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Sacmi CCM 001 User Manual

Rotary hydraulic compression press
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D O C U M E N TA Z I O N E
T
E
ROTARY HYDRAULIC COMPRESSION PRESS
TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION
DOCUMENTAÇAO
C
N
USER'S MANUAL
002AZ001A
CCM 001
I
C
TECNICA
TÉCNICA
A

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  • Page 1 D O C U M E N TA Z I O N E USER’S MANUAL 002AZ001A ROTARY HYDRAULIC COMPRESSION PRESS CCM 001 TECHNICAL DOCUMENTATION DOCUMENTATION TECHNIQUE TECHNISCHE DOKUMENTATION DOCUMENTACION TECNICA DOCUMENTAÇAO TÉCNICA...
  • Page 2 002AZ001A TABLE OF CONTENTS 0 - 2...
  • Page 3 002AZ001A TABLE OF CONTENTS USER’S MANUAL ROTARY HYDRAULIC COMPRESSION PRESS CCM 001 MANUFACTURER SACMI IMOLA Via Selice Provinciale, 17/A 40026 IMOLA (Bologna) - ITALIA PUBLISHED ON 25.10.2001 VERSIONS CCM00100005 - CCM001A 0 - 3...
  • Page 4 002AZ001A TABLE OF CONTENTS 0 - 4...

  • Page 5: Table Of Contents

    002AZ001A TABLE OF CONTENTS Page GENERAL INFORMATION ........................1 - 1 INTRODUCTION ........................1 - 1 WHERE TO KEEP THE MANUAL ..................1 - 1 HOW TO USE THE MANUAL ....................1 - 1 USERS OF THE MANUAL ...................... 1 - 1 WARRANTY ..........................1 - 2 SUPPLEMENTS ........................
  • Page 6 002AZ001A TABLE OF CONTENTS Page SAFETY EQUIPMENT AND PRECAUTIONS ..................3 - 1 SAFETY DEVICES AND GUARDS ..................3 - 1 3.1.1 GENERAL SAFETY RULES ....................3 - 1 3.1.2 SAFETY DEVICES INSTALLED ..................... 3 - 1 3.1.2.1 Shutdown devices ........................3 - 1 3.1.2.2 Indicating a shutdown ......................
  • Page 7 002AZ001A TABLE OF CONTENTS Page ADJUSTMENTS ............................7 - 1 PLASTICIZATION UNIT ......................7 - 1 7.1.1 EXTRUDER ..........................7 - 1 7.1.2 METERING PUMP ........................7 - 1 7.1.3 FEED TUBE ..........................7 - 2 7.1.4 BY-PASS SYSTEM ......................... 7 - 2 INSERTION DRUM .........................
  • Page 8 002AZ001A TABLE OF CONTENTS Page 8.1.2.4.3 Changing the oil in the polymer metering pump geared motor ..........8 - 24 8.1.2.4.4 Checking the oil level in the extruder thrust block and topping up ........8 - 24 8.1.2.4.5 Changing the oil in the extruder thrust block ................ 8 - 25 8.1.2.4.6 Cleaning the polymer metering pump ...................
  • Page 9 002AZ001A TABLE OF CONTENTS Page 8.1.2.9.9 Cleaning control valve Pb ..................... 8 - 45 8.1.2.9.10 Cleaning control valve Ph ..................... 8 - 45 8.1.2.9.11 Cleaning solenoid control valves Pb and Ph ................ 8 - 45 8.1.2.9.12 Checking for condensate on the bottom of the tank ............. 8 - 45 8.1.2.9.13 Checking the accumulator precharge ...................
  • Page 10 002AZ001A TABLE OF CONTENTS 0 - 10...

  • Page 11: General Information

    This manual contains important information for safeguarding the operators, the maintenance staff as well as the machine itself. SACMI reserves the right to make changes to the machine and in the manual without giving prior notice. Copyright. All rights reserved. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI.

  • Page 12: Warranty

    SACMI 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 personnel or duly authorized by SACMI’S Engineering Dept.
  • Page 13 002AZ001A GENERAL INFORMATION Risk of entanglement in moving parts. E0010 Danger of falling. E0017 Risk of explosion. E0035P Keep a safe distance away. E0015 WARNING SYMBOLS Never perform maintenance or lubrication operations on moving parts. E0001 Do not use oxygen to recharge the accumulators. E0034D ALERT SYMBOLS Heavy-duty work gloves must be worn.

  • Page 14: Machine Identification Plate

    002AZ001A GENERAL INFORMATION MACHINE IDENTIFICATION PLATE T2525 1 - 4...

  • Page 15: Machine Features

    002AZ001A MACHINE FEATURES MACHINE FEATURES MACHINE DESCRIPTION The CCM series of hydraulic presses is specially designed to produce thermoplastic products by means of compression. A continuous work-cycle is carried out during which plastic material is fed from an extruder, cut into suitably gauged pellets and then inserted inside the dies.
  • Page 16 002AZ001A MACHINE FEATURES Figure 2.1 - OVERALL VIEW T2524 T2523 1 Extruder Pneumatic system 2 Metering pump Hydraulic system 3 Feed tube Cooling system 4 By-pass system Electric cabinet 5 Drive unit Tooling 6 Insertion drum Control panel 7 Forming unit Exit channel 2 - 2...

  • Page 17: Main Devices

    002AZ001A MACHINE FEATURES 2.1.1 MAIN DEVICES 2.1.1.1 Plasticization unit The function of this unit is to melt down the plastic compound and then push it out through the nozzles. The temperature and flow rate of these operations are controlled. The unit includes an extruder (1), metering pump (2), a heated feed tube (3) and a by-pass system (4).
  • Page 18 002AZ001A MACHINE FEATURES Extruder The extruder melts down the plastic compound and homogenizes it with any colorings and lubricants that may have been added. The granular material is let in through a hopper (1) and is pushed in the cylinder (2) by the auger (3) through the four thermal conditioning zones.
  • Page 19 002AZ001A MACHINE FEATURES Figure 2.1.1.1/B - 100 kg/h EXTRUDER 1 Hopper 2 Cylinder 3 Auger 4 Extruder gearbox T1544 2 - 5...
  • Page 20 002AZ001A MACHINE FEATURES Figure 2.1.1.1/C - 150/200 kg/h EXTRUDER 1 Hopper 2 Cylinder 3 Auger 4 Hydraulic motor 5 Motor-pump unit 6 Tank T1702 2 - 6...
  • Page 21 002AZ001A MACHINE FEATURES Metering pump The metering pump controls the flow of the melt and determines the weight of the pellets. The material enters the pump casing (1) (heated by elements EH7) through a suction flange (6) and is pushed by suitable gears (2) (driven by geared motor M8) towards a delivery flange (7).
  • Page 22 002AZ001A MACHINE FEATURES Feed tube This carries the melt from the metering pump to the insertion drum unit. The melt enters through a flange (1) and is fed by the by-pass unit. While traveling along the path, the material is kept at a constant temperature by heating elements EH8.
  • Page 23 002AZ001A MACHINE FEATURES By-pass system The by-pass system is used to either feed the insertion unit or discharge the material into the waste container. The melt is fed through a flange (1) and can either be carried to a nozzle (3) where it is extruded or to the discharge outlet (4), depending on the position of the diverter (5).

