TECHNICAL DOCUMENTATION

DOCUMENTATION TECHNIQUE

TECHNISCHE DOKUMENTATION

DOCUMENTACION TECNICA

DOCUMENTAÇÃO TÉCNICA

DOCUMENTAZ IONET E C N I C A

USER’S MANUAL

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ROTARY COMPRESSION MOLDING PRESS

CCM001

ENGLISH

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TABLE OF CONTENTS

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TABLE OF CONTENTS

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USER’S MANUAL

ROTARY COMPRESSION MOLDING PRESS

CCM001

MANUFACTURER

SACMI IMOLAVia Selice Provinciale, 17/A

40026 IMOLA (Bologna) - ITALIA

PUBLISHED ON

February 5, 2003 - December 11, 2003

VERSIONS

CCM001C

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TABLE OF CONTENTS

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TABLE OF CONTENTS

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Page1 GENERAL INFORMATION........................................................................................................................1 - 1

1.1 INTRODUCTION ....................................................................................................................1 - 11.2 WHERE TO KEEP THE MANUAL ........................................................................................ 1 - 11.3 HOW TO USE THE MANUAL ............................................................................................... 1 - 11.4 USERS OF THE MANUAL.................................................................................................... 1 - 11.5 WARRANTY ...........................................................................................................................1 - 21.6 SUPPLEMENTS.................................................................................................................... 1 - 21.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN

THE MANUAL ........................................................................................................................1 - 21.8 MACHINE IDENTIFICATION PLATE ................................................................................... 1 - 4

2 MACHINE FEATURES ............................................................................................................................. 2 - 12.1 MACHINE DESCRIPTION .................................................................................................... 2 - 12.1.1 MAIN DEVICES......................................................................................................................2 - 32.1.1.1 Plasticization unit .................................................................................................................. 2 - 32.1.1.2 Drive unit ............................................................................................................................. 2 - 102.1.1.3 Insertion drum unit .............................................................................................................. 2 - 112.1.1.4 Forming unit ........................................................................................................................ 2 - 132.1.1.5 Exit channel ......................................................................................................................... 2 - 162.1.1.6 Pneumatic system ............................................................................................................... 2 - 162.1.1.7 Hydraulic system ................................................................................................................. 2 - 162.1.1.8 Cooling system .................................................................................................................... 2 - 162.1.1.9 Electric system: control board ............................................................................................. 2 - 162.1.1.10 Tooling ................................................................................................................................. 2 - 162.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE .......................................... 2 - 182.2 OVERALL DIMENSIONS .................................................................................................... 2 - 192.3 TECHNICAL DATA ............................................................................................................. 2 - 262.3.1 SPECIFICATIONS .............................................................................................................. 2 - 262.3.2 OPERATIONAL CHARACTERISTICS ............................................................................... 2 - 272.3.3 AIRBORNE NOISE EMISSION LEVELS ............................................................................ 2 - 282.3.3.1 Sound pressure level (ISO/DIS 11202) .............................................................................. 2 - 282.3.3.2 Livello di potenza sonora (ISO 3746) ................................................................................. 2 - 282.4 DIAGRAMS ......................................................................................................................... 2 - 302.4.1 PNEUMATIC SYSTEM DIAGRAM ..................................................................................... 2 - 302.4.2 HYDRAULIC SYSTEM DIAGRAM ...................................................................................... 2 - 332.4.3 COOLING SYSTEM DIAGRAM .......................................................................................... 2 - 36

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Page3 SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 1

3.1 SAFETY DEVICES AND GUARDS ...................................................................................... 3 - 13.1.1 GENERAL SAFETY RULES ................................................................................................. 3 - 13.1.2 SAFETY DEVICES INSTALLED ........................................................................................... 3 - 13.1.2.1 Shutdown devices ................................................................................................................. 3 - 13.1.2.2 Indicating a shutdown ........................................................................................................... 3 - 13.1.2.3 Devices to safeguard the operator ........................................................................................ 3 - 13.1.2.4 Emergency stop buttons ........................................................................................................3 - 23.2 SAFETY RULES FOR HANDLING ........................................................................................3 - 33.2.1 LIFTING PROCEDURES ...................................................................................................... 3 - 33.2.2 HANDLING PROCEDURES ................................................................................................. 3 - 33.2.3 PLACING THE LOAD ........................................................................................................... 3 - 33.3 INSTALLATION ......................................................................................................................3 - 43.3.1 GENERAL RULES ................................................................................................................ 3 - 43.4 OPERATOR TRAINING ........................................................................................................ 3 - 53.4.1 END-USER.............................................................................................................................3 - 53.4.2 OPERATORS ........................................................................................................................ 3 - 53.4.3 MAINTENANCE STAFF ........................................................................................................ 3 - 53.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING

THE MACHINE...................................................................................................................... 3 - 63.5.1 GENERAL SAFETY RULES ................................................................................................. 3 - 63.5.2 GUIDELINES FOR OPERATION AND MAINTENANCE ..................................................... 3 - 73.5.2.1 Risks deriving from high temperatures ................................................................................. 3 - 73.5.2.2 Risk of explosion ....................................................................................................................3 - 73.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED ............................................3 - 83.6.1 GENERAL ............................................................................................................................. 3 - 8

4 INSTALLATION ........................................................................................................................................ 4 - 14.1 SHIPPING AND HANDLING ................................................................................................. 4 - 14.2 POSITIONING ........................................................................................................................4 - 44.3 CONNECTIONS AND HOOK UPS ........................................................................................4 - 54.3.1 CONNECTING THE EXTRUDER TO THE PRESS ............................................................. 4 - 54.3.2 HYDRAULIC CONNECTION: FROM THE POWER UNIT TO THE PRESS ....................... 4 - 64.3.3 HOOKING UP THE COOLANT SYSTEM............................................................................. 4 - 74.3.4 HOOKING UP THE PNEUMATIC SYSTEM ..........................................................................4 - 84.3.5 ELECTRIC HOOK UP ........................................................................................................... 4 - 9

5 START UP ............................................................................................................................................... 5 - 15.1 INTRODUCTION ....................................................................................................................5 - 15.2 PRELIMINARY CHECKS ...................................................................................................... 5 - 15.3 CHECKING OPERATION ......................................................................................................5 - 25.4 PRELIMINARY OPERATIONS ............................................................................................. 5 - 35.5 STARTING THE AUTOMATIC CYCLE .................................................................................5 - 45.6 SUBSEQUENT START UPS .................................................................................................5 - 4

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Page6 OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1

6.1 CONTROL AND MONITORING UNIT .................................................................................. 6 - 16.2 STARTING AND STOPPING THE MACHINE ...................................................................... 6 - 46.3 AUTOMATIC CYCLE .............................................................................................................6 - 56.4 PRODUCTION CYCLE ......................................................................................................... 6 - 66.5 EMERGENCY CYCLES AND RESET OPERATIONS ..........................................................6 - 96.5.1 ACTUATOR DOWNSTROKE CONTROL ............................................................................ 6 - 96.5.2 ACTUATOR UPSTROKE / BROKEN ROD CONTROL ..................................................... 6 - 106.5.3 DOUBLE PRODUCT DETECTION ..................................................................................... 6 - 116.5.4 EMPTY DIE CONTROL ...................................................................................................... 6 - 126.5.5 DETECTION OF PRODUCTS HEAVIER OF LIGHTER THAN NORMAL WEIGHT ......... 6 - 126.5.6 CORRECT POSITION FOR START OF FORMING CONTROL ........................................ 6 - 136.5.7 ACTUATOR UPSTROKE CONTROL ................................................................................. 6 - 136.6 PRODUCT SAMPLING ....................................................................................................... 6 - 14

7 ADJUSTMENTS ........................................................................................................................................ 7 - 17.1 PLASTICIZATION UNIT ........................................................................................................ 7 - 17.1.1 EXTRUDER........................................................................................................................... 7 - 17.1.2 METERING PUMP ................................................................................................................ 7 - 17.1.3 FEED TUBE ...........................................................................................................................7 - 27.1.4 BY-PASS SYSTEM ............................................................................................................... 7 - 27.2 INSERTION DRUM ............................................................................................................... 7 - 37.2.1 ADJUSTING THE PRE-LOAD OF THE DRUM’S CONNECTING ROD .............................. 7 - 37.2.1.1 Adjusting the drum’s connecting rod precharge ...................................................................7 - 37.2.1.2 Checking the drum’s connecting rod precharge ................................................................... 7 - 47.2.2 ADJUSTING THE CUTTER .................................................................................................. 7 - 47.2.3 ADJUSTING PELLET INSERTION TIMING ..........................................................................7 - 67.3 FORMING UNIT .................................................................................................................... 7 - 97.3.1 PRODUCT REMOVAL ADJUSTMENT .................................................................................7 - 97.3.2 ADJUSTING THE QUALITY CONTROL UNIT ................................................................... 7 - 107.4 PNEUMATIC SYSTEM ....................................................................................................... 7 - 127.5 HYDRAULIC SYSTEM ........................................................................................................ 7 - 127.5.1 ADJUSTING THE OIL FLOW UNDER LOW PRESSURE ................................................. 7 - 127.5.2 ADJUSTING THE FORMING STAGE (HIGH PRESSURE) ............................................... 7 - 127.5.3 ADJUSTING THE ACTUATOR DOWNSTROKE ............................................................... 7 - 127.6 COOLING SYSTEM ............................................................................................................ 7 - 147.7 INSTALLING AND REMOVING THE TOOLING ................................................................ 7 - 147.8 ADJUSTING THE EXIT CONVEYOR BELT ....................................................................... 7 - 167.9 REPLACING THE INDUCTIVE SENSORS ........................................................................ 7 - 177.10 RESETTING THE ENCODERS .......................................................................................... 7 - 17

