Sacmi CCM001 User manual

TECHNICAL DOCUMENTATION
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ENGLISH
USER’S MANUAL
002AZ001A
ROTARY HYDRAULIC COMPRESSION PRESS
CCM 001

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002AZ001A
USER’S MANUAL
ROTARY HYDRAULIC COMPRESSION PRESS
CCM 001
MANUFACTURER
SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
PUBLISHED ON
25.10.2001
VERSIONS
CCM00100005 - CCM001A

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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 - 2
1.8 MACHINE IDENTIFICATION PLATE ......................................................................................1 - 4
2MACHINE FEATURES ............................................................................................................................. 2 - 1
2.1 MACHINE DESCRIPTION ...................................................................................................... 2 - 1
2.1.1 MAIN DEVICES........................................................................................................................2 - 3
2.1.1.1 Plasticization unit .................................................................................................................... 2 - 3
2.1.1.2 Drive unit ............................................................................................................................... 2 - 10
2.1.1.3 Insertion drum unit ................................................................................................................ 2 - 11
2.1.1.4 Forming unit .......................................................................................................................... 2 - 14
2.1.1.5 Exit channel ........................................................................................................................... 2 - 17
2.1.1.6 Pneumatic system ................................................................................................................. 2 - 17
2.1.1.7 Hydraulic system ................................................................................................................... 2 - 17
2.1.1.8 Cooling system ...................................................................................................................... 2 - 17
2.1.1.9 Electric system: control board ............................................................................................... 2 - 17
2.1.1.10 Tooling................................................................................................................................... 2 - 17
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ............................................ 2 - 18
2.2 OVERALL DIMENSIONS ...................................................................................................... 2 - 19
2.3 TECHNICAL DATA ...............................................................................................................2- 23
2.3.1 SPECIFICATIONS ................................................................................................................ 2 - 23
2.3.2 OPERATIONAL CHARACTERISTICS.................................................................................. 2 - 24
2.3.3 AIRBORNE NOISE EMISSION LEVELS .............................................................................. 2 - 25
2.3.3.1 Sound pressure level (ISO/DIS 11202)................................................................................. 2 - 25
2.3.3.2 Sound power level (ISO 3746) ............................................................................................. 2 - 25
2.4 DIAGRAMS ........................................................................................................................... 2 - 27
2.4.1 PNEUMATIC SYSTEM DIAGRAM ....................................................................................... 2 - 27
2.4.2 HYDRAULIC SYSTEM DIAGRAM ........................................................................................ 2 - 30
2.4.3 COOLING SYSTEM DIAGRAM ............................................................................................ 2 - 33

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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
3.5.2.2 Risk of explosion ......................................................................................................................3 - 7
3.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED ............................................. 3 - 8
3.6.1 GENERAL ............................................................................................................................... 3 - 8
4INSTALLATION ........................................................................................................................................ 4 - 1
4.1 SHIPPING AND HANDLING ....................................................................................................4 - 1
4.2 POSITIONING ......................................................................................................................... 4 - 4
4.3 CONNECTIONS AND HOOK UPS ..........................................................................................4 - 5
4.3.1 CONNECTING THE EXTRUDER TO THE PRESS ............................................................... 4 - 5
4.3.2 HYDRAULIC CONNECTION: FROM THE POWER UNIT TO THE PRESS ..........................4 - 6
4.3.3 HOOKING UP THE COOLANT SYSTEM............................................................................... 4 - 7
4.3.4 HOOKING UP THE PNEUMATIC SYSTEM ........................................................................... 4 - 8
4.3.5 ELECTRICAL HOOK-UP ........................................................................................................ 4 - 9
4.3.5.1 Wiring connections .................................................................................................................. 4 - 9
4.3.5.2 Earth connection ................................................................................................................... 4 - 10
4.3.5.3 Connection to the supply mains ............................................................................................ 4 - 10
5START UP ..................................................................................................................................................5 - 1
5.1 INTRODUCTION ......................................................................................................................5 - 1
5.2 PRELIMINARY CHECKS ........................................................................................................ 5 - 1
5.3 CHECKING OPERATION ........................................................................................................5 - 2
5.4 PRELIMINARY OPERATIONS ............................................................................................... 5 - 3
5.5 STARTING THE AUTOMATIC CYCLE................................................................................... 5 - 4
5.6 SUBSEQUENT START UPS .................................................................................................. 5 - 4
6OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1
6.1 CONTROL AND MONITORING UNIT .................................................................................... 6 - 1
6.2 STARTING AND STOPPING THE MACHINE ........................................................................ 6 - 4
6.3 AUTOMATIC CYCLE ...............................................................................................................6 - 5
6.4 PRODUCTION CYCLE ........................................................................................................... 6 - 6
6.5 EMERGENCY CYCLES AND RESET OPERATIONS ............................................................6 - 9
6.5.1 ACTUATOR DOWNSTROKE CONTROL............................................................................... 6 - 9
6.5.2 ACTUATOR UPSTROKE CONTROL ................................................................................... 6 - 10
6.5.3 DOUBLE PRODUCT DETECTION ....................................................................................... 6 - 11
6.5.4 EMPTY DIE CONTROL ........................................................................................................ 6 - 12
6.5.5 DETECTION OF PRODUCTS HEAVIER OF LIGHTER THAN NORMAL WEIGHT............ 6 - 12
6.5.6 CORRECT POSITION FOR START OF FORMING CONTROL .......................................... 6 - 13
6.6 PRODUCT SAMPLING ......................................................................................................... 6 - 14

