TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇAO TÉCNICA
DOCUMENTAZ IONET E C N I C A
ENGLISH
USER MANUAL
026AZ001A
MACHINE FOR BENDING SAFETY BANDS FOR PLASTIC CAPS
TVC 003
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TABLE OF CONTENTS
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USER MANUAL
MACHINE FOR BENDING SAFETY BANDS FOR PLASTIC CAPS
TVC 003
MANUFACTURER
SACMI IMOLAVia Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
PUBLISHED ON
July 13, 2001
VERSIONS
TVC003A
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TABLE OF CONTENTS
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Page1 GENERAL INFORMATION........................................................................................................................1 - 1
1.1 INTRODUCTION ........................................................................................................................ 1 - 11.2 WHERE TO KEEP THE MANUAL ............................................................................................. 1 - 11.3 HOW TO USE THE MANUAL .................................................................................................... 1 - 11.4 USERS OF THE MANUAL ......................................................................................................... 1 - 11.5 WARRANTY ............................................................................................................................... 1 - 21.6 SUPPLEMENTS ......................................................................................................................... 1 - 21.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN
THE MANUAL .............................................................................................................................1 - 21.8 MACHINE IDENTIFICATION PLATE..........................................................................................1 - 3
2 MAIN FEATURES ......................................................................................................................................2 - 12.1 MACHINE DESCRIPTION ......................................................................................................... 2 - 12.1.1 MAIN DEVICES...........................................................................................................................2 - 22.1.1.1 CAP FEED CHANNEL ............................................................................................................... 2 - 22.1.1.2 WORK UNIT ............................................................................................................................... 2 - 32.1.1.3 TOOLING ....................................................................................................................................2 - 42.1.1.4 EXIT CHANNEL ......................................................................................................................... 2 - 52.1.1.5 CONVEYING CHANNEL.............................................................................................................2 - 52.1.1.6 LOWER STRUCTURE ............................................................................................................... 2 - 62.1.1.7 DRIVE UNIT ............................................................................................................................... 2 - 62.1.1.8 PNEUMATIC SYSTEM ...............................................................................................................2 - 72.1.1.9 ELECTRICAL CABINET............................................................................................................. 2 - 72.1.1.10 SAFETY DEVICES INSTALLED .................................................................................................2 - 72.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ................................................. 2 - 82.2 OVERALL DIMENSIONS ........................................................................................................... 2 - 92.3 TECHNICAL DATA .................................................................................................................. 2 - 102.3.1 SPECIFICATIONS ................................................................................................................... 2 - 102.3.2 ALLOWABLE FLUCTUATION OF THE VARIABLES .............................................................. 2 - 112.3.3 RATING PLATE ....................................................................................................................... 2 - 112.3.4 OPERATIONAL CHARACTERISTICS..................................................................................... 2 - 122.3.5 AIRBORNE NOISE LEVELS .................................................................................................... 2 - 132.3.5.1 SOUND PRESSURE LEVEL (ISO/DIS 11202) ....................................................................... 2 - 132.3.5.2 SOUND POWER LEVEL (ISO 3746) ....................................................................................... 2 - 142.4 DIAGRAMS .............................................................................................................................. 2 - 152.4.1 PNEUMATIC SYSTEM DIAGRAM .......................................................................................... 2 - 15
3 SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 13.1 SAFETY DEVICES......................................................................................................................3 - 13.1.1 SAFETY GUIDELINES............................................................................................................... 3 - 13.1.2 SAFETY DEVICES INSTALLED .................................................................................................3 - 13.1.2.1 SHUTDOWN DEVICES ............................................................................................................. 3 - 13.1.2.2 FAULT SIGNALING ....................................................................................................................3 - 13.1.2.3 SAFETY DEVICES FOR THE OPERATOR ...............................................................................3 - 13.1.2.4 EMERGENCY STOP BUTTONS ............................................................................................... 3 - 13.2 SAFETY RULES FOR HANDLING .............................................................................................3 - 33.2.1 SLINGING THE LOADS ............................................................................................................. 3 - 33.2.2 HOISTING .................................................................................................................................. 3 - 33.2.3 PLACEMENT...............................................................................................................................3 - 33.3 INSTALLATION ...........................................................................................................................3 - 43.3.1 GENERAL RULES ......................................................................................................................3 - 43.4 OPERATOR TRAINING ............................................................................................................. 3 - 53.4.1 END-USER ..................................................................................................................................3 - 53.4.2 OPERATORS ............................................................................................................................. 3 - 53.4.3 MAINTENANCE STAFF ............................................................................................................. 3 - 53.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THE
MACHINE ....................................................................................................................................3 - 63.5.1 GENERAL SAFETY RULES ...................................................................................................... 3 - 63.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED .................................................3 - 73.6.1 GENERAL RULES ......................................................................................................................3 - 7
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Page4 INSTALLATION ........................................................................................................................................ 4 - 1
4.1 SHIPPING AND HANDLING ...................................................................................................... 4 - 14.2 POSITIONING .............................................................................................................................4 - 34.3 CONNECTIONS AND HOOK UPS .............................................................................................4 - 54.3.1 CONNECTING THE MACHINE TO THE COMPRESSED AIR MAINS..................................... 4 - 54.3.2 CONNECTING THE ELECTRIC CABLES ................................................................................. 4 - 6
5 MACHINE START-UP ............................................................................................................................... 5 - 15.1 INTRODUCTION ........................................................................................................................ 5 - 15.2 PRELIMINARY CHECKS ........................................................................................................... 5 - 15.3 DAILY START-UP ...................................................................................................................... 5 - 2
6 OPERATING INSTRUCTIONS ................................................................................................................. 6 - 16.1 CONTROL DEVICES ...........................................................................................................................6 - 16.1.1 ELECTRICAL CABINET............................................................................................................. 6 - 26.2 OPERATION IN MANUAL MODE ...............................................................................................6 - 46.3 OPERATION IN AUTOMATIC MODE ........................................................................................6 - 4
7 ADJUSTMENTS ........................................................................................................................................ 7 - 17.1 CAP FEED CHANNEL ............................................................................................................... 7 - 17.1.1 ADJUSTING THE AIR PRESSURE IN THE PNEUMATIC CYLINDER .....................................7 - 17.1.2 REPLACING THE FEED CHANNEL TO HANDLE A NEW PRODUCT SIZE ............................7 - 37.2 ADJUSTING THE CAP STRIPPER RODS .................................................................................7 - 47.3 ADJUSTING THE HEIGHT OF THE TOOLS ............................................................................ 7 - 57.4 REPLACING THE CAP TRANSFER TURN-TABLE...................................................................7 - 67.5 EXIT CHANNEL ......................................................................................................................... 7 - 77.5.1 ADJUSTING THE CHANNEL JAMMING CONTROL DEVICE ................................................. 7 - 77.5.2 REPLACING THE CAP EXIT CHANNEL TO HANDLE A NEW PRODUCT SIZE .....................7 - 87.6 CONVEYANCE CHANNEL ........................................................................................................ 7 - 97.7 PNEUMATIC SYSTEM ...............................................................................................................7 - 9
8 MAINTENANCE ........................................................................................................................................ 8 - 18.1 ROUTINE MAINTENANCE ........................................................................................................ 8 - 28.1.1 SCHEDULED MAINTENANCE CHART .................................................................................... 8 - 28.1.2 SCHEDULED MAINTENANCE .................................................................................................. 8 - 38.1.2.1 CLEANING THE TOOLS.............................................................................................................8 - 38.1.2.2 CLEANING THE ELECTRIC PARTS ..........................................................................................8 - 38.1.3 LUBRICATION ...........................................................................................................................8 - 38.1.3.1 LUBRICANT SPECIFICATIONS .................................................................................................8 - 38.2 SPECIAL MAINTENANCE OPERATIONS .................................................................................8 - 48.3 TROUBLESHOOTING THE MACHINE ......................................................................................8 - 48.3.1 TROUBLESHOOTING GUIDE ....................................................................................................8 - 4
9 DISMANTLING THE MACHINE................................................................................................................ 9 - 1
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GENERAL INFORMATION 1
026AZ001A
1 GENERAL INFORMATION
1.1 INTRODUCTION
E0004PWARNING!
