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Sacmi BTA 900 Instruction Manual

Knurling machine for aluminum caps, cutting machine for plastic caps
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D O C U M E N TA Z I O N E
T
Revision 00 Date 18.10.1998
E
C
INSTRUCTIONS MANUAL
166.07
KNURLING MACHINE FOR ALUMINUM CAPS
CUTTING MACHINE FOR PLASTIC CAPS
BTA 900
TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION
DOCUMENTAÇAO
N
I
.A02
TECNICA
TÉCNICA
C
A

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  • Page 1 D O C U M E N TA Z I O N E INSTRUCTIONS MANUAL 166.07 .A02 KNURLING MACHINE FOR ALUMINUM CAPS CUTTING MACHINE FOR PLASTIC CAPS BTA 900 TECHNICAL DOCUMENTATION DOCUMENTATION TECHNIQUE TECHNISCHE DOKUMENTATION DOCUMENTACION TECNICA DOCUMENTAÇAO TÉCNICA Revision 00 Date 18.10.1998...
  • Page 2 166.07 .A02 Revision 00 Date 18.10.1998 TABLE OF CONTENTS 0 - 2...
  • Page 3 KNURLING MACHINE FOR ALUMINUM CAPS CUTTING MACHINE FOR PLASTIC CAPS BTA 900 MANUFACTURER SACMI IMOLA Via Selice Provinciale, 17/A 40026 IMOLA (Bologna) - ITALIA SERIAL NUMBER YEAR OF MANUFACTURE PUBLISHED ON 18.10.1998 REVISED VERSIONS BTA 900.00.002/003 - BTA900A 0 - 3...
  • Page 4 166.07 .A02 Revision 00 Date 18.10.1998 TABLE OF CONTENTS 0 - 4...

  • Page 5: Table Of Contents

    166.07 .A02 Revision 00 Date 18.10.1998 TABLE OF CONTENTS Page GENERAL INFORMATION ........................1 - 1 INTRODUCTION ........................1 - 1 WHERE TO KEEP THE MANUAL ..................... 1 - 1 HOW TO USE THE MANUAL ....................1 - 1 USERS OF THE MANUAL ......................1 - 1 WARRANTY ..........................
  • Page 6 166.07 .A02 Revision 00 Date 18.10.1998 TABLE OF CONTENTS Page USE OF THE MACHINE ........................... 6 - 1 CONTROL DEVICES ......................... 6 - 1 6.1.1 SWITCHBOARD ........................6 - 2 MANUAL OPERATION .......................6 - 4 AUTOMATIC OPERATION ......................6 - 4 ADJUSTMENTS ............................

  • Page 7: General Information

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

  • Page 8: Warranty

    SACMI shall be held responsible only for the machine as it was configured at the time of delivery. Any operations that alter the configuration of the machine or operating cycle must be carried out by SACMI personnel or duly authorized by SACMI’S Engineering Dept.

  • Page 9: Machine Identification Plate

    166.07 .A02 Revision 00 Date 18.10.1998 GENERAL INFORMATION ALERT SYMBOLS Heavy duty work gloves must be worn (when plastic caps are handled) E0005O Machine must be connected to an effectively grounded power point E0006O ADDITIONAL SYMBOLS A list of the tools required to carry out maintenance is provided E0009C MACHINE IDENTIFICATION PLATE TIPO...
  • Page 10 166.07 .A02 Revision 00 Date 18.10.1998 GENERAL INFORMATION 1 - 4...

  • Page 11: Main Features

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES MAIN FEATURES MACHINE DESCRIPTION The BTA900 is a rotary machine that operates on a horizontal axis . The particular feature of this machine is its ability to knurl, profile and cut the cylindrical part of formed aluminum caps. When plastic caps are handled, the machine is also capable of cutting the plastic to form the safety seal.

