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T E C H N I C A L D O C U M E N TAT I O N
USER’S MANUAL
002AZ019A ROTARY COMPRESSION MOLDING PRESS
CCM32M
LISH
ENG
Translation of original instructions
002AZ019A USER’S MANUAL ROTARY COMPRESSION MOLDING PRESS
CCM32M
MANUFACTURER S.C. Via Selice Provinciale, 17/A 40026 IMOLA (Bologna) - ITALIA www.sacmi.com
PUBLISHED ON 30.07.2008 - 15.09.2010
VERSIONS CCM32MA
002AZ019A
002AZ019A TABLE OF CONTENTS Page 1
GENERAL INFORMATION............................................................................................................................ 1-1 1.1 INTRODUCTION......................................................................................................................... 1-1 1.2 WHERE TO KEEP THE MANUAL............................................................................................... 1-1 1.3 HOW TO USE THE MANUAL.....................................................................................................1-2 1.4 USERS OF THE MANUAL..........................................................................................................1-2 1.5 WARRANTY................................................................................................................................1-3 1.6 SUPPLEMENTS..........................................................................................................................1-3 1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL........................................................................................................................1-4 1.8 MACHINE IDENTIFICATION PLATE...........................................................................................1-6 1.9 DECLARATION OF CONFORMITY............................................................................................ 1-7
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MACHINE FEATURES...................................................................................................................................2-1 2.1 MACHINE DESCRIPTION........................................................................................................... 2-1 2.1.1 MAIN DEVICES...........................................................................................................................2-2 2.1.1.1 Plasticization unit........................................................................................................................2-2 2.1.1.1.1 Extruder......................................................................................................................................2-3 2.1.1.1.2 Metering pump (optional)...........................................................................................................2-4 2.1.1.1.3 Feed tube....................................................................................................................................2-5 2.1.1.1.4 By-pass system.......................................................................................................................... 2-7 2.1.1.2 Drive unit.....................................................................................................................................2-8 2.1.1.3 Insertion turret............................................................................................................................2-9 2.1.1.4 Molding unit.............................................................................................................................. 2-12 2.1.1.5 Exit conveyor belt..................................................................................................................... 2-15 2.1.1.6 Pneumatic system.................................................................................................................... 2-15 2.1.1.7 Hydraulic system...................................................................................................................... 2-15 2.1.1.8 Cooling system......................................................................................................................... 2-15 2.1.1.9 Electric system: control board................................................................................................. 2-15 2.1.1.10 Molds........................................................................................................................................ 2-15 2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE................................................... 2-16 2.2 OVERALL DIMENSIONS.......................................................................................................... 2-17 2.3 TECHNICAL DATA.................................................................................................................... 2-18 2.3.1 SPECIFICATIONS..................................................................................................................... 2-18 2.3.2 ALLOWABLE FLUCTUATIONS................................................................................................. 2-19 2.3.3 RATING PLATE......................................................................................................................... 2-19 2.3.4 OPERATIONAL CHARACTERISTICS.......................................................................................2-20 2.3.5 AIRBORNE NOISE EMISSION LEVELS...................................................................................2-22 2.3.5.1 Sound pressure level . .............................................................................................................2-22 2.3.5.2 Acoustic power level ...............................................................................................................2-23 2.3.6 DATA SHEET............................................................................................................................. 2-24 2.4 DIAGRAMS...............................................................................................................................2-26 2.4.1 PNEUMATIC SYSTEM DIAGRAM............................................................................................2-26 2.4.2 HYDRAULIC SYSTEM DIAGRAM............................................................................................2-29 2.4.3 COOLING SYSTEM DIAGRAM.................................................................................................2-32
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002AZ019A TABLE OF CONTENTS Page 3
SAFETY EQUIPMENT AND PRECAUTIONS...............................................................................................3-1 3.1 SAFETY DEVICES AND GUARDS..............................................................................................3-1 3.1.1 GENERAL SAFETY RULES........................................................................................................3-1 3.1.1.1 Required environmental conditions for correct machine operation .........................................3-1 3.1.2 SAFETY DEVICES INSTALLED..................................................................................................3-2 3.1.2.1 Shutdown devices......................................................................................................................3-2 3.1.2.2 Indicating a shutdown................................................................................................................3-2 3.1.2.3 Devices to safeguard the operators...........................................................................................3-2 3.1.2.4 Emergency stop buttons............................................................................................................3-2 3.2 SAFETY RULES FOR HANDLING..............................................................................................3-4 3.2.1 SLINGING THE LOADS..............................................................................................................3-4 3.2.2 HOISTING...................................................................................................................................3-4 3.2.3 PLACEMENT..............................................................................................................................3-4 3.2.4 GUIDE LINES FOR USING THE LIFT EQUIPMENT...................................................................3-5 3.3 INSTALLATION.......................................................................................................................... 3-6 3.3.1 GUIDELINES.............................................................................................................................. 3-6 3.4 OPERATOR TRAINING...............................................................................................................3-7 3.4.1 END-USER.................................................................................................................................3-7 3.4.2 OPERATORS..............................................................................................................................3-7 3.4.3 MAINTENANCE STAFF..............................................................................................................3-8 3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THE MACHINE...3-9 3.5.1 GENERAL SAFETY RULES........................................................................................................3-9 3.5.2 NOTES REGARDING USE AND MAINTENANCE.................................................................... 3-12 3.5.2.1 Risks deriving from high temperatures.................................................................................... 3-12 3.5.2.2 Risk of explosion...................................................................................................................... 3-12 3.5.2.3 Accessing the machine............................................................................................................ 3-13 3.5.2.3.1 Accessing the waste container compartment......................................................................... 3-14 3.5.2.3.2 Safety guards with mechanical lock........................................................................................ 3-15 3.5.2.4 Accessing the extruder outlet ................................................................................................. 3-16 3.5.2.5 Risks from excessive air pressure............................................................................................ 3-17 3.5.2.6 Cut hazards.............................................................................................................................. 3-18 3.6 MACHINE DECOMMISSIONING AND DISASSEMBLY............................................................ 3-19 3.6.1 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED.................................................. 3-19 3.6.2 DISASSEMBLING THE MACHINE............................................................................................3-20
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INSTALLATION..............................................................................................................................................4-1 4.1 SHIPPING, HANDLING AND POSITIONING THE MACHINE.....................................................4-1 4.1.1 MACHINE DIVISION...................................................................................................................4-3 4.1.2 DIMENSION AND WEIGHTS......................................................................................................4-3 4.1.3 SYSTEMS FOR LIFTING INDIVIDUAL PARTS...........................................................................4-3 4.2 INSTALLATION...........................................................................................................................4-4 4.3 CONNECTIONS AND HOOK UPS.............................................................................................4-6 4.3.1 CONNECTING THE HYDRAULIC SYSTEM...............................................................................4-6 4.3.2 HOOKING UP THE COOLANT SYSTEM....................................................................................4-8 4.3.3 HOOKING UP THE PNEUMATIC SYSTEM.............................................................................. 4-10 4.3.4 CONNECTING THE VACUUM SYSTEM................................................................................... 4-11 4.3.5 ELECTRIC HOOK UP............................................................................................................... 4-12 4.3.5.1 Connecting the electric cables................................................................................................. 4-13 4.3.5.2 Earth connection...................................................................................................................... 4-15 4.3.5.3 Connecting the power cable.................................................................................................... 4-16
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002AZ019A TABLE OF CONTENTS Page 5
START UP 5.1 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.3
....................................................................................................................................................5-1 INTRODUCTION.........................................................................................................................5-1 FIRST TIME START UP...............................................................................................................5-2 PRELIMINARY CHECKS............................................................................................................5-2 CHECKING OPERATION............................................................................................................5-3 PRELIMINARY OPERATIONS....................................................................................................5-4 STARTING THE AUTOMATIC CYCLE.........................................................................................5-5 SUBSEQUENT START UPS.......................................................................................................5-5
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OPERATING INSTRUCTIONS......................................................................................................................6-1 6.1 OPERATOR INTERFACE............................................................................................................6-1 6.2 WORK CYCLES......................................................................................................................... 6-4 6.2.1 WORK CYCLES IN MANUAL/SET UP MODE........................................................................... 6-4 6.2.1.1 Draining the nozzle.................................................................................................................... 6-4 6.2.1.2 Actuator upstroke to install/remove tools ................................................................................ 6-5 6.2.2 AUTOMATIC CYCLE...................................................................................................................6-7 6.2.2.1 Preheating..................................................................................................................................6-7 6.2.2.2 Running the machine................................................................................................................. 6-8 6.2.2.3 Stopping the machine............................................................................................................... 6-8 6.3 PRODUCTION CYCLE................................................................................................................6-9 6.4 SHUTDOWN CYCLES AND RESET OPERATIONS.................................................................. 6-12 6.4.1 EMERGENCY SHUTDOWN WITH FAULT MESSAGE 1........................................................... 6-12 6.4.2 EMERGENCY SHUTDOWN WITH FAULT MESSAGE 3…....................................................... 6-13 6.5 PRODUCT SAMPLING............................................................................................................. 6-14
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002AZ019A TABLE OF CONTENTS Page 7
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ADJUSTMENTS............................................................................................................................................. 7-1 7.1 PLASTICIZATION UNIT.............................................................................................................. 7-1 7.1.1 EXTRUDER................................................................................................................................. 7-1 7.1.2 METERING PUMP ADJUSTMENTS........................................................................................... 7-2 7.1.3 FEED TUBE, MIXER (IF PRESENT), NOZZLE CASING, NOZZLE..............................................7-3 7.2 INSERTION TURRET..................................................................................................................7-4 7.2.1 ADJUSTING THE TURRET’S CONNECTING ROD....................................................................7-4 7.2.1.1 Adjusting turret’s connecting rod precharge.............................................................................7-6 7.2.1.2 Checking turret connecting rod precharge................................................................................ 7-7 7.2.2 ADJUSTING THE CUTTER.........................................................................................................7-8 7.2.3 ADJUSTING PELLET INSERTION TIMING................................................................................7-9 7.2.3.1 Resetting the encoder.............................................................................................................. 7-10 7.2.3.2 Adjusting the pellet insertion stage.......................................................................................... 7-10 7.2.3.3 Adjusting the position and length of insertion..........................................................................7-11 7.2.3.4 Adjusting the stripper wheels................................................................................................... 7-12 7.2.3.5 Adjusting the transfer wheel with vacuum .............................................................................. 7-12 7.3 ADJUSTING THE MOLDING TURRET..................................................................................... 7-13 7.3.1 ADJUSTING THE PRODUCT STRIPPER CAMS...................................................................... 7-13 7.3.2 ADJUSTING THE QUALITY CONTROL UNIT.......................................................................... 7-13 7.3.2.1 Transducer BQ2 mechanical adjustments............................................................................... 7-13 7.3.2.2 Setting / saving the reference distance .................................................................................. 7-14 7.3.2.3 Adjusting sensitivity.................................................................................................................. 7-15 7.4 PNEUMATIC SYSTEM ADJUSTMENTS................................................................................... 7-16 7.4.1 PRESSURE SWITCH SP1......................................................................................................... 7-16 7.4.2 PRESSURE SWITCH SP7......................................................................................................... 7-17 7.5 HYDRAULIC SYSTEM ADJUSTMENTS................................................................................... 7-18 7.5.1 ADJUSTING THE APPROACH STAGE (LOW PRESSURE)...................................................... 7-20 7.5.2 ADJUSTING THE MOLDING STAGE (HIGH PRESSURE)........................................................ 7-20 7.5.3 ADJUSTING THE ACTUATOR DOWNSTROKE........................................................................ 7-20 7.6 ADJUSTING THE TEMPERATURE CONTROLLER.................................................................. 7-21 7.7 ADJUSTING THE MOLDS........................................................................................................ 7-21 7.8 ADJUSTING THE EXIT CONVEYOR BELT............................................................................... 7-22 7.8.1 ADJUSTING THE HEIGHT OF THE EXIT CONVEYOR BELT................................................... 7-23 7.8.2 TENSIONING THE CONVEYOR BELT . ................................................................................... 7-23 7.8.3 ADJUSTING THE GUIDES........................................................................................................ 7-23 7.9 REPLACING THE SENSORS.................................................................................................... 7-24 7.10 ADJUSTING THE EMERGENCY BRAKING SYSTEM.............................................................. 7-28 7.10.1 BRAKING ANGLE WIDER THAN NORMAL BUT IN ANY CASE ACCEPTABLE...................... 7-28 7.10.2 BRAKING ANGLE TOO WIDE.................................................................................................. 7-28 7.10.3 EMERGENCY BRAKING SYSTEM ADJUSTMENT PROCEDURE........................................... 7-29
002AZ019A TABLE OF CONTENTS Page 8
MAINTENANCE.............................................................................................................................................8-1 8.1 ROUTINE MAINTENANCE ........................................................................................................8-2 8.1.1 SCHEDULED MAINTENANCE CHART......................................................................................8-2 8.1.2 PERIODIC MAINTENANCE OPERATIONS.................................................................................8-9 8.1.2.1 Drive unit.....................................................................................................................................8-9 8.1.2.1.1 Checking the condition of the drive belts ............................................................................... 8-10 8.1.2.1.2 Tensioning the molding turret transmission belts ................................................................... 8-10 8.1.2.1.3 Replacing the molding turret transmission belts .................................................................... 8-10 8.1.2.1.4 Tensioning the insertion unit transmission belt ...................................................................... 8-10 8.1.2.1.5 Replacing the insertion unit transmission belt . ...................................................................... 8-11 8.1.2.1.6 Checking the oil level in the molding turret gear motor .......................................................... 8-11 8.1.2.1.7 Changing the oil in the molding turret gear motor .................................................................. 8-11 8.1.2.2 Plasticization unit...................................................................................................................... 8-12 8.1.2.2.1 Overhauling the extruder auger................................................................................................ 8-13 8.1.2.2.2 Checking the oil level and adding oil in the extruder gearbox................................................. 8-15 8.1.2.2.3 Changing the oil in the extruder gearbox................................................................................. 8-16 8.1.2.2.4 Cleaning the polymer metering pump...................................................................................... 8-16 8.1.2.2.5 Replacing/overhauling the polymer metering pump................................................................ 8-16 8.1.2.2.6 Lubricating the universal joint.................................................................................................. 8-18 8.1.2.2.7 Cleaning the nozzle.................................................................................................................. 8-19 8.1.2.2.8 Checking and setting pressure transducers BP1 and BP2..................................................... 8-19 8.1.2.2.9 Lubricating the extruder motor bearings.................................................................................8-21 8.1.2.3 Insertion turret..........................................................................................................................8-22 8.1.2.3.1 Cutters with insertion blower...................................................................................................8-24 8.1.2.3.1.1 Sharpening the blades.............................................................................................................8-24 8.1.2.3.1.2 Replacing the blades................................................................................................................8-24 8.1.2.3.1.3 Cleaning the cutters ................................................................................................................8-24 8.1.2.3.1.4 Replacing the blades . .............................................................................................................8-24 8.1.2.3.1.5 Cleaning or replacing the nozzles............................................................................................8-25 8.1.2.3.2 Cutters with insertion piston....................................................................................................8-26 8.1.2.3.2.1 Rotating the blades..................................................................................................................8-26 8.1.2.3.2.2 Sharpening the blades.............................................................................................................8-26 8.1.2.3.2.3 Replacing the blades................................................................................................................8-26 8.1.2.3.2.4 Cleaning the cutters with insertion piston...............................................................................8-26 8.1.2.3.2.5 Replacing the cutters ..............................................................................................................8-26 8.1.2.3.3 Cleaning the compressed air distributor..................................................................................8-27 8.1.2.3.4 Replacing the compressed air distributor................................................................................8-27 8.1.2.3.5 Checking precharge of the turret connecting rod....................................................................8-27 8.1.2.3.6 Adjusting precharge of the turret connecting rod....................................................................8-27 8.1.2.3.7 Tensioning the insertion turret drive belt..................................................................................8-28 8.1.2.3.8 Replacing the insertion turret drive belt...................................................................................8-28 8.1.2.3.9 Replacing the pulley (item 10)..................................................................................................8-29 8.1.2.3.10 Replacing the toothed wheel (item 5).......................................................................................8-29 8.1.2.3.11 Replacing the toothed wheel (item 7).......................................................................................8-30 8.1.2.3.12 Replacing the pulley (item 8)....................................................................................................8-30 8.1.2.3.13 Checking wear and tear and lubricating the gears..................................................................8-30 8.1.2.4 Molding turret ..........................................................................................................................8-31 8.1.2.4.1 Cleaning....................................................................................................................................8-32 8.1.2.4.2 Overhauling the actuator valve.................................................................................................8-32 8.1.2.4.3 Greasing the actuator valve rollers...........................................................................................8-32 8.1.2.4.4 Greasing the stripper rod rollers..............................................................................................8-32 8.1.2.4.5 Replacing the hydraulic actuator gasket..................................................................................8-33 8.1.2.4.6 Replacing the upper flange gaskets.........................................................................................8-34 8.1.2.4.7 Replacing the lower flange gaskets.........................................................................................8-34 8.1.2.4.8 Lubricating the stripper rod guide bushes...............................................................................8-35 8.1.2.4.9 Greasing the central tool wheel (optional)................................................................................8-35 8.1.2.4.10 Greasing the turret bearings....................................................................................................8-35 0-9
002AZ019A TABLE OF CONTENTS Page 8.1.2.4.11 8.1.2.4.12 8.1.2.5 8.1.2.5.1 8.1.2.5.2 8.1.2.5.3 8.1.2.5.4 8.1.2.5.5 8.1.2.6 8.1.2.6.1 8.1.2.6.2 8.1.2.6.3 8.1.2.6.4 8.1.2.6.5 8.1.2.6.6 8.1.2.6.7 8.1.2.7 8.1.2.7.1 8.1.2.7.2 8.1.2.7.3 8.1.2.8 8.1.2.8.1 8.1.2.8.1.1 8.1.2.8.1.2 8.1.2.9 8.1.2.9.1 8.1.2.9.2 8.1.2.10 8.1.2.11 8.1.2.11.1 8.1.2.11.2 8.1.2.11.3 8.1.2.12 8.1.2.12.1 8.1.2.12.2 8.1.2.12.3 8.2 8.3 8.4 8.4.1 9
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Replacing the gaskets and rotary distributor bearings............................................................8-35 Checking tightness of the lower flange ring nuts.....................................................................8-39 Cams........................................................................................................................................8-40 Greasing and checking............................................................................................................8-41 Replacing the stripper cams (central movement) (optional) ...................................................8-41 Replacing the stripper cams (side movement) . ......................................................................8-41 Replacing the actuator control cams ......................................................................................8-41 Replacing the cams for injecting air in the punches ...............................................................8-41 Hydraulic system......................................................................................................................8-42 Checking the accumulator’s precharge...................................................................................8-42 Checking the oil level in the hydraulic power unit................................................................... 8-44 Changing the oil in the hydraulic power unit........................................................................... 8-45 Replacing the filter in the hydraulic power unit....................................................................... 8-45 Replacing the hydraulic power unit couplings and suction filter............................................ 8-45 Checking for condensate on the bottom of the tank.............................................................. 8-45 Cleaning the solenoid valves................................................................................................... 8-46 Cooling system.........................................................................................................................8-47 Cleaning/changing the filters....................................................................................................8-47 Checking the coolant level/topping up................................................................................... 8-48 Changing the coolant.............................................................................................................. 8-48 Pneumatic system....................................................................................................................8-49 Air injection device...................................................................................................................8-49 Checking the valves.................................................................................................................8-49 Replacing the valves.................................................................................................................8-49 Product exit conveyor belt.......................................................................................................8-50 Replacing the conveyor belt.....................................................................................................8-51 Cleaning the slots in the exit conveyor belt slide surface........................................................8-51 Vacuum systems .....................................................................................................................8-52 Safety devices......................................................................................................................... 8-53 Checking operation of the emergency stop buttons.............................................................. 8-53 Checking the door interlocking devices.................................................................................. 8-53 Checking the visual/audible indicators................................................................................... 8-53 Electrical system..................................................................................................................... 8-54 Cleaning and servicing the electrical cabinets....................................................................... 8-54 Checking cabinet and electrical box closure.......................................................................... 8-54 Air conditioner maintenance (if present)................................................................................. 8-54 EXTRAORDINARY MAINTENANCE OPERATIONS.................................................................8-55 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS..........................................................8-56 TROUBLESHOOTING GUIDE..................................................................................................8-57 Troubleshooting the machine.....................................................................................8-57
DECOMMISSIONING....................................................................................................................................9-1 9.1 MACHINE DECOMMISSIONING................................................................................................9-1 9.2 DISASSEMBLY...........................................................................................................................9-2
002AZ019A
GENERAL INFORMATION
1
GENERAL INFORMATION
1.1
INTRODUCTION
E0004
1
WARNING!