  • Page 24: Drive Unit

    002AZ001A MACHINE FEATURES 2.1.1.2 Drive unit The drive unit transmits motion to the entire machine. This unit includes a epicyclic geared motor M9 mounted on the vertical axis, a handwheel (2) to carry out operations in manual mode, a cogged belt (3) that drives the forming unit and a tension unit (4) that controls the tension of the belt. A cock for draining oil (5), a filler and breather plug (6) and a level indicator (7) are also provided.

  • Page 25: Insertion Drum Unit

    002AZ001A MACHINE FEATURES 2.1.1.3 Insertion drum unit The insertion drum unit has the dual function of cutting and placing the plastic pellets in the cavities of the forming drum and transferring the finished product onto the exit conveyor belt. The unit basically consists of the following parts: Drive unit (References given in figure 2.1.1.3/A) The drive unit (1), secured beneath the insertion drum mount, is driven by a pulley (2) keyed to the forming unit.
  • Page 26 002AZ001A MACHINE FEATURES 23 Cutter Figure 2.1.1.3/A - DRIVE UNIT - Drum pivot point 24 Distributor SUPPORT - PIVOT POINT 10 Support unit 28 Support 11 Pneumatic cylinder 29 Back-plate YV33 Solenoid valve 13 Connecting rod 31 Wheel Drive unit 14 Tensioner 32 Wheel Forming unit pulley...
  • Page 27 002AZ001A MACHINE FEATURES Figure 2.1.1.3/B - INSERTION DRUM Connecting rod Belt Stripper wheel Insertion unit disk Cutter 23A Insertion nozzle 23B Body 23C Cutter 23D Screw Distributor Pulley Wheel drive mechanism 26A Shaft 26B Sleeve 26C Toothed wheel 26D Toothed wheel 26E Toothed wheel 26F Toothed wheel T2492...

  • Page 28: Forming Unit

    002AZ001A MACHINE FEATURES 2.1.1.4 Forming unit (References given in figures 2.1.1.4/A and 2.1.1.4/B) The hydraulic actuators and dies are located in the forming unit. They are used to form, cool down and remove the pellets of molten plastic that are sent to them from the insertion drum. The finished product is then placed on the stripper wheel. The forming drum consists of a support shaft (1) on which the drum body (2) is mounted.
  • Page 29 002AZ001A MACHINE FEATURES Figure 2.1.1.4/A - FORMING DRUM T2493 2 - 15...
  • Page 30 002AZ001A MACHINE FEATURES Figure 2.1.1.4/B - TOOL WITH CENTRAL DRIVE T2529 2 - 16...

  • Page 31: Exit Channel

    002AZ001A MACHINE FEATURES 2.1.1.5 Exit channel (References given in figure 2.1.1.5) The exit channel receives the product from the stripper wheel and carries it in an orderly manner to the zone where it is fed to the next machine in the production line. A belt with paddles (1), driven by a pulley (2) keyed to the drive shaft, receives the product from the stripper wheel (3) and pushes it into the exit channel (4).

  • Page 32: Intended, Prohibited And Misuse Of The Machine

    002AZ001A MACHINE FEATURES Figure 2.1.1.5 - EXIT CHANNEL YV4 Solenoid valve Belt with paddles Stripper wheel Exit channel Conveyor T2514 2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE INTENDED USE OF THE MACHINE The machine is specially designed and constructed to produce products that have the characteristics indicated in the specifications.

  • Page 33: Overall Dimensions

    002AZ001A MACHINE FEATURES OVERALL DIMENSIONS Figure 2.2/A - OVERALL DIMENSIONS WITH 50 kg/h EXTRUDER T2569 VOLT 440 - 415 - 380 5480 480 - 220 5880 2 - 19...
  • Page 34 002AZ001A MACHINE FEATURES Figure 2.2/B - OVERALL DIMENSIONS WITH 100 kg/h EXTRUDER 1815 T2496 VOLT 440 - 415 - 380 5670 480 - 220 6070 2 - 20...
  • Page 35 002AZ001A MACHINE FEATURES Figure 2.2/C - OVERALL DIMENSIONS WITH 150 kg/h EXTRUDER 3520 5680 T2511 2 - 21...
  • Page 36 002AZ001A MACHINE FEATURES Figure 2.2/D - OVERALL DIMENSIONS WITH 200 kg/h EXTRUDER 4045 5680 T2495 2 - 22...

  • Page 37: Technical Data

    002AZ001A MACHINE FEATURES TECHNICAL DATA 2.3.1 SPECIFICATIONS EXTRUDER kg/h PRODUCTION OUTPUT Pieces/minute up to Required delivery rate (at 0.5 MPa) Consumption (at 0.5 Mpa) Minimum required pressure Hose to air mains diameter mm POWER Thermal power to be dissipated kcal/h 22.000 28.000 36.000...

  • Page 38: Operational Characteristics

    In addition, this data can be stored and called up whenever the material handled is changed. ATTENTION! E0004P If material that is not included on the data sheet (facsimile given below) is used, contact SACMI’s laboratory before starting processing. PRODUCTION CAPACITY The product output is strictly related to the type of object formed and material used.

  • Page 39: Airborne Noise Emission Levels

    002AZ001A MACHINE FEATURES 2.3.3 AIRBORNE NOISE EMISSION LEVELS 2.3.3.1 Sound pressure level (ISO/DIS 11202) Test conditions - Operating conditions: trial run with material and 100 kg/h extruder - Type of operation: plastic cap production - Operating cycle: material feed and cap formation - Test environment: factory with reflecting flooring.
  • Page 40 002AZ001A MACHINE FEATURES Compilato da Scheda di lavorazione Data Scheda n° CCM001A (Data sheet) Filled by Date Sheet # Cliente (Customer) Contratto (Contract) Matricola (Serial Nr.) Versione di progr. (Program Nr.) Tipo (Type) Campionatura no. (Sampling #) Capsula (Cap) °C T °C fondo panel...