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Page8 MAINTENANCE ........................................................................................................................................ 8 - 1

8.1 SCHEDULED MAINTENANCE ............................................................................................. 8 - 28.1.1 SCHEDULED MAINTENANCE CHART ............................................................................... 8 - 28.1.2 PERIODIC MAINTENANCE OPERATIONS ..........................................................................8 - 88.1.2.1 Drive unit ............................................................................................................................... 8 - 88.1.2.1.1 Checking the condition of the drive belts ...............................................................................8 - 88.1.2.1.2 Tensioning the forming unit transmission belts .................................................................... 8 - 88.1.2.1.3 Replacing the forming unit transmission belts ...................................................................... 8 - 88.1.2.1.4 Tensioning the insertion unit transmission belt ......................................................................8 - 88.1.2.1.5 Replacing the insertion unit transmission belt ...................................................................... 8 - 98.1.2.1.6 Checking the oil level in the forming unit’s geared motor ..................................................... 8 - 98.1.2.1.7 Changing the oil in the forming unit’s geared motor ............................................................. 8 - 98.1.2.2 50 kg/h Extruder .................................................................................................................. 8 - 118.1.2.2.1 Overhauling the extruder auger .......................................................................................... 8 - 118.1.2.2.2 Checking the oil level in the extruder geared motor and topping up .................................. 8 - 128.1.2.2.3 Changing the oil in the extruder geared motor ................................................................... 8 - 128.1.2.2.4 Cleaning the nozzle ............................................................................................................. 8 - 128.1.2.2.5 Checking and setting pressure transducers BP1 and BP2................................................. 8 - 148.1.2.3 100 kg/h Extruder ................................................................................................................ 8 - 168.1.2.3.1 Overhauling the extruder auger .......................................................................................... 8 - 178.1.2.3.2 Checking the oil level in the extruder geared motor and topping up .................................. 8 - 188.1.2.3.3 Changing the oil in the extruder geared motor ................................................................... 8 - 188.1.2.3.4 Cleaning the polymer metering pump ................................................................................. 8 - 188.1.2.3.5 Replacing/overhauling the polymer metering pump ........................................................... 8 - 188.1.2.3.6 Lubricating the universal joint ............................................................................................. 8 - 198.1.2.3.7 Cleaning the nozzle ............................................................................................................. 8 - 198.1.2.3.8 Checking and setting pressure transducers BP1 and BP2................................................. 8 - 198.1.2.3.9 Checking the condition and tensioning the extruder drive belt ........................................... 8 - 218.1.2.3.10 Tensioning the extruder drive belt ....................................................................................... 8 - 218.1.2.3.11 Replacing the extruder drive belt ........................................................................................ 8 - 218.1.2.3.12 Lubricating the extruder motor’s bearings .......................................................................... 8 - 218.1.2.4 150-200 kg/h Extruder ......................................................................................................... 8 - 228.1.2.4.1 Overhauling the extruder auger .......................................................................................... 8 - 238.1.2.4.2 Checking the oil level in the polymer metering pump geared motor and topping up ......... 8 - 248.1.2.4.3 Changing the oil in the polymer metering pump geared motor .......................................... 8 - 248.1.2.4.4 Checking the oil level in the extruder thrust block and topping up ..................................... 8 - 248.1.2.4.5 Changing the oil in the extruder thrust block ...................................................................... 8 - 258.1.2.4.6 Cleaning the polymer metering pump ................................................................................. 8 - 258.1.2.4.7 Replacing/overhauling the polymer metering pump ........................................................... 8 - 258.1.2.4.8 Lubricating the universal joint ............................................................................................. 8 - 268.1.2.4.9 Cleaning the nozzle ............................................................................................................. 8 - 268.1.2.4.10 Checking and setting pressure transducers BP1 and BP2................................................. 8 - 268.1.2.4.11 Setting pressure switch SP8 and pressure relief valve YV8 .............................................. 8 - 288.1.2.5 Insertion drum ..................................................................................................................... 8 - 308.1.2.5.1 Sharpening the blades ........................................................................................................ 8 - 308.1.2.5.2 Replacing the blades ........................................................................................................... 8 - 308.1.2.5.3 Cleaning the cutters ............................................................................................................ 8 - 308.1.2.5.4 Replacing the cutters .......................................................................................................... 8 - 308.1.2.5.5 Cleaning the nozzles ........................................................................................................... 8 - 308.1.2.5.6 Replacing the nozzles ......................................................................................................... 8 - 328.1.2.5.7 Cleaning the compressed air distributor ............................................................................. 8 - 328.1.2.5.8 Replacing the compressed air distributor ........................................................................... 8 - 328.1.2.5.9 Checking the pre-load of the drum’s connecting rod .......................................................... 8 - 328.1.2.5.10 Adjusting the pre-load of the drum’s connecting rod .......................................................... 8 - 328.1.2.5.11 Replacing pulley A .............................................................................................................. 8 - 328.1.2.5.12 Removing cogged wheel B ................................................................................................. 8 - 348.1.2.5.13 Replacing cogged wheel C ................................................................................................. 8 - 348.1.2.5.14 Removing pulley D .............................................................................................................. 8 - 34

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Page8.1.2.5.15 Replacing toothed belt E ..................................................................................................... 8 - 368.1.2.5.16 Tensioning belt E ................................................................................................................ 8 - 368.1.2.5.17 Lubricating the gears ........................................................................................................... 8 - 368.1.2.6 Forming unit ........................................................................................................................ 8 - 388.1.2.6.1 Cleaning .............................................................................................................................. 8 - 398.1.2.6.2 Overhauling the actuator valve ........................................................................................... 8 - 398.1.2.6.3 Greasing the roller ............................................................................................................... 8 - 398.1.2.6.4 Replacing the hydraulic actuator gasket ............................................................................. 8 - 398.1.2.6.5 Replacing the upper flange gaskets .................................................................................... 8 - 408.1.2.6.6 Replacing the lower flange gaskets .................................................................................... 8 - 408.1.2.6.7 Greasing the roller and stripper rod pin .............................................................................. 8 - 418.1.2.6.8 Lubricating the stripper rod guide bushes ........................................................................... 8 - 418.1.2.6.9 Greasing the central tool wheel (optional) .......................................................................... 8 - 418.1.2.7 Cams ................................................................................................................................... 8 - 428.1.2.7.1 Greasing and checking ....................................................................................................... 8 - 438.1.2.7.2 Replacing the stripper cams (central movement) (optional) ............................................... 8 - 438.1.2.7.3 Replacing the stripper cams (side movement) ................................................................... 8 - 438.1.2.7.4 Replacing the actuator control cams .................................................................................. 8 - 438.1.2.7.5 Replacing the cams for injecting air in the punches ........................................................... 8 - 438.1.2.8 Rotary distributor ................................................................................................................. 8 - 448.1.2.8.1 Replacing the gaskets ......................................................................................................... 8 - 448.1.2.9 Hydraulic system ................................................................................................................. 8 - 448.1.2.9.1 Checking the oil level in the hydraulic power unit ............................................................... 8 - 468.1.2.9.2 Changing the oil in the hydraulic power unit ....................................................................... 8 - 468.1.2.9.3 Replacing the flexible coupling in the hydraulic power unit ................................................ 8 - 468.1.2.9.4 Replacing the filter in the hydraulic power unit ................................................................... 8 - 468.1.2.9.5 Checking the oil level in the hydraulic power unit for 150/200 kg/h extruders ................... 8 - 468.1.2.9.6 Changing the oil in the hydraulic power unit for 150/200 kg/h extruders ........................... 8 - 468.1.2.9.7 Replacing the flexible coupling for the 150/200 kg/h extruder motor-pump unit ................ 8 - 468.1.2.9.8 Replacing the filter in the hydraulic power unit for the 150/200 kg/h extruder ................... 8 - 468.1.2.9.9 Cleaning control valve Pb ................................................................................................... 8 - 478.1.2.9.10 Cleaning control valve Ph ................................................................................................... 8 - 478.1.2.9.11 Cleaning solenoid control valves Pb and Ph ...................................................................... 8 - 478.1.2.9.12 Checking for condensate on the bottom of the tank ........................................................... 8 - 478.1.2.9.13 Checking the accumulator’s precharge .............................................................................. 8 - 478.1.2.10 Air supply system ................................................................................................................ 8 - 488.1.2.10.1 Cleaning the filter ................................................................................................................ 8 - 488.1.2.10.2 Cleaning and replacing the silencers .................................................................................. 8 - 488.1.2.11 Cooling system .................................................................................................................... 8 - 498.1.2.11.1 Checking the coolant level .................................................................................................. 8 - 498.1.2.11.2 Adding coolant .................................................................................................................... 8 - 498.1.2.11.3 Cleaning the filters .............................................................................................................. 8 - 498.1.2.11.4 Changing the coolant .......................................................................................................... 8 - 498.1.2.12 Safety devices ..................................................................................................................... 8 - 508.1.2.12.1 Checking the efficiency of the safety devices ..................................................................... 8 - 508.1.2.13 Air injection device .............................................................................................................. 8 - 518.1.2.13.1 Checking the valves ............................................................................................................ 8 - 518.1.2.13.2 Replacing the valves ........................................................................................................... 8 - 518.1.2.14 Product exit conveyor belt ................................................................................................... 8 - 528.1.2.14.1 Replacing the conveyor belt ................................................................................................ 8 - 528.1.2.14.2 Cleaning the counter photocell ........................................................................................... 8 - 528.1.2.14.3 Cleaning the slots in the exit conveyor belt slide surface ................................................... 8 - 528.1.3 LUBRICATION .................................................................................................................... 8 - 548.1.3.1 Lubricant specifications ....................................................................................................... 8 - 548.1.4 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS.................................................. 8 - 558.2 TROUBLESHOOTING ........................................................................................................ 8 - 56

