D O C U M E N TA Z I O N E

T E C N I C A

USER’S MANUAL

002AZ001A

ROTARY HYDRAULIC COMPRESSION PRESS

CCM 001

TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇAO TÉCNICA

LISH
ENG
002AZ001A
TABLE OF CONTENTS

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TABLE OF CONTENTS
USER’S MANUAL

ROTARY HYDRAULIC COMPRESSION PRESS

CCM 001

MANUFACTURER

SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA

PUBLISHED ON

25.10.2001

VERSIONS

CCM00100005 - CCM001A

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TABLE OF CONTENTS

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TABLE OF CONTENTS
Page
1 GENERAL INFORMATION ........................................................................................................................1 - 1
1.1 INTRODUCTION ......................................................................................................................1 - 1
1.2 WHERE TO KEEP THE MANUAL .......................................................................................... 1 - 1
1.3 HOW TO USE THE MANUAL ................................................................................................. 1 - 1
1.4 USERS OF THE MANUAL ...................................................................................................... 1 - 1
1.5 WARRANTY .............................................................................................................................1 - 2
1.6 SUPPLEMENTS ...................................................................................................................... 1 - 2
1.7 KEY TO THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL ... 1 - 2
1.8 MACHINE IDENTIFICATION PLATE ......................................................................................1 - 4

2 MACHINE FEATURES ............................................................................................................................. 2 - 1

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

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3 SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 1
3.1 SAFETY DEVICES AND GUARDS ........................................................................................ 3 - 1
3.1.1 GENERAL SAFETY RULES ....................................................................................................3 - 1
3.1.2 SAFETY DEVICES INSTALLED ............................................................................................. 3 - 1
3.1.2.1 Shutdown devices ....................................................................................................................3 - 1
3.1.2.2 Indicating a shutdown ............................................................................................................. 3 - 1
3.1.2.3 Devices to safeguard the operator .......................................................................................... 3 - 1
3.1.2.4 Emergency stop buttons ......................................................................................................... 3 - 2
3.2 SAFETY RULES FOR HANDLING ..........................................................................................3 - 3
3.2.1 LIFTING PROCEDURES ........................................................................................................ 3 - 3
3.2.2 HANDLING PROCEDURES ....................................................................................................3 - 3
3.2.3 PLACING THE LOAD...............................................................................................................3 - 3
3.3 INSTALLATION ........................................................................................................................3 - 4
3.3.1 GENERAL RULES .................................................................................................................. 3 - 4
3.4 OPERATOR TRAINING .......................................................................................................... 3 - 5
3.4.1 END-USER ...............................................................................................................................3 - 5
3.4.2 OPERATORS ...........................................................................................................................3 - 5
3.4.3 MAINTENANCE STAFF .......................................................................................................... 3 - 5
3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THE MACHINE .. 3 - 6
3.5.1 GENERAL SAFETY RULES ....................................................................................................3 - 6
3.5.2 GUIDELINES FOR OPERATION AND MAINTENANCE ........................................................3 - 7
3.5.2.1 Risks deriving from high temperatures ................................................................................... 3 - 7
3.5.2.2 Risk of explosion ......................................................................................................................3 - 7
3.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED ............................................. 3 - 8
3.6.1 GENERAL ............................................................................................................................... 3 - 8

4 INSTALLATION ........................................................................................................................................ 4 - 1
4.1 SHIPPING AND HANDLING ....................................................................................................4 - 1
4.2 POSITIONING ......................................................................................................................... 4 - 4
4.3 CONNECTIONS AND HOOK UPS ..........................................................................................4 - 5
4.3.1 CONNECTING THE EXTRUDER TO THE PRESS ............................................................... 4 - 5
4.3.2 HYDRAULIC CONNECTION: FROM THE POWER UNIT TO THE PRESS ..........................4 - 6
4.3.3 HOOKING UP THE COOLANT SYSTEM ............................................................................... 4 - 7
4.3.4 HOOKING UP THE PNEUMATIC SYSTEM ........................................................................... 4 - 8
4.3.5 ELECTRICAL HOOK-UP ........................................................................................................ 4 - 9
4.3.5.1 Wiring connections .................................................................................................................. 4 - 9
4.3.5.2 Earth connection ................................................................................................................... 4 - 10
4.3.5.3 Connection to the supply mains ............................................................................................ 4 - 10

5 START UP ..................................................................................................................................................5 - 1
5.1 INTRODUCTION ......................................................................................................................5 - 1
5.2 PRELIMINARY CHECKS ........................................................................................................ 5 - 1
5.3 CHECKING OPERATION ........................................................................................................5 - 2
5.4 PRELIMINARY OPERATIONS ............................................................................................... 5 - 3
5.5 STARTING THE AUTOMATIC CYCLE ................................................................................... 5 - 4
5.6 SUBSEQUENT START UPS .................................................................................................. 5 - 4

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

6.1 CONTROL AND MONITORING UNIT .................................................................................... 6 - 1
6.2 STARTING AND STOPPING THE MACHINE ........................................................................ 6 - 4
6.3 AUTOMATIC CYCLE ...............................................................................................................6 - 5
6.4 PRODUCTION CYCLE ........................................................................................................... 6 - 6
6.5 EMERGENCY CYCLES AND RESET OPERATIONS ............................................................6 - 9
6.5.1 ACTUATOR DOWNSTROKE CONTROL ............................................................................... 6 - 9
6.5.2 ACTUATOR UPSTROKE CONTROL ................................................................................... 6 - 10
6.5.3 DOUBLE PRODUCT DETECTION ....................................................................................... 6 - 11
6.5.4 EMPTY DIE CONTROL ........................................................................................................ 6 - 12
6.5.5 DETECTION OF PRODUCTS HEAVIER OF LIGHTER THAN NORMAL WEIGHT ............ 6 - 12
6.5.6 CORRECT POSITION FOR START OF FORMING CONTROL .......................................... 6 - 13
6.6 PRODUCT SAMPLING ......................................................................................................... 6 - 14
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7 ADJUSTMENTS ........................................................................................................................................ 7 - 1
7.1 PLASTICIZATION UNIT .......................................................................................................... 7 - 1
7.1.1 EXTRUDER ............................................................................................................................. 7 - 1
7.1.2 METERING PUMP .................................................................................................................. 7 - 1
7.1.3 FEED TUBE .............................................................................................................................7 - 2
7.1.4 BY-PASS SYSTEM ................................................................................................................. 7 - 2
7.2 INSERTION DRUM ................................................................................................................. 7 - 3
7.2.1 ADJUSTING THE PRECHARGE OF THE DRUM’S CONNECTING ROD ............................ 7 - 3
7.2.2 ADJUSTING THE CUTTER .................................................................................................... 7 - 4
7.2.3 ADJUSTING THE PELLET INSERTION STAGE ................................................................... 7 - 6
7.3 FORMING UNIT ...................................................................................................................... 7 - 7
7.3.1 PRODUCT REMOVAL ADJUSTMENT ................................................................................... 7 - 9
7.3.2 ADJUSTING THE QUALITY CONTROL UNIT ..................................................................... 7 - 10
7.4 PNEUMATIC SYSTEM ......................................................................................................... 7 - 12
7.5 HYDRAULIC SYSTEM .......................................................................................................... 7 - 12
7.5.1 ADJUSTING THE OIL FLOW UNDER LOW PRESSURE ................................................... 7 - 12
7.5.2 ADJUSTING THE FORMING STAGE (HIGH PRESSURE) ................................................. 7 - 12
7.5.3 ADJUSTING THE ACTUATOR DOWNSTROKE ................................................................. 7 - 12
7.6 COOLING SYSTEM .............................................................................................................. 7 - 14
7.7 INSTALLING AND REMOVING THE TOOLING .................................................................. 7 - 14
7.8 ADJUSTING THE EXIT CHANNEL ...................................................................................... 7 - 16
7.9 REPLACING THE INDUCTIVE SENSORS .......................................................................... 7 - 18
7.10 RESETTING THE ENCODERS ............................................................................................ 7 - 19

8 MAINTENANCE ........................................................................................................................................ 8 - 1
8.1 SCHEDULED MAINTENANCE ............................................................................................... 8 - 2
8.1.1 SCHEDULED MAINTENANCE CHART ................................................................................. 8 - 2
8.1.2 PERIODIC MAINTENANCE OPERATIONS ........................................................................... 8 - 8
8.1.2.1 Drive unit ..................................................................................................................................8 - 8
8.1.2.1.1 Checking the condition of the drive belts .................................................................................8 - 8
8.1.2.1.2 Tensioning the forming unit transmission belts ........................................................................8 - 8
8.1.2.1.3 Replacing the forming unit transmission belts ........................................................................ 8 - 8
8.1.2.1.4 Tensioning the insertion unit transmission belt ........................................................................8 - 8
8.1.2.1.5 Replacing the insertion unit transmission belt ........................................................................ 8 - 9
8.1.2.1.6 Checking the oil level in the forming unit’s geared motor ........................................................8 - 9
8.1.2.1.7 Changing the oil in the forming unit’s geared motor ............................................................... 8 - 9
8.1.2.2 50 kg/h Extruder .................................................................................................................... 8 - 11
8.1.2.2.1 Overhauling the extruder auger ............................................................................................ 8 - 11
8.1.2.2.2 Checking the oil level in the extruder geared motor and topping up .................................... 8 - 12
8.1.2.2.3 Changing the oil in the extruder geared motor ..................................................................... 8 - 12
8.1.2.2.4 Cleaning the nozzle ............................................................................................................... 8 - 12
8.1.2.2.5 Checking and setting pressure transducers BP1 and BP2 ................................................... 8 - 14
8.1.2.3 100 kg/h Extruder .................................................................................................................. 8 - 16
8.1.2.3.1 Overhauling the extruder auger ............................................................................................ 8 - 17
8.1.2.3.2 Checking the oil level in the extruder geared motor and topping up .................................... 8 - 18
8.1.2.3.3 Changing the oil in the extruder geared motor ..................................................................... 8 - 18
8.1.2.3.4 Cleaning the polymer metering pump ................................................................................... 8 - 18
8.1.2.3.5 Replacing/overhauling the polymer metering pump ............................................................. 8 - 18
8.1.2.3.6 Lubricating the universal joint ............................................................................................... 8 - 19
8.1.2.3.7 Cleaning the nozzle ............................................................................................................... 8 - 19
8.1.2.3.8 Checking and setting pressure transducers BP1 and BP2 ................................................... 8 - 19
8.1.2.3.9 Checking the condition and tensioning the extruder drive belt ............................................. 8 - 21
8.1.2.3.10 Tensioning the extruder drive belt ......................................................................................... 8 - 21
8.1.2.3.11 Replacing the extruder drive belt .......................................................................................... 8 - 21
8.1.2.4 150-200 kg/h Extruder ........................................................................................................... 8 - 22
8.1.2.4.1 Overhauling the extruder auger ............................................................................................ 8 - 23
8.1.2.4.2 Checking the oil level in the polymer metering pump geared motor and topping up ........... 8 - 24

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

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

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

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GENERAL INFORMATION 1

1 GENERAL INFORMATION

1.1 INTRODUCTION

WARNING!
E0004P

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 the
machine 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 the
part of SACMI.
The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,
reproduced, disclosed or transferred.
Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.

1.2 WHERE TO KEEP THE MANUAL

WARNING!
E0004P

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

1.3 HOW TO USE THE MANUAL

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

IMPORTANT!
E0004P

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

1.4 USERS OF THE MANUAL

In this manual the machine operators are categorized as follows:

- Operator: this is the person responsible for supervising and operating the machine.
- Routine maintenance men.
For a more detailed description, see the OPERATOR TRAINING paragraph in chapter 3 - SAFETY EQUIPMENT AND
PRECAUTIONS.

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1 GENERAL INFORMATION
1.5 WARRANTY

SACMI 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 personnel
or duly authorized by SACMI’S Engineering Dept.
SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.

ATTENTION!
E0004

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

1.6 SUPPLEMENTS

Information regarding the electric and electronic components of the machine are given in three handbooks provided
under separate cover and entitled:
- USE OF THE MICROPROCESSOR CONTROL SYSTEM (Instructions B manual)
- DESCRIPTION OF THE ELECTRONIC CARDS
- LIST OF DEVICES

These handbooks are supplied with this manual.

1.7 KEY TO THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE
MANUAL

DANGER SYMBOLS

General hazard.
E0004

Danger of being burnt by hot surfaces.

E0002

Danger of getting your hands crushed.

E0003

Danger of electrocution.
E0007

Risk of serious injury.

E0011

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GENERAL INFORMATION 1

Risk of entanglement in moving parts.

E0010

Danger of falling.
E0017

Risk of explosion.
E0035P

Keep a safe distance away.

E0015

WARNING SYMBOLS

Never perform maintenance or lubrication operations on moving parts.

E0001

O2

Do not use oxygen to recharge the accumulators.

E0034D

ALERT SYMBOLS

Heavy-duty work gloves must be worn.

E0005

The point indicated must be effectively earthed.

E0006

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1 GENERAL INFORMATION
1.8 MACHINE IDENTIFICATION PLATE

T2525

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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 of compression.
A continuous work-cycle is carried out during which plastic material is fed from an extruder, cut into suitably gauged
pellets and then inserted inside the dies. A hydraulic system is employed to close the dies at a pressure that can be
regulated while the production cycle is being performed. The time required for cooling down is strictly related to the speed
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
- Electric cabinet with control system for the production cycle
- Pneumatic system
- Hydraulic system
- Temperature control system

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2 MACHINE FEATURES

Figure 2.1 - OVERALL VIEW

1

11 3 2 13 4 14
T2524

T2523

8 12 5 9 10

1 Extruder 8 Pneumatic system

2 Metering pump 9 Hydraulic system
3 Feed tube 10 Cooling system
4 By-pass system 11 Electric cabinet
5 Drive unit 12 Tooling
6 Insertion drum 13 Control panel
7 Forming unit 14 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 temperature
and flow rate of these operations are controlled. The unit includes an extruder (1), metering pump (2), a heated feed
tube (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 on a track.
The machine may be equipped with various extrusion devices, depending on the flow rate required for the plastic
material.

Figure 2.1.1.1 - PLASTICIZATION UNIT

1 Extruder
2 Metering pump
3 Feed tube
4 By-pass system

T2486

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2 MACHINE FEATURES
Extruder
The extruder melts down the plastic compound and homogenizes it with any colorings and lubricants that may have been
added.
The granular material is let in through a hopper (1) and is pushed in the cylinder (2) by the auger (3) through the four
thermal conditioning zones. The auger is driven by a geared motor (4). The zones are supplied with heating elements
and electric cooling fans. The temperature in each individual zone is measured by thermocouples provided for this
purpose.

Figure 2.1.1.1/A - 50 kg/h EXTRUDER

1 Hopper
2 Cylinder
3 Auger
4 Extruder gearbox

1
4

T1701

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MACHINE FEATURES 2

Figure 2.1.1.1/B - 100 kg/h EXTRUDER

1 Hopper
2 Cylinder
3 Auger
4 Extruder gearbox

4 1

3
2

T1544

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2 MACHINE FEATURES

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

1 Hopper
2 Cylinder
3 Auger
4 Hydraulic motor
5 Motor-pump unit
6 Tank

1
4

2 3

T1702

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MACHINE FEATURES 2
Metering pump
The metering pump controls the flow of the melt and determines the weight of the pellets. The material enters the pump
casing (1) (heated by elements EH7) through a suction flange (6) and is pushed by suitable gears (2) (driven by geared
motor 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 pump
temperature is controlled by thermocouple BT7.

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

Figure 2.1.1.1/B - METERING PUMP

BP1
1 Pump body
2 Gears A
6 Suction line
7 Delivery line B BP2
BP1 Sensor, Suction pressure
BP2 Sensor, Delivery pressure
BT7 Thermocouple
EH7 Heating element
M8 Geared motor T2489
1

6
7
A B

BT7
2

EH7

EH7

M8

2-7
002AZ001A
2 MACHINE FEATURES
Feed tube
This carries the melt from the metering pump to the insertion drum unit. The melt enters through a flange (1) and is fed
by the by-pass unit. While traveling along the path, the material is kept at a constant temperature by heating elements
EH8. 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 the
molten material are homogenous.
The mixer (2) is mounted between the flange (1) and tube (4). Heating element EH19 keeps its temperature constant.
Thermocouple BT9 measures its temperature.

Figure 2.1.1.1/C -FEED TUBE

1 Flange
2 Mixer
4 Tube
BT8 Thermocouple 1
EH8 Heating element

BT8

EH8

T2490

2-8
 002AZ001A
MACHINE FEATURES 2
By-pass system
The by-pass system is used to either feed the insertion unit or discharge the material into the waste container. The melt
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 along the
path, the material is kept at a constant temperature by heating elements EH15 and EH16. The temperature is measured
by thermocouples BT15 and BT16 while the temperature of the melt is measured by probe BT17.

Figure 2.1.1.1/D - BY-PASS SYSTEM

1 Flange
3 Extruder nozzle
4 Discharge outlet
5 Diverter
6 Pneumatic cylinder
BT15 Body thermocouple
BT16 Nozzle thermocouple
BT17 Molten material thermocouple BT17
EH15 Heating element
EH16 Heating element

3
BT16

1
EH16
EH15

4 5

BT15

T2488

2-9
002AZ001A
2 MACHINE FEATURES
2.1.1.2 Drive unit
The 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 operations
in manual mode, a cogged belt (3) that drives the forming unit and a tension unit (4) that controls the tension of the belt.
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

M9

6
7

8 4

2 Handwheel
3 Cogged belt
4 Tension unit
5 Drain cock
6 Filler
7 Level indicator
8 Set screw
M9 Epicyclic geared motor

T1495

2 - 10
 002AZ001A
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 drum
and transferring the finished product onto the exit conveyor belt. The unit basically consists of the following parts:

Drive unit
(References given in figure 2.1.1.3/A)
The drive unit (1), secured beneath the insertion drum mount, is driven by a pulley (2) keyed to the forming unit. Motion
is transmitted to the pinion (3), keyed to the transmission shaft, through a cogged belt (4). In addition, a roller (33) that
tensions the belt is also provided.
A torque limiter (22) and encoder (6) are mounted on the drive shaft. The latter records information regarding the work
position of the machine and sends it to the microprocessor based system.

