Sacmi CCM001 User manual

TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇÃO TÉCNICA
DOCUMENTAZIONE
TECNICA
USER’S MANUAL
002AZ005A
ROTARY COMPRESSION MOLDING PRESS
CCM001
ENGLISH

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002AZ005A
USER’S MANUAL
ROTARY COMPRESSION MOLDING PRESS
CCM001
MANUFACTURER
SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
PUBLISHED ON
February 5, 2003 - December 11, 2003
VERSIONS
CCM001C

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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 LEGEND OF 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 - 13
2.1.1.5 Exit channel ......................................................................................................................... 2 - 16
2.1.1.6 Pneumatic system ............................................................................................................... 2 - 16
2.1.1.7 Hydraulic system ................................................................................................................. 2 - 16
2.1.1.8 Cooling system .................................................................................................................... 2 - 16
2.1.1.9 Electric system: control board ............................................................................................. 2 - 16
2.1.1.10 Tooling................................................................................................................................. 2 - 16
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE .......................................... 2 - 18
2.2 OVERALL DIMENSIONS .................................................................................................... 2 - 19
2.3 TECHNICAL DATA ............................................................................................................. 2 - 26
2.3.1 SPECIFICATIONS .............................................................................................................. 2 - 26
2.3.2 OPERATIONAL CHARACTERISTICS ............................................................................... 2 - 27
2.3.3 AIRBORNE NOISE EMISSION LEVELS ............................................................................ 2 - 28
2.3.3.1 Sound pressure level (ISO/DIS 11202) .............................................................................. 2 - 28
2.3.3.2 Livello di potenza sonora (ISO 3746) ................................................................................. 2 - 28
2.4 DIAGRAMS ......................................................................................................................... 2 - 30
2.4.1 PNEUMATIC SYSTEM DIAGRAM ..................................................................................... 2 - 30
2.4.2 HYDRAULIC SYSTEM DIAGRAM ...................................................................................... 2 - 33
2.4.3 COOLING SYSTEM DIAGRAM .......................................................................................... 2 - 36

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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 ELECTRIC HOOK UP ...........................................................................................................4-9
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

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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 / BROKEN ROD 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
6.5.7 ACTUATOR UPSTROKE CONTROL ................................................................................. 6 - 13
6.6 PRODUCT SAMPLING ....................................................................................................... 6 - 14
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 PRE-LOAD OF THE DRUM’S CONNECTING ROD .............................. 7 - 3
7.2.1.1 Adjusting the drum’s connecting rod precharge ...................................................................7 - 3
7.2.1.2 Checking the drum’s connecting rod precharge ................................................................... 7 - 4
7.2.2 ADJUSTING THE CUTTER .................................................................................................. 7 - 4
7.2.3 ADJUSTING PELLET INSERTION TIMING ..........................................................................7 - 6
7.3 FORMING UNIT .................................................................................................................... 7 - 9
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 CONVEYOR BELT ....................................................................... 7 - 16
7.9 REPLACING THE INDUCTIVE SENSORS ........................................................................ 7 - 17
7.10 RESETTING THE ENCODERS .......................................................................................... 7 - 17

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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
8.1.2.3.12 Lubricating the extruder motor’s bearings .......................................................................... 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
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 - 30
8.1.2.5.1 Sharpening the blades ........................................................................................................ 8 - 30
8.1.2.5.2 Replacing the blades........................................................................................................... 8 - 30
8.1.2.5.3 Cleaning the cutters ............................................................................................................ 8 - 30
8.1.2.5.4 Replacing the cutters .......................................................................................................... 8 - 30
8.1.2.5.5 Cleaning the nozzles ........................................................................................................... 8 - 30
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 pre-load of the drum’s connecting rod .......................................................... 8 - 32
8.1.2.5.10 Adjusting the pre-load of the drum’s connecting rod .......................................................... 8 - 32
8.1.2.5.11 Replacing pulley A .............................................................................................................. 8 - 32
8.1.2.5.12 Removing cogged wheel B ................................................................................................. 8 - 34
8.1.2.5.13 Replacing cogged wheel C ................................................................................................. 8 - 34
8.1.2.5.14 Removing pulley D .............................................................................................................. 8 - 34