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7ADJUSTMENTS ........................................................................................................................................ 7 - 1
7.1 PLASTICIZATION UNIT..........................................................................................................7-1
7.1.1 EXTRUDER............................................................................................................................. 7 - 1
7.1.2 METERING PUMP .................................................................................................................. 7 - 1
7.1.3 FEED TUBE .............................................................................................................................7 - 2
7.1.4 BY-PASS SYSTEM ................................................................................................................. 7 - 2
7.2 INSERTION DRUM ................................................................................................................. 7 - 3
7.2.1 ADJUSTING THE PRECHARGE OF THE DRUM’S CONNECTING ROD ............................ 7 - 3
7.2.2 ADJUSTING THE CUTTER .................................................................................................... 7 - 4
7.2.3 ADJUSTING THE PELLET INSERTION STAGE ................................................................... 7 - 6
7.3 FORMING UNIT ...................................................................................................................... 7 - 7
7.3.1 PRODUCT REMOVAL ADJUSTMENT................................................................................... 7 - 9
7.3.2 ADJUSTING THE QUALITY CONTROL UNIT ..................................................................... 7 - 10
7.4 PNEUMATIC SYSTEM ......................................................................................................... 7 - 12
7.5 HYDRAULIC SYSTEM.......................................................................................................... 7 - 12
7.5.1 ADJUSTING THE OIL FLOW UNDER LOW PRESSURE ................................................... 7 - 12
7.5.2 ADJUSTING THE FORMING STAGE (HIGH PRESSURE) ................................................. 7 - 12
7.5.3 ADJUSTING THE ACTUATOR DOWNSTROKE ................................................................. 7 - 12
7.6 COOLING SYSTEM .............................................................................................................. 7 - 14
7.7 INSTALLING AND REMOVING THE TOOLING .................................................................. 7 - 14
7.8 ADJUSTING THE EXIT CHANNEL ...................................................................................... 7 - 16
7.9 REPLACING THE INDUCTIVE SENSORS .......................................................................... 7 - 18
7.10 RESETTING THE ENCODERS ............................................................................................ 7 - 19
8MAINTENANCE ........................................................................................................................................ 8 - 1
8.1 SCHEDULED MAINTENANCE ............................................................................................... 8 - 2
8.1.1 SCHEDULED MAINTENANCE CHART ................................................................................. 8 - 2
8.1.2 PERIODIC MAINTENANCE OPERATIONS ........................................................................... 8 - 8
8.1.2.1 Drive unit ..................................................................................................................................8 - 8
8.1.2.1.1 Checking the condition of the drive belts .................................................................................8 - 8
8.1.2.1.2 Tensioning the forming unit transmission belts........................................................................8 - 8
8.1.2.1.3 Replacing the forming unit transmission belts ........................................................................ 8 - 8
8.1.2.1.4 Tensioning the insertion unit transmission belt ........................................................................8 - 8
8.1.2.1.5 Replacing the insertion unit transmission belt ........................................................................ 8 - 9
8.1.2.1.6 Checking the oil level in the forming unit’s geared motor ........................................................8 - 9
8.1.2.1.7 Changing the oil in the forming unit’s geared motor ............................................................... 8 - 9
8.1.2.2 50 kg/h Extruder .................................................................................................................... 8 - 11
8.1.2.2.1 Overhauling the extruder auger ............................................................................................ 8 - 11
8.1.2.2.2 Checking the oil level in the extruder geared motor and topping up .................................... 8 - 12
8.1.2.2.3 Changing the oil in the extruder geared motor ..................................................................... 8 - 12
8.1.2.2.4 Cleaning the nozzle............................................................................................................... 8 - 12
8.1.2.2.5 Checking and setting pressure transducers BP1 and BP2................................................... 8 - 14
8.1.2.3 100 kg/h Extruder .................................................................................................................. 8 - 16
8.1.2.3.1 Overhauling the extruder auger ............................................................................................ 8 - 17
8.1.2.3.2 Checking the oil level in the extruder geared motor and topping up .................................... 8 - 18
8.1.2.3.3 Changing the oil in the extruder geared motor ..................................................................... 8 - 18
8.1.2.3.4 Cleaning the polymer metering pump ................................................................................... 8 - 18
8.1.2.3.5 Replacing/overhauling the polymer metering pump ............................................................. 8 - 18
8.1.2.3.6 Lubricating the universal joint ............................................................................................... 8 - 19
8.1.2.3.7 Cleaning the nozzle............................................................................................................... 8 - 19
8.1.2.3.8 Checking and setting pressure transducers BP1 and BP2................................................... 8 - 19
8.1.2.3.9 Checking the condition and tensioning the extruder drive belt ............................................. 8 - 21
8.1.2.3.10 Tensioning the extruder drive belt......................................................................................... 8 - 21
8.1.2.3.11 Replacing the extruder drive belt .......................................................................................... 8 - 21
8.1.2.4 150-200 kg/h Extruder........................................................................................................... 8 - 22
8.1.2.4.1 Overhauling the extruder auger ............................................................................................ 8 - 23
8.1.2.4.2 Checking the oil level in the polymer metering pump geared motor and topping up ........... 8 - 24