Support
(References given in figure 2.1.1.3/A)
The support (10) is mounted on the base of the machine and is used to hold the pivot unit, insertion drum and the exit
conveyor belt for the finished products.
A drive shaft is located inside the support. The latter transmits motion from the drive pulley to the pivot unit of the insertion
drum.

Drum unit pivot point

(References given in figure 2.1.1.3/A)
The 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 a pneumatic
cylinder (11). The pivot unit includes a connecting rod (13) that holds up the insertion unit. The wheel (31) (that receives
motion from the drive shaft through wheel 32), tensioner (14) for the belt (15) (that transmits motion to the insertion unit)
and solenoid valve YV33 (that controls the air jets for inserting the pellets inside the cavities of the forming unit) are found
in this unit.
Air ducts (19 and 20) for inserting the pellets and ejecting the ones that have not been inserted are machined in the
connecting rod.

Drum unit
(References given in figure 2.1.1.3/B)
The insertion drum basically cuts and picks up the plastic material being pushed out of the extruder nozzle by means
of cutters (23) and then deposits the pellets in the cavities of the forming unit. In addition, this unit is used to transfer
the finished products onto the exit conveyor belt. The stripper wheel (16) is used for this purpose.
The drum consists of a disc (21) which a number of cutters (23) are mounted on. Each cutter includes an insertion nozzle
(23A), a body (23B) and a blade (23C) held in place with screw 23D.
A belt (15) transfers motion from the wheel (31) to the insertion unit’s drive shaft.
The air ducts for inserting (19) and ejecting (20) the pellets (see figure 2.1.1.3/A), 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).
A mechanism (26) (consisting of toothed wheels) is mounted over the disk (21). Its function is to transfer motion to the
stripper wheel (16) so that it is timed with the forming unit.

2 - 11
002AZ001A
2 MACHINE FEATURES

Figure 2.1.1.3/A - DRIVE UNIT - 9 Drum pivot point 23 Cutter

SUPPORT - PIVOT POINT 10 Support unit 24 Distributor
11 Pneumatic cylinder 28 Support
YV33 Solenoid valve 13 Connecting rod 29 Back-plate
1 Drive unit 14 Tensioner 31 Wheel
2 Forming unit pulley 15 Toothed belt 32 Wheel
3 Drive unit pinion 16 Stripper wheel 33 Tensioner roller
4 Cogged belt 19 Air duct for pellet insertion 34 Button
6 Encoder 20 Air duct for pellet ejection
7 Adjustment screw 21 Insertion drum unit
8 Nut 22 Torque limiter

19 YV33 9 11

16 13

23
21
13

20

7
29
28

34

10 A

T2513

1
2 4 8 33 22 6 3
24 15 14 31 32

2 - 12
 002AZ001A
MACHINE FEATURES 2

Figure 2.1.1.3/B - INSERTION DRUM

16
26
21

24
23

23A 13
23B

23C

23D

25
15

31

26
30

16 13 Connecting rod
15 Belt
16 Stripper wheel
29 21 Insertion unit disk
23 Cutter
26F 26D 23A Insertion nozzle
23B Body
26E 23C Cutter
26C 23D Screw
26B 24 Distributor
25 Pulley
26 Wheel drive mechanism
26A Shaft
26B Sleeve
26C Toothed wheel
26D Toothed wheel
26E Toothed wheel
26A 26F Toothed wheel
21 T2492
29 Disk
30 Mounting screws
31 Wheel

2 - 13
002AZ001A
2 MACHINE FEATURES
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 the pellets
of molten plastic that are sent to them from the insertion drum. The finished product is then placed on the stripper wheel.
The forming drum consists of a support shaft (1) on which the drum body (2) is mounted. Motion is transmitted from the
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 cooling
fluid to the upper tools while the lower one feeds the coolant to the lower tools and oil under pressure to 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 of
the 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 is
mounted 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 the
cartridge (12), which in turn, is mounted on the upper drum body (13). The relative rod (14), that drives the devices
used for stripping the product is found inside each cartridge. A fork (15), whose task is to act on the stripper, is keyed
to 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 by
blowing air into the upper 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 and
then through a ring that directs it to valves (25). The latter are controlled by a cam. The air then reaches the flow controls
found near the dies.
Two operations can be carried out to remove the product when some particular tools are installed (fig. 2.1.1.4/B). The
die (12) is driven by both a stripper rod (14) and cam (21). The latter acts on a wheel placed in a central position in relation
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 shaft
2 Drum body
3 Pulley
4 Belt
5 Upper distributor
6 Lower distributor
7 Drum’s lower body
8 Hydraulic actuators
9 Die
10 Actuator control valve
11 Coolant duct (lower dies)
12 Tool cartridge
13 Upper drum body
14 Stripper drive rod
15 Fork
17 Fixed cam
18 Roller
19 Coolant duct (upper dies)
21 Cam
25 Valve

2 - 14
 002AZ001A
MACHINE FEATURES 2

Figure 2.1.1.4/A - FORMING DRUM

25 5

12
13

17

19

15

10

6
A

18

T2493
14
11

4
1
3

2 - 15
002AZ001A
2 MACHINE FEATURES

Figure 2.1.1.4/B - TOOL WITH CENTRAL DRIVE 5 25

A
18

14

21

17

12

13

19

15

10

T2529

11 4 3 1

2 - 16
 002AZ001A
MACHINE FEATURES 2
2.1.1.5 Exit channel

(References given in figure 2.1.1.5)

The exit channel receives the product from the stripper wheel and carries it in an orderly manner to the zone where it
is fed to the next machine in the production line.
A belt with paddles (1), driven by a pulley (2) keyed to the drive shaft, receives the product from the stripper wheel (3)
and pushes it into the exit channel (4).
Any defective products are ejected on to conveyor (7) through solenoid valve YV4.

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 the
forming 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 keeps the
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 a graduated
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 the
following parts:
- hydraulic power unit’s water/oil exchanger
- extruder
- upper dies
- lower dies
The system includes a chiller (optional) which delivers the fluid at a low temperature to a thermal control unit (optional)
that provides 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 the OPERATING INSTRUCTIONS chapter and the
Instructions 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 into contact
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.

2 - 17
002AZ001A
2 MACHINE FEATURES

Figure 2.1.1.5 - EXIT CHANNEL YV4

YV4 Solenoid valve

1 Belt with paddles
3 Stripper wheel
4 Exit channel
7 Conveyor 3

7
T2514 1

2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE

INTENDED USE OF THE MACHINE

The machine is specially designed and constructed to produce products that have the characteristics indicated in the
specifications.
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.

E0004P
WARNING!
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
- automatic
Use the mode selector on the control panel to select the desired mode of operation

UNINTENDED AND PROHIBITED OPERATIONS

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

MISUSE OR ERRONEOUS USE

The manufacturer shall not be held responsible for any injury to persons or damage to the machine deriving
from incorrect and erroneous use of the machine. Generally speaking, the most common causes of incorrect use
are listed 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!

2 - 18
 002AZ001A
MACHINE FEATURES 2

2.2 OVERALL DIMENSIONS

Figure 2.2/A - OVERALL DIMENSIONS WITH 50 kg/h EXTRUDER

2200
2100

1350
1400

990
Y

800

200
1000

1680
3140

365

520
T2569

VOLT Y
440 - 415 - 380 5480
480 - 220 5880

2 - 19
002AZ001A
2 MACHINE FEATURES

Figure 2.2/B - OVERALL DIMENSIONS WITH 100 kg/h EXTRUDER

2200
1650

1350
1815 Y

400
3245

300

T2496
450

VOLT Y
440 - 415 - 380 5670
480 - 220 6070

2 - 20
 002AZ001A
MACHINE FEATURES 2

Figure 2.2/C - OVERALL DIMENSIONS WITH 150 kg/h EXTRUDER

2200
1720

1380
3520 5680

905
1430
3510

300

450 T2511

2 - 21
002AZ001A
2 MACHINE FEATURES

Figure 2.2/D - OVERALL DIMENSIONS WITH 200 kg/h EXTRUDER

2230
1780

1380
4045 5680

540
1430
3510

800

T2495
450

2 - 22
 002AZ001A
MACHINE FEATURES 2

2.3 TECHNICAL DATA

2.3.1 SPECIFICATIONS
EXTRUDER kg/h
50 100 150 200
PRODUCTION OUTPUT
Pieces/minute up to 600 600 600 600
AIR
Required delivery rate (at 0.5 MPa) dm3/1' 450 450 450 450
Consumption (at 0.5 Mpa) dm3/1' 200 200 200 200
Minimum required pressure MPa 0,5 0,5 0,5 0,5
Hose to air mains diameter mm 17 17 17 17
POWER
Thermal power to be dissipated kcal/h 22.000 28.000 36.000 42.000
Power requirements (50 Hz) kVA 105 174 204 229
Power for cable sizing (50 Hz) kVA 57 95 112 125
Maximum electricity absorbed (50 Hz) kW 35 55 65 73
Average 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°C
Pressure MPa 0,3 0,3 0,3 0,3
Flow rate l/1' 90 115 145 168
Average consumption (10°C) l/1' 75 95 120 140
PRODUCT
Type of plastic PP - HDPE - LDPE
Temperature of molten plastic up to 280°C 280°C 280°C 280°C
Dimensions and weights See product specifications
Number of cavities 32 32 32 32
Minimum speed of rotation rpm 8,5 8,5 8,5 8,5
Maximum speed of rotation rpm 18,75 18,75 18,75 18,75
Forming cylinder stroke mm 115 115 115 115
Maximum forming force kN 20 20 20 20
Color change time min 25(*) 25(*) 25(*) 25(*)

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

(**) antibacterial product that prevents corrosion and incrustation.

WARNING!
E0004P

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.

2 - 23
002AZ001A
2 MACHINE FEATURES
2.3.2 OPERATIONAL CHARACTERISTICS

TYPE OF PRODUCT
The machine can produce thermoplastic products whose dimensions have been previously agreed upon with SACMI’s
Engineering Dept.

TYPE OF MATERIAL
The 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.

ATTENTION!
E0004P

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

PRODUCTION CAPACITY
The 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 CHARACTERISTICS

The dimensions given in the figure are for reference purposes
only and are not binding in any way. 43

MAX 600 PCS/m’

MAX 3.3 Kg/1'

25

20

Max

Min T1498

2 - 24
 002AZ001A
MACHINE FEATURES 2
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 employed
Class 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 floor

P2 - Noisiest position of the ideal machine perimeter, measured at a distance of 1 meter from the surface of the
machinery
LbA - Background noise level.
LpA - Continuous A-weighted sound pressure level.
LpC peak - Peak C-weighted instantaneous sound pressure level.

2.3.3.2 Sound power level (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 employed
Class 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.

2 - 25
002AZ001A
2 MACHINE FEATURES

Compilato da
Scheda di lavorazione Data Scheda n°

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 #)

T fondo (Tpanel) °C T parete (Twall ) °C

Tipo base (Base type) Produttore (Manufacturer)

Tipo master (Master type) Produttore (Manufacturer) %miscelata (%mixed) Reg. mescolatore (Mixer set)
Plastica (Compound)
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 Temp.[°C] Pres.1[MPa] Pres.2[MPa]. Vel. (Speed) [%]

(Metering pump)
Grp. estrusione Temp.[°C]
(Extrusion unit) Tubo (Pipe)
Miscelatore (Mixer) Temp.[°C]

Corpo ugello Temp.[°C]

(Nozzle.support)
Temp.[°C] Diametro (Diameter) [mm]
Ugello (Nozzle)
Tranciante Tipo (Type) Larghezza (Width) [mm] Altezza
(Cutter holder) coltello [mm]

Giostra dosatrice Tipo (Type) Fase meccanica [mm]

Coltello (Cutter)
(Insertion unit)
Soffio inserim. Tipo (Type) Durata (Duration) Ritardo (Lag) Press. [MPa] (min 0.1 max 0.4)
(Insertion air jet)
Temperatura punzone °C (min 15 max40)
(Punch temperature)
Termoregolatore Temperatura cavità °C (min 15 max40)
(Thermoregulator) (Die.temperature)
Raffreddamento estr. °C (min 15 max 40)
(Extruder cooling)
Temperatura °C (min 8 max 18)
Tipo (Type) (Temperature)
Frigorifero (Chiller)
Camma 1 di estrazione Codice (Code) Posizione (Position)
(Stripper cam 1)
Camma 2 di estrazione Codice (Code) Posizione (Position)
(Stripper cam 2)
Pressione olio Alta (High) [MPa] Bassa (Low) [MPa] Rit. (Ret.)[MPa]
Stampaggio
(Forming) (Hydraulic.pressure)
Regolazione portata Alta (High) Bassa (Low)
(Flow.rate regulation)
Produttività Tappi/min (Caps/min)
(Production)
Alta (High) [MPa] Bassa (Low) [MPa] Rit. (Ret.)[MPa]
Precarica
accumulatori
Iniezione aria Lungh. Camma (Cam length) [mm] Press. [MPa] Posizione (Position) Cod.camma (Cam code)
(air injection)
NOTE (Notes)

2 - 26
 002AZ001A
MACHINE FEATURES 2

2.4 DIAGRAMS

2.4.1 PNEUMATIC SYSTEM DIAGRAM

(References given in figures 2.4.1/A and 2.4.1/B)

YV Solenoid valves
PA Air preparation

1 Filter and pressure regulator

2 Pressure regulator, Pellet insertion
3 Accumulator
4 Pneumatic cylinder, Insertion drum movement
5 Throttle
6 Pneumatic cylinder, Product diverter movement
7 Cylinder, By-pass movement
8 Cylinder, By-passed cut
9 Pressure regulator, Air injection in dies
10 Shut off valve and pressure gauge
11 Accumulator
12 Die injection valve

SP1 Pressure switch, Mains pressure

SP7 Pressure switch, Machine air supply
YV1/2 Solenoid valve, Product diverter operation
YV3 Solenoid valve, Pellet ejection
YV4 Solenoid valve, Product rejection
YV6 Actuating solenoid valve, Insertion drum control
YV9 Solenoid valve, Air injection in dies
YV17 Solenoid valve, Compressed air mains
YV22 Solenoid valve, By-passed cut
YV23 Actuating solenoid valve, By-pass system
YV25/26 Actuating solenoid valve, Insertion unit
YV33 Solenoid valve, Pellet insertion

2 - 27
002AZ001A
2 MACHINE FEATURES

Figure 2.4.1/A - AIR SUPPLY SYSTEM DRAWING

12

11

EV

YV22 YV9 YV23

YV1/2

4 YV3
YV25/26 YV6

10

3
2 PA

1
YV33

SP7 YV17 SP1

T2567
YV4

2 - 28
 002AZ001A
MACHINE FEATURES 2

Figure 2.4.1/B - LAYOUT OF ELEMENTS IN THE 12

AIR SUPPLY SYSTEM

10

YV4
YV33

T2516

YV23 YV1/2 YV22 YV9 YV3

YV6

YV25/26

YV17
9

SP7 SP1 1
T2512

2 - 29
002AZ001A
2 MACHINE FEATURES
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 reservoir

1 Suction filter
2 High pressure pump
3 Low pressure pump
4 Oil filter
5 Heat exchanger
14 Gate, Oil drain
BT10 Thermocouple
M1 Electric motor
M4 Oil recirculation motor
SL2 Sensor, Oil level
SP4 Pressure switch, Filter clogging

B Hydraulic control assembly

6 Control valve, Low pressure
7 Non-return valve, Low pressure circuit
8 Non-return valve, High pressure circuit
9 Pressure gauge, Low pressure
10 Pressure gauge, High pressure
11 Accumulator, High pressure
12 Accumulator, Low pressure
13 Control valve, High pressure
24 Non-return valve, Drain circuit
SP6 Pressure switch, Low pressure present
YYV21 Solenoid valve, Drain closure, High pressure circuit
YV27 Solenoid valve, Drain closure, Low pressure circuit

C Flow control assembly

15 Control valve, Pressure in actuator return circuit
16 restrictor, Drain circuit
17 Gauge, Pressure in actuator return circuit
18 Accumulator, Actuator return circuit
19 Flow regulator, Low pressure circuit
20 Flow regulator, High pressure circuit
21 Rotary joint
22 Actuator control valve
23 Hydraulic actuator
YV30 Shut off solenoid valve, Actuator approach circuit

2 - 30
 002AZ001A
MACHINE FEATURES 2

Figure 2.4.2/A - HYDRAULIC SYSTEM DIAGRAM

23

22

A
B
T
R

21

16

C
YV30

20 19
17
18

15

10 SP6
12 9
11

13
YV27

YV21 8 7
6

SP4
4 5
M1 M4
BT10 T

3
SL2
2 1 1

14
A
T2576

2 - 31
002AZ001A
2 MACHINE FEATURES

Figure 2.4.2/B - LAYOUT OF ELEMENTS IN HYDRAULIC SYSTEM

21 16

12 A

11 M1

23

22 14

T2523

A A
M1

12 SP4 4 BT10 5

11

YV21 SL2
T2522

B
18
SP6
YV30

YV27

13 9 10 M4 17

15

20
19
T2498
T2520

2 - 32
 002AZ001A
MACHINE FEATURES 2
2.4.3 COOLING SYSTEM DIAGRAM
(References given in figures 2.4.3/A and 2.4.3/B)

A Chiller
B Temperature regulator
C Press
D Hydraulic power unit
E Plasticization unit

UI Lower tools
US Upper tools

6 Heat exchanger
8 Non-return valve
9 Flow meter, Upper tools
10 Flow meter, Lower tools
11 Flow meter, Power unit
12 Thermostatic valve
13 Metering pump
14 Extruder gearbox
15 Extruder supply system
16 By-pass valves
17 Reservoir

BT18 Thermocouple, Lower tools temperature control

BT19 Thermocouple, Upper tools temperature control
BT20 Thermocouple, Extruder and hydraulic power unit temperature control
EH18 Heating element, Lower tools temperature control circuit
EH19 Heating element, Upper tools temperature control circuit
EH20 Heating element, Extruder and hydraulic power unit temperature control circuit
M18 Pump motor, Lower tools temperature control
M19 Pump motor, Upper tools temperature control
M20 Pump motor, Extruder and hydraulic power unit temperature control
SP2F Pressure switch, Lower tools cooling circuit
SP3F Pressure switch, Upper tools cooling circuit
SP18 Differential pressure switch, Lower tools temperature control
SP19 Differential pressure switch, Upper tools temperature control
SP20 Differential pressure switch, Extruder and hydraulic power unit temperature control
YV5 Solenoid valve, Cooling system shut off, Metering pump
YV7 Solenoid valve, Cooling system shut off, Extruder and hydraulic power unit
YV18 Solenoid valve, Exchanger shut off, Lower tools
YV19 Solenoid valve, Exchanger shut off, Upper tools
YV20 Solenoid valve, Exchanger shut off, Extruder and hydraulic power unit
YV28 Solenoid valve, Cooling system shut off, Upper tools
YV29 Solenoid valve, Cooling system shut off, Lower tools

2 - 33
002AZ001A
2 MACHINE FEATURES

Figure 2.4.3/A - LAYOUT OF ELEMENTS IN COOLING SYSTEM

6
C 10 9 D E

13 14 15
UI US

12

11 YV5
SP3F SP2F
8 8
YV17
YV29 YV28

M R M R M R

B
SP18 SP19 SP20

BT18 T BT19 T BT20 T

YV18 YV19 YV20

17

EH18 EH19 EH20

16 16 16

T2568

2 - 34
 002AZ001A
MACHINE FEATURES 2

Figure 2.4.3/B - LAYOUT OF ELEMENTS IN COOLING SYSTEM

B C

YV18 BT18
SP18

SP19
YV19

BT19
SP20

10
16 9

T1574

EH18 BT20 D

12
EH19
6

11
YV20
T2510

EH20

C YV7
SP2F T2522

YV5 E
SP3F

YV28

YV29

T2500 8 T1590

2 - 35
002AZ001A
2 MACHINE FEATURES

2 - 36
 002AZ001A
SAFETY EQUIPMENT AND PRECAUTIONS 3

3 SAFETY EQUIPMENT AND PRECAUTIONS

3.1 SAFETY DEVICES AND GUARDS

E0004P
WARNING!