Carefully read the entire Maintenance and Operations Manual before working on the machine and/or the packaging ofthe various parts.This manual contains important information for safeguarding the operators, the maintenance staff as well as themachine itself.SACMI reserves the right to make changes to the machine and in the manual without giving prior notice.Copyright. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI.The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,reproduced, disclosed or transferred.Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.
1.2 WHERE TO KEEP THE MANUAL
E0004PWARNING!
This manual is to be considered an essential part of the machine and must be kept along with it even if the machineis sold. Always keep the manual near the machine where it can be easily consulted. The manual must always be at handso that the operator and maintenance staff are able to consult it rapidly at any time.
1.3 HOW TO USE THE MANUAL
The lay out of this manual allows it to be easily consulted as all the information and instructions provided are groupedtogether and divided into chapters and paragraphs. The user has to simply refer to the table of contents.The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to theoperator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols andare written in italics, as shown below.
E0004PWARNING!
Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must be carefully read in its entirety as it containsimportant information and warnings regarding safety.
1.4 USERS OF THE MANUAL
In this manual the machine operators are categorized as follows:- Operator: this is the person responsible for supervising and operating the machine.- Routine maintenance men.For a more detailed description, see the paragraph dealing with OPERATOR TRAINING in chapter 3 - SAFETYEQUIPMENT AND PRECAUTIONS.
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1 GENERAL INFORMATION
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1.5 WARRANTYSACMI shall be held responsible only for the machine as it was configured at the time of delivery.Any operations that alter the configuration of the machine or operating cycle must be carried out by SACMI personnelor duly authorized by SACMI’S Engineering Dept.SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.
E0004PATTENTION!
The machine operator or maintenance staff are not responsible for carrying out operations under warranty, specialmaintenance and repairs. These operations are to be performed only by the manufacturers specially trainedtechnicians. For this reason, these types of operations are not dealt with in this manual.
1.6 SUPPLEMENTSInformation regarding the electric and electronic components of the machine are given in three handbooks providedunder separate cover and are entitled:- USE OF THE MICROPROCESSOR CONTROL SYSTEM (Instructions B manual)- LIST OF DEVICES, SETTING THE OPERATING DATA AND NOTES REGARDING USE
These handbooks are supplied with this manual.
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THEMANUAL
WARNING SYMBOLS
E0004P
General hazard
E0002P
Danger of being burnt on hot surfaces (when plastic caps are handled)
E0003P
Danger of hands being crushed
E0007P
High tension, danger of being electrocuted
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GENERAL INFORMATION 1
026AZ001A
ALERT SYMBOLS
E0005O
Heavy duty work gloves must be worn (when plastic caps are handled)
E0006O Machine must be connected to an effectively grounded power point
ADDITIONAL SYMBOLS
E0009CA list of the tools needed to carry out maintenance is provided
1.8 MACHINE IDENTIFICATION PLATE
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1 GENERAL INFORMATION
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MAIN FEATURES 2
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2 MAIN FEATURES
2.1 MACHINE DESCRIPTION
The TVC003 is a rotary upright machine designed to bend the safety band applied around plastic caps. It includes atool holding unit fitted with two sets of punches (top ones turn while the bottom ones translate) that bend the band asrequired. A channel is used to feed the caps to this unit. Once the operations have been completed, the caps are sentto an exit channel and discharged from the machine.A microprocessor based system is used to operate the control cabinet. This system provides all required informationin real time.The machine can be divided into the parts indicated in the figures below:
T1356
7
92
3
4
6
5
1
8
10
Figure 2.1 - OVERALL VIEW
1 - Base2 - Drive unit3 - Work unit4 - Spindle5 - Tooling6 - Cap feed channel7 - Exit channel8 - Pneumatic system9 - Electric cables10 - Electrical cabinet
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2 MAIN FEATURES
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2.1.1 MAIN DEVICES
2.1.1.1 Cap feed channel(See figure 2.1.1.1)
The caps enter the machine (directed) through the feed channel (1) fixed to the base. It is possible to inspect a sectionof the channel by opening the door (2). To open the door, turn the knob (3).Blowers (18 and 19), both of which are adjustable, are installed on the door. The function of the blowers is to feed capswithout interrupting the flow of incoming products.A fiber optic photocell (6) placed on a mount is attached to the feed channel. This photocell detects when the minimumcap level is reached. The pneumatic cylinder (4) controls the cap flow. In fact, this cylinder holds the caps back, whennecessary, thereby preventing them from flowing. This happens when the fiber optic photocell (6), located at the feedchannel inlet, is free (no caps) or when the photocell located in the exit channel is activated (channel full).
Figure 2.1.1.1 - CAP FEED CHANNEL
2
6 1
4
19
3
18
T1357
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2.1.1.2 Work unit(See figure 2.1.1.2)
The work unit picks up the caps from the feed channel and places them on the support (1) through the turntable (2).The latter sees that the caps are moved around the axis of the unit. Thanks to the upper fixed cam (3), the upper movableassembly fitted with a spring loaded pin (4) moves down. These devices provide a reference for the caps on the lowermovable assembly (5). The latter is operated by the fixed cam (6). The upper and lower movable assemblies are timedand move up thereby bringing the cap to the tool (7). The particular shape of the latter allows the band to be shapedas required. The assembly (5), along with the pin (4), then move down releasing the caps that have already been bentfrom the tools so that they can be let out through the discharge channel.
Figure 2.1.1.2 - WORK UNIT
3
2
8
6
5
1
7
4
T1358
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2 MAIN FEATURES
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2.1.1.3 Tooling
The fixed and movable tools are used to produce caps that meet the customer’s individual requirements. A data sheetis provided with each group of tools. This sheet gives all the information the user needs to know to interchange thevarious parts that need to be replaced.
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MAIN FEATURES 2
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2.1.1.4 Exit channel(See figure 2.1.1.4)The caps leave the exit channel in an orderly manner and are directed as required.This unit includes a plate (1) which acts as a mount for the various parts that make up the unit.The inspection door (2), located in the end section, can be opened by turning the knob (3).The blowers (5) are used to remove the caps from the channel.A mount for the fiber optic photocell (6) is attached to the exit channel. The function of this photocell is to detect whenthe maximum level has been reached in order to interrupt the cap flow in the feed channel, when required.
Cap control deviceThe cap control device detects any caps that have remained in the zone (12). This is accomplished through the lever(11). In fact, the lever moves thereby inactivating a proximity sensor (17) which stops the machine.
2.1.1.5 Conveying channelThe conveying channel sends the caps either to a downstream machine or a diverter with cap counter for filling theboxes, depending on the configuration of the production line employed.
Figure 2.1.1.4 - EXIT CHANNEL
1
11
5
2
6
3
5
3
17
12
11
T1359
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2.1.1.6 Lower structure
The lower structure consists of a base which is joined to the upper plate by four load-bearing corner sections. Adjustableheight feet are used to sustain the frame. The structure is enveloped with safety panels.
2.1.1.7 Drive unit
The drive unit consists of a motor-worm reduction unit whose driving end is keyed directly to the work unit shaft. A controlis provided for manual operation. The latter is inactivated by a safety switch which acts directly on the input shaft of thegearbox.
Figure 2.1.1.7 - DRIVE UNIT
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2.1.1.8 Pneumatic system
The pneumatic system includes a control unit, located in the machine base, that contains the air preparation elements(filters and pressure regulators), control devices for the pneumatic actuators (blower solenoid valve and solenoid valvewhich operates the pneumatic cylinder that regulates cap flow in the feed channel) as well as the blower manifold.