  • Page 12: Main Devices

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.1.1 MAIN DEVICES 2.1.1.1 Cap infeed channel (see figures 2.1.1.1/A and 2.1.1.1/B) The caps are directed into the machine by the infeed channel (1) secured to the base. A section of the channel can be inspected by opening the door (2) with the knob (3).
  • Page 13 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES Fig. 2.1.1.1/A - FIXED ALUMINIUM CAP INFEED CHANNEL Cap infeed channel Door Knob Pneumatic cylinder Fiber optic photocell Screw Fiber optic mount Fiber optic 14 Bracket 15 Nut 16 Insert 17 Grub screw 18 Air blower 19 Air blower T1167...
  • Page 14 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES Fig. 2.1.1.1/B - FIXED INFEED CHANNEL FOR PLASTIC CAPS 1 - Infeed channel 2- Door 3 - Knob 4 - Air cylinder 6 - Fiber optic photocell 7 - Screw 8 - Fiber optic mount 9 - Fiber optic 14 - Bracket 15 - Nut...
  • Page 15 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.1.1.2 Infeed turn-table (see figure 2.1.1.2) The infeed turn-table picks up the caps from the channel and deposits them on the spindles of the work drum. The feed rods (2) are mounted on the drum body (1). The incoming caps are held in place against the wheel (3) until they are finally placed in the cavity (4) mounted on the rod (2).
  • Page 16 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES Figure 2.1.1.2 - INFEED TURN-TABLE Turn-table body Feed rod Wheel Cavity Guard Guide tab Rollers 11 Screw 12 Screw 15 Vacuum distributor 16 Spring assembly 19 Shaft 20 Mount 21 Extension 2 - 6...
  • Page 17 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.1.1.3 Work drum (see figure 2.1.1.3) The spindles are mounted on the work drum which turns them and ejects the caps into the feed units. The shaft (1), keyed to the mount (2), sees that the body of the work drum (3) rotates. The gear (4) secured to a sleeve acts as a fixed gear wheel which drives the spindles.
  • Page 18 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES Figure 2.1.1.3 - WORK DRUM Shaft Mount Drum body Gear Distributor Ring Disk Spring unit 10 Nozzle 11 First flange bearing 15 Wedge 16 Screw 17 Section 18 Dowel 19 Spindle T1140 T1142 2 - 8...
  • Page 19 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.1.1.4 Tools Fixed and movable tools need to be used to produce caps that meet the customer’s own individual requirements. A data sheet is provided for all the tools, whether they be fixed or movable, which states the dimensions and specifications of each individual part.
  • Page 20 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES Figure 2.1.1.5 - SPINDLE Bush Shaft Pinion Wedge Flange Drum 11 Movable tools T1140 T1143 2 - 10...
  • Page 21 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.1.1.6 Exit channel (see figure 2.1.1.6) The caps are directed and orderly when they are in the exit channel. The unit consists of a plate (1) that acts as a support for the various parts that make up the unit. The inspection door (2), located at the end, can be opened by simply turning the knob (3) 1/4 of a turn.
  • Page 22 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES Figure 2.1.1.6 - EXIT CHANNEL Plate Inspection door Knob Air blower Photocell Screw Fiber optic mount Fiber optic 10 Spring 11 Lever 12 Spindle 17 Sensor 18 Disk 19 Nut 20 Screw 21 Mount T1165 2 - 12...
  • Page 23 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.1.1.8 Lower frame The lower frame consists of a lower base, four feet and an upper base. It is held up by feet that can be adjusted in height and is enclosed with safety guards. The drive unit is secured to the base. 2.1.1.9 Drive unit (see figure 2.1.1.9)
  • Page 24 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES Figure 2.1.1.9 - DRIVE UNIT Geared motor Drive shaft Cogged pulley Cogged belt Torque limiter Pinion Pinion Bush Crank 10 Knob 11 Handwheel 12 Tensioner 13 Tensioner 14 Tensioner 15 Screw 16 Ring-nut 17 Self-locking nut 18 Nut 19 Grub screw...
  • Page 25 166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.1.1.10 Pneumatic system (references given in paragraph 2.4.1 - PNEUMATIC SYSTEM DIAGRAM) The control unit located in the machine base monitors the pneumatic system. The air preparation elements (filters and pressure regulators), the controls for the points of use (solenoid valve for air jets and solenoid valve that controls the pneumatic cylinder which regulates the cap flow in the infeed channel) and the manifold for air jets are also found here.