3.1.1 GENERAL SAFETY RULES

The machine is provided with a number of electrical and/or mechanical safety devices in order to safeguard the
operators 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 simply for
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 to
observe 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 beacon
on 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 parts
or other dangerous components such as live or hot parts.

3-1
002AZ001A
3 SAFETY EQUIPMENT AND PRECAUTIONS
3.1.2.4 Emergency stop buttons

Emergency stop buttons on-board the machine

They 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 that controls the
solenoid valves.
- Reset: turn the button on the control panel to release it

Emergency stop button on the switchboard control panel

It 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 that controls the
solenoid valves.
- Reset: turn the button on the control panel to release it

Figure 3.1.2 - SAFETY DEVICES INSTALLED

1 Emergency stop button

2 Mechanical guards electrically interlocked
3 Fixed mechanical barriers 3 2

1 T2515

3-2
 002AZ001A
SAFETY EQUIPMENT AND PRECAUTIONS 3

3.2 SAFETY RULES FOR HANDLING

E0004P
WARNING!

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 being
used.
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 emergency
exits.
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.

3-3
002AZ001A
3 SAFETY EQUIPMENT AND PRECAUTIONS
3.3 INSTALLATION

E0004P
WARNING!

3.3.1 GENERAL RULES

Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations in
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 level
of 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 and
that there is a system for protection against voltage fluctuation in the electricity supply line. These must conform to laws
currently 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.

3-4
 002AZ001A
SAFETY EQUIPMENT AND PRECAUTIONS 3

3.4 OPERATOR TRAINING

E0004P
WARNING!

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 tasks
The 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 can
carry out the operations they are responsible for (as specified in the manual) in complete safety using suitable tools and
equipment.

Tasks for the maintenance staff

The 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.).

3-5
002AZ001A
3 SAFETY EQUIPMENT AND PRECAUTIONS
3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THE
MACHINE

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 to warn
operators of the danger.

E0007 E0010

Before performing any operation on the machine, including the replacement of components of the control panel or
electrical cabinet, the maintenance staff must shut off the electricity supply by using the main switch located on the
control panel. This switch should then be locked in position by using a padlock so that the machine cannot be accidentally
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 circuit
breakers.

E0017

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

E0004P

It may be necessary to temporarily remove or disable certain safety devices when making adjustments or servicing the
machine. Once these operations have been completed, it is highly important that the safety devices are put back in 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’s
instructions carefully. Carry out the scheduled maintenance operations exactly as described and at the time intervals
recommended.
In particular, regularly check all the safety devices for proper functioning. Also check the insulation of the electrical cables
and replace if necessary.
3-6
 002AZ001A
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 GUARDS

Temperatures 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 under
emergency conditions.

E0004P
WARNING!

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

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

3.5.2.2 Risk of explosion

O2

WARNING!
E0035P E0034D

Only use dry nitrogen, in cylinders provided with a pressure reducer, in order to pre-charge the accumulators.
Never, under any circumstances, use air compressors and/or oxygen.

3-7
002AZ001A
3 SAFETY EQUIPMENT AND PRECAUTIONS
3.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED

E0004P
WARNING!

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.

WARNING!
E0035P

Discharge the gas under pressure from the accumulators by using the tester/inflator provided. Follow the
instructions given in Chapter 8 in the CHECKING THE ACCUMULATOR PRE-CHARGE paragraph.

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 with
or dust from getting in.
Follow the instructions given in Chapter 9 - DECOMMISSIONING and observe current standards in force and safety
regulations regarding lifting and handling the machine and its parts.

3-8
 002AZ001A
INSTALLATION 4

4 INSTALLATION
4.1 SHIPPING AND HANDLING

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

DIMENSION AND WEIGHTS

The weights and dimensions of the individual parts, in relation to the shipping requirements, are approximate therefore
they are given for reference purposes only.

SYSTEMS FOR LIFTING INDIVIDUAL PARTS

The best systems for lifting and handling the heaviest and largest parts as well as those that require special care and
tools 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 safety
precautions.

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

E0004P
WARNING!
The manufacturer shall not be held responsible for any property damage or personal injury resulting from failure
to 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.

E0004P
WARNING!
The parts must be lifted and handled only by authorized persons who are specialized in carrying out this type of
operation.
It is vital that no persons are near the hanging load and/or within the range of action of the lift equipment while the
machine 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.

4-1
002AZ001A
4 INSTALLATION

Figure 4.1/A - DIMENSIONS AND WEIGHTS

1
kg 4600

11

2050

1650
1700 L.=1800 19
L.=1500

3
kg 450

13
L.=1000

6 17
kg 320

14
L.=2400

12

4 8
15

9 18
kg 520

16 10
T1548

4-2
 002AZ001A
INSTALLATION 4

Figure 4.1/B - DIMENSIONS AND WEIGHTS

1800

4200
1350 1400

2.1 50 kg/h 700

kg 600

3650 2.4 200 kg/h

2800 kg 4500
1360
1100

1350

2.3 150 kg/h

2.2 100 kg/h kg 4000 1100
700
kg 1300

5.2 50 kg/h - 220/480V

5.1 50 kg/h
kg 1350
kg 1250

2100 2100

2800 3200

600 600
T2530

5.3 100/150/200 kg/h 5.4 100/150/200 kg/h - 220V

kg 1700 kg 1900

2100 2100

4000
3600

600 600

Figure 4.1/A - 4.1/B - DIMENSIONS AND WEIGHTS

1 Press 8 Press lock 14 Slings for lifting electrical cabinet
2 Extruder 9 Tube trunk 15 Extruder feeder
3 Hydraulic power unit 10 Electric wires trunk 16 Feed hopper
4 Extruder connecting tube 11 Control panel 17 Temperature regulator
5 Electric cabinet 12 Crate with tubes and accessories 18 Chiller
6 Extruder tracks 13 Slings for lifting press 19 Extruder lift slings

4-3
002AZ001A
4 INSTALLATION
4.2 POSITIONING

The various parts of the machine are to be placed in the order given below, referring to figure 4.2.
- Position the press (1).
- Put the extruder tracks (6) in place.
- Place the extruder (2) on the tracks.
- Install the extruder connecting tube (4) making sure the coupling flange is clean. Tighten the nuts and bolts with a
torque wrench.
- Level the press (1) with the adjustable height legs.
- Secure the press (1) using the fixing blocks (8).
- Put the hydraulic power unit (3) in place.
- Position the temperature regulator (17).
- Put the chiller (18) in place.
- Put the electric cabinet (5) in its correct position.
- Install the plastic compound feed hopper (16) on the extruder.
- Mount the plastic compound feeder (15) on the hopper.
- Put the trunks (9 and 10) that protect the tubes and electric wires in place
- Put the control panel (11) in place.

Figure 4.2 - PUTTING THE PARTS IN PLACE

1 Press 6 Extruder tracks 15 Extruder feeder (optional)

2 Extruder 8 Press fixing block 16 Feed hopper (optional)
3 Hydraulic power unit 9 Tube trunk 17 Temperature regulator
4 Extruder connecting tube 10 Electric wires trunk 18 Chiller (optional)
5 Electric cabinet 11 Control panel

18 17 3 9 1

T1585

6 16 15 5 2 10 4 11

4-4
 002AZ001A
INSTALLATION 4

4.3 CONNECTIONS AND HOOK UPS

The machine must be hooked up to the various systems exclusively by specialized persons.

4.3.1 CONNECTING THE EXTRUDER TO THE PRESS

(References given in figure 4.3.1)
- Connect the extruder tube (1) to the flange (2) of the press by using the screws (3). Make sure the mating surfaces
are clean. Tighten with a torque wrench.
- Refit the tube (1) cover (4).

E0004P
WARNING!
Be very careful not to damage the electric wires of the heating elements while carrying out this operation.

Figure 4.3.1 - CONNECTING THE EXTRUDER TO THE PRESS

1 Extruder tube
2 Flange
3 Connecting screws
4 Cover

3
2

T2499

4-5
002AZ001A
4 INSTALLATION
4.3.2 HYDRAULIC CONNECTION: FROM THE POWER UNIT TO THE PRESS
(References given in figure 4.3.2)

Three tubes with different diameters are used to connect the hydraulic power unit to the press: 1", 3/4", 1/2".

- Connect the tubes on the hydraulic power unit (1) and press (2) in the order given starting from the biggest one 1"
then 3/4" then 1/2".
- Connect the 1/8" drain tube.

Figure 4.3.2 - HYDRAULIC CONNECTION

1 Hydraulic power unit

2 Press

2
1

T2531

1"

3/4"

500

1/2" 3/4" 1" 1/2" T1576

1/8"

4-6
 002AZ001A
INSTALLATION 4
4.3.3 HOOKING UP THE COOLANT SYSTEM
(References given in figure 4.3.3)

- Connect zones A and B of the temperature regulator by using two pairs of tubes (1" diameter) to the press (4), as
shown in the figure.
- Connect zone C of the temperature regulator (1) to the distribution block (5) mounted on the hydraulic power unit (2)
using a pair of tubes (1" diameter).
- Connect the distribution block (5) to the extruder (3) with the related delivery and return tubes (D).

Figure 4.3.3 - HOOKING UP THE COOLANT SYSTEM

1 Temperature regulator
2 Hydraulic power unit
3 Extruder
4 Press
5 Distribution block
AM Delivery line
AR Return line
BM Delivery line
BR Return line 3
CM Delivery line
CR Return line D 5
DM Delivery line
DR Return line 4
C
2 B 1
A
T2531

1 5

5
DM
CM BM AM
CR BR AR

DR CR
T2509
1 CM
T1589

4 3

BR
DR
BM
DM

T2500 AR AM T1579

4-7
002AZ001A
4 INSTALLATION
4.3.4 HOOKING UP THE PNEUMATIC SYSTEM
(References given in figure 4.3.4)

PNEUMATIC CONTROL UNIT

- Attach a hose whose inside diameter is as stated in the specifications to the fitting (A) from the compressed air supply.

PLASTIC COMPOUND FEEDER, located over the extruder hopper.

- Connect the tube B with quick-connect coupler provided on the extruder.
- Connect the plastic compound feeder to the pneumatic diverter control unit with the relative hose in the point marked
C in the figure.
The hose must have an inside diameter of 6 mm.

E0004P
WARNING!

The machine’s control unit is to be connected to the compressed air supply by the customer in compliance with
the regulations in force in the country where the machine is installed.

Figure 4.3.4 - CONNECTING THE PLASTIC COMPOUND FEEDER AND MAINS AIR

A Compressed air mains fitting

B Extruder quick-connect coupler C
C Plastic compound feeder coupler

T2512

4-8
 -
1 - Electric cabinet SCAT OIL (OIL BOX) - Hydraulic power unit box

4.3.5
2 - Press base SCAT P ESTR (EXTR P BOX) - Extruder power box

4.3.5.1
3 - Hydraulic power unit SCAT S ESTR (EXTR S BOX) - Extruder signal box
4 - Temperature regulator SCAT S TUBO (TUBE S BOX) - Extruder tube signal box
5 - Keyboard SCAT P TUBO (TUBE P BOX) - Extruder tube power box
6 - Extruder SCAT S UG (NOZZ S BOX) - Nozzle signal box
BQ1 - Encoder SCAT SUP DX (RH UPPER BOX) - Upper right-hand box
BQ2 - Thickness transducer SCAT SUP SX (LH UPPER BOX) - Upper left-hand box
BT10 - Thermocouple SCAT YV (YV BOX) - Pneum. control unit box
M1 - Motor SCAT BT (BT BOX) - Thermocouple box
M9 - Forming unit motor
Wiring connections

SCAT B INF (LOWER B BOX) - Left lower base box

SCAT MOT (MOTOR BOX) - Motor box
ELECTRICAL HOOK-UP

3
4
BT10
Figure 4.3.5.1 - WIRING CONNECTIONS

M4 M9
SCAT
2
M1 SCAT YV
OIL
SCAT
B INF SCAT
SUP.
DX
6
BQ2
BQ1
M6
SCAT SCAT
SUP SX S UG
SCAT SCAT
M2 M8
SCAT SCAT S TUBO P TUBO
S ESTR P ESTR
XJ23 XJ22

XT40 XJ21 XJ20 XJ18 XT8 XJ10 XJ9 XJ7 XJ5 XJ15 XT11

XJ19
XT30

XJ13
XJ3
XJ14

XJ3A
XJ4

XJ2
XJ12

XJ1

XT31 XJ17 XJ121 XJ16

1
M21 M10
INSTALLATION

identification numbers used in the diagram are those marked on the points to be connected and wires.

T2566
Make the electric connections between the various parts of the machine as indicated in figure 4.3.5.1. The
4

5
002AZ001A

4-9
002AZ001A
4 INSTALLATION
4.3.5.2 Earth connection

WARNING!
E0004P

The machine must be connected to an effective earth electrode. Join the earth electrode to the point marked PE
(EN60445).

In addition, join the earth electrode to the connection points on the machine frame marked with the symbol
E0006

(417-IEC-5019).

WARNING!
E0004P

Failure to earth the indicated parts may cause serious machine damage and personal injury.

4.3.5.3 Connection to the supply mains

The electrical cabinet has to be connected to the supply mains. Use a suitably sized four-pole cable as indicated in
the SPECIFICATIONS paragraph. The three wires R.S.T. are to be joined to the main switch terminals. Connect the
earth wire to the terminal marked PE located inside the electrical cabinet.

WARNING!
E0004P

As there are a number of electronic converters inside the electrical cabinet, make sure the ground fault circuit
interrupters on the power supply are of the B type (as recommended by CEI 64-8 specifications, par. 532.2.1.4)
thereby ensuring adequate protection against leakage currents.

4 - 10
 002AZ001A
START UP 5

5 START UP
5.1 INTRODUCTION

Initial machine start up is to be carried out by personnel specialized in both the mechanical and electric fields.

E0004P
WARNING!

Solely the manufacturer’s technicians responsible for starting up the machine are authorized to carry out these
operations, as indicated in chapter 1, GENERAL INFORMATION.
Severe damage to the machine and/or serious injury to persons may occur if carried out by other persons.
See chapter 6, OPERATING INSTRUCTIONS, for detailed information regarding the control keys.

The customer’s machine operator and maintenance staff must simply look on when the machine is started up (to better
understand the operating principle of the machine, how to adjust the auxiliary equipment, accessories and safety
devices and guards employed) and trial runs are carried out to check the adjustments made.

5.2 PRELIMINARY CHECKS

CONDITIONS:
- machine hooked up to the supply and air mains.

PROCEDURE
- Make sure the air mains pressure is as required (see paragraph 2.3 SPECIFICATIONS).
- Make sure the hoses that join the forming unit to the hydraulic power unit are correctly attached (see chapter 4 -
INSTALLATION).
- Make sure the hoses that join the forming unit, extruder and hydraulic power unit to the temperature regulator are
correctly attached (see chapter 4 - INSTALLATION).
- Make sure the hoses that join the temperature regulator to the chiller (if provided) or central cooling system are
correctly attached (see chapter 4 - INSTALLATION).
- Check to see whether all the shut off valves are open.
- Check the oil level in the hydraulic power unit.
- Check all the safety devices for efficiency.

5-1
002AZ001A
5 START UP
5.3 CHECKING OPERATION
(References in figure 6.1)

The instructions for setting the operating parameters, stated in this paragraph, are given in the Instructions B manual.

