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Zigler Z-2312 Instruction Manual

Semi-automatic bov crimping machine
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INSTRUCTIONS MANUAL
Semi-automatic BOV Crimping Machine
Type: Z-2312
Signature: A0310.01.2312.905.1.EN
TRANSLATION OF THE ORIGINAL INSTRUCTIONS.  2018. No part of this document may be reprinted or
copied by any means, without the written permission of ZIGLER POLSKA

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  • Page 1 INSTRUCTIONS MANUAL Semi-automatic BOV Crimping Machine Type: Z-2312 Signature: A0310.01.2312.905.1.EN TRANSLATION OF THE ORIGINAL INSTRUCTIONS.  2018. No part of this document may be reprinted or copied by any means, without the written permission of ZIGLER POLSKA...

  • Page 2: Table Of Contents

    3.1. Transport......................... 10 3.2. Installation ........................10 3.3. Storage ..........................11 4. Construction of Semi-automatic BOV Crimping Machine Z-2312 ........... 12 4.1. Construction of air preperation unit ................14 5. Operation manual of Z-2312 machine ..................16 5.1. Preparation for start-up ....................16 5.2.
  • Page 3 OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 6. Z-2312 working parameters adjustment ................21 6.1. Regulation of working pressure ..................21 6.2. Adjusting the height of BOV crimping head ..............22 6.3. Adjusting crimping parameters ..................23 6.4. Adjusting pre-gassing time ....................26 6.5.

  • Page 4: Equipment Manufacturer

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 EQUIPMENT MANUFACTURER A0310.01.2312.905.1.EN Page 4/33...

  • Page 5: General Information

    Semi-automatic BOV Crimping Machine Z-2312 1. General information 1.1. Intended use Semi-automatic BOV Crimping Machine Z-2312 is a device used for crimping Bag-On-Valve types onto aerosol containers after process of injecting air or nitrogen. 1.2. Technical specification Tab. 1. Basic technical specification of Z-2312...
  • Page 6 OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 Fig. 1. Overall dimensions of Z-2312 The Manufacturer reserves the right to change the design of the produced machine. A0310.01.2312.905.1.EN Page 6/33...

  • Page 7: Safety Instructions

    ZIGLER POLSKA company, persons who have been sufficiently trained and prepared by the user to operate the device.

  • Page 8: Use According To The Purpose

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 NOTE: This machine has been designed and constructed with a view to use by operators who are not disabled. For use by persons with disabilities, the device should be adjusted accordingly after prior consultation with the manufacturer.

  • Page 9: Safety Rules During Repairs And Maintenance

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 9. All spanners and wrenches as well as other tools serving for regulation of devices, tightening screws etc. should be removed from the device after completing regulation or assembling works. Before starting the device again, check, whether this has really been done.

  • Page 10: Transport, Installation And Storage Of Z-2312

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 3. Transport, installation and storage of Z-2312 3.1. Transport Before transporting the device it’s necessary to disconnect compressed air supply, propellant supply (if it is other than air) and electric power supply. Also, set height of working unit at the lowest possible level (using height adjustment wheel on support stand).

  • Page 11: Storage

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 Standard design of the device assumes injection of compressed air into containers; in case of injection of other propellant it’s necessary to provide gas into propellant connection Factory-made new machines may contain traces of oil. Before main exploitation begins it is advised to gasify several containers using propellant to flush dispensing wires.

  • Page 12: Construction Of Semi-Automatic Bov Crimping Machine Z-2312

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 4. Construction of Semi-automatic BOV Crimping Machine Z-2312 In construction of Z-2312 following elements can be distinguished [Fig. 2]: 1. Footing; 2. Support stand; 3. Height adjustment wheel; 4. Can limiters;...
  • Page 13 OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 Fig. 2. General construction of Z-2312 The Manufacturer reserves the right to change the design of the produced machine. A0310.01.2312.905.1.EN Page 13/33...

