uso manutenzione R2

SIDEL S.P.A.

USE AND MAINTENANCE

TRANSLATION OF THE ORIGINAL INSTRUCTIONS

Version2

Edition03/2014

ModelTSI - NEXT PK ASEPTIC

Serial number13982

Pitch diameter360 mm

Nr of heads10

Manufacturing year2014

WARNING

BEFORE START UP THE PARTLY COMPLETED MACHINERY, READ CAREFULLY THE TECHNICAL INSTRUCTIONS IN THIS PUBLICATION AND SCRUPULOUSLY FOLLOW THE INDICATIONS IN THIS MANUAL.KEEP THE MANUAL IN A PLACE EASY TO GET AND WEEL KNOWN BY THE USER (OPERATORS AND PERSONNEL CHARGED WITH THE MAINTENANCE).

ITHIS MANUAL IS PROPERTY OF AROL S.p.A.. ANY REPRODUCTION OR MODIFICATION, EVEN IN PART, IS PROHIBITED.

WARNING

BEFORE START UP THE PARTLY COMPLETED MACHINERY, READ CAREFULLY THE TECHNICAL INSTRUCTIONS IN THIS PUBLICATION AND SCRUPULOUSLY FOLLOW THE INDICATIONS IN THIS MANUAL.KEEP THE MANUAL IN A PLACE EASY TO GET AND WEEL KNOWN BY THE USER (OPERATORS AND PERSONNEL CHARGED WITH THE MAINTENANCE).

GENERAL INFORMATION ..................................................................................3A1 CERTIFICATIONS ................................................................................................4A2 IDENTIFICATION .................................................................................................5A3 INTRODUCTION TO THE MANUAL ....................................................................6A3.1 PROFESSIONAL ROLES OF USERS .................................................................7A3.1.1 OPERATOR ..........................................................................................................7A3.1.2 MAINTENANCE MAN ..........................................................................................7A3.2 INFORMATION - JOB INSTRUCTIONS - TRAINING ..........................................8A3.2.1 INFORMATION - JOB INSTRUCTIONS...............................................................8A3.2.2 TRAINING ............................................................................................................8A3.3 PRECAUTIONS FOR THE SAFETY ....................................................................8A4 CONSULTATION MODE OF THE MANUAL.........................................................9A5 KEEPING THIS USE INSTRUCTION MANUAL ..................................................9A6 REPRODUCTION RESTRICTION, RESPONSIBILITY AND COPYRIGHT .........9A7 CUSTOMER'S OBLIGATIONS ...........................................................................10A8 WARRANTY AND FINAL TEST ..........................................................................10A9 REVISIONS ........................................................................................................11A10 MEASURES BY THE CUSTOMER ....................................................................11A11 HOW TO ASK FOR INTERVENTIONS ..............................................................12A12 HOW TO ORDER SPARE PARTS .....................................................................13A13 MACHINE DESCRIPTION - DATA AND TECHNICAL SPECIFICATIONS .........14A13.1 GENERAL DESCRIPTION .................................................................................14A13.1.1 CLOSURE PROCESS ........................................................................................14A13.2 MACHINE TECHNICAL DATA ............................................................................16A14 USE RESTRICTIONS.........................................................................................19A14.1 EXPLOSIVE ATMOSPHERE ..............................................................................19A14.2 USE ENVIRONMENTAL CONDITIONS .............................................................19A14.3 LIGHTING ...........................................................................................................19A14.4 RESIDUES AND ENVIRONMENTAL CONTAMINATION ...................................20A14.5 SCRAPPING AND DISPOSING .........................................................................20A15 SECURITY AND ACCIDENT PREVENTION ......................................................21A15.1 GENERAL INFORMATION .................................................................................21A15.2 INTENDED, NOT INTENDED AND MISTAKEN USES ......................................22A15.3 RISKS - PROTECTIONS - CAUTIONS AND PRECAUTIONS...........................23A15.3.1 GENERAL SAFETY ............................................................................................23A15.3.1.1 PASSIVE SAFETIES ..........................................................................................23A15.3.1.2 POSITION OF THE SAFETIES ..........................................................................23

IITHIS MANUAL IS PROPERTY OF AROL S.p.A.. ANY REPRODUCTION OR MODIFICATION, EVEN IN PART, IS PROHIBITED.

FIRST START UP, OPERATING AND USE .......................................................25B1 SETTING UP, CHECKS AND TEST FOR THE FIRST START UP .....................26B1.1 CHECKS BEFORE THE START UP ..................................................................26B2 ZONES-OPERATORS AND RULES ..................................................................27B2.1 WORKING AREA - CONTROL AREA .................................................................27B2.2 RESIDUAL RISKS ..............................................................................................27B2.3 NUMBER OF OPERATORS ...............................................................................27B2.4 SAFETY PROCEDURES FOR THE OPERATION .............................................28B3 OPERATING MODES .........................................................................................29B4 PRELIMINARY CHECKS ...................................................................................29

IIITHIS MANUAL IS PROPERTY OF AROL S.p.A.. ANY REPRODUCTION OR MODIFICATION, EVEN IN PART, IS PROHIBITED.

CLEANING AND MAINTENANCE .....................................................................31C1 MACHINE CLEANING ........................................................................................32C1.1 MAINTENANCE PREPARATION .......................................................................33C1.2 GENERAL SAFETY WARNINGS .......................................................................33C1.3 WARNINGS FOR A CORRECT MAINTENANCE...............................................33C2 MAINTENANCE GENERAL INFORMATION......................................................34C2.1 MAINTENANCE SCHEDULE .............................................................................34C2.2 WARNING SYMBOLOGY...................................................................................35C3 MAINTENANCE INTERVALS .............................................................................36C4 MAINTENANCE AND LUBRICATION PLANNING .............................................36C5 PK515 HEAD WEARING PARTS .......................................................................37C6 PKSG-EE CLOSURE CHUCK WEARING PARTS .............................................37C7 SCHEDULED MAINTENANCE ..........................................................................38C7.1 EVERY 40 WORKING HOURS ..........................................................................38C7.2 EVERY 120 WORKING HOURS ........................................................................39C7.3 EVERY 500 WORKING HOURS ........................................................................40C7.4 EVERY 1000 WORKING HOURS ......................................................................41C7.5 EVERY 3000 WORKING HOURS ......................................................................43C7.6 EVERY 6000 WORKING HOURS ......................................................................44C7.7 EVERY 12000 WORKING HOURS ....................................................................45C8 LUBRICATION ....................................................................................................46C8.1 GENERAL INFORMATION .................................................................................46C8.2 LUBRICANT TYPE-APPROVAL ACCORDING TO NSF ....................................46C8.3 TYPES OF LUBRICANTS ..................................................................................46C8.3.1 OIL ......................................................................................................................46C8.3.2 GREASE .............................................................................................................47C8.3.3 FEATURES OF THE USED LUBRICANTS ........................................................48C8.3.4 LUBRICANT RE-ORDERING .............................................................................49C8.4 LEGEND FOR LUBRICATION SCHEMES .........................................................49C8.5 POINTS TO BE LUBRICATED ...........................................................................50C8.5.1 INSTRUCTIONS FOR READING THE "LUBRICATION POINT

LIST" TABLE .......................................................................................................50C8.6 LEVEL CHECK AND OIL FILLING UP ...............................................................53C8.7 OIL REPLACEMENT INTO THE TANK ..............................................................55C8.8 SEW REDUCERS LUBRICATION .....................................................................57C8.8.1 GENERAL INFORMATION .................................................................................57C8.8.2 REDUCER MAINTENANCE ...............................................................................57

IVTHIS MANUAL IS PROPERTY OF AROL S.p.A.. ANY REPRODUCTION OR MODIFICATION, EVEN IN PART, IS PROHIBITED.

C8.8.2.1 INSPECTION INTERVALS AND MAINTENANCE .............................................57C8.8.2.2 CHECKING THE OIL LEVEL ..............................................................................58C8.8.2.3 CHECKING THE OIL ..........................................................................................58C8.8.2.4 OIL REPLACEMENT ..........................................................................................59C8.8.2.5 SEALING RING REMPLACEMENT ...................................................................60C8.8.3 LUBRICANT TABLE ...........................................................................................60C8.8.3.1 LEGEND FOR LUBRICANT TABLE ...................................................................60C8.8.3.2 BEARINGS GREASES .......................................................................................61C8.8.4 LUBRICANTS CHARACTERISTICS TABLE ......................................................62C8.8.5 LUBRICANT FILL QUANTITIES .........................................................................63C9 EXTRAORDINARY MAINTENANCE - TIMING ..................................................64C9.1 HEADS DRIVING SPINDLES.............................................................................64C9.1.1 CHECKING THE WEAR OF THE SLIDING ROLLERS .....................................64C9.1.2 REPLACEMENT THE SLIDING ROLLERS OF THE SPINDLE .........................64C9.1.3 REMOVING OF THE BELLOWS COUPLING ....................................................68C9.2 REPLACEMENT OF TOOTHED CENTERING DEVICE ....................................70C9.3 CAPS DISTRIBUTING TIMING ON TRANSFER DISK ......................................71

SIZE CHANGE ...................................................................................................73D1 CONTAINERS SIZE CHANGE ...........................................................................74D1.1 BOTTLE-NECK GUIDE SECTOR ......................................................................74D1.2 EXTERNAL BOTTLE-BODY GUIDES ................................................................76D1.2.1 UPPER EXTERNAL BOTTLE-BODY GUIDE .....................................................76D1.2.2 LOWER EXTERNAL BOTTLE-BODY GUIDE ....................................................78D1.3 BOTTLE-BODY GUIDE CENTRAL STAR-WHEELS ..........................................80D2 CAP SIZE CHANGE ...........................................................................................82D2.4 CAPS CHANGE..................................................................................................83D2.4.1 FROM FLAT CAP TO SPORT CAP ....................................................................83D2.4.2 FROM SPORT CAP TO FLAT CAP ....................................................................84

INSTALLATION AND REMOVAL OF THE BOTTLES NECK GUIDE EQUIPMENT ......................................................................................................85E1 BOTTLE NECK CENTERING DEVICE ..............................................................86E1.1 REMOVAL...........................................................................................................86E1.2 INSTALLATION ...................................................................................................87

VTHIS MANUAL IS PROPERTY OF AROL S.p.A.. ANY REPRODUCTION OR MODIFICATION, EVEN IN PART, IS PROHIBITED.

COMPONENTS ON THE MACHINE .................................................................89F1 CAPS CHUTE.....................................................................................................90F1.1 CAPS CHUTE DISCHARGE ..............................................................................90F2 CAP TRANSFER DISK .......................................................................................91F2.2 CAPS TRANSFER GROUP ...............................................................................91F2.2.1 CAPS GUIDE SECTORS ...................................................................................91F2.2.1.1 REMOVAL ..........................................................................................................91F2.2.1.2 INSTALLATION ...................................................................................................93F2.2.2 CAPS TRANSFER STAR-WHEEL .....................................................................95F2.2.2.1 REMOVAL ..........................................................................................................95F2.2.2.2 INSTALLATION ...................................................................................................96F2.2.3 EXIT CAPS GUIDE ............................................................................................97F2.2.3.1 REMOVAL ..........................................................................................................97F2.2.3.2 INSTALLATION ...................................................................................................97F2.1 CAP TRANSFER DISK TIMING .........................................................................98F2.1.1 ALIGNMENT OF THE TRANSFER STAR-WHEEL

WITH THE CLOSURE HEADS...........................................................................98F3 "PK515" SERIES CLOSURE HEAD ...................................................................99F3.1 MAIN COMPONENTS ........................................................................................99F3.2 TOOLS FOR THE REMOVAL AND MAINTENANCE .......................................100F3.3 REMOVAL AND INSTALLATION ......................................................................101F3.3.1 REMOVAL ........................................................................................................101F3.3.2 INSTALLATION .................................................................................................102F3.4 ADJUSTMENT ..................................................................................................103F3.4.1 TIGHTENING TORQUE ADJUSTMENT ..........................................................103F3.4.2 HEAD OPENING AND VERTICAL LOAD CHANGE ........................................105F3.5 CLOSURE HEAD CLEANING ..........................................................................108F3.5.1 AUTOCLAVE CAPPING HEADS STERILIZATION ..........................................109F3.5.2 CAPPING HEADS STERILIZATION PROCEDURE.........................................109F3.6 MAINTENANCE AND OVERHAUL ..................................................................110F3.6.1 SPRINGS REMOVAL .......................................................................................110F3.6.1.1 COMPENSATING SPRING REMOVAL ............................................................110F3.6.1.2 RING-NUT PRESSURE SPRING REMOVAL .................................................. 111F3.6.2 MAGNETIC RING OVERHAUL ........................................................................112F3.6.2.1 MAGNETIC RING CHECKING .........................................................................112F3.6.2.2 PREPARATION FOR MAGNETIC RING OVERHAUL .....................................112F3.6.2.3 REMOVING OF LOWER MAGNETIC RING ....................................................115

VITHIS MANUAL IS PROPERTY OF AROL S.p.A.. ANY REPRODUCTION OR MODIFICATION, EVEN IN PART, IS PROHIBITED.