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8.1.2.4.3 Changing the oil in the polymer metering pump geared motor............................................. 8 - 24
8.1.2.4.4 Checking the oil level in the extruder thrust block and topping up ....................................... 8 - 24
8.1.2.4.5 Changing the oil in the extruder thrust block ........................................................................ 8 - 25
8.1.2.4.6 Cleaning the polymer metering pump ................................................................................... 8 - 25
8.1.2.4.7 Replacing/overhauling the polymer metering pump ............................................................. 8 - 25
8.1.2.4.8 Lubricating the universal joint ............................................................................................... 8 - 26
8.1.2.4.9 Cleaning the nozzle............................................................................................................... 8 - 26
8.1.2.4.10 Checking and setting pressure transducers BP1 and BP2................................................... 8 - 26
8.1.2.4.11 Setting pressure switch SP8 and pressure relief valve YV8................................................. 8 - 28
8.1.2.5 Insertion drum ....................................................................................................................... 8 - 29
8.1.2.5.1 Sharpening the cutters .......................................................................................................... 8 - 31
8.1.2.5.2 Replacing the cutters ............................................................................................................ 8 - 31
8.1.2.5.3 Cleaning the cutters .............................................................................................................. 8 - 31
8.1.2.5.4 Replacing the cutters ............................................................................................................ 8 - 31
8.1.2.5.5 Cleaning the nozzles ............................................................................................................. 8 - 31
8.1.2.5.6 Replacing the nozzles ........................................................................................................... 8 - 32
8.1.2.5.7 Cleaning the compressed air distributor ............................................................................... 8 - 32
8.1.2.5.8 Replacing the compressed air distributor ............................................................................. 8 - 32
8.1.2.5.9 Checking the precharge of the drum’s connecting rod ......................................................... 8 - 32
8.1.2.5.10 Adjusting the precharge of the drum’s connecting rod ......................................................... 8 - 32
8.1.2.5.11 Lubricating the epicycloid gears............................................................................................ 8 - 32
8.1.2.5.12 Replacing gears F ................................................................................................................. 8 - 32
8.1.2.5.13 Replacing gears G ................................................................................................................ 8 - 33
8.1.2.5.14 Replacing gears H................................................................................................................. 8 - 33
8.1.2.5.15 Replacing pulley A ................................................................................................................ 8 - 33
8.1.2.5.16 Disassembling the pulley/toothed wheel C ........................................................................... 8 - 34
8.1.2.5.17 Disassembling the pulley/toothed wheel D ........................................................................... 8 - 34
8.1.2.5.18 Tensioning belt B .................................................................................................................. 8 - 34
8.1.2.5.19 Replacing the toothed belt B ................................................................................................. 8 - 35
8.1.2.5.20 Lubricating the gears............................................................................................................. 8 - 35
8.1.2.6 Forming unit .......................................................................................................................... 8 - 36
8.1.2.6.1 Cleaning ................................................................................................................................ 8 - 37
8.1.2.6.2 Overhauling the actuator valve ............................................................................................. 8 - 37
8.1.2.6.3 Greasing the roller................................................................................................................. 8 - 37
8.1.2.6.4 Replacing the hydraulic actuator gasket ............................................................................... 8 - 37
8.1.2.6.5 Replacing the upper flange gaskets...................................................................................... 8 - 38
8.1.2.6.6 Replacing the lower flange gaskets ...................................................................................... 8 - 38
8.1.2.6.7 Greasing the roller and stripper rod pin ................................................................................ 8 - 39
8.1.2.6.8 Lubricating the stripper rod guide bushes............................................................................. 8 - 39
8.1.2.6.9 Greasing the central tool wheel (optional) ............................................................................ 8 - 39
8.1.2.7 Cams ..................................................................................................................................... 8 - 40
8.1.2.7.1 Greasing and checking ......................................................................................................... 8 - 41
8.1.2.7.2 Replacing the stripper cams (central movement) (optional) ................................................. 8 - 41
8.1.2.7.3 Replacing the stripper cams (side movement) ..................................................................... 8 - 41
8.1.2.7.4 Replacing the actuator control cams..................................................................................... 8 - 41
8.1.2.7.5 Replacing the cams for injecting air in the punches ............................................................. 8 - 41
8.1.2.8 Rotary distributor ................................................................................................................... 8 - 42
8.1.2.8.1 Replacing the gaskets ........................................................................................................... 8 - 42
8.1.2.9 Hydraulic system ................................................................................................................... 8 - 42
8.1.2.9.1 Checking the oil level in the hydraulic power unit ................................................................. 8 - 44
8.1.2.9.2 Changing the oil in the hydraulic power unit ......................................................................... 8 - 44
8.1.2.9.3 Replacing the flexible coupling in the hydraulic power unit .................................................. 8 - 44
8.1.2.9.4 Replacing the filter in the hydraulic power unit ..................................................................... 8 - 44
8.1.2.9.5 Checking the oil level in the hydraulic power unit for 150/200 kg/h extruders ..................... 8 - 44
8.1.2.9.6 Changing the oil in the hydraulic power unit for 150/200 kg/h extruders ............................. 8 - 44
8.1.2.9.7 Replacing the flexible coupling for the 150/200 kg/h extruder motor-pump unit .................. 8 - 44
8.1.2.9.8 Replacing the filter in the hydraulic power unit for the 150/200 kg/h extruder ..................... 8 - 44

