Sacmi PMV 224 User manual

TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇAO TÉCNICA
DOCUMENTAZIONE
TECNICA
MAINTENANCE AND OPERATIONS MANUAL
176.12.A03_01
MACHINE FOR FORMING LINERS INSIDE PLASTIC CAPS
PMV 224 - PMV 238
ENGLISH

TABLE OF CONTENTS
176.12.A03
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Revision 01 Date 14.11.2001

176.12.A03
TABLE OF CONTENTS
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Revision 01 Date 14.11.2001
MAINTENANCE AND OPERATIONS MANUAL
MACHINE FOR FORMING LINERS INSIDE PLASTIC CAPS
PMV 224 - PMV 238
MANUFACTURER
SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
PUBLISHED ON
30.10.2000
REVISION
01 - 14.11.2001
VERSIONS
PMV 224.00.000/001 - PMV 224A - PMV 238.00.002/003 - PMV 238A
SERIAL NUMBER
YEAR OF MANUFACTURE

TABLE OF CONTENTS
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176.12.A03
TABLE OF CONTENTS
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Page
1GENERAL 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 - 1
1.4 USERS OF THE MANUAL ..........................................................................................................1 - 1
1.5 WARRANTY ................................................................................................................................1 - 2
1.6 SUPPLEMENTS..........................................................................................................................1 - 2
1.7 KEY TO THE SAFETY SYMBOLS USED ON THE MACHINE
AND/OR IN THE MANUAL..........................................................................................................1 - 3
1.8 MACHINE IDENTIFICATION PLATE...........................................................................................1 - 4
2MAIN FEATURES.......................................................................................................................................2 - 1
2.1 MACHINE DESCRIPTION ..........................................................................................................2 - 1
2.1.1 MAIN MACHINE ASSEMBLIES ..................................................................................................2 - 2
2.1.1.1 EXTRUDER.................................................................................................................................2 - 2
2.1.1.2 INSERTION DRUM ....................................................................................................................2 - 3
2.1.1.3 1ST TRANSFER UNIT ................................................................................................................2 - 4
2.1.1.4 FORMING UNIT ..........................................................................................................................2 - 5
2.1.1.5 2ND TRANSFER UNIT................................................................................................................2 - 6
2.1.1.6 QUALITY CONTROL UNIT .........................................................................................................2 - 6
2.1.1.7 DISCHARGE UNIT......................................................................................................................2 - 7
2.1.1.8 EXIT CONVEYOR BELT .............................................................................................................2 - 7
2.1.1.9 DRIVE UNIT & MANUAL OPERATION ......................................................................................2 - 8
2.1.1.10 PNEUMATIC SYSTEM ................................................................................................................2 - 9
2.1.1.11 COOLING SYSTEM ....................................................................................................................2 - 9
2.1.1.12 ELECTRICAL SYSTEM: CONTROL PANEL...............................................................................2 - 9
2.1.1.13 TOOLS ........................................................................................................................................2 - 9
2.1.2 INTENDED, PROHIBITED USE AND MISUSE OF THE MACHINE ........................................2 - 10
2.2 OVERALL DIMENSIONS ..........................................................................................................2 - 11
2.3 MACHINE SPECIFICATIONS ...................................................................................................2 - 13
2.3.1 TECHNICAL DATA ....................................................................................................................2 - 13
2.3.3 RATING PLATE .........................................................................................................................2 - 14
2.3.2 ALLOWABLE FLUCTUATION OF THE VARIABLES ................................................................2 - 14
2.3.4 USE OF THE MACHINE............................................................................................................2 - 15
2.3.5 NOISE EMISSION LEVELS ......................................................................................................2 - 16
2.3.5.1 ACOUSTIC RADIATION PRESSURE LEVEL (ISO/DIS 11202) ...............................................2 - 16
2.3.5.2 ACOUSTIC POWER LEVEL (ISO 3746)...................................................................................2 - 17
2.4 SCHEMATICS ...........................................................................................................................2 - 18
2.4.1 PNEUMATIC SYSTEM ..............................................................................................................2 - 18
2.4.2 COOLING SYSTEM ..................................................................................................................2 - 19
2.4.3 VACUUM SYSTEM....................................................................................................................2 - 21