F3.6.2.4 REMOVING OF UPPER MAGNETIC RING .....................................................116F3.6.3 REMOVING OF CENTRAL BEARING .............................................................118F3.6.4 GASKET OVERHAUL ......................................................................................122F3.6.4.1 SEALING RING OVERHAUL ...........................................................................122F3.6.4.2 REMOVING OF THE O-RINGS........................................................................123F3.6.5 REMOVING OF BUSH FOR DOWEL ..............................................................126F3.6.6 REMOVING OF BELLOWS COUPLING ..........................................................127F3.6.7 PARTS LUBRICATION .....................................................................................128F3.6.8 CLOSURE HEAD INSTALLATION ...................................................................132F3.6.8.1 MOUNTING OF THE ADJUSTMENT RING-NUTS ..........................................132F4 "PKSG-EE" CLOSURE CHUCK .......................................................................134F4.1 MAIN COMPONENTS ......................................................................................134F4.2 TOOLS FOR THE REMOVAL AND MAINTENANCE .......................................134F4.3 REMOVAL AND INSTALLATION ......................................................................135F4.3.1 REMOVAL ........................................................................................................135F4.3.2 INSTALLATION .................................................................................................136F4.4 CLEANING OF THE CLOSURE CHUCK .........................................................137F4.5 MAINTENANCE AND OVERHAUL ..................................................................138F4.5.1 OVERHAUL OF THE CLOSURE CHUCK ........................................................138F4.5.1.1 REMOVING OF THE O-RINGS AND SPHERES .............................................138F4.5.1.2 REMOVING OF CHUCK RELEASE SPRING ..................................................140F4.5.1.3 PARTS LUBRICATION .....................................................................................141

PRODUCTION CHECKS .................................................................................143G1 CLOSURE APPLICATION DATA TABLE ..........................................................144

FAULTS AND REMEDIES ...............................................................................147H1 INTRODUCTION ..............................................................................................148

3THIS MANUAL IS PROPERTY OF AROL S.p.A.. ANY REPRODUCTION OR MODIFICATION, EVEN IN PART, IS PROHIBITED.

A GENERAL INFORMATION


A1 CERTIFICATIONSThe partly completed machinery, term defined by the European Directive 2006/42/EC art.2 para g), is provided with DECLARATION OF INCORPORATION.

The original copy of the DECLARATION OF INCORPORATION is supplied as annex to the machine documentation of the partly completed machinery and must be filed until its disposal.

Here is a fac-simile copy of the DECLARATION OF INCORPORATION.


A2 IDENTIFICATIONThe partly completed machinery has an identification plate, placed in the upper part of the turret (See Figures).On the plate are reported:

• The Machine Model (MACHINE)

• Type of machine (TYPE)

• Pitch diameter (P.D. in mm)

• Number of heads (HEADS)

• Serial number (SERIAL N.)• Manufacturing year (YEAR)

Fig. 1

Fig. 2

To make easy the reading of this manual, the serial number refering to this manual, in the remaining part of the publication will be commonly called "machine" rather than "partly completed machinery", as provided in the European Directive 2006/42/CE.


A3 INTRODUCTION TO THE MANUALThis manual is addressed to the operators and specialized staff to enable a correct machine use.

The user finds here instructions and indications for:

• a correct machine installation.

• A functional description of the machine and of each component, including also the accident-preventing safety norms.

• Adjustments on the machine while setting and starting it up.

• A correct scheduled and routine maintenance.

• Pay attention to the most elementary safety and accident-preventing norms.

The user can thus know the machine features and operation.

The used terms and symbols are specified here below to understand the manual fully:GRAPHIC SYMBOL DESCRIPTION

Pay attention to the accident-preventing norms

Possibility of damaging the machine and/or its components

Notes, usage tips, or additional information

Part of the Manual dedicated to personnel delegate for the normal conduction of the machine. OPERATORS

Part of the Manual dedicated to personnel delegate for the mechanical maintenance, ordinary and extraordinary, of the machine. (MECHANICAL MAINTENANCE MAN)Part of the manual dedicated to personnel delegate for electrical maintenance, ordinary and extraordinary, of the machine. (ELECTRICAL MAINTENANCE MAN)


A3.1 PROFESSIONAL ROLES OF USERS

The User shall check that the operators have the following requierements:

• had red and understood the indications that are in the manual.

• had received job instruction and training appropriate to their tasks;

• had received specific training for the correct use of the machine. (See also sub-chapter A7 CUSTOMER'S OBLIGATIONS page 10).

A3.1.1 OPERATOR

The Operator must have:

• Knowledge of the technology and specific experience of conduction.

• base general knowledge and sufficient technical knowledge to read and understand the manual content and the annexes, included the correct interpretation of the drawings.

• particular familiarity in the use of the ceck system (operator interface),with capacity of ceck the correlation between the set data and the effect of these on the production ;

• Sufficient technical knowledge to carry out intervention specified in the manual, in safe operation condition.

• Knowledge of the accident-preventing norms.

▫ General Health and safety, prevention of the accidents on the work place.

▫ specification for the type of product processed by the machine, according the laws in force of the country in which the machine is installed.

Besides the conduction of the machine from the productive point of view the operator must:

• Know the operation of all the safety devices (for the operator and for the machine) to ceck the efficiency and notice about any faults to the personnel in charge.

• Prohibite access to unautorized person in work areas.

When the operator finds a failure that can compromise the security, the machine must beimmediately stopped and can be re-started only after the repair.

it is forbidden to esecute any intervention on the electic and/or pneumatic equipement.

A3.1.2 MAINTENANCE MAN

The Maintenance Man (mechanical/electrical), besides the above characteristics, must also have a good technical preparation and a suitable working experience in the relevant field. Further, he must have specific and special (mechanical and electrical) technical knowledge needed for the operations described in this manual.


A3.2 INFORMATION - JOB INSTRUCTIONS - TRAINING

A3.2.1 INFORMATION - JOB INSTRUCTIONS

The customer shall inform and train the personnel charged to use the machine and make sure that:

• On the work place there are suitable information concerning dangers, risks and prevention and protection solutions including the use of P.P.M., if provided.

• the workers the task of using of work equipment receive a suitable training accordingly.

• The workers the task of using of equipment requiring special knowledge and responsibility receive a suitable and specific training, so that they can use such equipment safely and suitably, also as far as risks caused to other people are concerned.

A3.2.2 TRAINING

Training is the activity aimed at understanding the correct machine use, thus complying with the obligations described in the European Directive in force.

A3.3 PRECAUTIONS FOR THE SAFETY

When container parts must be removed from the machine it is necessary: to switch off all the energy sources, to wear protective gloves and to remove any container or cap remaining using a small broom and a dustpan.

To install, maintenance or change size, sometimes it is necessary to change some parts of the sorter and/or the delivery chute. Due to the weight of these components and to their positioning in the machine upper part, this operation must be carried out with the machine in "maintenance status", using suitable lifting systems. (For the"maintenance status" see sub-chapter C1.1 MAINTENANCE PREPARATION page 33).


A4 CONSULTATION MODE OF THE MANUALThe consultation of the manual is made easy by the insertion in the front page of a general index that allows to find in an immediate way the subject of interest. Chapters are organized in a hierarchy structure that makes easy the finding of the desired information.

Before any operation with or on the machine read the procedures and warnings herein carefully.

IMAGES OF ANY GENERAL KIND ARE NOT USED IF THE DETECTION OF SPECIFIC STRUCTURE OF MACHINE IS ESSENTIAL IN THE CONTEXT TO THE SUBJECT MATTER. The reported instructions and use modes for all described components anyway remain valid.

A5 KEEPING THIS USE INSTRUCTION MANUALTo keep the "Manual" correctly, it is recommended to:

• keep the manual in the room where the machine operates and in areas protected against humidity, so as not to jeopardize its life in time.

• Use the manual not damaging it.

• Not to remove, add, modify or edit any part of the document; possible updates shall be made exclusively by AROL S.p.A..

• Give the manual to the other owner of the machine.

A6 REPRODUCTION RESTRICTION, RESPONSIBILITY AND COPYRIGHT

Copyright by AROL S.p.A..

The reproduction of this manual is allowed only for training and information purposes of the staff charged with the machine use.

No reproduction allowed for other purposes, without explicit authorization by AROL S.p.A..

Since AROL S.p.A. tends to constantly improve its products, the information contained in this manual is subject to change without notice. The preparation of this manual was extremely careful. The AROL S.p.A. does not assume responsibility for use of the machine which is different from that described in this manual.


A7 CUSTOMER'S OBLIGATIONSthe customer shall guarantee a appropriate training and information of all the professional roles of the machine on the following topics:

• Instruction and specific procedures for use and maintenance of the machine.

• General accident-preventing norms, or norms specified by international directives and/or by laws of the machine destination country.

After the training, the customer must ensure the operators and the person charged with the maintenance have understood the above points, and have signed the "PERFORMED TRAINING SHEET" enclosed herewith.

Only the operators and the person charged with the maintenance with a suitable training can use the machine.

The customer shall deliver the P.P.M. (Personal Protection Means) required for all operations on the machine needing them (maintenance, cleaning, etc.).

A8 WARRANTY AND FINAL TESTThe machine is delivered to the customer ready to be installed, after having passed all tests arranged by the manufacturer at the factory, according to the laws in force. During the warranty, the manufacturer engages to eliminate possible faults or defects provided that the machine has been used correctly, in compliance with the instructions of the use and maintenance manuals.

For everything not specifically indicated in this manual, refer to the “GENERAL SALES CONDITIONS point 8 WARRANTY - LIABILITY RESTRICTIONS”.

AROL S.p.A. shall not be liable for inconveniences, breakage, accidents, etc., due to the non-knowledge (or anyway to the failed application) of the specifications herein. The same applies to changes, modifications and/or installation of non-genuine accessories or spare parts without previous authorization.In particular, AROL S.p.A. declines all liabilities for damage due to:• Natural disasters.

• Wrong maneuvers.

• Failed maintenance.

• Damage of the electric or electronic components due to condensate or contact with outer conductors.

AROL S.p.A. further declines all liabilities resulting from an incorrect or improper machine use.

The warranty shall be cancelled if machine components are modified or replaced, or if the software of programmable components is varied, without previous authorization by the manufacturer.


A9 REVISIONSThe manufacturer engages to issue future revisions of the manual following to modifications on the machine.

A10 MEASURES BY THE CUSTOMERExcluding special contract conditions, the customer must arrange the following:

• Connect with the power supply mains, including the protection lead commonly called "GROUND WIRE".

• Compressed air mains connection.

• The protection of the power line from overcurrents and indirect contacts (it is recommended to install a differential switch).

• Generic tools for the machine maintenance and consumables.

• Lifting means suitable for the machine handling.


A11 HOW TO ASK FOR INTERVENTIONSAROL S.p.A. puts its own Technical Service at the disposal of its customers to solve any problem regarding the machine use and maintenance.

The interventions must be required after carefully evaluating the faults and their reasons, and stating:

• The details on the occurred faults.

• The performed checks.

• The performed adjustments and resulting effects.

• Any further information deemed useful.

AROL S.p.A.Viale Italia, n° 19314053 CANELLI (Asti) - ITALYph. +39 0141 820 500 - Fax +39 0141 820 555http://www.arol.comAROL HEXAGONE17 Boulevard KENNEDY34500 BEZIERS - FRANCEph. +33 4 67 98 93 53AROL ESPAÑAC/LLULL, 321-329-Edificio CINC08019 BARCELONA - ESPAÑAph. +34 933 091 646 - Fax +34 935 579 974AROL GERMANYKarl-Brauckmann-Str. 1459469 AHLZWICKEDE - DEUTSCHLANDph. +49 0 2301 949 39 76 - Fax +49 0 151 270 689 56AROL NORTH AMERICA(USA, Canada, Mexico)450 Satellite Blvd. NESUWANEE, GEORGIA 30024 - U.S.A.ph. +1 678 318 1290 - Fax +1 678 318 1296AROL BRASIL(Brasil, South America)Pc. das Dracenas, 26 -1° an./sl.7Centro Comercial de AlphavilleBARUERI / SP - CEP: 06453 064 - BRASILph. +55 11 4156 2176AROL CHINAYuXiu Road No. 136Factory N. 15Songjiang District - SHANGHAI - CHINAph. +86 021 57771952 - Fax +86 021 57771952AROL INDIAPune IT ParkC-101-102, Unit No. 534 Aundh Road Pune - INDIA 411 020ph. 020 - 30226105


A12 HOW TO ORDER SPARE PARTSAll orders for spare parts must be sent to AROL S.p.A..

