten the locking handle and close the guard door.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.2.2 Crimp Diameter and Depth Adjustment

! WARNING!

PARTS OF THE FOLLOWING PROCEDURE REQUIRES THE MACHINE TO BE LIVE, AND SHOULD ONLY BE CARRIED OUT BY TRAINED PERSONNEL.

(i) Refer to Chapter 1, Section 7 - Operation, and prepare the machine for operation.

(ii) Position a sample container with valve: w Place a sample can, complete with valve, in the starwheel under the crimp head to be set.

(iii) Perform a single crimp cycle: w There is a "SINGLE CRIMP" key switch mounted on the control console next to each crimp head. Insert the correct key in the switch on the corresponding console and turn then return to perform a single crimp cycle on the sample valve in the can.

It is important that the key is returned immediately since if the crimp head is left down for longer than during a normal crimp cycle, the resultant crimp diameter will be larger due to the prolonged force applied.

(iv) Measure the crimp diameter: w Remove the sample can and measure the crimp diameter using the appropriate dial gauge.

(v) Adjust the crimp diameter as required: w Refer to the valve manufacturers' recommended dimensions for crimp diameter and adjust as required.

w Adjustment is by means of the knurled thumb nut at the top of the crimper assembly. This contains a spring loaded ball mechanism which provides click-stop adjustment of the crimp diameter in increments of 0.05mm. To adjust, rotate the adjustment nut anti-clockwise to increase the crimp diameter, or clockwise to decrease.

w Repeat steps (ii) to (v) until the required crimp diameter is achieved, then proceed to step (vi).

(vi) Repeat steps (ii) and (iii), then measurethe crimp depth:

w Once the crimp diameter has been set, repeat steps (ii) and (iii), then remove the sample can and measure the crimp depth using the appropriate dial gauge.

continued...

(vii) Adjust the crimp depth as required: w Refer to the valve manufacturers' recommended dimensions for crimp depth and adjust as required.

w Adjustment is by means of the crimp depth adjustment ring at the top of the vacuum shroud assembly. This is fitted with a spring loaded locking pin which provides adjustment of the crimp depth in increments of 0.01mm. Pull out the locking pin on the adjustment ring, and rotate the ring anti-clockwise to increase the crimp depth, or clockwise to decrease. Ensure that the pin is returned to it’s locked position.

w Repeat steps (vi) and (vii) until the required crimp depth is achieved.

(vii) Repeat for all crimp heads: w Repeat steps (i) to (vii) as required until each of the crimper units are correctly set.

(viii) Close the guard door and isolate the machine.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.2.3 Vacuum To Non-Vacuum Changeover

w If required, the crimper can be made to operate as both the standard vacuum crimper, and also as a conventional non-vacuum crimper.

! WARNING!


(i) Remove the vacuum seal retainer: w Unscrew the vacuum seal retainer from the bottom of the vacuum shroud.

(ii) Extract the vacuum shroud.

(iii) Replace the seal retainer.

(iv) Disable or turn off the vacuum generator.

(v) Check the crimper settings: w Check that the crimp depth and diameter settings are still correct for the valve type to be crimped.

(vi) To revert to vacuum crimping, reverse steps (i) to (iv) above, then repeat step (v).

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.3 MAINTENANCE

! WARNING!


1.3.1 Per Shift

w The lubrication of crimp jaws and wedge cannot be emphasised too highly. This will minimise wear to both the jaw set and the crimp wedge, and also greatly reduce the risk of breakage, helping to maximise the operating life of costly replacement items.

! IMPORTANT!

There are several areas within the crimper assemblies where sliding components are subject to metal-to-metal contact under high loading. As a consequence, regular and frequent lubrication is essential to prevent the rapid wear of components contained in this assembly.

(i) Lubricate the crimp jaws: w The inside of the crimp collet should be smeared with Molykote 165LT grease or equivalent at the start of, and half way through, each shift. This should be applied all round the outer face of the crimp collet, ensuring that the whole surface is covered.

w If long shifts are in operation, or if the units are being used at high cycle rates, then the time between applications should be reduced accordingly. Lubrication twice per shift, or even three times in extreme conditions, should be considered.

1.3.2 Daily

(i) Lubricate the crimper: w General lubrication of the head is facilitated by the grease nipple fitted to the body of the assembly, and should be performed at least once a day.

(ii) Clean the exterior of the crimper: w The exterior of the crimper should be cleaned daily in accordance with Chapter 1, Section 6.1.

1.3.3 Weekly

As daily, plus...

(i) Inspect the crimper unit: w

w

The crimp wedge and jaws should be regularly inspected for wear and / or damage in the form of scoring, cracks etc.

Attention should be paid to structural joints to identify any possible leaking of seals. All pipework should be checked for leaks, ensuring that all fittings and unions are secure.

continued...NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........


~ Replacement Interval: 6 Months

w The reciprocating action of the crimper will eventually cause the primary and secondary cylinder piston seals to wear. This would cause a drop in efficiency in the unit as the air used to power the unit will leak past the seals and cause inconsistencies in the air pressure. Also, the 'O' rings will become compressed over a period of time which could cause air leaks. Consequently, the seals and 'O' rings in the crimper assembly should be changed every 6 months.

Parts Required:

Spares Kit No.



K404-47-0P Vacuum Crimp Head - - -- - V404-40-13 Buffer 1- - V404-47-20 Vacuum Seal - 45 / 50mm 1- - V404-47-21 Vacuum Seal - 53mm 1- - V404-47-22 Jaw Spring Mod. 1- - 940-37-80 External Seal - 70mm 1- - 940-37-81 Rod Wear Ring - 65mm 1

- - 940-37-82 Internal Seal - 65mm 1- - 940-37-83 Rod Wear Ring - 56mm 1- - 940-37-84 Internal Seal - 56mm 1- - 940-70-33 'O' Ring 1- -

K404-62-0A Tandem Crimper - - -- - V404-62-03 Adjusting Nut Buffer 1- - V404-62-07 Internal Buffer 2- - V404-62-27 Internal Buffer 1- - 940-25-32 'O' Ring 1- - 940-37-69 Internal Seal 2

- - 940-37-70 Rod Wear Ring - 18mm 4- - 940-37-71 External Seal - 75mm 3- - 940-37-72 Pstn Wear Ring - 75mm 4- - 940-37-73 External Seal - 48mm 1- - 940-37-74 Pstn Wear Ring - 48mm 2- - 940-37-75 Internal Seal - 28mm 1- - 940-37-76 Rod Wear Ring - 28mm 2- - 940-37-77 Internal Seal - 30mm 2- - 940-37-78 Rod Wear Ring - 30mm 4- - 940-70-25 'O' Ring 1- - 940-70-26 'O' Ring 2

- - 940-70-27 'O' Ring 1- - 940-70-32 'O' Ring 1

1.4.1 Crimper Removal

The vacuum seal and vacuum shroud seals can be replaced with the crimper 'in situ'. However, to replace the seals and 'O' rings in the main crimper assemblies, the unit will first need to be removed from the machine a follows:

! WARNING!


(i) Disconnect the crimper: w Disconnect all pipework leading to and from the crimper unit, and blank off all ports using pieces of clean, dry, lint-free rag to prevent ingestion of any foreign matter.

(ii) Remove the crimper from the machine: w

w

w

If not already done, remove the crimp head as stated in 1.4.2 steps (i) to (iii).