  • Page 41: Diagrams

    002AZ001A MACHINE FEATURES DIAGRAMS 2.4.1 PNEUMATIC SYSTEM DIAGRAM (References given in figures 2.4.1/A and 2.4.1/B) Solenoid valves Air preparation Filter and pressure regulator Pressure regulator, Pellet insertion Accumulator Pneumatic cylinder, Insertion drum movement Throttle Pneumatic cylinder, Product diverter movement Cylinder, By-pass movement Cylinder, By-passed cut Pressure regulator, Air injection in dies Shut off valve and pressure gauge...
  • Page 42 002AZ001A MACHINE FEATURES Figure 2.4.1/A - AIR SUPPLY SYSTEM DRAWING YV22 YV23 YV1/2 YV25/26 YV33 YV17 T2567 2 - 28...
  • Page 43 002AZ001A MACHINE FEATURES Figure 2.4.1/B - LAYOUT OF ELEMENTS IN THE AIR SUPPLY SYSTEM YV33 T2516 YV23 YV1/2 YV22 YV25/26 YV17 T2512 2 - 29...

  • Page 44: Hydraulic System Diagram

    002AZ001A MACHINE FEATURES 2.4.2 HYDRAULIC SYSTEM DIAGRAM (References given in figures 2.4.2/A and 2.4.2/B) The hydraulic system is illustrated in block diagrams, each of which has a specific location in the machine Hydraulic power unit reservoir Suction filter High pressure pump Low pressure pump Oil filter Heat exchanger...
  • Page 45 002AZ001A MACHINE FEATURES Figure 2.4.2/A - HYDRAULIC SYSTEM DIAGRAM YV30 YV27 YV21 BT10 T2576 2 - 31...
  • Page 46 002AZ001A MACHINE FEATURES Figure 2.4.2/B - LAYOUT OF ELEMENTS IN HYDRAULIC SYSTEM T2523 BT10 YV21 T2522 YV30 YV27 9 10 T2498 T2520 2 - 32...

  • Page 47: Cooling System Diagram

    002AZ001A MACHINE FEATURES 2.4.3 COOLING SYSTEM DIAGRAM (References given in figures 2.4.3/A and 2.4.3/B) Chiller Temperature regulator Press Hydraulic power unit Plasticization unit Lower tools Upper tools Heat exchanger Non-return valve Flow meter, Upper tools Flow meter, Lower tools Flow meter, Power unit Thermostatic valve Metering pump Extruder gearbox...
  • Page 48 002AZ001A MACHINE FEATURES Figure 2.4.3/A - LAYOUT OF ELEMENTS IN COOLING SYSTEM SP2F SP3F YV17 YV29 YV28 SP18 SP19 SP20 BT18 BT19 BT20 YV18 YV19 YV20 EH18 EH19 EH20 T2568 2 - 34...
  • Page 49 002AZ001A MACHINE FEATURES Figure 2.4.3/B - LAYOUT OF ELEMENTS IN COOLING SYSTEM YV18 BT18 SP18 SP19 YV19 BT19 SP20 T1574 BT20 EH18 EH19 YV20 T2510 EH20 SP2F T2522 SP3F YV28 YV29 T2500 T1590 2 - 35...
  • Page 50 002AZ001A MACHINE FEATURES 2 - 36...

  • Page 51: Safety Equipment And Precautions

    Always take all necessary safety precautions before working on the machine. SACMI shall not be held responsible for any injury to personnel or damage to the machine resulting from failure to observe these precautions or use the safety devices provided.

  • Page 52: Emergency Stop Buttons

    002AZ001A SAFETY EQUIPMENT AND PRECAUTIONS 3.1.2.4 Emergency stop buttons Emergency stop buttons on-board the machine They are installed in the position shown in the figure. - Operation: manual - Effect: the drive system, machine motors and vacuum and suction pumps (required for product handling) immediately stop running.

  • Page 53: Safety Rules For Handling

    002AZ001A SAFETY EQUIPMENT AND PRECAUTIONS SAFETY RULES FOR HANDLING WARNING! E0004P 3.2.1 LIFTING PROCEDURES To safely and correctly lift the machine always: - use the most suitable lifting equipment with an adequate lift capacity; - cover all sharp edges with cloths and/or cardboard; - make sure the safety device for the lift hook works properly;...

  • Page 54: Installation

    These must conform to laws currently 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. 3 - 4...

  • Page 55: Operator Training

    002AZ001A SAFETY EQUIPMENT AND PRECAUTIONS OPERATOR TRAINING WARNING! E0004P 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.

  • Page 56: Safety Precautions For Operating, Adjusting And Servicing The Machine

    Always take the necessary safety precautions before working on the motors. E0009 E0007 In order to ensure that the machine operates efficiently, safely and in a trouble-free manner always follow SACMI’s instructions carefully. Carry out the scheduled maintenance operations exactly as described and at the time intervals recommended.

  • Page 57: Guidelines For Operation And Maintenance

    002AZ001A SAFETY EQUIPMENT AND PRECAUTIONS 3.5.2 GUIDELINES FOR OPERATION AND MAINTENANCE 3.5.2.1 Risks deriving from high temperatures ACCESSING THE INSIDE OF THE EXTRUDER GUARDS Temperatures up to 280 °C are reached inside the area protected by the extruder guards. Never touch the external surfaces provided with warnings indicating danger of being burnt. The safety guards may have to be opened to clean the machine or make checks when the machine is shut down under emergency conditions.

  • Page 58: What To Do When The Machine Is No Longer Used

    002AZ001A SAFETY EQUIPMENT AND PRECAUTIONS WHAT TO DO WHEN THE MACHINE IS NO LONGER USED WARNING! E0004P 3.6.1 GENERAL When the machine is no longer to be used, make it inoperative by shutting off the electricity and air supplies etc. WARNING! E0035P Discharge the gas under pressure from the accumulators by using the tester/inflator provided.

  • Page 59: Installation

    The best systems for lifting and handling the heaviest and largest parts as well as those that require special care and tools provided by Sacmi are shown in the figure. When lifting the smaller parts and packages, be careful and use the most suitable equipment observing the safety precautions.
  • Page 60 002AZ001A INSTALLATION Figure 4.1/A - DIMENSIONS AND WEIGHTS kg 4600 2050 1650 1700 L.=1800 L.=1500 kg 450 L.=1000 kg 320 L.=2400 kg 520 T1548 4 - 2...
  • Page 61 002AZ001A INSTALLATION Figure 4.1/B - DIMENSIONS AND WEIGHTS 1800 4200 1350 1400 50 kg/h kg 600 3650 200 kg/h 2800 kg 4500 1360 1100 1350 150 kg/h 100 kg/h 1100 kg 4000 kg 1300 50 kg/h - 220/480V 50 kg/h kg 1350 kg 1250 2100...