Carefully read the entire User’s Manual before working on the machine and/or the packaging of the various parts. This manual contains important information for safeguarding the operators, the maintenance staff as well as the machine itself. The company using the machine must always assure all operators have completely read and become familiar with the operating instructions. Notwithstanding the machine is equipped with active and passive safety devices, all risks resulting from incorrect use cannot be avoided. SACMI shall not be held responsible for failure to heed to the safety and accident prevention rules and standards underlined in this manual and property damage and personal injury resulting from unintended, inappropriate and erroneous use of the machine. Any changes to the machine must be duly authorized by SACMI in advance. All work done on the machine (maintenance, adjustments, repairs, cleaning) must be carried out by properly trained personnel following the directions contained in this manual. SACMI reserves the right to make technical changes to the machine and this manual without giving prior notice. Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department. Copyright. All rights reserved. This publication or parts of it are valuable trade secrets and must not be copied, stored, reproduced, disclosed, transferred or translated into any language, spoken or computer, in any form or by any means without the express written consent of SACMI. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI SACMI guarantees the contents of this publication. It is severely forbidden to use this publication for other purposes, whatever they may be, that are extraneous to operation of the machine for which this publication has been drawn up. The information contained herein is guaranteed as being correct only if the user carefully follows all the guidelines and instructions provided in this publication.
1.2
E0004
WHERE TO KEEP THE MANUAL
WARNING!
This manual and supplements: - are to be considered an essential part of the machine and must be kept along with it even if the machine is sold; - must always be kept in an easy-to-reach place near the machine protected against environmental agents that may ruin them; - must always be available and close by so that operators are able to consult them rapidly at any time.
1-1
002AZ019A 1 1.3
GENERAL INFORMATION 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 grouped together 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. Notes fundamental for the safety or health of operators are given inside a block pointed out by alert, warning and/or danger symbols and written in italics, as shown below.
E0004
IMPORTANT!
Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must be carefully read in its entirety several times as it contains important 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 OPERATOR TRAINING paragraph in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.
E0004
IMPORTANT!
The term “operator” is also generically used to identify a person who has to work on the machine: operator, maintenance worker, etc..
1-2
002AZ019A
GENERAL INFORMATION
1.5
1
WARRANTY
As set forth in the assumed warranty, SACMI shall be held responsible only for the machine in its original configuration and towards the individual who stipulated the sales contract with SACMI or, in the case of leased machinery, the user named by the leasing company. Any operations that alter the configuration of the machine or work cycle must be carried out or duly authorized by SACMI. SACMI shall not be held responsible for any consequences deriving from installation or use of non-original spare parts, operations performed by the purchaser’s technicians or in the case of leased machinery, the user named by the leasing company and/or technicians not duly authorized by SACMI and not described in this manual and/or for whom supervision by SACMI is required and/or whom have not been expressly authorized by SACMI. The warranty is contingent on proper use of the machine in accordance with the instructions provided by the manufacturer. The warranty does not cover parts subject to wear and tear. The warranty is void in the following cases: - required maintenance jobs not performed; - altering, tampering or misuse of the machine; - if spare parts different from the ones originally installed in the machine are used; - if modifications are made SACMI shall not be held liable for machine damage caused by misuse or malfunctioning of other equipment connected to the machine. The warranty covers only machine damage and/or malfunctions with explicit exclusion of compensation for any additional damage. In any case, the seller shall not be held responsible for loss due to lack of or reduced production, as well as any special, indirect or consequential loss of any nature whatsoever. As regards any annexes or modifications to the above, in any case the general terms and conditions set forth in the contract shall be abided. In any case, any other warranty other than that assumed by contract by SACMI towards the machine purchaser or, in the case of leased machinery, the user named by the leasing company, is excluded.
E0004
IMPORTANT INFORMATION!
The machine operators and maintenance staff are not responsible for carrying out operations under warranty or extraordinary maintenance and repairs. These operations are to be performed only by the manufacturer’s properly trained technicians and/or technicians who have been duly appointed. For this reason, these types of operations are not dealt with in this manual and the machine purchaser or, in the case of leased machinery, the user named by the leasing company, should contact SACMI to schedule service or receive the necessary instructions.
1.6
SUPPLEMENTS
The following documents supplement this Instructions manual. - INSTRUCTIONS B (This document may be split into several handbooks containing instructions on how to use the control system and the electric and electronic machine components). - WIRING DIAGRAMS - COOLING MIXES, ADHESIVES AND LUBRICANTS DATA SHEET - VISION SYSTEM INSTRUCTIONS MANUAL (if present) - INSTRUCTIONS MANUAL FOR METERING UNIT/MIXER (if present) - FEEDER'S USER MANUAL (if provided) - DEHUMIDIFIER INSTRUCTION MANUAL (if present). - AIR CONDITIONER DOCUMENTATION (if present) 1-3
002AZ019A 1
GENERAL INFORMATION
1.7
LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL
DANGER SYMBOLS
General hazard.
E0004
E0137
E0003
E0007
E0011
E0010
E0134
E0035
1-4
Danger of being burnt on hot surfaces.
Danger of hands being crushed.
High tension. Risk of electrical shock.
Risk of entanglement, amputation.
Risk of entanglement in moving parts.
Risk of falling.
Risk of explosion.
002AZ019A
GENERAL INFORMATION
1
WARNING SIGNS
E0001
Do not lubricate or work on moving parts under any circumstances.
O2
E0034
E0136
Do not use oxygen to recharge the accumulators.
Do not put arms in the openings.
ALERT SYMBOLS
E0138
E0006
E0038
Always wear heavy duty work gloves.
Machine must be connected to an effectively grounded power point.
Lift point.
ADDITIONAL SIGNALS
E0133
Dispose of carefully in accordance with current environmental regulations.
1-5
002AZ019A 1 1.8
E0004
GENERAL INFORMATION MACHINE IDENTIFICATION PLATE
IMPORTANT!
The CE mark is affixed only in the European Economic Community or in cases where foreseen.
FIGURE 1.8 - MACHINE IDENTIFICATION PLATE
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1-6
002AZ019A 1.9
GENERAL INFORMATION
1
DECLARATION OF CONFORMITY (only within the European Community or cases in which it is foreseen)
The declaration of conformity, when provided, accompanies the machine. Drawn up in accordance with Annex II letter A of Directive 2006/42/EC and any subsequent amendments and/or supplements. Fixed installation in accordance with Directive 2004/108/EC. S.C. declares: · this machine is defined as machinery in conformity with the provisions of Council Directive 2006/42/EC and any subsequent amendments and/or supplements and that the “CE” mark has been affixed; · this machine complies with the provisions of the following European Directives (references to standards are also extended to any subsequent amendments and/or supplements): - 2006/42/EC; - 97/23/EC. ·
S.C. is authorized to hold the technical file.
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002AZ019A 1
1-8
GENERAL INFORMATION
002AZ019A
MACHINE FEATURES
2
MACHINE FEATURES
2.1
MACHINE DESCRIPTION
2
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 a plasticization unit, cut into suitably gauged pellets and then inserted inside the molds. A hydraulic system is employed to close the molds at a pressure that can be regulated while the production cycle is being performed. The time required for cooling down is strictly related to the speed at which the molding turret runs. The main machine parts are illustrated in the figure. FIGURE 2.1 - OVERALL VIEW 1 2
Plasticization unit Drive unit
3
3 4 5 6 7 8 9 10
Insertion turret Molding turret Pneumatic system Hydraulic system Cooling system Electrical cabinet Control panel Exit conveyor belt
5
9
4
1
10
2
8 7 6
2-1
002AZ019A 2
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, a link unit 3 (that may vary according to the type of plastic compound and delivery rate used) and a by-pass system 2. In order to compensate for any thermal expansion and to allow maintenance to be carried out the unit is mounted on a track. The machine may be equipped with various extrusion devices, depending on the flow rate required for the plastic material. FIGURE 2.1.1.1 - PLASTICIZATION UNIT 1 2 3A* 3B* (*)
Extruder By-pass system Feed flange Metering pump and feed pipe As an alternative between each other
3B
3A
1
2
T4723
2-2
002AZ019A
MACHINE FEATURES
2.1.1.1.1
2
Extruder
Extruder The extruder melts down the plastic compound and homogenizes it with any colorings and lubricants that may have been added. The granular material, picked up by feeder 5 (Refer to the manufacturer's manual), is let in through a hopper 1A or, as an alternative a metering unit/mixer 1B (see the instructions manual provided by the manufacturer) and is pushed into the cylinder 2 by the auger 3 through the various heat conditioning zones. The auger is driven by a geared motor 4. The zones are supplied with heating elements and electric cooling fans. The temperature in each individual zone is measured by thermocouples provided for this purpose.
E0004
E0003
WARNING!
Never start the machine and/or extruder without the hopper or metering unit/mixer, danger of shearing. If the hopper or metering unit/mixer need to be removed for maintenance/replacement, firmly secure in place before attempting to start the machine and/or extruder.
FIGURE 2.1.1.1.1 - EXTRUDER 1A 1B 2 3 4 5 (*)
5
Hopper (*) Metering unit/mixer (*) Cylinder Auger Extruder gearbox Feeder The hopper and metering unit/mixer are alternatives to one another
1A
1B 3
4
2
T4724
2-3
002AZ019A 2 2.1.1.1.2
MACHINE FEATURES Metering pump (optional)
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. The latter then sends the material to the feed tube. A cooling circuit is installed at the ends of the shaft to prevent the plastic compound from flowing out abruptly. The pressures of the suction and delivery lines are measured by transducers BP1 and BP2 respectively. The pump temperature is controlled by thermocouple BT7.
FIGURE 2.1.1.1.2 - METERING PUMP 1 2 6 7 BP1 BP2 BT7 EH7 M8
Pump casing Gears Suction flange Delivery flange Sensor for suction line pressure Sensor for delivery line pressure Thermocouple Heating element Geared motor
BP1
A B
BP2
BT7 6
1 7
A
B
2
EH7
M8
T4551
2-4
002AZ019A
MACHINE FEATURES
2.1.1.1.3
2
Feed tube
This carries the melt from the metering pump to the by-pass unit. It consists of a tube and a static mixer (optional), which is used to ensure that the characteristics and temperature of the plastic compound are even throughout. While traveling along the path from the tube to the mixer, the material is kept at a constant temperature by heating elements EH8 and EH9. The temperature is measured by thermocouples BT8 and BT9 respectively. FIGURE 2.1.1.1.3/A - FLANGE AND FEED TUBE WITHOUT MIXER BP2 BT6 BT8 EH6 EH8
Delivery pressure sensor Thermocouple Thermocouple Heating element Heating element
EH6 EH8
BP2
T4725
BT6
BT8
2-5
002AZ019A 2
MACHINE FEATURES
FIGURE 2.1.1.1.3/B - FLANGE AND FEED TUBE WITH MIXER AND METERING PUMP BT8 BT9 EH8 EH9
Thermocouple Thermocouple Heating element Heating element
EH8
EH9
T4726
BT8
2-6
BT9
002AZ019A
MACHINE FEATURES
2.1.1.1.4
2
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. The latter is driven by a pneumatic cylinder 6. While traveling along the path, the material is kept at a constant temperature by heating elements EH15 and EH16. The temperature is measured by thermocouples BT15 and BT16 while the temperature of the melt is measured by probe BT17. FIGURE 2.1.1.1.4 - BY-PASS SYSTEM 1 3 4 5 6 BT15 BT16 BT17 EH15 EH16
Flange Extruder nozzle Discharge outlet Diverter Pneumatic cylinder Body thermocouple Nozzle thermocouple Molten material thermocouple Heating element Heating element
BT17
BT16 3
EH15
EH16
6 1 4
BT15
5
T3964
2-7
002AZ019A 2
MACHINE FEATURES
2.1.1.2
Drive unit
The drive unit transmits motion to the entire machine. This unit includes an epicyclic geared motor with self-braking motor M9 mounted on the vertical axis, a handwheel 16 to carry out operations in manual mode, a toothed belt 4 that drives the molding turret and a tensioning unit 17 used to tension the belt. An oil drain cock 13, filler and bleeder plug 14 and level indicator 15 are also provided. FIGURE 2.1.1.2 - DRIVE UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 M9
Screw Nut Screw Belt Belt Nut Screw Pulley Counter-device Screw Nut Screw Cock Filler plug Level indicator Manual handwheel Tensioner Epicyclic gear motor
16 M9 14 15
13
4 9
7 17 3
2
1
11 12 3 8 2-8
5
6
T2964
10
T1495
002AZ019A 2.1.1.3
MACHINE FEATURES
2
Insertion turret
The insertion turret has the dual function of cutting and placing the plastic pellets in the cavities of the molding turret and transferring the finished product onto the exit conveyor belt. The insertion turret is driven by the drive unit through a toothed belt 9 and pulley 1. A torque limiter 2 and encoder 3 are mounted on the drive shaft. The encoder sends information about the machine’s work position to the microprocessor based control system. The mount 4, that sustains the insertion turret, is installed on the machine base. The drive shaft that transmits motion from the pulley 2 to the toothed wheel 5 operates inside the mount. The insertion turret moves in and out of the work position in the molding turret as pneumatic cylinder 6 turns it around the pivot 5. The toothed wheel 5 transmits motion to toothed wheel 7 and pulley 10 through pulley 8 and toothed belt 9. Toothed belt 9 is kept tight by tensioner 11. The cutters 12 cut the plastic material flowing out of the extruder nozzle into pellets and place them in the molding turret cavities through a mechanical/pneumatic action. The finished product is placed on the disk 13, equipped with a vacuum hold down system, and carried to the exit conveyor belt by the stripper wheels 14 and 15.