2.1.1.9 Electrical cabinet
The electrical cabinet includes both a power section and a control section.The power section includes all the equipment required for the electric actuators (contactors, relays, etc..) as well as theparts for processing the signals transmitted by the controls mounted on the machine or from the keyboard(microprocessor based control system, motor drives, etc..).The control section allows the user to operate the machine and monitor functioning. The machine can be run in eithermanual or automatic mode. A programmable logic controller is used. The following operations can be carried out fromthe keyboard:
- Setting the work-cycle- Setting or modifying the operating parameters- Displaying the operating data
2.1.1.10 Safety devices installed
The machine is equipped with mechanical and electric safety devices that ensure safe machine operation and use. Inaddition, the machine is provided with fixed and movable guards fitted with interlocks or mechanical shutdown devices.A detailed description of the devices is given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.
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2 MAIN FEATURES
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2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE
INTENDED USE OF THE MACHINEThe machine is specially designed and constructed to produce products that have the characteristics indicated in thespecifications.
The machine operates safely if:- it is used under the conditions and within the limits prescribed and indicated in this paragraph- maintenance is performed at the intervals indicated in chapter 8 - MAINTENANCE- it is used properly by following the directions given in chapter 6 - OPERATING INSTRUCTIONS.
E0004PWARNING!
If the machine is remote controlled, suitable signs must be put up while the machine is running.
The machine can be run only in the following two modes:- manual- automaticUse the mode selector on the control panel to select the desired mode of operation
UNINTENDED AND PROHIBITED OPERATIONSNo other operations can be carried out unless expressly authorized by the manufacturer. The manufacturer shall notbe held responsible for injury to personnel or damage to the machine caused by failure to observe these warnings.
MISUSE OR ERRONEOUS USEThe manufacturer shall not be held responsible for any damage, injury or other consequences deriving from incorrector erroneous use of the machine.
The most common causes of incorrect machine operation are:- inadequate training of the operating personnel- fatigue, tiredness (especially during the night shift) or distraction- negligence due to superficiality or incorrect habits.
Remember that machine supervision and operation can be carried out only by expert competent personnel who havebeen well trained and able to:- use the machine under normal operating conditions- know what to do in an emergency
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MAIN FEATURES 2
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2.2 OVERALL DIMENSIONS
The dimensions of the machine and electrical cabinet (the distance they have to be away from each other is given inchapter 4 - INSTALLATION) are indicated in the figure below:
Figure 2.2 - OVERALL DIMENSIONS
1 Machine2 Electrical cabinetA Cap entryB Cap exit
C Compressed air inletD Work zoneE Electrical hook-up
C
1
AD
B
742
350
600
800
497
1712
1270
+25 -5
2030
380
50
1300
2400
4000
E
300
100
860
2100
2515
2
E
600
986
800
T1884
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2.3 TECHNICAL DATA
2.3.1 SPECIFICATIONS
Speed/1' (per 28 mm ROP) up to 1200Diameter mm from 25 to 100Height mm from 12 to 30Power requirements (Hz 50) kW 2,7Absorbed power (Hz 50) kW 1,5Electric motor power output (Hz 50) kW 1,1Auxiliary voltage 110 VAG - 24 VDCAir consumption (pressure 0.5 MPa) dm3/1' 900Air pressure MPa 0,5Operating temperature °C 5 ÷ 40Humidity (no condensate) % 30 ÷ 95Machine weight see chapter 4 INSTALLATIONCabinet connecting cable RST + Earth 380V-50Hz: four-pole, copper (*) mm2 4 x 4Hose to compressed air mains, inside diameter mm 13
(*) With different voltages and frequencies or when material other than copper is used the cable has to be adequatelysized by a qualified electrician.
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2.3.2 ALLOWABLE FLUCTUATION OF THE VARIABLES
ELECTRICVoltage ±10%Frequency ±2%
PNEUMATICFlow rate ±15%Minimum pressure MPa 0,5Maximum pressure MPa 1
COOLANTFlow rate ±10%Pressure +20% - 10%
2.3.3 RATING PLATE
The figure below illustrates the rating plate on which the customer’s individual operating data (voltage-frequency-auxiliary circuits) is given. The plate is attached to the electrical cabinet door.
Figure 2.3.3 - LOCATION OF THE RATING PLATE
T1984
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2.3.4 OPERATIONAL CHARACTERISTICS
TYPE OF PRODUCTThe machine can handle thermoplastic caps whose dimensions have been previously agreed upon with SACMI’sEngineering Dept (See example in figure 2.3.4).
E0004P IMPORTANT!
The machine has to be set-up in different ways depending on the type of cap being handled. For this reason, specialparts need to be used. Refer to the “data sheet” provided by Sacmi.
PRODUCTION CAPACITYThis is strictly related to the type of cap being handled and its dimensions.The maximum production output is given in paragraph 2.3.1 - SPECIFICATIONS.
Figure 2.3.4 - PRODUCT CHARACTERISTICS
The dimensions given in the figure are for reference purposes only and are not binding in any way.
PLASTIC CAPS
T2731
Ø 100
30
12
Ø 25
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MAIN FEATURES 2
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2.3.5 AIRBORNE NOISE LEVELS
2.3.5.1 Sound pressure level (ISO/DIS 11202)
Test conditions- Operating conditions: machine running with load.- Type of operation: bending of safety band for plastic caps- Operating cycle: cap feed and bending- Test facility: factory with reflecting flooring.
Instruments employedClass 1 instruments (IEC 804)
Values measured
LbA LpA LpC peakP1 61,7 91,5 104,0
P2 63,0 94,5 111,0
P1 - Control post, measured at a height of 1.55 m from the floorP2 - Noisiest position of the ideal machine perimeter, measured at a distance of 1 meter from the surface of the machineryLbA - Background noise level.LpA - Continuous A-weighted sound pressure level.LpC peak - Peak C-weighted instantaneous sound pressure level.
FIGURE 2.3.5.1 - NOISE LEVELS
A Reference surfacesB Surfaces from which measurements were taken
1400
1000
1000
3400
1000
1000
5900
TVC
ATV
BTA
7900
A
B
P2
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2.3.5.2 Sound power level (ISO 3746)
Test conditions- Operating conditions: run with load.- Type of operation: bending of safety band for plastic caps- Operating cycle: cap feed and bending- Test facility: factory with reflecting flooring.
Instruments employedClass 1 instruments (IEC 804)
Results
LpA = A-weighted sound pressure level in dB at surface of the machinery 92,0 dBALwA = A-weighted sound power level 111 dBA
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MAIN FEATURES 2
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2.4 DIAGRAMS
2.4.1 PNEUMATIC SYSTEM DIAGRAM
Figure 2.4.1 - PNEUMATIC SYSTEM DIAGRAM
PA Air preparationAZ ActuatorsSO Blowers1 Filter2 Pressure regulator3 Flow divider4 Solenoid valve manifold8 Blower flow divider9 Pressure regulator10 Quick-connect coupler15 Cap stop
A Blowers, Feed channelB Blowers, Feed channelC Blowers, Feed channelD Blowers, Feed channelE Blowers, Exit channelF Blowers, Exit channelX Line, Cylinder openY Line, Cylinder closed
SP1 Pressure switchYV3 Solenoid valve, Incoming cap stoppageYV9 Solenoid valve, Blowers
T1363
PA AZ
SO
FA B C D E
8
YV9
4
YV3 9
1
2
3
10
SP1
XY Y Y Y
X
15
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2 MAIN FEATURES
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SAFETY EQUIPMENT AND PRECAUTIONS 3
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3 SAFETY EQUIPMENT AND PRECAUTIONS
3.1 SAFETY DEVICES
E0004PWARNING!