  • Page 62: Positioning

    002AZ001A INSTALLATION POSITIONING The various parts of the machine are to be placed in the order given below, referring to figure 4.2. - Position the press (1). - Put the extruder tracks (6) in place. - Place the extruder (2) on the tracks. - Install the extruder connecting tube (4) making sure the coupling flange is clean.

  • Page 63: Connections And Hook Ups

    002AZ001A INSTALLATION CONNECTIONS AND HOOK UPS The machine must be hooked up to the various systems exclusively by specialized persons. 4.3.1 CONNECTING THE EXTRUDER TO THE PRESS (References given in figure 4.3.1) - Connect the extruder tube (1) to the flange (2) of the press by using the screws (3). Make sure the mating surfaces are clean.

  • Page 64: Hydraulic Connection: From The Power Unit To The Press

    002AZ001A INSTALLATION 4.3.2 HYDRAULIC CONNECTION: FROM THE POWER UNIT TO THE PRESS (References given in figure 4.3.2) Three tubes with different diameters are used to connect the hydraulic power unit to the press: 1", 3/4", 1/2". - Connect the tubes on the hydraulic power unit (1) and press (2) in the order given starting from the biggest one 1" then 3/4"...

  • Page 65: Hooking Up The Coolant System

    002AZ001A INSTALLATION 4.3.3 HOOKING UP THE COOLANT SYSTEM (References given in figure 4.3.3) - Connect zones A and B of the temperature regulator by using two pairs of tubes (1" diameter) to the press (4), as shown in the figure. - Connect zone C of the temperature regulator (1) to the distribution block (5) mounted on the hydraulic power unit (2) using a pair of tubes (1"...

  • Page 66: Hooking Up The Pneumatic System

    002AZ001A INSTALLATION 4.3.4 HOOKING UP THE PNEUMATIC SYSTEM (References given in figure 4.3.4) PNEUMATIC CONTROL UNIT - Attach a hose whose inside diameter is as stated in the specifications to the fitting (A) from the compressed air supply. PLASTIC COMPOUND FEEDER, located over the extruder hopper. - Connect the tube B with quick-connect coupler provided on the extruder.

  • Page 67: Electrical Hook-Up

    002AZ001A INSTALLATION 4.3.5 ELECTRICAL HOOK-UP 4.3.5.1 Wiring connections Make the electric connections between the various parts of the machine as indicated in figure 4.3.5.1. The identification numbers used in the diagram are those marked on the points to be connected and wires. Figure 4.3.5.1 - WIRING CONNECTIONS T2566 4 - 9...

  • Page 68: Earth Connection

    002AZ001A INSTALLATION 4.3.5.2 Earth connection WARNING! E0004P The machine must be connected to an effective earth electrode. Join the earth electrode to the point marked PE (EN60445). In addition, join the earth electrode to the connection points on the machine frame marked with the symbol E0006 (417-IEC-5019).

  • Page 69: Start Up

    002AZ001A START UP START UP INTRODUCTION Initial machine start up is to be carried out by personnel specialized in both the mechanical and electric fields. WARNING! E0004P Solely the manufacturer’s technicians responsible for starting up the machine are authorized to carry out these operations, as indicated in chapter 1, GENERAL INFORMATION.

  • Page 70: Checking Operation

    002AZ001A START UP CHECKING OPERATION (References in figure 6.1) The instructions for setting the operating parameters, stated in this paragraph, are given in the Instructions B manual. CONDITIONS - Machine on PROCEDURE The operations described in this paragraph serve to check machine operation before starting the production run. - Turn the mode selector (19-23) on the control panel to SET-UP.

  • Page 71: Preliminary Operations

    002AZ001A START UP PRELIMINARY OPERATIONS (References given in figure 6.1) The instructions for setting the operating parameters, stated in this paragraph, are given in the Instructions B manual. - Machine on. - Call up the pre-set operating data for the material and product selected. This data can be set by following the indications given on the data sheet.

  • Page 72: Starting The Automatic Cycle

    002AZ001A START UP STARTING THE AUTOMATIC CYCLE CONDITIONS - Machine on and at the correct temperature - Guards closed - Turn the mode selector on the control panel to AUT - Start the automatic cycle by using key 1. SUBSEQUENT START UPS - Perform only the operations described in the PRELIMINARY OPERATIONS paragraph.

  • Page 73: Operating Instructions

    002AZ001A OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS WARNING! E0004P Closely follow the directions given in this manual and operate in accordance with all safety standards. CONTROL AND MONITORING UNIT The control and monitoring unit consists of an electric cabinet and a control keyboard. The electric cabinet houses all the parts required for the electric drives of the devices (contactors, relays, etc.) and processing devices for the signals that are transmitted from the sensors on the machine or keyboard (microprocessor rack, motor drives, etc.).
  • Page 74 002AZ001A OPERATING INSTRUCTIONS Figure 6.1 - CONTROL KEYBOARD 6 - 2...
  • Page 75 002AZ001A OPERATING INSTRUCTIONS OPERATION 1st key 2nd Key Reset/safety module fault Automatic cycle start Extruder heating start Machine start Encoder reset SET-UP Automatic cycle stop Extruder heating stop Machine stop Hydraulic power unit start SETUP/MAN Extruder by-pass start SETUP/MAN High pressure on/off SETUP/MAN Low pressure on/off Hydraulic power unit stop...

  • Page 76: Starting And Stopping The Machine

    002AZ001A OPERATING INSTRUCTIONS STARTING AND STOPPING THE MACHINE SET-UP OPERATIONS All the operations which the user has to access the machine directly, that is with the safety guards open are considered part of set up. Use maximum care when carrying out these operations. The mode selector (19-23) on the keyboard must be turned to SET UP.

  • Page 77: Automatic Cycle

    002AZ001A OPERATING INSTRUCTIONS AUTOMATIC CYCLE Turn selector 19-23 to AUT to set the machine for automatic operation. RUNNING THE MACHINE Press key 1 on the control keyboard to run the machine in automatic mode. This will take place only if all the safety and work conditions are met.

  • Page 78: Production Cycle

    002AZ001A OPERATING INSTRUCTIONS PRODUCTION CYCLE The production cycle for continuous forming by means of compression develops from a complete rotation of the forming drum as illustrated in figures 6.4/A and 6.4/B. N.B. The work position of the actuators are shown in the figures. These correspond to the numbers actually marked on the actuators.
  • Page 79 002AZ001A OPERATING INSTRUCTIONS Figure 6.4/A - PRODUCTION CYCLE DM - Pellet - Stripper - Insertion drum MA - Die - Central product panel - Formed product PU - Punch - Stripper wheel T1594 T1550 Figure 6.4/B - PRODUCTION CYCLE - Valve down: oil at high pressure - Valve in first position upwards: oil at low pressure - Valve in second position upwards: oil at high pressure - Insertion drum...
  • Page 80 002AZ001A OPERATING INSTRUCTIONS Figure 6.4/B - PRODUCTION CYCLE T1598 6 - 8...