  • Page 26: Intended, Prohibited And Misuse Of The Machine

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE INTENDED USE OF THE MACHINE The machine is specially engineered and constructed to produce products that have the characteristics indicated in the specifications. Safe machine operation is ensured only if the following conditions are satisfied: - the machine is used under the required conditions and within the set limits stated in this paragraph;...

  • Page 27: Overall Dimensions

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES OVERALL DIMENSIONS The dimensions of the machine and electric cabinet (distance required for installation between the two parts is given in chapter 4, INSTALLATION) are given in the figure below. Figure 2.2 - OVERALL DIMENSIONS Machine Switchboard Cap inlet...

  • Page 28: Technical Characteristics

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES TECHNICAL CHARACTERISTICS 2.3.1 SPECIFICATIONS PLASTIC CAPS Speed/1' (per 28 mm ROP) up to 1200 Diameter from 22 to 50 Height from 12 to 60 Power requirements (50 Hz) Absorbed power (50 Hz) Electric motor output (50 Hz) Switchboard cable 380 V - 50 Hz: four pole, copper...

  • Page 29: Allowable Fluctuations

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.3.2 ALLOWABLE FLUCTUATIONS ELECTRIC ±10% Voltage ±2% Frequency PNEUMATIC ±15% Flow rate Minimum pressure Maximum pressure COOLANT ±10% Flow rate Pressure +20% - 10% 2.3.3 RATING PLATE The data regarding the machine (voltage - frequency - auxiliary circuits) is stamped on the plate shown in the figure and is found on the door of the switchboard.

  • Page 30: Materials That Can Be Handled

    E0004P The machine needs to be set up differently for each cap size, therefore special parts have to be used. Refer to the “data sheet” provided by Sacmi. PRODUCTION CAPACITY Depends primarily on the type of caps handled and their dimensions The maximum production output is given in paragraph 2.3.1 SPECIFICATIONS.

  • Page 31: Noise Emission Levels

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.3.5 NOISE EMISSION LEVELS 2.3.5.1 Acoustic radiation pressure level (ISO/DIS 11202) Test conditions - Operating conditions: machine running with load. - Type of operation: cutting of plastic caps - Operating cycle: cap infeed and cutting - Test environment: factory with reflecting flooring.

  • Page 32: Lubricant Specifications

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.3.5.2 Acoustic power level (ISO 3746) Test conditions - Operating conditions: run with load. - Type of operation: plastic cap cutting - Operating cycle: cap infeed and cutting - Test environment: factory with reflecting flooring. Instruments employed Class 1 instruments (IEC 804) Results...

  • Page 33: Diagrams

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES DIAGRAMS 2.4.1 DIAGRAM OF PNEUMATIC UNIT Figure 2.4.1 - DIAGRAM OF PNEUMATIC UNIT Filter 4th blower, Infeed channel Pressure regulator 5th blower, Infeed channel Flow divider 1st blower, Discharge channel or last blower Solenoid valve manifold in infeed channel Pressure regulator...

  • Page 34: Cooling System Diagram

    166.07 .A02 Revision 00 Date 18.10.1998 MAIN FEATURES 2.4.2 COOLING SYSTEM DIAGRAM Figure 2.4.2 - COOLING SYSTEM DIAGRAM Solenoid valve Bearing mount, Knurling drum Water delivery line Water drain line YV20 T1893 2.4.3 VACUUM SYSTEM DIAGRAM Figure 2.4.3 - VACUUM SYSTEM DIAGRAM 1 Pump 2 Manifold 3 Vacuum meter...