3.1.1 SAFETY GUIDELINES
The machine is provided with a number of electrical and/or mechanical safety devices in order to safeguard theoperators and the machine itself.These devices must never be removed, disabled or altered in any way.Some illustrations provided in the manual show the machine, or parts of it, with the guards removed. This is simply foradded clarity. Never actually use the machine with the guards removed or safety devices disabled.Warning signs are provided on the machine to indicate any hazards in the zone where the sign is attached.Always take all necessary safety precautions before working on the machine.SACMI shall not be held responsible for any personal injury or property damage resulting from failure to observe theseprecautions or use the safety devices provided.
3.1.2 SAFETY DEVICES INSTALLED
3.1.2.1 Shutdown devices
These devices detect and indicate malfunctioning and prevent the machine from being run or actually stop it.
3.1.2.2 Fault signaling
Whenever a fault is present, a red flashing light located over the electrical cabinet comes on to inform the operator. Thetrouble that shut the machine down appears on the display of the control keyboard. Refer to the INSTRUCTIONS Bmanual for a full description of the fault messages.
3.1.2.3 Safety devices for the operator
The machine is equipped with mobile safety guards that are interlocked with electric devices. In addition, fixedmechanical barriers are also installed that prevent accidental access to moving parts of the machine as well asdangerous parts that are live or very hot.
3.1.2.4 Emergency stop buttons
Emergency stop button on-board the machineIt is installed in the position shown in the figure.- Operation: manual- Action: machine immediately stopped- Reset: turn it on the control panel to release
Emergency stop button on the switchboard control panelIt is installed on the switchboard control panel in the position shown in the figure.- Operation: manual- Action: machine immediately stopped- Reset: turn it on the control panel to release
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Figure 3.1.2 - SAFETY DEVICES INSTALLED
HL Machine state indication lightsSB1B Remote emergency stop buttonSB100 Emergency stop button on control panelSQ33 Limit switch, Manual operation handwheel engagedSQ35 Interlocking device for movable guards: when
the guards are opened the machine shuts down
1 Panels (on the four sides) attached with screws(1/4 of a turn)
3 Pneumatic control unit cabinet5 Pressure switch, No air pressure7 Proximity sensor, Caps not removed9 Safety chain (manually installed)
T1377
1
9
3
5
SQ35
1
SB1B
SQ33
7
SQ35
HL
SB100
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3.2 SAFETY RULES FOR HANDLING
E0004PWARNING!
3.2.1 SLINGING THE LOADS
To safely and correctly lift and handle the machine always:- use equipment which best suits the characteristics and has an adequate lift capacity;- cover all sharp edges;- make sure the safety device for the lift hook works properly;Before lifting:- make sure all personnel is safely away and that no one can enter the area where the machine is being moved- make sure the load is stable- work vertically in order to avoid banging the parts.
3.2.2 HOISTING
While being moved, the load must always remain perfectly horizontal regardless of the type of lift equipment used.To facilitate the lifting and handling operations use bars, levers and ramps. Never use your hands. The person in chargemust:- know the path to be followed and be able to clearly see it;- give information to the crane operator from a position where he/she can be clearly see;- stop immediately is dangerous conditions arise;
3.2.3 PLACEMENT
Before placing the machine make sure the floor is perfectly level and its load bearing capacity is suitable for the weightof the machine.Do not place the loads in areas where they may create potential dangers or prevent access to equipment and/oremergency exits.The machine must be placed on the cross-bars provided so that it is stable and the slings can be easily removed. Donot place worn containers or those with protruding material on top of it.Do not stack material at a dangerous height.
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3.3 INSTALLATION
E0004PWARNING!
3.3.1 GENERAL RULES
Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations inforce in your country.It is extremely important that the machine is properly connected to adequate earth electrodes.Make sure there is enough space around the machine so that it can be operated and serviced easily.The area surrounding the machine must always be kept free of obstacles, clean, dry and well-lit.The lighting in the areas around the machine and, in particular, in the work zone should be efficient and have a levelof illumination not less than 300 lux.The customer must make sure that fire-fighting equipment is provided in the area where the machine is installed andthat there is a system for protection against voltage fluctuation in the electricity supply line. These must conform to lawscurrently in force in the country where the machine is installed.SACMI shall not be held responsible for any property damage or personal injury resulting from improper installation.
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3.4 OPERATOR TRAINING
E0004PWARNING!
3.4.1 END-USER
The company using this equipment must see that their personnel:- match the requirements listed below- read and understand the manual in its entirety- are adequately instructed and trained on how to safely carry out their tasks- receive specific training on how to operate this machine correctly.
3.4.2 OPERATORS
The machine operator must:- understand the technology employed and have specific experience in operating this type of machine- be well educated enough to read and fully understand the contents of this manual as well as properly interpret the
drawings provided- know all the safety rules and standards
- general (hygiene and on-the-job safety, accident prevention)- specific (for the type of product handled by the machine)
in force in the country where the machine is installed.
Operator tasksThe operator is only authorised use the controls and instruments provided on the machine’s control panel.
3.4.3 MAINTENANCE STAFF
The maintenance staff must be selected according to the same criteria as that indicated for the operators.In addition, they must be trained in specific technological areas (mechanical, electric, pneumatic etc.) so that they cancarry out the operations they are responsible for (as specified in the manual) in complete safety using suitable tools andequipment.
Tasks for the maintenance staffThe maintenance staff are responsible for carrying out the routine maintenance operations described in this manual.It is important that the members of staff carry out only the tasks in the areas they are specifically responsible for(mechanical, electric, pneumatic, etc.).
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SAFETY EQUIPMENT AND PRECAUTIONS3
026AZ001A
3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THEMACHINE
3.5.1 GENERAL SAFETY RULES
E0001
Never inspect, repair or service moving parts. Clear warning signs should be attached near the parts in question to warnoperators of the danger.
E0007
E0010
Before performing any operation on the machine, including the replacement of components of the control panel orelectrical cabinet, the maintenance staff must shut off the electricity supply by using the main switch located on thecontrol panel. This switch should then be locked in position by using a padlock so that the machine cannot be accidentallystarted up.The electrical cabinet can be accessed even when the system is energised.As laid down by the EN 60204-1 directive, access to the electrical cabinet should only be possible with a special key.This key should be kept by one member of staff qualified and trained to work on live parts.When the electrical cabinet is energised, the only task that this member of staff should perform is to reset the circuitbreakers.
E0017
When working on the machine never climb up on any part other than the service floor or ladders. The machine guardsand enclosing barriers are not designed to bear the weight of a person. If climbed on, they may collapse causing injuryto personnel and damage to the machine.
E0004P
It may be necessary to temporarily remove or disable certain safety devices when making adjustments or servicing themachine. Once these operations have been completed, it is highly important that the safety devices are put back in placeand reactivated before the machine is started up.
E0002
E0005
During operations, the electric motors can reach extremely high temperatures which would cause burning if touched.Always take the necessary safety precautions before working on the motors.
E0007
E0009
In order to ensure that the machine operates efficiently, safely and in a trouble-free manner always follow SACMI’sinstructions carefully. Carry out the scheduled maintenance operations exactly as described and at the time intervalsrecommended.In particular, regularly check all the safety devices for proper functioning. Also check the insulation of the electrical cablesand replace if necessary.
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SAFETY EQUIPMENT AND PRECAUTIONS 3
026AZ001A
3.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED
E0004PWARNING!
3.6.1 GENERAL RULES
When the machine is no longer to be used, make it inoperative by shutting off the electricity and air supplies etc.Use suitable safety devices.Thoroughly clean the entire machine, especially the working parts, and if necessary apply a protective lubricant.Close the door of the electrical cabinet and any machine access doors to prevent any parts being tampered with or dustgetting in.Follow the instructions given in Chapter 9 - DECOMMISSIONING and observe current standards in force and safetyregulations regarding lifting and handling the machine and its parts.
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SAFETY EQUIPMENT AND PRECAUTIONS3
026AZ001A
4 - 1
INSTALLATION 4
026AZ001A
4 INSTALLATIONAfter the machine has been delivered, make sure the environmental conditions (temperature, humidity, etc..) are asspecified and agreed upon at the time of purchase. This is important as the machines are always constructed accordingto the data provided.