Insert a tommy bar in one of the holes in the crimp head body, grip the secondary cylinder, then unscrew and remove the crimp head and 'O' ring from the end of the primary shaft.

Have an assistant support the unit, then slacken and remove the clamp collar and shim from the secondary cylinder under the head plate support block.

(iii) Place on a suitable work bench.

! CAUTION!

THIS ASSEMBLY IS HEAVY! Have an assistant ready to support the assembly while the clamp collar is being removed, and to assist when removing the assembly from the machine.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.2 Vacuum Seal

w If difficulties have been encountered when attempting to draw off high vacuums, try replacing the vacuum seal, as follows, before investigating the problem any further.

! WARNING!


(i) Remove the vacuum seal retainer: w Using a suitable 'C' spanner, slacken and remove the vacuum seal retainer from the bottom of the vacuum shroud.

(ii) Extract the vacuum seal and inspect for wear and / or damage.

(iii) Fit a new vacuum seal if required: w Fit a new vacuum seal if required, ensuring that it is of the correct type for the container being processed.

(iv) Re-fit the seal retaining ring.

(v) Test the new seal: w Perform some trial crimp cycles to see whether this has cured the problem. If it has not, suspect seal failure within the vacuum shroud assembly.

i IMPORTANT!

Where the use of a 'C' spanner is stipulated, it is important that this tool is used. Other methods, especially the use of punches, will damage the components and eventually render them useless.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.4.3 Vacuum Shroud

If difficulties have been encountered when attempting to draw off high vacuums, first try replacing the vacuum seal, as stated previously in 1.4.1 - Vacuum Seal. If replacing the vacuum seal fails to cure the problem, replace the seals in the vacuum shroud.

The crimp head will first have to be removed from the main unit.

i IMPORTANT!


Spares Required:

From Spares Kit:



K404-47-0P Vacuum Crimp Head - - -- - 940-37-81 Rod wear Ring - 65mm 1- - 940-37-82 Internal Seal - 65mm 1

- - 940-37-83 Rod Wear Ring - 56mm 1- - 940-37-84 Internal Seal - 56mm 1- - 940-70-33 'O' Ring 1

K404-62-0A Tandem Crimper - - -- - 940-25-32 'O' Ring 1

(i) Disconnect the vacuum shroud: w Disconnect all pipework leading to and from the vacuum shroud assembly, and blank off all ports using pieces of clean, dry, lint-free rag to prevent ingestion of any foreign matter.

(ii) Remove the single cap head screw that retains the crimp wedge.

(iii) Remove t he crimp head: w Using a suitable 'C' spanner applied to the body of the assembly, unscrew the crimp head from the primary shaft, and place on a suitable work bench.

(iv) Remove the vacuum shroud assemblyfrom the crimp head:

w Using a suitable 'C' spanner, unscrew the shroud retaining ring, then carefully pull the vacuum shroud assembly from the crimp head.

(v) Remove the adjustment pin: w Carefully remove the adjustment pin retaining spring then extract the adjustment pin.

continued...

(vi) Unscrew the adjustment sleeve from the body.

(vii) Remove the adjustment ring and theshroud retainer:

w Slacken and remove the four cap head screws from the adjustment ring, remove the ring, then slide off the shroud retainer.

(viii) Remove the vacuum seal: w Using a suitable 'C' spanner, slacken and remove the vacuum seal retainer from the bottom of the vacuum shroud, and extract the vacuum seal. If this has recently been replaced, set it aside to be re-fitted on assembly.

(ix) Remove all old seals: w Remove all the old 'O' rings, seals and wear rings from the shroud retaining ring, the shroud body, and the adjustment sleeve.

w If desired, the components contained within the crimp housing can now be extracted for inspection. If this is the case, check the components for wear and / or damage, noting that a certain amount of light wear is normal. However, if any components bear heavy wear marks, scoring and / or cracks, they should be replaced.

i IMPORTANT!

It is critical that crimp jaws are replaced as a matched set. Jaw sets are marked as such to aid identification. Under no circumstances whatsoever should individual jaws from different sets be mixed.

(x) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new 'O' rings, seals and wear rings are to be fitted.

(xi) Fit the new seals to the shroud retainer: w Fit the new internal seal (940-37-82) and wear ring (940-37-81) to the groove in the shroud retainer.

(xii) Fit the new seals to the shroud: w Fit the new 'O' ring (940-70-33), internal seal (940-37-84) and wear ring (940-37-83) to the shroud.

(xiii) Fit the new seal to the adjustment sleeve: w Fit the new external seal (940-70-80) to the groove in the adjustment sleeve.

(xiv)

Re-assemble the vacuum shroudassembly:

w Re-assemble the vacuum shroud assembly in reverse order of steps (iii) to (viii) above taking, care not to damage any of the new seals, etc.

If the main crimper unit is to be serviced, go to 1.4.4 now.continued...

(xv) Refit the crimp head: w Refit the crimp head to the crimper unit in the reverse order of steps (i) to (iii) above, not forgetting to fit the new 'O' ring (940-25-32) to the end of the primary shaft.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

w Main Crimper Unit

i IMPORTANT!


1.4.5 Secondary Cylinder Top Cap

Spares Required:

From Spares Kit:



K404-62-0A Tandem Crimper - - -- - 940-37-69 Internal Seal 1- - 940-37-70 Rod Wear Ring - 18mm 2

(i) Remove the crimp diameter adjustmentnut:

w Unscrew the crimp diameter adjustment nut from the top of the assembly.

(ii) Remove the top cap from the secondary cylinder body:

w Remove the six cap head screws from the top of the secondary cylinder top cap, and remove the top cap from the secondary cylinder body, exposing the upper secondary piston.

(iii) Remove the old seal and wear rings from within the top cap.

(iv) Clean the top cap: w Clean the top cap using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(v) Fit the new seals: w Carefully fit the new seal (940-37-69) and wear rings (940-37-70 x 2) to the piston assembly.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.6 Upper Secondary Piston

Spares Required:

Spares Kit No.



K404-62-0A Tandem Crimper - - -- - V404-62-27 Internal Buffer 1- - 940-37-71 External Seal - 75mm 1- - 940-37-72 Pstn Wear Ring - 75mm 1- - 940-70-25 'O' Ring 1

(i) Remove the upper secondary piston assembly:

w Insert a tommy bar in the through hole in the crimp diameter adjustment shaft, unscrew the shaft, and remove the upper secondary piston assembly.

(ii) Split the piston and remopve the old seals: w

w

Remove the four cap head screws from the piston, and split the piston into it’s two halves.

Remove the old seal, wear ring, and buffer from the piston, and the shaft 'O' ring.

(iii) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(iv) Inspect the buffer: w Inspect the buffer. If worn or damaged, replace the buffer with a new item (W404-62-27). If not, refit the buffer.

(v) Fit the new seals: w Carefully fit the new seal (940-37-71) to the piston, the new wear ring (940-37-72) to the piston cap, and the new 'O' ring (940-70-25) to the shaft.

(vi) Re-assemble the piston in the reverse order of step (ii) above.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.7 Secondary Cylinder Manifold

Spares Required:

Spares Kit No.



K404-62-0A Tandem Crimper - - -- - 940-70-26 'O' Ring 2- - 940-37-69 Seal 1- - 940-37-70 Wear Ring 2

(i) Remove the secondary cylinder manifold: w Pull the secondary cylinder manifold from the lower secondary piston spigot and cylinder body.