  • Page 35: Safety Equipment And Precautions

    166.07 .A02 Revision 00 Date 18.10.1998 SAFETY EQUIPMENT AND PRECAUTIONS SAFETY EQUIPMENT AND PRECAUTIONS SAFETY DEVICES INSTALLED (See figure 3.1) The machine is provided with a number of mechanical and electric safety devices that safeguard the operator as well as protect the machine. Shut down devices The shut down devices detect and signal malfunctioning and prevent the machine from being started or stop it if running.
  • Page 36 166.07 .A02 Revision 00 Date 18.10.1998 SAFETY EQUIPMENT AND PRECAUTIONS Figure 3.1/B - SAFETY DEVICES INSTALLED 1 - Guard 2 - Belt cover 3 - Pneumatic unit door 4 - Pressure switch, No air pressure 5 - Proximity sensor, Torque limiter disengaged 6 - Vacuum control, No vacuum HA3 - Audible warning device, Machine shutdown SQ35...

  • Page 37: General

    166.07 .A02 Revision 00 Date 18.10.1998 SAFETY EQUIPMENT AND PRECAUTIONS GENERAL WARNING! E0004P INSTALLATION Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations in force in your country. It is extremely important that the machine is properly connected to adequate earth electrodes. The Manufacturer shall not be held responsible for any damage to the machine or injury to personnel resulting from improper installation.

  • Page 38: Safety Rules For Handling

    166.07 .A02 Revision 00 Date 18.10.1998 SAFETY EQUIPMENT AND PRECAUTIONS SAFETY RULES FOR HANDLING ATTENTION! E0004P SLINGING THE LOADS To safely and correctly lift and handle the machine always: - use equipment which best suits the characteristics and has an adequate lift capacity; - cover all sharp edges;...

  • Page 39: Operator Training

    166.07 .A02 Revision 00 Date 18.10.1998 SAFETY EQUIPMENT AND PRECAUTIONS OPERATOR TRAINING WARNING! E0004P COMPANY USING THE MACHINE The company using this equipment must see that the machine operators: - match the requirements listed below - read and understand the manual in its entirety - are adequately instructed and trained on how to safely carry out their tasks - are specifically instructed and receive adequate training on how to operate the machine correctly.

  • Page 40: Safety Rules For Operation And Maintenance

    This must never be done. Before performing any type of operation on the machine, always consult the manual for information on how to correctly carry out the procedures. In addition, the manual contains important information concerning safety. If any doubts arise, contact SACMI’s Customer Service Department.

  • Page 41: Hazards That May Be Encountered In The Mechanical System

    166.07 .A02 Revision 00 Date 18.10.1998 SAFETY EQUIPMENT AND PRECAUTIONS 3.5.1 HAZARDS THAT MAY BE ENCOUNTERED IN THE MECHANICAL SYSTEM NON-LOAD BEARING STRUCTURES WARNING! E0004P The movable guards the machine is equipped with are not constructed to bear the weight of a person. It is therefore forbidden to climb onto the surface formed by the guards or lean on the perimetral structure.

  • Page 42: Hazards That May Be Encountered In The Electric System

    166.07 .A02 Revision 00 Date 18.10.1998 SAFETY EQUIPMENT AND PRECAUTIONS RISKS PRESENT IN THE PRODUCT HANDLING SYSTEM WARNING! E0004P The product handling system exposes the operators to the following risks, as they may accidentally come into contact with moving parts: hands and/or limbs may be crushed, caught and dragged and cut off.

  • Page 43: Hazards Present In The Heat System

    166.07 .A02 Revision 00 Date 18.10.1998 SAFETY EQUIPMENT AND PRECAUTIONS 3.5.3 HAZARDS PRESENT IN THE HEAT SYSTEM ACCESSING THE FIXED TOOLS FOR WORKING PLASTIC CAPS The tools used for working plastic caps reach temperatures of up to 200°. Never touch the external surfaces provided with warnings indicating danger of being burnt (see indications). WARNING! E0004P When the fixed tools employed with the plastic caps need to be serviced or repaired always use adequate gear...
  • Page 44 166.07 .A02 Revision 00 Date 18.10.1998 SAFETY EQUIPMENT AND PRECAUTIONS 3 - 10...