  • Page 81: Emergency Cycles And Reset Operations

    002AZ001A OPERATING INSTRUCTIONS EMERGENCY CYCLES AND RESET OPERATIONS The machine is supplied with a control system that ensures safety under any working conditions. In fact, the entire process is monitored for faults and precarious situations. 6.5.1 ACTUATOR DOWNSTROKE CONTROL DESCRIPTION To more precisely identify the components stated in this paragraph, refer to chapter 7 - ADJUSTMENTS.

  • Page 82: Actuator Upstroke Control

    002AZ001A OPERATING INSTRUCTIONS 6.5.2 ACTUATOR UPSTROKE CONTROL DESCRIPTION To more precisely identify the components stated in this paragraph, refer to chapter 7 - ADJUSTMENTS. An inductive sensor secured to the base detects any incomplete forming strokes. If this sensor is activated by the measurement rod, the machine performs the emergency cycle illustrated in the flow chart below.

  • Page 83: Double Product Detection

    002AZ001A OPERATING INSTRUCTIONS 6.5.3 DOUBLE PRODUCT DETECTION DESCRIPTION A proportional inductive sensor secured to the upper frame detects the position of the actuator once the product has been formed. The product is determined to be double, heavier than the standard weight, equal to the standard weight, lighter than the standard weight or missing (not deposited) according to this position.

  • Page 84: Empty Die Control

    002AZ001A OPERATING INSTRUCTIONS 6.5.4 EMPTY DIE CONTROL DESCRIPTION If an empty die is detected, the machine performs the emergency cycle illustrated in the flow chart below. DIAGRAM empty die detected counter for empty dies per run activated counter control > 3 end of cycle RESET See “Double product detection”.

  • Page 85: Correct Position For Start Of Forming Control

    002AZ001A OPERATING INSTRUCTIONS 6.5.6 CORRECT POSITION FOR START OF FORMING CONTROL DESCRIPTION A pair of inductive sensors, secured to the base near the point in which the box distributor opens the high pressure port, detect the start of the forming stroke. If both or none of these sensors are activated by the measurement rod, the machine performs the emergency cycle illustrated in the flow chart below.

  • Page 86: Product Sampling

    002AZ001A OPERATING INSTRUCTIONS PRODUCT SAMPLING Press key 34 (see figure 2.1.1.3) to obtain samples consisting of several finished caps. The conveyor is used for this purpose. As a result, the quality of the product can be checked. 6 - 14...

  • Page 87: Adjustments

    002AZ001A ADJUSTMENTS ADJUSTMENTS PLASTICIZATION UNIT 7.1.1 EXTRUDER Adjusting the operating parameters The parameters that can be set are found on the “Extruder” page of the electronic control system. The following parameters are included: 1 - Temperature of the heat treatment zones (it affects the quality, characteristics and dimensions of the caps; it must correspond to the value given on the data sheet) 2 - Extruder motor speed % (only for manual operations;...

  • Page 88: Feed Tube

    002AZ001A ADJUSTMENTS 7.1.3 FEED TUBE Adjusting the operating parameters The parameters that can be set are found on the “Extruder” page of the electronic control system. The following parameters are included: - Temperature (it affects the quality, characteristics and dimensions of the caps; it must correspond to the value given on the data sheet) ATTENTION! E0004P...

  • Page 89: Insertion Drum

    002AZ001A ADJUSTMENTS INSERTION DRUM Conditions: - Mode selector turned to SET-UP The adjustments given below are to be made with the machine at the correct work temperature. 7.2.1 ADJUSTING THE PRECHARGE OF THE DRUM’S CONNECTING ROD - Loosen the nut that secures the upper eccentric pin (11 or 16) located at the end of the connecting rod (9). - Push the insertion drum inside the forming drum by hand.

  • Page 90: Adjusting The Cutter

    002AZ001A ADJUSTMENTS 7.2.2 ADJUSTING THE CUTTER Conditions: - Mode selector turned to SET-UP - Extruder nozzle at correct temperature and machine safety guards open. The temperature of the plasticization unit will continue to be controlled. - The adjustments given below are to be made with the machine at the correct work temperature. Adjustment - Put the cutter in its work position by hand.
  • Page 91 002AZ001A ADJUSTMENTS Figure 7.2.2 - INSERTION DRUM T2527 31 25 Connecting rod 26A Shaft Stripper wheel 26B Sleeve Insertion drum 26C Toothed wheel Cutter 26D Toothed wheel 23A Insertion nozzle 26E Toothed wheel 23B Casing 26F Toothed wheel 23C Cutter Disk 23D Screw Mounting screws...

  • Page 92: Adjusting The Pellet Insertion Stage

    002AZ001A ADJUSTMENTS 7.2.3 ADJUSTING THE PELLET INSERTION STAGE Two operations are to be carried out to adjust the pellet insertion stage. (References given in figure 7.2.2) Conditions: - Mode selector turned to SET-UP Mechanical adjustment This adjustment allows the cutters to be in the correct position in relation to the cavity when the pellet is inserted. This position can be changed by performing the following operations: - Turn on the electrical cabinet.

  • Page 93: Forming Unit

    002AZ001A ADJUSTMENTS Adjusting the position and length of insertion The position for insertion can be precisely adjusted (even during normal operation in automatic) by setting the parameters (delayed insertion) and (length of insertion) given on page “CCM” of the control display. The compressed air pressure can also be modified with the relative pressure regulator (see pneumatic system).
  • Page 94 002AZ001A ADJUSTMENTS Figure 7.3 - FORMING DRUM T2493 7 - 8...

  • Page 95: Product Removal Adjustment

    002AZ001A ADJUSTMENTS 7.3.1 PRODUCT REMOVAL ADJUSTMENT The strippers are mechanically controlled by cams. The position of the cams is given on the “Data sheet”. WARNING! E0004P Changing the position of the stripper cams among themselves and in relation to the actuator pilot cam may severely damage the tools and the mechanical stripping parts.

  • Page 96: Adjusting The Quality Control Unit

    002AZ001A ADJUSTMENTS 7.3.2 ADJUSTING THE QUALITY CONTROL UNIT MECHANICAL ADJUSTMENTS For proper operation, each reference surface must be 3 +/- 0.05 mm away from the sensor while the actuators carrying out the pressing cycle. Proceed as follows: - turn the mode key selector to set-up - open the safety guards - start the hydraulic power unit with the related button - activate the high pressure valve with the related button...
  • Page 97 002AZ001A ADJUSTMENTS ADJUSTING SENSITIVITY The sensitivity for quality checking can be adjusted by setting the “low threshold, defective caps” and the “high threshold, defective caps” parameters on the “CCM” page of the control display. This allows the dimension field within which the product is considered acceptable to be defined.