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Page9 DECOMMISSIONING ................................................................................................................................ 9 - 1

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GENERAL INFORMATION 1

1 GENERAL INFORMATION

1.1 INTRODUCTION

E0004PWARNING!

Carefully read the entire User’s Manual before working on the machine and/or the packaging of the various parts.This manual contains important information for safeguarding the operators, the maintenance staff as well as themachine itself.SACMI reserves the right to make changes to the machine and in the manual without giving prior notice.Copyright. All rights reserved. Unauthorized reproduction can result in civil damages and criminal prosecution on thepart of SACMI.The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,reproduced, disclosed or transferred.Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.

1.2 WHERE TO KEEP THE MANUAL

E0004PWARNING!

This manual is to be considered an essential part of the machine and must be kept along with it even if the machineis sold. Always keep the manual near the machine where it can be easily consulted. The manual must always be athand so that the operator and maintenance staff are able to consult it rapidly at any time.

1.3 HOW TO USE THE MANUAL

The lay out of this manual allows it to be easily consulted as all the information and instructions provided are groupedtogether and divided into chapters and paragraphs. The user has to simply refer to the table of contents.The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to theoperator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols andare written in italics, as shown below.

E0004PIMPORTANT!

Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must be carefully read in its entirety several times as itcontains important information and warnings regarding safety.

1.4 USERS OF THE MANUAL

In this manual the machine operators are categorized as follows:- Operator: this is the person responsible for supervising and operating the machine.- Routine maintenance men.For a more detailed description, see the OPERATOR TRAINING paragraph in chapter 3 - SAFETY EQUIPMENT ANDPRECAUTIONS.

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1 GENERAL INFORMATION

1.5 WARRANTYSACMI shall be held responsible only for the machine as it was configured at the time of delivery.Any operations that alter the configuration of the machine or operating cycle must be carried out by SACMI personnelor duly authorized by SACMI S Engineering Dept.SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.

E0004PATTENTION!

The machine operator or maintenance staff are not responsible for carrying out operations under warranty, specialmaintenance and repairs. These operations are to be performed only by the manufacturers specially trainedtechnicians. For this reason, these operations are not dealt with in this manual.

1.6 SUPPLEMENTSInformation regarding the electric and electronic components of the machine is given in four handbooks provided underseparate cover, entitled:- USE OF THE MICROPROCESSOR CONTROL SYSTEM (Instructions B manual)- DESCRIPTION OF THE ELECTRONIC CARDS- LIST OF DEVICES

These handbooks are supplied with this manual.

1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THEMANUAL

DANGER SYMBOLS

E0004General hazard

E0002Danger of being burnt on hot surfaces

E0003Danger of hands being crushed

E0007High tension. Risk of electrical shock

E0011Risk of entanglement, amputation

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GENERAL INFORMATION 1

E0010Risk of entanglement in moving parts

E0017Risk of falling

E0035PRisk of explosion

E0015Keep a safe distance away

WARNING SIGNS

E0001Do not lubricate or work on moving parts under any circumstances

E0034D

O2

Do not use oxygen to recharge the accumulators

ALERT SYMBOLS

E0005Always wear heavy duty work gloves

E0006 Machine must be connected to an effectively grounded power point

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1 GENERAL INFORMATION

1.8 MACHINE IDENTIFICATION PLATE

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MACHINE FEATURES 2

2 MACHINE FEATURES

2.1 MACHINE DESCRIPTION

The CCM series of hydraulic presses is specially designed to produce thermoplastic products by means ofcompression.A continuous work-cycle is carried out during which plastic material is fed from an extruder, cut into suitably gaugedpellets and then inserted inside the dies. A hydraulic system is employed to close the dies at a pressure that can beregulated while the production cycle is being performed. The time required for cooling down is strictly related to thespeed at which the forming unit runs.

The machine basically consists of the following parts:

- Unit for plasticizing and extruding the material- Unit for inserting the plastic pellets- Forming unit- Electrical cabinet with control system for the production cycle- Pneumatic system- Hydraulic system- Temperature control system

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2 MACHINE FEATURES

128 105 9

Figure 2.1 - OVERALL VIEW1

7

14

6

41311 3 2

1 Extruder2 Metering pump3 Feed tube4 By-pass system5 Drive unit6 Insertion drum7 Forming unit

8 Pneumatic system9 Hydraulic system10 Cooling system11 Electrical cabinet12 Tooling13 Control panel14 Exit channel

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MACHINE FEATURES 2

2.1.1 MAIN DEVICES

2.1.1.1 Plasticization unit

The function of this unit is to melt down the plastic compound and then push it out through the nozzles. The temperatureand flow rate of these operations are controlled. The unit includes an extruder (1), metering pump (2), a heated feedtube (3) and a by-pass system (4). In order to compensate for any thermal expansion and to allow maintenance to be carried out the unit is mounted ontracks.According to how they are installed the tracks may allow the extruder to be removed lengthwise or crosswise.The machine may be equipped with various extrusion devices, depending on the flow rate required for the plasticmaterial.

Figure 2.1.1.1 - PLASTICIZATION UNIT

1 Extruder2 Metering pump3 Feed tube4 By-pass system

1

3

4

2

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2 MACHINE FEATURES

ExtruderThe extruder melts down the plastic compound and homogenizes it with any colorings and lubricants that may havebeen added.The granular material is let in through a hopper (1) and is pushed into the cylinder (2) by the auger (3) through thevarious thermal conditioning zones. The auger is driven by a geared motor (4) or by a hydraulic motor. The zones aresupplied with heating elements and electric cooling fans. The temperature in each individual zone is measured bythermocouples provided for this purpose.

Figure 2.1.1.1/A - 50 kg/h EXTRUDER

1 Hopper2 Cylinder3 Auger4 Extruder gearbox

T1701

2

1

3

4

T1701

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MACHINE FEATURES 2

Figure 2.1.1.1/B - 100 kg/h EXTRUDER

1 Hopper2 Cylinder3 Auger4 Extruder gearbox

T1544

2

1

3

4

T1544

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2 MACHINE FEATURES

T1702

Figure 2.1.1.1/C - 150/200 kg/h EXTRUDER

1 Hopper2 Cylinder3 Auger4 Hydraulic motor5 Motor-pump unit6 Tank

1

3

4

2

6

5

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MACHINE FEATURES 2

7

1

2

M8

BP2

6

EH7

BT7

BP1

EH7

Metering pumpThe metering pump controls the flow of the melt and determines the weight of the pellets. The material enters the pumpcasing (1) (heated by elements EH7) through a suction flange (6) and is pushed by suitable gears (2) (driven by gearedmotor M8) towards a delivery flange (7). The latter then sends the material to the feed tube.The pressures of the suction and delivery lines of the material is controlled by transducers BP1 and BP2. The pumptemperature is controlled by thermocouple BT7.

NOTEThe metering pump is not provided in the 50 kg/h extruder.