CONDITIONS
- Machine on

PROCEDURE
The operations described in this paragraph serve to check machine operation before starting the production run.
- Turn the mode selector (19-23) on the control panel to SET-UP.
- Open the guards of the forming unit and turn the handwheel for manual movements.
- Make sure there are no obstructions by allowing the forming drum to complete at least one full turn.
- Close the guards of the forming unit and turn the mode selector on the control panel to MAN.
- Press button 2 to start the temperature regulator for the extruder and dies.
- Make sure the coolant does not leak in any part of the machine (extruder, metering pump, forming unit, hydraulic
power unit).
The pre-set temperatures are related to the inert plastic compound fed to the extruder before the conveyor. The
temperatures flash on the “HEAT SYSTEM” page of the control unit.
- Make sure the charge pressure of the hydraulic accumulators is correct (low pressure = 2.5 MPa = high pressure =
9.0 MPa - actuator return circuit = 1.5 MPa).
- Start the hydraulic power unit by pressing key 8.
- Activate the high pressure circuit with key 10.
All the actuators will move up except for those found near the control cams for the hydraulic valves.
- Make sure the pressure in the high pressure circuit corresponds to that required as stated on the “Data Sheet”.
- Activate the low pressure circuit with key 16 and inactivate the shut-off system for the actuator drive circuit by using
key 11.
- Make sure the pressures in the low pressure circuit and actuator return circuit are as prescribed (see “Data sheet”).
- Make sure there are no oil leaks.
- Set the speed of the main motor to about 20% (see Instructions B).
- Start the main motor with key 3 and make sure the actuators run correctly while the drum is turning.
- Increase the speed until the desired production output (caps/min.) is reached.
- Make sure the actuators operate properly by referring to the control unit display and adjust the flow rate of the low
and high pressure circuits (see “Data Sheet”).
- Inactivate the high pressure circuits (key 10) and actuators (key 11).
- Wait until all the actuators have moved down and stop the forming unit (key 7)
- Inactivate the hydraulic power unit by pressing key 12.
- When the temperatures stop flashing on the “HEAT SYSTEM” page of the control unit display, start the plasticization
unit by using key 9.
- Make sure the extruder and metering pump can turn freely.
- Inactivate the plasticization unit by using key 13.

5-2
 002AZ001A
START UP 5

5.4 PRELIMINARY OPERATIONS

(References given in figure 6.1)

The instructions for setting the operating parameters, stated in this paragraph, are given in the Instructions B manual.

- Machine on.
- Call up the pre-set operating data for the material and product selected. This data can be set by following the
indications given on the data sheet.
- Make sure the temperatures of the temperature regulator coolant, extruder and oil are as indicated on the data sheet.
- Make sure the pressure in the pneumatic circuit for inserting the pellets is as indicated on the “data sheet”.
- Turn the mode selector switch to AUTOMATIC and press keys 2 and 28. The extruder heater, hydraulic power unit
heater and cooling unit will automatically start operating.
- Make sure the data for the molten material pressure, temperature of the upper punches, temperature of the lower
punches and the temperature for cooling down the hydraulic power unit correspond to those set for the related
instruments.
- Wait until the oil has reached the set temperature.
- Wait until the temperature in the various zones of the extruder has reached the required values.
- Make certain the temperatures given on the heat system page are not flashing.
- Load the feed hopper (if provided) drawing in the granular material by using key 21. Once the hopper is full, granular
material intake will automatically stop.
- Start the plasticization unit and wait until a certain amount of material flows through the by-pass system (when the
machine is started up for the first time, for example after the machine has not been used for several hours, all the
material inside the extruder has to be by passed).
- Stop the plasticization unit.
- Turn the mode selector on the control panel to SET-UP and open the guards of the forming unit.
- Start the plasticization unit and drain the nozzle (key 20). See the Operating Instructions chapter: SET-UP operations.
- Close the safety guards.
- Reset the temperature regulator (key 2).
- Turn the mode selector switch to AUTOMATIC
- Press keys 1 and 28.

5-3
002AZ001A
5 START UP
5.5 STARTING THE AUTOMATIC CYCLE

CONDITIONS
- Machine on and at the correct temperature
- Guards closed

- Turn the mode selector on the control panel to AUT

- Start the automatic cycle by using key 1.

5.6 SUBSEQUENT START UPS

- Perform only the operations described in the PRELIMINARY OPERATIONS paragraph.

5-4
 002AZ001A
OPERATING INSTRUCTIONS 6

6 OPERATING INSTRUCTIONS

E0004P
WARNING!

Closely follow the directions given in this manual and operate in accordance with all safety standards.

6.1 CONTROL AND MONITORING UNIT

The control and monitoring unit consists of an electric cabinet and a control keyboard.
The electric cabinet houses all the parts required for the electric drives of the devices (contactors, relays, etc.) and
processing devices for the signals that are transmitted from the sensors on the machine or keyboard (microprocessor
rack, motor drives, etc.).
The control keyboard allows the operator to run and control the machine. The keyboard is located on a pedestal at
the side of the machine. Its special design allows it to be placed in the most convenient position.
The following operations can be carried out from the control keyboard:
- Work cycle setting
- Setting or changing the operating parameters even during the production cycle
- Display of messages and operating parameters
- Storage and retrieval of the desired operating parameters
- Display of some statistics regarding production
- Self-diagnosis
- Maintenance control

NOTES:
- To better understand the following chapters, the figure showing the control keyboard and a description of the
keys is given below.
- Key 28 is the enable key. This key is to be pressed at the same time as the one selected to activate the function
controlled by it.

Figure 6.1 - CONTROL KEYBOARD

PANNELLO SUPERIORE

TOP PANEL

A Display
B Function keys
C Numeric keypad
D Write enable key selector
E Not used
F Cancels last character typed in
G Cancels last line written
H Cursor keys

+5 Keyboard supply (+5V)

R Reset
WD Watch-dog
SL Serial line (comes on if the keyboard is not properly connected to the microprocessor system)
SC Scan control (comes on to signal key malfunctioning)
B Comes on when a key is pressed
A1/A2 Keyboard address (both on ➝ first keyboard)

6-1
 6

6-2
002AZ001A

D
A
Figure 6.1 - CONTROL KEYBOARD

E
C
F
OPERATING INSTRUCTIONS

G
H

0 1 2 3 8 9 10 11 16 17 18 25 25 26

27 29

19-23
24 4 5 6 7 12 13 14 15 20 21 22 30 30 31
T2517
 002AZ001A
OPERATING INSTRUCTIONS 6

OPERATION 1st key 2nd Key KEY

Reset/safety module fault 0

Automatic cycle start 28 1 AUT
Extruder heating start 28 2
Machine start 28 3 MAN
Encoder reset 28 4 SET-UP
Automatic cycle stop 5 AUT
Extruder heating stop 6
Machine stop 7 MAN
Hydraulic power unit start 28 8 SETUP/MAN
Extruder by-pass start 28 9 SETUP/MAN
High pressure on/off 28 10 SETUP/MAN
Low pressure on/off 28 11 MAN
Hydraulic power unit stop 12 SETUP/MAN
Extruder by-pass stop 13 SETUP/MAN
Insertion drum in on/off 28 14 MAN
Insertion drum out on/off 28 15 MAN
Low pressure switch on/off 28 16 MAN
Temperature regulators start/stop 28 17
Jog start 28 18 MAN
By-pass valve on 28 20 SETUP/MAN
Plastic compound feeder start/stop 28 21 MAN
Preheating 28 22 AUT

Note: Two keys need to pressed for almost all the operations. However, some operations are carried out by
pressing a single key: in these cases the number of the key to press is given in the “2ND KEY column”.

6-3
002AZ001A
6 OPERATING INSTRUCTIONS
6.2 STARTING AND STOPPING THE MACHINE

SET-UP OPERATIONS
All the operations which the user has to access the machine directly, that is with the safety guards open are considered
part of set up.
Use maximum care when carrying out these operations. The mode selector (19-23) on the keyboard must be turned
to SET UP.

NOZZLE DRAIN
- Start the plasticization unit by using key 9.
- Press key 20 and keep it pressed until some molten material flows out. Collect and throw this material in the by-pass
collection box.
- Thoroughly clean the top of the nozzle.

ACTUATOR UPWARD MOVEMENT

Start the hydraulic power unit by using key 8.
Start the high pressure circuit by using key 10.

E0004P
WARNING!

The actuators move slowly up due to the low flow rate of the hydraulic fluid but exert the forming force once they
have reached the end of their stroke. It is therefore necessary to make sure nobody’s hands are between the tools
and that there are no objects have accidentally been left between them.

OPERATION IN MANUAL MODE

The mode selector (19-23) on the keyboard has to be turned to MAN.
The safety guards must be closed.
Under these conditions all the control keys are active except for key 20.

PREHEATING
The machine can automatically be preheated by setting the date and time the system is to come on.
Access the “Extruder programming” page and enter the data.
For further information on how to enter data, refer to the “Instructions B” manual.

6-4
 002AZ001A
OPERATING INSTRUCTIONS 6

6.3 AUTOMATIC CYCLE

Turn selector 19-23 to AUT to set the machine for automatic operation.

RUNNING THE MACHINE

Press key 1 on the control keyboard to run the machine in automatic mode. This will take place only if all the safety and
work conditions are met.
Messages that indicate faults which prevent the machine from operating will be shown on the keyboard display (see
Instructions B manual).
The sequence of operations carried out by the machine during an automatic cycle are shown in the flow chart below:

1 Cycle start key is pressed

2 Start of plasticization
Start of rotation
Actuators start

3 Drum speeds up to reach required speed

Insertion drum entry

4 Start of pellet ejection

5 Pellets inserted
Start of product rejection

6 End of product rejection

Start of production

STOPPING THE MACHINE

To stop the automatic cycle, press key 5 on the control keyboard. The sequence of operations carried out by the machine
during an automatic cycle are shown in the flow chart below:

1 Stop cycle key is pressed

2 End of pellet insertion

Extruder stops
3 Insertion drum exit
Actuators move down
Rotation stops

6-5
002AZ001A
6 OPERATING INSTRUCTIONS
6.4 PRODUCTION CYCLE

The production cycle for continuous forming by means of compression develops from a complete rotation of the forming
drum as illustrated in figures 6.4/A and 6.4/B.
N.B. The work position of the actuators are shown in the figures. These correspond to the numbers actually marked on
the actuators.

PRODUCTION STAGE

1 PELLET INSERTION
The pellets of plastic compound (DM) are picked up by the nozzle through the insertion drum (GI) and are deposited
in the die (MA) of the actuator.
32 ACTUATOR PAUSE
The die (MA), that contains the pellet, turns while staying down (A).
31-30 APPROACH
The valve that controls the actuators when up (B) (with oil at low pressure) opens thereby causing the die of the actuator
(MA) to move up until it reaches its “forming start” position.
29 FORMING
The valve that controls the actuators when up (C) (with oil at high pressure) opens a second time thereby causing the
die to move up until the pellets of plastic compound (DM) are completely formed.
28-7 PRODUCT COOLING
While the drum is turning, the formed product (PS) stays in its pressing position and cools down.
6 ACTUATOR DOWNWARD MOVEMENT
The valve that controls the actuators when down (A) is activated thereby causing the die to move down while the formed
product remains attached to the upper punch (PU).
2 ACTUATOR PAUSE
The die is empty and waits for another pellet (DM) to be inserted.
PRODUCT REMOVAL
The formed product (PS) is removed from the stripper ring (ES) and placed on the stripper wheel (SE) which carries
it to the exit channel.

CONTROL STAGES

29 START OF FORMING POSITION CONTROL

An inductive sensor controls the correct position for start of forming (see chapter 7 ADJUSTMENTS).
14 ACTUATOR CONTROL POSITION
An inductive sensor detects when the actuator fails to complete its forming stroke.
13 PRODUCT CONTROL
A proportional inductive sensor detects the position of the die during pressing.
The formed product is classified as follows depending on the position reached by the die:
- double weight (with double pellets)
- weight greater than standard nominal value
- weight corresponds to standard nominal value
- weight lower than standard nominal value
- no product (pellet not deposited)
DOUBLE WEIGHT
If a piece whose weight is double the standard one is detected, the machine automatically carries out an emergency
cycle (see “emergency cycles and resetting the machine for operation”).
PRODUCT WEIGHT GREATER OR LESS THAN STANDARD VALUE
If a piece whose weight is greater or less than the standard one is detected, the machine automatically carries out an
emergency cycle (see “emergency cycles and resetting the machine for operation”).
NO PRODUCT
If an empty die (MA) is detected because the pellet was not inserted, the machine carries out an emergency cycle (see
“emergency cycles and resetting the machine for operation”).

E0004P
ATTENTION!

When the machine is equipped to form products PS with a thin central panel pc, only the controls that detect “double
weight” and “no product” are active.

6-6
 002AZ001A
OPERATING INSTRUCTIONS 6

Figure 6.4/A - PRODUCTION CYCLE

DM - Pellet PS
ES - Stripper
GI - Insertion drum
MA - Die
pc - Central product panel
PS - Formed product
PU - Punch
SE - Stripper wheel

PU
pc
PC T1594

ES

PS
SE

GI
DM

MA

T1550

Figure 6.4/B - PRODUCTION CYCLE

A - Valve down: oil at high pressure

B - Valve in first position upwards: oil at low pressure
C - Valve in second position upwards: oil at high pressure
GI - Insertion drum
GS - Forming unit
1 - Pellet insertion product removal
6 - Actuator downstroke
28 - Product cooling
13 - Product control
14 - Actuator position control
29 - Start of forming position control
31 - Approach

6-7
002AZ001A
6 OPERATING INSTRUCTIONS

Figure 6.4/B - PRODUCTION CYCLE

16 17 18
15 19
14 20
13 21
12 22
11 23
10 24
9 GS 25
8 26
7 27
6 28
5 29
4 30
3 31
2 1 32

GI

17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 32 31 30
30 29 28 27 26
8 25 24 23 22 21 20 19 18

C C C C C C C C C C C C C C C C C C C C C C C
B B
A A A A A A A

C C C C
B
A A

T1598

6-8
 002AZ001A
OPERATING INSTRUCTIONS 6

6.5 EMERGENCY CYCLES AND RESET OPERATIONS

The machine is supplied with a control system that ensures safety under any working conditions. In fact, the entire
process is monitored for faults and precarious situations.

6.5.1 ACTUATOR DOWNSTROKE CONTROL

DESCRIPTION
To more precisely identify the components stated in this paragraph, refer to chapter 7 - ADJUSTMENTS. An inductive
sensor, secured to the base near the point in which the valve opens the drain, detects the start of the downstroke. If
this sensor is activated by the measurement rod, the machine performs the emergency cycle illustrated in the flow chart
below.
This system comes into action as the start of the actuator downstroke is delayed in relation to the theoretical point for
starting the downstroke. The most likely cause is the product is jammed between the tools.

DIAGRAM

1 actuator is detected up

2 stoppage with forming drum motor brake

insertion drum inactivated
by-pass opening
hydraulic power drained

3 plasticization unit stopped

hydraulic power unit stopped

RESET
As seen in the flow chart, the above mentioned safety feature causes the machine to stop running immediately. To
reset it, free the product from the tools.
To do this, proceed as follows:
- Turn the mode selector to MAN.
- Reset the machine with key 0.
- Start the hydraulic power unit with key 8.
- Press key 16 for low pressure.
- Press jog key 18 until the product is removed from the tools.
- Turn the mode selector to SET-UP.
- Open the safety guards.
- Locate and remedy the trouble.
- Carefully remove the product removed from the tools.

E0004P
ATTENTION!

Pay careful attention to the product and pellets located inside the lower tools or jammed in the upper tool.

- Close the safety guards.

- Turn the mode selector to AUT.
- Reset the machine with key 0.
- Restart the machine with key 1.

6-9
002AZ001A
6 OPERATING INSTRUCTIONS
6.5.2 ACTUATOR UPSTROKE CONTROL

DESCRIPTION
To more precisely identify the components stated in this paragraph, refer to chapter 7 - ADJUSTMENTS. An inductive
sensor secured to the base detects any incomplete forming strokes. If this sensor is activated by the measurement rod,
the machine performs the emergency cycle illustrated in the flow chart below.

DIAGRAMMA

1 actuator is detected down

2 forming drum stops

by-pass opening
hydraulic power drained

3 plasticization unit stopped

hydraulic power unit stopped

RESET
See the ACTUATOR DOWNSTROKE CONTROL paragraph.

6 - 10
 002AZ001A
OPERATING INSTRUCTIONS 6
6.5.3 DOUBLE PRODUCT DETECTION

DESCRIPTION
A proportional inductive sensor secured to the upper frame detects the position of the actuator once the product has
been formed. The product is determined to be double, heavier than the standard weight, equal to the standard weight,
lighter than the standard weight or missing (not deposited) according to this position. If a double product is detected,
the machine performs the emergency cycle illustrated in the flow chart below.

DIAGRAM

1 double product detected

2 pellet insertion in die in question stopped

product ejected

4 feed restarted

next detection: die empty

3
next detection: double product

5 counter activation
counter control > 3
6 end of cycle

RESET
As seen in the flow diagram, the above mentioned safety feature causes the machine to stop in the order for end of
cycle. No product is inside the tools except for the detected double product.
Proceed as follows:
- Turn the mode selector to SET-UP.
- Open the safety guards.
- Locate and remove the double product.
- Close the safety guards.
- Turn the mode selector to AUT.
- Reset the machine with key 0.
- Restart the machine with key 1.

6 - 11
002AZ001A
6 OPERATING INSTRUCTIONS
6.5.4 EMPTY DIE CONTROL

DESCRIPTION
If an empty die is detected, the machine performs the emergency cycle illustrated in the flow chart below.

DIAGRAM

1 empty die detected

2 counter for empty dies per run activated

counter control > 3
3 end of cycle

RESET
See “Double product detection”.

6.5.5 DETECTION OF PRODUCTS HEAVIER OF LIGHTER THAN NORMAL WEIGHT

DESCRIPTION
If a product that is heavier or lighter than normal weight is detected, the machine performs the emergency cycle
illustrated in the flow chart below.

DIAGRAM

1 heavy/light product detected

2 counter for empty heavy/light product per run is activated

start of delay time for stoppage due to defective product
product rejection
counter control = 32
3 yellow warning light comes on
message: “check extr. flow rate” appears
control end of delay time for stoppage due to defective product
4 end of cycle

RESET
As seen in the diagram a time during which the operator can intervene to reset the correct flow of molten plastic material
can be set. If no action is taken, the machine carries out the operations for end of cycle and then proceeds as described
in the DOUBLE PRODUCT DETECTION paragraph.

6 - 12
 002AZ001A
OPERATING INSTRUCTIONS 6
6.5.6 CORRECT POSITION FOR START OF FORMING CONTROL

DESCRIPTION
A pair of inductive sensors, secured to the base near the point in which the box distributor opens the high pressure port,
detect the start of the forming stroke. If both or none of these sensors are activated by the measurement rod, the machine
performs the emergency cycle illustrated in the flow chart below.