The installation of not original spare parts will invalidate the warranty.

To order spare parts, fill in the suitable form in the “SPARE PART CATALOGUE” for the machine.

Spare part replacement must be carried out by specialized technicians following the procedures and using ALL SAFETY PRECAUTIONS described in the chapters. "CLEANING AND MAINTENANCE OF THE MACHINE".


A13 MACHINE DESCRIPTION - DATA AND TECHNICAL SPECIFICATIONS

A13.1 GENERAL DESCRIPTION

The NEXT PK ASEPTIC has been designed and built for the application of pre-threaded caps (namely screw caps) on bottles/containers.

See chapter A13.2 MACHINE TECHNICAL DATA page 16.

A13.1.1 CLOSURE PROCESS

The closure process of the caps on the containers, occurs in the following way:• A transport system, conducts the caps from caps

sorter to transfer disk.

Fig. 3

• A transfer disk, called "pick & place", carries the caps under the closure head.

Fig. 4


• The capping head follows the profile of a cam and picks the cap from the conveying device by a chuck with balls.

• After the closure, the exiting container is released, then there is a reset for the following closure.

Fig. 5


A13.2 MACHINE TECHNICAL DATATECHNICAL SPECIFICATIONS

Model NEXT PK ASEPTIC

Serial number 13982

Pitch diameter 360 mm

Nr of heads 10

Direction of rotation counter-clockwise

Manufacturing year 2014

NOMINAL PRODUCTIONPieces/hour 18000 bph

MACHINE WEIGHTWeight 1100 kg.

ELECTRICAL DATAPOWER SUPPLY VOLTAGE:

main400 V ~

50 Hz

auxiliary 24 V =

Installed power:

heads rotation motor 0,75 kW

Total installed power: 0,75 kW

PNEUMATIC DATATotal installed power 200 ca Nl/min

Sterile air min. pressure 6 bar

Sterile air max. pressure 8 bar


CLOSURE TYPE



A14 USE RESTRICTIONS

A14.1 EXPLOSIVE ATMOSPHERE

The machine is not suitable for being used in premises where atmospheres with explosion risk are expected or expectable. The customer must not use the machine in explosive or partially explosive atmosphere.

A14.2 USE ENVIRONMENTAL CONDITIONS

The machine is built for working in industrial environment with a suitable aeration and lighting.

The temperature of work environment must be included between 5 °C and 40 °C.

A14.3 LIGHTING

The machine uses the illumination provided at the installation site. It should be noted, however, that the machine should never be operated in dark areas.

For processing the machine does not need special lighting, just the normal lighting provided in the workplace. In the case of maintenance work in poorly lit areas of the machine, carry portable lamp.


A14.4 RESIDUES AND ENVIRONMENTAL CONTAMINATION

If the processed material is that the contract provides, there aren't noxius substances.

A14.5 SCRAPPING AND DISPOSING

As there are in force different norms of observation, it is necessary to follow the prescriptions fixed by laws and authorities of the states where the machine will be installed.

Proper precautions must be taken for out-of-order and scrapping of the machine in order to avoid possible dangerous situations.

In particular, follow these general instructions:

• disconnect the machine from the electric network and check that no residual voltage exists.

• Empty all the lubrication points of oil paying attention in not dispersing and dispose it according the laws in forces in the country where the machine has been used.

• Lock all the moving parts of the machine, making sure that there are no possibilities of movement, also due to accidental collision during the transfer operation.

• With the help of qualified and authorized personnel proceed to the dismounting of components and the differentiated collection of materials (steel, plastic, electrical components, wires, etc.) in order to dispose everything according to the indications forseen by the laws in force.

Always use security clothes during the operations that require direct intervention on the machine.


A15 SECURITY AND ACCIDENT PREVENTION

A15.1 GENERAL INFORMATION

The employer will must provide for the training of the staff about dangers caused by accidents, about equipments arranged for the operator safety, about dangers of noise emission and about the general accident rules provided by international directives and by legislation of the country of designation of the machine.

Anyway the behaviour of staff, maintenance operator, cleaning, control, etc. will must scrupulously respect the accident norms of the country of designation of the machine.

Before starting the work, the operator must be thoroughly familiar with the location and operation of all controls and characteristics of the machine must also have fully read this manual.

The machine must be used only from operators that had received a training and understand totally the instructions of this manual.

It is necessary to respect totally instructions, cautions, general accident rules that are in this manual.

It is basic that the maintenance operator works around and inside the machine only after the activation of all safety equipments intended by the constructor that put the machine in safety conditions. In addition, access to the surrounding areas the machine must be limited to maintenance personnel working on the machine itself.


A15.2 INTENDED, NOT INTENDED AND MISTAKEN USES

The machine has been made to proceed caps on preformed rigid containers with production limits reported in chapter A13.2 MACHINE TECHNICAL DATA page 16 of this manual; having characteristics (material, dimensions, weight, ecc) agreed with the customer and declared in the contract and work in a closed industrial environment, protected from atmospherics agents, and with a correct lightning See also Chapter A14.3 LIGHTING page 19.

The machine receives caps correctly orientated by the its orientation system.

Besides the conduction of the machine out of what underlined in the chapter A13.2 M A C H I N E TECHNICAL DATA page 16 , just as an example and not exhaustive purpose, is considered as incorrect or not provided use of the machine, if the machine is used to:

• proceed caps or containers not sampled during the order, designing and manufacturing phases.

• Load the machine (caps and containers) in different ways from the provided ones by AROL S.p.A. (the machine is loaded automatically).

• Invert the rotation direction of one or more motors on the machine.

• Avoid or defeat in everyway active or passive safety devices (See Chapter A15.3 RISKS - PROTECTIONS - CAUTIONS AND PRECAUTIONS page 23).

• Carry out maintenance operation and/or size change without putting the machine in safety conditions.

• Feed with tensions or pressures different from the ones reported on the plate data on the machine.


A15.3 RISKS - PROTECTIONS - CAUTIONS AND PRECAUTIONS

A15.3.1 GENERAL SAFETY

To guarantee health and safety of the people exposed, the machine is provided with this safeties:

A15.3.1.1 PASSIVE SAFETIES

FIXED GUARDS

All the fixed guards installed on the machine are connected to the structure by means of fastening devices which do not allow manual removal, since they necessarily require the use of specific tools.

This condition to assign an objective tampering responsibility to the operator who uses the machine after removing the fixed guards.

The housing of the fixed guards in vertical position in the structure of the machine has been designed so that the guards, once the fastening devices have been removed, do not remain in closed position, falling by gravity.

It is not possible to operate the machine with the guards simply resting on the structure, in closed position.

To access the area protected by the guard, it is necessary to put the machine in maintenance mode.

A15.3.1.2 POSITION OF THE SAFETIES

PASSIVE SAFETIES• Fixed guards.

▫ Head protection guard.

Fig. 6


INTENTIONALLY LEFT BLANK PAGE


B FIRST START UP, OPERATING AND USE


B1 SETTING UP, CHECKS AND TEST FOR THE FIRST START UP

The stting up operations of the machine for the first start up must be carried out by qualified technicians.

The machine has been tested by the Manufacturer premises before the shipping; all the calibration and eventual adjustments have been carried out during the test.

B1.1 CHECKS BEFORE THE START UP

In order to prevent errors and/or accidents, before the start up of the machine it is necessary to carry out some checks:

• Check the correct motor absorption.

• Check the correct rotation direction of motors.

• Check that there are no leaks in the pneumatic unit.


B2 ZONES-OPERATORS AND RULES

Are briefly reported definitions already listed in chapter A15 SECURITY AND ACCIDENT PREVENTION page 21.

B2.1 WORKING AREA - CONTROL AREA

WORKING AREA: is the place where the operator can stay to check the production and has the possibility to intervene in case of necessity according to his duty.

CONTROL AREA: is the place where the operator can carry out the controlling and check operations on the machine, carrying out on the suitable controlling panels.

The specialised staff able to work on this machine must have requirements indicated into the introduction of this manual and moreover must have a good knowledge of this manual and all information about security.

On the contrary the Manufacturer declines all responsibility derivating caused by the non respect of these conditions.

Any other different use from the one indicated by the Manufacturer and according the values greater than characteristics of the machine, is considered "improper use", causing the loss of warranties and the full responsibility by the user.

B2.2 RESIDUAL RISKS

The eventual residual risks present on the machine are highlighted on the machine by suitable signals and reported in the relevant sections of this manual.

B2.3 NUMBER OF OPERATORS

The operations described in this manual, referring the cycle of life of the machine, have been analyzed by AROL S.p.A.. So the number of phases and operations indicated is the one most suitable to carry out the functions in a optimal way.

The machine has been designed and built for being conducted by an operator charged to refill of raw materials and check the good flowing of the production.

A number lower or greater of operators, can modify the expected result or create a danger for the security of personnel involved.


B2.4 SAFETY PROCEDURES FOR THE OPERATION

Wrenches and tools used for the maintenance or the access to machine hazardous sections must not be left at the disposal of operators not suitably trained for the size change or the maintenance.

All check, adjustment, maintenance and lubrication steps must be carried out by staff previously trained and instructed.All check, adjustment and maintenance steps of the electric system must be carried out by staff previously trained and instructed.People on drugs, alcohol or drowsiness-causing medicines are not allowed to use or maintain the machine.All check, adjustment, maintenance and lubrication steps must be carried out with the machine STOPPED and DISCONNECTED POWER.

The cap/cork feeding system has been designed and manufactured to be loaded by an automatic elevator with ground loading.

If caps/corks are loaded manually, this operation must be performed with the machine off.For interventions in the machine upper part, with machine STOPPED and DISCONNECTED ALIMENTATION, exclusively use climbing means (ladders, scaffolds) equipped with guards and according to the laws in force. Do not carry out any intervention climbing on the machine structure or parts.


B3 OPERATING MODES

The turret cannot work autonomously.

The customer must thus install the turret on his machine under his own responsibility and according to the European Community directives and take care that all requirements and specifications of the laws in force are complied with.

B4 PRELIMINARY CHECKS

Before starting the turret up, check the following:

• Check all machine components are lubricated (See Chapter C8 LUBRICATION page 46).

• Make sure the specific installed equipment are suitable for the size to be processed.

• Check the correspondence between container and cork to be treated.

Each set of equipment is marked as indicated in the relevant tables in chapter A13.2 MACHINE TECHNICAL DATA page 16. Each mark corresponds to a size to be processed.

• Check the height of the closure unit according to the container height.

• After checking and possibly adjusting the turret height, make sure the equipment is aligned.

• Check that the working pressure is correct (the pressure is indicated on the pressure gauges).




C CLEANING AND MAINTENANCE


C1 MACHINE CLEANING

Hereinafter are described the indications for the cleaning of the machine and its components.

Over the isolator it is allowed to carry out a cleaning of parts using a wet cloth with the following products:PRODUCT Max. temp. (°C) pH

Water 35Neutral detergents 35 5 ÷ 9

For the cleaning of the isolator, it is allowed the use of squirting nozzles and static and rotating cleaning heads (feeding maximum pressure 5 bar).

It is allowed to use the following foaming products:

PRODUCT CONCENTRATION Max. temp. (°C) pHAlkaline solutions of hydroxide sodium (NaOH) and/or potassium (KOH)

1 ÷ 2 [%] 35 12 ÷ 13

Acid detergents containing nitric acid (HNO3)

1 ÷ 2 [%] 35 1 ÷ 2

Acid detergents containing phosphoric acid (H3PO4)

1 ÷ 2 [%] 35 1 ÷ 2

Disinfectant non chlorinated (Aldehyde, quaternary ammonium)

1 ÷ 2 [%] 35 2 ÷ 6

Acid detergents containing peracetic acid (PAA)

2000 ppm 60

Before carrying out cleaning, you should refer to the product data sheets relating to detergents.

To clean the components of the machine, please read the chapters related to the components themselves. See the section COMPONENTS ON THE MACHINE page 89.