2-9
002AZ019A 2
MACHINE FEATURES
FIGURE 2.1.1.3 - INSERTION TURRET YV33 1 2 3 4 5 6 7 8 9 10 11 12.1 12.2 12A 12B 12C 12D 12E 12F 12G 12H 12L 12M 13 14 15 16 17 18 19 20 21 22 23
2-10
Solenoid valve Pulley Torque limiter Encoder Mount Toothed wheel Pneumatic cylinder Toothed wheel Pulley Toothed wheel Pulley Tensioner Cutter without insertion piston Cutter with insertion piston Disk Piston Gasket Sleeve Knife Screw Cutter Screw Nozzle Gasket Disk Wheel Wheel Screw Spacer Distributor Flange Screw Nut Pin Nut
24 25 26 27 28 29 30 31 32 33 34 38 39 40 41 42 43 44 45 46 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63
Pin Counter-device Screw Connecting rod Screw Screw Screw Disk Screw Spring Pin Cover Screw Screw Spacer Ring nut Flange Nut Screw Screw Shaft Screw Flange Nut Washer Spring Spacer Screw Pin Ring nut Spacer Snap ring Screw Snap ring Cover
002AZ019A
2
MACHINE FEATURES FIGURE 2.1.1.3 - INSERTION TURRET YV33 14
30
28
20
17
34
19 16
18
33
31
32 13
12.2 27 41 43 42
51 15
12H 26
50
12.1
29 56
21
6
46
23 22
45
24
58
38 5
40
8
7
11
57 61 39
60
9
59
10 44
4
62
49 12M
12.1
12L 53 12G
52
12E
55
12F
54
12.2 12A 12B 12C
25
12D 1
12G 12E 12F
12H
2 3
63 T4817
2-11
002AZ019A 2 2.1.1.4
MACHINE FEATURES Molding unit
The hydraulic actuators and molds are located in the molding unit. They are used to form, cool down and remove the pellets of molten plastic that are sent to them from the insertion turret. The finished product is then placed on the stripper wheel. Motion is transmitted from the drive unit to the molding unit through a pulley 14 and belt 13. The distributor 11 delivers the cooling fluid to the upper and lower tools, oil under pressure to the hydraulic actuators and compressed air to the molds. The hydraulic actuators 8 are mounted on the lower body of the turret 9. A mold 7 (lower) is provided with each of the actuators. The mold receives the pellets that are then formed and cooled down. The actuator 8 is hydraulically driven. The various stages of its movement are piloted by a ball valve 10, that is mounted next to the actuator itself. A duct 12, for the mold’s 7 coolant, passes through the actuator’s rod. The upper molds are mounted on the upper turret body 3. The relative rods 16, that drive the devices used for stripping the product, are mounted on the circumference further inside compared to that of the upper molds. A fork 6, whose task is to act on the stripper, is keyed to the rod. The stripper rods 16 are controlled by a fixed cam 4 that acts on rollers 15 secured to the same rods. In addition, the machine is equipped with a number of pneumatic valves 1 so that the product can be removed by blowing air into the upper molds. These valves send air under pressure to each mold. From the air supply system the compressed air first flows through an accumulator that keeps its pressure constant and then through a ring that directs it to the valves 1. The air then reaches the flow controls found near the molds. The upper molds are cooled down by the coolant that runs through the duct 5. Two drive systems may be performed to remove the product when certain tools (fig. 2.1.1.4/B) are used. The upper mold 2 is driven both by the stripper rod 16 and cam 17 that acts on a wheel found in the middle of the mold. FIGURE 2.1.1.4/A - MOLDING TURRET 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
2-12
Valve Upper mold Turret’s upper body Fixed cam Coolant duct (upper molds) Fork Lower mold Hydraulic actuators Turret’s lower body Actuator control valve Distributor Coolant duct (lower molds) Belt Pulley Wheel Stripper drive rod Cam
002AZ019A
MACHINE FEATURES
2
FIGURE 2.1.1.4/A - MOLDING TURRET 1
A 2 3 4 5 6 7 8
9 10
11
A 15
16 T3004
12
13
14 2-13
002AZ019A 2
MACHINE FEATURES
FIGURE 2.1.1.4/B - MOLDING TURRET WITH TOOLS WITH CENTRAL DRIVE SYSTEM 1
A 15
16
A
17 4 2 3 5 6 7 8 9 10
11
12 2-14
13
14
T3891
002AZ019A 2.1.1.5
MACHINE FEATURES
2
Exit conveyor belt
The exit channel receives the product from the stripper wheels and brings it in an orderly manner to the area where it is fed to the next machine in the production line. The belt has devices that reject any defective caps or pick up sample caps. 2.1.1.6
Pneumatic system
The pneumatic system includes a control unit that contains the air preparation elements (filters, pressure regulators, pressure switches, safety valves) and the control devices for the pneumatic actuators (i.e., solenoid valves). 2.1.1.7
Hydraulic system
The hydraulic system supplies the oil at a controlled pressure and flow rate that is used to drive the actuators of the molding turret. The hydraulic system basically consists of the following parts: - The hydraulic power unit that generates the oil flow required for operation and controls the oil pressure and temperature. It also filters the oil. - A unit that controls the oil flow rate (mounted on the press). Two manual control valves to adjust the flow rate and actuator return pressure are also provided in this unit. - A rotary distributor. - Ball control valves with relative actuators. - Ducts that run from the rotary distributor to the valves and related actuators inside the molding turret. 2.1.1.8
Cooling system
The cooling system is used to deliver coolant at a controlled temperature (refer to the data sheet for the values) to the following parts: - hydraulic power unit’s water/oil exchanger - extruder - upper molds - lower molds The system includes a cooling unit (optional) which delivers the fluid at a low temperature to a thermal control unit that provides the flow of coolant. Each delivery is brought to a certain temperature and sent to the respective points of use. 2.1.1.9
Electric system: control board
All the information regarding the control board is given in chapter 6 - OPERATING INSTRUCTIONS and the Instructions B manual. 2.1.1.10
Molds
The molds are strictly related to the kind of product being handled as they include the parts that come into contact with the plastic material and form it. As these are size related parts, they are described in detail during the training sessions.
2-15
002AZ019A 2 2.1.2
MACHINE FEATURES 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. 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.
E0004
WARNING!
If the machine is remote controlled, suitable signs must be posted while the machine is running. The machine can be run only in the following two modes: - manual - automatic Use the mode selector on the control panel to select the desired mode of operation. UNINTENDED AND PROHIBITED OPERATIONS The machine must be used only for the tasks it was expressly designed for unless otherwise authorized by the Manufacturer. The Manufacturer will not be held responsible for any personal injury or equipment damage caused by failure to observe this safety precaution. MISUSE OR ERRONEOUS USE SACMI shall not be held responsible for malfunctions or personal injury or property damage deriving from incorrect and erroneous use of the machine. Generally speaking, the most common causes of incorrect use are listed below: - failure to observe the safety standards, rules and guidelines given in this manual; - unintended and inappropriate use of the machine; - personnel not adequately trained; - fatigue (above all during the night shift) or distraction; - negligence caused by superficiality or wrong habits. Remember that the machine is to be controlled and run exclusively by expert well trained personnel who are able to: - correctly operate the machine under normal conditions - and face any emergencies, this is fundamental!
E0004
IMPORTANT!
The machine must never be used under the conditions given below and, in any case, the following operations must never be carried out: - never remove, lock out or disable any safety devices or guards; - never lubricate or in any case perform maintenance jobs while the machine is running; - never climb and/or get on the machine or any parts of it; - never take out the waste container while the plasticization unit is running if the production cycle is not in progress and no products are clearly seen being carried on the exit conveyor belt; - never access the waste container while the plasticization unit and/or machine is running, danger of burns and amputation.
2-16
002AZ019A
2
MACHINE FEATURES
2.2
OVERALL DIMENSIONS
FIGURE 2.2/A - OVERALL DIMENSIONS WITH Ø 60 mm EXTRUDER A C E HI HO T X Y
Pneumatic connection Material supply Electrical connection Cooling system connection (inlet) Cooling system connection (outlet) Cooling system connection (leaks) Minimum connecting height for lifting Maximum height for maintenance
3460
3400
2940
2690
0 1350 -50
2175
X Y
2500
2200
2700
C
A
E 8280 7580
600
(700)
6880 1610
740 1690 290 680
300
570
1500
4770
1000 455 630 785
800 870 800 800
2400
520
2210 1970
6310
HI
T
HO
T4727
2-17
002AZ019A 2
MACHINE FEATURES
2.3
TECHNICAL DATA
2.3.1
SPECIFICATIONS EXTRUDER
PRESS
Ø 60 mm Maximum production output
pieces/min
Maximum rpm
rpm
Number of cavities
800
800
25
25
32
32
Molding cylinder stroke
mm
115
115
Maximum molding force
kN
21
21
PP
PE
Extruder delivery rate
Kg/h
100
150
Temperature of molten plastic
°C
280
280
EXTRUDER Type of plastic compound
ELECTRICAL WIRING Power requirements
kVA (50Hz)
189
189
Power for cable sizing
kVA (50Hz)
104
104
Maximum power absorbed
kW (50Hz)
60
60
Average power absorbed
kW (50Hz)
49
49
PNEUMATIC SYSTEM Required delivery rate (at 0.5 Mpa)
Nl/min
600
600
Average consumption (at 0.5 Mpa)
Nl/min
500
500
Minimum required pressure
MPa
0.5
0.5
Maximum allowable pressure
MPa
1.0
1.0
644
644
Ø mm
17
17
Thermal power to be dissipated
kcal/h
39000
42000
Required flow rate
l/min
130
140
Pressure drop
MPa
0.1
0.1
Air cleanliness class (ISO 8573-1) Connecting hose COOLING SYSTEM
2-18
Maximum allowable pressure
MPa
1.0
1.0
Temperature
°C
10
10
System hose
Ø mm
40
40
002AZ019A
2
MACHINE FEATURES
2.3.2
ALLOWABLE FLUCTUATIONS
ELECTRIC Voltage = 400 V ±10% Voltage ≠ 400 V ±5% Frequency ±2%
PNEUMATIC Delivery rate ±15%
COOLING FLUID Delivery rate ±10%
2.3.3
E0004
RATING PLATE
IMPORTANT!
The CE mark is affixed only in the European Economic Community or in cases where foreseen.
FigurE 2.3.3 - RATING PLATE
M A D E
Matr.Nr. Serial No.
I N
Cod. Mat.
Cert. Cert.
Ic c
Un
I T A L Y
O.d.V. Order No.
In
fn
Te
Anno Year
SACMI IMOLA S.C. VIA SELICE PROVINCIALE 17/A IMOLA - ITALIA
04076369
E0146
2-19
002AZ019A 2 2.3.4
MACHINE FEATURES OPERATIONAL CHARACTERISTICS
TYPE OF PRODUCT The machine can produce thermoplastic products whose dimensions have been previously agreed upon with SACMI’s Engineering Dept. TYPE OF MATERIAL The machine can handle the following types of thermoplastic material:
- POLYPROPYLENE (PP) - POLYETHYLENE (HDPE;LDPE)
The machine is set up in a different way depending upon the material used. In addition, special parts may be required. A “Data Sheet” is provided with each machine on which the processing parameters for the selected material are given. In addition, this data can be stored and called up whenever the material handled is changed.
E0004
ATTENTION!
If material that is not included on the data sheet (facsimile given below) is used, contact SACMI’s laboratory before starting processing.
E0004
WARNING!
Never use any material that may be hazardous in the event of skin or eye contact, ingestion, inhalation or that may produce fumes and/or toxic or dangerous phenomena during processing. PRODUCTION CAPACITY The product output is strictly related to the type of object formed and material used. The maximum production output is given in the specifications.
2-20
002AZ019A
MACHINE FEATURES
2
FIGURE 2.3.4 - PRODUCT CHARACTERISTICS The dimensions given in the figure are for reference purposes only and are not binding in any way. MAX MAX
800 Pieces/min 6 g/piece
43
25
20 Max
5
Min T1498
2-21
002AZ019A 2 2.3.5
MACHINE FEATURES AIRBORNE NOISE EMISSION LEVELS
2.3.5.1 Sound pressure level (EN ISO 11202) Test conditions - Operating conditions: trial run with Ø 60 mm extruder - Type of operation: plastic cap production (600 caps/min.). - Operating cycle: material feed and cap formation - Test environment: factory with reflecting flooring. Instruments employed Class 1 instruments (IEC 804) Values measured
LpA LpC peak dB(A) dB(C)
P1 84.0 102.5
P1 - Control post, measured at a height of 1.55 m from the floor. LpA - Continuous A-weighted sound pressure level. LpC peak- Peak C-weighted instantaneous sound pressure level. .
FIGURE 2.3.5.1 - SOUND PRESSURE LEVEL
T4729
P1
2-22
002AZ019A
MACHINE FEATURES
2
2.3.5.2 Acoustic power level (EN ISO 3746) Test conditions - Operating conditions: trial run with Ø 60 mm extruder - Type of operation: plastic cap production (600 caps/min.). - Operating cycle: material feed and cap molding - Test environment: factory with reflecting flooring. Instruments employed Class 1 instruments (IEC 804) Results LwA = 104.0 dB(A) LwA = A-weighted sound power level in dB.
2-23
002AZ019A 2 2.3.6
MACHINE FEATURES DATA SHEET
Sales order: Customer:
Position: Equipment no.
Product
General info
CCM ACQUISITION PROFILE Operator
Type of operation
Date
PLC program
Output per minute [pieces/min]
Number pieces produced
Work hours
Cap code
Cap name
Tooling code
Tooling mounted in machine
Thickness of cap bottom
Nominal D [mm]
Maximum D [mm]
Shell H [mm]
Master type
Master manufacturer
Plastification Hydraulic system
Wall Temperature [°C]
% mixed
Actual melt temperature [°C]
Extruder
Temperature 1 Temperature 2 Temperature 3 Temperature 4 Temperature 5 Flange temperature [°C] [°C] [°C] [°C] [°C] [°C]
Manual speed [%]
Automatic Speed [%]
Metering pump
Temperature [°C]
Manual speed [%]
Automatic Speed [%]
Set pressure 1 Actual pressure 1 [Bar] [Bar] Min. value Max. value Mixer temperature [°C]
Actual pressure 2 [Bar] Min. value Max. value Nozzle temperature [°C]
Hydraulic system preheat temperature [°C]
Cooling system
Bottom Temperature [°C]
Compound manufacturer
Pipe temperature [°C]
CCM64M/32M/48S/24S/24L tooling
/
Type of pressing
Type of compound
PLC indicated melt temperature [°C]
/
Nozzle body temperature [°C] Hydraulic system operating temperature [°C]
Accumulator precharge High [Bar]
Accumulator precharge Low [Bar]
Accumulator precharge Return [Bar]
Oil pressure High [Bar] (average value)
Oil pressure Low [Bar] (average value)
Oil pressure Return [Bar] (average value)
Flow regulation High
Flow regulation Low
Actuator height under low pressure [mm]
Cavity (zone 1)
PLC tempera - Real temperature Pressure ture [°C] [°C] [Bar]
Flow rate
Punches (zone 2)
PLC tempera - Real temperature Pressure ture [°C] [°C] [Bar]
Flow rate
Auxiliary equip. (zone 3)
PLC tempera - Real temperature Pressure ture [°C] [°C] [Bar]
Control unit flow rate Distributor cooling capacity
Chiller temperature [°C]
Chiller model
Tool holder – stripper height [mm]
Disk-wheel height [mm]
Actuator downstroke cam
Cutter code
Cutter width [mm]
Cutter height [mm]
Blade code
Blade height [mm]
Nozzle end diameter [mm]
Insertion blower code
Insertion air jet time
Insertion air jet delay
Insertion air jet pressure [bar]
Fast upstroke pressure [bar]
Cooling pressure [bar]
Degree of vacuum [cmHg]
Cylinder/cavity distance [mm]
Side stripper cam code
Position
Central stripper cam code
Position
Tooling code
Extruder auger code
Upper coupler
Lower coupler
Inner guide code
Stripper code
Wheel code
Mechanical phase [mm]
T4380
2-24
002AZ019A Air injection cam code
Air injection pressure [Bar]
Position 1st cam (lh)
Punch injection cam (long/short side)
Air injection pressure [Bar]
Punch injection cam position
Cavity injection cam
Air injection pressure [Bar]
Position
2
Position 2nd cam (rh)
Division notes
CCM24L
CCM64M /48S/24L/24S
CCM32M
MACHINE FEATURES
Main motor serial number
Hydraulic power unit motor serial number
Recirculation control unit serial number
Extruder drive motor serial number Belt blower serial number Burr suction blower serial number T4381
2-25
002AZ019A 2
MACHINE FEATURES
2.4
DIAGRAMS
2.4.1
PNEUMATIC SYSTEM DIAGRAM
FIGURE 2.4.1/A - PNEUMATIC SYSTEM DIAGRAM SP7 YV3 YV6 YV9 YV13
Pressure switch, Machine air supply Solenoid valve, Pellet rejection Solenoid valve, Insertion turret adjustments Solenoid valve, Air injection in molds Solenoid valve, Insertion accumulator discharge YV17 Solenoid valve, Compressed air mains YV23B/P Solenoid valve, By-pass air drive YV25 Solenoid valve, Insertion turret connecting rod piston drive YV26 Solenoid valve, Connecting rod piston, Insertion turret drive YV31 Solenoid valve, Storage unit YV33 Solenoid valve, Pellet insertion YV35 Solenoid valve, Product rejection YV41 Solenoid valve, Piston cleaning YV44 Solenoid valve, Heater YV50 Solenoid valve, Piston safety YV101 Solenoid valve, CVS reject
E Plasticization unit EV Solenoid valves J Jet stream PA Air preparation unit T Temperature controller 1 2 3 5 7 9 11 12 13 14 15 16 17 SP1
Filter Pressure regulator Pressure regulator, Pellet insertion Throttle Cylinder, By-pass unit drive Pressure regulator, Air injection in molds Accumulator Injection valve, Molds Pressure gauge Pressure regulator, Piston Pressure regulator, Piston pellet rejection Pressure regulator, Piston cleaning Pressure regulator, Heater Pressure switch, Mains pressure YV25/26 5
EV
YV6
4
17
YV44
5 YV50
YV41
5
16
YV23P/23B YV3
7
T E
15
11
YV13
14
13
J 2
3
YV33 SP7 YV17
12 5
YV31 11
YV35
1
PA
SP1
YV101
YV9 13 9 T4730
2-26
002AZ019A
MACHINE FEATURES
2
FIGURE 2.4.1/B - LAYOUT OF ELEMENTS IN AIR SUPPLY SYSTEM
YV50
YV44
YV41
YV3
SP7
YV17
SP1
2
1
YV23P 3 YV26
YV6
9
YV25
YV23B
16-17
14
15
2-27
002AZ019A 2
MACHINE FEATURES
FIGURE 2.4.1/C - LAYOUT OF ELEMENTS IN AIR SUPPLY SYSTEM YV13
11
11
YV9 YV33
YV31
YV35
2-28
002AZ019A
2
MACHINE FEATURES
2.4.2
HYDRAULIC SYSTEM DIAGRAM
The hydraulic schematic is described in functional units, each of which has a specific location in the machine. A
Hydraulic power unit reservoir
1 2 3 4 5 14 BT10 M1 M4 SL2 SP4
Suction filter High pressure pump Low pressure pump Oil filter Heat exchanger Gate, Oil drain Thermocouple Electric motor Oil recirculation motor Sensor, Oil level Pressure switch, Filter clogging
B
Hydraulic control assembly
6 7 8 9 10 11 12 13 SP12/SP13 SP14/SP15 YV21 YV27
Control valve, Low pressure Non-return valve, Low pressure circuit Non-return valve, High pressure circuit Pressure gauge, Low pressure Pressure gauge, High pressure Accumulator, High pressure Accumulator, Low pressure Control valve, High pressure Pressure switches, Low pressure present Pressure switches, High pressure present Solenoid valve, Drain closure, High pressure circuit Solenoid valve, Drain closure, Low pressure circuit
C
Flow control assembly
15 16 17 18 19 20 21 22 23 SP115 YV30
Control valve, Actuator return circuit pressure Restrictor, Drain circuit Pressure gauge, Actuator return circuit pressure Accumulator, Actuator return circuit Flow regulator, Low pressure circuit Diaphragm Rotary joint Actuator control valve Hydraulic actuator Pressure switch, Dampener Solenoid valve, Actuator approach circuit shut off
2-29
002AZ019A 2
MACHINE FEATURES
FigurE 2.4.2/A - HYDRAULIC SYSTEM SCHEMATIC
23 22
A B T R
21
SP115
16 YV30
20 19
17 18
C
15
10
B
SP14/SP15
11
SP12/SP13
9 12
YV27
YV21 13
8
7
6
SP4 M1 M
T BT10
4
5 M M4
3
A
2
1
SL2
T3961
2-30
002AZ019A
2
MACHINE FEATURES FigurE 2.4.2/B - LAYOUT OF ELEMENTS IN HYDRAULIC SYSTEM 21
16
12
18
11
13
10
M4
M1
YV21 YV27
6 9
14
17
15
19
YV30
5 23
BT10
SP15 SP14 SP13 SP12
SP4 4 SL2 22
2-31
002AZ019A 2 2.4.3
MACHINE FEATURES COOLING SYSTEM DIAGRAM
A B C D E
Cooling unit Temperature regulator Press Hydraulic power unit Plasticization unit
DS M R UI US
Distributor Delivery line Return line Lower tools Upper tools
6 8 9 10 13 14 15 16 17
Heat-exchanger Non-return valve Flow meter, Upper tools Flow meter, Lower tools Metering pump Extruder gearbox Extruder supply By-pass valves Reservoir
BT18 BT19 BT20 EH18 EH19 EH20 M18 M19 M20 SP18 SP19 SP20 YV10 YV18 YV19 YV20 YV38
Thermocouple, Temperature control for lower tools Thermocouple, Temperature control for upper tools Thermocouple, Temperature control for extruder and hydraulic power unit Heating element, Temperature control circuit, Lower tools Heating element, Temperature control circuit, Upper tools Heating element, Temperature control circuit, Extruder and hydraulic power unit Motor, Temperature control pump, Lower tools Motor, Temperature control pump, Upper tools Motor, Temperature control pump, Extruder and hydraulic power unit Differential pressure switch, Lower tool temperature control Differential pressure switch, Upper tool temperature control Differential pressure switch, Extruder and hydraulic power unit temperature control Solenoid valve, Manifold bypass, Cooling unit Solenoid valve, Exchanger shut off, Lower tools Solenoid valve, Exchanger shut off, Upper tools Solenoid valve, Exchanger shut off, Extruder and hydraulic power unit Solenoid valve, Heat exchanger water
2-32
002AZ019A
MACHINE FEATURES
2
FIGURE 2.4.3/A - COOLING SYSTEM SCHEMATIC DS C
6
9
10 UI
D
E 13
US
14
15
YV38
8
8
M
R
M
R
M
R
B YV10
SP18
SP20
SP19
YV20
YV19 YV18 BT19 T BT18
T
BT20 T
EH19
17 EH20
EH18 M19
M20
M18
A
T4739
2-33
002AZ019A 2
MACHINE FEATURES
FIGURE 2.4.3/B - LAYOUT OF PARTS IN COOLING SYSTEM 8
9
10
6 11
2-34
YV38
002AZ019A
MACHINE FEATURES
2
FIGURE 2.4.3/C - LAYOUT OF PARTS IN COOLING SYSTEM 17 SP19 SP18 SP20 EH18 EH20
BT18
BT19
BT20
EH19 M19 M18 M20
YV20
YV19
SP18 BT18
YV18
YV10
2-35
002AZ019A 2
2-36
MACHINE FEATURES
002AZ019A
SAFETY EQUIPMENT AND PRECAUTIONS
3
SAFETY EQUIPMENT AND PRECAUTIONS
3.1
SAFETY DEVICES AND GUARDS
E0004
3.1.1
3
WARNING!