DIAGRAM

1 incorrect position detected

2 error counter per run activated

counter control = 32

3 start of delay time for stoppage due to defective product

yellow warning light comes on
control end of delay time for stoppage due to defective caps
4 end of cycle

RESET
As seen in the diagram a time during which the operator can intervene to reset the correct flow of oil under low pressure.
If no action is taken, the machine carries out the operations for end of cycle and then proceeds as described in the
DOUBLE PRODUCT DETECTION paragraph.

6 - 13
002AZ001A
6 OPERATING INSTRUCTIONS
6.6 PRODUCT SAMPLING

Press key 34 (see figure 2.1.1.3) to obtain samples consisting of several finished caps. The conveyor is used for this
purpose.
As a result, the quality of the product can be checked.

6 - 14
 002AZ001A
ADJUSTMENTS 7

7 ADJUSTMENTS
7.1 PLASTICIZATION UNIT

7.1.1 EXTRUDER

Adjusting the operating parameters

The parameters that can be set are found on the “Extruder” page of the electronic control system.
The following parameters are included:
1 - Temperature of the heat treatment zones (it affects the quality, characteristics and dimensions of the caps; it must
correspond to the value given on the data sheet)
2 - Extruder motor speed % (only for manual operations; used for by-passing, changing color)
3 - Coolant temperature (used to lower the oil temperature of the geared motor and the area under the hopper where
the material must be solid).

The values of these parameters are given on the “Data sheet”

E0004P
WARNING!

- Refer to the Instructions B manual for the control system for information on how to set the parameters.
- When carrying out operations in manual mode, never set the extruder motor to a speed % higher than the speed
% used for the metering pump. This may cause over pressure in the pump suction line consequently shutting down
the machine.

7.1.2 METERING PUMP

Adjusting the operating parameters

The parameters that can be set are found on the “Extruder” page of the electronic control system.
The following parameters are included:
- Speed % of the pump motor (used to change the pellet weight; it has to correspond to the value indicated on the “Data
sheet”).
- Suction pressure that has to correspond to that indicated on the “Data sheet”.
- Pump-casing temperature (it affects the quality, characteristics and dimensions of the caps; it must correspond to the
value given on the data sheet)

E0004P
WARNING!

- Refer to the Instructions B manual for the control system for information on how to set the parameters.
- When carrying out operations in manual mode, never set the extruder motor to a speed % higher than the speed
% used for the metering pump. This may cause over pressure in the pump suction line consequently shutting down
the machine.

7-1
002AZ001A
7 ADJUSTMENTS
7.1.3 FEED TUBE

Adjusting the operating parameters

The parameters that can be set are found on the “Extruder” page of the electronic control system.
The following parameters are included:
- Temperature (it affects the quality, characteristics and dimensions of the caps; it must correspond to the value given
on the data sheet)

E0004P
ATTENTION!

Refer to the Instructions B manual for the control system for information on how to set the parameters.

7.1.4 BY-PASS SYSTEM

Adjusting the operating parameters

The parameters that can be set are found on the “Extruder” page of the electronic control system.
The following parameters are included:
- Temperature (it affects the quality, characteristics and dimensions of the caps; it must correspond to the value given
on the data sheet)

E0004P
ATTENTION!

Refer to the Instructions B manual for the control system for information on how to set the parameters.

7-2
 002AZ001A
ADJUSTMENTS 7

7.2 INSERTION DRUM

Conditions:
- Mode selector turned to SET-UP
The adjustments given below are to be made with the machine at the correct work temperature.

7.2.1 ADJUSTING THE PRECHARGE OF THE DRUM’S CONNECTING ROD

- Loosen the nut that secures the upper eccentric pin (11 or 16) located at the end of the connecting rod (9).
- Push the insertion drum inside the forming drum by hand. As a result, the pin (11) will be under the back plate (12).
- Place the magnetic strip of a comparator (13) on the surface (14) of the actuator cam’s support. The comparator’s
sensor should rest on the disk (15).
- Reset the comparator.
- Tighten the eccentric pin (11) (the comparator will detect the vertical movement of the disk 15) until 0.25 mm is read.
- Tighten the nut for the eccentric pin (11).
- Bring the pin (16) against the plate (12).
- Fully tighten the nut for the pin (16).

Figure 7.2.1 - INSERTION DRUM

9 Connecting rod
11 Eccentric pin 13
12 Plate
13 Comparator 14
0
14 Cam support
15 Disk 0,25
16 Pin

15

12

16
11
9

T2526

7-3
002AZ001A
7 ADJUSTMENTS
7.2.2 ADJUSTING THE CUTTER

Conditions:
- Mode selector turned to SET-UP
- Extruder nozzle at correct temperature and machine safety guards open. The temperature of the plasticization unit
will continue to be controlled.
- The adjustments given below are to be made with the machine at the correct work temperature.

Adjustment
- Put the cutter in its work position by hand. Push it towards the forming unit until the end of the pneumatic cylinder’s
stroke is reached.
- Use the manual control handwheel to turn the drums clockwise until one of the 4 cutters 23B is in the middle of the
nozzle orifice.
- Loosen the two screws 23D (M3x8 mm) that secure the cutter blade.
- Place a strip whose thickness is as indicated on the data sheet (if the value is not given, use a strip that is 0.02 - 0.05
mm thick) between the cutting edge of the blade 23C and the upper edge of the nozzle.
- Put a screwdriver between the cutter 23B and blade 23C. Press on the blade until the cutting edge comes into contact
with the edge of the nozzle.
- Keep the cutter in place and fully tighten the two screws 23D that secure the blade.
- Repeat this procedure for the remaining three cutters.

E0004P
ATTENTION!

This operation is to be performed for all the cutters.

7-4
 002AZ001A
ADJUSTMENTS 7

Figure 7.2.2 - INSERTION DRUM

16
C
21

T2527

23
23A
23B 26
23C
23D
24

13

31 25 13 Connecting rod 26A Shaft

16 Stripper wheel 26B Sleeve
21 Insertion drum 26C Toothed wheel
30 23 Cutter 26D Toothed wheel
26
23A Insertion nozzle 26E Toothed wheel
23B Casing 26F Toothed wheel
23C Cutter 29 Disk
16
23D Screw 30 Mounting screws
24 Rotary distributor
26 Wheel drive mechanism
29

26F
26D
26E C

26B 26C

X mm

21 26A
T2577

T2571

7-5
002AZ001A
7 ADJUSTMENTS
7.2.3 ADJUSTING THE PELLET INSERTION STAGE
Two operations are to be carried out to adjust the pellet insertion stage.
(References given in figure 7.2.2)

Conditions:
- Mode selector turned to SET-UP

Mechanical adjustment
This adjustment allows the cutters to be in the correct position in relation to the cavity when the pellet is inserted.
This position can be changed by performing the following operations:
- Turn on the electrical cabinet.
- Select SET UP with selector switch SA1 (SET UP / MAN / AUT).
- Wait until the extruder has reached the set up temperature.
- Open the guards that protect the “pellet insertion” station.
- Put the cutter in its work position by hand. Push it towards the forming unit until the end of the pneumatic cylinder’s
stroke is reached.
- Use the manual control handwheel to turn the drums clockwise until the encoder reads 0°.
- Remove the guard that protects the belt found under the insertion drum’s connecting rod. Place a 6 mm socket head
wrench in the fitting at the bottom of the insertion drum’s pin. Keeping it blocked, loosen the screws (31) that secure
the pulley A with a 13 mm box wrench.
- Turn the insertion drum until the front end of the nozzle is at value X from the front edge of the cutter as shown on
the data sheet.
- Fully tighten the screws that secure the pulley without modifying the adjustments previously made.
- Put the safety cover back on.
- Start the machine in automatic mode to verify that the pellets are correctly inserted.

E0004P
WARNING!

The timing between the forming and insertion drums is correctly set before the machine leaves the factory.
Modifying this value may cause the machine to malfunction and/or damage it. Whenever the cogged belts, that
transmit motion from the forming drum to the insertion drum, are tensioned check for correct timing and restore
it as required.

7-6
 002AZ001A
ADJUSTMENTS 7
Adjusting the position and length of insertion
The position for insertion can be precisely adjusted (even during normal operation in automatic) by setting the
parameters (delayed insertion) and (length of insertion) given on page “CCM” of the control display. The compressed
air pressure can also be modified with the relative pressure regulator (see pneumatic system).
Refer to the Instructions B manual for further information on how to enter the data.

E0004P
ATTENTION!

The (insertion delay) and (length of insertion) parameters are strictly related to the type of material handled as well
as other variables. Therefore, observe the values given on the “Data sheet”.

Adjusting the stripper wheel

Conditions:
- Mode selector turned to SET-UP
Adjustments:
- Loosen the screws (30) that secure the wheel (16) to the disk (29).
- Put in the wheel (16) allowing it to turn in the slots for the screws (30).
- Fully tighten the screws (30).

7.3 FORMING UNIT

Figure 7.3 FORMING UNIT

1 Support shaft
2 Drum body
3 Pulley
4 Belt
5 Upper distributor
6 Lower distributor
7 Lower drum body
8 Hydraulic actuators
9 Die
10 Actuator control valve
11 Coolant duct (lower dies)
12 Tool cartridge
13 Upper drum body
14 Stripper drive rod
15 Fork
17 Fixed cam
18 Roller
19 Coolant duct (upper dies)

7-7
002AZ001A
7 ADJUSTMENTS

Figure 7.3 - FORMING DRUM

25 5

12
13

17

19

15

10

6
A

18

T2493
14
11

4
1
3

7-8
 002AZ001A
ADJUSTMENTS 7
7.3.1 PRODUCT REMOVAL ADJUSTMENT

The strippers are mechanically controlled by cams. The position of the cams is given on the “Data sheet”.

E0004P
WARNING!

Changing the position of the stripper cams among themselves and in relation to the actuator pilot cam may severely
damage the tools and the mechanical stripping parts.

7-9
002AZ001A
7 ADJUSTMENTS
7.3.2 ADJUSTING THE QUALITY CONTROL UNIT

MECHANICAL ADJUSTMENTS
For proper operation, each reference surface must be 3 +/- 0.05 mm away from the sensor while the actuators carrying
out the pressing cycle.
Proceed as follows:
- turn the mode key selector to set-up
- open the safety guards
- start the hydraulic power unit with the related button
- activate the high pressure valve with the related button
- wait until the actuators start the pressing cycle
- loosen the ring nuts (1)
- place a thickness gauge between the sensor (2) and the reference surface (3)
- adjust the height of the reference surface (3)
- tighten the ring nuts (1)
- close the safety guards and turn the mode key selector to MAN
- start the hydraulic power unit with the related button
- activate the low pressure valve with the related button
- turn the forming drum until all the actuators have moved down
- stop rotation

E0004P
WARNING!

The actuators move up slowly due to the low pressure at which the hydraulic fluid flows but exert the required force
for formation once they reach the end of their stroke.
Always make sure no one has their hands between the tools and that no objects are accidentally between them.

Figure 7.3.2/A - MECHANICAL ADJUSTMENT

A Precharge
2
1 Ring nuts
2 Sensor 3 ± 0,05
3 Reference surface 3
1
A

T1596

7 - 10
 002AZ001A
ADJUSTMENTS 7
ADJUSTING SENSITIVITY
The sensitivity for quality checking can be adjusted by setting the “low threshold, defective caps” and the “high threshold,
defective caps” parameters on the “CCM” page of the control display. This allows the dimension field within which the
product is considered acceptable to be defined. The system is able to detect 0.25 mm thickness variations of the “central
panel” of the product. Refer to the Instructions B manual for further information on how to set this data.

Figure 7.3.2/B - SENSITIVITY ADJUSTMENT

T1898

X+(> 0,25) X X-(> 0,25 )

7 - 11
002AZ001A
7 ADJUSTMENTS
7.4 PNEUMATIC SYSTEM

The following can be adjusted in the pneumatic system:

- mains supply 0.5 MPa
- pellet insertion line (consult the “Data sheet”)
- product removal (consult the “Data sheet”)

7.5 HYDRAULIC SYSTEM

7.5.1 ADJUSTING THE OIL FLOW UNDER LOW PRESSURE

The stroke the actuator carries out to reach the punch is approximately 15 mm less than its total stroke and is carried
out with oil under low pressure. The time employed to carry out this stroke depends on the speed of the forming unit.
As a result, the flow rate of the low pressure circuit is strictly related to the rpm. The position of the flow control valve
of this circuit is indicated on the “Data sheet”.
Defective products may be produced if the oil flow rate is incorrectly set. The yellow warning light on the electric cabinet
comes on to signal a fault condition. A pair of inductive sensors (20), located near the point where the valve is opened
a second time (i.e., oil starts flowing under high pressure), detect the point at which the forming stroke starts. If both
sensors are activated by the measurement rod (21), or neither of them are energized, the machine will emergency shut
down as described in the ‘OPERATING INSTRUCTIONS” chapter.
The position in which forming starts can be adjusted by using the position indicator given on the “CCM DATA” page of
the control unit display. The actuators are in the correct position when the above mentioned indicator is in position =.
If the indication is >, the actuators are higher than the theoretical position and the low pressure oil flow has to be
decreased. On the other hand, if < is indicated, the actuators are lower than the theoretical position, therefore the low
pressure oil flow needs to be increased. To make the required corrections work on the flow control (24).
The pressure of the low pressure circuit has no real technological functions, as it is not used during product formation.
If this value varies, restore the correct value (see the “Data sheet”) by working on the adjustment valve (22) located in
the hydraulic power unit.

7.5.2 ADJUSTING THE FORMING STAGE (HIGH PRESSURE)

To obtain good quality products, a certain speed and force have to be used during the forming stage. These are based
on the flow and pressure of the high pressure oil circuit respectively. The pressure is regulated by working on the relative
valve (25) located in the hydraulic power unit while the oil flow rate is set by the relative flow control (23).
The values are given on the “Data sheet”.

7.5.3 ADJUSTING THE ACTUATOR DOWNSTROKE

An inductive sensor detects when the downstroke starts. If this sensor is not activated by the measurement rod (21),
the machine carries out an emergency cycle. (See chapter 6 - “OPERATING INSTRUCTIONS”).
If the machine shuts down because a safety device for the actuators return stroke has come into action, the return
pressure for the actuator (hydraulic spring) may need to be adjusted to restore the correct value. This value is also strictly
related to the characteristics of the product used. The value is given on the “Data sheet”. To adjust this value, work on
the related valve (26).

E0004P
WARNING!

Excessive pressure during the actuator’s return stroke may cause the cylinders to bang violently against their end
stops.

7 - 12
 002AZ001A
ADJUSTMENTS 7

Figure 7.5 - PRODUCT REMOVAL ADJUSTMENT

20 Inductive sensors
21 Measurement rod
22 Low pressure adjustment valve
23 High pressure flow control
24 Low pressure flow control
25 High pressure valve
26 Actuator downstroke valve

22

25

T2498

21
(>)

(=)

(<)

20
T1580
23
24
26
T2520

7 - 13
002AZ001A
7 ADJUSTMENTS
7.6 COOLING SYSTEM

E0004P
ATTENTION!
Do not modify the values used for the thermostatic valve and temperatures set for the upper and lower tools,
indicated on the Data sheet, under any circumstances.

The thermostatic valve changes the oil temperature in the hydraulic system. This valve is adjusted manually.
The temperature of the tools are set on the EXTRUDER PAGE of the microprocessor control system.
The temperature set for the upper and lower tools affect the quality, characteristics and dimensions of the caps. See
the Data sheet for further information.

7.7 INSTALLING AND REMOVING THE TOOLING

The tooling to be used is strictly related to the type of product handled. The specifications for this unit are given in the
spare parts catalogue for the tools.

E0004P
WARNING!

The actuators move up slowly due to the low pressure at which the hydraulic fluid flows but exert the required force
for formation once they reach the end of their stroke.
Always make sure no one has their hands and/or limbs between the tools and that no objects are accidentally
between them.

7 - 14
 002AZ001A
ADJUSTMENTS 7

Figure 7.7 - TOOLING

7 Anti-rotation pin
2 Coolant manifold 8 Stripper
4 Nuts 9 Ring nut
5 Flange 10 Die
6 Tool cartridge 11 Support plate

4
2

9
10

11

T1597

7 - 15
002AZ001A
7 ADJUSTMENTS
7.8 ADJUSTING THE EXIT CHANNEL

Adjusting the angular position

The exit channel can be turned to center the product with the downstream machine’s entry.
Conditions:
- Mode selector turned to set-up.
Adjustments:
- Loosen the screw (12).
- Turn the cam (11) until the cap (16) is correctly positioned.
- Loosen the screws (14) and adjust the position of the back-plate (17), if necessary.
- Fully tighten the screws (14).
- Fully tighten the screw (12).

Adjusting timing in relation to the stripper wheel

Conditions:
- Mode selector turned to set-up.
Adjustments:
- Loosen the screw (18) by placing the wrench through the holes (9).
- Turn the belt (1) to change the position of its tooth (19) in relation to the stripper wheel’s compartment (20).
- Fully tighten the screws (18).

Tensioning the belt with compartments

Conditions:
- Mode selector turned to set-up.
Adjustments:
- Loosen the nut (21).
- Work on the adjuster (22) to loosen or tighten the belt (1).
- Fully tighten the nut (21).

7 - 16
 002AZ001A
ADJUSTMENTS 7

Figure 7.8 - ADJUSTING THE EXIT CHANNEL 1 Belt with compartments

9 Hole for wrench
11 Cam
12 Screw
14 Screw
16 Product
17 Back-plate
20 18 Screw
19 Paddle
9 20 Wheel compartment
21 Nut
22 Adjuster

19

18
A

16 21
1

17
22
T2514

A B

14 11 12

7 - 17
002AZ001A
7 ADJUSTMENTS
7.9 REPLACING THE INDUCTIVE SENSORS

When replacing the inductive sensors consult the chart below as they must be placed the correct distance away in order
to read properly.
If inductive proximity sensors SQ7, SQ23, SQ21, SQ22 or SQ24 are replaced, mark the position of the relative mounts
on the base so that they can be put back in the same spot when replaced.

SENSOR REFERENCE OBJECT DISTANCE X

SQ1 block 1 mm
SQ2 actuator rod 2 mm
SQ7 actuator rod 1 mm
SQ11 cap in wheel 1 mm
SQ21 actuator rod 1.5 mm
SQ22 actuator rod 1.5 mm
SQ23 actuator rod 2 mm
SQ24 actuator rod 1.5 mm

Figure 7.9 - REPLACING THE INDUCTIVE SENSORS

T2578

7 - 18
 002AZ001A
ADJUSTMENTS 7

7.10 RESETTING THE ENCODERS

- Turn the mode selector switch to set-up.