Detergents residuals or residuals of liquids used for the cleaning of the machine must be disposed according the laws in force of the country in which the machine is used.


C1.1 MAINTENANCE PREPARATION

C1.2 GENERAL SAFETY WARNINGS

The safety for the machine and the operators also depends on a regular maintenance according to the manufacturer's indications.

The routine and extraordinary maintenance interventions must be exclusively charged to skilled staff, that is to technicians qualified according to the specifications in the manual introduction.

If outsourced operators intervene, they must ensure the same performance of the inhouse qualified technicians and must work in safe operating conditions.

The qualified technicians must:

• respects the limits of their tasks (mechanical, electrical, etc.).

• Follow the procedures and warnings in the manual, within their tasks.

• Follow the times and intervals indicated in the manual for scheduled maintenance interventions.

The following general warnings must be noted:

• Electrocution hazard due to direct contact with the machine power supply terminal boards and in the electrical system connector blocks (the hazard is signalled by plates with the suitable triangle with yellow bottom).

• Be extremely careful during the interventions on the electrical system, if the system must be left live. Such interventions must be carried out by staff skilled in this type of maintenance only, trained and correctly equipped for the steps to be made. The intervention with live system must always be authorized in advance by the employer who must oversee its operations by assessing the specific risk situations.

• Repair pneumatic systems and components only after having cut them off and having checked there is no residual pressure inside the components.

• It is forbidden to carry out maintenance and lubrication interventions on moving components.

• When working on heated parts, always wait for them to cool down to avoid burns or scalds.

C1.3 WARNINGS FOR A CORRECT MAINTENANCE

For a good maintenance:

• follow the maintenance intervention intervals indicated in the manual; the interval (indicated in time or in working cycles) between interventions must be meant as max. limit not to be exceeded. If necessary, it can be shorter.

• A correct preventive maintenance requires a constant care and continuous monitoring of the system and of the machines. Promptly check the cause for possible faults such as excessive noise, overheating, etc. and solve it.

• In case of doubts, contact the manufacturer.


C2 MAINTENANCE GENERAL INFORMATION

C2.1 MAINTENANCE SCHEDULE

From the constructive point of view, interventions concern mechanical, electrical and pneumatic parts.

For practical reasons the provided interventions are grouped according to time and complexity criteria. Each intervention or group of interventions can concern about mechanical, electrical and pneumatic aspects. For practical reasons again, there is a distinction between ordinary and extraordinary maintenance.

The ordinary maintenance is divided in two categories:

• scheduled ordinary maintenance (or preventive).

• Ordinary maintenance according to the conditions (caused by wear and tear).

The scheduled ordinary maintenance (so called periodical or preventive) includes inspections, checks and interventions that, to prevent stops and faults, keep under control:

• the lubrication state of the machine.

• The state of parts that can be affected by wear and tear.

The ordinary maintenance according to the conditions on the contrary, concerns components of the machine that are not subject to periodical checks and wear and tear previously qualifiable. Must be checked or replaced according to their state of wear.


C2.2 WARNING SYMBOLOGY

The following symbols indicate the warnings that MUST be followed by the person charged with the maintenance during the maintenance operations.

ProhibitionsMay not lubricate, repair or adjust during motion

Do not remove the safety devices.

No access by unauthorized persons. Do not extinguish with water.

Types of inspection and interventionVisual inspection. Intervention of oil lubrication.

Inspection hearing. Intervention of grease lubrication.

Do not touch the resistances and the components with which they are in contact until they have cooled down.

Manual intervention.

Personal protective equipmentMandatory use of protective gloves. Mandatory use of safety glasses.


C3 MAINTENANCE INTERVALS

The following tables show the maintenance deadlines and the operations needed for a correct operation and long life of the machine.

The interventions described below have been arranged at intervals of time expressed in hours.Interval(hours)

Working in1 shift

Working in2 shifts

Working in3 shifts

8 - - -40 1 week - -120 3 weeks - 1 week250 6 weeks 3 weeks 2 weeks500 3 months 6 weeks 1 month1000 3 months 3 months 2 months3000 12 9 months 3 months6000* * * 12 months(*) every 6000 hours or anyway once a year.

C4 MAINTENANCE AND LUBRICATION PLANNING

Interval Intervention type40 hours Ordinary maintenance120 hours lubrification

Ordinary maintenance250 hours lubrification500 hours lubrification

Ordinary maintenance1000 hours lubrification

Ordinary maintenance3000 hours Ordinary maintenance5000 hours Ordinary maintenance6000 hours lubrification

Ordinary maintenance12000 hours Ordinary maintenance18000 hours Ordinary maintenance20000 hours Ordinary maintenance


C5 PK515 HEAD WEARING PARTS

It is recommended to stock a spare part kit.SPARE PART KIT Working hours

3000 6000Compensating spring xRing-nut pressure spring xCentral oblique bearing xBush for dowel xMagnetic rings xO-ring xSeal ring gasket xBellows x

Carry out the head overhaul, following the instructions in the chapter referring to the capping head.

C6 PKSG-EE CLOSURE CHUCK WEARING PARTS

It is recommended to stock a spare part kit.SPARE PART KIT Working hours

1000 12000Ejector inner spring xSpheres xO-ring xCaps ejection device x

Carry out the head overhaul, following the instructions in the chapter refering to the capping head.


C7 SCHEDULED MAINTENANCE

C7.1 EVERY 40 WORKING HOURS

OPERATION AIM NOTESAir pressure check. Check the air supply pressure to

the various utilization points.

Check by the gauges, that the pressure reducers are adjusted at the work pressure (see table PNEUMATIC DATA page 16



OPERATION AIM NOTESCapping head cleaning. Clean the head so that the

bottled substances do not alter its performance and do not spoil its components.

See sub-chapter F3.5 CLOSURE HEAD CLEANING page 108.

Closure chuck cleaning. Clean the chuck so that the bottled substances do not alter its performance and do not spoil its components.

See sub-chapter F4.4 CLEANING OF THE CLOSURE CHUCK page 137.



OPERATION AIM NOTESCheck the conditions of the closure chuck.

Verify the state of wear of the chuck.

See sub-chapter F4.5 MAINTENANCE AND OVERHAUL page 138.

Lubrication of the closure chuck.

Lubricate the chuck. See sub-chapter F4.5.1.3 PARTS LUBRICATION page 141.

Verify the conditions of the bottle centering devices.

Check if the teeth of the centering devices are worn and, if necessary, replace them.

See sub-chapter C9.2 REPLACEMENT OF TOOTHED CENTERING DEVICE page 70.

Check of the sliding rollers of the heads controlling spindles.

Check the state of wear of the sliding rollers.

This operation must be carried out from the 3000 operating hours and must be carried out up to the reaching of 6000 hours.

See sub-chapter C9.1.2 REPLACEMENT THE SLIDING ROLLERS OF THE SPINDLE page 64.



OPERATION AIM NOTESVisual check of the lifting heads device's sliding guides bellows.

Check the wholeness of the bellows pressing the head and visually making sure there is no crack nor breakage. If damaged, replace them.

See sub-chapter F3.6.6 REMOVING OF BELLOWS COUPLING page 127.

Check of the closure chuck. Check the functioning of the closure chuck.


Closure chuck cleaning. Clean the chuck so that the bottled substances do not alter its performance and do not spoil its components.

See sub-chapter F4.4 CLEANING OF THE CLOSURE CHUCK page 137.

Check of the bellows coupling. Visually verify that the bellows couplings located on the spindles are not worn.

See sub-chapter C9.1.3 REMOVING OF THE BELLOWS COUPLING page 68.

Check of the turret vertical sliding.

Check the correct vertical sliding, making the turret slide from the min. to the max. value, so as to ensure a correct component sliding in time.


OPERATION AIM NOTESElectric connection check. Carefully check all the connectors

and connection cables and if necessary replace all the damaged parts.

If even a minor water seepage is found, look for the reason immediately and solve the problem.

Sight and sound check of possible noises, clearances and unbalancing.

Check, starting and stopping the machine several times without bottles, for possible noises, faults, clearances and vibrations in the motor-drive components (motors, reducers, gears, bearings).

Replace possible worn components.

Lubricate the new installed components.

Clean and lubricate the disassembled components.

Report any anomalies you need to contact Technical Support.

Pneumatic system check. Check the correct operation and possible leaks (from fittings, lines, etc.):

• verify the air pressure at the machine entry.

• Supplying the pneumatic system with compressed air, check there is no leak, broken or disconnected pipe.

• Check that the machine pressure gauges indicate the pressure specified on the suitable plate on them.



OPERATION AIM NOTESClosure head overhaul. Overhaul the capping head,

replacing the compensating spring.


Replace the compensating spring.

• The balls of the chuck release device.

Check the head correct tightening torque.

Lubrication of the capping head movable parts.

Lubricate the springs.

Lubricate the upper bush and the seat of the head central body.

Lubricate the bush for dowel.

See sub-chapter F3.6.7 PARTS LUBRICATION page 128.

Check the caps ejection device off the closure chuck.

Verify the correct operating of the caps ejection device.

Check of the sliding rollers of the heads controlling spindles.

Check the state of wear of the sliding rollers.

This operation must be repeated every 500 operating hours and up to the reaching of 6000 hours.




OPERATION AIM NOTESClosure head overhaul. Completely overhaul the closure

head, replacing the wear components.


Dismount the head completely and replace:

• the springs.

• The bearings.

• The sealing rings.

• The magnetic rings.

• The dowel bushes.

• The balls of the chuck release device.

Check the head correct tightening torque.

Replacement of the bellows of the capping head.

Replace the bellows of the capping head.

See sub-chapter F3.6.6 REMOVING OF BELLOWS COUPLING page 127.

Overhaul of the head controlling spindle.

It is necessary to carry out a complete overhaul of the spindles.

Contact the Technical Service.

Replacement of the sliding rollers of the heads controlling spindles.

Replace the sliding rollers.

Once the rollers are replaced it is necessary to restart the scheduled maintenance cycle of the rollers.


Replacement of the bellows coupling of the spindles.

Replace the bellows couplings located on the spindles.

See sub-chapter C9.1.3 REMOVING OF THE BELLOWS COUPLING page 68.



OPERATION AIM NOTESMachine general check. Check the correct operation of

the machine; if faults are found, contact the Technical Service.


C8 LUBRICATION

C8.1 GENERAL INFORMATION

Before any lubrication operation set the machine in "Maintenance status", and wear protective gloves and goggles.

Before starting the machine, check the lubrication of all components described in this chapter.

If the machine is not used for a long time, lubricate it again.

Mineral oils, when not used for over six months, loose their properties and must be changed.

C8.2 LUBRICANT TYPE-APPROVAL ACCORDING TO NSF

The type-approval according to NSF includes two categories: NSF - H1 and NSF - H2.

• H1 indicates Food grade lubricants, that can thus be used in all friction points of machines and systems for the food and pharmaceutical industries, where occasional, and technically unavoidable, contacts can occur between lubricant and food.

• H2 indicates lubricants that are recommended for the general use in the food and pharmaceutical industries, supposing that a contact with the fool is totally to be excluded.

C8.3 TYPES OF LUBRICANTS

The R&D department of AROL S.p.A., after careful studies and functional tests, has decided to use the lubricants indicated in the table below to lubricate its machines:

C8.3.1 OILSIGNS

C Paraliq P 150 L0115FG - -D Klübersummit FG46 L04346FG Purity FG EP 150 -I - - Purity MF spray -N Klüberoil 4 UH1 220 N L1122FG Purity FG gear oil 220 -


C8.3.2 GREASESIGNS

A Klübersynth UH1 64-62 G4501 - -B Klüberlub NH1 11-222 - - -E - - Purity FG Synth -F Klüberpaste UH1 84-201 P1900 - -G Barrierta L55/1 - - Krytox GPL 226H Klübersynth UH1 64-62 G4501 - -J Klübersynth UH1 64-62 G4501 - -K Paraliq GB 363 - - -L Paraliq GB 363 - - -M Klüberlub NH1 11-222 - - -O Klübersynth UH1 64-62 G4501 - -P Klübersynth UH1 64-1302 - - -


C8.3.3 FEATURES OF THE USED LUBRICANTSProduct Name NSF NLGI Basic oil Thickener Viscosity

indexBasic oil viscosity

(cSt)

Processed penetration

(0.1 mm)

Min. temp. (°C)

Max. temp. (°C)

KLUBERParaliq P 150 H1 WO 150 -15 100Klübersummit FG46

H1 PAO 130 46 -45 135

Klüberoil 4 UH1 220 N

H1 PAO 150 220 -25 120

K l ü b e r s y n t h UH1 64-62

H1 2 PAO gel-silica 60 265-295 -40 150

Klüberlub NH1 11-222

H1 2 WO complex aluminum

220 265-295 -15 110

K l ü b e r p a s t e UH1 84-201

H1 1 PAO PTFE 200

Barrierta L55/1 H1 1 PFPE PTFE 400 -40 260Paraliq GB 363 H1 2 MO silicate 215-245 -30 140K l ü b e r s y n t h UH1 64-1302

H1 2 Synth silicate 1300 265-295 -10 150

MOLIKOTEL0115FG H1 MO 100 140 -18L0346FG H1 MO 100 46 -21L1122FG H1 PAO/MO 142 197 -33G4501 H1 1 PAO complex

aluminum100 310-340 -40 150

P1900 H1 1 MO complex aluminum

85 290-340 -30 300

PETRO-CANADAPurity FG EP 150

H1 HT/MO 95 144 -18

Purity MF spray H1 HT/MO 150 151 -9 150Purity FG Gear Oil 220

H1 HT/MO 92 206 -18

Purity FG Synth H1 2 PAO Complex - sulfonate - calcium

46 294 -45 200

DUPONTKrytox GPL 226 H1 2 PFPE PTFE 155 240 -30 288


C8.3.4 LUBRICANT RE-ORDERING

The lubricants used for the machine can be directly ordered to AROL S.p.A. or to the local distributors.