GENERAL SAFETY RULES
The machine is provided with a number of electrical and/or mechanical safety devices in order to safeguard the operators 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 for added 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 injury to personnel or damage to the machine resulting from failure to observe these precautions or use the safety devices provided. The presence of safety devices does not exempt the operators from exercising extreme caution during work, avoiding actions that may endanger him/herself or damage the machine at all times. In particular, the operators must never touch rotating machine parts. 3.1.1.1
Required environmental conditions for correct machine operation
The conditions required are those commonly found in an industrial environment: The machine foundations must be constructed on solid ground, with no water seepage and suitable to withstand the indicated loads. The environment must be adequately ventilated with openings that admit fresh air to replace stale air. The user must assure that the lighting in the work areas allows the operations and all machine parts to be clearly seen. The lighting must meet standard EN 12464-1. In particular, it must be free of shadows, bothersome glaring and stroboscopic effects. Some environmental conditions such as sea level, high relative humidity and high temperatures may affect the motors selected therefore these particular conditions should be specified at the time of order. - The machine is designed to work only indoors. - The machine is designed to work at a temperature ranging from +5°C to +40°C. - The machine is designed to work at a maximum temperature of 40 °C with relative humidity 0,15)
X
X-(> 0,15)
7-15
002AZ019A 7
ADJUSTMENTS
7.4
PNEUMATIC SYSTEM ADJUSTMENTS
7.4.1
PRESSURE SWITCH SP1
Check and adjust the pressure that activates pressure switch SP1. Conditions - Machine energized and air supplied. Adjustment - Work on pressure regulator 1 until the pressure reaches 0.3 MPa, making certain led SP1 on the electronic cards in the electrical cabinet or control system go out. - On the contrary, work on the adjustment screws 2 located on the head of the pressure switch until the pressure switch comes on once the pressure reaches 0.3 MPa.
FIGURE 7.4.1 - PRESSURE SWITCH SP1 1 2
Pressure controller Adjustment screw
1
2 7-16
002AZ019A
ADJUSTMENTS
7.4.2
7
PRESSURE SWITCH SP7
Check and adjust the pressure that activates pressure switch SP7. Conditions - Machine energized and air supplied. - Pressure switch SP1 correctly set. Adjustment - Work on pressure regulator 1 until the pressure reaches 0.4 MPa, making certain led SP7 on the electronic cards in the electrical cabinet or control system go out. - On the contrary, work on the adjustment screws 2 located on the head of the pressure switch until the pressure switch comes on once the pressure reaches 0.4 MPa. FIGURE 7.4.2 - PRESSURE SWITCH SP7 1 2
Pressure controller Adjustment screw
1
2
7-17
002AZ019A 7 7.5
ADJUSTMENTS HYDRAULIC SYSTEM ADJUSTMENTS
FIGURE 7.5 - HYDRAULIC SYSTEM ADJUSTMENTS A
Hydraulic power unit reservoir
1 2 3 4 5 14 BT10 M1 M4 SL2 SP4
Suction filter High pressure pump Low pressure pump Oil filter Heat exchanger Oil drain valve Thermocouple Electric motor Oil recirculation motor Oil level sensor Pressure switch, Filter clogged
B
Hydraulic power unit
6 Low pressure control valve 7 Non-return valve, Low pressure circuit 8 Non-return valve, High pressure circuit 9 Pressure gauge, Low pressure 10 Pressure gauge, High pressure 11 Accumulator, High pressure 12 Accumulator, Low pressure 13 Control valve, High pressure SP12/SP13 Pressure switches, Low pressure detection SP14/SP15 Pressure switches, High pressure detection YV21 Solenoid valve, High pressure circuit discharge closure YV27 Solenoid valve, Low pressure circuit discharge closure C
Flow control assembly
15 Control valve, Actuator return pressure 16 Restrictor, Discharge circuit 17 Pressure gauge, Actuator return circuit pressure 18 Accumulator, Actuator return circuit 19 Flow control, Low pressure circuit 20 Diaphragm 21 Rotary joint 22 Actuator control valve 23 Hydraulic actuator SP115 Pressure switch, Restrictor YV30 Solenoid valve, Actuator approach circuit cut off
7-18
002AZ019A
7
ADJUSTMENTS FIGURE 7.5 - HYDRAULIC SYSTEM ADJUSTMENTS 21
16
12
18
11
13
10
M4
M1
YV21 YV27
6 9
14
17
15
19
YV30
5 23
BT10
SP15 SP14 SP13 SP12
SP4 4 SL2 22
7-19
002AZ019A 7
E0004
ADJUSTMENTS
WARNING!
The control valves are equipped with a ring nut to tighten the threaded control rod only to the value set for the valve. Do not remove the ring nut and fully tighten the control rod to avoid creating dangerously high pressures in the hydraulic system. Always monitor the pressure with the relative pressure gauge while making adjustments/performing maintenance. 7.5.1
ADJUSTING THE APPROACH STAGE (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. The time employed to carry out this stroke depends on the speed of the molding turret . As a result, the flow rate of the low pressure circuit is strictly related to the rpm. The position of the flow control valve of this circuit is indicated on the “Data sheet”. If the flow rate is incorrectly set, the products may have defects and the yellow warning light found on the electrical cabinet comes on. A sensor, located near the point where the valve is opened a second time (i.e., oil starts flowing under high pressure), detects the path of the back-plates that stop the actuators from turning. If the sensor detects a number of backplates equal to the total number with a path different from the nominal one consecutively, the machine performs a controlled shutdown procedure as described in chapter 6 - OPERATING INSTRUCTIONS. Adjust the flow rate of the low pressure circuit with flow control 19. Adjust the pressure of the low pressure circuit by working on adjustment valve 6 located. The values are given on the “Data sheet”.
E0004
ATTENTION!
If the delivery rate of oil under low pressure is too high, the machine and molds may be seriously damaged. 7.5.2
ADJUSTING THE MOLDING STAGE (HIGH PRESSURE)
The pressure is regulated by working on valve 13 located in the hydraulic power unit. The value is given on the “Data sheet”. 7.5.3
ADJUSTING THE ACTUATOR DOWNSTROKE
Work on valve 15 located in the hydraulic power unit to adjust the pressure. The value is given on the “Data sheet”.
E0004
ATTENTION!
If the return pressure of the actuator is too high, the piston may violently bang its end-stop.
7-20
002AZ019A
ADJUSTMENTS
7.6
E0004
7
ADJUSTING THE TEMPERATURE CONTROLLER
ATTENTION!
Do not change the settings, given on the data sheet, of the thermostatic valve and temperatures set for the upper and lower molds. Set the temperature of the molds and auxiliary equipment from the control system The values are given on the “Data sheet”.
7.7
ADJUSTING THE MOLDS
The molds are strictly related to the type of product handled. The instructions concerning specific tooling are given during the training session attended by the customer’s personnel.
7-21
002AZ019A 7 7.8
ADJUSTMENTS ADJUSTING THE EXIT CONVEYOR BELT
FIGURE 7.8 - ADJUSTING THE EXIT CONVEYOR BELT 1 2 3 4 5 6 7 8 9 10 11
Conveyor belt Screw Guide Nut Screw Nut Screw Nut Guide Screw Cover
12 13 14 15 16 17 18
Screw Screw Screw Plate Cover Screw Conveyor
8
7
6
1 2 9
14
3 13 10
15
17
16
5
17
17
18
17 7-22
4
12
11
002AZ019A
ADJUSTMENTS
7.8.1
7
ADJUSTING THE HEIGHT OF THE EXIT CONVEYOR BELT
- Loosen fixing screws 6 and nut 8. - Adjust the height of the belt with screw 7. - Fully tighten fixing screws 6 and nut 8. 7.8.2 - - - -
TENSIONING THE CONVEYOR BELT
Loosen nuts 4. Tension the belt with screws 5. Make sure the clearance between the screw head and plate is the same for both adjustments screws. Fully tighten nuts 4.
7.8.3
ADJUSTING THE GUIDES
- Loosen screws 2 and 9. - Adjust the guides 3 and 9. - Tighten screws 2 and 9.
7-23
002AZ019A 7
ADJUSTMENTS
7.9
REPLACING THE SENSORS
When replacing the sensors consult the chart below as they must be placed the correct distance away in order to read properly. SENSOR
REFERENCE OBJECT
BQ2
See paragraph ADJUSTING THE QUALITY CONTROL UNIT
BQ21
See the procedure to set the sensor given in the INSTRUCTIONS B manual; adjust the position of the sensor so that its reading surface is parallel with the surface to be detected.
SQ1
Block
1 mm
SQ2
Actuator clamp
2 mm
SQ11
Cap on turret
1 mm
SQ18
Limiter mobile ring, with limiter pick up
0.5 mm
SQ21
Cap on turret
1 mm
SQ39
Stripper rod head
SQ59
Punch lower surface
SQ62
Actuator clamp (down)
2 mm
SQ62C
Cap on turret
2 mm
7-24
DISTANCE X
8.5 mm 8 mm (L=95 mm)
002AZ019A
ADJUSTMENTS
7
FIGURE 7.9/A - REPLACING THE SENSORS 1 2 3 4 5 6
Insertion Cavity lift Molding Cooling Cavity opening Stripping SQ39 SQ2 4
SQ1 SQ11 SQ62C
5
6
BQ2
1
2
3 BQ21 SQ21
SQ62 SQ59
SQ18
T4822
T2578
X
7-25
002AZ019A 7
ADJUSTMENTS
FIGURE 7.9/B - REPLACING THE SENSORS
X
SQ1
X
X
SQ18
X
SQ11
SQ39
SQ21
7-26
X
002AZ019A
ADJUSTMENTS
7
FIGURE 7.9/C - REPLACING THE SENSORS
SQ59
SQ2
X
L
X
SQ62C
X
SQ62
X
7-27
002AZ019A 7 7.10
ADJUSTMENTS ADJUSTING THE EMERGENCY BRAKING SYSTEM
Purpose This operation is performed to assure the emergency braking system works efficiently. The emergency braking system is used in the event of an emergency to immediately shutdown the turrets and prevent the molding turret from coming into contact with the insertion turret. The machine is able to measure the braking angle at the time of emergency shutdown. 7.10.1
BRAKING ANGLE WIDER THAN NORMAL BUT IN ANY CASE ACCEPTABLE
The following message is displayed: 4011 CHECK BRAKING The braking system has braking longer that the required value. This message is displayed so that the machine can restart the automatic cycle.
E0004
ATTENTION!
Adjust the emergency braking system as instructed in paragraph EMERGENCY BRAKING SYSTEM ADJUSTMENT PROCEDURE. 7.10.2
BRAKING ANGLE TOO WIDE
The following message is displayed: 3148 BRAKING SYSTEM FAILURE The braking system has braked longer than the allowable value. Under this condition, the machine CANNOT restart the automatic cycle. In fact, the safety conditions required for the turrets and their parts are not guaranteed.
E0004
ATTENTION!
Immediately adjust the emergency braking system as instructed in paragraph EMERGENCY BRAKING SYSTEM ADJUSTMENT PROCEDURE.
7-28
002AZ019A
ADJUSTMENTS
7.10.3
7
EMERGENCY BRAKING SYSTEM ADJUSTMENT PROCEDURE
Checking the emergency braking system - Turn mode selector switch 19-23 on the keyboard to SETUP or MAN. - Press the reset button “0” to reset the machine. - Set the turret speed to 5%. - Turn on the hydraulic power unit (keys 28-8). - Turn on the lower mold downstroke circuit (keys 28-11). - Turn on the molding turret (keys 28-3) and make sure all the caps present in the molds have been removed and all the lower molds are down. - Stop the turrets (key 7). - Open the safety guards and verify that the molds, above all the cavities, are clean and that there are no pieces of plastic or other objects present. - Close the safety guards and reset the machine (keys 28-0). - Open the lower safety guards on the operator’s side. - Remove the cap of the self-braking motor. - Loosen the nuts 2. - Adjust air gap T with screws 1 bringing it down to the lowest value shown in the figure. Make sure the value is the same around the entire circumference. - Fully tighten nuts 2 keeping screws 1 in place. - Make sure the value around the entire circumference has not been affected.
E0004
IMPORTANT!
Value “X” must be greater than or equal to the value given in the figure.
E0004
IMPORTANT!
Disengagement lever 3 should not be installed while the machine is operating to avoid affecting operation of the brake system. - - - - - -
Put the cap on the self-braking motor. Close the safety guards. Make sure the hydraulic accumulators are correctly precharged (see data sheet). Make sure the hydraulic system flow rate and pressures are correctly set (see data sheet). Press buttons 28-15 to bring the insertion turret to its home position, i.e. away from the molding turret. Set the machine rpm so that > 800 caps per minute are produced.
E0004
IMPORTANT!
In order to correctly finish the procedure, the production should never be below < 800 caps. - Turn on the hydraulic power unit (keys 28-8). - Turn on the lower mold downstroke circuit (keys 28-11). - Turn on the turrets (keys 28-3).
7-29
002AZ019A 7
ADJUSTMENTS
- Turn on the high pressure circuit (keys 28-10). - Turn on the low pressure circuit (keys 28-16). - Wait for the oil to reach the operating temperature (48-50 °C) and in any case at least one minute. Depending on the machine settings for the automatic cycle, during this stage the lower molds may not complete the upstroke and therefore they do not come into contact with the upper molds. This is normal. - Press one of the emergency stop buttons to simulated an emergency shutdown. Three conditions may arise: - Fault message 3148 BRAKING SYSTEM FAILURE is displayed: repeat the adjustment procedure. - Message 4011 CHECK BRAKING is displayed; even though the machine can restart the automatic cycle, the adjustment procedure should be repeated to assure the braking system works efficiently. - Fault message 3148 BRAKING SYSTEM FAILURE is not longer displayed and other messages do not appear, the adjustments have been correctly made. - - - - - - - - -
Reset the machine (keys 28-0). Set the machine speed to 10% of the production speed.. Turn on the hydraulic power unit (keys 28-8). Turn on the lower mold downstroke circuit (keys 28-11). Turn on the turrets (keys 28-3). Wait until all the lower molds have been lowered. Stop the turrets (key 7). Shut off the power unit (key 12). The braking system has been correctly adjusted.