- Turn the unit with the handwheel for manual operations until inductive proximity sensors SQ1 and SQ11 are both
activated (both of them must be activated).
- Zero set the encoder (key turned to set-up).
- Turn the unit counter-clockwise 8.8° and zero set again by keeping keys 4 and 28 on the control panel pressed for
at least two seconds.

7 - 19
002AZ001A
7 ADJUSTMENTS

7 - 20
 002AZ001A
MAINTENANCE 8

8 MAINTENANCE
GENERAL INFORMATION AND SAFETY PRECAUTIONS

E0004P
WARNING!

Only expert personnel who know how the machine and plant in general operate well can carry out maintenance,
as indicated in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.
Take all the precautionary steps in order to prevent accidental machine start-up.
- turn the main switch on the board to OFF
- remove the safety key
- post a “maintenance in progress” sign on the electrical cabinet
- make sure the emergency stop buttons are pressed
Always keep in mind the potential risks and follow the safety rules given in chapter 3 - SAFETY EQUIPMENT AND
PRECAUTIONS.

The maintenance operations are subdivided as follows:

- routine maintenance (to be carried out by the customer’s maintenance staff)
- special maintenance (to be carried out by the manufacturer’s technicians or customer’s workers who have been
specially trained).

The following are some examples of routine maintenance:

- mechanical jobs: lubricating and cleaning the mechanical parts, replacing and tensioning the belts, replacing and
cleaning the hydraulic valves
- electric jobs: replacing the fuses in the electrical cabinet

Special attention is to be given to cleaning and/or replacing the tooling. These operations are to be performed as
directed in chapter 7 - ADJUSTMENTS.

E0004P
WARNING!

While centering, the lower tools move slowly while coming into contact with the upper ones but exert the forming
force once they have all reached the end of the stroke. Be extremely careful. The maintenance men’ hands or limbs
can get crushed.

8-1
 8

8.1

8-2
8.1.1
Interval (h) Lubricant time
Unit or part to be checked (***) Operation (min)
720 4320 8640 25920****
180 360 1440 2160 12960 Type (*) Q.ty (**)
(1 month) (6 months) (1 year) (3 years)

DRIVE UNIT
8.1.2.1.1
Check for wear and see if tight ● 10
Forming unit drive belt 8.1.2.1.2
002AZ001A

8.1.2.1.3 Replace, if required ● 180

MAINTENANCE

8.1.2.1.1
Forming drum transmission belt- Check belt for wear and see if tight ● 10
8.1.2.1.4
insertion unit shaft
8.1.2.1.5 Replace, if required ● 60
Oil in forming drum geared motor Check level ● 5
8.1.2.1.6
Add oil if necessary ● A 10
SCHEDULED MAINTENANCE

8.1.2.1.7 Change ❍ ● A 60
SCHEDULED MAINTENANCE CHART

50 Kg/h EXTRUDER
Extruder auger 8.1.2.2.1 Completely overhaul ● 300
Oil in extruder geared motor Check level ● 5
8.1.2.2.2
Add oil if necessary ● A 10
8.1.2.2.3 Change ❍ ● A 50
Nozzle 8.1.2.2.4 Clean nozzle ● 10
Clean connecting rod-nozzle coupler ● 10
Pressure transducers BP1, BP2 8.1.2.5 Check and set if necessary ● (2) 45
(*) Refer to the LUBRICANT SPECIFICATIONS paragraph.
(**) Estimated machine downtime to complete the operation.
(***) Refer to the relevant paragraphs.
(****) Contact SACMI's Customer Service Department before performing the indicated jobs to obtain any additional information.

❍ This symbol indicates when the operation is to be performed the first time if different from the intervals indicated by the ● symbol.
(2) Operation to be carried out even when fault messages 3071 (High melt pressure) and 3072 (low melt pressure) are displayed.
T2560
 Interval (h) Lubricant time
Unit or part to be checked (***) Operation (min)
720 4320 8640 25920****
180 360 1440 2160 12960 Type (*) Q.ty (**)
(1 month) (6 months) (1 year) (3 years)

100 Kg/h EXTRUDER

Extruder auger 8.1.2.3.1 Complete overhaul 300
Oil in extruder geared motor Check level ● 1
8.1.2.3.2
Add oil if necessary ● A 10

8.1.2.3.3 Change ❍ ● A 60
Extruder drive belts 8.1.2.3.9
Check for wear and see if tight ● 5
8.1.2.3.10
8.1.2.3.11 Replace, if required ● 60
Polymer metering pump 8.1.2.3.4 Clean outside ● 5

8.1.2.3.5 Complete overhaul ●

Nozzle Clean ● 10
8.1.2.3.7
Clean connecting rod-nozzle coupler ● 10
Universal joint 8.1.2.3.6 Lubrificate ● 10
Pressure transducers BP1, BP2 8.1.2.3.8 Check and set if necessary ● (3) 45
(*) Refer to the LUBRICANT SPECIFICATIONS paragraph.
(**) Estimated machine downtime to complete the operation.
(***) Refer to the relevant paragraphs.
(****) Contact SACMI's Customer Service Department before performing the indicated jobs to obtain any additional information.

❍ This symbol indicates when the operation is to be performed the first time if different from the intervals indicated by the ● symbol.
(3) To be carried out even if operations are performed on the polymer metering pump and fault messages 3071 (High melt pressure) and 3072 (low melt pressure) are displayed.
T2561
MAINTENANCE
8
002AZ001A

8-3
 8

8-4
Interval (h) Lubricant time
Unit or part to be checked (***) Operation (min)
720 4320 8640 25920****
180 360 1440 2160 12960 Type (*) Q.ty (**)
(1 month) (6 months) (1 year) (3 years)

150/200 Kg/h EXTRUDER

Extruder auger 8.1.2.4.1 Complete overhaul ● 300
Oil in polymer metering pump Check level ● 2
002AZ001A

geared motor 8.1.2.4.2

MAINTENANCE

Add oil if necessary ● A 10

8.1.2.4.3 Change ❍ ● A 60
Oil in extruder thrust block Check level ● 5
8.1.2.4.4
Add oil if necessary ● A 10

8.1.2.4.5 Change ❍ ● A 60 45
Polymer metering pump 8.1.2.4.6 Clean outside ● 5

8.1.2.4.7 Complete overhaul ● 180

Nozzle Clean ● 10
8.1.2.4.9
Clean connecting rod-nozzle coupler ● 10
Universal joint 8.1.2.4.8 Lubricate ● D 10
8.1.2.3.10
Pressure transducers BP1, BP2 Check and set if necessary ● (3) 45
8.1.2.4.10
Pressure switch SP8 and 8.1.2.3.11
Check and set if necessary ● (4) 45
pressure relief valve YV8 8.1.2.4.11
(*) Refer to the LUBRICANT SPECIFICATIONS paragraph.
(**) Estimated machine downtime to complete the operation.
(***) Refer to the relevant paragraphs.
(****) Contact SACMI's Customer Service Department before performing the indicated jobs to obtain any additional information.

❍ This symbol indicates when the operation is to be performed the first time if different from the intervals indicated by the ● symbol.
(3) Operation to be carried out even when fault messages 3071 (High melt pressure) and 3072 (low melt pressure) are displayed.
(4) Operation to be carried out even if fault message 3047 (Check SP8) is displayed.
 Interval (h) Lubricant time
Unit or part to be checked (***) Operation (min)
720 4320 8640 25920****
180 360 1440 2160 12960 Type (*) Q.ty (**)
(1 month) (6 months) (1 year) (3 years)

INSERTION DRUM
Cutter blades 8.1.2.5.1 Sharpen ● 20
8.1.2.5.2 Replace, if required ● 20
Cutters 8.1.2.5.3 Clean ● 10
8.1.2.5.4 Replace, if required ● 45
Pellet ejection and insertion nozzles 8.1.2.5.5 Clean ● 10
8.1.2.5.6 Replace, if required ● 45
Compressed air distributor 8.1.2.5.7 Clean ● 45
8.1.2.5.8 Replace, if required ● 45
Drum connecting rod 8.1.2.5.9 Check precharge ● 10
8.1.2.5.10 Adjust as required ● 10
Epicycloid gears 8.1.2.5.11 Lubricate and check condition ● D/G 5
8.1.2.5.12
8.1.2.5.13 Replace, if required ● 60
8.1.2.5.14
Gears 8.1.2.5.20 Lubricate and check condition ● D/G 5
8.1.2.5.16
Replace, if required ● 120
8.1.2.5.17
Insertion drum drive belt and relative 8.1.2.5.18
Check condition and see if tight ● 5
pulley 8.1.2.5.19
8.1.2.5.15
Replace, if required ● 120
8.1.2.5.16
FORMING DRUM
Forming unit 8.1.2.6.1 Clean ● 15
Actuator valves 8.1.2.6.2 Overhaul ● 500
8.1.2.6.3 Grease roller ● D/G 20
Hydraulic actuator: gasket 8.1.2.6.4 Replace ● 850
Upper flange: gaskets 8.1.2.6.5 Replace ● 850
Lower flange: gaskets 8.1.2.6.6 Replace ● 850
Stripper rod: roller and pin 8.1.2.6.7 Grease ● D/G 60
Stripper rod guide bush 8.1.2.6.8 Lubricate ● D/G 60
Central tool (optional): roller 8.1.2.6.9 Grease ● D/G 60
(*) Refer to the LUBRICANT SPECIFICATIONS paragraph.
MAINTENANCE

(**) Estimated machine downtime to complete the operation.

(***) Refer to the relevant paragraphs.
(****) Contact SACMI's Customer Service Department before performing the indicated jobs to obtain any additional information.
8
002AZ001A

8-5
❍ This symbol indicates when the operation is to be performed the first time if different from the intervals indicated by the ● symbol.
T2562
 Interval (h) Lubricant time

8-6
Unit or part to be checked (***) Operation (min)
720 4320 8640 25920****
180 360 1440 2160 12960 Type (*) Q.ty (**)
(1 month) (6 months) (1 year) (3 years)

CAMS
Stripper cam 8.1.2.7.1 Grease and check condition ● D/G 2
8.1.2.7.3 Replace, if necessary ● 120
Central cam drive cam (optional) 8.1.2.7.1 Grease and check condition ● D/G 2
8.1.2.7.2 Replace, if necessary ● 10
Actuator valve pilot cam 8.1.2.7.1 Grease and check condition ● D/G 2
002AZ001A

8.1.2.7.4 Replace, if necessary ● 45

MAINTENANCE

Cam if injecting air in punches 8.1.2.7.1 Grease and check condition ● D/G 2
8.1.2.7.5 Replace, if necessary ● 10
ROTARY DISTRIBUTOR
Gaskets 8.1.2.8.1 Replace ● 1200
HYDRAULIC SYSTEM
Press hydraulic power unit 8.1.2.9.1 Check oil level ● 2
8.1.2.9.2
8.1.2.9.3 Change oil/filter/flexible coupling ● B 290 300
8.1.2.9.4
Hydraulic power unit for 200 Kg/h 8.1.2.9.5 Check oil level ● 10
extruder
8.1.2.9.6
8.1.2.9.7 Change oil/filter/flexible coupling ● F 280 300
8.1.2.9.8
Pb pressure valve 8.1.2.9.9 Clean ● 15
Ph pressure valve 8.1.2.9.10 Clean ● 15
Pb pressure control solenoid valve 8.1.2.9.11 Clean ● 15
Ph pressure control solenoid valve 8.1.2.9.11 Clean ● 15
Reservoir 8.1.2.9.12 Check for condensate on bottom ● 5
Low pressure accumulator 8.1.2.9.13 Check and precharge, if necessary (1) ● 5
High pressure accumulator 8.1.2.9.13 Check and precharge, if necessary (1) ● 5
Actuator return circuit pressure 8.1.2.9.13 Check and precharge, if necessary (1) ● 5
(*) Refer to the LUBRICANT SPECIFICATIONS paragraph.
(**) Estimated machine downtime to complete the operation.
(***) Refer to the relevant paragraphs.

(****) Contact SACMI's Customer Service Department before performing the indicated jobs to obtain any additional information.

❍ This symbol indicates when the operation is to be performed the first time if different from the intervals indicated by the ● symbol.

(1) see the Data sheet for the values.

T2564
 Interval (h) Lubricant time
Unit or part to be checked (***) Operation (min)
720 4320 8640 25920****
180 360 1440 2160 12960 Type (*) Q.ty (**)
(1 month) (6 months) (1 year) (3 years)

PNEUMATIC SYSTEM
System 8.1.2.10.1 Clean filter ● 5
8.1.2.10.2 Clean silencer/replace ● 5
COOLING SYSTEM
Coolant 8.1.2.11.1 Check level ● 2
8.1.2.11.2 Add coolant, if necessary ● 10
8.1.2.11.4 Change filter ● 45
Filters 8.1.2.11.3 Clean ● 45
GUARDS
Safety devices 8.1.2.12.1 Check efficiency ● 5
AIR INJECTION DEVICE
Valves 8.1.2.13.1 Check ● 5
8.1.2.13.2 Replace, if necessary ● 240
PRODUCT EXIT CONVEYOR BELT
Belt 8.1.2.14.1
Check condition and see if tight ● 5
8.1.2.14.2
8.1.2.14.3 Replace, if necessary ● 60
Photocell for counting products 8.1.2.14.4 Clean ● 2
Slideways 8.1.2.14.5 Clean ● 5
(*) Refer to the LUBRICANT SPECIFICATIONS paragraph.
(**) Estimated machine downtime to complete the operation.
(***) Refer to the relevant paragraphs.
(****) Contact SACMI's Customer Service Department before performing the indicated jobs to obtain any additional information.

❍ This symbol indicates when the operation is to be performed the first time if different from the intervals indicated by the ● symbol.
T2563
MAINTENANCE
8
002AZ001A

8-7
002AZ001A
8 MAINTENANCE
8.1.2 PERIODIC MAINTENANCE OPERATIONS

8.1.2.1 Drive unit

8.1.2.1.1 Checking the condition of the drive belts

- Take the covers off to reach toothed belts (4 and 5).
- Make sure the teeth are not ruined (chipped or parts missing) and that there is not too much play between the tooth
and pulley. Replace the belt if ruined.

8.1.2.1.2 Tensioning the forming unit transmission belts

- Take off the bottom covers to reach the transmission belts
- Loosen the screws (1).
- Loosen the nut (2).
- Turn the screw (3) (screw it to tighten).
- Fully tighten the nut (2).
- Fully tighten the screws (1).

8.1.2.1.3 Replacing the forming unit transmission belts

- Take off the bottom covers to reach the transmission belts
- Loosen the nut (6).
- Loosen the screw (7).
- As soon as possible, pull the belt (5) off the pulley (8).
- Loosen the screws (1).
- Loosen the nut (2).
- Loosen the screw (3) until the belt (4) can be removed.
- Change the belt (4).
- Tighten the screw (3) to tension the belt.
- When the belt is tensioned, fully tighten the nut (2).
- Tighten the screws (1).
- Put the belt (5) on the pulley (6).
- Tighten the screw (7) until the reference plate is 0.1 mm (check the distance with a thickness gauge) from the end
of the support or transmission unit.
- Fully tighten the nut (6).
- Time the forming unit, insertion unit, exit wheel and exit channels (see chapter 7 - ADJUSTING THE PELLET
INSERTION STAGE).

8.1.2.1.4 Tensioning the insertion unit transmission belt

The belt is tensioned by loosening the nut (6) and then working on the screw (7) until the reference plate (9) is 0.1 mm
(check the distance with a thickness gauge) from the stop on the transmission unit support.
Fully tighten the nut (6).

8-8
 002AZ001A
MAINTENANCE 8
8.1.2.1.5 Replacing the insertion unit transmission belt
- Take off the bottom covers to reach the transmission belt.
- Loosen the screw (12) and remove the sensor mount with the sensor.
- Loosen the screws (10).
- Loosen the nuts (11) and remove the plate with the encoder.
- Loosen the nut (6).
- Loosen the screw (7) until the belt (5) can be removed.
- Change the belt.
- Tighten the screw (7) until the reference plate is 0.1 mm (check the distance with a thickness gauge) from the end
of the support or transmission unit.
- Fully tighten the nut (6).
- Install the mount with encoder by tightening the nuts (11).
- Fully tighten the screws (10).
- Install the mount with sensor by tightening the screw (12).
- Make sure the sensor is activated.
- Time the forming unit, insertion unit, exit wheel and exit channels (see chapter 7 - ADJUSTING THE PELLET
INSERTION STAGE).

8.1.2.1.6 Checking the oil level in the forming unit’s geared motor
- Make certain the oil level does not fall below the collar fixed to the level indicator’s tube (15). If it does, add oil through
the filler plug (14).

8.1.2.1.7 Changing the oil in the forming unit’s geared motor

- Attach the hose to the drain cock (13).
- Open the cock (13) and filler plug (14).
- Wait until the oil has completely flown out.
- Close the cock (13).
- Put oil in through the filler plug (14), checking the level by observing the indicator (15).
- Close the filler plug (14).

8-9
002AZ001A
8 MAINTENANCE

Figure 8.1.2.1 - DRIVE UNIT

22

21

9
7

11
8

12
5 6
T2513
16 17 18 19 20
10

15

14

13

1
2

3 4
T2528

8 - 10
 002AZ001A
MAINTENANCE 8
8.1.2.2 50 kg/h Extruder

8.1.2.2.1 Overhauling the extruder auger

- Remove the plastic compound from the auger chamber with the extruder at its operating temperature. To do this,
carry out a by-pass operation until the plastic compound no longer flows out of the nozzle.

E0004P
ATTENTION!
Stop feeding plastic compound to the extruder when cleaning.

- Shut off the machine with the main switch located on the electrical cabinet.
- Install the guide extensions provided.
- Loosen the screws (5).
- Disconnect the cables from the electrical boxes with the quick-connect couplers.
- Move the extruder to the end of the guides with the connecting tube attached. Clean up the plastic compound that
flows out of the tube and nozzle as soon as possible.