Figure 2.1.1.1/D - METERING PUMP

1 Pump body2 Gears6 Suction line7 Delivery lineBP1 Sensor, Suction pressureBP2 Sensor, Delivery pressureBT7 ThermocoupleEH7 Heating elementM8 Geared motor

T2489

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2 MACHINE FEATURES

2

EH8

Feed tubeThis carries the melt from the metering pump to the by-pass system. The melt enters through a flange (1) and is fedto the by-pass unit. While traveling along the path, the material is kept at a constant temperature by heating elementsEH8. The temperature is measured by thermocouple BT8.In some cases, the feed tube can be supplied with a mixer which sees that the characteristics and temperature of themolten material are homogenous.The mixer (2) is kept at a constant temperature thanks to heating element EH9. The temperature is measured bythermocouple BT9.

Figure 2.1.1.1/E - FEED TUBE

1 Flange2 MixerBT8 ThermocoupleBT9 ThermocoupleEH8 Heating elementEH9 Heating element

EH9

1

BT8

BT9

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MACHINE FEATURES 2

Figure 2.1.1.1/F - BY-PASS SYSTEM

1 Flange3 Extruder nozzle4 Discharge outlet5 Diverter6 Pneumatic cylinderBT15 Body thermocoupleBT16 Nozzle thermocoupleBT17 Molten material thermocoupleEH15 Heating elementEH16 Heating element

By-pass systemThe by-pass system is used to either feed the insertion unit or discharge the material into the waste container. Themelt is fed through a flange (1) and can either be carried to a nozzle (3) where it is extruded or to the discharge outlet(4), depending on the position of the diverter (5). The latter is driven by a pneumatic cylinder (6). While traveling alongthe path, the material is kept at a constant temperature by heating elements EH15 and EH16. The temperature ismeasured by thermocouples BT15 and BT16 while the temperature of the melt is measured by probe BT17.

3

BT16

1

4BT15

5

6

BT17

EH16

EH15

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2 MACHINE FEATURES

T1495

3

48

5

1 Nut2 Handwheel3 Toothed belt4 Tensioner assembly5 Drain cock6 Oil filler7 Level indicator8 Set screw9 ScrewM9 Epicyclic geared motor

2.1.1.2 Drive unitThe drive unit transmits motion to the entire machine.This unit includes a epicyclic geared motor M9 mounted on the vertical axis, a handwheel (2) to carry out operationsin manual mode, a cogged belt (3) that drives the forming unit and a tension unit (4) that controls the tension of thebelt. A cock for draining oil (5), a filler and breather plug (6) and a level indicator (7) are also provided.

Figure 2.1.1.2 - DRIVE UNIT

76

M9

2

1

9

T1495

002AZ005A

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MACHINE FEATURES 2

2.1.1.3 Insertion drum unit

The insertion drum unit has the dual function of cutting and placing the plastic pellets in the cavities of the forming drumand transferring the finished product onto the exit conveyor belt. The unit basically consists of the following parts:

Drive unitThe drive unit (1), secured beneath the insertion drum mount, is driven by a pulley (2) keyed to the forming unit. Motionis transmitted to the pinion (3), keyed to the transmission shaft, through a cogged belt (4). In addition, a roller (33) thattensions the belt is also provided.A torque limiter (22) and encoder (6) are mounted on the drive shaft. The latter records information regarding the workposition of the machine and sends it to the microprocessor based system.

SupportThe support (10) is mounted on the base of the machine and is used to hold the pivot unit and insertion drum.A drive shaft is located inside the support. The latter transmits motion from the drive pulley to the pivot unit of theinsertion drum.

Drum unit pivot pointThe pivot point (9) of the insertion drum unit is located over the support (10). This unit allows the insertion drum (21)to move in and out of its work position inside the forming unit. Rotation around the pivot point is controlled by apneumatic cylinder (11).A connecting rod (13) acts as a support to hold up the insertion unit. The pulley (30) of the drive shaft transmits motionto a wheel (32) by means of a belt (15). The latter is kept taut by a tensioner (14). The wheel (32) drives another wheel(31) in the insertion drum. Solenoid valve YV33 controls the jets of air blown to insert the pellets inside the cavities ofthe forming unit.Air ducts (19 and 20) for inserting the pellets and ejecting the ones that have not been inserted are machined in theconnecting rod.

Drum unitThe insertion drum basically cuts and picks up the plastic material being pushed out of the extruder nozzle by meansof cutters (23) and then deposits the pellets in the cavities of the forming unit. In addition, this unit is used to transferthe finished products onto the exit conveyor belt by means of stripper wheels (16 and 17).The wheel (32) and shaft (25) drive a disc (21) on which a number of cutters (23) are installed. Each cutter includesan insertion nozzle (23A), a body (23B) and a blade (23C) held in place with screw 23D.The air ducts for inserting (19) and ejecting (20) the pellets run through the connecting rod (13) leading to a distributor(24) located under the rotary disk (21). This set-up ensures that air is delivered to each cutter (23).

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2 MACHINE FEATURES

13 Connecting rod14 Tensioner15 Toothed belt16 Stripper wheel17 Stripper wheel18 Screw19 Air duct for pellet insertion20 Air duct for pellet ejection21 Insertion drum unit disk22 Torque limiter23 Cutter23A Insertion nozzle23B Body

T2972T2973T2974

YV33 Solenoid valve1 Drive unit2 Forming unit pulley3 Drive unit pinion4 Toothed belt5 Screw6 Encoder7 Adjustment screw8 Nut9 Drum pivot point10 Support unit11 Air cylinder12 Screw

Figure 2.1.1.3 - INSERTION DRUM UNIT

23C Blade23D Screw24 Distributor25 Shaft26 Screw27 Flange28 Support29 Back-plate31 Wheel32 Wheel33 Tensioner roller.

19 13 9

20

23A

23B

23C

23D

21 26 27 25 16 18 5 YV33 17 12

11

30321514

3124

7

28

29

10

842

6133

3

22

23

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MACHINE FEATURES 2

2.1.1.4 Forming unit(References given in figures 2.1.1.4/A and 2.1.1.4/B)The hydraulic actuators and dies are located in the forming unit. They are used to form, cool down and remove thepellets of molten plastic that are sent to them from the insertion drum. The finished product is then placed on the stripperwheel.The forming drum consists of a support shaft (1) on which the drum body (2) is mounted. Motion is transmitted fromthe drive unit to the shaft through a pulley (3) and belt (4).The upper (5) and lower (6) rotary distributors are found inside the body (2). The upper distributor delivers the coolingfluid to the upper tools and air to tools (12) while the lower one feeds the coolant to the lower tools and oil under pressureto the hydraulic actuators.The hydraulic actuators (8) are mounted on the lower body of the drum (7). A die (9) (lower) is provided with each ofthe actuators. These dies receive the pellets that are then formed and cooled down.The actuator (8) is hydraulically driven. The various stages of its movement are piloted by a ball valve (10), that ismounted next to the actuator itself.A duct (11), for the die’s (9) coolant, passes through the actuator’s rod. The upper dies (or punches) are part of thecartridge (12), which in turn, is mounted on the upper drum body (13). The relative rod (14), that drives the devicesused for stripping the product is found inside each cartridge. A fork (15), whose task is to act on the stripper, is keyedto the rod.The stripper rod (14) is controlled by a fixed cam (17) that acts on a roller (18) secured to the same rod (14).In addition, the machine is equipped with a number of pneumatic valves (25) so that the product can be removed byblowing air into the upper and lower dies. These valves send air under pressure to each tool (12).From the air supply system the compressed air first flows through an accumulator that keeps its pressure constant andthen through a ring that directs it to the valves (25). The latter are controlled by a cam. The air then reaches the flowcontrols found near the upper dies. Four pipes that cross the drum are used to send air to the lower dies. As a result,the upper ring is joined to the lower ring. A number of cam-controlled valves are mounted on the lower ring. These sendair to the die cavities.Two operations can be carried out to remove the product when some particular tools are installed (fig. 2.1.1.4/B). Thedie (12) is driven by both a stripper rod (14) and cam (21). The latter acts on a wheel placed in a central position inrelation to the die.The upper tools are cooled down by the coolant that runs through the duct (19).

Figure 2.1.1.4 - FORMING DRUM

1 Support shaft2 Drum body3 Pulley4 Belt5 Upper distributor6 Lower distributor7 Drum’s lower body8 Hydraulic actuators9 Die10 Actuator control valve11 Coolant duct (lower dies)12 Tool cartridge13 Upper drum body14 Stripper drive rod15 Fork17 Fixed cam18 Roller19 Coolant duct (upper dies)21 Cam25 Valve

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2 MACHINE FEATURES

T3004

A

A

Figure 2.1.1.4/A - FORMING DRUM525

12

13

17

19

15

9

8

2

7

10

6

18

144

1311

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MACHINE FEATURES 2

T3028

A

A

B

B

Figure 2.1.1.4/B - TOOL WITH CENTRAL DRIVE

21

17

12

13

19

15

9

2

7

10

6

14

18

254 13

8

5 25

11

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2 MACHINE FEATURES

2.1.1.5 Exit channel

The exit channel receives the product from the stripper wheel (16) (figure 2.1.1.3) and carries it in an orderly mannerto the zone where it is fed to the next machine in the production line.The conveyor belt (1) is driven by the motor (2) and kept taut by the tensioner (3).Any defective products are ejected on to the conveyor (4) through solenoid valve YV4.The button (5) is used to eject the products in order to check their state.