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3SAFETY EQUIPMENT AND PRECAUTIONS............................................................................................3 - 1
3.1 SAFETY DEVICES AND GUARDS .............................................................................................3 - 1
3.1.1 GENERAL SAFETY RULES........................................................................................................3 - 1
3.1.2 SAFETY DEVICES INSTALLED..................................................................................................3 - 1
3.1.2.1 SHUTDOWN DEVICES...............................................................................................................3 - 1
3.1.2.2 INDICATING A SHUTDOWN .......................................................................................................3 - 1
3.1.2.3 DEVICES TO SAFEGUARD THE OPERATOR...........................................................................3 - 1
3.1.2.4 EMERGENCY STOP BUTTONS.................................................................................................3 - 2
3.2 SAFETY RULES FOR HANDLING .............................................................................................3 - 3
3.2.1 LIFTING PROCEDURES ............................................................................................................3 - 3
3.2.2 HANDLING PROCEDURES........................................................................................................3 - 3
3.2.3 PLACING THE LOAD ..................................................................................................................3 - 3
3.3 INSTALLATION............................................................................................................................3 - 4
3.3.1 GENERAL RULES.......................................................................................................................3 - 4
3.4 OPERATOR TRAINING...............................................................................................................3 - 5
3.4.1 END-USER..................................................................................................................................3 - 5
3.4.2 OPERATORS ..............................................................................................................................3 - 5
3.4.3 MAINTENANCE STAFF ..............................................................................................................3 - 5
3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THE MACHINE... 3 - 6
3.5.1 GENERAL SAFETY RULES........................................................................................................3 - 6
3.5.2 GUIDELINES FOR OPERATION AND MAINTENANCE.............................................................3 - 7
3.5.2.1 RISKS DERIVING FROM HIGH TEMPERATURES....................................................................3 - 7
3.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED ..................................................3 - 7
3.6.1 GENERAL ...................................................................................................................................3 - 7

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4INSTALLATION ..........................................................................................................................................4 - 1
4.1 MACHINE SHIPMENT ................................................................................................................4 - 1
4.1.1 HOW THE MACHINE IS SUBDIVIDED FOR SHIPMENT ..........................................................4 - 1
4.1.2 WEIGHTS AND DIMENSIONS....................................................................................................4 - 2
4.1.3 HANDLING THE MACHINE PARTS............................................................................................4 - 4
4.2 ASSEMBLING THE MACHINE....................................................................................................4 - 5
4.2.1 DRUM BASE ...............................................................................................................................4 - 5
4.2.2 EXTRUDER BASE ......................................................................................................................4 - 6
4.2.3 PLASTIC COMPOUND FEEDER AND HOPPER .......................................................................4 - 7
4.2.4 ELECTRICAL CABINET ..............................................................................................................4 - 8
4.2.5 SAFETY GUARDS AND DEVICES .............................................................................................4 - 8
4.3 CONNECTIONS ..........................................................................................................................4 - 9
4.3.1 CONNECTING THE HOSES FOR THE COOLING SYSTEM.....................................................4 - 9
4.3.1.1 HOSES FOR JOINING THE HEAT-EXCHANGER TO THEAUXILIARY CIRCUIT TANK ..........4 - 9
4.3.1.2 HOSES FOR JOINING THE CHILLER TO THE MANIFOLDS (M & R) .....................................4 - 9
4.3.1.3 FORMING CAM COOLING LINES............................................................................................4 - 10
4.3.1.4 AUXILIARY CIRCUIT COOLING TANK - COOLING TANK AND PLUNGER HEATER ............4 - 10
4.3.2 CONNECTING THE PNEUMATIC SYSTEM.............................................................................4 - 11
4.3.2.1 PNEUMATIC UNIT ....................................................................................................................4 - 11
4.3.2.2 PLASTIC COMPOUND FEEDER..............................................................................................4 - 11
4.3.2.3 EXTRUDER HEAD PLUNGER .................................................................................................4 - 11
4.3.3 CONNECTIONS TO THE VACUUM SYSTEM ..........................................................................4 - 12
4.3.3.1 PLASTIC COMPOUND FEEDER..............................................................................................4 - 12
4.3.3.2 VACUUM PUMP........................................................................................................................4 - 12
4.3.3.3 WASTE AND BURR SUCTION SYSTEM .................................................................................4 - 13
4.3.4 INSTALLING THE PROXIMITY SENSORS ..............................................................................4 - 14
4.3.5 ELECTRICAL CONNECTIONS .................................................................................................4 - 15
4.3.5.1 CONNECTING THE ELECTRICAL CABLES ............................................................................4 - 15
4.3.5.2 EARTH CONNECTION .............................................................................................................4 - 18
4.3.5.3 CONNECTION TO THE SUPPLY MAINS ................................................................................4 - 18
5START-UP ..................................................................................................................................................5 - 1
5.1 GENERAL ...................................................................................................................................5 - 1
5.2 PRELIMINARY CHECKS ............................................................................................................5 - 1
5.3 CHECKING OPERATION............................................................................................................5 - 1
5.4 OPERATIONS TO BE PERFORMED BEFORE STARTING THE PRODUCTION CYCLE.........5 - 2
5.5 STARTING AN AUTOMATIC CYCLE ..........................................................................................5 - 3
5.6 SUBSEQUENT START-UP PROCEDURES ...............................................................................5 - 3
6OPERATING INSTRUCTIONS ...................................................................................................................6 - 1
6.1 CONTROL KEYBOARD ..............................................................................................................6 - 1
6.2 WORK CYCLE ............................................................................................................................6 - 5