  • Page 45: Installation

    The best systems for lifting and handling the heaviest and largest parts as well as those that require special care and tools provided by Sacmi are shown in figure 4.1. Use suitable lifing equipment and ropes (refer to fig. 2) to hoist the machine body (1). The ropes should be attached to the machine base at the four points indicated (A).
  • Page 46 166.07 .A02 Revision 00 Date 18.10.1998 INSTALLATION Figure 4.1 - DIMENSIONS AND WEIGHTS OF THE CRATES AND PACKAGING 1 - Machine body 2 - Switchboard 3 - Packaging of spare parts supplied 4 - Packaging of tools provided 5 - Crate containing parts: 1-2-3-4 Kg 600 1580 1050...

  • Page 47: Positioning The Machine

    166.07 .A02 Revision 00 Date 18.10.1998 INSTALLATION POSITIONING THE MACHINE (references in figure 4.2/A) The various parts that make up the machine, whose specifications, weights, dimensions and hook-up points to the lift systems have already been dealt with, are to be assembled and placed as shown in the figure. Follow the order and methods given below.
  • Page 48 166.07 .A02 Revision 00 Date 18.10.1998 INSTALLATION Figure 4.2/A - PLACING THE PARTS 1 Machine 2 Switchboard A Cap infeed channel B Cap exit channel C Cooling and compressed air inlet D Work area A - B T1152 Figure 4.2/B - LEVELING THE MACHINE T1153 4 - 4...

  • Page 49: Connecting And Hooking Up The Machine

    CONNECTING AND HOOKING UP THE MACHINE WARNING! E0004P The machine must be hooked up to the various systems exclusively by specialized persons according to the directions provided by SACMI. 4.3.1 CONNECTING THE MACHINE TO THE COMPRESSED AIR LINE (references in figure 4.3.1) Connect the air preparation unit, fitted with snap-in coupling A located in the pneumatic control unit, to the compressed air line by using a hose whose specifications meet those indicated in paragraph 2.3, TECHNICAL...
  • Page 50 166.07 .A02 Revision 00 Date 18.10.1998 INSTALLATION 4.3.3 ELECTRIC CONNECTIONS 4.3.3.1 Connecting the electric cables (References in figure 4.3.3.1) WARNING! E0004P After the machine has been tested the cables are set up for shipment, disconnected from the switchboard and wound up inside the machine.
  • Page 51 166.07 .A02 Revision 00 Date 18.10.1998 INSTALLATION Figure 4.3.3.1 - CONNECTING THE ELECTRIC CABLES XJ1 - Cable, Connection to power box XJ2 - Cable, Connection to signal box XJ5 - Heater cable (only for plastic cap cutter) XJ10 - Motor M8 power cable XJ14 - Signal connector for downstream machine interface XJ16 - Signal connector for upstream machine interface XJ16...
  • Page 52 166.07 .A02 Revision 00 Date 18.10.1998 INSTALLATION 4.3.3.2 Earth connection WARNING! E0004P The machine must be connected to an effective earth. Join the earth electrode to the point marked PE (EN60445). In addition, join the earth electrode to the connection points on the machine frame marked with the symbol (417-IEC-5019).

  • Page 53: Start Up

    166.07 .A02 Revision 00 Date 18.10.1998 START UP START UP GENERAL WARNING! E0004P Solely the manufacturer’s technicians responsible for starting up the machine are authorized to carry out these operations, as indicated in chapter 1, GENERAL INFORMATION. Severe damage to the machine and/or serious injury to persons may occur if carried out by other persons. See chapter 6, USE OF THE MACHINE, for detailed information regarding the control keys.