See the table here below for the international addresses.http://www.klueber.com

http://www.molykote.com

http://www.petro-canada.ca

http://www.krytox.com

C8.4 LEGEND FOR LUBRICATION SCHEMESSYMBOL DESCRIPTION

Lubricate with manual pump for grease

Lubricate with brush for grease

Lubrication glass with disposable cartridge

Lubricate with spray

Lubricate with manual pump for oil

Grams are referred to each lubrication point.


C8.5 POINTS TO BE LUBRICATED

To protect the machine from wear, seizure or other severe damage to the mechanisms, it is necessary to lubricate and grease periodically all indicated points.

AROL S.p.A. guarantees the maintenance intervals indicated hereby and the correct operation of the mechanisms exclusively with these lubricants.

C8.5.1 INSTRUCTIONS FOR READING THE "LUBRICATION POINT LIST" TABLE

The scheme showing the position of the lubrication points (Lubrication point scheme) and the time interval table (Lubrication point table) relevant to time intervals, methods and used lubricants for the maintenance interventions on the machine herein are to be found in the following pages.

The "Lubrication point scheme" indicates the position of the points described in the table on the machine.

The points marked by a double frame indicate that the lubrication is carried out in a centralized way. Thus, the quantity of lubricant indicated in the table must be filled; then, the system will distribute the correct quantities to the different components.

The table "Lubrication point list" is designed to find immediately the operations to be carried out for the machine lubrication.POINT CODE The column indicates the reference of the point to be lubricated,

indicated on the machine next to the greaser and in the "Lubrication point scheme"

POINT DESCRIPTION This column briefly describes the greasing point.LUBRICANT TYPE The reference letter for the lubricant to be used is indicated in this

column. See the table for the lubricant type to be used.METHOD This column shows the tool by which the relevant greasing point must

be greased.INLET NUMBER [NO.] It indicates the number of greasing points on the machine.QUANTITY/POINT [gr.] It indicates the lubricant quantity to be fed in each greasing point.TOTAL QUANTITY [gr.] It indicates the total lubricant quantity to be used.INTERVAL [h] It indicates every how many hours the different lubrication points must

be greased.


Fig. 7 Lubrication point scheme


Fig. 8 Lubrication point table


C8.6 LEVEL CHECK AND OIL FILLING UP

On the turret there is a sensor that detects automatically the oil level. If the same does not give a signal, verify the oil level inside the tank or the sensor functioning.

Fig. 9For the oil check of the tank and the following filling up, proceed as follows:

• For the oil check of the tank and the following filling up, proceed as follows:

▫ unscrew and remove the oil level rod.

Fig. 10• Check that the oil level into the tank is between

the minimum and maximum indication of the level rod.

Fig. 11


• If the level is lower than the minimum level, it is necessary to refill as follows:

▫ Unscrew and remove the charging plug.

Fig. 12

▫ supply oneself with a pump for oil.

• Gradually refill by the charging hole, with “D” type oil, always checking the level to reach.

Fig. 13

• When the operation is over, remount the charging plug.


C8.7 OIL REPLACEMENT INTO THE TANK

For the oil replacement into the tank, proceed as follows:

• open the upper turret gate.

Fig. 14• Make the machine rotate in manual jog, until the

discharge tap is located in correspondance to the opening of the guard.

Fig. 15• Position a container near the drain poin.

• Unscrew the drain plug.

Fig. 16


• Screw the rubber complete of the nipple in place of the discharge plug.

• Turn the discharge tap on.

• Leave to go out the oil until the tank is completely empty.

• A emptying completed, remove the rubber used for unloading.

• Turn the discharge tap off and screw the drain plug.

• Unscrew and remove the charging plug.

Fig. 17

• supply oneself with a pump for oil.

• Gradually refill by the charging hole, with “D” type oil, always checking the level to reach.

For the quantities of oil to insert into the tank, see “LUBRICATION POINTS TABLE”. C8.5.1 INSTRUCTIONS FOR READING THE "LUBRICATION POINT LIST" TABLE page 50.

Fig. 18

• When the operation is over, remount the charging plug.


C8.8 SEW REDUCERS LUBRICATION

C8.8.1 GENERAL INFORMATION

Do not intermix synthetic lubricants and do not mix synthetic and mineral lubricants together! The standard lubricant is mineral oil.

The reducers are supplied with a lubricant fill adapted for the specific reducer and mounting position. The decisive factor is the mounting position.

C8.8.2 REDUCER MAINTENANCE

C8.8.2.1 INSPECTION INTERVALS AND MAINTENANCETIME INTERVAL OPERATION

Every 3.000 machine hours, at least every 6 months. Check oil and oil level.Check the seals visually for leakage.For gear units with a torque arm: checks the rubber pad and change it, if necessary.

Depending on the operating conditions, every 3 years at the latest. (*).

Change mineral oil.Change the bearings grease (recommended)Replace the sealing ring (do not install it the same track).

Depending on the operating conditions, every 3 years at the latest. (*).

Change synthetic oil.Change the bearings grease (recommended)Replace the sealing ring (do not install it the same track).

Variable (depending on external factors). Touch up or renew the surface/anticorrosion coating.(*) According to oil temperature.


C8.8.2.2 CHECKING THE OIL LEVEL

De-energize the gearmotor and secure it to prevent it from being switched on inadvertently!

Reduction unit surface must allow to lean hands (danger of burn due to oil at high temperature)!

For reducers with an oil level plug:

• remove the plug.

• Check the fill level.

• If necessary, top and screw the plug.

C8.8.2.3 CHECKING THE OIL



Cheking the oil, proceed as described below:

• Remove a little oil from the oil drain plug.

• Check the oil consistency (viscosity and color).

• If the oil is heavily contaminated, you may want to change it, even if you have not yet reached the end of the expected range (See sub-chapter C8.8.2.1 INSPECTION INTERVALS AND MAINTENANCE page 57.


C8.8.2.4 OIL REPLACEMENT



Carry out the oil replacement only when the reducer reaches the operating temperature, as the cold oil does not allow a correct emptying.

Carry out the oil replacement, proceeding in the following way:

• put a vesser under the discharge plug.

• Remove the level plug, drain plug with or without spring and discharge plug.

• Let the oil completely discharge.

• Screw the discharge plug.

• Pour in new oil of the same type trough the vent hole.

Do not intermix synthetic lubricants and do not mix synthetic and mineral lubricants together! If necessary please contact the Technical Service.

• Pour in the volume of oil in accordance with the mounting position (See sub-chapter C8.8.5 LUBRICANT FILL QUANTITIES page 63) or as specified on the nameplate.

• Check oil and oil level. (See sub-chapter C8.8.2.2 CHECKING THE OIL LEVEL page 58)

• Screw the pipe plug with or without spring.

The exhausted oil must be disposed according to the environment protection norms.


C8.8.2.5 SEALING RING REMPLACEMENT



When replace the sealing ring, ensure that thee is a sufficient grease reservoir between the dust lip and protective lip.

If you use double sealing rings, the space has to be filled 1/3 with grease.

C8.8.3 LUBRICANT TABLE

C8.8.3.1 LEGEND FOR LUBRICANT TABLE

The lubricant table on the following page shows the permitted lubricants for SEW-EURODRIVE reducers Please note the following legend to the lubricant table.

Abbreviations used, meaning of shading and notes:Abbrev. Description

CLP mineral oilCLP PG poliglicole (W reducer, conforms to USDA-H1)CLP HC synthetic hydrocarbonsE Ester oil (water pollution danger category WGK 1)HCE synthetic hydrocarbons + ester oil (USDA-H1 certification)HLP hydraulic oilSYNTHETIC synthetic lubricant ( = synthetic anti-friction bearing grease)MINERAL mineral lubricant ( = mineral-based anti-friction bearing grease)(1) helical-worm gear units with polyglycols oil. Please contact SEW EURODRIVE(2) special lubricant for Spiroplan® gear units only(3) we recommend SEW EURODRIVE fB ≥ 1..2(4) pay attention to critical starting behavior at low temperature!(5) low-viscosity grease(6) ambient temperature

lubricant for the food industry (compatible with food products)

biodegradable oil (lubricant for use in agriculture, forestry and water resources)


C8.8.3.2 BEARINGS GREASES

The bearings of the bearings and motors are given a factory-fill with the greases listed below.

SEW-EURODRIVE recommeds regreasing bearings with a grease fill at the same time as changing the oil.ambient

temperatureManufacturer Type

Bearing for reducers -20 °C ... +60 °C Mobilux EP 2 MINERAL-40 °C ... +80 °C Mobiltemp SHC 100 SYNTHETIC

Bearing for motors -20 °C ... +80 °C Unirex EQ3 MINERAL

-20 °C ... +60 °C Alvania RL3 MINERAL-45 °C ... -25 °C Aero Shell Grease 16 SYNTHETIC

+80 °C ... +100 °C Barrierta L55/2 SYNTHETIC

Special greases for bearings for reducers:-30 °C ... +40 °C Eural Grease EP 2 SYNTHETIC

-20 °C ... +40 °C Aralube BAB EP2 SYNTHETIC

The following grease quantities are required:

• for fast-running bearings (motor and reducer input side): fill the cavities between the rolling elements one third full with grease.

• For slow-running bearings (in reducer and at reducer output side): fill the cavities between the rolling elements two thirds full with grease.


C8.8.4 LUBRICANTS CHARACTERISTICS TABLE

S… (HS…)

R…, K… (HK…, F…, S… (HS)

Temperature °CSYNTHETIC MINERAL SYNTHETIC MINERAL

s t a n d a r d 0…+40

-20…+60 (4) -30…+80

(4) -40…+10

-20…+10 -25…+20 (6) -40…0 (6) -30…+40

-20…+40

DIN (ISO)

CLP(CC)

CLPPG

CLPHC

CLP(CC)

CLPPG

CLPHC HCE E

ISO; NLGI

VG 680 (1)VG680

VG 460 VG 150 VG 150VG 100

(1)VG 220

VG 32 VG 460 VG 460

Mobilgear

636

Mobil

SHC 634

Mobil

SHC 629

Mobilgear

627

Mobil

Glygoyle

30

Mobil

SHC 624

Shell

Omala

680

Shell

Tivela

S 680

Shell

Omala

HD 460

Shell

Omala

HD 150

Shell

Omala

100

Shell

Tivela

S 220

Shell

Cassida

Fluid

GL460Klüberoil

GEM

1-680

Klübersynth

GH

6-680

Klübersynth

EG

4-460

Klübersynth

EG

4-150

Klüberoil

GEM

1-150

Klübersynth

GH

6-220

KlüberSummit

HySyn

FG-32

Klüberoil

4UH1

-460N

Klüberbio

CA2

460Aral

Degol

BG 680

Aral

Degol

BG 100

Aral

Eural

Gear 460

Aral

Degol

BAB 460BP

Energol

GR-XP 680

BP

Enersyn

SG-XP 680

BP

Energol

GR-XP 100Tribol

1100/680

Tribol

800/680

Tribol

1100/100

Tribol

800/220

Meropa

680

Synlube

CLP 680

Pinnacle

EP460

Pinnacle

EP150

Meropa

100

Synlube

CLP 220

Cetus

PAO 46

Optigear

BM680

Optigear

BM100

Optiflex

A 220

Optileb

GT 460

Optisynt

BS 460

Renolin

CLP 680

Renolin

CLP 150


C8.8.5 LUBRICANT FILL QUANTITIES

The specified fill quantities are guideline values. The precise values vary depending on the number of stages and gear ratio. When filling, it is essential to check the oil level plug since it indicates the precise oil capacity.