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7ADJUSTMENTS .........................................................................................................................................7 - 1
7.1 ADJUSTING THE EXTRUDER ...................................................................................................7 - 1
7.1.1 ADJUSTING THE POSITION OF THE EXTRUDER NOZZLE HOLE .........................................7 - 2
7.1.2 EXTRUDER NOZZLE HEIGHTADJUSTMENT ..........................................................................7 - 3
7.1.3 CUTTER CLEARANCE ADJUSTMENT .....................................................................................7 - 4
7.1.4 POSITIONING THE EXTRUDER NOZZLE.................................................................................7 - 5
7.1.5 PELLET WEIGHTADJUSTMENT ..............................................................................................7 - 6
7.1.6 TEMPERATURE CONTROL ......................................................................................................7 - 6
7.2 INSERTION DRUMADJUSTMENT ............................................................................................7 - 7
7.2.1 CUTTER HEIGHTADJUSTMENT...............................................................................................7 - 8
7.2.2 PLUNGER HEIGHTADJUSTMENT............................................................................................7 - 9
7.2.3 ADJUSTING THE AIR SUPPLY ................................................................................................7 - 10
7.2.4 TIMING PELLET CUTTING.......................................................................................................7 - 11
7.2.5 CENTERING THE PELLETS ....................................................................................................7 - 12
7.3 ADJUSTING THE 1ST TRANSFER TURN-TABLE ...................................................................7 - 13
7.4 ADJUSTING THE FORMING UNIT...........................................................................................7 - 14
7.4.1 FORMING PLUNGER CLEARANCE ........................................................................................7 - 14
7.4.2 STRIPPER HEIGHTADJUSTMENT .........................................................................................7 - 15
7.4.3 PLUNGER TEMPERATURE SETTING.....................................................................................7 - 16
7.5 ADJUSTING THE QUALITY CONTROL UNIT .........................................................................7 - 17
7.5.1 ADJUSTING THE HEIGHT OF THE SENSING EQUIPMENTAND CENTRAL SENSOR .......7 - 18
7.5.2 ADJUSTING THE HEIGHT OF THE SENSING SPINDLES .....................................................7 - 19
7.5.3 ADJUSTING THE POSITION OF THE SENSING SPINDLE/LINER.........................................7 - 20
7.5.4 ADJUSTING THE SENSOR FOR DOUBLE LINERS ...............................................................7 - 21
7.5.5 ADJUSTING THE QUALITY CONTROL UNIT .........................................................................7 - 23
7.5.6 SENSITIVITY LEVELADJUSTMENT........................................................................................7 - 25
7.5.7 ADJUSTING THE DEFECTIVE PRODUCT CONTROL DEVICES ...........................................7 - 25
7.6 DISCHARGE CONVEYOR BELT ADJUSTMENT .....................................................................7 - 26
8MAINTENANCE .........................................................................................................................................8 - 1
8.1 SCHEDULED MAINTENANCE ...................................................................................................8 - 2
8.1.1 SCHEDULED MAINTENANCE CHART......................................................................................8 - 2
8.1.2 SCHEDULED MAINTENANCE ...................................................................................................8 - 6
8.1.2.1 REMOVING AND CLEANING THE EXTRUDER AUGER AND FILTER ....................................8 - 6
8.1.2.2 REPLACING AND RE-SHARPENING THE CUTTERS ..............................................................8 - 9
8.1.2.3 REMOVING THE LOWER PLUNGER FROM THE FORMING DRUM.....................................8 - 11
8.1.2.4 DISASSEMBLING THE FORMING PLUNGER.........................................................................8 - 13
8.1.2.5 DISASSEMBLING THE LOWER PLUNGER.............................................................................8 - 14
8.1.3 LUBRICATION...........................................................................................................................8 - 15
8.1.3.1 LUBRICANT SPECIFICATIONS................................................................................................8 - 15
8.1.3.2 GEAR LUBRICATION................................................................................................................8 - 16
8.1.4 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS .........................................................8 - 17
8.2 SPECIAL MAINTENANCE OPERATIONS ................................................................................8 - 18
8.2.1 TIMING THE DRUMASSEMBLIES & TURN-TABLES .............................................................8 - 18
8.2.1.1 TIMING THE FORMING UNIT/1ST TURNTABLE .....................................................................8 - 19
8.2.1.2 TIMING THE 1ST TURNTABLE/INSERTION DRUM ...............................................................8 - 20
8.2.1.3 TIMING THE FORMING DRUM/2ND TURN-TABLE.................................................................8 - 20
8.2.1.4 TIMING THE 2ND TURN-TABLE/QUALITY CONTROL UNIT ..................................................8 - 21
8.2.1.5 TIMING THE QUALITY CONTROL UNIT/DISCHARGE UNIT .................................................8 - 22
8.3 TROUBLESHOOTING ..............................................................................................................8 - 23
8.3.1 TROUBLESHOOTING THE MACHINE.....................................................................................8 - 23
8.3.2 TROUBLE-SHOOTING THE CAPS ..........................................................................................8 - 27
9DECOMMISSIONING ................................................................................................................................9 - 1