  • Page 54: Daily Start Up

    166.07 .A02 Revision 00 Date 18.10.1998 START UP DAILY START UP (references for the controls given in chapter 6, USE OF THE MACHINE) - Connect the machine to the compressed air line. - Turn on the electricity supply by using main switch QS1. The machine is now ready to run in either manual or automatic mode.
  • Page 55 166.07 .A02 Revision 00 Date 18.10.1998 USE OF THE MACHINE USE OF THE MACHINE WARNING! E0004P The instructions given in this manual must be closely followed and all safety precautions carefully observed. CONTROL DEVICES (See figure 6.1) The machine controls are found on the switchboard and machine. Figure 6.1 - CONTROL DEVICES SB2B 1 - Control panel...

  • Page 56: Switchboard

    166.07 .A02 Revision 00 Date 18.10.1998 USE OF THE MACHINE 6.1.1 SWITCHBOARD (References in figures 6.1 and 6.1.1) The switchboard includes a power section that contains all the parts used to drive the utilities (contactors, relays, etc.) and a logic section with the devices that process the signals transmitted from the keyboard and controls located on the machine.
  • Page 57 166.07 .A02 Revision 00 Date 18.10.1998 USE OF THE MACHINE Figure 6.1.1 - TOP DISPLAY AND CONTROL PANEL SB102 SB103 SA18 SB30M SB6M SB33M SB8M SA40 SB101 SB100 SB30A SB6A SB33A SB22 SB8A SB11 SA100 SA30 SB31 T2021 6 - 3...

  • Page 58: Manual Operation

    166.07 .A02 Revision 00 Date 18.10.1998 USE OF THE MACHINE MANUAL OPERATION If the machine is set to operate in manual mode (selector switch SA100 turned to MAN), the motors can be run individually with the control buttons on the panel. In addition, the tool heater can be operated, if provided. This operation can also be carried out if the machine is set to run in automatic mode.

  • Page 59: Adjustments

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS ADJUSTMENTS The adjustments described below are to be carried out when deemed necessary by the operator due to malfunctioning or after maintenance has been performed, parts replaced, etc.. Carefully observe all the safety precautions when carrying out these operations WARNING! E0004P...
  • Page 60 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS FIGURE 7.1/A - CAP INFEED CHANNEL Infeed channel Door Knob Pneumatic cylinder Fiber optic photocell Screw Fiber optic mount Fiber optic 10 Pressure gauge 11 Knob 12 Cap stoppage solenoid valve YV3 14 Bracket 15 Nut 16 Insert 17 Grub screw...
  • Page 61 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS ADJUSTING THE LENGTH OF THE PNEUMATIC CYLINDER’S ROD FOR ALUMINIUM CAPS (references in figure 7.1/B) - Disassemble the cylinder (4) by removing the screws that secure the bracket (14). - Loosen the nut (15) that secures the insert (16). - Place the Allen wrench provided in the grub screw (17).

  • Page 62: Infeed Turn-Table

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS INFEED TURN-TABLE (references in figure 7.2) SIZE CHANGE-OVER Some parts of the unit need to be replaced when different sized caps are to be handled. Use the crank provided to move the infeed turn-table away from the work drum. REPLACING THE CAVITY Remove the screw (11), take out the cavity (4) and replace it (repeat this operation for each cavity).
  • Page 63 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS Figure 7.2 - INFEED TURN-TABLE Turn-table body Wheel Cavity Guard Guide tab Rollers 11 Screw 12 Screw 15 Distributor 16 Spring assembly 19 Shaft 20 Mount 21 Extension 7 - 5...

  • Page 64: Work Drum

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS WORK DRUM (references in figure 7.3) ADJUSTING THE AIR PRESSURE FOR CAP EJECTION - Check the value given on the pressure gauge (20) (the correct value is given in paragraph 2.3.1 - SPECIFICATIONS) - Adjust as required by turning the knob (21).
  • Page 65 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS Figure 7.3 - WORK DRUM T1142 T1142 T1140 7 - 7...