4.1 SHIPPING AND HANDLING
MACHINE DIVISIONThe machine is divided into groups according to the shipping and installation requirements.
DIMENSIONS AND WEIGHTSThe weights and dimensions of the individual parts, according to the shipping requirements, are approximate thereforethey are given for reference purposes only.
SYSTEMS FOR LIFTING INDIVIDUAL PARTSThe best systems for lifting and handling the heaviest and largest parts as well as those that require special care andtools provided by Sacmi are shown in figure 4.1.As far as the machine body is concerned, the slings (shown in the figure) have to be attached to the four points (A) ofthe base. Proceed as follows: Insert the screw (1) in the washers (2), slings (3) and nut (4). Place the screw in the hole(A) and tighten. Only the nut (4) should be fully tightened so that the slings (3) are able to move freely.Before hoisting, make sure the slings are correctly positioned in points B.When lifting the smaller parts and packages, be extremely careful and use equipment with an adequate lift capacity.All safety rules and precautions must be observed at all times.Upon receiving the machine, handle the crates with care. Always use means that are able to sustain their weightwhenever moving the crates both inside and out. It is fundamental that the user weighs all the parts when they arriveon site to verify their exact weight.
LIFTING PRECAUTIONS- Use lift equipment whose range of action and capacity are adequate for the weight and dimensions to be sustained.- Protect the points where the slings come into contact with the machine with cardboard or rags.- Gradually move the load until it is perfectly stable.- Make sure no people or things are in the path to be followed while the load is being lifted.- Slowly lift and move the parts with extreme caution avoiding any kind of swaying, even the slightest.
WARNING!
The manufacturer shall not be held responsible for damage to things or injury to personnel caused by failure toheed the safety standards in force regarding lifting and handling material inside the user’s factory.
Lifting and handling can be carried out only by persons specially trained and authorized to perform theseoperations.Make sure there are no people near the lifted load and/or in the range of action of the lift equipment while themachine is being lifted and moved.
- Follow the lifting instructions given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.- When being moved, the load must remain perfectly horizontal regardless of the type of equipment used to carryout the operations.
E0004P
4 - 2
4 INSTALLATION
026AZ001A
Figure 4.1 - DIMENSIONS AND WEIGHTS OF THE CRATES
1 - Machine body2 - Electrical cabinet3 - Crate containing spare parts4 - Crate containing machine outfit5 - Crate containing parts 1-2-3-4
kg 250
kg 570
A
B
1
2
3 4
kg 25kg 50
5
kg 950
T1887
T1887
260
260 350
18001500
2200
1800
600 800
1
3
24
A B
T1379
986800
25152100
4 - 3
INSTALLATION 4
026AZ001A
4.2 POSITIONING(References given in figure 4.2/A)
The various parts that make up the machine, whose specifications, weights, dimensions and hook up points havealready been dealt with, are to be placed and installed as shown in the figure. Carry out the operations in the order givenand carefully follow the directions given below.
E0004PWARNING!
Be very careful to install the cap feed channel (A) and exit channel (B) that conveys the caps to the next machinein the correct position.In addition, the work area around the machine should always be kept as indicated in the figure.
- Lift the machine body (see figure 4.1)- Place the machine body in the established position (see figure 4.2/A)- Remove the guards to access the feet (see figure 4.2/B)- Level the machine body by adjusting the feet, tightening or loosening them as required. Use a spirit level to check.
Fully tighten the lock nuts of the feet.
E0004PWARNING!
Pay careful attention to the amount of space the cap feed and exit channels (A and B) are off the ground. The exactmeasurements are given in the figure.
- Lift the electrical cabinet (see figure 4.1)- Place the electrical cabinet in the required position. Follow the directions given in figure 4.2/A and make sure it is the
correct distance away from the machine.
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4 INSTALLATION
026AZ001A
Figure 4.2/A - POSITIONING THE PARTS
1 Machine2 Electrical cabinetA Cap feed channelB Cap exit channelC Compressed air inletD Work area
Figure 4.2/B - LEVELING THE MACHINE
T1153
T1886
800800
800
800
1270
2
A
B
D
1
C
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INSTALLATION 4
026AZ001A
4.3 CONNECTIONS AND HOOK UPS
E0004PWARNING!
The various systems are to be hooked up to the mains by specialized personnel instructed by SACMI.
4.3.1 CONNECTING THE MACHINE TO THE COMPRESSED AIR MAINS(References given in figure 4.3.1)
Use a hose to connect the air preparation unit, equipped with a fitting (A) located in the pneumatic control unit, to thecompressed air mains. The specifications of the hose are indicated in paragraph 2.3 TECHNICAL DATA.
Figure 4.3.1 - CONNECTING THE MACHINE TO THE COMPRESSED AIR MAINS
A Compressed air supply
T1366
T1888
A
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4 INSTALLATION
026AZ001A
4.3.2 CONNECTING THE ELECTRIC CABLES(References given in figure 4.3.2)
E0004PWARNING!
Due to the presence of electronic converters inside the electrical cabinet, make sure the power supply circuitbreakers are of the B type, in compliance with CEI 64-8 specifications, Art. 532.2.1.4. In this way, the system isprotected against d.c. leakage currents.
E0004PWARNING!
After machine testing, the cables are disconnected from the electrical cabinet, rolled up and prepared for shipment.
- Unwind the electric cables- Plug the cables into the electrical cabinet as shown in the figure. The cables are marked with the symbols illustrated
in the figure.The power cable has to run into the cabinet and be plugged into the terminal block in the points marked RST andconnected to earth. The rating plate and fixing screws for the earth connection are found in the lower base.
E0004PWARNING!
The power cable is not supplied with the machine. Its specifications and dimensions are given in paragraphSPECIFICATIONS.
E0004PWARNING!
The machine is to be earthed to the outside. For this reason, connect the earth line to the copper bar located insidethe main electrical cabinet. The connections are marked PE (EN60445).
Also join the connections on the machine marked (417-IEC-5019) to the external earth terminals.
E0004PWARNING!
Failure to ground the parts indicated may cause serious machine damage and severe personal injury.
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INSTALLATION 4
026AZ001A
Figure 4.3.2 - CONNECTING THE ELECTRIC CABLES
XJ1 Power lead connector, Power supply boxXJ2 Signal lead connector, Signal emitter boxXJ3 Power lead connector, M17 control (only w/cap counters)XJ5 Power lead connector, Heating elementXJ8 Signal lead connector, Heating element controlXJ10 Power lead connector, Motor M8 power supplyXJ14 Signal lead connector, Interface to next machine in lineXJ16 Signal lead connector, Interface to preceding machine in line
T1999
XJ1XJ2
XJ14
XJ16
XJ10
XJ3
XJ5
XJ8
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4 INSTALLATION
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5 - 1
MACHINE START-UP 5
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5 MACHINE START-UP
5.1 INTRODUCTION
E0004PWARNING!
These operations can be carried out solely by the manufacturer’s specialized technicians who are responsible forstarting up the machine as specified in chapter 1 - GENERAL INFORMATION. If these operations are carried outby other persons, dangerous situations may be created that can cause serious injury to persons and/or damageto the machine. The control key references are given in chapter 6 - OPERATING INSTRUCTIONS.
First time machine start up is to be carried out by personnel specialized in both the mechanical and electric fields.The customer’s operator and maintenance staff have to be available and look on when the machine is started up (thisis useful to better understand machine operation, how to adjust the auxiliary equipment, accessories, and safety guardsand devices employed) and when the machine is tested to see that it has been properly adjusted.
5.2 PRELIMINARY CHECKS
CONDITIONSThe machine is factory tested prior to delivery therefore it simply has to be checked to see if it was damaged duringshipment or installation.
PROCEDURE(The control references are given in chapter 6 - OPERATING INSTRUCTIONS)
- Operate the machine in manual mode to make sure nothing obstructs the parts.- Open the feed channel door and put in one cap for each spindle.- Bend the cap bands corresponding to the spindles.- Check the results obtained.