(ii) Remove the old seals: w Remove the two 'O' rings from the outer edges of the manifold, and the two wear rings and seal from the central bore.

(iii) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(iv) Fit the new seals: w Carefully fit the new outer 'O' rings (940-70-26 x 2), the new seal (940-37-69) and the new wear rings (940-37-70 x 2) to the manifold.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.8 Lower Secondary Piston

Spares Required:

Spares Kit No.



K404-62-0A Tandem Crimper - - -- - 940-37-71 Seal 1- - 940-37-72 Wear Ring 1

(i) Remove the lower secondary piston and secondary shaft:

w Withdraw the lower secondary piston and secondary shaft from the cylinder body and primary shaft assembly.

(ii) Split the piston and remove the old seals: w Remove the four cap head screws from the piston assembly, and split the piston into it’s two halves.

Remove the old seal, wear ring, and buffer from the piston, and the 'O' ring from the shaft.


(v) Inspect the buffer: w Inspect the buffer for wear and / or damage. If any is found, replace the buffer with a new item. If not, refit the buffer to the piston.

(vi) Fit the new seals: w Carefully fit the new seal (940-37-71) to the piston, and the new wear ring (940-37-72) to the piston cap.

(vii) Re-assemble the piston in the reverse order of step (ii) above.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.9 Primary Piston

Spares Required:

Spares Kit No.



K404-62-0A Tandem Crimper - - -- - W404-62-07 Buffer 1- - 940-37-71 Seal 1

- - 940-37-72 Wear Ring 2- - 940-37-75 Seal 1- - 940-37-76 Wear Ring 1

(i) Remove the primary shaft locknut: w Slacken and remove the locknut.

(ii) Remove the secondary cylinder body: w Pull the secondary cylinder body away from the primary shaft. Note the primary piston may be withdrawn with the body.

(iii) Remove the primary piston: w Remove the primary piston from the primary shaft or the secondary cylinder body, whichever is applicable.

(iv) Remove the buffer and old seals: w Remove the buffer, the old seal and wear rings from the skirt of the piston, and the seal and wear ring from the central bore.

(v) Clean the piston: w Clean the piston using a high flashpoint solvent, ensuring that no foreign matter is present where the new seals are to be fitted.

(vi) Inspect the buffer: w Inspect the buffer for wear and / or damage. If any is found, replace the buffer with a new item (W404-62-07). If not, refit the buffer.

(vii) Fit the new seals: w Carefully fit the new seal (940-37-71) and wear rings (940-37-72 x 2) to the skirt of the piston, and the new seal (940-37-75) and wear ring (940-37-76) in the central bore.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.10 Primary Cylinder Top Cap

Spares Required:

Spares Kit No.



(i) Remove the fixed shield: w Remove the three countersunk screws from the fixed shield, and slide the shield off the primary cylinder top cap.

(ii) Remove the primary shaft clamp ring: w Unscrew the two screws from the primary shaft clamp ring on the primary shaft, and remove the two clamp ring halves.

(iii) Remove the top cap: w Remove the six cap head screws from the top cap, and slide the cap off the primary shaft.

(iv) Remove the buffer and the old seals: w Remove the buffer, the 'O' ring from the outer boss of the cap, and the two wear rings and seal from the central bore.

(v) Clean the top cap: w Clean the top cap using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(vi) Inspect the buffer: w Inspect the buffer for wear and / or damage. If any is found, replace the buffer with a new item (W404-62-07). If not, refit the buffer to the piston.

(vii) Fit the seals: w Carefully fit the new outer 'O' ring (940-70-32), and the new seal (940-37-77) and wear rings (940-37-78 x 2) to the central bore.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.11 Primary Shaft

Spares Required:

Spares Kit No.



K404-62-0A Tandem Crimper - - -- - 940-37-73 Seal 1- - 940-37-74 Wear Ring 2- - 940-70-27 'O' Ring 1

(i) Remove the primary shaft: w Grasp the primary shaft and withdraw the shaft from the primary cylinder body.

(ii) Remove the old seals: w Remove the old seal and wear rings from the shaft piston, and the 'O' ring from the top end of the shaft.

(iii) Clean the shaft: w Clean the shaft using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(iv) Fit the new seals: w Carefully fit the new seal (940-37-73) and wear rings (940-37-74 x 2) to the shaft piston, and the new 'O' ring (940-70-27) to the top end of the shaft.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.12 Primary Cylinder Body

Spares Required:

Spares Kit No.



K404-62-0A Tandem Crimper - - -- - 940-37-77 Seal 1- - 940-37-78 Wear Ring 2

(i) Remove the old seals: w Remove the old seal and wear rings from the lower bore of the cylinder body.

(ii) Clean the cylinder body: w Clean the cylinder body using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(iii) Carefully fit the new seals: w Carefully fit the new seal (940-37-77) and wear rings (940-37-78 x 2) in the lower bore of the cylinder body.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.13 Re-assembly

w To re-assemble the crimper unit, reverse the dis-assembly procedures given in 1.4.1 to 1.4.12.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

1.5 FAULT FINDING

Fault Remedy

w Crimp head fails to descend: „ Check air speed control valve is not closed.

„ Check pilot valve operation.

„ Check pressure regulator is operational.

w Crimper fails to crimp valve ontocontainer:

„ Check air speed control is open.

„ Check air supply pressure.

„ Check height setting of crimp head.

„ Check crimp depth.

„ Check crimp diameter.

„ Check valve is not displaced during positioning.

„ Check for broken crimp jaw.

„ Check centre starwheel alignment to crimper.

„ Check crimper seals are not leaking.

w Poor Crimp: „ Check air supply pressure.


„ Check crimp depth.

„ Check crimp diameter.

„ Check for broken crimp jaw.

„ Check pneumatic connectors are secure.

„ Check for wear on crimp jaws.

w Poor vacuum: „ Check vacuum pump operation.


continued...„ Check crimp head vacuum seal.

„ Check crimp head vacuum shroud seals.

w Crimp head fails to return: „ Check speed control valve is open.

„ Check pilot valve operation.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

CHAPTER 3.3

LIQUID PROPELLENT FILLERS

Contents

1. 90ml Propellent Ram.................................... 94

2. Nozzle Air Cylinder........................................ 110

3. Propellent Nozzle Body................................. 115

4. Nozzle Adaptor.............................................. 121

Chapter 3.3Liquid Propellent Fillers

SECTION 190ml PROPELLENT RAM

w Ref. Dwg. No's. Y167-88-ME & X169-25-0C

The machine is equipped with a 90ml propellent ram assembly, mounted on the side of the base unit, to measure and dispense a set volume of up to 90ml of propellent to the propellent filling nozzle.

The propellent ram consists of two main assemblies, namely a 41/2" air cylinder (Y167-88-ME) and a 90ml metering ram (X169-25-0C). The air cylinder is the large diameter cylindrical unit forming the upper half of the ram assembly, and provides stroke adjustment and pneumatic power for the metering ram assembly mounted below. The metering ram receives it’s propellent supply from an external source, and delivers a pre-set dose of propellent into the aerosol container through the filling nozzle.

The metering ram receives it’s propellent supply from an external source, and delivers a pre-set dose of propellent into the aerosol container through the filling nozzle. The air cylinder contains an upper piston and a lower piston. The air cylinder contains an upper piston and a lower piston. The upper piston is mounted on the hollow helical screw shaft at the top of the assembly, and provides fill volume adjustment by means of the sleeve mounted on the top of the screw, with the piston acting as a stroke back-stop for the lower piston. The lower piston is connected to a rod that runs down into the metering ram.