2.1.1.6 Pneumatic system

The pneumatic system includes a control unit that contains the air preparation elements (filters, pressure regulators,pressure switches, safety valves) and the control devices for the pneumatic actuators (i.e., solenoid valves).

2.1.1.7 Hydraulic system

The hydraulic system supplies the oil at a controlled pressure and flow rate that is used to drive the actuators of theforming drum.The hydraulic system basically consists of the following parts:- The hydraulic power unit that generates the oil flow required for operation and controls the oil pressure and

temperature. It also filters the oil. The hydraulic power unit is provided with a double inside gear pump that keepsthe noise level down and ensures a long service life.

- An oil flow control unit (mounted on the machine) that is fitted with two flow rate control valves provided with agraduated scale. In addition, a pressure control valve for the actuator’s return stroke is provided.

- A rotary distributor.- Ball control valves with relative actuators.- Ducts that run from the rotary distributor to the valves and related actuators are located inside the forming drum.

2.1.1.8 Cooling system

The cooling system is used to deliver coolant at a controlled temperature (refer to the data sheet for the values) to thefollowing parts:- hydraulic power unit’s water/oil exchanger- extruder- upper dies- lower dies- rotary distributorThe system includes a chiller (optional) which delivers the fluid at a low temperature to a thermal control unit thatprovides the flow of coolant. Each delivery is brought to a certain temperature and sent to the respective points of use.

2.1.1.9 Electric system: control board

All the information regarding the control board is given in chapter 6 - OPERATING INSTRUCTIONS and theInstructions B manual.

2.1.1.10 Tooling

The machine’s tooling is strictly related to the kind of product being handled as it includes the parts that come intocontact with the plastic material and form it.As these are size related parts, they are described in detail during the training sessions.Further specifications for the unit are given in the spare parts catalogue for the tools.

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MACHINE FEATURES 2

Figure 2.1.1.5 - EXIT CHANNEL

YV4 Solenoid valve1 Conveyor belt2 Motor3 Tensioner4 Conveyor5 Sample pick-up button6 Nut7 Screw

8 Screw9 Screw10 Casing11 Screw12 Screw13 Plate14 Support15 Slide surface16 Stripper wheel

T2978T2977

7

6138

10

9

3

YV4

14

4

5

2

76

1211

15

1

16

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2 MACHINE FEATURES

2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE

INTENDED USE OF THE MACHINEThe machine is specially designed and constructed to produce products that have the characteristics indicated in thespecifications.The machine operates safely if:- it is used under the conditions and within the limits prescribed and indicated in this paragraph- maintenance is performed at the intervals indicated in chapter 8 - MAINTENANCE- it is used properly by following the directions given in chapter 6 - OPERATING INSTRUCTIONS.

E0004PWARNING!

If the machine is remote controlled, suitable signs must be posted while the machine is running.

The machine can be run only in the following two modes:- manual- automaticUse the mode selector on the control panel to select the desired mode of operation

UNINTENDED AND PROHIBITED OPERATIONSThe machine must be used only for the tasks it was expressly designed for unless otherwise authorized by theManufacturer. The Manufacturer will not be held responsible for any personal injury or equipment damage caused byfailure to observe this safety precaution.

MISUSE OR ERRONEOUS USEThe manufacturer shall not be held responsible for any personal injury or property damage deriving fromincorrect and erroneous use of the machine. Generally speaking, the most common causes of incorrect use arelisted below:- personnel not adequately trained to perform the required operations- fatigue (above all during the night shift) or distraction- negligence caused by superficiality or wrong habits.Remember that the machine is to be controlled and run exclusively by expert well trained personnel who are able to:- correctly operate the machine under normal conditions- and face any emergencies, this is fundamental!

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MACHINE FEATURES 2

2200

1650

2100

W

1350

0-50

Y

5100

1000 500

3145

175

370

150

2370

600

5935

805

900

5165

3235

4600

140

300

1400

780

120

450

1326

1430630 725

X

1430

300

620

T3016

2.2 OVERALL DIMENSIONS

Figure 2.2/A - OVERALL DIMENSIONS WITH 50 kg/h EXTRUDER (CROSSWISE REMOVAL)

VOLT X Y W

380 - 415 - 440 2800 4870 /

220 - 480 3200 5270 2600

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2 MACHINE FEATURES

1650

2200

1350

0 -50

2100

W

5330

Y

3550

450

120

780

1900

300

Z

140

4600

3235

5760

900

6530

805

5935

600

2370

150

370

275

5001000

1430

300

620

X

1430630 725

T3017

Figure 2.2/B - OVERALL DIMENSIONS WITH 100 kg/h EXTRUDER (CROSSWISE REMOVAL)

VOLT X Y W

380 - 415 - 440 3600 5670 /

220 - 480 4000 6070 2600

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MACHINE FEATURES 2

T3018

Y

275

450

120

780

1900

300

Z

140

4600

3235

2000

1635 5760

2290

900

8165

805

5935

1260

600

2370

150

370

5001000

7490

1430

300

620

X

1430630 725

1650

2200

1350

0 -502

100W

Figure 2.2/C - OVERALL DIMENSIONS WITH 100 kg/h EXTRUDER (LENGTHWISE REMOVAL)

VOLT X Y W

380 - 415 - 440 3600 5670 /

220 - 480 4000 6070 2600

002AZ005A

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2 MACHINE FEATURES

6140

Y

982

120

780

1900

300

Z

140

450

360

3500

1175

6590445 3820 2325

810

910

905

350

540

5001000

3785

5780

1250

1430

300

620

140

X

1430630 725

2370

600

1720

2230

2100W

1380

0 -50

T3009

Figure 2.2/D - OVERALL DIMENSIONS WITH 150 kg/h EXTRUDER (CROSSWISE REMOVAL)

VOLT X Y W

380 - 415 - 440 3600 5680 /

220 - 480 4000 6080 2600

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MACHINE FEATURES 2

1720

1380

0 -50

2230

2100

W

Y

3100

1000 500

540

350

905

910

8102860

232538203830

9975

1175

3500

360

450

982

140

Z

300

1900

780

120

1250

2610

6305

9200

2370

600

1430630 725

140

X

1430

300

620

T3020

Figure 2.2/E - OVERALL DIMENSIONS WITH 150 kg/h EXTRUDER (LENGTHWISE REMOVAL)

VOLT X Y W

380 - 415 - 440 3600 6080 /

220 - 480 4000 5680 2600

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2 MACHINE FEATURES

1720

2230

1380

0 -50

W

2100

6670

Y

120

780

1900

300

Z

140

982

450

360

3500

1175

7115

970 3820 2325

810

910

905

350

3510

540

5001000

3785

6305

1250

1430

300

620

140

X

1430630 725

2370

600

T3021

Figure 2.2/F - OVERALL DIMENSIONS WITH 200 kg/h EXTRUDER (CROSSWISE REMOVAL)

VOLT X Y W

380 - 415 - 440 3600 5680 /

220 - 480 4000 6080 2600

002AZ005A

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MACHINE FEATURES 2

1720

2230

1380

0 -50

2100

W

9730

6305

2610

1250

1175

120

780

1900

300

Z

140

982

450

360

3500

1175

10500

4355 3820 2325

3385 810

910

905

3100

350

3510

540

5001000

Y

1430

300

620

140

X

1430630 725

2370

600

T3022

Figure 2.2/G - OVERALL DIMENSIONS WITH 200 kg/h EXTRUDER (LENGTHWISE REMOVAL)

VOLT X Y W

380 - 415 - 440 3600 5680 /

220 - 480 4000 6080 2600

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2 MACHINE FEATURES

2.3 TECHNICAL DATA

2.3.1 SPECIFICATIONSEXTRUDER kg/h

50 100 150 200PRODUCTION OUTPUT

Pieces/minute up to 600 600 600 600AIR

Required delivery rate (at 0.5 MPa) dm3/1' 450 450 450 450Consumption (at 0.5 Mpa) dm3/1' 200 200 200 200Minimum required pressure MPa 0.5 0.5 0.5 0.5Hose to air mains diameter mm 17 17 17 17

POWERThermal power to be dissipated kcal/h 22,000 28,000 36,000 42,000Power requirements (50 Hz) kVA 105 174 204 229Power for cable sizing (50 Hz) kVA 57 95 112 125Maximum electricity absorbed(50 Hz) kW 35 55 65 73Average electricity absorbed(50 Hz) kW 30 45 55 62

COOLANT (****)Demineralized water (***) 86% 86% 86% 86%Polypropylene glycol 10% 10% 10% 10%Syneco FTR-S protective fluid (**) 4% 4% 4% 4%Temperature 10°C 10°C 10°C 10°CPressure MPa 0.3 0.3 0.3 0.3Flow rate l/1' 90 115 145 168Average consumption (10°C) l/1' 75 95 120 140

PRODUCTType of plastic PP - HDPE - LDPETemperature of molten plastic up to 280°C 280°C 280°C 280°CDimensions and weights See product specificationsNumber of cavities 32 32 32 32Minimum speed of rotation rpm 8,5 8,5 8,5 8,5Velocità di rotazione massima rpm 18.75 18.75 18.75 18.75Forming cylinder stroke mm 115 115 115 115Maximum forming force kN 20 20 20 20Color change time min 25(*) 25(*) 25(*) 25(*)

(*) Approximate time, varies according to type of plastic and color.