7-30
002AZ019A
ADJUSTMENTS
7
FIGURE 7.10.3 - EMERGENCY BRAKING SYSTEM ADJUSTMENT PROCEDURE
1
2
3 X
1,2mm
1,5mm 1,5mm
T = 0,4
0,55mm
T3965
7-31
002AZ019A 7
7-32
ADJUSTMENTS
002AZ019A
MAINTENANCE
8
8
MAINTENANCE
GENERAL INFORMATION AND SAFETY PRECAUTIONS
E0004
WARNING!
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. - isolate electrical power with personal devices (for example pad locks) stamped with the name of the operator who put it on; - remove the keys to the locks and personally hold on to them; - post a “maintenance in progress” sign on the electrical cabinet; Always keep in mind the potential risks and follow the safety rules given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.
E0004
IMPORTANT!
The pressure control valves have a ring nut that allow the threaded rod to be tightened only up to the valve setting. Do not take off the ring nut or fully tighten the rod to avoid creating excessively high pressures in the hydraulic system. Always monitor the pressure with the gauge provided when making adjustments/performing maintenance. The 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 properly trained technicians). The following are some examples of routine maintenance: - mechanical jobs: lubricating and cleaning the mechanical parts, replacing and tensioning the belts, replacing and cleaning the hydraulic valves; - electric jobs: replacing the fuses in the electrical cabinet.
E0004
WARNING!
SACMI shall not be held responsible for any personal injury or property damage if: - non-genuine spare parts are used; - spare parts are incorrectly installed; - jobs or modifications not authorized by SACMI are carried out; - tampering or altering the machine.
8-1
8-2
Replace if necessary
8.1.2.1.5
Replacing the flexible coupler
Lubricate bearings
Clean
Clean
Check and set (5)
• •
•
•
º
•
•
•
•
4320
• (6)
(1 year)
8460
•
12960
•
25920
(18 months) (3years) (4)
G.04
G.04
O.05
O.05
O.05
O.05
(1)
Type Qty
º
•.
120
10
10
10
45
10
5
60
10
1
420
60
10
5
60
10
180
10
(min) (2)
(6) The actual time is strictly dependent on the work conditions. This symbol indicates the time interval after which the maintenance operation is to be performed for the first time, if different from thesubsequent maintenance time interval indicated by symbol
(5) Operation to be performed when polymer metering pump is serviced and when fault messages 3071 (High melt pressure) and 3072 (Low melt pressure) are displayed.
(4) Contact SACMI customer service before attempting to perform operations for additional information.
(3) Refer to the paragraphs that deal with the operation.
(2) Estimated machine downtime required to perform the maintenance operation.
(1) Refer to the COOLING MIXES, ADHESIVES AND LUBRICANTS DATA SHEET supplied under separate cover.
Extruder motor
8.1.2.2.9
8.1.2.2.7
Nozzle
Nozzle - connecting rod insert
8.1.2.2.8
Lubricate universal joint
8.1.2.2.6
Pressure transducers BP1 (if present), BP2
Overhaul completely
Clean outside
8.1.2.2.4
8.1.2.2.5
Change oil
8.1.2.2.3
Add oil if necessary
• •
• • • •
2160
SCHEDULED MAINTENANCE CHART
Check oil level
Check wear and tear and replace if necessary (4)
º
• •
1440
(1 month) (2 months) (3 months) (6 months)
720
Time
8.1.1
8.1.2.2.2
8.1.2.2.1
Change oil
Add oil
360
Product
ROUTINE MAINTENANCE
Polymer metering pump (if present)
Check wear and tear
8.1.2.1.1 8.1.2.1.4
Check oil level
Replace if necessary
8.1.2.1.3
8.1.2.1.6 8.1.2.1.7
Check wear and tear
180
To be carried out every
8.1
Extruder gearbox
Extruder auger
PLASTICIZATION UNIT
Molding turret gear motor
Insertion turret shaft molding turret drive belt
Molding turret drive belt
Operation
8.1.2.1.1 8.1.2.1.2
(3)
8
DRIVE UNIT
Unit and part
002AZ019A MAINTENANCE
• •
1440
•
4320 (1 year)
8460 12960
25920
(18 months) (3years) (4)
G.04
(1)
Type Qty
5/120
5/120
5
10
45
45
45
60
30
40
45
15
30
40
(min) (2)
Time
This symbol indicates the time interval after which the maintenance operation is to be performed for the first time, if different from the subsequent maintenance time interval indicated by symbol .
º
(4) Contact SACMI customer service before attempting to perform operations for additional information.
(3) Refer to the paragraphs that deal with the operation.
2160
Product
(2) Estimated machine downtime required to perform the maintenance operation.
(1) Refer to the COOLING MIXES, ADHESIVES AND LUBRICANTS DATA SHEET supplied under separate cover.
•
Check precharge
8.1.2.3.5
Lubricate and check wear and tear. Change if necessary
Change if necessary
8.1.2.3.4
• •
8.1.2.3.13
Clean
8.1.2.3.3
Gears
Change if necessary
8.1.2.3.2.5
• •
•
Clean
8.1.2.3.2.4
Insertion turret drive belts
Rotate/change cutters
8.1.2.3.2.1 8.1.2.3.2.3
• •
720
To be carried out every (1 month) (2 months) (3 months) (6 months)
Check wear and tear and tension. Change if necessary
Sharpen cutters
8.1.2.3.2.2
•
•
360
Adjust if necessary
Change if necessary
8.1.2.3.1.4 8.1.2.3.1.5
• •
180
8.1.2.3.7 8.1.2.3.8
Clean
Change cutters
8.1.2.3.1.2
8.1.2.3.1.3 8.1.2.3.1.5
Sharpen cutters
Operation
8.1.2.3.1.1
(3)
8.1.2.3.6
Turret connecting rod
Compressed air and vacuum distributor
Cutters with insertion piston
Cutters with insertion blower
INSERTION TURRET
Unit and part
002AZ019A
MAINTENANCE 8
8-3
8-4
Overhaul
8.1.2.4.3
8.1.2.4.2
8.1.2.4.4
8.1.2.4.8
8.1.2.4.9
Stripper rods: wheels and pins
Stripper rods: guide bushes
Central molds (optional): wheels
Change if necessary
Check and lubricate
Change if necessary
8.1.2.5.1
8.1.2.5.2
Check and lubricate
8.1.2.5.1
8.1.2.5.5
Change if necessary
Check and lubricate
8.1.2.5.1
8.1.2.5.4
Change if necessary
8.1.2.5.3
Check and lubricate
Lubricate
Lubricate
Lubricate
Check tightness
•
180
• • •
•
360
1440
•
4320 (1 year)
8460
480
20
10
15
(min) (2)
G.04
G.04
G.04
G.04
G.04
O.01
10
2
10
2
45
2
120
2
30
30
30
60
Qty
• G.04
G.04
G.06
(1)
Type
600
25920
Time
•
•
12960
(18 months) (3years) (4)
Product
This symbol indicates the time interval after which the maintenance operation is to be performed for the first time, if different from the subsequent maintenance time interval ºindicated by symbol •.
(4) Contact SACMI customer service before attempting to perform operations for additional information.
(3) Refer to the paragraphs that deal with the operation.
(2) Estimated machine downtime required to perform the maintenance operation.
• • • • • • • •
2160
(1 month) (2 months) (3 months) (6 months)
720
To be carried out every
(1) Refer to the COOLING MIXES, ADHESIVES AND LUBRICANTS DATA SHEET supplied under separate cover.
Central stripper cam (optional)
Upper mold air injection cam
Actuator valve control cams
Stripper cam
8.1.2.5.1
8.1.2.4.12
Lower flange ring nut
CAMS
8.1.2.4.5 8.1.2.4.6 8.1.2.4.7
Hydraulic actuator: gasket Upper flange: gaskets Lower flange: gaskets
Change
Lubricate wheel
8.1.2.4.10
Turret bearings
Actuator valves
Lubricate
8.1.2.4.1
Clean
Operation
Molding turret
(3)
8
MOLDING TURRET
Unit and part
002AZ019A MAINTENANCE
Change suction filter and flexible coupling
8.1.2.6.5
•
Check and precharge if necessary (7)
Check and precharge if necessary (7)
8.1.2.6.1
8.1.2.6.1
Low pressure accumulator
High pressure accumulator
720
•
•
1440
•
•
•
(1 year)
8460
•
12960
25920
(18 months) (3years) (4)
O.03 O.04
(1)
Type
290
Qty
5
5
30
5
240
15
10
2
960
(min) (2)
Time
This symbol indicates the time interval after which the maintenance operation is to be performed for the first time, if different from the subsequent maintenance time interval indicated by symbol .
•
•
4320
Product
º
(7) The values are given on the “DATA SHEET”
(4) Contact SACMI customer service before attempting to perform operations for additional information.
(3) Refer to the paragraphs that deal with the operation.
(2) Estimated machine downtime required to perform the maintenance operation.
•
2160
(1 month) (2 months) (3 months) (6 months)
To be carried out every
(1) Refer to the COOLING MIXES, ADHESIVES AND LUBRICANTS DATA SHEET supplied under separate cover.
•
Clean
360
8.1.2.6.7
Check condensate on bottom of reservoir
Change oil
8.1.2.6.3
8.1.2.6.6
Change filter
8.1.2.6.4
180
Solenoid valves YV21, YV27, YV30
Hydraulic power unit
Check oil level
Replace
Replace
Operation
8.1.2.6.2
8.1.2.4.11
Bearings
HYDRAULIC POWER UNIT
8.1.2.4.11
(3)
Gaskets
ROTARY DISTRIBUTOR
Unit and part
002AZ019A
MAINTENANCE 8
8-5
8-6
Check
Replace if necessary
8.1.2.8.1.2
Change
8.1.2.7.3
8.1.2.8.1.1
Check level and top up, if necessary
Change
Clean
8.1.2.7.2
8.1.2.7.1
Clean silencers/change
Clean filter
Check and precharge if necessary (7)
Operation 180
•
•
•
360
1440
•
•
•
4320 (1 year)
8460
•
12960
25920
(18 months) (3years) (4)
MR_A MR_B
MR_A MR_B
(1)
Type
100 I
Qty
Product
150
5
45
2/10
45
45
5
5
5
(min) (2)
Time
This symbol indicates the time interval after which the maintenance operation is to be performed for the first time, if different from the subsequent maintenance time interval indicated by symbol .
º
(7) The values are given on the “DATA SHEET”
(4) Contact SACMI customer service before attempting to perform operations for additional information.
(3) Refer to the paragraphs that deal with the operation.
(2) Estimated machine downtime required to perform the maintenance operation.
• •
•
2160
(1 month) (2 months) (3 months) (6 months)
720
To be carried out every
(1) Refer to the COOLING MIXES, ADHESIVES AND LUBRICANTS DATA SHEET supplied under separate cover.
Valves
AIR INJECTION DEVICE
Coolant
Filters
COOLING SYSTEM
System
PNEUMATIC SYSTEM
8.1.2.6.1
(3)
8
Actuator return accumulator
Unit and part
002AZ019A MAINTENANCE
Clean
Clean
Replace if necessary
8.1.2.9.1
Clean and replace blower filter, if necessary
Clean and change suction and waste container filters
Clean and replace blower filter, if necessary
Clean and change main filter
Check wear and tear and tension
8.1.2.9.2
•
•
(1 year)
8460 Qty
5
5
5
(min) (2)
•
This symbol indicates the time interval after which the maintenance operation is to be performed for the first time, if different from the subsequent maintenance time interval indicated by symbol .
2
5
60
(1)
Type
•
25920
5
•
•
12960
(18 months) (3years) (4)
Time
•
(4) Contact SACMI customer service before attempting to perform operations for additional information.
(3) Refer to the paragraphs that deal with the operation.
(2) Estimated machine downtime required to perform the maintenance operation.
•
•
4320
Product
º
2160
•
1440
Check and replace pump vane, if necessary
720
(1 month) (2 months) (3 months) (6 months)
• •
360
(1) Refer to the COOLING MIXES, ADHESIVES AND LUBRICANTS DATA SHEET supplied under separate cover.
Count photocell
Slide surface slots
Conveyor belt
180
To be carried out every
Clean and replace pump filter, if necessary
Clean and change main and auxiliary filters
Operation
SEE ADJUSTMENTS
8.1.2.10
Waste and burr suction (if present)
PRODUCT EXIT CONVEYOR BELT
8.1.2.10
8.1.2.10
(3)
Product exit conveyor belt
Insertion turret: Cap hold down and pellet insertion piston
VACUUM SYSTEMS
Unit and part
002AZ019A
MAINTENANCE 8
8-7
8-8
IMPORTANT INFORMATION!
(1 year)
8460 12960
25920
(18 months) (3years) (4) (1)
Type Qty
5
30
15
1
5
5
5
20
30
60
5
(min) (2)
Time
This symbol indicates the time interval after which the maintenance operation is to be performed for the first time, if different from the subsequent maintenance time interval indicated by symbol .
•
(4) Contact SACMI customer service before attempting to perform operations for additional information.
(3) Refer to the paragraphs that deal with the operation.
(2) Estimated machine downtime required to perform the maintenance operation.
(1) Refer to the COOLING MIXES, ADHESIVES AND LUBRICANTS DATA SHEET supplied under separate cover.
º
•
•
4320
Product
As regards machinery equipped with components that fall within the field of application of Directive 97/23/EC, the client must conduct tests after putting it into service in compliance with the established methods and times.
E0004
COMPONENTS THAT FALL WITHIN THE FIELD OF APPLICATION OF DIRECTIVE 97/23/EC
Check efficiency
•
Check connections and condition of cables
Electric cables
Differential protection devices for switches
•
Check connections and condition of cables
Check efficiency
8.1.2.11.3
Visual/audible indicators
• • •
•
2160
Grounding system
Check operation of limit switches
8.1.2.11.2
Doors
Check operation
Maintenance (consult specific documentation)
•
•
1440
To be carried out every (1 month) (2 months) (3 months) (6 months)
720
Make sure the condensate drain hose is not clogged
360
•
180
Clean filters
Check seals
Clean and service
8.1.2.11.1
8.1.2.12.3
8.1.2.12.2
8.1.2.12.1
Remove condensate and other liquids
Operation
Emergency stop buttons
SAFETY DEVICES
Electrical cabinet air conditioners (if present)
Electrical cabinet fans (if present)
Electric boxes and boards
Electrical cabinets
(3)
8
ELECTRICAL SYSTEM
Unit and part
002AZ019A MAINTENANCE
002AZ019A
MAINTENANCE
8.1.2
PERIODIC MAINTENANCE OPERATIONS
8.1.2.1
Drive unit
8
FIGURE 8.1.2.1 - DRIVE UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 M9
Screw Nut Screw Belt Belt Nut Screw Pulley Back plate Screw Nut Screw Cock Filler plug Level gauge Manual control handwheel Tensioning unit Epicyclic gear motor
16 M9 14 15
13
4 9
7 17 3
2
1
11 12 3 8
5
6
T2964
10
T1495
8-9
002AZ019A 8 8.1.2.1.1
MAINTENANCE 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. Replace the belt if ruined. 8.1.2.1.2 - - - - - -
Tensioning the molding turret transmission belts
Take off the bottom covers to reach the transmission belts Loosen the screws 1. Loosen the nut 2. Turn the screw 3 (screw it to tighten). Fully tighten the nut 2. Fully tighten the screws 1.
8.1.2.1.3
Replacing the molding turret transmission belts
- - - - - - - - - - - - -
Take off the bottom covers to reach the transmission belts Loosen the nut 6. Loosen the screw 7. As soon as possible, pull the belt 5 off the pulley 8. Loosen the screws 1. Loosen the nut 2. Loosen the screw 3 until the belt 4 can be removed. Change the belt 4. Tighten the screw 3 to tension the belt. When the belt is tensioned, fully tighten the nut 2. Tighten the screws 1. Put the belt 5 on the pulley 8. Tighten the screw 7 until the reference plate 9 is 0.1 mm (check the distance with a thickness gauge) from the end of the support or transmission unit. - Fully tighten the nut 6. - Time the molding unit, insertion unit and stripper wheels (see chapter 7 - ADJUSTING PELLET INSERTION TIMING). 8.1.2.1.4
Tensioning the insertion unit transmission belt
The belt is tensioned by loosening the nut 6 and then working on the screw 7 until the reference plate 9 is 0.1 mm (check the distance with a thickness gauge) from the stop on the transmission unit support. Fully tighten the nut 6.
8-10
002AZ019A
MAINTENANCE
8.1.2.1.5 - - - - - - - - - - - - - -
8
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. Loosen the screw 7 until the belt 5 can be removed. Change the belt. Tighten the screw 7 until the reference plate is 0.1 mm (check the distance with a thickness gauge) from the end of the support or transmission unit. Fully tighten the nut 6. Install the mount with encoder by tightening the nuts 11. Fully tighten the screws 10. Install the mount with sensor by tightening the screw 12. Make sure the sensor is activated. Time the molding unit, insertion unit and stripper wheels (see chapter 7 - ADJUSTING PELLET INSERTION TIMING).
8.1.2.1.6
Checking the oil level in the molding turret gear motor
- Make certain the oil level does not fall below the collar fixed to the level indicator’s tube 15. If it does, add oil through the filler plug 14. 8.1.2.1.7 - - - - - -
Changing the oil in the molding turret gear motor
Attach the hose to the drain cock 13. Open the cock 13 and filler plug 14. Wait until the oil has completely flown out. Close the cock 13. Put oil in through the filler plug 14, checking the level by observing the indicator 15. Close the filler plug 14.
8-11
002AZ019A 8
MAINTENANCE
8.1.2.2
Plasticization unit
FIGURE 8.1.2.2 - PLASTICIZATION UNIT 14
7
10
7
18
1
4
5
17
16
9
11
2
6
A 13
A
15
T4558
8-12
8
12
19
3
002AZ019A
MAINTENANCE
8.1.2.2.1
E0004
8
Overhauling the extruder auger
ATTENTION!