At the lower end of this piston rod, inside the metering ram, there is a third piston assembly. The propellent feeds into the metering ram from an external supply through the port in its upper flange. The lower piston is constructed using a ported floating piston which slides open when retracted to allow the propellent above it in the metering ram to flow through the piston, then when the piston rod is extended by the downstroke of the air cylinder, the piston is closed and the propellent is forced out of the exhaust port in the bottom cap,

w Sequence of Operation

First a container is positioned under the propellent nozzle. Then, a pneumatic signal initiates the downstroke of the nozzle air cylinder, which forces the nozzle assembly down onto the valve of the container below, opening the shut off piston inside the nozzle assembly. The filling stroke of the ram air cylinder is then initiated, forcing the metering ram piston rod down, discharging the propellent into the can via the nozzle. When the air cylinder lower piston reaches the bottom of it’s stroke, the underside of the piston strikes a pilot valve assembly which switches the pneumatic signal to the underside of the lower piston to return the piston to it’s rest position. This action retracts the metering ram piston, which slides open to allow the product above to pass through to prime the ram, resetting the whole assembly for the next cycle. Simultaneously, a signal activates the nozzle air cylinder’s return stroke, raising the nozzle assembly to reset the whole assembly ready for the next cycle.

continued...

1.2SETTING & ADJUSTMENT

1.2.1 Fill Volume Adjustment

! WARNING!


w The propellent ram assembly is adjustable to provide fill volumes of up to 90ml. The upper outer sleeve of the assembly provides this adjustment as described below.

i NOTE:

There is a scale mounted vertically on the side of the ram air cylinder, running up under the sleeve. This is a calibrated scale in increments of 5ml to provide a simple visual reference for setting the propellent fill volume.

(i) Cut air supply to the ram air cylinder: w The air supply to the ram air cylinder must first be cut by operating the sliding dump valve located on the pipework next to the pump housing. This dumps the air on the air cylinder lower piston.

(ii) Adjust the fill volume setting as required: w

w

w

To increase the fill volume, turn the sleeve anti-clockwise. This raises the upper piston in the air cylinder, allowing the lower piston a longer stroke, giving a higher fill volume.

To decrease the fill volume, turn the sleeve clockwise. This lowers the upper piston in the air cylinder, limiting the lower piston to a shorter stroke, giving a lower fill volume.

Set the sleeve so that its bottom edge

(iii) Re-engage the air supply to the ram air cylinder:

w Slide the dump valve back to it's original position to re-engage the air supply to the ram air cylinder.

(iv) Perform a single fill cycle: w

w

Refer to Chapter 1, Section 7 - Operation, and perform a single fill cycle on a sample container.


(v) Check that the actual volume deliveredis correct:

w If for any reason there is a discrepency between the set volume and the actual volume delivered, repeat steps (ii) or (iii) and (iv) and (v) to trim the unit to the required setting.

continued...

1.2.2 Propellent Change

w If the propellent type is to be changed, the propellent fillers must first be flushed through to remove all traces of the previous propellent type, then primed with the new type, as follows.

! WARNING!


(i) Turn on the air supply: w Engage the pneumatic mains supply as if for normal operation.

(ii) Disconnect the external propellent supply: w Shut off the external propellent supply to the heads, then close the inlet shut-off valves and disconnect the supply.

(iii) Disconnect the new propellent supply: w Connect the required replacement propellent supply and open the shut-off valves.

(iv) Place valved containers in the starwheel: w Place a sufficient number of valved, crimped containers in the starwheel leading up to the propellent heads, to allow the heads to perform 2 -3 cycles each.

(v) Run the machine for 2 - 3 cycles on each propellent ram:

w

w

Referring to Chapter 1, Section 7 - Operation, engage the selector switches of the propellent heads to be flushed, then run the machine for 2 - 3 cycles. This is sufficient to both flush and prime the heads.


(vi) De-select the propellent heads and remove the containers.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.3 MAINTENANCE

! WARNING!


1.3.1 Weekly

(i) Clean the exterior of the propellentram(s):

w Cleanliness is highly important. A build up of dirt or debris may impair the efficiency of the propellent ram assembly. This could cause an unsafe operating condition within the machine, and as such the assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1.

(ii) Inspect the propellent ram(s): w

w

w

The propellent rams should be inspected, paying attention to the following:


Inspect all structural joints to identify any possible leaking of seals, particularly the gland seal where the lower piston rod enters the metering ram. Should propellent be found escaping from this point, simply tighten the gland nut with the

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...


~ Seal Replacement Intervals: 6 months

w The reciprocating action of the piston assemblies will eventually cause the piston seals to wear. This would cause a drop in efficiency in the unit as the air used to power the unit will leak past the seals and cause inconsistencies in the air pressure, and variations in fill volume will occur due to propellent bleeding past the ram piston. Also, the 'O' rings will become compressed over a period of time which could cause air / propellent leaks.

Spares Required:

Spares Kit No.



K167-88ME 41/2" Air Cylinder - - -- - W167-01-12 Gland Seal 3- - W167-20-01 Buffer 1- - V592-06-15 Valve Op. Lever 1- - 940-25-05 'O' Ring 1- - 940-25-08 'O' Ring 1

- - 940-25-09 'O' Ring 1- - 940-25-19 'O' Ring 1- - 940-25-66 'O' Ring 1- - 940-33-10 P.T.F.E. 'O' Ring 1- - 940-34-61 Seal 1- - 940-34-86 Oil Seal 1- - 940-46-050 Spring 1- - 940-70-20 'O' Ring 1- - 943-40-95 3 Way Valve Cam Op. 1- - 992-11-19 Cup Washer 2

K169-25-0C 90ml Prop. Ram - - -

- - W169-12-02 Piston Back Seal 1- - 940-25-11 ‘O’ Ring 1- - 940-33-08 P.T.F.E ‘O’ Ring 1- - 940-33-10 P.T.F.E ‘O’ Ring 1- - 940-37-34 Slydring 1- - 940-37-39 Disc Seal 1

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.4.1 Propellent Ram Removal

w To replace the seals and 'O' rings in the propellent ram assembly, the assembly will first need to be removed from the machine a follows:

! WARNING!


(i) Disconnect the propellent ram assembly: w Disconnect all pipework leading to and from the propellent ram assembly, and blank off all ports using pieces of clean, dry, lint-free rag to prevent ingestion of any foreign matter.

(ii) Remove the propellent ram from the machine:

w Support the assembly, slacken and remove the mounting bolts, then carefully withdraw the ram assembly from the side of the machine.

! CAUTION!

THIS ASSEMBLY IS HEAVY! Have an assistant ready to support the assembly while the retaining bolts are being removed, and to help when removing the assembly from the machine.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.4.2 Bottom Cap (Ref. Dwg. No. Y169-18-0M)


Spares Required:

From Spares Kit:

Description ComponentPart No.


K169-25-0C 90ml Prop. Ram - - -- - 940-33-08 P.T.F.E. 'O' ring 1

(i) Remove the lower cap from the rambarrel:

w

w

Support the bottom cap and remove the four socket head screws that secure the cap to the lower flange of the metering ram barrel.

Withdraw the bottom cap and remove the old 'O' ring from the boss.

(ii) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(iii) Fit the new 'O' ring: w Carefully fit the new 'O' ring (940-33-08) to the bottom cap boss.