E0004P
ATTENTION!
Move the electrical cables away from under the extruder to avoid cutting them.

- Loosen the nuts (3) and remove the connecting tube. Clean up the plastic compound that flows out of the tube and
nozzle as soon as possible.
- Remove the filter (1).
- Take off the cover (6) found on the back of the extruder near the screw axis.
- Put in the fixture (7). While turning it, push the screw (8) forwards until it protrudes approximately 10 cm out of the
opposite side.
- Remove by hand being extremely careful when working near the auger as it is still very hot.
- Take out the fixture used to remove the extruder auger.
- Clean the auger, filter and extruder chamber as directed below.

E0004P
ATTENTION!
This operation is to be performed with the plastic compound at room temperature.

- Thoroughly clean the auger with hand tools, removing the resin sheath. If the surface is opaque and has turned dark,
polish it with brushes and abrasive pastes.
- Clean the inside of the cylinder with a brush, removing any material stuck to the cylinder.
- Thoroughly clean the filter (1). Replace it if worn. To open the filter holes, use a drill bit with 2.3 mm Ø (max.).
- Install the auger.
- Install the filter (1).
- Put in the connecting tube, tightening the nuts (3).
- Move the extruder near the nozzle body and tighten the screws (5).
- Hook up the electrical boxes.
- Put on the cover (6).
- Turn on the machine with the main switch.

8 - 11
002AZ001A
8 MAINTENANCE
8.1.2.2.2 Checking the oil level in the extruder geared motor and topping up
- Make sure the oil level, shown by the gauge (33), is correct. If it is not, top up as follows:
- Take off the cap (31).
- Add oil until the correct level (33) is reached.
- Screw the caps (31) back on.

8.1.2.2.3 Changing the oil in the extruder geared motor

- Take off caps (31 and 32); wait until all the oil has flown out of the geared motor or thrust block and then put the cap
(32) back on.
- Add oil until the correct level (33) is reached.
- Screw the caps (31) back on.

8.1.2.2.4 Cleaning the nozzle

- Remove any plastic compound that has built up on the nozzle (17) during operation. Be careful not to ruin the top
part where the cutters that cut the pellets pass by.

8 - 12
 002AZ001A
MAINTENANCE 8

Figure 8.1.2.2 - 50 kg/h EXTRUDER

6 31
33

32

17

T2575

8 - 13
002AZ001A
8 MAINTENANCE
8.1.2.2.5 Checking and setting pressure transducers BP1 and BP2
If one or both of the transducers read a pressure other than zero while the extruder is not working, set them as directed
below.
The procedure given below also has to be carried out when a new transducer is installed before starting the machine.
A - Start the temperature regulator for the extruder and wait until all the work zones reach the work temperature. Under
these conditions, the plastic compound in the polymer metering pump station will melt and the transducer’s probe
inside the pump can be completely tightened, when a new transducer is installed.

E0004P
ATTENTION!
The transducers have to be set while the polymer meter pump station is at the operating temperature.

B - Make sure the transducer probes are properly installed and relative cables connected:
BP1 (inlet pressure) cable XJ98;
BP2 (outlet pressure) cable XJ99.
C - First of all adjust transducer BP1.
D - Call up the DATA page on the display.
E - Adjust trimmer N until the display reads zero Bar while the extruder is at a standstill.
Remove the protective screw seen from the outside in order to access trimmer N, located on the bottom of the
transducer body.
F - Simulate the calibration pressure by placing a jumper between wires 752 and 753, leaving both wires connected.
Under this condition, the value displayed should be 80% of the nominal pressure value of the transducer (for 0
- 350 bar transducers the value should be 280 bar). If this value is not displayed, set trimmer B, located on the
bottom of the transducer, until the correct value is reached.
G - If trimmer B was adjusted, remove the jumper between wires 752 and 753. Zero set again by performing the
operations given at steps E and F.
H - Adjust transducer BP2, repeating the operations given at steps D, E, F and G. Work on wires 758 and 759 instead
of wires 752 and 753.

8 - 14
 002AZ001A
MAINTENANCE 8

Figure 8.1.2.2.5 - CHECKING AND SETTING PRESSURE TRANSDUCERS BP1 AND BP2

SYSTEM SYSTEM

T2580

8 - 15
002AZ001A
8 MAINTENANCE
8.1.2.3 100 kg/h Extruder

Figure 8.1.2.3 - 100 kg/h EXTRUDER

11 29 A
12
28
30

9
17 3
10

18
14
19
20
23

6
2 4 15
7
T2532

16 5

BT6 8
BT7
8
13
21
22

T2535

8 - 16
 002AZ001A
MAINTENANCE 8
8.1.2.3.1 Overhauling the extruder auger
- Remove the plastic compound from the auger chamber with the extruder at its operating temperature. To do this,
carry out a by-pass operation until the plastic compound no longer flows out of the nozzle.

E0004P
ATTENTION!
Stop feeding plastic compound to the extruder when cleaning.

- Shut off the machine with the main switch located on the electrical cabinet.
- Install the guide extensions provided.
- Disconnect the pressure transducers (4) with the quick-connect couplers found beneath the extruder mounting
brackets. Unscrew the probe attached to the pump being careful not to twist or bend the transducer cable.
- Take off the cover (10).
- Disconnect the electrical box cables with the quick-connect couplers.
- Remove the thermocouple (15) mounted on the nozzle body.
- Take off the covers that protect the connecting tube (14).
- Loosen the screws (13).
- Move the extruder to the end of the guides with the connecting tube attached. Clean up the plastic compound that
flows out of the tube and nozzle as soon as possible.

E0004P
ATTENTION!
Move the electrical cables away from under the extruder to avoid cutting them.

- Loosen the nuts (6) and remove the connecting tube. Clean up the plastic compound that flows out of the tube and
nozzle as soon as possible.
- Remove the heating elements (8) by loosening the mounting screw found under the volumetric pump.
Loosen the quick-connect coupler and take out thermocouples BT6 and BT7.
- Loosen the screw (9) to loosen the heating element.
- Remove the two screws (7) from the top of the volumetric pump and put in two longer screws passing them through
the eyebolts in the holes left free by screws (7). They are used to lift the pump.
- Loosen the screws (2) and remove the volumetric pump (5). Keep it up with the chains that have hooks attached
to the eyebolts previously installed.
- Remove the extruder filter (3) using the threaded holes that can be seen.
- Loosen the screws (11) and take off the cover that protects the threaded coupler for the fixture used to remove the
extruder.
- Put in the fixture supplied with the extruder, screwing it to the threaded coupler.
- Install the threaded extensions (12) provided with the extruder and tighten it until the auger comes out.
- Take out the fixture used to remove the extruder auger.
- Clean the auger (1), filter (3) and extruder chamber as directed below:

E0004P
ATTENTION!
This operation is to be performed with the plastic compound at room temperature.

- Thoroughly clean the auger with hand tools, removing the resin sheath. If the surface is opaque and has turned dark,
polish it with brushes and abrasive pastes.
- Clean the inside of the cylinder with a brush, removing any material stuck to the cylinder.
- Thoroughly clean the filter (3). Replace it if worn. To open the filter holes, use a drill bit with 2.3 mm Ø (max.).

8 - 17
002AZ001A
8 MAINTENANCE
- Install the auger in the extruder. Make sure the grooved extruder profile properly mats with the auger. Make certain
the cover on the extruder head is completely tightened (make sure the auger is fully in).
- Install the filter (3).
- Install the heating elements (9).
- Install the flange with the volumetric pump by fully tightening the screws (2) (when tightening, always work on the
diagonally opposite screw so that the filter is tightened evenly; once installed check the distance between the two
flanges with a thickness gauge to make sure installation is correct).
- Remove the two eyebolts and tighten the mounting screws (7) for the pump cover.
- Install the heating elements (8).
- Install the two thermocouples BT6 and BT7.
- Install the pressure transducers (4), screwing the probe attached to the pump and quick-connect coupler. Be careful
not to twist or bend the transducer cable.
- Attach the connecting tube to the extruder, tightening the nuts (6).
- Move the tube near the nozzle body and connect by tightening the screws (13) (make sure the ball is aligned with
the nozzle body).
- Connect the tube’s cables to the relative boxes.
- Put on the covers.
- Connect the thermocouple to the nozzle.
- Put on the covers (10).
- Screw the cover on the extruder assembly with the screws (11).
- Turn on the machine with the main switch.

8.1.2.3.2 Checking the oil level in the extruder geared motor and topping up
- Make sure the oil level, shown by the gauge (28), is correct. If it is not, top up as follows:
- Take off the cap (29).
- Add oil until the correct level (28) is reached.
- Screw the caps (29) back on.

8.1.2.3.3 Changing the oil in the extruder geared motor

- Take off cap (29).
- Take off cap (30) and drain the oil from the geared motor.
- Put the cap (30) back on.
- Add oil until the correct level (28) is reached.
- Screw the cap (29) back on.

8.1.2.3.4 Cleaning the polymer metering pump

- Remove all the plastic that flows out of the pump (5) being careful not to cut the pressure transducer and heating
element cables.

8.1.2.3.5 Replacing/overhauling the polymer metering pump

- Remove the plastic compound from the auger chamber with the extruder at its operating temperature. To do this,
carry out a by-pass operation until the plastic compound no longer flows out of the nozzle.

E0004P
ATTENTION!
Stop feeding plastic compound to the extruder when cleaning.

- Shut off the machine with the main switch located on the electrical cabinet.
- Install the guide extensions provided.
- Disconnect the pressure transducers (4) by loosening the quick-connect couplers found under the extruder
mounting bracket. Loosen the probe attached to the pump being careful not to twist or bend the transducer cable.
- Take off the cover (10).
- Disconnect the cables from the electrical boxes with the quick-connect couplers.
- Remove the thermocouple (15) mounted on the nozzle body.
- Take off the covers that protect the connecting tube (14).
- Loosen the screws (13).

8 - 18
 002AZ001A
MAINTENANCE 8
- Move the extruder to the end of the guides with the connecting tube attached. Clean up the plastic compound that
flows out of the tube and nozzle as soon as possible.

E0004P
ATTENTION!
Move the electrical cables away from under the extruder to avoid cutting them.

- Loosen the nuts (6) and remove the connecting tube. Clean up the plastic compound that flows out of the tube and
nozzle as soon as possible.
- Remove the heating elements (8) by loosening the mounting screw found under the volumetric pump.
- Loosen the quick-connect coupler and take out thermocouples BT6 and BT7.
- Loosen the screw (9) to loosen the heating element.
- Remove the two screws (7) from the top of the volumetric pump and put in two longer screws passing them through
the eyebolts in the holes left free by screws (7). They are used to lift the pump.
- Loosen the screws (2) and remove the volumetric pump (5). Keep it up with the chains that have hooks attached
to the eyebolts previously installed.
- Loosen the screws (16) and take out the flange attached to the metering pump.
- When overhauling the pump, follow the directions given in the User Manual furnished by the manufacturer supplied
with the pump or contact SACMI Customer Service Department.
- Install the overhauled or new pump by carrying out the operations in reverse order.

8.1.2.3.6 Lubricating the universal joint

- Take off the cover (21).
- Clean the universal joint and surrounding areas removing any extruded plastic material.
- Grease with the grease fittings (22).
- Put the cover (21) back on.

8.1.2.3.7 Cleaning the nozzle

- Remove the plastic compound that has deposited on the nozzle (23) during operation. Be careful not to ruin the top
part where the cutters that cut the pellets pass by.

8.1.2.3.8 Checking and setting pressure transducers BP1 and BP2

If one or both of the transducers read a pressure other than zero while the extruder is not working, set them as directed
below.
The procedure given below also has to be carried out when a new transducer is installed before starting the machine.
A - Start the temperature regulator for the extruder and wait until all the work zones reach the work temperature. Under
these conditions, the plastic compound in the polymer metering pump station will melt and the transducer’s probe
inside the pump can be completely tightened, when a new transducer is installed.

E0004P
ATTENTION!
The transducers have to be set while the polymer meter pump station is at the operating temperature.

B - Make sure the transducer probes are properly installed and relative cables connected:
BP1 (inlet pressure) cable XJ98;
BP2 (outlet pressure) cable XJ99.
C - First of all adjust transducer BP1.
D - Call up the DATA page on the display.

8 - 19
002AZ001A
8 MAINTENANCE
E - Adjust trimmer N until the display reads zero Bar while the extruder is at a standstill.
Remove the protective screw seen from the outside in order to access trimmer N, located on the bottom of the
transducer body.
F - Simulate the calibration pressure by placing a jumper between wires 752 and 753, leaving both wires connected.
Under this condition, the value displayed should be 80% of the nominal pressure value of the transducer (for 0
- 350 bar transducers the value should be 280 bar). If this value is not displayed, set trimmer B, located on the
bottom of the transducer, until the correct value is reached.
G - If trimmer B was adjusted, remove the jumper between wires 752 and 753. Zero set again by performing the
operations given at steps E and F.
H - Adjust transducer BP2, repeating the operations given at steps D, E, F and G. Work on wires 758 and 759 instead
of wires 752 and 753.

Figure 8.1.2.3.8 - CHECKING AND SETTING PRESSURE TRANSDUCERS BP1 AND BP2

SYSTEM SYSTEM

T2580

8 - 20
 002AZ001A
MAINTENANCE 8
8.1.2.3.9 Checking the condition and tensioning the extruder drive belt
- Take off the side panels found in the area where the motor is installed.
- Take off the cover (17).
- Make sure the belt (18) has not slackened and that the teeth are not ruined. If one of these problems is present,
proceed as directed below.

8.1.2.3.10 Tensioning the extruder drive belt

- Loosen the screws (19) with the covers and panels removed.
- Use the screws (20) to move the motor to tension the drive belt.
- Fully tighten the screws (19).
- Put the covers back in place.

8.1.2.3.11 Replacing the extruder drive belt

- Loosen the screws (19) with the covers and panels removed.
- Loosen the screws (20) and move the extruder to reduce the distance between the two pulleys until the toothed belt
can be removed.
- Replace the belt (18).
- Tension the belt as illustrated in the step above and tighten the screws (19).
- Put the covers back in place.

8 - 21
002AZ001A
8 MAINTENANCE
8.1.2.4 150-200 kg/h Extruder

Figure 8.1.2.4 - 150-200 kg/h EXTRUDER

2

28 5

BT6 8
BT7
8
29
11 30

21
22
16 27

12 26

25

T2535

17 15

23

3
4
10
6

T2534

14
15
24

20

13

8 - 22
 002AZ001A
MAINTENANCE 8
8.1.2.4.1 Overhauling the extruder auger
- Remove the plastic compound from the auger chamber with the extruder at its operating temperature. To do this,
carry out a by-pass operation until the plastic compound no longer flows out of the nozzle.

E0004P
ATTENTION!
Stop feeding plastic compound to the extruder when cleaning.

- Shut off the machine with the main switch located on the electrical cabinet.
- Install the guide extensions provided.
- Disconnect the pressure transducers (4) with the quick-connect couplers found beneath the extruder mounting
brackets. Unscrew the probe attached to the pump being careful not to twist or bend the transducer cable.
- Take off the cover (10).
- Disconnect the cables (20) from the electrical box with the quick-connect couplers.
- Remove the thermocouple (15) mounted on the nozzle body.
- Take off the covers that protect the connecting tube (14).
- Loosen the screws (13).
- Move the extruder to the end of the guides with the connecting tube attached. Clean up the plastic compound that
flows out of the tube and nozzle as soon as possible.

E0004P
ATTENTION!
Move the electrical cables away from under the extruder to avoid cutting them.

- Loosen the nuts (6) and remove the connecting tube. Clean up the plastic compound that flows out of the tube and
nozzle as soon as possible.
- Remove the heating elements (8) by loosening the mounting screw found under the volumetric pump (5).
Loosen the quick-connect coupler and take out thermocouples BT6 and BT7.
- Loosen the screw (9) to loosen the heating element.
- Remove the two screws (7) from the top of the volumetric pump and put in two longer screws passing them through
the eyebolts in the holes left free by screws (7). They are used to lift the pump.
- Loosen the screws (2) and remove the volumetric pump (5). Keep it up with the chains that have hooks attached
to the eyebolts previously installed.
- Remove the extruder filter (3).
- Disconnect the hydraulic lines mounted on the hydraulic motor (21).
- Loosen the screws (11) and remove the hydraulic motor (21).
- Put in the fixture supplied with the extruder, screwing it in the threaded holes in the thrust block (three screws 22
that secure the flange to the thrust block body have to be removed).
- Install the threaded extensions (12) provided with the extruder and tighten it until the auger comes out.
- Loosen the screw of the fixture used to remove the extruder auger (do not remove the plate).
- Clean the auger, filter and extruder chamber as directed below:

E0004P
ATTENTION!
This operation is to be performed with the plastic compound at room temperature.

- Thoroughly clean the auger with hand tools, removing the resin sheath. If the surface is opaque and has turned dark,
polish it with brushes and abrasive pastes.
- Clean the inside of the cylinder with a brush, removing any material stuck to the cylinder.
- Thoroughly clean the filter (3). Replace it if worn. To open the filter holes, use a drill bit with 2.3 mm Ø (max.).

8 - 23
002AZ001A
8 MAINTENANCE
- Install the auger in the extruder. Make sure the grooved extruder profile properly mats with the auger. Make certain
the cover on the extruder head is completely tightened (make sure the auger is fully in).
- Install the filter (3).
- Install the heating element (9).
- Install the flange with the volumetric pump by fully tightening the screws (2) (when tightening, always work on the
diagonally opposite screw so that the filter is tightened evenly; once installed check the distance between the two
flanges with a thickness gauge to make sure installation is correct).
- Remove the two eyebolts and tighten the mounting screws (7) for the pump cover.
- Install the heating elements (8).
- Install the two thermocouples BT6 and BT7.
- Install the pressure transducers (4), screwing the probe attached to the pump and quick-connect coupler. Be careful
not to twist or bend the transducer cable.
- Attach the connecting tube to the extruder, tightening the nuts (6).
- Move the tube near the nozzle body and connect by tightening the screws (13) (make sure the ball is aligned with
the nozzle body).
- Connect the tube’s cables to the relative boxes.
- Put on the covers.
- Connect the thermocouple to the nozzle.
- Put on the covers (10).
- Remove the plate for the fixture used to remove the auger. Tighten the three screws used to secure the plate.
- Install the hydraulic motor (21).
- Connect the hydraulic lines.
- Turn on the machine with the main switch.