If the dimensions need to be adjusted, see chapter 7 - ADJUSTMENTS.
- Supply power to the electrical cabinet by turning the main switch QS1 to on.- Turn on the compressed air supply and make sure an adequate pressure value is read on the gauge. The exact value
is given in paragraph 2.3 - TECHNICAL DATA.- Make sure the motors run in the right direction. If they do not, reverse two supply wires of the cabinet’s power cable
(figure 4.3.3), disconnect the conductors from terminals R and S and reverse them.
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5 MACHINE START-UP
026AZ001A
E0004PWARNING
In the event of malfunctioning for which adjustments need to be made, stop the machine and carry out theoperations given in chapter 7 - ADJUSTMENTS.
5.3 DAILY START-UP
(The control references are given in chapter 6 - OPERATING INSTRUCTIONS)
- Join the machine to the compressed air mains.- Supply power to the machine by turning the main switch QS1 to on.
The machine can now be run in either manual or automatic mode.
- Turn selector SA100 to “manual” to operate the machine in manual mode.- The start (green) and stop (red) buttons are used for manual operation.- Turn selector SA100 to “automatic” to set the machine to run in automatic mode, in line with the next machine.- Selector SA6 enables the vibrator.- Press button SB101 to reset any faults and set the machine up for operation.- Press button SB30M to start the automatic cycle if the machine is set-up to run in “local” (selector SA30 turned to
“local”).- Press button SB30A to stop the automatic cycle if the machine is set-up to run in “local” (selector SA30 turned to
“local”).- Make sure no leds are on (red alarm). If they are, remedy the problem and reset the machine by pressing button
SB101.
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OPERATING INSTRUCTIONS 6
026AZ001A
6 OPERATING INSTRUCTIONS
E0004PWARNING!
Closely follow the directions given in this manual and operate in accordance with all safety standards.
6.1 CONTROL DEVICES(See figure 6.1)Some controls are located on the control panel while others are to be found on the machine.
Figure 6.1 - CONTROL DEVICES
1 Electrical cabinet2 Top indicator panel3 Control panel4 Machine5 Manual control with limit switch SQ33QS1 Main switchSB1B Remote emergency stop button
3
2
1
QS1T1368
SB1B
5
4
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6 OPERATING INSTRUCTIONS
026AZ001A
6.1.1 ELECTRICAL CABINET(References given in figures 6.1 and 6.1.1)
The electrical cabinet (1) consists of a power section (5) that houses all the parts needed to operate the variouscomponents (contactors, relays, etc) and a logic section (2) that contains the devices for processing the signalstransmitted by the machine controls or from the keyboard.A control keyboard (4) is located in the logic section. This keyboard allows the operator to control and monitor machineoperation.A programmable logic controller and control keyboard (4) are used. This set-up allows the operator to set the work-cycleas required.Fault messages and the most important stages of the work-cycle are shown on the display (3).
E0004P WARNING!
Enable button SB31 has to be pressed whenever a run button is pressed.All the information regarding use of the control panel is given in the Instructions B manual, Use of themicroprocessor-based control system.
AP2 Temperature regulator, Tool heating (optional)AP3 Temperature regulator, Tool cooling (optional)
PC1 Counter, Caps producedPC2 Electronic counter, Caps rejected to FDP (only with FDP)
QS1 Main switch
SA1 Selector switch, Machine OFF-ONSA18 Selector switch, Tool heating OFF-ONSA30 Mode selector switch, LOCAL - OFF - REMOTESA40 Selector switch, Cap discharge control OFF - ONSA100 Mode selector switch, MANUAL - OFF - AUTOMATIC
SB6A Stop button, Motor M6 in manual modeSB6M Run button, Motor M6 in manual modeSB7 Start/Stop button, Motor M7 in manual modeSB8A Stop button, Motor M8 in manual modeSB8M Run button, Motor M8 in manual modeSB11 Start/stop button, Motor M11 in manual modeSB22 Start/stop button, Motor M22 in manual modeSB30A Stop button, Automatic cycle with machine in local modeSB30M Start button, Automatic cycle (enabled with machine in automatic and local mode, to be pressed together with
SB31)SB31 Pushbutton, Control panel enablingSB33A Stop button, Motor M33 in manual modeSB33M Run button, Motor M33 in manual modeSB100 Emergency stop button on electrical cabinetSB101 Reset button, ShutdownSB102 Reset button, PC1SB103 Pushbutton, Box change (only with cap counter; PC1 output)
6 - 3
OPERATING INSTRUCTIONS 6
026AZ001A
Figure 6.1.1 - TOP INDICATION AND PUSHBUTTON PANEL
R
QS1
QS1 PC1 AP2 AP3
SB30A SB7 SB6A SB33A SB22 SB8A SB11 SA100 SA30 SB31
SB100
SB101 SB30M SB6M SB33M SB8M SA1 SA40
SB102 SB103 SA18
T1994
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6 OPERATING INSTRUCTIONS
026AZ001A
6.2 OPERATION IN MANUAL MODE
If the machine is set to run in manual mode (selector switch SA100 turned to MAN), the motors can be run individuallyby pressing the relevant buttons located on the control panel.
6.3 OPERATION IN AUTOMATIC MODETurn selector switch SA100 to AUT to set the machine to run in automatic mode.
OPERATIONIf selector switch SA30 is turned to “local”, the automatic cycle is started by pressing button SB30M located on the controlpanel. If the machine is set up for “remote” operation, the trigger for operation is provided by the next machine.The automatic cycle is started only if all the safety and operating conditions have been satisfied.The fault messages shown on the top display indicate the troubles that prevent the machine from running (see theInstructions B Manual).The machine starts the operations for processing the caps automatically in the following order:- The compressed air solenoid valve opens- Caps are fed- Cap conveyor starts running- Machine motor starts running
PRODUCTION CYCLEThe feed unit picks up the caps from the feed channel and places them on the work unit spindles. The latter bring thecaps to the tools which give them their final shape. The caps are then discharged into the exit channel and are sent toeither the next machine or counter for filling the boxes.
HOW TO STOP THE MACHINEIf selector switch SA30 is turned to “local”, the automatic cycle is stopped by pressing button SB30A. On the other hand,if the machine is set for “remote” operation, the trigger for stopping the machine is provided by the next machine.
The following operations are carried out:- Cap feed at machine inlet is interrupted- The motors stop running after the last cap processed has been discharged from the machine.
7 - 1
ADJUSTMENTS 7
026AZ001A
7 ADJUSTMENTS
The adjustments described below are to be made when deemed necessary by the operator to remedy malfunctioningor after maintenance has been carried out, parts replaced, etc.. Always carefully observe all safety rules andprecautions.
E0004PWARNING!
The operations can be carried out only after the machine has come to a full stop taking all the precautions describedin the introductory part of this manual. In particular, use extreme caution and wear heavy-duty work gloves whenworking near signs indicating hot parts - danger of being burnt.It is fundamental that the power to the machine is shut off before accessing the electrical cabinet, cable boxes andwherever there is a sign indicating danger of being electrocuted.
7.1 CAP FEED CHANNEL
7.1.1 ADJUSTING THE AIR PRESSURE IN THE PNEUMATIC CYLINDER(References given in figure 7.1.1)
E0004PWARNING!
This operation is carried out with the machine running, therefore take all the necessary precautions.
- Read the pressure given on the gauge (10) and check the solenoid valve (12) (YV3) used to stop incoming caps. Thevalue given in paragraph 2.3.1 - SPECIFICATIONS should be read.
- To adjust the pressure, if required, turn the knob (11) until the correct value is obtained.