  • Page 98: Pneumatic System

    002AZ001A ADJUSTMENTS PNEUMATIC SYSTEM The following can be adjusted in the pneumatic system: - mains supply 0.5 MPa - pellet insertion line (consult the “Data sheet”) - product removal (consult the “Data sheet”) HYDRAULIC SYSTEM 7.5.1 ADJUSTING THE OIL FLOW UNDER LOW PRESSURE The stroke the actuator carries out to reach the punch is approximately 15 mm less than its total stroke and is carried out with oil under low pressure.
  • Page 99 002AZ001A ADJUSTMENTS Figure 7.5 - PRODUCT REMOVAL ADJUSTMENT 20 Inductive sensors 21 Measurement rod 22 Low pressure adjustment valve 23 High pressure flow control 24 Low pressure flow control 25 High pressure valve 26 Actuator downstroke valve T2498 (>) (<) T1580 T2520 7 - 13...

  • Page 100: Cooling System

    002AZ001A ADJUSTMENTS COOLING SYSTEM ATTENTION! E0004P Do not modify the values used for the thermostatic valve and temperatures set for the upper and lower tools, indicated on the Data sheet, under any circumstances. The thermostatic valve changes the oil temperature in the hydraulic system. This valve is adjusted manually. The temperature of the tools are set on the EXTRUDER PAGE of the microprocessor control system.
  • Page 101 002AZ001A ADJUSTMENTS Figure 7.7 - TOOLING Anti-rotation pin Stripper Coolant manifold Ring nut Nuts 10 Die Flange 11 Support plate Tool cartridge T1597 7 - 15...

  • Page 102: Adjusting The Exit Channel

    002AZ001A ADJUSTMENTS ADJUSTING THE EXIT CHANNEL Adjusting the angular position The exit channel can be turned to center the product with the downstream machine’s entry. Conditions: - Mode selector turned to set-up. Adjustments: - Loosen the screw (12). - Turn the cam (11) until the cap (16) is correctly positioned. - Loosen the screws (14) and adjust the position of the back-plate (17), if necessary.
  • Page 103 002AZ001A ADJUSTMENTS Figure 7.8 - ADJUSTING THE EXIT CHANNEL Belt with compartments Hole for wrench Screw Screw Product Back-plate Screw Paddle Wheel compartment Adjuster T2514 7 - 17...

  • Page 104: Replacing The Inductive Sensors

    002AZ001A ADJUSTMENTS REPLACING THE INDUCTIVE SENSORS When replacing the inductive sensors consult the chart below as they must be placed the correct distance away in order to read properly. If inductive proximity sensors SQ7, SQ23, SQ21, SQ22 or SQ24 are replaced, mark the position of the relative mounts on the base so that they can be put back in the same spot when replaced.

  • Page 105: Resetting The Encoders

    002AZ001A ADJUSTMENTS 7.10 RESETTING THE ENCODERS - Turn the mode selector switch to set-up. - Turn the unit with the handwheel for manual operations until inductive proximity sensors SQ1 and SQ11 are both activated (both of them must be activated). - Zero set the encoder (key turned to set-up).
  • Page 106 002AZ001A ADJUSTMENTS 7 - 20...

  • Page 107: Maintenance

    002AZ001A MAINTENANCE MAINTENANCE GENERAL INFORMATION AND SAFETY PRECAUTIONS WARNING! E0004P Only expert personnel who know how the machine and plant in general operate well can carry out maintenance, 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 board to OFF - remove the safety key - post a “maintenance in progress”...

  • Page 108: Scheduled Maintenance

    002AZ001A MAINTENANCE SCHEDULED MAINTENANCE 8.1.1 SCHEDULED MAINTENANCE CHART 8 - 2...
  • Page 109 002AZ001A MAINTENANCE 8 - 3...
  • Page 110 002AZ001A MAINTENANCE 8 - 4...
  • Page 111 002AZ001A MAINTENANCE 8 - 5...
  • Page 112 002AZ001A MAINTENANCE 8 - 6...
  • Page 113 002AZ001A MAINTENANCE 8 - 7...

  • Page 114: Periodic Maintenance Operations

    002AZ001A MAINTENANCE 8.1.2 PERIODIC MAINTENANCE OPERATIONS 8.1.2.1 Drive unit 8.1.2.1.1 Checking the condition of the drive belts - Take the covers off to reach toothed belts (4 and 5). - Make sure the teeth are not ruined (chipped or parts missing) and that there is not too much play between the tooth and pulley.

  • Page 115: Replacing The Insertion Unit Transmission Belt

    002AZ001A MAINTENANCE 8.1.2.1.5 Replacing the insertion unit transmission belt - Take off the bottom covers to reach the transmission belt. - Loosen the screw (12) and remove the sensor mount with the sensor. - Loosen the screws (10). - Loosen the nuts (11) and remove the plate with the encoder. - Loosen the nut (6).
  • Page 116 002AZ001A MAINTENANCE Figure 8.1.2.1 - DRIVE UNIT T2513 17 18 19 20 T2528 8 - 10...

  • Page 117: 50 Kg/H Extruder

    002AZ001A MAINTENANCE 8.1.2.2 50 kg/h Extruder 8.1.2.2.1 Overhauling the extruder auger - Remove the plastic compound from the auger chamber with the extruder at its operating temperature. To do this, carry out a by-pass operation until the plastic compound no longer flows out of the nozzle. ATTENTION! E0004P Stop feeding plastic compound to the extruder when cleaning.

  • Page 118: Checking The Oil Level In The Extruder Geared Motor And Topping Up

    002AZ001A MAINTENANCE 8.1.2.2.2 Checking the oil level in the extruder geared motor and topping up - Make sure the oil level, shown by the gauge (33), is correct. If it is not, top up as follows: - Take off the cap (31). - Add oil until the correct level (33) is reached.
  • Page 119 002AZ001A MAINTENANCE Figure 8.1.2.2 - 50 kg/h EXTRUDER T2575 8 - 13...

  • Page 120: Checking And Setting Pressure Transducers Bp1 And Bp2

    002AZ001A MAINTENANCE 8.1.2.2.5 Checking and setting pressure transducers BP1 and BP2 If one or both of the transducers read a pressure other than zero while the extruder is not working, set them as directed below. The procedure given below also has to be carried out when a new transducer is installed before starting the machine. A - Start the temperature regulator for the extruder and wait until all the work zones reach the work temperature.
  • Page 121 002AZ001A MAINTENANCE Figure 8.1.2.2.5 - CHECKING AND SETTING PRESSURE TRANSDUCERS BP1 AND BP2 SYSTEM SYSTEM T2580 8 - 15...