(**) antibacterial product that prevents corrosion and incrustation

E0004PWARNING!

THIS IS NOT AN ANTI-FREEZE.EMPTY THE CIRCUIT COMPLETELY IF THE MACHINE IS SUBJECT TO TEMPERATURES BELOW 2 °C.

(***) Demineralized water with hardness less than 5 °F.

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MACHINE FEATURES 2

2.3.2 OPERATIONAL CHARACTERISTICS

TYPE OF PRODUCTThe machine can produce thermoplastic products whose dimensions have been previously agreed upon with SACMI’sEngineering Dept.

TYPE OF MATERIALThe machine can handle the following types of thermoplastic material:

- POLYPROPYLENE (PP)- POLYETHYLENE (HDPE;LDPE)

The machine is set up in a different way depending upon the material used. In addition, special parts may be required.A “Data Sheet” is provided with each machine on which the processing parameters for the selected material are given.In addition, this data can be stored and called up whenever the material handled is changed.

E0004PATTENTION!

If material that is not included on the data sheet (facsimile given below) is used, contact SACMI’s laboratory beforestarting processing.

PRODUCTION CAPACITYThe product output is strictly related to the type of object formed and material used.The maximum production output is given in the SPECIFICATIONS.

Figure 2.3.2 - PRODUCT CHARACTERISTICSThe dimensions given in the figure are for referencepurposes only and are not binding in any way.

MAX 600 PCS/m’MAX 3.3 Kg/1'

T1498

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2 MACHINE FEATURES

2.3.3 AIRBORNE NOISE EMISSION LEVELS

2.3.3.1 Sound pressure level (ISO/DIS 11202)

Test conditions- Operating conditions: trial run with material and 100 kg/h extruder- Type of operation: plastic cap production- Operating cycle: material feed and cap formation- Test environment: factory with reflecting flooring.

Instruments employedClass 1 instruments (IEC 804)

Values measured

LbA LpA LpC peak

P1 67.0 83.0 101.0

P2 66.6 81.0 98.0

P1 - Control post, measured at a height of 1.55 m from the floorP2 - Noisiest position of the ideal machine perimeter, measured at a distance of 1 meter from the surface of the

machineryLbA - Background noise level.LpA - Continuous A-weighted sound pressure level.LpC peak - Peak C-weighted instantaneous sound pressure level.

2.3.3.2 Livello di potenza sonora (ISO 3746)

Test conditions- Operating conditions: trial run with material and 100 kg/h extruder- Type of operation: plastic cap production- Operating cycle: material feed and cap forming- Test environment: factory with reflecting flooring.

Instruments employedClass 1 instruments (IEC 804)

Results

LpA = 80.3 dBA

LwA = 101.0 dBA

LpA = A-weighted sound pressure level in dB at surface of the machinery.

LwA = A-weighted sound power level.

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MACHINE FEATURES 2

Scheda di lavorazione Data Scheda n°Compilato da

CCM001A

(Data sheet) Date Sheet # Filled by

Cliente (Customer) Contratto (Contract)

Matricola (Serial Nr.) Versione di progr. (Program Nr.)

Capsula (Cap) Tipo (Type) Campionatura no. (Sampling #)

Tfondo (Tpanel) °C Tparete (Twall) °C

Tipo base ( Base type) Produttore (Manufacturer)

Plastica (Compound)Tipo master (Master type) Produttore (Manufacturer) %miscelata (%mixed) Reg. mescolatore (Mixer set)

Temperatura fuso (Melt.temperature) Indicativa (disp.) °C

Dosatore (Batching) Costruttore (Manufacturer) Articolo (Article) Matricola (Serial Nr.)

Estrusore (Extruder) Temp.1[°C] Temp.2[°C] Temp.3[°C] Temp.4[°C] Temp.5[°C] T.flangia[°C]

Pompa dosatrice

(Metering pump)

Temp.[°C] Pres.1[MPa] Pres.2[MPa]. Vel. (Speed) [%]

Grp. estrusione

(Extrusion unit)Tubo (Pipe)

Temp.[°C]

Miscelatore (Mixer) Temp .[°C]

Corpo ugello

(Nozzle.support)

Temp.[°C]

Ugello (Nozzle)Temp.[°C] Diametro (Diameter) [mm]

Tranciante

(Cutter holder)

Tipo (Type) Larghezza (Width) [mm] Altezza

coltello [mm]

Giostra dosatrice

(Insertion unit)Coltello (Cutter)

Tipo (Type) Fase meccanica [mm]

Soffio inserim.

(Insertion air jet)

Tipo (Type) Durata (Duration) Ritardo (Lag) Press. [MPa] (min 0.1 max 0.4)

Temperatura punzone

(Punch temperature)

°C (min 15 max40)

Termoregolatore

(Thermoregulator)

Temperatura cavità

(Die.temperature)

°C (min 15 max40)

Raffreddamento estr.

(Extruder cooling)

°C (min 15 max 40)

Frigorifero (Chiller)Tipo (Type)

Temperatura °C (min 8 max 18)

(Temperature)

Camma 1 di estrazione

(Stripper cam 1)

Codice (Code) Posizione (Position)

Camma 2 di estrazione

(Stripper cam 2)

Codice (Code) Posizione (Position)

Stampaggio

(Forming)

Pressione olio

(Hydraulic.pressure)

Alta (High) [MPa] Bassa (Low) [MPa] Rit. (Ret.)[MPa]

Regolazione portata

(Flow.rate regulation)

Alta (High) Bassa (Low)

Produttività

(Production)

Tappi/min (Caps/min)

Precarica

accumulatori

Alta (High) [MPa] Bassa (Low) [MPa] Rit. (Ret.)[MPa]

Iniezione aria

(air injection)

Lungh. Camma (Cam length) [mm] Press. [MPa] Posizione (Position) Cod.camma

NOTE (Notes)

(Cam code)

CCM001C

(Approximate)

(Flange temp.)

(Cutter height)

(Mechanical phase)

(Accumulator precharge)

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2 MACHINE FEATURES

2.4 DIAGRAMS

2.4.1 PNEUMATIC SYSTEM DIAGRAM(References given in figures 2.4.1/A and 2.4.1/B)

YV Solenoid valvesPA Air preparation

1 Filter and pressure regulator2 Pressure regulator, Pellet insertion3 Accumulator4 Pneumatic cylinder, Insertion drum movement5 Throttle7 Cylinder, By-pass movement9 Pressure regulator, Air injection in dies10 Pressure gauge11 Accumulator12 Injection valve, Upper dies13 Pressure gauge14 Injection valve, Lower cavitiesSP1 Pressure switch, Mains pressureSP7 Pressure switch, Machine air supplyYV3 Solenoid valve, Pellet ejectionYV4 Solenoid valve, Product rejectionYV6 Actuating solenoid valve, Insertion drum controlYV9 Solenoid valve, Air injection in diesYV17 Solenoid valve, Compressed air mainsYV23 Actuating solenoid valve, By-pass systemYV25/26 Actuating solenoid valve, Insertion unitYV33 Solenoid valve, Pellet insertion

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MACHINE FEATURES 2

2.4.1/A - AIR SUPPLY SYSTEM DRAWING

11

SP1

PA

SP7 YV17

1

2

3

10

YV33

YV4

YV34

5

YV6YV25/26

YV23YV9

9

12

EV

13

9

7

14

T3005

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2 MACHINE FEATURES

T3006

2.4.1/B - LAYOUT OF ELEMENTS IN THE AIR SUPPLY SYSTEM

YV33

T2944

13

10

29

12

T2983

YV4

YV9YV23 YV3

SP7 SP1

YV17

1

YV6

YV25/26

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MACHINE FEATURES 2

2.4.2 HYDRAULIC SYSTEM DIAGRAM(References given in figures 2.4.2/A and 2.4.2/B)

The hydraulic system is illustrated in block diagrams, each of which has a specific location in the machine