  • Page 14: Construction Of Air Preperation Unit

    Compressed air provided to the device must be preliminarily cleaned. Achieving quality of supply air class 4 (according to ISO 8573-1 norm), required to power pneumatic devices produced by ZIGLER POLSKA company, is obtained using an air preparation unit. Implemented air preparation unit consist of following elements [Fig. 3]: Cut-off valve [pos.
  • Page 15 The above description relates to the air preparation unit manufactured by FESTO. In manufactured by ZIGLER POLSKA products there are air preparation units from the following producers: FESTO, CAMOZZI, SMC, CKD, METALWORK. Principle of operation and construction of all types of units conforms to the previously given description.

  • Page 16: Operation Manual Of Z-2312 Machine

    3. Use the footswitch to start a single cycle [Fig. 2, pos. 10]. 5.3. Stopping the machine. Emergency Stop Stopping the operation of Semi-automatic BOV Crimping Machine Z-2312 proceeds in a similar way to its starting: 1. Disable electric power supply by setting main switch in “OFF” position.

  • Page 17: Turning The Bag-On-Valve Function On And Off

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 5.4. Turning the Bag-On-Valve function on and off Device was equipped with switch which enables to turn Bag-On-Valve function on or off. Switch is located at front panel and is marked as BOV - NORMAL. After disabling Bag-On-Valve function device continues to work as a standard Semi-automatic Crimper.
  • Page 18 OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 Fig. 5. Instruments made by Zigler Polska used in crimp parameters measurement: a) PPHZ – for measuring crimp height, b) PPDZ - for measuring crimp diameter, c) PPHK - for measuring contact height Typical thickness values of the valve hood are: 0,3 mm –...

  • Page 19: Causes Of The Bad Results Of Crimping

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 Example: Contact height (KH) = 4.15 mm Thickness of the valve hood (e) = 0.3 mm Thickness of the crimped seal (J) = 0.5 mm Target crimp height (CH) to set = 4.95 mm...
  • Page 20 OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 Tab. 4. Crimping Module Defects, causes and elimination DEFECTS CAUSES ELIMINATION 1. Open the compressed air Crimping diameter changes. supply Actuator is incorrectly locked on Control measurements show a 2. Unscrew the crimping head...

  • Page 21: Z-2312 Working Parameters Adjustment

    6.1. Regulation of working pressure Choosing the correct amount of working pressure directly determines the course of production process. Semi-automatic BOV Crimping Machine Z-2312 was equipped with three points of pressure control, they are: Pressure regulator of main air preparation unit [Fig. 3, pos. 1.];...

  • Page 22: Adjusting The Height Of Bov Crimping Head

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 6.2. Adjusting the height of BOV crimping head Height of the head needs to be adjusted in relation to the height of currently used containers. Height adjustment must always be performed with enabled electric and pneumatic supply. Setting of height must always be verified paying special attention to correct work cycle of the device.

  • Page 23: Adjusting Crimping Parameters

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 6.3. Adjusting crimping parameters The most important parts of BOV crimping head that are involved in adjustment of crimp parameters, are listed below [Fig. 9]: 1. Lower sleeve; 2. Lower sleeve lock;...
  • Page 24 OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 A standard part of the delivery is the set of dedicated special keys, provided for the adjustment or disassembly of specific components of the BOV crimping head. The keys' purpose is as follows: 9312.46.004.0 –...
  • Page 25 OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 3. In case of necessity to replace the can sealing [Fig. 9, pos. 3], remove it from lower sleeve using special key 9312.46.003.1. Unscrew mounting nut [Fig. 9, pos. 4] matching the key pins to holes on top face of the nut after dismounting the lower sleeve unit.

  • Page 26: Adjusting Pre-Gassing Time

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 6.4. Adjusting pre-gassing time Filling time is regulated with the help of time relay knob placed on front panel of the machine. Knob is marked as TIME PRE-GASSING. There is a scale on knob which helps choosing the right value. The range of scale comprises of 10 elementary units.