To ease cleaning, use polypropylene when by-passing and increase the extruder’s operating temperature so that it does not cool down excessively when disassembling.
E0004
E0137
E0003
WARNING!
Heed to all safety rules and standards - risk of burns and crushing. - 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.
E0004
ATTENTION!
Stop feeding plastic compound to the extruder when cleaning. - - - - - - - - -
Install the guide extensions 1 provided. Shut off the machine with the main switch located on the electrical cabinet. Take the safety guards off the extruder. Take off the cover 4 on the extruder connecting tube. Disconnect the pressure transducers 2 loosening the quick-connect coupler located under the mounting bracket joined to the extruder. Unscrew the probe attached to the pump being careful not to twist or bend the transducer cable. Disconnect the cable connectors 3 from the electrical boxes. Disconnect the thermocouple mounted on the nozzle case. Remove screws 5. Back up the extruder with the connecting tube attached to the end of the guide’s longitudinal stroke. Clean up the plastic compound that flows out of the tube and nozzle as soon as possible.
E0004
ATTENTION!
Move the electrical cables away from under the extruder to avoid cutting them. - Loosen the nuts 18 and turn the extruder’s wheels 90°. - Move the extruder outwards cross-wise. - Loosen the nuts 6 and remove the connecting tube. Clean up the plastic compound that flows out of the tube and volumetric pump as soon as possible. - Pull out the heating elements 7 removing the relative mounting screws. - Disconnect the connectors of the thermocouples 8. - Loosen the heating elements 9 loosening the fixing screws. - Loosen the two screws 10 from the top of the volumetric pump and replace them with two longer screws to secure the two eyebolts used to lift the pump. 8-13
002AZ019A 8
MAINTENANCE
- Loosen grub screw 19. - Loosen nuts 11 and remove volumetric pump 12 keeping it raised with the chains fitted with hooks secured to the eyebolts previously put in. - Remove extruder filter 13 using the screws to be tightened in the threaded holes. - Remove screws 14 and take off the cover that protects the threaded fitting for the fixture used to remove the auger. - Put in fixture 15 supplied with the machine. Tighten it to the threaded fitting and screw on the threaded extensions until the extruder auger 16 is removed. - Take out the fixture 15 used to remove the extruder auger. - Clean auger 16, filter 13 and extruder chamber as directed below.
E0004
ATTENTION!
This operation is to be performed with the plastic compound at room temperature. - Thoroughly clean the auger with soft metal hand tools (for example bronze or copper), removing the resin sheath. - Clean the inside of the cylinder with a brush, removing any material stuck to the cylinder. - Thoroughly clean filter 13. Replace it if worn. To open the filter holes, use a drill bit whose diameter is slightly smaller than the holes in the filer. - Make certain cover 17 on the extruder head (that may have different shapes) is completely tightened. - Lubricate the grooved profile of the auger (use type G.10 grease, see ADHESIVES AND LUBRICANTS DATA SHEET). - Install the auger on the extruder mating the extruder’s grooved profile correctly with the auger, making sure the auger is fully in. - Install filter 13. - Install heating elements 9. - Install the volumetric pump by fully tightening nuts 11 (when tightening, always work on the diagonally opposite screw so that the filter is tightened evenly; once installed check the distance between the two flanges with a thickness gauge to make sure installation is correct). - Remove the two eyebolts and tighten the original mounting screws 10 for the pump cover. - Fully tighten the fixing screws for heaters 9. - Reconnect the connectors for thermocouples 8. - Install the heating elements 7 fully tightening the relative screws. - Mount the extruder’s connecting tube fully tightening nuts 6 with a 6 kgm torque. - Move the extruder crosswise towards the machine. - Turn the extruder’s wheels 90 ° and tighten nuts 18. - Bring the tube near the nozzle body and connect it tightening screws 5 being careful to align the ball of the connecting tube with the nozzle body. - Connect the nozzle body’s thermocouple. - Connect the connectors 3 of the electric cables to the relative boxes. - Install the pressure transducers 2, screwing the probe attached to the pump and quick-connect coupler. Be careful not to twist or bend the transducer cable. - Put the safety guard 4 on the extruder’s connecting tube. - Put the cover on the extruder auger’s fitting securing with screws 14. - Remove the extensions for guides 1. - Install the extruder safety guards. - Turn on the machine with the main switch.
8-14
002AZ019A
MAINTENANCE
8.1.2.2.2 - - - -
8
Checking the oil level and adding oil in the extruder gearbox
Make sure the oil level, shown by the gauge 2, is correct. If it is not, top up as follows: Take off cap 1. Add oil until sight glass 2 shows the correct level has been reached. Screw the cap 1 back on. FIGURE 8.1.2.2.2 - CHECKING THE OIL LEVEL AND ADDING OIL IN THE EXTRUDER GEARBOX 1
2
3
8-15
002AZ019A 8
MAINTENANCE
8.1.2.2.3 Changing the oil in the extruder gearbox (See figure 8.1.2.2) - - - - -
Take off cap 1. Take off cap 3 and drain the oil from the gearbox. Screw the cap 3 back on. Add oil until sight glass 2 shows the correct level has been reached. Screw the cap 1 back on.
8.1.2.2.4
E0004
Cleaning the polymer metering pump
E0137
E0003
WARNING!
Heed to all safety rules and standards - risk of burns and crushing. - Remove all the plastic that flows out of the pump 12 being careful not to cut the pressure transducer and heating element cables. 8.1.2.2.5
E0004
Replacing/overhauling the polymer metering pump
ATTENTION!
To ease cleaning, use polypropylene when by-passing and increase the extruder’s operating temperature so that it does not cool down excessively when disassembling.
E0004
E0137
E0003
WARNING!
Heed to all safety rules and standards - risk of burns and crushing. - 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.
E0004
ATTENTION!
Stop feeding plastic compound to the extruder when cleaning. - - - -
Shut off the machine with the main switch located on the electrical cabinet. Take the safety guards off the extruder. Take the cover 4 off the extruder connecting tube. Disconnect the pressure transducers 2, unscrewing the quick-connect coupler found under the extruder’s mounting bracket and loosen the probe attached to the pump being careful not to twist or bend the transducer cable.
8-16
002AZ019A - - - -
MAINTENANCE
8
Disconnect the cable connectors 3 from the electrical boxes. Disconnect the thermocouple mounted on the nozzle body. Remove screws 5. Back up the extruder with the connecting tube attached to the end of the guide’s longitudinal stroke. Clean up the plastic compound that flows out of the tube and volumetric pump as soon as possible.
E0004
ATTENTION!
Move the electrical cables away from under the extruder to avoid cutting them. - Loosen the nuts 6 and remove the connecting tube. Clean up the plastic compound that flows out of the tube and nozzle as soon as possible. - Remove the heating elements 7 removing the mounting screws. - Disconnect the connectors of thermocouples 8. - Loosen the screws to loosen heating elements 9. - Remove the two screws 10 from the top of the volumetric pump and put in two longer screws to secure the two eyebolts used to lift the pump. - Loosen grub screw 19. - Loosen nuts 11 and remove volumetric pump 12. Keep it up with the chains that have hooks attached to the eyebolts previously installed. - Take out the flange attached to the metering pump. - 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.
8-17
002AZ019A 8
MAINTENANCE
8.1.2.2.6 - - - -
Lubricating the universal joint
Take off the side covers in the area where the universal joint is found. Clean the universal joint and surrounding areas removing any extruded plastic material. Grease with the grease fittings 1 until grease runs out from between the parts of the universal joint. Put the side covers back on. FIGURE 8.1.2.2.6 - LUBRICATING THE UNIVERSAL JOINT
1
8-18
002AZ019A
MAINTENANCE
8.1.2.2.7
8
Cleaning the nozzle
- Remove the plastic compound that has deposited on the nozzle during operation. Be careful not to ruin the top part where the cutters that cut the pellets pass by.
E0004
E0137
E0003
WARNING!
Heed to all safety rules and standards - risk of burns and crushing. 8.1.2.2.8
E0004
Checking and setting pressure transducers BP1 and BP2
E0137
E0003
WARNING!
Heed to all safety rules and standards - risk of burns and crushing. 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. Under these conditions, the plastic compound in the polymer metering pump station will melt and the transducer’s probe inside the pump can be completely tightened, when a new transducer is installed.
E0004
ATTENTION!
The transducers have to be set while the polymer meter pump station is at the operating temperature. B - Make sure the transducer probes are properly installed and relative cables connected: BP1 (inlet pressure) cable XB98; BP2 (outlet pressure) cable XB99. C - First of all adjust transducer BP1. D - Call up the DATA page on the display. E - Remove the protective screw 1 on the transducer casing and press button 2, located inside with the extruder stopped (this means that pressure does not reached the pump). F - Adjust transducer BP2 repeating the operations given for step E. G - Verify that the pressure values (pump input and output) shown on the display screen read zero.
8-19
002AZ019A 8
MAINTENANCE
FIGURE 8.1.2.2.8 - CHECKING AND SETTING PRESSURE TRANSDUCERS BP1 AND BP2
1
2
8-20
002AZ019A
MAINTENANCE
8.1.2.2.9
8
Lubricating the extruder motor bearings
- Take off the side covers in the area where the motor is found. - Grease the motor bearings with grease fittings 1 until grease runs out from under the motor shaft. - Put the side covers back on. FIGURE 8.1.2.2.9 - LUBRICATING THE EXTRUDER MOTOR BEARINGS
1
8-21
002AZ019A 8 8.1.2.3
E0004
MAINTENANCE Insertion turret
E0137
E0003
WARNING!
Heed to all safety rules and standards - risk of burns and crushing.
E0004
E0138
WARNING!
Cut hazard at the insertion turret cutting blades; adequate personal protective equipment must be worn (grippers, protective gloves, etc…). YV33 1 2 3 4 5 6 7 8 9 10 11 12.1 12.2 12A 12B 12C 12D 12E 12F 12G 12H 12L 12M 13 14 15 16 17 18 19 20 21 22 23
8-22
Solenoid valve Pulley Torque limiter Encoder Mount Toothed wheel Pneumatic cylinder Toothed wheel Pulley Toothed wheel Pulley Tensioner Cutter without insertion piston Cutter with insertion piston Disk Piston Gasket Sleeve Knife Screw Cutter Screw Nozzle Gasket Disk Wheel Wheel Screw Spacer Distributor Flange Screw Nut Pin Nut
24 25 26 27 28 29 30 31 32 33 34 38 39 40 41 42 43 44 45 46 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63
Pin Counter-device Screw Connecting rod Screw Screw Screw Disk Screw Spring Pin Cover Screw Screw Spacer Ring nut Flange Nut Screw Screw Shaft Screw Flange Nut Washer Spring Spacer Screw Pin Ring nut Spacer Snap ring Screw Snap ring Cover
002AZ019A
8
MAINTENANCE FIGURE 8.1.2.3 - INSERTION TURRET YV33 14
30
28
20
17
34
19 16
18
33
31
32 13
12.2 27 41 43 42
51 15
12H 26
50
12.1
29 56
21
6
46
23 22
45
24
58
38 5
40
8
7
11
57 61 39
60
9
59
10 44
4
62
49 12M
12.1
12L 53 12G
52
12E
55
12F
54
12.2 12A 12B 12C
25
12D 1
12G 12E 12F
12H
2 3
63 T4817
8-23
002AZ019A 8 8.1.2.3.1
MAINTENANCE Cutters with insertion blower
8.1.2.3.1.1 Sharpening the blades - - - -
Loosen screws 12F and take out the blades 12E. Sharpen the blades at a work bench with vice with a grinding stone. Install the blades 12E by tightening the screws 12F. Adjust the height of the blades as instructed in chapter 7 - paragraph ADJUSTING THE CUTTER.
8.1.2.3.1.2 Replacing the blades - Loosen screws 12F and take out the blades 12E. - Put in the new blades. - Adjust the height of the blades as instructed in chapter 7 - paragraph ADJUSTING THE CUTTER. 8.1.2.3.1.3 Cleaning the cutters - - - - - - - - - - - - - - -
Remove the guides mounted on top of wheels 14 and 15. Remove the screws 29. Remove the flange 51 that the wheel 15 is mounted on. Loosen the screws 28. Remove the wheel 14. Loosen the screws 30. Remove the disk 13. Loosen the screws 12H and remove the cutter 12G. Clean the cutter to remove any burrs of plastic compound and degrease the part with diluent. Install the cutter 12G and tighten the screws 12H. Install the disk 13 by tightening the screws 30. Install the wheel 14 by tightening the screws 28. Install the flange 51 with the wheel 15 by tightening the screws 29. Install the guides over the wheels 14 and 15. Adjust the cutters, pellet insertion and the wheels as directed in the ADJUSTING THE CUTTER and ADJUSTING PELLET INSERTION TIMING paragraphs in chapter 7.
8.1.2.3.1.4 Replacing the blades - - - - - - - - - - - - - - -
Remove the guides mounted on top of wheels 14 and 15. Remove the screws 29. Remove the flange 51 that the wheel 15 is mounted on. Loosen the screws 28. Remove the wheel 14. Loosen the screws 30. Remove the disk 13. Loosen the screws 12H and remove the cutter 12G. Install the blade 12F, taken off the old cutter, on the new one 12G. Install the cutter 12G and tighten the screws 12H. Install the disk 13 by tightening the screws 30. Install the wheel 14 by tightening the screws 28. Install the flange 51 with the wheel 15 by tightening the screws 29. Install the guides over the wheels 14 and 15. Adjust the cutters, pellet insertion and the wheels as directed in the ADJUSTING THE CUTTER and ADJUSTING PELLET INSERTION TIMING paragraphs in chapter 7.
8-24
002AZ019A
MAINTENANCE
8
8.1.2.3.1.5 Cleaning or replacing the nozzles - - - - - - - - - - - - - - - - -
Remove the guides mounted on top of wheels 14 and 15. Remove the screws 29. Remove the flange 51 that the wheel 15 is mounted on. Loosen the screws 28. Remove the wheel 14. Loosen the screws 30. Remove the disk 13. Loosen the screws 12H and remove the cutter 12G and nozzle 12L. Clean the nozzle 12L with diluent. Blow compressed air in the holes to remove any dirt; replace the nozzle if damaged. Check the condition of gasket 12M. Replace it if worn. Install the nozzle 12L on the cutter 12G. Install the cutter 12G by tightening the screws 12H. Install the disk 13 by tightening the screws 30. Install the wheel 14 by tightening the screws 28. Install the flange 51 with the wheel 15 by tightening the screws 29. Install the guides over the wheels 14 and 15. Adjust the cutters, pellet insertion and the wheels as directed in the ADJUSTING THE CUTTER and ADJUSTING PELLET INSERTION TIMING paragraphs in chapter 7.
8-25
002AZ019A 8
MAINTENANCE
8.1.2.3.2
Cutters with insertion piston
8.1.2.3.2.1 Rotating the blades - - - -
Loosen screw 12F and take out the blades 12E. Turn the blades 12E 180° to use the other edge. Install the blades 12E by tightening the screws 12F. Adjust the height of the blades as instructed in chapter 7 - paragraph ADJUSTING THE CUTTER.
8.1.2.3.2.2 Sharpening the blades - - - -
Loosen screws 12F and take out the blades 12E. Sharpen the blades at a work bench with vice with a grinding stone. Install the blades 12E by tightening the screws 12F. Adjust the height of the blades as instructed in chapter 7 - paragraph ADJUSTING THE CUTTER.
8.1.2.3.2.3 Replacing the blades - Loosen screws 12F and take out the blades 12E. - Put in the new blades. - Adjust the height of the blades as instructed in chapter 7 - paragraph ADJUSTING THE CUTTER. 8.1.2.3.2.4 Cleaning the cutters with insertion piston Loosen screws 12H. Remove cutter 12G paying attention to disc 12A as it is free inside the housing. Remove the piston 12B. Remove the sleeve 12D. Clean the cutter 12G of any plastic burrs and degrease the part with a thinner. Blow compressed air in the holes to remove the thinner and any dirt. Clean the sleeve 12D and piston 12B with alcohol. Install the sleeve 12D in the cutter 12G without using any grease or oil. Install the piston 12B without using any grease or oil, making sure gasket 12C is present. Make sure the piston 12B and sleeve 12D are able to move freely without any seizure. If this is not the case, clean the parts again. - Install the cutter 12G and disc 12A in the disc housing 31. - Adjust the height of the blades as instructed in chapter 7 - paragraph ADJUSTING THE CUTTER.
- - - - - - - - - -
8.1.2.3.2.5 Replacing the cutters - Loosen screws 12H. - Remove cutter 12G paying attention to disc 12A as it is free inside the housing.
8-26
002AZ019A
MAINTENANCE
8
- Mount the sleeve 12D, previously removed from the old cutter, in the new cutter 12G without using any grease or oil. - Mount the piston 12B, previously removed from the old cutter, in the new cutter 18C without using any grease or oil, making sure gasket 12C is present. - Make sure the piston 12B and sleeve 12D are able to move freely without any seizure. If this is not the case, clean the parts with alcohol. - Install the blade 12E, removed from the old cutter, on the new body 12G. - Install the cutter 12G and disc 12A in the disc housing 31. - Adjust the height of the blades as instructed in chapter 7 - paragraph ADJUSTING THE CUTTER. 8.1.2.3.3
Cleaning the compressed air distributor
Loosen the screw 16. Remove the spacer 17. Loosen the screw 32. Raise the distributor 18 and flange 19. Blow compressed air in the holes in the distributor 18 and remove any dust present both on the distributor and nearby parts. - Perform the steps in reverse to reinstall the parts.
- - - - -
8.1.2.3.4 - - - - - - - - - - - -
Replacing the compressed air distributor
Loosen the screw 16. Remove the spacer 17. Loosen the screw 32. Raise the distributor 18 and flange 19. Remove the flange 19. Remove the springs 33. Detach the air lines from the distributor. Remove solenoid valve YV33. Remove the pneumatic fittings. Remove the dowel 34. Replace the distributor 18. Perform the steps in reverse to reinstall the parts.