  • Page 122: Kg/H Extruder

    002AZ001A MAINTENANCE 8.1.2.3 100 kg/h Extruder Figure 8.1.2.3 - 100 kg/h EXTRUDER T2532 T2535 8 - 16...

  • Page 123: Overhauling The Extruder Auger

    002AZ001A MAINTENANCE 8.1.2.3.1 Overhauling the extruder auger - Remove the plastic compound from the auger chamber with the extruder at its operating temperature. To do this, carry out a by-pass operation until the plastic compound no longer flows out of the nozzle. ATTENTION! E0004P Stop feeding plastic compound to the extruder when cleaning.

  • Page 124: Checking The Oil Level In The Extruder Geared Motor And Topping Up

    002AZ001A MAINTENANCE - Install the auger in the extruder. Make sure the grooved extruder profile properly mats with the auger. Make certain the cover on the extruder head is completely tightened (make sure the auger is fully in). - Install the filter (3). - Install the heating elements (9).

  • Page 125: Lubricating The Universal Joint

    - When overhauling the pump, follow the directions given in the User Manual furnished by the manufacturer supplied with the pump or contact SACMI Customer Service Department. - Install the overhauled or new pump by carrying out the operations in reverse order.
  • Page 126 002AZ001A MAINTENANCE E - Adjust trimmer N until the display reads zero Bar while the extruder is at a standstill. Remove the protective screw seen from the outside in order to access trimmer N, located on the bottom of the transducer body.

  • Page 127: Checking The Condition And Tensioning The Extruder Drive Belt

    002AZ001A MAINTENANCE 8.1.2.3.9 Checking the condition and tensioning the extruder drive belt - Take off the side panels found in the area where the motor is installed. - Take off the cover (17). - Make sure the belt (18) has not slackened and that the teeth are not ruined. If one of these problems is present, proceed as directed below.

  • Page 128: Kg/H Extruder

    002AZ001A MAINTENANCE 8.1.2.4 150-200 kg/h Extruder Figure 8.1.2.4 - 150-200 kg/h EXTRUDER T2535 T2534 8 - 22...

  • Page 129: Overhauling The Extruder Auger

    002AZ001A MAINTENANCE 8.1.2.4.1 Overhauling the extruder auger - Remove the plastic compound from the auger chamber with the extruder at its operating temperature. To do this, carry out a by-pass operation until the plastic compound no longer flows out of the nozzle. ATTENTION! E0004P Stop feeding plastic compound to the extruder when cleaning.

  • Page 130: Checking The Oil Level In The Polymer Metering Pump Geared Motor And Topping Up