The following tables show guide values for lubricant fill quantities in relation to the mounting position M1... M6.

S…Gear-box

typeLubricant quantity in liters

M1 M2 M3(1) M4 M5 M6S37 0,25 0,40 0,50 0,55 0,40 0,40S47 0,35 0,80 0,70 / 0,90 1,00 0,80 0,80S57 0,50 1,20 1,00 / 1,20 1,45 1,30 1,30S67 1,00 2,00 2,20 / 3,10 3,10 2,60 2,60S77 1,90 4,20 3,70 / 5,40 5,90 4,40 4,40S87 3,30 8,10 6,90 / 10,4 11,30 8,40 8,40S97 6,80 15,00 13,40 / 18,00 21,80 17,00 17,00

SF…Gear-box


M1 M2 M3(1) M4 M5 M6SF37 0,25 0,40 0,50 0,55 0,40 0,40SF47 0,40 0,90 0,90 / 1,05 1,05 1,00 1,00SF57 0,50 1,20 1,00 / 1,50 1,55 1,40 1,40SF67 1,00 2,20 2,30 / 3,00 3,20 2,70 2,70SF77 1,90 4,10 3,90 / 5,80 6,50 4,90 4,90SF87 3,80 8,00 7,10 / 10,10 12,00 9,10 9,10SF97 7,40 15,00 13,80 / 18,80 22,60 18,00 18,00

SA…, SH…, SAF…, SAZ…, SHA…Gear-box


M1 M2 M3(1) M4 M5 M6S...37 0,25 0,40 0,50 0,50 0,40 0,40S...47 0,40 0,80 0,70 / 0,90 1,00 0,80 0,80S...57 0,50 1,10 1,00 / 1,50 1,50 1,20 1,20S...67 1,00 2,00 1,80 / 2,60 2,90 2,50 2,50S...77 1,80 3,90 3,60 / 5,00 5,80 4,50 4,50S...87 3,80 7,40 6,00 / 8,70 10,80 8,00 8,00S...97 7,00 14,00 11,40 / 16,00 20,50 15,70 15,70

(1) In the combined reducers, the largest reducer should be filled with amount of lubricant greater.


C9 EXTRAORDINARY MAINTENANCE - TIMINGC9.1 HEADS DRIVING SPINDLES

C9.1.1 CHECKING THE WEAR OF THE SLIDING ROLLERS

Check the state of wear of the sliding rollers in the following way:

• Verify that on the roller there are not cracks, stains not caused by dirt, removal of materials, etc.

• Verify that the diameter is not smaller than 46 mm.

Fig. 19C9.1.2 REPLACEMENT THE SLIDING

ROLLERS OF THE SPINDLE

To replace the sliding rollers of the spindle, proceed as follows:

Fig. 20

Fig. 21


• Make the machine rotate in manual jog until the spindle on which operating is located in correspondance to the extraction hole of the spindles controlling cam.

Fig. 22

• Using a 10 mm hexagonal wrench, unscrew and remove the fixing bolts.

Fig. 23

• Remove the antirotation rod case.

Fig. 24


• Using a 13 mm hexagonal wrench, unscrew and remove the fixing bolts.

Fig. 25

• Remove the antirotation rod and the relative spacers.

Fig. 26

• Using a 19 mm hexagonal wrench, unscrew and remove the rollers fastening nuts.

Fig. 27


• Remove the plate.

Fig. 28

• Slide out the upper sliding roller through the extraction slot of the cam.

Reverse the above procedure to assemble the upper roller.

Fig. 29

• Pull out the lower sliding roller.

• Reassemble everything in the reverse to that described for the removal.

Fig. 30


C9.1.3 REMOVING OF THE BELLOWS COUPLING

To remove the bellows coupling placed on the spindles proceed as follow:

• Using two 10 mm hexagonal wrenches, unscrew the bolt of the upper bellows locking ring.

Fig. 31• Lift up the upper bellows locking ring in such way

to free the bellows coupling.

Fig. 32• Unscrew the bolt of the lower bellows locking

ring.

Fig. 33


• Pull down the lower bellows locking ring in such way to free the bellows coupling.

Fig. 34

• Slide out the bellows coupling from the spindle.

Fig. 35


C9.2 REPLACEMENT OF TOOTHED CENTERING DEVICE

The teeth of the centering devices to carry out their bottle anti rotation task have a triangular shape. If the teeth are no longer sharp, it is necessary to replace them.

Fig. 36To replace the worn centering devices, operate as follows:

• unscrew the fastening bolts.

Fig. 37• Remove the bottle centering devices

Fig. 38


C9.3 CAPS DISTRIBUTING TIMING ON TRANSFER DISK

Before any operation set the machine in "Maintenance status".

To obtain a correct distribution of the caps is necessary that the release and the block of caps, obtained by the caps stopping cylinder, are always implemented in position when the tip of the transfer star-wheel is located 1 mm beyond the central axis of the caps chute.

Fig. 39

Fig. 40 Remembers that in case of continuous flow of bottles the solenoid valve must remain energized.




D SIZE CHANGE


D1 CONTAINERS SIZE CHANGE

All the size change steps must be carried out with the machine stopped. Close the air supply.

The machine is equipped with " Multibody " bottle body handling unit with manual adjustment, therefore having to change the bottles format to be treated, is necessary to:

• adjust the bottle-neck guide sector.

Adjust the external bottle-body guides.

Adjust the bottle-body central star-wheels.

With the "Multibody" system, it is possible to handle bottles having body diameter within ø 42 and ø 105 and having height up under the neck within 85 and 347 mm.

D1.1 BOTTLE-NECK GUIDE SECTOR

To adjust the position of the bottles-neck guide sector, proceed as follows:

• press on the knob.

To adjust the position of the bottle-neck guide sector, operate the controls related to motor identified with number 73.

Fig. 41• Holding it pressed, turn until the measurement

dipstick is located in correspondence of the correct size shown on the millimetric rule plate.

Fig. 42


• After the adjustment, release the knob checking the correct returning to the rest position; if not, lightly turn the knob until to allow the release from the work position.

Fig. 43

The position reference measurements are shown in theEQUIPMENT COLOR TABLE in the chapter A13.2 M A C H I N E TECHNICAL DATA page 16.


D1.2 EXTERNAL BOTTLE-BODY GUIDES

D1.2.1 UPPER EXTERNAL BOTTLE-BODY GUIDE

To adjust the position of the upper external body guide, proceed as follows:




Fig. 45

Fig. 46



Fig. 47



D1.2.2 LOWER EXTERNAL BOTTLE-BODY GUIDE

To adjust the position of the lower external body guide, proceed as follows:


Fig. 48

• Holding it pressed, turn until the measurement dipstick is located in correspondence of the correct size shown on the millimetric rule plate.

Fig. 49

Fig. 50



Fig. 51



D1.3 BOTTLE-BODY GUIDE CENTRAL STAR-WHEELS

To adjust the bottle-body guide central star-wheels proceed as follows:

• make rotate the turret so that the knob is in an accessible area.

Fig. 52• Press the knob.




Fig. 54



Fig. 55


D2 CAP SIZE CHANGE

The instructions for replacement of parts for caps size change is given in section COMPONENTS ON THE MACHINE page 89 in each chapter to which they refer.

Having to change the format of the caps to be treated, must be replaced:• The closure chucks

Fig. 56

• Replace the caps transfer group on the transfer disk, if provided.

Fig. 57


D2.4 CAPS CHANGE

The machine is set to proceed both FLAT and SPORT caps having the same threaded diameter, so when it is necessary to change the type of cap to proceed, adjust the caps upper guide position on the transfer disc, proceeding as follows:

D2.4.1 FROM FLAT CAP TO SPORT CAP

• Carry out on the pneumatic cylinder operating contro to lift the cover adjustment plate.

Fig. 58

Fig. 59


D2.4.2 FROM SPORT CAP TO FLAT CAP

• Carry out on the pneumatic cylinder operating contro to lower the cover adjustment plate.

Fig. 60

Fig. 61


E INSTALLATION AND REMOVAL OF THE BOTTLES NECK GUIDE EQUIPMENT



E1 BOTTLE NECK CENTERING DEVICE

E1.1 REMOVAL

To remove proceed in the following way:

• Make the machine rotate in manual jog until a half centering device holder flange is located in front of the turret.

Fig. 62• Using the 17 mm exagonal wrench, unscrew

and remove the fixing bolts of the half centering device holder flange.

Fig. 63• Lift and remove the half centering device holder

flange.

• Make the machine rotate in manual jog until having the second half centering devices holder flange in the removal position.

• Proceed with removal of the half centering device holder flange as previously indicated.

Fig. 64


E1.2 INSTALLATION

For installation proceed as follows:

• Position the half centering device holder flange on the support.

Fig. 65

• Fasten the half centering device holder flange by fixing bolts. For this operation, use the 17 mm hexagonal wrench.

Fig. 66

• Make the machine rotate in manual jog to install the second half centering device holder flange.

• Proceed with installation of the half centering device holder flange as previously indicated.




F COMPONENTS ON THE MACHINE

In the following chapters, there are, in a complete way, the instructions about the components that are supplied with the machine.

The instructions about the components are grouped in only one chapter for each component, in such way the customer can easily refer the information about their use.

All operations must be carried out with the machine in "Maintenance status", and wear protective gloves and goggles.


F1 CAPS CHUTE

F1.1 CAPS CHUTE DISCHARGE

To empty the caps chute, proceed as described below:

Put a collecting container under the caps chute, close to the discharge opening

Carry out on the controls of the pneumatic discharge of the caps chute.

Fig. 67


F2 CAP TRANSFER DISKF2.2 CAPS TRANSFER GROUP

F2.2.1 CAPS GUIDE SECTORS

F2.2.1.1 REMOVAL

Proceed as follows:

• Disconnect the caps stopping cylinder actioning air fittings.

Fig. 68• Unscrew bolts that fastening the caps guide

secotrs of the base disc

Fig. 69

Fig. 70


• Lift and extract the caps guide sectors.

Fig. 71


F2.2.1.2 INSTALLATION

Proceed as follows:

• Place the caps guide sectors on the base disk.

Fig. 72

• Screw the bolts to the base disc.

Fig. 73

Fig. 74


• Connect the compressed air fittings.

Fig. 75


F2.2.2 CAPS TRANSFER STAR-WHEEL

F2.2.2.1 REMOVAL

Proceed as follows:

• Remove the caps guide sectors as described in subsection F2.2.1 CAPS GUIDE SECTORS page 91.

Fig. 76

• Loosen the star-wheel fixing knobs.

Fig. 77

• Lift the sectors that make the star-wheel in such way to let them go out from the centering pins.

Fig. 78



Proceed as follows:

• insert the sctors that make the star-wheel on the centering pins.

Fig. 79

• Firmly tighten the mounting knobs.

Fig. 80


F2.2.3 EXIT CAPS GUIDE

F2.2.3.1 REMOVAL

Proceed as follows:

• Remove the caps transfer star-wheel as described in paragraph F2.2.2 CAPS TRANSFER STAR-WHEEL page 95.

• Unscrew the knobs fastening the exit caps guides to the base disc.

Fig. 81

• Lift and remove the exit caps guides

Fig. 82


Proceed as follows:

• Position the caps guide on the base disc.

• Tighten the fixing knobs on the base disc.


F2.1 CAP TRANSFER DISK TIMINGF2.1.1 ALIGNMENT OF THE

TRANSFER STAR-WHEEL WITH THE CLOSURE HEADS

If the transfer star-wheel and the closure heads are not perfectly aligned, the complete transfer disk must be timed, operating as follows:

Fig. 83• Make the machine jog till a cavity of the star-

wheel is aligned with the turret center and the closure head center.

• If the centers are not aligned:


▫ Loosen the bolts that secure the star-wheel holding flange.

Fig. 84 ▫ Rotate the caps transfer star-wheel till getting

the required alignment.

▫ Strongly lock the bolts that secure the star-wheel holding flange.

Fig. 85


F3 "PK515" SERIES CLOSURE HEAD

BEFORE CARRYING OUT ANY MAINTENANCE OPERATIONS, the machine must be in safety conditions to avoid untimely screwing and/or electrocution.