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8.1.2.5.15 Replacing toothed belt E ..................................................................................................... 8 - 36
8.1.2.5.16 Tensioning belt E ................................................................................................................ 8 - 36
8.1.2.5.17 Lubricating the gears........................................................................................................... 8 - 36
8.1.2.6 Forming unit ........................................................................................................................ 8 - 38
8.1.2.6.1 Cleaning .............................................................................................................................. 8 - 39
8.1.2.6.2 Overhauling the actuator valve ........................................................................................... 8 - 39
8.1.2.6.3 Greasing the roller............................................................................................................... 8 - 39
8.1.2.6.4 Replacing the hydraulic actuator gasket ............................................................................. 8 - 39
8.1.2.6.5 Replacing the upper flange gaskets.................................................................................... 8 - 40
8.1.2.6.6 Replacing the lower flange gaskets .................................................................................... 8 - 40
8.1.2.6.7 Greasing the roller and stripper rod pin .............................................................................. 8 - 41
8.1.2.6.8 Lubricating the stripper rod guide bushes........................................................................... 8 - 41
8.1.2.6.9 Greasing the central tool wheel (optional) .......................................................................... 8 - 41
8.1.2.7 Cams ................................................................................................................................... 8 - 42
8.1.2.7.1 Greasing and checking ....................................................................................................... 8 - 43
8.1.2.7.2 Replacing the stripper cams (central movement) (optional) ............................................... 8 - 43
8.1.2.7.3 Replacing the stripper cams (side movement) ................................................................... 8 - 43
8.1.2.7.4 Replacing the actuator control cams .................................................................................. 8 - 43
8.1.2.7.5 Replacing the cams for injecting air in the punches ........................................................... 8 - 43
8.1.2.8 Rotary distributor ................................................................................................................. 8 - 44
8.1.2.8.1 Replacing the gaskets ......................................................................................................... 8 - 44
8.1.2.9 Hydraulic system ................................................................................................................. 8 - 44
8.1.2.9.1 Checking the oil level in the hydraulic power unit ............................................................... 8 - 46
8.1.2.9.2 Changing the oil in the hydraulic power unit ....................................................................... 8 - 46
8.1.2.9.3 Replacing the flexible coupling in the hydraulic power unit ................................................ 8 - 46
8.1.2.9.4 Replacing the filter in the hydraulic power unit ................................................................... 8 - 46
8.1.2.9.5 Checking the oil level in the hydraulic power unit for 150/200 kg/h extruders ................... 8 - 46
8.1.2.9.6 Changing the oil in the hydraulic power unit for 150/200 kg/h extruders ........................... 8 - 46
8.1.2.9.7 Replacing the flexible coupling for the 150/200 kg/h extruder motor-pump unit ................ 8 - 46
8.1.2.9.8 Replacing the filter in the hydraulic power unit for the 150/200 kg/h extruder ................... 8 - 46
8.1.2.9.9 Cleaning control valve Pb ................................................................................................... 8 - 47
8.1.2.9.10 Cleaning control valve Ph ................................................................................................... 8 - 47
8.1.2.9.11 Cleaning solenoid control valves Pb and Ph ...................................................................... 8 - 47
8.1.2.9.12 Checking for condensate on the bottom of the tank ........................................................... 8 - 47
8.1.2.9.13 Checking the accumulator’s precharge .............................................................................. 8 - 47
8.1.2.10 Air supply system ................................................................................................................ 8 - 48
8.1.2.10.1 Cleaning the filter ................................................................................................................ 8 - 48
8.1.2.10.2 Cleaning and replacing the silencers ..................................................................................8- 48
8.1.2.11 Cooling system .................................................................................................................... 8 - 49
8.1.2.11.1 Checking the coolant level .................................................................................................. 8 - 49
8.1.2.11.2 Adding coolant .................................................................................................................... 8 - 49
8.1.2.11.3 Cleaning the filters .............................................................................................................. 8 - 49
8.1.2.11.4 Changing the coolant .......................................................................................................... 8 - 49
8.1.2.12 Safety devices ..................................................................................................................... 8 - 50
8.1.2.12.1 Checking the efficiency of the safety devices ..................................................................... 8 - 50
8.1.2.13 Air injection device .............................................................................................................. 8 - 51
8.1.2.13.1 Checking the valves ............................................................................................................ 8 - 51
8.1.2.13.2 Replacing the valves ........................................................................................................... 8 - 51
8.1.2.14 Product exit conveyor belt................................................................................................... 8 - 52
8.1.2.14.1 Replacing the conveyor belt................................................................................................ 8 - 52
8.1.2.14.2 Cleaning the counter photocell ........................................................................................... 8 - 52
8.1.2.14.3 Cleaning the slots in the exit conveyor belt slide surface ................................................... 8 - 52
8.1.3 LUBRICATION .................................................................................................................... 8 - 54
8.1.3.1 Lubricant specifications ....................................................................................................... 8 - 54
8.1.4 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS.................................................. 8 - 55
8.2 TROUBLESHOOTING ........................................................................................................ 8 - 56

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9DECOMMISSIONING................................................................................................................................ 9 - 1