    002AZ001A MAINTENANCE - Install the auger in the extruder. Make sure the grooved extruder profile properly mats with the auger. Make certain the cover on the extruder head is completely tightened (make sure the auger is fully in). - Install the filter (3). - Install the heating element (9).
  • Page 131 - When overhauling the pump, follow the directions given in the User Manual furnished by the manufacturer supplied with the pump or contact SACMI Customer Service Department. - Install the overhauled or new pump by carrying out the operations in reverse order.
  • Page 132 002AZ001A MAINTENANCE 8.1.2.4.8 Lubricating the universal joint - Take off the cover (29). - Clean the universal joint and surrounding areas removing any extruded plastic material. - Grease with the grease fittings (30). - Put the cover (29) back on. 8.1.2.4.9 Cleaning the nozzle - Remove the plastic compound that has deposited on the nozzle (24) during operation.
  • Page 133 002AZ001A MAINTENANCE Figure 8.1.2.4.10 - CHECKING AND SETTING PRESSURE TRANSDUCERS BP1 AND BP2 SYSTEM SYSTEM T2580 8 - 27...
  • Page 134 002AZ001A MAINTENANCE 8.1.2.4.11 - Setting pressure switch SP8 and pressure relief valve YV8 - Disconnect the delivery hose from the hydraulic motor. - Plug the disconnected hose. - Place a pressure gauge with a 400 bar end scale value in the seat provided on the extruder’s hydraulic control assembly.
  • Page 135 002AZ001A MAINTENANCE 8.1.2.5 Insertion drum Figure 8.1.2.5/A - INSERTION DRUM T2548 T2574 8 - 29...
  • Page 136 002AZ001A MAINTENANCE Figure 8.1.2.5/B - INSERTION DRUM T2551 SURFACE TO BE ADAPTED T2552 CORRECT POSITION POSITION WITH BELT SLACKENED 8 - 30...
  • Page 137 002AZ001A MAINTENANCE 8.1.2.5.1 Sharpening the cutters - Loosen the two screws (26) and remove the cutter (25). - Use an oilstone on the worktable with clamp to sharpen the cutting edges. - Install the cutters and adjust as directed in the ADJUSTING THE CUTTER paragraph in chapter 7. 8.1.2.5.2 Replacing the cutters - Loosen the two screws (26) and remove the cutter (25).
  • Page 138 002AZ001A MAINTENANCE 8.1.2.5.6 Replacing the nozzles - Carry out the same operations as those indicated in the CLEANING THE NOZZLES paragraph, replacing the old nozzle with the new one. 8.1.2.5.7 Cleaning the compressed air distributor - Loosen the screws (13) and ring nut (17). - Pull out the insertion drum lifting the entire unit up from the cutter holder.
  • Page 139 002AZ001A MAINTENANCE 8.1.2.5.13 Replacing gears G - Loosen the screws (13, 14 and 16) and ring nut (17). - Remove the parts left free by screw ( 14). - Pull out the insertion drum. lifting the entire unit up from the cutter holder. - Loosen the screws (18) at the worktable.
  • Page 140 002AZ001A MAINTENANCE 8.1.2.5.16 Disassembling the pulley/toothed wheel C - Loosen the nut (4). - Loosen the screws (40) that secure the tensioner so that the belt can be slackened. - Loosen the self-locking nut (7) and pull out the cap exit conveyor belt. - Loosen the screws (10) and remove the plate.
  • Page 141 002AZ001A MAINTENANCE 8.1.2.5.19 Replacing the toothed belt B - Loosen the nut (4). - Loosen the screws (40) that secure the tensioner so that the belt can be slackened. - Loosen the self-locking nut (7) and pull out the cap exit conveyor belt. - Loosen the screws (10) and remove the plate.
  • Page 142 002AZ001A MAINTENANCE 8.1.2.6 Forming unit Figure 8.1.2.6 - FORMING UNIT T2537 T2553 8 - 36...
  • Page 143 002AZ001A MAINTENANCE 8.1.2.6.1 Cleaning - Remove any extraneous matter, paying special attention to the following parts: • Check and remove any caps or waste material found on the machine base. • Clean the cavities (5) inside and outside as well as the surrounding area, removing any plastic compound or caps present.
  • Page 144 002AZ001A MAINTENANCE ATTENTION! E0004P Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself. 8.1.2.6.5 Replacing the upper flange gaskets - Shut off electricity to the machine with the main switch located on the cabinet. ATTENTION! E0004P The actuators...
  • Page 145 002AZ001A MAINTENANCE ATTENTION! E0004P Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself. 8.1.2.6.7 Greasing the roller and stripper rod pin - Grease the rod wheel with grease fitting (15) found on the support pin for the wheel. Use the grease gun provided. 8.1.2.6.8 Lubricating the stripper rod guide bushes - Loosen the nut (10) and take out the spacer.
  • Page 146 002AZ001A MAINTENANCE 8.1.2.7 Cams Figure 8.1.2.7 - CAMS T2538 T2539 8 - 40...
  • Page 147 002AZ001A MAINTENANCE 8.1.2.7.1 Greasing and checking - Check the condition of the cam raceway. If the raceway is worn, replace it without delay. - Grease the cam raceway. To grease the actuator control cams, take off the covers (8) using the mounting screws provided.
  • Page 148 002AZ001A MAINTENANCE 8.1.2.8 Rotary distributor 8.1.2.8.1 Replacing the gaskets - Contact SACMI’S CUSTOMER SERVICE DEPARTMENT when carrying out this operation. 8.1.2.9 Hydraulic system Figure 8.1.2.9/A - HYDRAULIC SYSTEM T2542 8 - 42...
  • Page 149 002AZ001A MAINTENANCE Figure 8.1.2.9/B - HYDRAULIC SYSTEM T2543 T2555 T2565 8 - 43...
  • Page 150 002AZ001A MAINTENANCE 8.1.2.9.1 Checking the oil level in the hydraulic power unit - Make sure the oil level falls within the full and low level marks indicated on gauge (1). If the level is below minimum pour in oil through the hole under the cap (7). 8.1.2.9.2 Changing the oil in the hydraulic power unit - Unscrew the cap (7)
  • Page 151 002AZ001A MAINTENANCE 8.1.2.9.9 Cleaning control valve Pb - Unscrew the control valve (21). - Loosen the screws (20) and lift up the block. - Remove the part (30) by hand. - Clean the regulator, block and part using compressed air. - Carry out the operations in reverse order to put the parts back in place.
  • Page 152 002AZ001A MAINTENANCE 8.1.2.10 Air supply system 8.1.2.10.1 Cleaning the filter - Loosen the screw (4), found under the filter (1), to let out any extraneous matter (for example: water created by the condensate). 8.1.2.10.2 Cleaning and replacing the silencers - Unscrew the silencers (3) and/or silencer (2). - Blow compressed air to clean or replace, if necessary.
  • Page 153 002AZ001A MAINTENANCE 8.1.2.11 Cooling system 8.1.2.11.1 Checking the coolant level - Make sure the coolant level does not fall below the low level mark indicated on gauge (1). If the level is near or below minimum add coolant as directed below. 8.1.2.11.2 Adding coolant - Unscrew the cap (2).
  • Page 154 002AZ001A MAINTENANCE 8.1.2.12 Safety devices 8.1.2.12.1 Checking the efficiency of the safety devices - With the machine set to automatic or manual mode, open one of the two protective panels (1). WARNING! E0004P The machine must not be running. - Make sure the “GUARDS OPEN” fault message appears on the control panel display. - Close the panels.
  • Page 155 002AZ001A MAINTENANCE 8.1.2.13 Air injection device 8.1.2.13.1 Checking the valves - See if air flows out of the valve (22) when it is not activated by cams (1 and 2). 8.1.2.13.2 Replacing the valves - Loosen the screws (21) when the valve is not activated (to be carried out on the side opposite the operator). - Detach the air hose from valve (22).
  • Page 156 002AZ001A MAINTENANCE 8.1.2.14 Product exit conveyor belt 8.1.2.14.1 Checking the condition of the belt - Check the condition of the belt (33). Make sure the teeth are not excessively rounded or broken. Make sure the paddles that convey the caps are not broken or damaged in any way. If problems are found, replace the belt as directed below.
  • Page 157 002AZ001A MAINTENANCE 8.1.3 LUBRICATION 8.1.3.1 Lubricant specifications 23°E - 50°C ISO 3498 - CC 320 (320 cSt. - 40°C) OIL HLP DIN 51524-2 VG46 OIL PRESS 3000 ISO 46 GREASE Dropping point 200 °C - Worked penetration (DIN 51804) 300 dmm - Dynamic toughness 7000 mPas Density at 20 °C 0.92 - Dropping point (DIN ISO 2176) >...
  • Page 158 002AZ001A MAINTENANCE 8.1.4 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS S.R. = Resisting section (mm = Tightening torque (kgm) = Pre-load (corresponding to the tightening torque) (Kg). NORMAL THREAD SCREWS DIAMETER THREAD 0.70 0.80 1.00 1.25 1.25 1.50 1.75 2.00 2.00 2.50 2.50...
  • Page 159 002AZ001A MAINTENANCE TROUBLESHOOTING Whenever the machine shuts down, an error code along with a brief description appear on the control unit display. Refer to the Instructions B manual for information on how to locate and clear the trouble. If safety devices come into action, reset the machine as described in chapter 6 - OPERATING INSTRUCTIONS.
  • Page 160 002AZ001A MAINTENANCE CAUSE TROUBLE REMEDY Operating parameters incorrectly set: Irregular pellet insertion; some Set the parameters as specified on operating pressure, length of pellets are rejected or lost; cutting the “Data sheet” insertion, insertion delay burrs Cutter blades worn Sharpen or replace Cutter body dirty Clean or replace Cutter body not the right size...
  • Page 161 002AZ001A MAINTENANCE TROUBLE CAUSE REMEDY Actuators do not operate Incorrect low pressure flow rate Set the parameter as required (see properly: the dies do not close “Data sheet”) correctly Hydraulic accumulator precharge Charge the accumulators with decreased nitrogen until the correct value is reached Oil temperature too high Thermostatic valve incorrectly set...
  • Page 162 002AZ001A MAINTENANCE 8 - 56...
  • Page 163 002AZ001A DECOMMISSIONING DECOMMISSIONING MAKING THE MACHINE INOPERATIVE WHEN NO LONGER USED The operations given below need to be carried out when the machine is no longer used: - Turn off the machine’s power supply by using the factory’s main switch. - Unplug the power cable from the electrical cabinet’s terminal block.
  • Page 164 002AZ001A DECOMMISSIONING 9 - 2...

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