  • Page 27: Adjusting Containers Limiters Position

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 6.5. Adjusting containers limiters position Semi-automatic BOV Crimping Machine Z-2312 was equipped with position limiters placed on device footing. Correct placement of limiters is obtained when container and working head are in coaxial position.
  • Page 28 OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 Regulation bolt Blocking nut Fig. 14. Non-return flow control valve GR type (mounted on cables) In case of non-return flow control valve GRLA type with socket for screwdriver [Fig. 13. a] regulation is conducted by turning regulation bolt (using flat screwdriver) in appropriate direction.

  • Page 29: Maintenance

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 7. Maintenance 7.1. General maintenance rules Label the pneumatic hoses before replacement. Pliers or pipe clamps usage is not allowed. Piston axle, cylinder, etc. damaged during dismantling may cause a serious machine failure.
  • Page 30 OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 additional crimping arbor will prevent the crimping jaws segments to decompose during the dismount. 6. Assembly the set composed of new crimping jaws, mounting sleeve and elastic clip according to Fig. 16. Insert additional crimping arbor inside the jaws to facilitate the process.

  • Page 31: The Conditions Of Functional Reliability Of The Pneumatic Control Systems

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 10. Install the lower sleeve unit (along with can sealing and the nut - Fig. 9, pos. 1 + pos. 3 + pos. 4) and tighten it with the correct end of special key 9312.46.004.0.

  • Page 32: Compressed Air Lubricator Maintenance

    OPERATION AND MAINTENANCE MANUAL Semi-automatic BOV Crimping Machine Z-2312 Tab. 6. Division into quality grades as per ISO 8573-1 standard 1. SOLIDS 2. WATER CONTENT 3. OIL CONTENT Grade Max. particle Max. particle density Max. pressure dew point Max. concentration( size(µm)