  • Page 66: Tool Adjustments

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS TOOL ADJUSTMENTS 7.4.1 ADJUSTMENTS 7.4.1.1 Adjusting the fixed scoring tools (see figure 7.4.1.1) The fixed scoring tools (1) should protrude approximately 0.17 - 0.20 mm (for aluminum caps) in relation to the die (2). - Mount the die (2) on a tool holder (3) (supplied with the machine).

  • Page 67: Disassembling And Replacing The Tools

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS 7.4.2 DISASSEMBLING AND REPLACING THE TOOLS 7.4.2.1 Disassembling the fixed tools for aluminum caps (see figure 7.4.2.1) DISASSEMBLING THE TOOLS - Loosen and remove the four screws (1). - Move the drum away by using the crank (3). - Disassemble the wedge (4) by loosening the two relative screws.
  • Page 68 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS Figure 7.4.2.1 - DISASSEMBLING THE FIXED TOOLS FOR ALUMINUM CAPS Screw Crank Wedge Middle grub screw Screw 10 Tool pack mount 11 Screw 12 Screw 13 Tool pack 14 Pin T1172 T2024 T1176 T1176 T1171 7 - 10...
  • Page 69 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS Figure 7.4.2.2 - DISASSEMBLING THE FIXED TOOLS FOR PLASTIC CAPS Screw Crank Wedge Middle grub screw Union Screw 10 Tool pack mount 11 Screw 12 Screw 13 Tool pack 14 Pin T1168 T2024 T1181 T1169 7 - 11...
  • Page 70 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS 7.4.2.3 Disassembling the movable tools for aluminum caps - Loosen the ring nut by using the wrench (1) supplied with the machine. - Remove the tools from the shaft by using the puller (2) supplied with the machine and replace the part in question. 7.4.2.3 - DISASSEMBLING THE MOVABLE TOOLS FOR ALUMINUM CAPS T1184 T1179...

  • Page 71: Spindle Adjustment

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS SPINDLE ADJUSTMENT Figure 7.5 - SPINDLE ADJUSTMENT Bush Shaft Pinion Wedge Flange Drum 11 Movable tools T1140 T1143 7 - 13...

  • Page 72: Adjusting The Radial Position Of The Spindles

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS 7.5.1 ADJUSTING THE RADIAL POSITION OF THE SPINDLES (references in figures 7.5.1/A - 7.5.1/B - 7.5.1/C) The radial position of the spindles, that is the distance between the movable tools (11) and the fixed ones (12) is extremely important for correct cap production.
  • Page 73 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS Figure 7.5.1/C - ADJUSTING THE RADIAL POSITION OF THE SPINDLES Wedge Flange 11 Movable tools 12 Fixed tools 13 Thickness gauge T1163 T1162 7 - 15...

  • Page 74: Adjusting The Knurling Stage For Aluminum Caps

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS 7.5.2 ADJUSTING THE KNURLING STAGE FOR ALUMINUM CAPS (references in figures 7.5.2/A - 7.5.2/B) Irregular knurling may result if the fixed and movable tools are not perfectly synchronized with each other. These cases are shown in figure 7.5.2/B.

  • Page 75: Replacing The Spindle Pinion For Size Change-Over

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS 7.5.3 REPLACING THE SPINDLE PINION FOR SIZE CHANGE-OVER (references in figure 7.5) - Remove the wedges (7) from the drums (9) and take out the spindle. - Loosen the nuts (5). - Remove the pinion (4) with the puller provided and replace it. - Put the nuts (5) back in.
  • Page 76 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS Figure 7.6 - EXIT CHANNEL Plate Inspection door Knob Air blower Photocell Screw Fiber optic mount Fiber optic 10 Spring 11 Lever 12 Spindle 17 Sensor 18 Disk 19 Nut 20 Screw 21 Mount 7 - 18...