8.1.2.3.5
Checking precharge of the turret connecting rod
- Verify that the connecting rod is charged while it engages itself with the nozzle case’s insert as indicated in chapter 7 - ADJUSTMENTS, paragraph ADJUSTING TURRET’S CONNECTING ROD PRECHARGE. 8.1.2.3.6
Adjusting precharge of the turret connecting rod
- Verify that the connecting rod is charged while it engages itself with the nozzle case’s insert as indicated in chapter 7 - ADJUSTMENTS, paragraph ADJUSTING TURRET’S CONNECTING ROD PRECHARGE.
8-27
002AZ019A 8 8.1.2.3.7
MAINTENANCE Tensioning the insertion turret drive belt
- Tighten the nut 52 so that the washer 53 rests against spacer 55 found inside the spring 54. 8.1.2.3.8 - - - - - - - - - - - - - - - - - - - - - - - - - -
Replacing the insertion turret drive belt
Remove the cover 63. Remove the guides mounted on top of wheels 14 and 15. Remove the screws 29. Remove the flange 51 that the wheel 15 is mounted on. Loosen the ring nut 42 and remove the flange 43. Loosen the screws 39 and take off the cover 38. Loosen the nut 52 of the tensioner to slacken the belt. Make sure the belt 9 is slack enough to remove the connecting rod 27. Loosen the screw 56. Remove the pin 11 with the toothed wheel 7 and pulley 8 mounted. Remove the screw 45. Loosen the screws 46. Raise the connecting rod 27. Change the belt 9. Put the connecting rod 27 back in place being careful to put the toothed belt in the pulley 10. Tighten the screws 46. Put in the pin 11 of the toothed wheel 7 and pulley 8 being careful to insert the toothed belt in the pulley without damaging it. Tighten the screw 56. Install the flange 43 and tighten the ring nut 42. Install the flange 51 with wheel 15 tightening the screws 29. Put in and tighten the screw 45. Tighten the belt 9 as directed In paragraph TENSIONING THE INSERTION TURRET DRIVE BELT. Put the cover 38 back in place and secure with screws 39. Put on the cover 63. Install the guides over the wheels 14 and 15. Adjust the cutters, pellet insertion and the wheels as directed in the ADJUSTING THE CUTTER and ADJUSTING PELLET INSERTION TIMING paragraphs in chapter 7.
8-28
002AZ019A
MAINTENANCE
8.1.2.3.9 - - - - - - - - - - - - - - - - - - - - - - - -
8
Replacing the pulley (item 10)
Remove the cover 63. Remove the guides mounted on top of wheels 14 and 15. Remove the screws 29. Remove the flange 51 that the wheel 15 is mounted on. Loosen the ring nut 42 and remove the flange 43. Loosen the screws 39 and take off the cover 38. Loosen the nut 52 of the tensioner to slacken the belt. Make sure the belt 9 is slack enough to remove the connecting rod 27. Loosen the screw 45. Remove the screws 46. Raise the connecting rod 27. Loosen the ring nut 58 and remove the spacer 59. Change the pulley 10. Put in the spacer 59 and tighten the ring nut 58. Put the connecting rod 27 back in place being careful to put the toothed belt in the pulley 10. Tighten the screws 46. Install the flange 43 and tighten the ring nut 42. Install the flange 51 with wheel 15 tightening the screws 29. Put in and tighten the screw 45. Tighten the belt 9 as directed in paragraph TENSIONING THE INSERTION TURRET DRIVE BELT. Put the cover 38 back in place and secure with screws 39. Put on the cover for the waste conveyor. Install the guides over the wheels 14 and 15. Adjust the cutters, pellet insertion and the wheels as directed in the ADJUSTING THE CUTTER and ADJUSTING PELLET INSERTION TIMING paragraphs in chapter 7.
8.1.2.3.10 Replacing the toothed wheel (item 5) - - - - - -
Take off the cover 63. Loosen the screws 39 and take off the cover 38. Loosen the screw 40. Take off the toothed wheel 5 and replace it. Perform the operations in reverse order to put the parts back in place. Check pellet insertion timing and how the turrets are adjusted as directed in chapter 7 ADJUSTMENTS paragraph ADJUSTING PELLET INSERTION TIMING.
8-29
002AZ019A 8
MAINTENANCE
8.1.2.3.11
Replacing the toothed wheel (item 7)
Take off the cover 63. Loosen the screws 39 and take off the cover 38. Loosen the nut 52 from the tensioner to slacken the belt. Loosen the screw 56. Pull out the pin 57 with the toothed wheel installed. Remove the snap ring 60 at the work bench. Loosen the screws 61. Replace the toothed wheel 7. Perform the operations in reverse order to put the parts back in place. Be careful not to damage the toothed belt when putting it in the pulley 8. - Tighten the belt 9 as directed in paragraph TENSIONING THE INSERTION TURRET DRIVE BELT. - Check timing and how the stripper turrets are adjusted as directed in chapter 7 ADJUSTMENTS - paragraph ADJUSTING PELLET INSERTION TIMING.
- - - - - - - - -
8.1.2.3.12 Replacing the pulley (item 8) Take off the cover 63. Loosen the screws 39 and take off the cover 38. Loosen the nut 52 from the tensioner to slacken the belt. Loosen the screw 56. Pull out the pin 57 with the toothed wheel installed. Remove the snap ring 60 at the work bench. Loosen the screws 61. Replace the toothed wheel 7. Remove the snap rings 62 that secure the pulley 8. Replace the pulley 8. Perform the operations in reverse order to put the parts back in place. Be careful not to damage the toothed belt when putting it in the pulley 8. - Tighten the belt 9 as directed in paragraph TENSIONING THE INSERTION TURRET DRIVE BELT. - Check timing and how the stripper turrets are adjusted as directed in chapter 7 ADJUSTMENTS - paragraph ADJUSTING PELLET INSERTION TIMING.
- - - - - - - - - - -
8.1.2.3.13 Checking wear and tear and lubricating the gears - Loosen the screws 39 and remove the guard 38. - Grease the gear teeth 5 and 7. - Turn the handwheel to grease all the teeth.
E0004
E0003
WARNING!
Heed to all safety rules and standards - risk of burns and crushing. - Install the guard 38 tightening the relative screws 39.
8-30
002AZ019A
8
MAINTENANCE
8.1.2.4
Molding turret
FIGURE 8.1.2.4 - MOLDING TURRET 1 2 3 4 4A 4B 5 6
Turret lower section Hydraulic actuator Lower mold Actuator drive valve Valve control Valve Coolant ducts (lower molds) Upper mold
7 8 9 11 14 15 16 17
18 19 20 21 22 23 24
Turret upper section Stripper drive rod Fork Wheel Grease fitting Grease fitting Screw Cover 4
11
14
9
Upper flange Nut Lower flange Nut Grease fitting Grease fitting Screw
15
16
21
23 8 7
4A
24 6 3
4B
18 4 1 2 20 T4825
19
5
22
22 T4824
T4827
17 8-31
002AZ019A 8 8.1.2.4.1
MAINTENANCE 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 3 inside and outside as well as the surrounding area, removing any plastic compound or caps present. - Clean the outside of the tools and the surrounding area, removing any plastic material present. - Remove any oil present on the surfaces of the turret. 8.1.2.4.2
Overhauling the actuator valve
- Shut off electricity to the machine with the main switch located on the cabinet.
E0004
ATTENTION!
The actuators must not be in the molding position. - - - - - - -
Loosen the screws 16. Remove the control for valve 4A. Remove the valve 4B using the two threaded holes present at the top of the valve. Carry out the following operations to overhaul the valve: - remove any oil present on the valve. - replace the gaskets and springs found inside and outside the valve. Put the valve parts back in place. Install valve 4B being careful not to cut the gaskets. Install the control for valve 4A by tightening the screws 16.
8.1.2.4.3
Greasing the actuator valve rollers
- Grease the valve roller with grease fitting 15. Use the grease gun provided. - Clean up any extra grease present on the valve. 8.1.2.4.4
Greasing the stripper rod rollers
- Grease the rod roller with grease fitting 14. Use the grease gun provided.
8-32
002AZ019A
MAINTENANCE
8.1.2.4.5
8
Replacing the hydraulic actuator gasket
- Shut off electricity to the machine with the main switch located on the cabinet.
E0004
ATTENTION!
The actuators must not be in the molding position. - Take off the cover 17. - Turn the molding turret manually with the handwheel found over the motor until the actuator corresponds to the hole in the base. - Disconnect the tubes 5 from the coupling mounted on the turret manifold. Pour the coolant that flows out of the tube into a container to avoid getting the machine dirty. - Remove the cavity 3. - Loosen the fixing screws and remove the flange 18. - Loosen the nut 19 and remove the clamp that prevents rotation. - Loosen the screws and remove the lower flange 20.
E0004
ATTENTION!
The oil in the turret cavity flows out when the lower flange is unscrewed. - Remove the hydraulic actuator and replace the gasket. - Carry out the operations in reverse order to put the parts back in place.
E0004
ATTENTION!
Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself.
8-33
002AZ019A 8 8.1.2.4.6
MAINTENANCE Replacing the upper flange gaskets
- Shut off electricity to the machine with the main switch located on the cabinet.
E0004
ATTENTION!
The actuators must not be in the molding position. - Disconnect the tubes 5 from the coupling mounted on the turret manifold. Pour the coolant that flows out of the tube into a container to avoid getting the machine dirty. - Remove the cavity 3. - Loosen the fixing screws and remove the flange 18. - Replace the gaskets. - Carry out the operations in reverse order to put the parts back in place.
E0004
ATTENTION!
Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself. 8.1.2.4.7
Replacing the lower flange gaskets
- Shut off electricity to the machine with the main switch located on the cabinet.
E0004
ATTENTION!
The actuators must not be in the molding position. - Disconnect the tubes 5 from the coupling mounted on the turret manifold. Pour the coolant that flows out of the tube into a container to avoid getting the machine dirty. - Loosen the nut 19 and remove the clamp that prevents rotation. - Loosen the fixing screws and remove the lower flange 20.
E0004
ATTENTION!
The oil in the turret cavity flows out when the lower flange is unscrewed. - Replace the gaskets. - Carry out the operations in reverse order to put the parts back in place.
E0004
ATTENTION!
Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself. 8-34
002AZ019A
MAINTENANCE
8.1.2.4.8
8
Lubricating the stripper rod guide bushes
- Loosen the nut 21 and take out the spacer, fork 9 and stripper 6. - Raise the rod and grease the cylindrical surface that has just been exposed. Push the rod inside the unit so that the grease lubricates the bushes. Repeat this operation several times to assure the lubricant penetrates. - Carry out the operations in reverse order to put the parts back in place. 8.1.2.4.9
Greasing the central tool wheel (optional)
- Grease the central tool wheel with grease fitting 23 found on the support pin for the wheel. Use the grease gun provided. 8.1.2.4.10 Greasing the turret bearings - Grease the turret bearings with grease fittings 22. 8.1.2.4.11
Replacing the gaskets and rotary distributor bearings
E0003
E0004
WARNING!
Exercise extreme caution when handling the parts: danger of being crushed.
E0004
IMPORTANT!
Discharge the pressurized gas in the accumulators with the tester/inflator provided as directed in chapter 8 MAINTENANCE, paragraph CHECKING ACCUMULATOR PRECHARGE.
E0004
IMPORTANT!
Use a container to collect the oil and one to collect the coolant contained in the hoses and components which will be removed. - - - - - - - - - -
Detach the tubes that connect the rotary joint 1, spring accumulator 39 and distributor 14 to the machine. Remove the accumulator 38. Remove the spring accumulator 39 by loosening the screws 40. Detach the hoses that join the distributor 21 to the machine. Loosen the screws 41 and remove all the manifolds 42. Remove all the tubes 43. Loosen the antirotation screws 2. Remove the rotary joint 1 using the attachment at its base. Remove parts 3 and 4 by loosening the fixing screws with tool 5 (item A). Install tool 6 and eyebolt 7 on the distributor 8 (item B). 8-35
002AZ019A 8 - - - - - - - - - - - - - - - - - - - -
MAINTENANCE
Loosen the screws 9 with tool 37 (item C). Raise the distributor using the eyebolt 7 previously installed. Place the distributor on a stable support. Loosen the eyebolt 7. Loosen the ring nut 10. Loosen four of the six screws 11 and install tool 12 on distributor 14 using the four threaded holes that contained the screws 11. Screw the threaded bar of tool 12 onto tool 6 and secure with nut 13. Remove the distributor 14 with nuts 24 of tool 12 (item D). Replace the gaskets 15. To replace the bearings, follow the directions given below: - Remove tool 12. - Loosen the last two screws 11 of the flange 27. - Remove the flange 27. - Replace the bearing 28. Use tool 29 to remove as shown in the figure (item G). - Remove the snap ring 30. - Replace the bearing 31. Use tool 29 to remove as shown in the figure (item G). Loosen the screws 16. Tighten the eyebolts 17 (item E). Raise the distributor 18 using the eyebolts previously installed. Place the distributor on a stable support. Loosen the screws 19. Loosen the eyebolts 17. Install the tool 20 as shown in the figure (item F). Screw the threaded bars to the distributor 18 and secure with nuts 22. Remove the distributor 21 with nuts 23 of tool 20. Replace the gaskets 25. To replace the bearings, follow the directions given below: - Remove tool 20. - Loosen the screws 26. - Remove the flange 32. - Replace the bearing 33. Use tool 29 to remove as shown in the figure (item G). - Loosen the screws 34. - Remove the flange 35. - Remove the flange 36. - Replace the bearing 37. Perform the operations in reverse order to put the parts back into place paying special attention while handling the parts.
8-36
002AZ019A
MAINTENANCE
8
FIGURE 8.1.2.4.11/A - REPLACING THE ROTARY DISTRIBUTOR BEARINGS AND/OR GASKETS
41 42
43 T4837
1 38 39 2
40
3 4
16
T4836
8-37
002AZ019A 8
MAINTENANCE
FIGURE 8.1.2.4.11/B - REPLACING THE ROTARY DISTRIBUTOR BEARINGS AND/OR GASKETS A
B
C 7
5
37
6
8
11 10
F
D
9
24
27
12
23
E 17
28
32 15
22
14
20 26
33
31 30
21
18 13
18
6
35 34
19
25
37 36
G
29
T4838
8-38
002AZ019A
MAINTENANCE
8.1.2.4.12
8
Checking tightness of the lower flange ring nuts
- Verify the ring nuts 2 are tight by hand. - Only in the event that the ring nuts are loose, tighten the ring nuts 2, using the torque indicated in the figure and A.03 adhesive (see the COOLANT MIXES, ADHESIVES AND LUBRICANTS DATA SHEET supplied under separate cover). Use tool 1.
FIGURE 8.1.2.4.12 - Checking tightness of the lower flange ring nuts
80 Nm
1
2 A.03 T5935
8-39
002AZ019A 8
MAINTENANCE
8.1.2.5
Cams
FigurE 8.1.2.5 - cams
9 4 10 3
8
T2969
15 11 20
16 19
12 13
18 17 14
T2538
1 2
T2538
8-40
T2970
002AZ019A
MAINTENANCE
8.1.2.5.1
8
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. 8.1.2.5.2 - - - - - -
Replacing the stripper cams (central movement) (optional)
Loosen the screws 9. Replace the cam 3. Position the cam as indicated on the “Data sheet”. Fully tighten the screws 9. Check the position of the cam. Grease the cam raceway.
8.1.2.5.3
Replacing the stripper cams (side movement)
- Remove seven stripper rods from the molding turret from the side opposite the operator, as indicated below (refer to figure 8.1.2.4). - Loosen the nut 21. - Remove the stripper ring 6 with the fork 9 installed. - Remove the stripper rod 8. - Turn the turret manually until the part of the turret without any rods corresponds to the stripper cam. - Loosen the screws 10. - Replace the cam 4. - Position the cam as indicated on the “Data sheet”. - Fully tighten the screws 10. - Check the position of the cam. - Grease the cam raceway. - Turn the turret manually until the part of the turret without any rods is on the side opposite the operator. - Install the stripper rods (refer to figure 8.1.2.4). - Install the ring 6 by inserting the fork 9 in the stripper rod 8, mount the spacer and fully tightening the nut 21 for all the rods. 8.1.2.5.4 - - - - - - - -
Loosen the screws 11 and 17. Take off the covers 12 and 18. Remove the pins 13. Loosen the screws 16. Remove the cam mount 15. Loosen the screws 14 and replace the cams. Carry out the operations in reverse order to put the parts back in place. Grease the cam raceway.
8.1.2.5.5 - - - -
Replacing the actuator control cams
Replacing the cams for injecting air in the punches
Loosen the screws 19 and/or 20 depending on the cam section to be replaced. Replace the cam and position it as indicated on the “Data sheet”. Fully tighten screws 19 and/or 20. Grease the cam raceway.
8-41
002AZ019A 8
MAINTENANCE
8.1.2.6
Hydraulic system
8.1.2.6.1
Checking the accumulator’s precharge
- Turn mode selector 19-23 to MAN - Press key 12 to shut off the hydraulic power unit. - Make sure there is no pressure in the hydraulic circuit.
O2
E0004
E0034
E0035
ATTENTION!
Wait for heat exchange caused by movement of the pressures has stabilized before attempting to check or precharge the accumulators. Unscrew regulator 1. Make sure bleeder valve 5 is closed. Unscrew the cap on the accumulator’s inflation valve. Screw the inflation tester on the accumulator’s inflation valve manually, screwing fitting 4. Secure fitting 4 manually positioning the pressure gauge as required. Screw regulator 1 observing the pressure gauge’s needle. When the needle moves from 0 continue turning (1/2 a turn is enough; there is no need to fully tighten). - Read the inflation pressure given on the gauge (to check the values, consult the DATA SHEET). - - - - - -
•
To reduce the pressure. - Slowly open bleeder valve 5 until the desired pressure is reached. - Close bleeder valve 5. - Loosen regulator 1 completely. - Open bleeder valve 5. - Remove the inflation tester by loosening fitting 4.
•
To increase the pressure. - Take off knurled cap 2. - Attach the end of the hose (1/4” BSO at 60°) to fitting 3. - Attach the other end of the hose to the nitrogen source and let it in. - Close the nitrogen source valve. - Completely loosen regulator 1. - Open bleeder valve 5. - Remove the inflation tester by loosening fitting 4.