  • Page 33: Pneumatic Oil Quality

    The prerequisite for maintaining the machine's warranty during its validity period is, among others, to respect the schedule of technical inspections of machinery performed by Zigler Polska service personnel. During the base warranty period of 24 months, according to the general terms, at least...
  • Page 35 § 6. Any defective components or parts after replacement shall become the property of the PRINCIPAL. § 7. This guarantee shall apply only to the equipment manufactured and supplied by ZIGLER POLSKA. §8. The operation of the equipment, used in accordance with the operating and maintenance conditions as described in the maintenance and operating manual, is guaranteed.
  • Page 36 PNEUMATIC DIAGRAMS...
  • Page 37 Page No: 2018-08-31 A0310 Complete diagram Designed by: Device name: Dawid Mroczek Semi-automatic BOV Crimping Machine Document No: Draw by: ZIGLER Polska Sp. z o.o. Dawid Mroczek ul. Braci Gutmanów 7 A0310 . 2312 .902. 1. Subtype: Device type: sR.Sze+p 2312...
  • Page 38 SPARE PARTS LIST WITH TECHNICAL DRAWINGS...
  • Page 39 9002.39.600.0 9002.39.605.0 9052.39.000.0/OR1 9002.39.600.0 9052.39.000.0/OR3 9002.39.602.1 9052.39.000.0/SV1 9052.39.000.0/LS1 9002.45.000.2 9002.39.601.0 9052.39.000.0/CP1 9002.39.604.1 9052.39.000.0/OR2 9052.39.600.0 A ( 1 : 1 ) 9052.39.000.0/OR1 9052.39.000.0/OR3 NOTE: When ordering spare parts, make sure to use drawing number as well as exact symbol/marking of particular part. Only complete information will allow to identify the part and properly process your order.
  • Page 40 9312.40.002.0/OR1 9312.40.002.0/OR2 9002.40.606.0 9312.40.002.0/OR2 9312.40.002.0/OR3 9312.40.002.0/OR4 9052.40.605.0 9312.40.002.0/LS1 9312.40.002.0/LS1 9052.40.600.3 9052.40.604.0 9052.40.601.2 9312.40.002.0/OR4 9312.40.002.0/OR3 9052.40.606.0 9002.40.605.1 9002.40.604.1 9002.40.605.1 9312.15.619.0 9312.15.617.0 NOTE: When ordering spare parts, make sure to use drawing number as well as exact symbol/marking of particular part. Only complete information will allow to identify the part and properly process your order.
  • Page 41 9002.45.000.2/SG1 9002.45.000.2/CP1 9002.45.600.0 9002.45.601.0 9002.45.603.1 9002.45.602.1 9002.45.000.2/CP2 9002.45.604.0 NOTE: When ordering spare parts, make sure to use drawing number as well as exact symbol/marking of particular part. Only complete information will allow to identify the part and properly process your order.
  • Page 42 9312.15.000.3/BL 1 9312.15.613.1 A ( 2 : 1 ) 9312.15.000.3/SG 1 9312.15.000.3/OR7 9312.15.611.3 9002.54.605.4 9312.15.601.1 9002.54.602.3 9312.15.600.0 9312.15.000.3/OR 1 9002.54.601.0 9312.15.000.3/OR 2 9312.15.000.3/OR 3 9312.15.000.3/OR 4 9312.15.604.3 9312.15.000.3/OR 5 9312.15.605.2 9312.15.000.3/OR 6 9312.15.602.3 9312.15.607.2 9312.15.603.1 9312.15.608.1 (can diameter 35) 9312.15.606.3 (can diameter 35) 9312.15.610.0 (can diameter 45...
  • Page 43 A-A ( 1 : 1 ) 9019.05.613.0 9019.00.002.1/HW1 9019.01.602.0 9019.00.600.0 9019.00.002.1/AH1 9019.05.613.0 9019.01.602.0 9019.05.615.0 9019.05.617.1 9019.01.050.0 NOTE: When ordering spare parts, make sure to use drawing number as well as exact symbol/marking of particular part. Only complete information will allow to identify the part and properly process your order.
  • Page 44 ELECTRIC DIAGRAMS...
  • Page 45 Page name: Page No: Revision: 2017-03-03 A0214 Supply Device Designed by: Majerowski M. Semi-automatic BOV name: ZIGLER Polska Sp. z o.o. Crimping Machine Document No: Draw by: Majerowski M. ul. Braci Gutmanów 7 A0214.08.2312.901.1.EN Device 43-600 Jaworzno POLSKA Z-2312 Client:...
  • Page 46 Page name: Page No: Revision: 2017-03-03 A0214 Safety Device Designed by: Majerowski M. Semi-automatic BOV name: ZIGLER Polska Sp. z o.o. Crimping Machine Document No: Draw by: Majerowski M. ul. Braci Gutmanów 7 A0214.08.2312.901.1.EN Device 43-600 Jaworzno POLSKA Z-2312 Client:...
  • Page 47 Page name: Page No: Revision: 2017-03-03 A0214 Inputs Device Designed by: Majerowski M. Semi-automatic BOV name: ZIGLER Polska Sp. z o.o. Crimping Machine Document No: Draw by: Majerowski M. ul. Braci Gutmanów 7 A0214.08.2312.901.1.EN Device 43-600 Jaworzno POLSKA Z-2312 Client:...
  • Page 48 Page name: Page No: Revision: 2017-03-03 A0214 Outputs 1 Device Designed by: Majerowski M. Semi-automatic BOV name: ZIGLER Polska Sp. z o.o. Crimping Machine Document No: Draw by: Majerowski M. ul. Braci Gutmanów 7 A0214.08.2312.901.1.EN Device 43-600 Jaworzno POLSKA Z-2312 Client:...
  • Page 49 Page name: Page No: Revision: 2017-03-03 A0214 Outputs 2 Device Designed by: Majerowski M. Semi-automatic BOV name: ZIGLER Polska Sp. z o.o. Crimping Machine Document No: Draw by: Majerowski M. ul. Braci Gutmanów 7 A0214.08.2312.901.1.EN Device 43-600 Jaworzno POLSKA Z-2312 Client:...

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