(iv) Re-fit the bottom cap: w Re-fit the bottom cap to the ram barrel in the reverse order of steps (i) to (iv) above.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.4.3 Air Cylinder Upper Piston (Ref. Dwg. No. Y167-88-ME)


Spares Required:

from spares kit:



K167-88ME 41/2" Air Cylinder - - -- - 940-25-66 'O' Ring 1- - 940-34-86 Oil Seal 1

(i) Slide the adjustment thimble down toaccess the air cylinder top cap:

w Unscrew the four countersunk screws that retain the adjustment thimble, and slide the thimble sleeve down to expose the air cylinder top cap.

(ii) Remove the upper assembly and screw shaft to expose the upper piston:

w Unscrew the four tie rod nuts that retain the top cap of the assembly. Hold the cylinder barrel and carefully withdraw the upper assembly and screw-shaft. This will expose the upper piston assembly on the end of the piston rod.

(iii) Remove the upper piston head, anddiscard the old seals:

w Slacken and remove the piston retaining nut from the underside of the piston head, and slide the piston off the screw-shaft. Remove the old lip seal and 'O' ring.


(v) Fit the new seals: w Carefully fit the new lip seal (940-34-86) and the new 'O' ring (940-25-66) to the piston.

(vi) Re-assemble the piston assembly: w Re-assemble the piston assembly in the reverse order of steps (iii) and (iv) above.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.4.4 Air Cylinder Lower Piston (Ref. Dwg. No. Y167-88-ME)


Spares Required:

From Spares Kit:



K167-88ME 41/2" Air Cylinder - - -- - 940-25-08 'O' Ring 1- - 940-70-20 'O' Ring 1- - 992-11-19 Cup Washer 2

w With the air cylinder upper piston removed:

(i) Remove the cylinder barrel and sealing washer:

w Carefully pull the cylinder barrel from the pump housing to expose the lower piston assembly, and remove the sealing washer from the barrel location groove in the housing.

(ii) Refer to 1.4.4 steps (i) to (iii) and remove the metering ram barrel.

(iii) Remove the lower piston assemblyretaining nut:

w Insert a tommy bar in the hole at the bottom end of the lower piston rod, and remove the nut that retains the lower piston assembly.

(iv) Disassemble the lower piston assembly: w Remove each component of the lower piston assembly from the piston rod - i.e. the top buffer, upper seal back plate, upper seal, middle buffer, lower seal, lower seal back plate, and piston head locator. Discard the old seals and 'O' ring.

(v) Clean the components: w Clean the other components using a high flashpoint solvent, ensuring that there is no foreign matter present where the new seals are to be fitted.

(vi) Re-assemble the piston assembly: w Re-assemble the piston assembly in the reverse order of step (iii) and (iv) above, fitting the new seals (992-11-19 x2) and 'O' ring (940-25-08).

(vii) Clean the pump housing as above.

(viii) Refit the cylinder barrel: w Fit the new 'O' ring (940-70-20) to the groove in the pump housing, then refit the cylinder barrel, taking care that the new 'O' ring is seated correctly.


go to 1.4.5 now.

(ix) Refer to 1.4.5 step (ix) and refit themetering ram barrel.

(x) Re-assemble the upper assembly: w Re-assemble the upper assembly in the reverse order of 1.4.3, steps (i) to (ii).

(xi) Refit the propellent ram to the machine: w Refit the propellent ram to the mounting plate in the reverse order of steps (i) to (iii) at the start of this chapter.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...1.4.5 90ml Ram Piston (Ref. Dwg. No. Y169-25-0C)


Spares Required:

From Spares Kit:



K169-25-0C 90ml Prop. Ram - - -- - W169-12-02 Piston Back Seal 1

- - 940-25-11 ‘O’ Ring 1- - 940-33-10 P.T.F.E ‘O’ Ring 1- - 940-37-34 Slydring 1- - 940-37-39 Disc Seal 1

(i) Disconnect the metering ram barrel and bottom cap assembly:

w If not already done, disconnect all pipework leading to and from the metering ram barrel and bottom cap assembly, and blank off all ports using pieces of clean, dry, lint-free rag to prevent ingestion of any foreign matter.

(ii) Remove the metering ram barrel: w

w

Support the ram barrel and remove the four socket head screws that secure the barrel to the air cylinder pump housing, and carefully withdraw the ram barrel to expose the metering ram piston assembly.

(iii) Unscrew the piston assembly: w Insert a tommy bar in the hole in the piston head, and another in the hole in the piston rod, then unscrew the piston assembly.

(iv) Remove the piston from the piston head: w Insert a tommy bar in the hole in the piston head, remove the piston retaining ring inside the piston, slide the piston assembly off the piston head, and remove the old buffer ring.

(v) Unscrew the seal retainer and discardThe old cup seal:

w Insert a tommy bar in both the piston and the seal retainer, unscrew the retainer and remove the lip seal, slydring and ‘O’ ring.


If the pump housing assembly is to be serviced, go to 1.4.5 now.

continued...

(vii) Fit the new seals and re-assemble the piston assembly:

w Re-assemble the piston assembly in the reverse order of steps (iii) to (v) above, fitting the new buffer seal (W169-12-02), slydring (940-37-34), ‘O’ ring (940-25-11) and the new lip seal (940-37-39).

(viii) Re-assemble the metering ram assembly: w Re-assemble the metering ram assembly in the reverse order of steps (i) to (iii) above fitting the new 'O' ring (940-33-10).

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.4.6 Pump Housing, Pilot Valve and Gland Housing (Ref. Dwg. No. Y167-88-ME)


Spares Required:

From Spares kit:



K167-88ME 41/2" Air Cylinder - - -- - W167-01-12 Gland Seal 3- - 940-25-05 'O' Ring 1- - 940-25-09 'O' Ring 1- - 940-33-10 P.T.F.E. 'O' Ring 1- - 940-34-61 Seal 1- - 940-34-86 Oil Seal 1

(i) Gain access to the gland housing: w Push the piston rod down through the pump housing to expose the gland housing.

(ii) Remove the gland housing from thepiston rod:

w Insert a tommy bar in the hole in the side of the gland housing, slacken the gland nut, then slide the gland housing down off the rod and set aside.

(iii) Remove the piston rod from the pump housing:

w Carefully withdraw the piston rod from the top of the pump housing.

(iv) Remove the cover plate in the top face of the pump housing:

w Remove the four countersunk screws that retain the central cover plate in the top face of the pump housing, and lift out the plate.

(v) Remove the valve operating pin anddiscard the old 'O' rings:

w Carefully lift out the valve operating pin complete with the seal holder and spring, and remove the old 'O' rings from the seal holder.


(vii) Re-assemble the operating pin assembly: w Re-assemble the operating pin assembly in the reverse order of steps (iv) and (v) above, fitting the new 'O' rings (940-25-05 & 940-25-09) to the seal holder.

(viii) Remove the external pilot valve assembly from the side of the pump housing.

continued...(ix) Remove the seal retainer plate in the

pump housing aperture and discard theold lip seal:

w Remove the four screws that hold the seal retainer plate in the top face of the pump housing aperture, remove the plate, and extract the lip seal that is now exposed.

(x) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(xi) Re-assemble the seal and valveassembly:

w Re-assemble the seal and valve assembly in the reverse order of steps (viii) and (ix) above, fitting the new lip seal (940-34-61) to the seal holder.

(xii) Remove the gland nut and lip seal, and the outer 'O' ring from the gland housing.