O2
E0004
E0034
E0035
ATTENTION!
The accumulators must be precharged with only dry nitrogen in tanks fitted with a reducer. Oxygen and/or air compressors must never be used under any circumstances. - Make sure the inflator valve on the accumulator is well sealed. - Screw the cap on the accumulator inflator valve.
8-42
002AZ019A
MAINTENANCE
8
FIGURE 8.1.2.6.1 - CHECKING THE ACCUMULATOR’S PRECHARGE
1 2 3 4
T3910
5
8-43
002AZ019A 8 8.1.2.6.2
MAINTENANCE 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, take off the cap 7 and pour in oil. FIGURE 8.1.2.6.2 - CHECKING THE OIL LEVEL IN THE HYDRAULIC POWER UNIT
7
9
10
5 1 11
13
3
2
4 12
YV21 YV27
6 14 8
T4826
8-44
002AZ019A
MAINTENANCE
8
8.1.2.6.3 Changing the oil in the hydraulic power unit (See figure 8.1.2.6.2) - - - - - -
Unscrew the cap 7. Place a container for collecting the oil under the valve 8. Open the valve 9 and let the oil flow out until the tank in the hydraulic power unit is empty. Close the valve 8. Add oil until the level falls within the full and low level marks indicated on gauge 1. Close cap 7.
8.1.2.6.4 Replacing the filter in the hydraulic power unit (See figure 8.1.2.6.2) - Replace the filter element 11. 8.1.2.6.5 Replacing the hydraulic power unit couplings and suction filter (See figure 8.1.2.6.2)
E0004
E0003
WARNING!
Heed to all safety rules and standards - risk of burns and crushing. Detach the electrical cables from the boxes of motors 9 and 10. Detach tubes 3, 4 and 5. Loosen the screws 2. Raise the plate 12 complete with motors and pumps. Replace the filters 6. Place the plate 12 on a secure support and remove the motors 9 and 10 by loosening the screws that secure the motors to the flanges, being careful not to drop the pumps, to reach the flexible coupling. - Replace the link wheels 13 and 14 of the motor’s flexible coupling. - Carry out the operations in reverse order to put the parts back in place.
- - - - - -
8.1.2.6.6 Checking for condensate on the bottom of the tank (See figure 8.1.2.6.2) - - - - -
See if there is any condensate on the bottom of the hydraulic power as instructed below: Place a container under the valve 8. Open the valve 8 and make sure water does not leak out and deposit on the bottom of the tank. Wait until oil starts to flow out and then close the valve. Restore the correct oil level as directed in paragraph CHECKING THE OIL LEVEL IN THE HYDRAULIC POWER UNIT.
8-45
002AZ019A 8 8.1.2.6.7
E0004
MAINTENANCE Cleaning the solenoid valves
IMPORTANT!
Before attempting to perform these operations, write down how the valve is directed as its position cannot be changed when re-installed. - - - - -
Loosen screws 1. Remove the solenoid valve. Divide bodies 2 and 3. Remove the piston 4 and thoroughly clean. Carry out the operations in reverse order to put the parts back in place. Be careful not to change the direction of the valve.
FIGURE 8.1.2.6.7 - CLEANING THE SOLENOID VALVES
1
2
4
3
T4510
8-46
002AZ019A
MAINTENANCE
8.1.2.7
8
Cooling system
FIGURE 8.1.2.7 - COOLING UNIT
T2545
2
4
1 3
6
8.1.2.7.1
Cleaning/changing the filters
- Shut off the temperature controller. - Close the valves 4. - Protect the parts under filter 3 with a container to protect them from the fluid that may flow out. - Remove the filter cartridge 3 and blow compressed air to clean or replace it according to the frequency stated in the SCHEDULED MAINTENANCE CHART. - Carry out the operations in reverse order to put the parts back in place. - Clean or change the other filters.
E0004
IMPORTANT INFORMATION!
After CLEANING/CHANGING THE FILTERS, always check the coolant level present.
8-47
002AZ019A 8 8.1.2.7.2
MAINTENANCE Checking the coolant level/topping up
- Shut off the temperature controller. - Check the gauge 1 to verify the coolant is nearly at the maximum allowable level. - If the coolant level shown on the gauge 1 is close to or below the minimum allowable level, top up as directed below: - Unscrew the cap 2. - Add the coolant mix, indicated in the SCHEDULED MAINTENANCE CHART, until the maximum allowable level is reached.
E0004
IMPORTANT INFORMATION!
Use only the coolant mix indicated in the SCHEDULED MAINTENANCE CHART. - Tighten the cap 2.
8.1.2.7.3 - - - - - - - - -
Changing the coolant
Shut off the temperature controller. Unscrew the cap 2. Place a container under the fittings 6 and detach the relative hoses. Open the fitting valves 6 and drain all the coolant present in the temperature controller. Close the fitting valves 6 and put the hoses back on. Take the top guard off the temperature controller and the cover off the coolant tank. Thoroughly clean the tank. Put the cover on the tank and the top guard on the temperature controller. Add the coolant mix, indicated in the SCHEDULED MAINTENANCE CHART, until the maximum allowable level is reached.
E0004
IMPORTANT INFORMATION!
Use only the coolant mix indicated in the SCHEDULED MAINTENANCE CHART. - Tighten the cap 2.
8-48
002AZ019A
8
MAINTENANCE
8.1.2.8
Pneumatic system
8.1.2.8.1
Air injection device
FIGURE 8.1.2.8.1 - AIR INJECTION DEVICE
1 2 4
5 T3967
T3968
8.1.2.8.1.1 Checking the valves - Verify that no air leaks out of valve 4 when it is not actuated by cam 1 and 2. 8.1.2.8.1.2 Replacing the valves - When the valve is not operating and the air system is not running (operation to be performed from the side of the machine opposite the operator), loosen screws 5. - Remove the air hose connected to valve 4. - Replace valve 4. - Tighten screws 5. - Connect the air hose to the fitting mounted in the valve.
8-49
002AZ019A 8 8.1.2.9
MAINTENANCE Product exit conveyor belt
FIGURE 8.1.2.9 -PRODUCT EXIT CONVEYOR BELT 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Belt Screw Guide Nut Screw Nut Screw Nut Guide
Screw Cover Screw Screw Screw Plate Guard Screw Conveyor 8
7
6
1 2 9
14
3 13 10
15
17
16
5
17
17
18
17 8-50
4
12
11
002AZ019A
MAINTENANCE
8.1.2.9.1 - - - - - - - -
8
Replacing the conveyor belt
Open the cover 16. Loosen the screws 17 and remove the conveyor 18. Loosen the screws 12 and remove the cover 11. Loosen the nuts 4 and screws 5 so that the belt 1 can be easily removed. Loosen the screw 13. Loosen the screws 14 and remove the plate 15. Replace the belt 1. To put back all the parts perform the above operations in reverse order taking care to tension the conveyor belt again as indicated in the ADJUSTING THE EXIT CONVEYOR BELT paragraph in Chapter 7 - ADJUSTMENTS.
8.1.2.9.2
Cleaning the slots in the exit conveyor belt slide surface
- Clean the slots in the slide surface located under the exit conveyor belt 1 to remove any plastic compound deposits which could block the suction channel.
8-51
002AZ019A 8
MAINTENANCE
8.1.2.10
Vacuum systems
FIGURE 8.1.2.10 - VACUUM SYSTEMS 1 Main system filter 2 Auxiliary system filter 3 Vacuum pump 4 Blower
1
2
3
4
8-52
002AZ019A
MAINTENANCE
8.1.2.11
Safety devices
8.1.2.11.1
Checking operation of the emergency stop buttons
8
- - - -
Turn on the machine with the main switch. Turn the mode selector on the keyboard to position MAN. Press key 0 to reset the machine. With the machine stopped, press one of the emergency stop buttons and make sure the relative fault message appears on the screen. - Press key 0 to reset the machine (the fault message should be cleared). - Proceed in the same manner for the other emergency stop buttons. 8.1.2.11.2 - - - - - - - - - - - - -
Checking the door interlocking devices
Close both doors. Turn on the machine with the main switch. Turn the mode selector on the keyboard to position MAN. Press key 0 to reset the machine. With the machine stopped, open one of the two doors and make sure the relative fault message appears on the screen. Close the door. Press key 0 to reset the machine (the fault message should be cleared). Open the other door and make sure the relative fault message appears on the screen. Close the door. Press key 0 to reset the machine (the fault message should be cleared). Start the machine with key 3-28. Try to open the two doors without forcing them to avoid damage to assure they are locked. Press key 7 to shutdown the machine.
8.1.2.11.3
Checking the visual/audible indicators
- Turn on the machine with the main switch. - When the cabinet comes on, the light tower and led indicators on the control panel light up and the audible alert signal on the indicator tower sounds during the first 3 seconds.
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MAINTENANCE
8.1.2.12
Electrical system
8.1.2.12.1
Cleaning and servicing the electrical cabinets
- Clean the components inside the electrical cabinets with an aspirator.
E0004
WARNING!
Do not blow compressed air. - Check and tighten the terminal blocks, bolts and connectors. 8.1.2.12.2 Checking cabinet and electrical box closure - Make sure the cabinet doors and covers of the electrical boxes close correctly and that the seals are in place and not worn to avoid compromising the degree of protection. 8.1.2.12.3 Air conditioner maintenance (if present) - Consult the specific documentation enclosed with the air conditioners to perform the maintenance jobs recommended by the manufacturer.
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002AZ019A 8.2
MAINTENANCE
8
EXTRAORDINARY MAINTENANCE OPERATIONS
The machine operators and maintenance staff are not responsible for carrying out extraordinary maintenance work. These operations are to be performed only by the manufacturers specially trained technicians. For this reason, these types of operations are not dealt with in this manual.
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002AZ019A 8 8.3
MAINTENANCE SETTINGS FOR TIGHTENING THE NUTS AND BOLTS
S.R. = Resisting section (mm2) MS = Tightening torque (Kg) V = Pre-load (corresponding to the tightening torque) (Kg)
E0004
WARNING!
12.9 class screws must be tightened with a torque wrench. The operation must be done as if they were of the 10.9K class. Example: A 12 mm dia. screw with a 1.75 pitch (class 12.9) must be tightened to 120.46 Nm instead of 144.59 Nm. STANDARD THREAD SCREWS DIAMETER mm 4 5 6 8 9 10 12 14 16 18 20 22 24 PITCH mm 0,70 0,80 1,00 1,25 1,25 1,50 1,75 2,00 2,00 2,50 2,50 2,50 3 S.R. mm2 8,11 13,31 18,68 34,57 45,77 55,28 79,92 110,16 150,49 185,16 236,52 294,16 338 5.8 MS = Nm 2,15 4,21 7,16 17,75 22,85 31,68 53,56 81,71 124,78 157,15 244,07 324,71 431,64 V = N 2226 3659 5130 9594 12576 15185 21954 30254 41339 50855 66933 82757 96922 8.8 MS = Nm 3,33 6,76 11,37 28,44 36,59 50,81 85,73 1 30,66 199,73 251,43 351,29 425,36 593,50 V = N 3561 5846 8210 15195 20110 24299 35119 48412 66139 81373 103946 129276 54998 10.9 MS = N m 4,80 9,41 16,08 32,92 51,50 71,41 120,46 183,83 280,86 353,55 494,03 598,11 834,14 V = N 5012 8230 11546 21366 28292 34168 49393 68081 93008 114433 146169 181798 213269 12.9 MS = Nm 5,68 11,37 19,22 47,97 61,80 85,64 144,59 220,62 337,07 424,28 592,81 717,69 989,82 V = N 6013 9868 13851 25633 33942 40995 59272 81697 111608 137320 174912 218154 255060
FINE THREAD SCREWS DIAMETER mm
-
-
- 8
- 10 12 14 16 18 20 22 24
PITCH mm
-
-
- 1,00
- 1,00 1,50 1,50 1,50 1,50 1,50 1,50 2
S.R. mm
-
-
- 37.14
- 61,87 83,83 119,42 161,29 209,44 263,86 324,58 374,5
5.8 MS = Nm
-
-
- 18,83
- 34,53 55,72 86,62 131,15 171,47 266,43 351,29 448,31
V = N
-
-
- 10202
- 16990 23024 32804 44301 57525 75419 92096 105948
8.8 MS = Nm
-
-
- 30,21
- 55,23 89,17 138,51 209,83 274,28 379,15 511,10 647,46
V = N
-
-
- 16323
- 27193 3 6846 52483 70887 92047 115964 141904 168732
10.9 MS = Nm
-
-
- 42,47
- 77,59 125,37 194,82 295,08 385,72 533,27 724,17 892,71
V = N
-
-
- 22955
- 38239 51806 73800 99679 129442 163071 208452 238383
12.9 MS = Nm
-
-
- 50,91
- 93,19 150,48 233,77 354,04 462,83 639,90 871,02 1079,10
V = N
-
-
- 27546
- 45881 62175 88339 119623 155331 195689 211287 286452
2
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8
MAINTENANCE
8.4
TROUBLESHOOTING GUIDE
8.4.1
Troubleshooting the machine
TROUBLE 1 Irregular pellet insertion; some pellets are rejected or lost; cutting burrs
2 Incomplete caps.
3 Caps too heavy.
4 Machine rejects caps even though their weight is correct
CAUSE
REMEDY
Operating parameters incorrectly set: operating pressure, length of insertion, insertion delay
Set the parameters as specified on the “Data sheet”
Cutter blades worn
Sharpen or replace
Cutter body dirty
Clean or replace
Cutter body not the right size
Replace (see “Data sheet”)
Incorrect pellet insertion nozzle
Replace (see “Data sheet”)
Cutter blades improperly adjusted
Adjust (see chapter 7 ADJUSTMENTS)
Mechanical phase in wrong position
Adjust (see chapter 7 ADJUSTMENTS)
Improper adjustment of insertion turret precharge
Adjust (see chapter 7 ADJUSTMENTS)
Malfunctioning of solenoid valve YV33 for pellet insertion
Replace
Rpm of polymer metering pump incorrectly set (too low)
Set the parameter as specified on the “Data sheet”
Incorrect rpm of the molding turret (too high)
Set the parameter as specified on the “Data sheet”
Incorrect high pressure flow rate
Set the parameter as specified on the “Data sheet”
Actuator gasket worn
Contact the Customer Service Department
Coupling gasket worn
Contact the Customer Service Department
Rpm of polymer metering pump incorrectly set (too high)
Set the parameter as specified on the “Data sheet”
Insertion turret transmission worn
Contact the Customer Service Department
Incorrect reject threshold
Set the parameter as required (see chapter 7 ADJUSTMENTS)
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MAINTENANCE TROUBLE
CAUSE
REMEDY
5 An actuator does not move up.
Relative hydraulic valve fails to operate properly
Remove and clean the valve, replace the return spring if necessary
6 Actuators do not operate properly: the molds do not close correctly.
Incorrect low pressure flow rate
Set the parameter as required (see “Data sheet”)
Hydraulic accumulator precharge decreased
Charge the accumulators with nitrogen until the correct value is reached
7 Oil temperature too high.
Coolant temperature incorrect
Restore the correct values (see “Data sheet”)
8 Actuators do not move down at the end of the production run.
Hydraulic valve used to move the actuators up is stuck in the “open” position
Clean the valve
9 Melt pressure high/low.
Plastic compound incorrectly fed
Check
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002AZ019A
DECOMMISSIONING
9
DECOMMISSIONING
9.1
MACHINE DECOMMISSIONING
9
E0004
WARNING!
Only skilled personnel specially trained on operating and handling procedure may work on the machine. Use only suitable lift equipment and means that meet current laws and standards. If the machine is no longer used or in the case of prolonged inactivity, first of all, perform the operations given below: - Turn off the machine’s power supply by using the factory’s main switch. - Unplug the power cable from the electrical cabinet’s terminal block. - Disconnect the cables that join the cabinet to the machine, detaching the connectors. - Disconnect the line between the factory’s compressed air mains and the control unit. - Disconnect the lines that join the cooling system to the water mains and factory drain line.
E0004
WARNING!
Release the gas under pressure inside the accumulators with the tester / inflator supplied with the machine as directed in the CHECKING ACCUMULATOR PRECHARGE paragraph in chapter 8. - Activate all the safety devices provided. - 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.
E0004
IMPORTANT!
If the machine has to be transferred from one facility to another, contact Sacmi Technical Support to obtain information regarding packaging and handling.
9-1
002AZ019A 9 9.2
E0004
DECOMMISSIONING DISASSEMBLY
WARNING!
Only skilled personnel specially trained on operating and handling procedure may work on the machine. Use only suitable lift equipment and means that meet current laws and standards. If the machine is to be dismantled, first of all, perform the operations given below: The operations given below need to be carried out when the machine is no longer used: - Turn off the machine’s power supply by using the factory’s main switch. - Unplug the power cable from the electrical cabinet’s terminal block. - Disconnect the cables that join the cabinet to the machine, detaching the connectors. - Disconnect the line between the factory’s compressed air mains and the control unit. - Disconnect the lines that join the cooling system to the water mains and factory drain line.
E0004
WARNING!
Release the gas under pressure inside the accumulators with the tester / inflator supplied with the machine as directed in the CHECKING ACCUMULATOR PRECHARGE paragraph in chapter 8. - Engage all the safety devices provided. - Drain the oil from the hydraulic system. - Empty the coolant from the cooling system.
E0004
IMPORTANT!
Remove the various parts of the machine observing all the safety precautions in force and following the instructions given in chapter 4 - INSTALLATION. Pay close attention to the safety precautions and warnings given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS, paragraphs SAFETY RULES FOR HANDLING and MACHINE DECOMMISSIONING AND DISASSEMBLY.
9-2
002AZ019A
DECOMMISSIONING
E0004
9
ATTENTION!
Dispose the lubricants and coolants used in compliance with environmental protection laws in force in the country the machine is installed in.
E0004
E0133
WARNING!
When the machine is disposed, the materials should be recycled to the greatest extent possible in compliance with laws in force in the country in which the machine is installed.
9-3
002AZ019A 9
9-4
DECOMMISSIONING