7 - 2
7 ADJUSTMENTS
026AZ001A
Figure 7.1.1 - ADJUSTING THE AIR PRESSURE IN THE PNEUMATIC CYLINDER
1012
11
T1888
7 - 3
ADJUSTMENTS 7
026AZ001A
7.1.2 REPLACING THE FEED CHANNEL TO HANDLE A NEW PRODUCT SIZE
The feed channel consists of two units: the bend and the straight part that feeds the work unit. The product size handledcan be varied in the following ways:1) The caps differ from the ones previously handled only in height, which is increased (Dh+)2) The caps differ from the ones previously handled only in height, which is decreased (Dh-)3) The caps differ from the ones previously handled only in diameter, which is increased (DØ+)4) The caps differ from the ones previously handled only in diameter, which is decreased (DØ-)5) The caps differ from the ones previously handled in both height and diameter (DØh)The various options and how the parts need to be adjusted are summarized in the chart below:
Dimensions of caps that vary from the previous ones
WHAT TO DO
Bend Straight section
∆h+ Replace the rails (1) with higher ones Replace the rails (2) with higher ones, theguide and support
∆h- Replace the rails (1) with lower ones Replace the rails (2) with higher ones, the guide(3) and support
Ư+ Replace the rails (1), base (4) and cover (5) Replace the rails (2), base (6), cover (7), guide(3) and relative support
Ư- Replace the rails (1) with wider ones Replace the rails (2) with wider ones, guide (3)and relative support
Ưh Replace the rails (1), base (4) and cover (5) Replace the rails (2), base (6), cover (7), guide(3) and relative support
Remove the parts to be replaced and install the new ones making sure they are perfectly aligned.
Figure 7.1.2 - REPLACING THE FEED CHANNEL TO HANDLE A NEW PRODUCT SIZE
7
3
5
6
2
41
T1357
7 - 4
7 ADJUSTMENTS
026AZ001A
01
7.2 ADJUSTING THE CAP STRIPPER RODS
The cap stripper rods are driven by the upper cam (1) which moves down, up and down synchronized with the lowercam and the upstroke. The rod has to press on the bottom of the cap. The pressure exerted is controlled by springpreloading as well as the height of the upper cam.The height of the upper cam is adjusted by loosening the screws (2) and adjusting the grub screws (3) to obtain axialmovement of the cam. Use three comparators (4) to check the adjustments made. The comparators should all read thesame value to maintain cam parallelism in relation to the conditions present prior to the adjustments.
Figure 7.2 - ADJUSTING THE CAP STRIPPER RODS
3
1
2
4
T1371
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ADJUSTMENTS 7
026AZ001A
7.3 ADJUSTING THE HEIGHT OF THE TOOLS
The height of the tools is adjusted by tightening or loosening the punch (1), as required. The grub screw (2) preventsthe punch from coming loose and is to be tightened once the punch has been set as required. Adjustments have to bemade to obtain proper operation as if the tool is too low it will permanently deform the caps. On the other hand, if it istoo high, the safety band will not be properly formed.
Figure 7.3 - ADJUSTING THE HEIGHT OF THE TOOLS
1
2
T1375
T1374
2
1
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7 ADJUSTMENTS
026AZ001A
7.4 REPLACING THE CAP TRANSFER TURN-TABLE
The transfer turn-table (2) has to be replaced when, for example, the diameter of the caps being handled is changedto a slight extent. Remove the screws, take off the two sections of the disk with cavities that make up the turn-table andreplace them.
NoteThe machine can be set-up to handle caps that differ in height and diameter only slightly (approximately ≤ 2 mm).If the caps that need to be processed differ greatly, the machine has to be fitted with different tools which are to bearranged for with SACMI’s Engineering Department. These tools are to be installed either by SACMI or specially trainedpersonnel.
Figure 7.4 - REPLACING THE CAP TRANSFER TURN-TABLE
3
2
8
6
5
1
7
4
T1358
7 - 7
ADJUSTMENTS 7
026AZ001A
7.5 EXIT CHANNEL(References given in figure 7.5)
7.5.1 ADJUSTING THE CHANNEL JAMMING CONTROL DEVICE
This device is able to detect when a cap is jammed in the channel. This is accomplished by means of a lever (8) which,when triggered, inactivates a proximity sensor (9) that stops the machine. The lever (8) has to be adjusted in relationto the sensor so that the sensor itself is constantly activated during normal operation.
Figure 7.5 - EXIT CHANNEL
T1378
8
9
3
7
2
6
4
15
7 - 8
7 ADJUSTMENTS
026AZ001A
7.5.2 REPLACING THE CAP EXIT CHANNEL TO HANDLE A NEW PRODUCT SIZE
The exit channel consists of two groups: the bend and the straight part that feeds the work unit. The product sizehandled can be varied in the following ways:1) The caps differ from the ones previously handled only in height, which is increased (Dh+)2) The caps differ from the ones previously handled only in height, which is decreased (Dh-)3) The caps differ from the ones previously handled only in diameter, which is increased (DØ+)4) The caps differ from the ones previously handled only in diameter, which is decreased (DØ-)5) The caps differ from the ones previously handled in both height and diameter (DØh)The various options and how the parts need to be adjusted are summarized in the chart below:
Dimensions of the caps that vary compared to the previous ones
WHAT TO DO
Bend Straight section
∆h+ Replace the rails (1) with higher ones Replace the rails (2) with higher ones,the guide and support
∆h- Replace the rails (1) with lower ones Replace the rails (2) with higher ones, the guide(3) and support
Ư+ Replace the rails (1), base (4) and cover (5) Replace the rails (2), base (6), cover (7), guide(3) and relative support
Ư- Replace the rails (1) with wider ones Replace the rails (2) with wider ones, guide (3)and relative support
Ưh Replace the rails (1), base (4) and cover (5) Replace the rails (2), base (6), cover (7), guide(3) and relative support
Remove the parts to be replaced and install the new ones making sure they are perfectly aligned.
7 - 9
ADJUSTMENTS 7
026AZ001A
7.6 CONVEYANCE CHANNEL
The conveyance channel does not need to be adjusted. The air flow rate of the blowers that advance the caps in thechannels can be set by adjusting the regulators located in the control unit.
E0004PIMPORTANT!
Further information regarding the conveyance channel is available on request.
7.7 PNEUMATIC SYSTEM
The air flow rate of the blowers that advance the caps in the channels can be set by adjusting the regulators locatedin the control unit. Adjust the blowers as required.The required pressure is given in paragraph 2.3.1 - SPECIFICATIONS.
7 - 10
7 ADJUSTMENTS
026AZ001A
8 - 1
MAINTENANCE 8
026AZ001A
8 MAINTENANCE
GENERAL INFORMATION AND PRECAUTIONS REGARDING SAFETY
E0004PWARNING!
Only expert personnel who fully understand how the machine and plant in general operate can carry outmaintenance, as indicated in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.Take all the precautionary steps in order to prevent accidental machine start-up.- turn the main switch on the electrical cabinet to OFF- remove the safety key- put a “maintenance in progress” sign on the electrical cabinet- make sure the emergency stop buttons are pressedAlways keep in mind the potential risks and follow the safety rules given in chapter 3 - SAFETY EQUIPMENT ANDPRECAUTIONS.
Maintenance operations are subdivided as follows:- routine maintenance (to be carried out by the customer’s maintenance staff)- special maintenance (to be carried out by the manufacturer’s technicians or customer’s personnel who have been
specially trained).
The following are some examples of routine maintenance:- mechanical jobs: lubricating and cleaning mechanical parts, replacing and tensioning the belts, replacing and
cleaning the pneumatic valves- electric jobs: replacing the fuses in the electrical cabinet.
8 - 2
8 MAINTENANCE
026AZ001A
8.1 ROUTINE MAINTENANCE
8.1.1 SCHEDULED MAINTENANCE CHART
T27
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8 - 3
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8.1.2 SCHEDULED MAINTENANCE
8.1.2.1 Cleaning the toolsThe fixed and movable tools have to be accurately cleaned at the intervals stated in the chart. Use the brass bristle brushsupplied with the machine and blow compressed air, if necessary.