(xiii) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new seals are to be fitted.

(xiv)

Re-assemble the gland housing assembly: w Re-assemble the gland housing assembly in the reverse order of step (xi) above, carefully fitting the new gland seals (W167-01-12 x3), and the new 'O' ring (940-33-10). Gently tighten the gland nut - this should be checked and adjusted once the unit is back on the machine.

(xv) Re-install the pump housing on the piston rod:

w Clean the piston rod as above and slide the lower end of the rod down through the gland housing, then slide the upper end of the rod up through the pump housing.

Refer back through the procedures and re-assemble the product ram assembly, and refit the assembly to the machine.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

1.5 FAULT FINDING

Fault Remedy

Metering ram fails to fill: „ Check propellent supply is available.

„ Check propellent ram inlet valve is open.

„ Check all air couplings are engaged.

„ Check air supply to ram air cylinder.

„ Check propellent nozzle opens.

„ Ensure gland seal nut is not too tight.

„ Check NCNF lever is not being actuated due to nozzle being set too high.

„ Check propellent piston head is not jammed.

„ Check air cylinder master valve assembly.

„ Ensure air cylinder piston seals are not leaking.

Fill volume not consistent: „ Check propellent supply.

„ Vent propellent metering ram.

„ Ensure air cylinder piston returns fast enough.

„ Check propellent nozzle closes at end of fill.

„ Check propellent piston slides freely.

„ Check propellent piston seals.

NOTES

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........


SECTION 2NOZZLE AIR CYLINDER

Ref. Ass’y. No. 405-03-0P


2.2 SETTING & ADJUSTMENTThe nozzle air cylinder is a pneumatically operated cylinder fitted to the machine to automatically apply the propellent filling nozzle that it carries to the valve of the container being processed. The assembly consists of a cylinder barrel which forms the main body of the assembly, and the mounting point for the mounting plate bracket, a hollow through-shaft piston rod which is connected to the propellent pipework from the propellent ram at the top, and carries the piston assembly inside the barrel. A pneumatic signal to the top of the piston forces the piston down, so lowering the nozzle onto the container. This signal is maintained while the filling cycle is taking place, then a signal to the underside of the piston retracts the nozzle assembly ready for the next cycle.

See the relevant section of this manual covering the nozzle adaptor(s).

2.3 MAINTENANCE

! WARNING!


2.3.1 Weekly

(i) Clean the exterior of the nozzle air cylinder(s):

w A build up of dirt or debris may impair the efficiency of the assembly. This could cause an unsafe operating condition within the machine, and as such the assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1.

(ii) Inspect the nozzle air cylinder(s): w

w

All pipework should be checked for leaks, and check that all fittings and unions are secure.

Also inspect all structural joints to identify any possible leaking of seals.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...



The reciprocating action of the nozzle air cylinder will eventually cause the cylinder piston seals to wear. This would cause a drop in efficiency in the unit as the air used to power the unit will leak past the seals and cause inconsistencies in the air pressure. Also, the 'O' rings will become compressed over a period of time which could cause air leaks. Consequently, the seals and 'O' rings in the air cylinder assembly should be changed every 12 months.

Spares Required:

Spares Kit No.



K405-04-0B Nozzle Air Cylinder - - -- - W011-43-04 Buffer 1- - W011-50-06 Buffer 1- - 940-25-29 'O' Ring 1- - 940-25-66 'O' Ring 1- - 940-34-88 Oil Seal 2

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

2.4.1 Nozzle Removal (Common to all types)

! WARNING!


(i) Disconnect any nozzle pipework: w Disconnect any pipework leading to or from the nozzle adaptor / body assembly and blank off all ports using pieces of clean, dry, lint-free rag to prevent ingestion of any foreign matter.

(ii) Remove the nozzle body / adaptor fromthe piston rod:

w Insert a tommy bar in the hole in the side of the nozzle body and another in the hole in the bottom flange of the air cylinder piston rod, and unscrew the body / adaptor assembly from the piston rod.

2.4.2 Nozzle Air Cylinder (Ref. Dwg. No. W405-03-0B)

! WARNING!


(i) Remove the assembly from the machine: w Support the assembly and remove the cap head screws that retain the support bracket clamp, remove the clamp, and withdraw the assembly from the machine.

(ii) Remove the cylinder top cap and discard the old seals:

w Remove the three cap head screws from the cylinder top cap, lift the top cap from the cylinder barrel, and remove the old 'O' rings from the cap and the lip of the barrel.

(iii) Remove the piston retaining ring, thenthe piston:

w

w

Slide the barrel down the piston rod to bring the piston assembly within reach, then remove the piston retaining ring.

Slide the piston assembly off the piston rod, then withdraw the piston rod from the base of the barrel.

(iv) Remove the piston and discard the old seals:

w

w

Slide the piston assembly off the piston rod, then withdraw the piston rod from the base of the barrel.

Remove the old lip seals from the piston head, the old 'O' ring from the barrel, and the buffers from within the barrel and the top of the setting ring on the piston rod. Note that there is no need to remove the setting ring from the piston rod.

continued...

(v) Clean the components: w Clean the components using a high flashpoint solvent, and ensure that there is no foreign matter present where the new 'O' rings are to be fitted.

(vi) Fit the new seals: w Fit the new 'O' rings (940-25-29 & 940-25-66) to the top cap and barrel, the new lip seals (940-34-88 x2) to the piston head, and the new buffer (W011-43-04) to the setting ring.

(vii) Re-assemble the nozzle air cylinder: w Re-assemble the nozzle air cylinder in the reverse order of steps (iii) to (v) above, not forgetting to fit the new buffer (W011-50-06) under the piston head.

(viii) Re-fit the assembly to the mounting plate in the reverse order of steps (i) and (ii) above.

(ix) Refer back through the procedures and refit the propellent nozzle assembly.

NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

continued...

2.5 FAULT FINDING

Fault Remedy

Air cylinder fails to descend: „ Check pneumatic supply.


„ Check pneumatic circuit.


Air cylinder fails to return: „ Check pneumatic supply.


„ Check pneumatic circuit.


NOTES:

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........

..........................................................................................................................................................................

.........


SECTION 3PROPELLENT NOZZLE BODY

w Ref. Dwg. No. V458-66-0C

The propellent nozzle body is the connecting piece between the nozzle air cylinder and the nozzle adaptor, and contains the main shut-off valve of the propellent filling nozzle assembly,

At the start of the filling cycle, the nozzle air cylinder lowers the nozzle assembly onto the valve of the container below. The seals in the tip of the adaptor seals on the tip of the valve nozzle, and the nozzle is depressed to open the valve. When the filling stroke of the ram is performed, the propellent dose travels through the air cylinder piston rod to the nozzle body, which contains a spring loaded piston. When the pressure of the propellent dose exceeds that applied to the piston by the spring, the piston will lift away from the seal in the top face of the nozzle adaptor, allowing the dose to pass into the can through the adaptor. On completion of the filling stroke, the resultant pressure drop allows the body spring to close the piston to prevent any leakage. The assembly is then retracted by the nozzle air cylinder, ready to repeat the cycle.



See the relevant section of this manual covering the propellent nozzle adaptor(s).

continued...

3.3MAINTENANCE

! WARNING!


3.3.1 Weekly

(i) Clean the exterior of the nozzle body: w Cleanliness is highly important. A build up of dirt or debris may impair the efficiency of the nozzle body assembly. This could cause an unsafe operating condition within the machine, and as such the assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1.