F3.1 MAIN COMPONENTS

Fig. 86

Legend:

• 1 Head upper bush

• 2 Bellows coupling

• 3 Slotted ring-nut

• 4 Magnet adjustment ring nut


F3.2 TOOLS FOR THE REMOVAL AND MAINTENANCE

In the table below are shown the necessary tools for disassembly and maintenance of the closure head.TOOL INCLUDED

Hook wrench 58-62 YESHook wrench 40-42 YESHook wrench 34-36 YES

Supporting tool YES

Ring-nut lifting tube YES

Ring-nut support YES

Ring-nut blocking plate YES

Ring-nut disassembly wrench YES

Compasses wrench YES

Allen wrench 3 mm NO


F3.3 REMOVAL AND INSTALLATION

Protect the centering device upper surface with rubber or similar material.

For tools necessary see sub-chapter F3.2 TOOLS FOR THE REMOVAL AND MAINTENANCE page 100.

F3.3.1 REMOVAL

To remove the closure head from the spindle, proceed as follows:

Fig. 87• Using the 45-50 hook wrench inserted in the

seats of the head fixing ring-nut, loosen the ring-nut itself.

• Loosen the ring-nut till releasing the head.

Fig. 88• Using the 58-62 hook wrench inserted in the

seats of the capping head, loosen the head itself.

• Remove the head loosening manually.

Fig. 89


F3.3.2 INSTALLATION

To install the closure head on the spindle, proceed as follows:

• Insert the capping head on the spindle.

• Screw the head on the spindle, manually as far as possible.

• Complete the screw to the bottom of the thread using the 58-62 hook wrench inserted in the seats of the capping head.

Fig. 90

• Tighten the head fixing ring-nut on the spindle by hand until possible to.

Fig. 91

• Tighten the head fixing ring-nut using the 34-36 hook wrench inserted in the seats of the ring-nut itself.

Fig. 92


F3.4 ADJUSTMENT For tools necessary see sub-chapter F3.2 TOOLS FOR THE REMOVAL AND MAINTENANCE page 100.

F3.4.1 TIGHTENING TORQUE ADJUSTMENT

This step can be carried out with the head installed on the machine.

The adjustment is made by a graduated scale engraved on the slotted ring-nut (in Pound x Inch) and a notch engraved on the magnet adjustment ring nut:

Fig. 93

• Lift the slotted ring-nut.

Fig. 94 If the slotted ring-nut is locked, must be inserted the ring-nut lifting tube on the head and bring it in contact with the ring-nut itself. Push the ring-nut lifting tube up to unlock the slotted ring-nut. A unlock occurred, remove the ring-nut lifting tube.

Fig. 95


• Rotate the magnet adjustment ring-nut till the values of the wished tightening torque and the notch "0" are aligned.

Fig. 96

Fig. 97

• After adjustment, lower the slotted ring-nut checking the correct coupling between the inner teeth of the slotted ring-nut and the outer teeth of the magnet adjustment ring-nut.

The adjustment must be made on all closure heads with the same tightening torque.

Fig. 98


F3.4.2 HEAD OPENING AND VERTICAL LOAD CHANGE

To change the vertical load, remove the head from the machine and replace the compensating spring:

• To remove the closure head, operate as indicated in sub-chapter F3.3 REMOVAL AND INSTALLATION page 101.

• Using a round-pointed toot, manually lower the upper part of the bellows coupling by removing it from the head upper bush.

Fig. 99

Fig. 100• Push the head upper bush downwards.

Fig. 101


• Turn the head upper bush counterclockwise, while maintaining the lower part, and pull upward.

Fig. 102

• Remove the compensating spring.

• Replace the spring with a fit to the vertical load to be achieved.

• Remount proceeding reversely than the removal, taking care to grease the spring.

Are available as standard, the springs shown in the table indicated below (1 kg f = 9.81 N).

Fig. 103

Load Kgf Colour Code4 None P07D006213008 YELLOW P07D0062170012 BROWN P56D0255590016 WHITE P07D0062190020 RED P03D0036350025 BLUE P52D0224010032 GREEN P52D0224030061 VIOLET P52D02240400100 BLACK P52D02240700


If the slotted ring-nut is locked, must be inserted the ring-nut lifting tube on the head and bring it in contact with the ring-nut itself. Push the ring-nut lifting tube up to unlock the slotted ring-nut. A unlock occurred, remove the ring-nut lifting tube.

Fig. 104

Fig. 105


F3.5 CLOSURE HEAD CLEANING

Hereinafter are described the indications for the cleaning of the head.

To keep a correct cleaning of the head it is allowed to carry out cleaning to remove from the components eventual dusts and product residuals.

For the external cleaning of the closure head it is allowed the use of squirting nozzles and static and rotating cleaning heads (feeding maximum pressure 5 bar).


1 ÷ 2 [%] 35 12 ÷ 13


1 ÷ 2 [%] 35 1 ÷ 2


1 ÷ 2 [%] 35 1 ÷ 2


1 ÷ 2 [%] 35 2 ÷ 6


2000 ppm 60


Detergents residuals or residuals of liquids used for the cleaning of the head must be disposed according the laws in force of the country in which the closure head is used.

Do not use wadding or others inconsistent materials.

It is dangerous to use compressed air.


F3.5.1 AUTOCLAVE CAPPING HEADS STERILIZATION

The capping heads thanks to their specific materials, following the instructions listed below, can be subjected to a sterilization process in autoclave.

The frequency of the sterilization in autoclave depends on the specifications and needs of the bottling process and must be determined by the customer according to his target and experiences.AROL S.p.A. suggests, anyway, that heads in bottling lines of sensitive products must be subjected to a sterilization process at least every time one proceeds to their maintenance, manipulation or after a long inactivity period.

AROL S.p.A. suggests that in bottling lines of sensitive products, these procedures must be stricter by the increasing the frequency of the sterilization cycles, considering some conditions linked to the context and specific needs or targets that only the costumer can define.

F3.5.2 CAPPING HEADS STERILIZATION PROCEDURE

To carry out a sterilization cycle, it is necessary:

• Carry out the ordinary maintenance and heads components lubrication.

• Insert the heads previously cleaned, into the fitting sacks.

• Close and hermetically seal the sack containing the cleaned head.

• Position the capping head into the autoclave.

• Close the autoclave door.

• Carry out a 20 minutes duration sterilization cycle having a pressure of 1 bar and a temperature of 121 °C.

• After the sterilization cycle, remove the capping head from the autoclave.

• The capping head must be removed from the sack ONLY in a sterile environment.

• Remove the sack. Install the capping head on the machine.


F3.6 MAINTENANCE AND OVERHAUL


F3.6.1 SPRINGS REMOVAL

F3.6.1.1 COMPENSATING SPRING REMOVAL

To remove the compensating spring proceed as described below:

• Open the closure head as described in sub-chapter F3.4.2 HEAD OPENING AND VERTICAL LOAD CHANGE page 105.

• Pull out the upper bush from the lower part of the head.

Fig. 106• Remove the compensating spring.

Fig. 107


F3.6.1.2 RING-NUT PRESSURE SPRING REMOVAL

To remove the ring-nut pressure spring proceed as described below:



Fig. 108

• Pull out the ring-nut pressure spring.

Fig. 109

The ring-nut pressure spring is tapered. Therefore must be mounted in such a way that the black painted spire is at the bottom.

Fig. 110


F3.6.2 MAGNETIC RING OVERHAUL

F3.6.2.1 MAGNETIC RING CHECKING

Magnetic rings are components that tend to lose their original features in time; thus, they must be replaced one or more times during the head life.

Check using a torquemeter that the torque corresponds (with a tolerance ±10%) to the static torque value set on the slotted ring nut.

If the tolerance is higher than the one indicated above, replace the magnetic rings.

F3.6.2.2 PREPARATION FOR MAGNETIC RING OVERHAUL

Note down the value of the screwing torque set on the graduated scale etched on the slotted ring nut.

Fig. 111

When you should overhaul the magnetic rings, proceed as follows:



Fig. 112


• Remove the compensating spring.

Fig. 113

• Pull out the ring-nut pressure spring.

Fig. 114

• Pull out the bellows coupling.

Fig. 115


• Using a screwdriver or a punch, remove the 2 spring supporting rings.

Fig. 116

Fig. 117

• Pull the slotted ring-nut out from the magnet adjustment ring-nut.

Fig. 118


• Loosen and remove the magnet adjustment ring-nut from the head central body.

Fig. 119

F3.6.2.3 REMOVING OF LOWER MAGNETIC RING

To remove the lower magnetic ring, proceed as follows:

• position the ring support on the bottom of a vice.

Place the magnets adjustment ring on the ring support and coupling the ring-nut blocking plate to the magnets adjustment ring.

Close the ring-nut blocking plate between the jaws of the vice.

Fig. 120

• Using 3 mm Allen wrench, loosen the Allen screws fastening the lower magnetic ring on the magnet adjustment ring nut.

Fig. 121


• Remove the lower magnetic ring.

Use a medium resistance thread locking agent when tightening the Allen screws during the installation of the magnetic rings.

Fig. 122

F3.6.2.4 REMOVING OF UPPER MAGNETIC RING

To remove the upper magnetic ring, proceed as follows:

• Fit the supporting tool fitting the pin in one of the holes of the upper magnetic ring.

Fig. 123

• Position the supporting tool so that the Allen screws of the upper magnetic ring can be seen from the suitable openings.

Fig. 124


• Holding the supporting tool in position and using the 3 mm Allen wrench, loosen the Allen screws that secure the magnetic ring

Fig. 125

Fig. 126

• Remove the magnetic ring from the head central body.

Use a medium resistance thread locking agent when tightening the Allen screws during the installation of the magnetic rings.

Fig. 127


F3.6.3 REMOVING OF CENTRAL BEARING

To remove the central bearing, proceed as follows:


Fig. 128• Remove the upper magnetic ring. (See

sub-chapter F3.6.2.2 PREPARATION FOR MAGNETIC RING OVERHAUL page 112 and the sub-chapter page F3.6.2.4 R E M O V I N G OF UPPER MAGNETIC RING page 116).

• Insert the head central body in a vice with soft jaws.

Fig. 129


• Using a compasses wrench, unscrew and remove the bearing external ring-nut.

Fig. 130

Fig. 131

• Extract the chuck holding bush complete of bearing from the head central body.

Fig. 132


• Fit the supporting tool on the chuck holding shaft and tighten three Allen screws in the hole using the 3 mm Allen wrench.

Fig. 133

• Fit the supporting tool locked in this way on the bearing by a vice.

Fig. 134

• Using the 40-42 hook wrench, loosen and remove the bearing locking ring-nut.

Fig. 135


• Remove the O-ring.

Fig. 136

• Extract the central bearing from the chuck holding shaft.

Fig. 137

Upon mounting the chuck holding shaft, distribute a substance of medium strength thread locker on the coupling threads of the chuck holding shaft and of the head central body.


F3.6.4 GASKET OVERHAUL

F3.6.4.1 SEALING RING OVERHAUL

To remove the sealing ring, proceed as follows:


Fig. 138• Remove the lower magnetic ring. (See sub-

chapter F3.6.2.2 PREPARATION FOR MAGNETIC RING OVERHAUL page 112 and the sub-chapter page F3.6.2.3 R E M O V I N G OF LOWER MAGNETIC RING page 115).

• Using a ring-nut disassembly wrench, unscrew and remove the magnet holding ring-nut.

Fig. 139 The magnet holding ring-nut thread is counter-clockwise.

Fig. 140


• After the ring-nut has been removed, remove the seal ring

Fig. 141

F3.6.4.2 REMOVING OF THE O-RINGS

To remove the O-rings, proceed as follows:


Fig. 142

• Using a screwdriver or suitable tool, remove the O-ring from the magnets adjustment ring-nut.

Fig. 143


• Remove the upper magnetic ring. (See sub-chapter F3.6.2.2 PREPARATION FOR MAGNETIC RING OVERHAUL page 112 and the sub-chapter page F3.6.2.4 R E M O V I N G OF UPPER MAGNETIC RING page 116).

• Insert the head central body in a vice with soft jaws.

Fig. 144

• Using a compasses wrench, unscrew and remove the bearing external ring-nut.

Fig. 145

• Extract the chuck holding bush complete of bearing from the head central body.

Fig. 146


• Fit the supporting tool on the chuck holding shaft and tighten three Allen screws in the hole using the 3 mm Allen wrench.

Fig. 147

• Using the 40-42 hook wrench, loosen and remove the bearing locking ring-nut.