E0004PWARNING!
Pay special attention when cleaning the tools.In particular, make sure no pieces of material are stuck between the tools.
8.1.2.2 Cleaning the electric partsThe electric parts (photocells, fiber optics, inductive sensors) need to be cleaned and operation (mechanical) of the limitswitches has to be checked to ensure proper machine operation.
8.1.3 LUBRICATIONLubrication is an extremely important operation. In fact, the parts need to be lubricated as indicated to prevent parts frombreaking or wearing down.
8.1.3.1 Lubricant specifications
OIL
A 23°E - 50°C ISO 3498 - CO 320 (320 cSt. - 40°C)
GREASE
B Dropping point < 200 °C Worked penetration (0.1 mm) DIN 51804 = 260 - 295 dmmC Dropping point 200 °C Worked penetration DIN 51804 = 300 dmm Dynamic toughness
7000 mPasD Density at 20°C 0.92 - Dropping point (DIN ISO 2176) > 250°C
Worked penetration (DIN ISO 2137) 310-340 dmm -Dynamic toughness 2000-4000 mPasApproved according to USDA-H1 standards for the food and pharmaceutical industries
When selecting the lubricants see the charts given in the LUBRICATION DATA SHEET.
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8 MAINTENANCE
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TROUBLE
Feed channel: caps jammed
Work unit: caps are not inserted
Exit channel: caps jammed
REMEDY
remove any deformed caps
clean the table the caps flow on
check the air mains pressure given onthe central gauge (values indicated inparagraph 2.3.1 SPECIFICATIONS)
set the air flow rate of the blowers
check the air mains pressure
set the flow regulators
CAUSE
there are deformed caps in the channel
the table the caps flow on in the feedchannel is dirty
insufficient compressed air
insufficient compressed air
8.2 SPECIAL MAINTENANCE OPERATIONS
Any special maintenance operations (therefore not given in the scheduled maintenance chart) can be carried out solelyby the manufacturer’s engineers or the customer’s personnel who have been specially trained. The operations mustbe carried out by carefully following the directions provided by the manufacturer.
8.3 TROUBLESHOOTING THE MACHINE
Whenever the machine shuts down, a red led on the control unit display comes on. Refer to the Instructions B manualfor information on how to locate and clear the trouble. If safety devices have been activated, reset the machine asdescribed in chapter 6 - OPERATING INSTRUCTIONS.
However, the following may cause malfunctioning:- faults during the work cycle- defects in the productThe troubles, causes and actions to be taken are described on the following page.
8.3.1 TROUBLESHOOTING GUIDE
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DISMANTLING THE MACHINE 9
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9 DISMANTLING THE MACHINE
MAKING THE MACHINE INOPERATIVE WHEN NO LONGER USEDThe operations given below need to be carried out when the machine is no longer used:- Turn off the machine’s power supply by using the factory’s main switch.- Unplug the power cable from the electrical cabinet’s terminal block.- Disconnect the cables that join the cabinet to the machine, detaching the connectors.- Disconnect the line between the factory’s compressed air mains and the control unit.- Thoroughly clean the machine paying particular attention to the moving parts. Lubricate as a protective measure, if
necessary.- Close the doors of the electrical cabinet and machine to prevent the parts from being tampered with, dust from building
up, etc.- Activate all the safety devices provided.
DISMANTLING THE MACHINERemove the various parts of the machine by carefully observing all current safety regulations as well as following thedirections given in chapter 4 - INSTALLATION in this manual. Special attention must be given to the procedures for liftingand handling the machine as well as the warnings and precautions given in paragraph 3.3 - SAFETY RULES FORHANDLING.
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9 DISMANTLING THE MACHINE
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026AZ001A_GBTABLE OF CONTENTS1 GENERAL INFORMATION1.1 INTRODUCTION1.2 WHERE TO KEEP THE MANUAL1.3 HOW TO USE THE MANUAL1.4 USERS OF THE MANUAL1.5 WARRANTY1.6 SUPPLEMENTS1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN 1.8 MACHINE IDENTIFICATION PLATE2 MAIN FEATURES2.1 MACHINE DESCRIPTION2.1.1 MAIN DEVICES2.1.1.1 Cap feed channel 2.1.1.2 Work unit2.1.1.3 Tooling2.1.1.4 Exit channel2.1.1.5 Conveying channel2.1.1.6 Lower structure2.1.1.7 Drive unit2.1.1.8 Pneumatic system2.1.1.9 Electrical cabinet 2.1.1.10 Safety devices installed2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE 2 - 82.2 OVERALL DIMENSIONS2.3 TECHNICAL DATA2.3.1 SPECIFICATIONS 2.3.2 ALLOWABLE FLUCTUATION OF THE VARIABLES2.3.3 RATING PLATE2.3.4 OPERATIONAL CHARACTERISTICS2.3.5 AIRBORNE NOISE LEVELS 2.3.5.1 Sound pressure level (ISO/DIS 11202)2.3.5.2 Sound power level (ISO 3746)2.4 DIAGRAMS2.4.1 PNEUMATIC SYSTEM DIAGRAM3 SAFETY EQUIPMENT AND PRECAUTIONS3.1 SAFETY DEVICES3.1.1 SAFETY GUIDELINES3.1.2 SAFETY DEVICES INSTALLED 3.1.2.1 Shutdown devices3.1.2.2 Fault signaling3.1.2.3 Safety devices for the operator3.1.2.4 Emergency stop buttons3.2 SAFETY RULES FOR HANDLING3.2.1 SLINGING THE LOADS3.2.2 HOISTING3.2.3 PLACEMENT3.3 INSTALLATION3.3.1 GENERAL RULES3.4 OPERATOR TRAINING3.4.1 END-USER3.4.2 OPERATORS 3.4.3 MAINTENANCE STAFF3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THE 3.5.1 GENERAL SAFETY RULES3.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED3.6.1 GENERAL RULES4 INSTALLATION 4.1 SHIPPING AND HANDLING4.2 POSITIONING4.3 CONNECTIONS AND HOOK UPS4.3.1 CONNECTING THE MACHINE TO THE COMPRESSED AIR MAINS4.3.2 CONNECTING THE ELECTRIC CABLES5 MACHINE START-UP5.1 INTRODUCTION5.2 PRELIMINARY CHECKS5.3 DAILY START-UP6 OPERATING INSTRUCTIONS6.1 CONTROL DEVICES6.1.1 ELECTRICAL CABINET6.2 OPERATION IN MANUAL MODE6.3 OPERATION IN AUTOMATIC MODE7 ADJUSTMENTS7.1 CAP FEED CHANNEL7.1.1 ADJUSTING THE AIR PRESSURE IN THE PNEUMATIC CYLINDER7.1.2 REPLACING THE FEED CHANNEL TO HANDLE A NEW PRODUCT SIZE 7.2 ADJUSTING THE CAP STRIPPER RODS7.3 ADJUSTING THE HEIGHT OF THE TOOLS7.4 REPLACING THE CAP TRANSFER TURN-TABLE7.5 EXIT CHANNEL7.5.1 ADJUSTING THE CHANNEL JAMMING CONTROL DEVICE7.5.2 REPLACING THE CAP EXIT CHANNEL TO HANDLE A NEW PRODUCT SIZE7.6 CONVEYANCE CHANNEL7.7 PNEUMATIC SYSTEM8 MAINTENANCE8.1 ROUTINE MAINTENANCE8.1.1 SCHEDULED MAINTENANCE CHART8.1.2 SCHEDULED MAINTENANCE8.1.2.1 Cleaning the tools 8.1.2.2 Cleaning the electric parts8.1.3 LUBRICATION8.1.3.1 Lubricant specifications8.2 SPECIAL MAINTENANCE OPERATIONS8.3 TROUBLESHOOTING THE MACHINE8.3.1 TROUBLESHOOTING GUIDE9 DISMANTLING THE MACHINE