(ii) Inspect the nozzle body: w

w

The nozzle body should be inspected, paying attention to the following:

All pipework should be regularly checked for leaks, and check that all fittings and unions are secure. Inspect all structural joints to identify any possible leaking of seals.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

w The reciprocating action of the nozzle body will eventually cause the piston and spring to wear. This would cause a drop in efficiency in the unit as the pressure required to open the body will decrease, causing inconsistencies in propellent fills. Also, the 'O' rings will become compressed over a period of time which could cause propellent leaks. Consequently, the spring and 'O' rings in the body be changed every 6 months.

Spares Required:

Spares Kit No.



K458-66-0C Nozzle Body - - -

- - V010-24-011 Spring 1- - 940-33-11 'O' Ring 1- - 940-35-12 Variseal 1

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

3.4.1 Nozzle Removal (Common to all types)

! WARNING!


(i) Disconnect any nozzle pipework: w Disconnect any pipework leading to or from the nozzle adaptor / body assembly and blank off all ports using pieces of clean, dry, lint-free rag to prevent ingestion of any foreign matter.

(ii) Remove the nozzle body / adaptor fromthe piston rod:

w Insert a tommy bar in the hole in the side of the nozzle body and another in the hole in the side of the nozzle adaptor, and unscrew the body / adaptor assembly from the piston rod.

3.4.2 Nozzle Body

! WARNING!


(i) Remove the nozzle adaptor: w Refer to the relevant section of this manual for the nozzle adaptor type fitted to the body, and remove the adaptor.

(ii) Unscrew the nozzle body from the nozzleair cylinder:

w Insert a tommy bar in the hole in the side of both the nozzle body and the bottom flange of the nozzle air cylinder piston rod, and unscrew the body from the cylinder.

(iii) Extract the piston components and old ‘O’ ring:

w Remove the old 'O' ring from the top face of the body, extract the piston, spring and washer from the nozzle body.

w Discard the piston, spring and ‘O’ ring, but retain the washer.

(iv) Clean the components: w Clean the body using a high flashpoint solvent, and ensure that there is no foreign matter present where the new components are to be fitted.

(v) Re-assemble the nozzle body, fitting the new spring (V010-24-11).

w Fit the new 'O' rings (940-33-11) to the body, then fit the washer to the piston, the spring over the washer, then install the piston in the body.

(vii) Re-assemble the nozzle assembly: w Re-assemble the nozzle assembly in the reverse order of steps (i) and (ii) above.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...3.5 FAULT FINDING

Fault Remedy

w Zero, low or inconsistent fill: „ Check propellent supply.

„ Check height setting.


„ Check piston operation.


NOTES

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........


SECTION 4NOZZLE ADAPTOR - SUMMIT RAISED BOSS

w Ref. Dwg. No. V458-28-0F


The propellent nozzle for "Summit raised boss" cup valves consists of three main sections, namely the adaptor body, the stripper ring and the nozzle probe. In operation the nozzle is mounted on a nozzle body assembly which is in turn mounted on the nozzle air cylinder.

When the air cylinder lowers the nozzle onto the aerosol valve of the container below, the stripper ring comes into contact with the shoulder of the aerosol container, and the stripper springs are compressed. The tip of the probe then enters the aerosol valve and contacts the valve mechanism inside. As the nozzle continues to descend, the probe forces open the valve mechanism, with the valve's internal seal forming a seal around the probe. Once the underside of the body section the lip of the aerosol valve, the filling cycle of the propellent ram is activated.The propellent dose travels through the hollow piston rod of the nozzle air cylinder to the nozzle body, which contains a spring loaded piston. When the pressure of the propellent dose exceeds that applied to the piston by the spring, the piston will lift away from the seal in the top face of the nozzle adaptor, allowing the dose to pass into the can through the adaptor and into the container through the drillings in the probe tip.

On completion of the filling stroke, the resultant pressure drop allows the spring to close the piston to prevent any leakage. The nozzle assembly is then withdraw by the nozzle air cylinder, the aerosol valve is closed by it's internal spring, and the stripper ring ensures that the container is not picked up by the probe. The assembly is now ready for the next cycle.

continued...4.2 SETTING & ADJUSTMENT

! WARNING!


4.2.1 Nozzle Adaptor Changeover

w If there is a change in valve type, the correct nozzle adaptor must be fitted.

THIS IS ESSENTIAL FOR SAFE, EFFICIENT FILLING.

(i) Unscrew the nozzle adaptor from thenozzle body:

w Insert a tommy bar or 'C' spanner in the hole in the side of both the nozzle adaptor and the nozzle body, and unscrew the adaptor from the body.

(ii) Select the required replacement nozzleadaptor:

w Select the correct replacement adaptor and check that the 'O' rings in the top face of the assembly are in good condition. If they are damaged of have become flattened, they must be replaced as in 4.4 - Seal Replacement.

(iii) Fit the replacement nozzle adaptor: w Carefully screw the replacement adaptor onto the nozzle body and tighten the adaptor using the tommy bar or 'C' spanner.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

4.2.2 Nozzle Height Adjustment

If there is a change in can height, the discharge height of the nozzle will need adjusting:

(i) Slacken the locking handle on the side of the nozzle mounting bracket:

(ii) Position a sample container under the nozzle:

w If the overall height of the container to be processed is greater than that which the machine is currently set for, turn the handwheel at the top of the support assembly clockwise to raise the nozzle sufficiently to allow a sample container, complete with crimped valve, to be placed in the starwheel pocket under the nozzle.

(iii) Adjust the nozzle height setting: w With the sample container in place, turn the adjustment wheel anti-clockwise to lower the nozzle, and set the height to give 3-4mm clearance between the top of the aerosol valve stem and the lowest point of the nozzle adaptor.

(iv) Tighten the locking handle to clamp the nozzle in position.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

4.3MAINTENANCE

! WARNING!


4.3.1 Weekly

(i) Clean the exterior of the nozzle adaptor: w Cleanliness is highly important. A build up of dirt or debris may impair the efficiency of the nozzle adaptor assembly. This could cause an unsafe operating condition within the machine, and as such the assembly should be cleaned regularly in accordance with Chapter 1, Section 6.1.

(ii) Inspect the nozzle adaptor: w

w

The nozzle adaptor should be inspected, paying attention to the following:

All pipework should be regularly checked for leaks, and check that all fittings and unions are secure. Inspect all structural joints to identify any possible leaking of seals.

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

4.4SEAL REPLACEMENT


The pressure at which the nozzle adaptor is applied to the aerosol valve will cause the seas in the tip to deform. This would allow propellent to leak past the seal instead of passing into the container, causing inconsistent fills and raising the gas levels in and around the machine. Also, the 'O' rings will become compressed over a period of time which could cause propellent leaks. Consequently, the seals and 'O' rings in the adaptor should be changed every 6 months.

Spares Required:

Spares Kit No.



K440-28-0F Nozzle Adaptor - - -- - V010-28-05 Stripper Spring 2- - 940-33-02 'O' Ring 1- - 940-33-05 'O' Ring 1

NOTES:

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

continued...

! WARNING!


(i) Remove the nozzle adaptor from thenozzle body:

w Insert a tommy bar in the hole in the side of both the nozzle adaptor and the nozzle body, and unscrew the adaptor from the body. Note that there is no need to remove the setting ring from the nozzle adaptor.