A Hydraulic power unit reservoir1 Suction filter2 High pressure pump3 Low pressure pump4 Oil filter5 Heat exchanger14 Gate, Oil drainBT10 ThermocoupleM1 Electric motorM4 Oil recirculation motorSL2 Sensor, Oil levelSP4 Pressure switch, Filter clogging

B Hydraulic control assembly6 Control valve, Low pressure7 Non-return valve, Low pressure circuit8 Non-return valve, High pressure circuit9 Pressure gauge, Low pressure10 Pressure gauge, High pressure11 Accumulator, High pressure12 Accumulator, Low pressure13 Control valve, High pressureSP6 Pressure switch, Low pressure presentYV21 Solenoid valve, Drain closure, High pressure circuitYV27 Solenoid valve, Drain closure, Low pressure circuit

C Flow control assembly15 Control valve, Pressure in actuator return circuit16 Restrictor, Drain circuit17 Gauge, Pressure in actuator return circuit18 Accumulator, Actuator return circuit19 Flow regulator, Low pressure circuit20 Flow regulator, High pressure circuit21 Rotary joint22 Actuator control valve23 Hydraulic actuatorYV30 Shut off solenoid valve, Actuator approach circuit

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2 MACHINE FEATURES

2.4.2/A - HYDRAULIC SYSTEM DIAGRAM

ABTR

B

A

C

23

22

21

16

1817

15

YV30

1920

1011

SP612 9

YV21 8

6

YV27

7

13

M1

3

2 1

4SP4

5M4

1

14

BT10

SL2

T

T2576

T2576

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MACHINE FEATURES 2

T3007

2.4.2/B - LAYOUT OF ELEMENTS IN HYDRAULIC SYSTEM

A1

B

B

A

21 16

23

22 14

11

12

M1

1920

15

17

YV30

12

11

SP6

YV27

6

13 9 10 M4

M1

BT10 5

YV21

SP4 4

A2

18

T2945

T2946 T2947

SL2

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2 MACHINE FEATURES

2.4.3 COOLING SYSTEM DIAGRAM(References given in figures 2.4.3/A and 2.4.3/B)

A ChillerB Temperature regulatorC PressD Hydraulic power unitE Plasticization unit

UI Lower toolsUS Upper tools

6 Heat exchanger8 Non-return valve9 Flow meter, Upper tools10 Flow meter, Lower tools11 Flow meter, Power unit13 Metering pump14 Extruder gearbox15 Extruder supply system16 By-pass valves17 Reservoir18 Flow meter, Distributor cooling

BT18 Thermocouple, Lower tools temperature controlBT19 Thermocouple, Upper tools temperature controlBT20 Thermocouple, Extruder and hydraulic power unit temperature controlEH18 Heating element, Lower tools temperature control circuitEH19 Heating element, Upper tools temperature control circuitEH20 Heating element, Extruder and hydraulic power unit temperature control circuitM18 Pump motor, Lower tools temperature controlM19 Pump motor, Upper tools temperature controlM20 Pump motor, Extruder and hydraulic power unit temperature controlSP2F Pressure switch, Lower tools cooling circuitSP3F Pressure switch, Upper tools cooling circuitSP9 Pressure switch, Distributor cooling circuitSP18 Differential pressure switch, Lower tools temperature controlSP19 Differential pressure switch, Upper tools temperature controlSP20 Differential pressure switch, Extruder and hydraulic power unit temperature controlYV5 Solenoid valve, Cooling system shut off, Metering pumpYV7 Solenoid valve, Cooling system shut off, Extruder and hydraulic power unitYV18 Solenoid valve, Exchanger shut off, Lower toolsYV19 Solenoid valve, Exchanger shut off, Upper toolsYV20 Solenoid valve, Exchanger shut off, Extruder and hydraulic power unitYV28 Solenoid valve, Cooling system shut off, Upper toolsYV29 Solenoid valve, Cooling system shut off, Lower toolsYV38 Solenoid valve, Heat exchanger water

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MACHINE FEATURES 2

2.4.3/A - LAYOUT OF ELEMENTS IN COOLING SYSTEM

DISTR.

A

TT

E

1514

T

B

13

DC

UI US

18

SP9

YV38

EH20EH19EH18

6

11

YV7

YV5

10 9

88SP2F

YV28YV29

SP3F

M R M R M R

17

16

BT18

SP18

YV18

16

BT19

SP19

YV19

16

SP20

BT20

YV20

T3008

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2 MACHINE FEATURES

T3014

YV5

2.4.3/B - LAYOUT OF ELEMENTS IN COOLING SYSTEM

E

B

D

C

C1

910

T2950

T1590

T2510

EH19

YV19

YV20

EH20

EH18

YV18

16

BT20

BT18

BT19

SP18

SP19

SP20

11

YV7

YV38

6

T3009

SP3F

SP2F

YV29

YV28

8

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SAFETY EQUIPMENT AND PRECAUTIONS 3

3 SAFETY EQUIPMENT AND PRECAUTIONS

3.1 SAFETY DEVICES AND GUARDS

E0004PWARNING!

3.1.1 GENERAL SAFETY RULES

The machine is provided with a number of electrical and/or mechanical safety devices in order to safeguard theoperators and the machine itself.These devices must never be removed, disabled or altered in any way.Some illustrations provided in the manual show the machine, or parts of it, with the guards removed. This is simplyfor added clarity. Never actually use the machine with the guards removed or safety devices disabled.Warning signs are provided on the machine to indicate any hazards in the zone where the sign is attached.Always take all necessary safety precautions before working on the machine.SACMI shall not be held responsible for any injury to personnel or damage to the machine resulting from failure toobserve these precautions or use the safety devices provided.

3.1.2 SAFETY DEVICES INSTALLED

3.1.2.1 Shutdown devices

The shutdown devices signal any malfunctioning and stop the machine or prevent it from being started up.

3.1.2.2 Indicating a shutdown

Each time a fault arises causing the machine to shut down, this is signalled to the operator by a red flashing beaconon top of the electrical cabinet.The cause of the fault which caused the machine to shut down is shown on the display of the control panel.The fault messages are described in detail in the INSTRUCTIONS B manual.

3.1.2.3 Devices to safeguard the operator

The machine is provided with a number of mobile safety guards which are connected to electrical shutdown devices.In addition, there are fixed mechanical guards which prevent the operator from coming into contact with moving partsor other dangerous components such as live or hot parts.

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3 SAFETY EQUIPMENT AND PRECAUTIONS

T2515

Figure 3.1.2 - SAFETY DEVICES INSTALLED

1 Emergency stop button2 Mechanical guards electrically interlocked3 Fixed mechanical barriers 3 2

3

1

3

1

3

1

3.1.2.4 Emergency stop buttons

Emergency stop buttons on-board the machineThey are installed in the position shown in the figure.- Operation: manual- Effect: the drive system, machine motors and vacuum and suction pumps (required for product handling)

immediately stop running. Voltage is no longer supplied to the auxiliary electric system as well as the system thatcontrols the solenoid valves.

- Reset: turn the button on the control panel to release it

Emergency stop button on the switchboard control panelIt is installed on the switchboard control panel in the position shown in the figure.- Operation: manual- Effect: the drive system, machine motors and vacuum and suction pumps (required for product handling)

immediately stop running. Voltage is no longer supplied to the auxiliary electric system as well as the system thatcontrols the solenoid valves.

- Reset: turn the button on the control panel to release it

T2515

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SAFETY EQUIPMENT AND PRECAUTIONS 3

3.2 SAFETY RULES FOR HANDLING

E0004PWARNING!

3.2.1 LIFTING PROCEDURES

To safely and correctly lift the machine always:- use the most suitable lifting equipment with an adequate lift capacity;- cover all sharp edges with cloths and/or cardboard;- make sure the safety device for the lift hook works properly;Before lifting:- make sure all personnel is safely away and that no one can enter the area where the machine is being moved- make sure the load is stable- lift the load vertically and gradually in order to avoid banging the parts.

3.2.2 HANDLING PROCEDURES

During handling operations, the load must remain on a perfectly horizontal plane whatever the type of equipment beingused.To facilitate the lifting and handling operations use bars, levers and ramps from a safe distance. Never use your hands.The person in charge must:- have a clear view of where the machine is to be moved- give instructions to the crane operator from a position where he/she can be clearly seen- stop the operation immediately if dangerous conditions arise.

3.2.3 PLACING THE LOAD

Before placing the machine make sure the floor is perfectly level and is able to support the weight of the machine.Do not place the loads in areas where they could create a hazard, prevent the use of equipment or obstruct emergencyexits.The machine must be placed so that it is stable and the slings can be easily removed.Do not place worn containers or those with protruding parts on top of each other.Do not stack material to a dangerous height.