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GENERAL INFORMATION
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1 GENERAL INFORMATION
1.1 INTRODUCTION
E0004
WARNING!
Carefully read the entire Maintenance and Operations 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 and the machine
itself.
SACMI reserves the right to make changes to the machine and in the manual without giving prior notice.
Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.
Copyright. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI.
The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,
reproduced, disclosed or transferred.
1.2 WHERE TO KEEP THE MANUAL
E0004
WARNING!
This manual is to be considered an essential part of the machine and must be kept along with it even if the machine
is sold. Always keep the manual near the machine where it can be easily consulted.
The manual must always be at hand so that the operator and maintenance staff are able to consult it rapidly at any
time.
1.3 HOW TO USE THE MANUAL
The lay out of this manual allows it to be easily consulted as all the information and instructions provided are 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. The notes pertinent to the
operator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and
are written in italics, as shown below.
E0004
WARNING!
Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS - must be carefully read in its entirety 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 staff.
For a more detailed description, see the paragraph dealing with OPERATOR TRAINING in chapter 3 - SAFETY
EQUIPMENT AND PRECAUTIONS.

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GENERAL INFORMATION
1
1.5 WARRANTY
SACMI shall be held responsible only for the machine as it was configured at the time of delivery.
Anyoperations that alter theconfigurationof the machine oroperatingcycle must be carriedout bySACMIpersonnel
or duly authorized by SACMI’S Engineering Dept.
SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.
E0004
ATTENTION!
The machine operator or maintenance staff are not responsible for carrying out operations under warranty, special
maintenance and repairs. 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.
1.6 SUPPLEMENTS
Information regarding the electric and electronic components of the machine are given in three handbooks provided
under separate cover and entitled:
- USE OF THE MICROPROCESSOR CONTROL SYSTEM (Instructions B manual)
- DESCRIPTION OF THE ELECTRONIC CARDS
- LIST OF DEVICES
These handbooks are supplied with this manual.