(ii) Carefully extract the insert and remove the two old 'O' rings.

(iii) Clean the components: w Clean the adaptor and insert using a high flashpoint solvent, and ensure that there is no foreign matter present where the new 'O' rings are to be fitted.

(iv) Fit the new 'O' rings: w Fit the new 'O' rings (940-33-02 & 940-33-05) to the nozzle adaptor.

(v) Re-fit the assembly to the nozzle bodyin the reverse order of step (i).

4.5 FAULT FINDING

Fault Remedy

w Zero, low or inconsistent fill: „ Check propellent supply.

„ Check height setting.


„ Check piston operation.


NOTES

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

..........................................................................................................................................................................

........

CHAPTER 4

SPARE PARTS & SERVICE

Contents

1. Spare Parts................................................... 129

2. Service.......................................................... 141

Chapter 4Spare Parts & Service

SECTION 1RECOMMENDED SPARE PARTS LIST

1.1 SPARE PARTS

The following tables list recommended spare parts and consumables for 6 months that should be kept in stock.

When ordering spare parts or making technical enquiries, please be sure to quote the machine serial number. This can be found on the machine identification plate, which will be affixed to the machine's base unit.

Also, spare parts should be ordered by part number, description and quantity required.

continued...

K167-74MEB 2 1 / 8" Product Air Cylinder

Spares Kit No.



K167-74-ME 21/8" Product Air Cylinder - - -- - W167-01-12 Gland Seal 3- - W167-20-01 Buffer 1- - V592-06-15 Valve Op. Lever 1- - 940-25-05 'O' Ring 1- - 940-25-09 'O' Ring 1- - 940-25-19 'O' Ring 1- - 940-25-66 'O' Ring 1

- - 940-33-10 P.T.F.E. 'O' Ring 1- - 940-34-61 Seal 1- - 940-34-84 Oil Seal 1- - 940-46-050 Spring 1- - 940-70-22 'O' Ring 1- - 943-40-95 3 Way Valve Cam Op. 1

K175-53-0MA 250ml Product Ram

Spares Kit No.



K175-53-0MA 250ml Product Ram - - -- - W168-09-02 Cup Seal 1- - W168-10-02 Back Seal 1- - 940-33-08 P.T.F.E. ‘O’ Ring 1- - 940-33-10 P.T.F.E. ‘O’ Ring 1- - 946-26-58 Ball Valve 1

K175-55-0P Product Master Valve

Spares Kit No.



K175-55-0P Product Master Valve - - -- - W002-23-02 Master Valve Seal 1- - W175-55-05 Master Valve Spring 1- - 940-33-08 P.T.F.E. ‘O’ Ring 1- - 940-33-10 P.T.F.E. ‘O’ Ring 1

K175-46-0J ½” Streamflow Nozzle

Spares Kit No.



K175-46-0J 1/2" Streamflow Nozzle - - -- - W120-54-04 P.T.F.E. Seal 1- - V120-54-08 Seal Washer 1- - 940-25-08 'O' Ring 1- - 940-25-66 'O' Ring 1- - 940-34-46 Lip Seal 1- - 940-34-81 Lip Seal 2

K404-47-0P Vacuum Crimp Head

Spares Kit No.



K404-47-0P Vacuum Crimp Head - - -- - V404-40-13 Buffer 1- - V404-47-20 Vacuum Seal - 45 / 50mm 1- - V404-47-21 Vacuum Seal - 53mm 1- - V404-47-22 Jaw Spring Mod. 1- - 940-37-80 External Seal - 70mm 1- - 940-37-81 Rod Wear Ring - 65mm 1- - 940-37-82 Internal Seal - 65mm 1

- - 940-37-83 Rod Wear Ring - 56mm 1- - 940-37-84 Internal Seal - 56mm 1- - 940-70-33 'O' Ring 1

K404-62-0A Tandem CrimperSpares Kit No.



K404-62-0A Tandem Crimper - - -- - V404-62-03 Adjusting Nut Buffer 1- - V404-62-07 Internal Buffer 2

- - V404-62-27 Internal Buffer 1- - 940-25-32 'O' Ring 1- - 940-37-69 Internal Seal 2- - 940-37-70 Rod Wear Ring - 18mm 4- - 940-37-71 External Seal - 75mm 3- - 940-37-72 Pstn Wear Ring - 75mm 4- - 940-37-73 External Seal - 48mm 1- - 940-37-74 Pstn Wear Ring - 48mm 2- - 940-37-75 Internal Seal - 28mm 1- - 940-37-76 Rod Wear Ring - 28mm 2- - 940-37-77 Internal Seal - 30mm 2

- - 940-37-78 Rod Wear Ring - 30mm 4- - 940-70-25 'O' Ring 1- - 940-70-26 'O' Ring 2- - 940-70-27 'O' Ring 1- - 940-70-32 'O' Ring 1

K167-88-ME 4 1 / 2” Air Cylinder

Spares Kit No.



K167-88-ME 41/2" Air Cylinder - - -- - W167-01-12 Gland Seal 3

- - W167-20-01 Buffer 1- - V592-06-15 Valve Op. Lever 1- - 940-25-05 'O' Ring 1- - 940-25-08 'O' Ring 1- - 940-25-09 'O' Ring 1- - 940-25-19 'O' Ring 1- - 940-25-66 'O' Ring 1- - 940-33-10 P.T.F.E. 'O' Ring 1- - 940-34-61 Seal 1- - 940-34-86 Oil Seal 1- - 940-46-050 Spring 1

- - 940-70-20 'O' Ring 1- - 943-40-95 3 Way Valve Cam Op. 1- - 992-11-19 Cup Washer 2

K169-25-0C 90ml Propellent Ram

Spares Kit No.



K169-25-0C 90ml Prop. Ram - - -- - W169-12-02 Piston Back Seal 1- - 940-25-11 ‘O’ Ring 1- - 940-33-08 P.T.F.E ‘O’ Ring 1- - 940-33-10 P.T.F.E ‘O’ Ring 1- - 940-37-34 Slydring 1- - 940-37-39 Disc Seal 1

K405-04-0B Nozzle Air Cylinder

Spares Kit No.



K405-04-0B Nozzle Air Cylinder - - -- - W011-43-04 Buffer 1- - W011-50-06 Buffer 1- - 940-25-29 'O' Ring 1

- - 940-25-66 'O' Ring 1- - 940-34-88 Oil Seal 2

K458-66-0C Nozzle Body

Spares Kit No.



K458-66-0C Nozzle Body - - -- - V010-24-011 Spring 1- - 940-33-11 'O' Ring 1- - 940-35-12 Variseal 1

K440-29-0F Nozzle Adaptor

Spares Kit No.



K440-28-0F Nozzle Adaptor - - -- - V010-28-05 Stripper Spring 2- - 940-33-02 'O' Ring 1- - 940-33-05 'O' Ring 1

Chapter 4Spare Parts & Service

SECTION 2SERVICE

If the information required does not appear in this manual, or if you require technical assistance or advice, please contact us at the address below or through your agent. When making technical enquiries, please be sure to quote the machine serial number. This can be found on the machine identification plate, which will be affixed to the machine's base unit.

BWI KP Aerofill,33-35 Clayton Road,Hayes, Middlesex,UB3 1RU

England.

Telephone: 0181-848 4501 (International: 0044 181 848 4501)Fax: 0181-561 3308 (International: 0044 181 561 3308)

Tech Manual

Documents

Transcript of Tech Manual