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3 SAFETY EQUIPMENT AND PRECAUTIONS

3.3 INSTALLATION

E0004PWARNING

3.3.1 GENERAL RULES

Install the machine by following the instructions provided by the Manufacturer and observing the safety regulationsin force in your country.It is extremely important that the machine is properly connected to adequate earth electrodes.Make sure there is enough space around the machine so that it can be operated and serviced easily.The area surrounding the machine must always be kept free of obstacles, clean, dry and well-lit.The lighting in the areas around the machine and, in particular, in the work zone should be efficient and have a levelof illumination not less than 300 lux.The customer must make sure that fire-fighting equipment is provided in the area where the machine is installed andthat there is a system for protection against voltage fluctuation in the electricity supply line. These must conform to lawscurrently in force in the country where the machine is installed.SACMI shall not be held responsible for any property damage or personal injury resulting from improper installation.

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SAFETY EQUIPMENT AND PRECAUTIONS 3

3.4 OPERATOR TRAINING

E0004PWARNING!

3.4.1 END-USER

The company using this equipment must see that their personnel:- match the requirements listed below- read and understand the manual in its entirety- are adequately instructed and trained on how to safely carry out their tasks- receive specific training on how to operate this machine correctly.

3.4.2 OPERATORS

The machine operator must:- understand the technology employed and have specific experience in operating this type of machine- be well educated enough to read and fully understand the contents of this manual as well as properly interpret the

drawings provided- know all the safety rules and standards

- general (hygiene and on-the-job safety, accident prevention)- specific (for the type of product handled by the machine)in force in the country where the machine is installed.

Operator tasksThe operator is only authorised use the controls and instruments provided on the machine’s control panel.

3.4.3 MAINTENANCE STAFF

The maintenance staff must be selected according to the same criteria as that indicated for the operators.In addition, they must be trained in specific technological areas (mechanical, electric, pneumatic etc.) so that they cancarry out the operations they are responsible for (as specified in the manual) in complete safety using suitable toolsand equipment.

Tasks for the maintenance staffThe maintenance staff are responsible for carrying out the routine maintenance operations described in this manual.It is important that the members of staff carry out only the tasks in the areas they are specifically responsible for(mechanical, electric, pneumatic, etc.).

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3 SAFETY EQUIPMENT AND PRECAUTIONS

3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THEMACHINE

3.5.1 GENERAL SAFETY RULES

E0001

Never inspect, repair or service moving parts. Clear warning signs should be attached near the parts in question towarn operators of the danger.

E0007

E0010

Before performing any operation on the machine, including the replacement of components of the control panel orelectrical cabinet, the maintenance staff must shut off the electricity supply by using the main switch located on thecontrol panel. This switch should then be locked in position by using a padlock so that the machine cannot beaccidentally started up.The electrical cabinet can be accessed even when the system is energised.As laid down by the EN 60204-1 directive, access to the electrical cabinet should only be possible with a special key.This key should be kept by one member of staff qualified and trained to work on live parts.When the electrical cabinet is energised, the only task that this member of staff should perform is to reset the circuitbreakers.

E0017

When working on the machine never climb up on any part other than the service floor or ladders. The machine guardsand enclosing barriers are not designed to bear the weight of a person. If climbed on, they may collapse causing injuryto personnel and damage to the machine.

E0004P

It may be necessary to temporarily remove or disable certain safety devices when making adjustments or servicingthe machine. Once these operations have been completed, it is highly important that the safety devices are put backin place and reactivated before the machine is started up.

E0002

E0005

During operations, the electric motors can reach extremely high temperatures which would cause burning if touched.Always take the necessary safety precautions before working on the motors.

E0007

E0009

In order to ensure that the machine operates efficiently, safely and in a trouble-free manner always follow SACMI’sinstructions carefully. Carry out the scheduled maintenance operations exactly as described and at the time intervalsrecommended.In particular, regularly check all the safety devices for proper functioning. Also check the insulation of the electricalcables and replace if necessary.

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SAFETY EQUIPMENT AND PRECAUTIONS 3

3.5.2 GUIDELINES FOR OPERATION AND MAINTENANCE

3.5.2.1 Risks deriving from high temperatures

ACCESSING THE INSIDE OF THE EXTRUDER GUARDSTemperatures up to 280 °C are reached inside the area protected by the extruder guards.Never touch the external surfaces provided with warnings indicating danger of being burnt.The safety guards may have to be opened to clean the machine or make checks when the machine is shut down underemergency conditions.

E0004PWARNING!

When the extruder needs to be serviced or repaired after reaching its operating temperature, always use adequategear to prevent being burnt (gloves, pliers, etc.).

HOT MATERIAL EXITING THE EXTRUDER, RISK OF BEING SCORCHED AND BURNTWait for the material to cool down or take adequate precautions (use grippers, gloves, etc.).

3.5.2.2 Risk of explosion

E0004

E0034D

O2

WARNING!

The accumulators must be precharged with only dry nitrogen in tanks fitted with a reducer. Oxygen and/or aircompressors must never be used under any circumstances.

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3 SAFETY EQUIPMENT AND PRECAUTIONS

3.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED

E0004PWARNING!

3.6.1 GENERAL

When the machine is no longer to be used, make it inoperative by shutting off the electricity and air supplies etc.

E0004

WARNING!

Release any pressurized gas contained in the accumulators with the tester / inflater supplied with the machine asdirected in the CHECKING ACCUMULATOR PRECHARGE paragraph in chapter 8.

Use suitable safety devices.Thoroughly clean the entire machine, especially the working parts, and if necessary apply a protective lubricant.Close the door of the electrical cabinet and any machine access doors to prevent any parts from being tampered withor dust from getting in.Follow the instructions given in Chapter 9 - DECOMMISSIONING and observe current standards in force and safetyregulations regarding lifting and handling the machine and its parts.

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INSTALLATION 4

4 INSTALLATION

4.1 SHIPPING AND HANDLING

MACHINE DIVISIONThe machine is divided into groups depending on the shipping and installation requirements.

DIMENSION AND WEIGHTSThe weights and dimensions of the individual parts, in relation to the shipping requirements, are approximate thereforethey are given for reference purposes only.

SYSTEMS FOR LIFTING INDIVIDUAL PARTSThe best systems for lifting and handling the heaviest and largest parts as well as those that require special care andtools provided by Sacmi are shown in the figure.When lifting the smaller parts and packages, be careful and use the most suitable equipment observing the safetyprecautions.

When the crates arrive on site, they must be handled with care and transported both inside and out, with means thatcan support the weight of the crate.It is fundamental that the user weighs all the parts when they arrive to verify their exact weight.

E0004PWARNING!

The manufacturer shall not be held responsible for any property damage or personal injury resulting from failureto observe current safety precautions regarding lifting and handling materials inside the factory.

PRECAUTIONS TO BE OBSERVED WHEN LIFTING PARTS- Use lift equipment that has an adequate range of action and lift capacity suitable for the dimensions and weight to

be sustained. Place the equipment as shown in figure 4.1.- Protect the points where the slings come into contact with the machine with cardboard or rags.- Gradually move the crane until the load is perfectly stable.- Slowly lift and move the load using extreme caution, avoid swaying it to even the slightest degree.

E0004PWARNING!

The parts must be lifted and handled only by authorized persons who are specialized in carrying out this type ofoperation.It is vital that no persons are near the hanging load and/or within the range of action of the lift equipment while themachine is being hoisted and moved.

- Follow the instructions for lifting the parts given in chapter 3, SAFETY EQUIPMENT AND PRECAUTIONS.- The load must remain perfectly level while it is being moved regardless of the lift equipment employed.

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4 INSTALLATION

Figure 4.1/A - DIMENSIONS AND WEIGHTS

18

12

14

17

13

19

11

1

kg 4600

3

kg 450

L.=1500

L.=1800

L.=1000

6kg 320

L.=2400

kg 520

T3062

2050

17001650

4

15

8

16

9

10

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INSTALLATION 4

Figure 4.1/B - DIMENSIONS AND WEIGHTS

Figure 4.1/A - 4.1/B - DIMENSIONS AND WEIGHTS1 Press2 Extruder3 Hydraulic power unit4 Extruder connecting tube5 Electrical cabinet6 Extruder tracks

8 Press fixing bracket9 Tube trunk10 Electric wires trunk11 Control panel12 Crate with tubes and accessories13 Slings for lifting press

14 Slings for lifting electrical cabinet15 Extruder feeder16 Feed hopper17 Temperature regulator18 Chiller19 Extruder lift slings

2.1

1800

1350

700

2800

1350

700

42001400

11001360

1100

2100

2800

600

3200

2100

600

3600

2100

600

2100

600

4000

50 kg/hkg 600

2.2 100 kg/hkg 1300

2.3 150 kg/hkg 4000

2.4 200 kg/hkg 4500

5.1 50 kg/hkg 1250

5.2 50 kg/h - 220/480Vkg 1350