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8.1.2.9.9 Cleaning control valve Pb ..................................................................................................... 8 - 45
8.1.2.9.10 Cleaning control valve Ph ..................................................................................................... 8 - 45
8.1.2.9.11 Cleaning solenoid control valves Pb and Ph ........................................................................ 8 - 45
8.1.2.9.12 Checking for condensate on the bottom of the tank ............................................................. 8 - 45
8.1.2.9.13 Checking the accumulator precharge ................................................................................... 8 - 45
8.1.2.10 Air supply system .................................................................................................................. 8 - 46
8.1.2.10.1 Cleaning the filter .................................................................................................................. 8 - 46
8.1.2.10.2 Cleaning and replacing the silencers .................................................................................... 8 - 46
8.1.2.11 Cooling system ...................................................................................................................... 8 - 47
8.1.2.11.1 Checking the coolant level .................................................................................................... 8 - 47
8.1.2.11.2 Adding coolant....................................................................................................................... 8 - 47
8.1.2.11.3 Cleaning the filters ................................................................................................................ 8 - 47
8.1.2.11.4 Changing the coolant ............................................................................................................ 8 - 47
8.1.2.12 Safety devices ....................................................................................................................... 8 - 48
8.1.2.12.1 Checking the efficiency of the safety devices ....................................................................... 8 - 48
8.1.2.13 Air injection device ................................................................................................................ 8 - 49
8.1.2.13.1 Checking the valves .............................................................................................................. 8 - 49
8.1.2.13.2 Replacing the valves ............................................................................................................. 8 - 49
8.1.2.14 Product exit conveyor belt ..................................................................................................... 8 - 50
8.1.2.14.1 Checking the condition of the belt ......................................................................................... 8 - 50
8.1.2.14.2 Checking belt tension ............................................................................................................ 8 - 50
8.1.2.14.3 Replacing the belt ................................................................................................................. 8 - 50
8.1.2.14.4 Cleaning and centering the photocell.................................................................................... 8 - 50
8.1.2.14.5 Cleaning the cap slide surface .............................................................................................. 8 - 50
8.1.3 LUBRICATION ...................................................................................................................... 8 - 51
8.1.3.1 Lubricant specifications ......................................................................................................... 8 - 51
8.1.4 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS.................................................... 8 - 52
8.2 TROUBLESHOOTING .......................................................................................................... 8 - 53
9DECOMMISSIONING................................................................................................................................ 9 - 1

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