  • Page 77: Conveying Channel

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS CONVEYING CHANNEL The conveying channel requires no adjustments. The flow rate of the air blown to move the caps in the channels can be adjusted by setting the regulators located in the pneumatic control unit as required. ATTENTION! E0004P Further information concerning the conveying channel can be provided under separate cover on request.
  • Page 78 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS Figure 7.9/A - DRIVE UNIT Figure 7.9/B Geared motor Drive shaft Cogged pulley Cogged belt Torque limiter Pinion Pinion Bush Crank 10 Knob 11 Handwheel 12 Tensioner 13 Tensioner 14 Tensioner 15 Screw 16 Ring-nut 17 Self-locking nut 18 Nut...

  • Page 79: Pneumatic System

    166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS 7.10 PNEUMATIC SYSTEM No adjustments are required. The flow rate of the air blown to move the caps in the channels can be adjusted by setting the regulators located in the pneumatic control unit as required. To adjust the pressure gauges see paragraph 2.3.1, SPECIFICATIONS.
  • Page 80 166.07 .A02 Revision 00 Date 18.10.1998 ADJUSTMENTS 7 - 22...

  • Page 81: Maintenance Operations

    166.07 .A02 Revision 00 Date 18.10.1998 MAINTENANCE OPERATIONS MAINTENANCE OPERATIONS GENERAL INFORMATION AND SAFETY PRECAUTIONS WARNING! E0004P Only expert personnel who know how the machine and plant in general operate well can carry out maintenance, as indicated in the “SAFETY EQUIPMENT AND PRECAUTIONS” chapter (chapter 3). Take all the precautionary steps in order to prevent accidental machine start-up.

  • Page 82: Scheduled Maintenance

    166.07 .A02 Revision 00 Date 18.10.1998 MAINTENANCE OPERATIONS SCHEDULED MAINTENANCE The machine does not require any particular type of maintenance. CLEANING THE TOOLS The fixed and movable tools must be cleaned at the intervals stated in the chart. Use the brass bristle brush provided and jets of compressed air, if required.
  • Page 83 166.07 .A02 Revision 00 Date 18.10.1998 MAINTENANCE OPERATIONS SCHEDULED MAINTENANCE CHART T2077 T1756 8 - 3...

  • Page 84: Special Maintenance

    166.07 .A02 Revision 00 Date 18.10.1998 MAINTENANCE OPERATIONS SPECIAL MAINTENANCE Any special maintenance operations which are not included in the chart for the scheduled operations are to be carried out only by the manufacturer’s technicians or the customer’s personnel who have been specially trained carefully following the instructions provided by the manufacturer.

  • Page 85: Troubleshooting The Machine

    166.07 .A02 Revision 00 Date 18.10.1998 MAINTENANCE OPERATIONS 8.3.1 TROUBLESHOOTING THE MACHINE TROUBLE CAUSE REMEDY deformed caps in the channel Cap infeed channel: caps jam the remove the deformed caps channel Infeed turn-table: caps do not enter cap infeed channel surface is dirty clean the surface the caps slide on insufficient compressed air check the pressure for the air mains...

  • Page 86: Troubleshooting The Product

    166.07 .A02 Revision 00 Date 18.10.1998 MAINTENANCE OPERATIONS 8.3.2 TROUBLESHOOTING THE PRODUCT CAUSE TROUBLE REMEDY Knurling stage not properly timed, movable tools not timed with the see paragraph for aluminum caps fixed ones 7.5, SPINDLE ADJUSTMENT radial position of the spindle Pinching not to the correct see paragraph incorrect...

  • Page 87: Dismantling

    166.07 .A02 Revision 00 Date 18.10.1998 DISMANTLING DISMANTLING WHAT TO DO WHEN THE MACHINE IS NO LONGER USED When the machine is no longer going to be used, it should be made inoperative by following the instructions given below: - Cut off the power supply to the machine by using the factory’s main switch - Unplug the power cable attached to the terminal block of the electric cabinet - Unplug the cables between the cabinet and the machine, disconnecting the connectors - Remove the compressed air connection between the power unit and the mains...
  • Page 88 166.07 .A02 Revision 00 Date 18.10.1998 DISMANTLING 9 - 2...

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