Fig. 148

• Using a screwdriver or suitable tool, remove the O-ring from the chuck holding shaft.

Fig. 149


F3.6.5 REMOVING OF BUSH FOR DOWEL

When it is necessary remove the bushes, proceed as follows:


Fig. 150• Remove the dowel bush pulling it out from the

dowel.

Fig. 151• Re-install the bush caring to position it correctly,

with the most curved side facing the head inner side.

The dowel bushes must be both replaced in the same intervention period.

Fig. 152


F3.6.6 REMOVING OF BELLOWS COUPLING

When it is necessary remove the bellows coupling, proceed as follows:



Fig. 153• Using a rounded tip tool, slide out the bellows

coupling.

Fig. 154

Fig. 155


F3.6.7 PARTS LUBRICATION

Since it is objectively difficult to express an amount of lubricant to be laid with a brush, with "stroke" refers to the amount of grease that is retained, plunging up to half the bristles of a brush number 8 off about 10 mm high 18 mm bristle.

For the lubricant reference, see sub-chapter C8.3 TYPES OF LUBRICANTS page 46.

Use lubricant "K" type.

• Clean the springs and using a brush apply a layer of lubricant on all the coils.

Fig. 156• Using a brush apply a layer of lubricant on the

inside of the head upper bush.

• Using a brush apply a layer of lubricant on the dowel bushes.

Fig. 157• Clean the bearing and using a brush, apply a

layer of lubricant on all surfaces.

Fig. 158


• Clean the magnetic rings and using a brush, apply a layer of lubricant on all surfaces.

Fig. 159

• Clean inside and outside the head central body; using a brush, apply a layer of lubricant inside and outside.

Do not lubricate the internal thread of the head central body.

Fig. 160

• Clean the release seats of the head central body; using a brush, apply a layer of lubricant inside the seats.

Fig. 161


• Clean the magnets holder ring-nut; using a brush, apply a layer of lubricant inside the ring-nut.

Fig. 162

• Clean the slotted ring-nut; using a brush, apply a layer of lubricant inside the ring-nut.

Fig. 163

• Using a brush apply a layer of lubricant on the bearing holding seat and seling ring holding seat of the chuck holding shaft.

Fig. 164


• Using a brush apply a layer of lubricant on the inside of the bearing blocking ring-nut.

Fig. 165

• Using a brush apply a layer of lubricant on the thread of the magnet holding ring-nut.

Fig. 166


F3.6.8 CLOSURE HEAD INSTALLATION

Remount, proceeding inversely to that described for disassembly.

Before reassemble the closure head, clean and grease all components.

F3.6.8.1 MOUNTING OF THE ADJUSTMENT RING-NUTS

In order to get the same torque as the one set before the maintenance operation when the head is restored, the head must be installed aligning correctly the references etched on the parts to be matched. Only after the components have been correctly matched the torque value can be adjusted by setting the one noted at the operation start.

For the correct mounting, operate as follows:

• screw the magnet adjustment ring-nut till its upper edge coincides with the horizontal reference engraving shaped as an overturned T made on the head central body.

Fig. 167• Align the vertical engraving with the engraving

"0" of the magnet adjustment ring-nut.

Fig. 168


• Fit the slotted ring-nut on the head central body so that the torque indication of 16 LBSxin engraved on the ring nut is aligned with the engraving "0" of the magnet adjustment ring nut.

Fig. 169

• Lower the slotted ring-nut till its inner teeth totally mesh with the outer teeth of the magnet adjustment ring-nut.

Fig. 170


F4 "PKSG-EE" CLOSURE CHUCK

BEFORE CARRYING OUT ANY MAINTENANCE OPERATIONS, the machine must be in safety conditions to avoid untimely screwing and/or electrocution. See "use and maintenance" manual of the monoblock, to proceed to status maintenance.

F4.1 MAIN COMPONENTSLegend:

• 1 Spheres protecting lid

• 2 Cone

• 3 Ejector driving ring

• 4 Chuck release device

Fig. 171

F4.2 TOOLS FOR THE REMOVAL AND MAINTENANCE

In the table below are shown the necessary tools for disassembly and maintenance of the closure chuck.TOOL INCLUDED

Hexagonal wrench 30 mm YES

Wrench for pin YES

Snap ring pliers NO


F4.3 REMOVAL AND INSTALLATION

F4.3.1 REMOVAL

To remove the closure chuck, operate as follows:

• fully press upward the caps release ring. The release locking spheres, during the lifting, fall within inside the extraction seat.

Fig. 172

Fig. 173• Remove downwards the closure chuck.

Fig. 174


F4.3.2 INSTALLATION

To install the closure chuck, proceed as follows:

• Insert the chuck into its seat on the head.

Fig. 175

• Push up the chuck until fully seated.

Check that the closure chuck is properly locked on the head.

Fig. 176


F4.4 CLEANING OF THE CLOSURE CHUCK

Hereinafter are described the indications for the cleaning of the chuck.

To keep a correct cleaning of the chuck it is allowed to carry out cleaning to remove from the components eventual dusts and product residuals.

It is allowed to use the following foaming products:


1 ÷ 2 [%] 35 12 ÷ 13


1 ÷ 2 [%] 35 1 ÷ 2


1 ÷ 2 [%] 35 1 ÷ 2


1 ÷ 2 [%] 35 2 ÷ 6


2000 ppm 60


Detergents residuals or residuals of liquids used for the cleaning of the closure chuck must be disposed according the laws in force of the country in which the chuck is used.

Do not use wadding or others inconsistent materials.

It is dangerous to use compressed air.


F4.5 MAINTENANCE AND OVERHAUL

F4.5.1 OVERHAUL OF THE CLOSURE CHUCK


F4.5.1.1 REMOVING OF THE O-RINGS AND SPHERES

To remove the O-rings and the spheres , proceed as follows:

• Using a pliers for elastic ring remove the cone lid blocking ring.

Fig. 177

Fig. 178• Pull out the cone protective cover.

Fig. 179


• Using a suitable tool (for example a screwdriver), remove the O-Rings (one or more depending on the type cap treated) from their seat.

If are damaged, replace the O-Rings.

If the O-rings are not damaged, replacing them has to happen from time to time as described in sub-section C6 PKSG-EE CLOSURE CHUCK WEARING PARTS page 37.

Fig. 180

Fig. 181

Removing the O-rings, the chuck spheres are free and can scatter.

Fig. 182


F4.5.1.2 REMOVING OF CHUCK RELEASE SPRING

For the removal of the chuck release cone, proceed as described below

• Fit the wrench for pin in the seat of the cone holding pin.

• Fit the hexagonal wrench in the seats of the closure chuck.

• Using the two wrenches, loosen the cone holding pin; if locked, it is sufficient to give a light stroke on the handle of the wrench for pin.

Fig. 183

• Slide out the complete chuck holding pin.

Fig. 184

• Slide out the chuck holding pin and pull out the cone release spring.

Removing the chuck holding pin, the release sphere are free and can scatter.

Fig. 185


F4.5.1.3 PARTS LUBRICATION

Since it is objectively difficult to express an amount of lubricant to be laid with a brush, with "stroke" refers to the amount of grease that is retained, plunging up to half the bristles of a brush number 8 off about 10 mm high 18 mm bristle.

For the lubricant reference, see sub-chapter C8.3 TYPES OF LUBRICANTS page 46.

Use lubricant "K" type.

• Using a brush apply a layer of lubricant on the release seat of the chuck holding pin.

Fig. 186




G PRODUCTION CHECKS


G1 CLOSURE APPLICATION DATA TABLETo facilitate the correct collection of the information on the closure, for example purposes only, is attached the table on the next page.

The user shall anyway refer to his own quality department and to the specifications given by the cap manufacturers, following them.

For the compilation of attached table, proceed as follows:

• indicate in the table heading:

▫ the machine model

▫ the serial number

▫ the used container type

▫ the used cap type

▫ the set static torque

▫ the number of bottles per minute

▫ the type of compensating spring

▫ the ejector spring type

▫ the type of closure terminal

• indicate in the “data collection” table:

▫ the number of bottles relevant to the closure head taken at the exit of the capper

▫ the value indicated by the torquemeter checking each single bottle and, in the last column, the average value.

To adjust the closure heads, see the relevant sub-chapter.

Photocopy the table to get the number of modules required for collection of data over time.


CUSTOMER DATEMachine model Serial numberContainer dimensions Container TypeCap dimensions Caps TypeHead static torque Bottles/minCompensating spring kg. Gripper/chuck typeN° Head DETECTED TORQUE AVERAGE NOTES

Lbs x inch Lbs x inch Lbs x inch Lbs x inch Lbs x inch Lbs x inch123456789101112131415161718192021222324252627282930313233343536




H FAULTS AND REMEDIES


H1 INTRODUCTIONThe list of the faults in the following pages is useful to detect as fastest as possible their reasons and possible solutions.

The research and the interventions must be carried out methodically (from the most probable to the less probable reason) and in logical sequence.

Proceed by steps: a first intervention, a test on the obtained result, then passage to the next intervention.

The main machine units are:

• Closure unit

• Caps distribution


FAULT CAUSE REMEDY

Lifting or lowering the turret, the same does not move vertically.

Interference with the container conveying equipment, foreign matters in the lifting mechanism, other.

Identify the reason for the overload (interference with the container conveying equipment, foreign matters in the lifting mechanism, other).

The fastening screw of the sliding bush has not been loosened.

Loosen the fastening screw.

Min. or max. limit of turret vertical range reached.

Make sure the machine has been preset for the container size to be processed. If so contact Technical Assistance Service.


FAULT CAUSE REMEDY

The containers break in the closure step.

The turret is too low. Position the turret at the correct height for the container to be processed.

Container transfer equipment not suitable.

Replace the equipment with the one suitable for the size to be processed.

The cap screws badly on the bottle.

Closure chuck not exact. Use the closure chuck suitable for the cap to be processed.

Cap fragments in the closure chuck.

Remove the fragments from the closure chuck inside.

The rubber spheres seal ring on the closure chuck is worn.

Replace it with one of the correct size.

Bottle-neck guides not suitable for the bottle size to be processed.

Replace the guides in the next with those suitable for the bottle size to be processed.

Broken compensating spring. Replace the spring with a spare one.

For the replacement see the relative sub-chapter of the capping head.

Container threads/cap not compatible.

Check that the bottle to be processed and the used cap correspond exactly.


FAULT CAUSE REMEDY

The cap is not totally screwed. Insufficient magnetic torque. Increase the head tightening torque.

For the adjustment see the relative sub-chapter of the capping head.

The cap slips in the chuck. Verify the wear of the chuck and possibly replace it with a spare one.

Verify if the closure chuck is suitable for the cap to be processed, possibly replace it with a suitable one.

The bottles rotate around themselves.

Check the wear of the centering device teeth.

Closure head springs not working. Push the head body upwards. The elastic reaction of the compensating spring must be felt.

For the replacement see the relative sub-chapter of the capping head.

The cap is too much screwed. Excessive magnetic torque. Decrease the head tightening torque.

For the adjustment see the relative sub-chapter of the capping head.


FAULT CAUSE REMEDY

Problems in the cap distribution. The caps fall from the closure head.

The rubber spheres seal ring is worn or the ball seats are dirty.

Replace the worn parts and clean carefully by an air jet (do not use water or liquids).

The caps do not enter the closure heads.

Check the regular operation of the electro-pneumatic circuit.

Check the perfect alignment between transfer star-wheel and closure heads.

AROL S.p.A. - Viale Italia, 193 - 14053 CANELLI (AT) - ITALY - tel. +39 0141 820 500 - Fax +39 0141 820 555 - www.arol.it

Report of the trainingEdited by employer

TURRET AUTOMATIC ROTATING

modell: NEXT PK ASEPTIC ____________serial number: 13982

Manufacturing year 2014 _______________Constructor AROL S.p.A.

On day: ____________________________at the Company: ______________________

from hour ___________________________ to hour ______________________________ a training course concerning the use of quasi-machine has been held.

Trainer/s:

Mr. ________________________________

Mr. ________________________________

Mr. ________________________________

Mr. ________________________________

Mr. ________________________________

The subject dealt with are the ones included in the “Use and maintenance” manual enclosed to the quasi-machine.

Has been provided practical training on the turret:

YES NO

Attending the course:NAME JOB SIGNATURE

The Attendee's signature implies the understanding of the dealt with subjects.

Trainer/s signature/s:

Mr. ________________________________

Mr. ________________________________

Mr. ________________________________

Mr. ________________________________

Mr. ________________________________



Documents

uso manutenzione R2