E0004P
ATTENTION!
If the extruder auger cannot be installed, proceed as directed below:
- Make sure the extruder chamber the auger is mounted on is not dirty.
- If the auger cannot be installed even after the extruder chamber has been cleaned, remove the auger, connect
the thermocouples and heat up the extruder (approximately 200°) to expand the chamber; when the extruder is
hot and power to the machine is turned off, install the auger.

8.1.2.4.2 Checking the oil level in the polymer metering pump geared motor and topping up
- Make sure the oil level, shown by the gauge (26), is correct. If it is not, top up as follows:
- Take off the cap (25).
- Add oil until the correct level (26) is reached.
- Screw the cap (25) back on.

8.1.2.4.3 Changing the oil in the polymer metering pump geared motor
- Take off cap (25).
- Take off cap (27) and drain the oil from the geared motor.
- Screw the cap (27) back on.
- Add oil until the correct level (26) is reached.
- Screw the cap (25) back on.

8.1.2.4.4 Checking the oil level in the extruder thrust block and topping up
- Make sure the oil level, shown by the gauge (17), is correct. If it is not, top up as follows:
- Take off the cap (16).
- Add oil until the correct level (17) is reached.
- Screw the cap (16) back on.

8 - 24
 002AZ001A
MAINTENANCE 8
8.1.2.4.5 Changing the oil in the extruder thrust block
- Take off cap (16).
- Take off cap (15) and drain the oil from the geared motor.
- Screw the cap (15) back on.
- Add oil until the correct level (17) is reached.
- Screw the cap (16) back on.

8.1.2.4.6 Cleaning the polymer metering pump

- Remove all the plastic that flows out of the pump (5) being careful not to cut the pressure transducer and heating
element cables.

8.1.2.4.7 Replacing/overhauling the polymer metering pump

- Remove the plastic compound from the auger chamber with the extruder at its operating temperature. To do this,
carry out a by-pass operation until the plastic compound no longer flows out of the nozzle.

E0004P
ATTENTION!
Stop feeding plastic compound to the extruder when cleaning.

- Shut off the machine with the main switch located on the electrical cabinet.
- Install the guide extensions provided.
- Disconnect the pressure transducers (4) by loosening the quick-connect couplers found under the extruder
mounting bracket. Loosen the probe attached to the pump being careful not to twist or bend the transducer cable.
- Take off the covers (10).
- Disconnect the cables from the electrical boxes with the quick-connect couplers.
- Remove the thermocouple (15) mounted on the nozzle body.
- Take off the covers that protect the connecting tube (14).
- Loosen the screws (13).
- Move the extruder to the end of the guides with the connecting tube attached. Clean up the plastic compound that
flows out of the tube and nozzle as soon as possible.

E0004P
ATTENTION!
Move the electrical cables away from under the extruder to avoid cutting them.

- Loosen the nuts (6) and remove the connecting tube. Clean up the plastic compound that flows out of the tube and
nozzle as soon as possible.
- Remove the heating elements (8) by loosening the mounting screw found under the volumetric pump.
- Loosen the quick-connect coupler and take out thermocouples BT6 and BT7.
- Loosen the screw (9) to loosen the heating element.
- Remove the two screws (7) from the top of the volumetric pump and put in two longer screws passing them through
the eyebolts in the holes left free by screws (7). They are used to lift the pump.
- Loosen the screws (2) and remove the volumetric pump (5). Keep it up with the chains that have hooks attached
to the eyebolts previously installed.
- Loosen the screws (28) and take out the flange attached to the metering pump.
- When overhauling the pump, follow the directions given in the User Manual furnished by the manufacturer supplied
with the pump or contact SACMI Customer Service Department.
- Install the overhauled or new pump by carrying out the operations in reverse order.

8 - 25
002AZ001A
8 MAINTENANCE
8.1.2.4.8 Lubricating the universal joint
- Take off the cover (29).
- Clean the universal joint and surrounding areas removing any extruded plastic material.
- Grease with the grease fittings (30).
- Put the cover (29) back on.

8.1.2.4.9 Cleaning the nozzle

- Remove the plastic compound that has deposited on the nozzle (24) during operation. Be careful not to ruin the top
part where the cutters that cut the pellets pass by.

8.1.2.4.10 Checking and setting pressure transducers BP1 and BP2

If one or both of the transducers read a pressure other than zero while the extruder is not working, set them as directed
below.
The procedure given below also has to be carried out when a new transducer is installed before starting the machine.
A - Start the temperature regulator for the extruder and wait until all the work zones reach the work temperature. Under
these conditions, the plastic compound in the polymer metering pump station will melt and the transducer’s probe
inside the pump can be completely tightened, when a new transducer is installed.

E0004P
ATTENTION!
The transducers have to be set while the polymer meter pump station is at the operating temperature.

B - Make sure the transducer probes are properly installed and relative cables connected:
BP1 (inlet pressure) cable XJ98;
BP2 (outlet pressure) cable XJ99.
C - First of all adjust transducer BP1.
D - Call up the DATA page on the display.
E - Adjust trimmer N until the display reads zero Bar while the extruder is at a standstill.
Remove the protective screw seen from the outside in order to access trimmer N, located on the bottom of the
transducer body.
F - Simulate the calibration pressure by placing a jumper between wires 752 and 753, leaving both wires connected.
Under this condition, the value displayed should be 80% of the nominal pressure value of the transducer (for 0 -
350 bar transducers the value should be 280 bar). If this value is not displayed, set trimmer B, located on the bottom
of the transducer, until the correct value is reached.
G - If trimmer B was adjusted, remove the jumper between wires 752 and 753. Zero set again by performing the
operations given at steps E and F.
H - Adjust transducer BP2, repeating the operations given at steps D, E, F and G. Work on wires 758 and 759 instead
of wires 752 and 753.

8 - 26
 002AZ001A
MAINTENANCE 8

Figure 8.1.2.4.10 - CHECKING AND SETTING PRESSURE TRANSDUCERS BP1 AND BP2

SYSTEM SYSTEM

T2580

8 - 27
002AZ001A
8 MAINTENANCE
8.1.2.4.11 - Setting pressure switch SP8 and pressure relief valve YV8
- Disconnect the delivery hose from the hydraulic motor.
- Plug the disconnected hose.
- Place a pressure gauge with a 400 bar end scale value in the seat provided on the extruder’s hydraulic control
assembly.
- Set the volumetric pump to the minimum allowable speed (10%).
- Set pressure switch SP8 to a value higher than the 200 bar indicated on the knob’s graduated scale.
- Run the extruder motor at 20% of it speed.
- Adjust pressure relief valve YV8 until the pressure gauge reads 200 bar. Mark the position of the valve.
- Adjust the pressure relief valve until the pressure gauge reads 190 bar.
- Adjust the pressure switch so that it is activated when the line pressure reaches 190 bar.
- Set pressure relief valve YV8 to the marked position so that it is activated when a pressure of 200 bar is reached.

Figure 8.1.2.4.11 - SETTING PRESSURE SWITCH SP8 AND PRESSURE RELIEF VALVE YV8

YV8 SP8

T2581

8 - 28
 002AZ001A
MAINTENANCE 8
8.1.2.5 Insertion drum

Figure 8.1.2.5/A - INSERTION DRUM

E 11 10 12 9 7

A 4

T2548

1 2 3 B C 22 41 5 D 8 6

35 23 14 19 16 20 17 13 G

T2574

26 25 24 27 29 H 21 18 28 15 F

8 - 29
002AZ001A
8 MAINTENANCE

Figure 8.1.2.5/B - INSERTION DRUM

42
40 43
T2551

SURFACE TO BE ADAPTED

T2552

CORRECT POSITION POSITION WITH BELT SLACKENED

8 - 30
 002AZ001A
MAINTENANCE 8
8.1.2.5.1 Sharpening the cutters
- Loosen the two screws (26) and remove the cutter (25).
- Use an oilstone on the worktable with clamp to sharpen the cutting edges.
- Install the cutters and adjust as directed in the ADJUSTING THE CUTTER paragraph in chapter 7.

8.1.2.5.2 Replacing the cutters

- Loosen the two screws (26) and remove the cutter (25).
- Install the new cutter.
- Adjust the height of the cutter as directed in the ADJUSTING THE CUTTER paragraph in chapter 7.

8.1.2.5.3 Cleaning the cutters

- Loosen the screws (13 and 16) and ring nut (17).
- Pull out the insertion drum lifting the entire unit up from the cutter holder.
- Loosen the screw (18) at the worktable.
- Take out the cutter holder.
- Loosen the screws (23) and remove the cutter.
- Clean the cutter removing any burrs of plastic compound. Scour the part with a diluent.
- Install the cutter (24) by tightening the screws (23).
- Attach the cutter holder to the drum with screws (18).
- Install the drum on the shaft and tighten screws (13 and 16) and ring nut (17).
- Adjust the height of the cutter, time the wheel and adjust the exit channel as directed in the ADJUSTING THE
CUTTER and ADJUSTING THE PELLET INSERTION STAGE paragraphs in chapter 7.

8.1.2.5.4 Replacing the cutters

- Loosen the screws (13 and 16) and ring nut (17).
- Pull out the insertion drum lifting the entire unit up from the cutter holder.
- Loosen the screw (18) at the worktable.
- Take out the cutter holder.
- Loosen the screws (23) and replace the cutter.
- Install the cutter (25) previously removed from the old cutter.
- Install the cutter by tightening the screws (23).
- Attach the cutter holder to the drum with screws (18).
- Install the drum on the shaft and tighten screws (13 and 16) and ring nut (17).
- Adjust the height of the cutter, time the wheel and adjust the exit channel as directed in the ADJUSTING THE
CUTTER and ADJUSTING THE PELLET INSERTION STAGE paragraphs in chapter 7.

8.1.2.5.5 Cleaning the nozzles

- Loosen the screws (13 and 16) and ring nut (17).
- Pull out the insertion drum lifting the entire unit up from the cutter holder.
- Loosen the screw (18) at the worktable.
- Take out the cutter holder.
- Loosen the screws (23) and remove the nozzle.
- Check the condition of the seals, replacing them if worn down.
- Clean the nozzle (35) with diluent. Blow compressed air in the holes to eliminate any obstructions.
- Install the nozzle securing it with the cutter with screws (23).
- Attach the cutter holder to the drum with screws (18).
- Install the drum on the shaft and tighten screws (13 and 16) and ring nut (17).
- Adjust the height of the cutter, time the wheel and adjust the exit channel as directed in the ADJUSTING THE
CUTTER and ADJUSTING THE PELLET INSERTION STAGE paragraphs in chapter 7.

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002AZ001A
8 MAINTENANCE
8.1.2.5.6 Replacing the nozzles
- Carry out the same operations as those indicated in the CLEANING THE NOZZLES paragraph, replacing the old
nozzle with the new one.

8.1.2.5.7 Cleaning the compressed air distributor

- Loosen the screws (13) and ring nut (17).
- Pull out the insertion drum lifting the entire unit up from the cutter holder.
- Remove the flange (27).
- Blow compressed air in the holes of the distributor (27). Dust the distributor and any nearby parts.
- Carry out the operations in reverse order to put the parts back in place.
- Adjust the height of the cutter, time the wheel and adjust the exit channel as directed in the ADJUSTING THE
CUTTER and ADJUSTING THE PELLET INSERTION STAGE paragraphs in chapter 7.

8.1.2.5.8 Replacing the compressed air distributor

- Loosen the screws (13) and ring nut (17).
- Pull out the insertion drum lifting the entire unit up from the cutter holder.
- Remove the flange (27).
- Make sure the height of the pad (28) is not less than 2.8 mm. Replace it if it is.
- Carry out the operations in reverse order to put the parts back in place.
- Adjust the height of the cutter, time the wheel and adjust the exit channel as directed in the ADJUSTING THE
CUTTER and ADJUSTING THE PELLET INSERTION STAGE paragraphs in chapter 7.

8.1.2.5.9 Checking the precharge of the drum’s connecting rod

- Make sure the connecting rod is charged 0.25 mm when engaged with the nozzle body insert as indicated in the
ADJUSTING THE PRECHARGE OF THE DRUM’S CONNECTING ROD paragraph in chapter 7.

8.1.2.5.10 Adjusting the precharge of the drum’s connecting rod

- Carry out the operations given in the ADJUSTING THE PRECHARGE OF THE DRUM’S CONNECTING ROD
paragraph in chapter 7.

8.1.2.5.11 Lubricating the epicycloid gears

- Loosen screws (13 and 14).
- Remove the parts left free by the screws so that the gears can be lubricated.
- Lubricate as required.
- Put the parts back in and tighten screws (13 and 14).
- Time the stripper wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph in chapter
7.

8.1.2.5.12 Replacing gears F

- Loosen the screws (13 and 16) and ring nut (17).
- Pull out the insertion drum. lifting the entire unit up from the cutter holder.
- Loosen the screw (18) at the worktable.
- Take out the cutter holder.
- Loosen the screws (15) and replace the gear F.
- Screw the wheel F to the cutter holder with screw (15).
- Screw the cutter holder to the flange with the screws (18).
- Mount the insertion drum on the drive shaft.
- Time the stripper wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph in chapter
7.

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MAINTENANCE 8
8.1.2.5.13 Replacing gears G
- Loosen the screws (13, 14 and 16) and ring nut (17).
- Remove the parts left free by screw ( 14).
- Pull out the insertion drum. lifting the entire unit up from the cutter holder.
- Loosen the screws (18) at the worktable.
- Take out the cutter holder.
- Remove the snap ring (19).
- Remove the wheel (G) at a worktable with vice.
- Remove the screws (29) that secure the bearings.
- Remove the bearings and replace the wheel (G).
- Put the bearings back in (clean and grease them before hand), tightening screws (29) that secure the flange to block
the bearings for last.
- Close the pack of bearings with the snap ring (19).
- Install the cutter holder with the screws (18).
- Place the insertion drum on the drive shaft.
- Install the parts held in place by screws (14 and 16) and fully tighten.
- Fully tighten screw (13) and ring nut (17).
- Time the stripper wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph in chapter
7.

8.1.2.5.14 Replacing gears H

- Loosen the screws (13, 14 and 16) and ring nut (17).
- Remove the parts left free by screw (14).
- Pull out the insertion drum. lifting the entire unit up from the cutter holder.
- Loosen the screws (18) at the worktable.
- Take out the cutter holder.
- Remove the snap ring (19).
- Remove the wheel (G) at a worktable with vice.
- Remove the snap ring (20).
- Take out the shaft (21) at a worktable with vice and remove the bearings remaining on the wheel (H).
- Put the wheel (H) back on part (21) using the bearings previously removed (clean and grease the bearings before
hand).
- Install the wheel (G) on part (H) (first clean and grease the bearings mounted between H and G).
- Install the cutter holder with the screws (18).
- Place the insertion drum on the drive shaft.
- Install the parts held in place by screws (14 and 16) and fully tighten.
- Fully tighten screw (13) and ring nut (17).
- Time the stripper wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph in chapter
7.

8.1.2.5.15 Replacing pulley A

- Loosen the nut (4).
- Loosen the screws (40) that secure the tensioner so that the belt can be slackened.
- Loosen the screws (3) that secure the guard to the connecting rod.
- Loosen the self-locking ring nut (2).
- Loosen the screws (1) that hold the pulley in place and replace the pulley with a new one.
- Put belt (B) in place.
- Tighten the tensioner’s screws.
- Tighten screws (1) and ring nut (2).
- Tighten the tensioner’s nuts.
- Check and time the stripper wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph
in chapter 7.

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8 MAINTENANCE
8.1.2.5.16 Disassembling the pulley/toothed wheel C
- Loosen the nut (4).
- Loosen the screws (40) that secure the tensioner so that the belt can be slackened.
- Loosen the self-locking nut (7) and pull out the cap exit conveyor belt.
- Loosen the screws (10) and remove the plate.
- Loosen the screws (8 and 6) and remove the connecting rod from the support shaft.
- Loosen the screws (3) that secure the guard to the connecting rod.
- Loosen the ring nut (9) and remove the flange (12).
- Loosen the ring nut (5) and remove the toothed wheel (D).
- Loosen the screws (41 and 11) and remove the pin with the toothed wheel/pulley installed.
- Replace the toothed wheel/pulley at a worktable with vice working on the shaft after disengaging it from the snap
ring (22).
- Install the new wheel and form the pack of bearings.
- Attach the shaft with wheel installed to the connecting rod by tightening screws (41 and 11) (check the position of
the drive belt).
- Center the drive belt with the pulleys. Tighten screws (40) that secure the tensioner and tighten the nut (4).
- Install the wheel (D) by tightening the ring nut (5).
- Install the safety guard by tightening the screws (3).
- Install the connecting rod on the drive support making sure the wheel teeth mesh properly and tighten the screw
(6).
- Install the flange (12) and tighten screws (8).
- Install the exit conveyor belt plate and tighten with screws (10).
- Install the spacer and rack and tighten with ring nut (9).
- Install the exit conveyor belt and secure it in place with nut (7).
- Check and time the stripper wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph
in chapter 7.

8.1.2.5.17 Disassembling the pulley/toothed wheel D

- Loosen the nut (4).
- Loosen the screws (40) that secure the tensioner so that the belt can be slackened.
- Loosen the self-locking nut (7) and pull out the cap exit conveyor belt.
- Loosen the screws (10) and remove the plate.
- Loosen the screws (8 and 6) and remove the connecting rod from the support shaft.
- Loosen the screws (3) that secure the guard to the connecting rod.
- Loosen the ring nut (9) and remove the flange (12).
- Loosen the ring nut (5) and remove the toothed wheel (D).
- Replace the wheel (D).
- Center the drive belt with the pulleys. Tighten screws (40) that secure the tensioner and tighten the nut (4).
- Install the wheel (D) by tightening the ring nut (5).
- Install the safety guard by tightening the screws (3).
- Install the connecting rod on the drive support making sure the wheel teeth mesh properly and tighten the screw
(6).
- Install the flange (12) and tighten screws (8).
- Install the exit conveyor belt plate and tighten with screws (10).
- Install the spacer and rack and tighten with ring nut (9).
- Install the exit conveyor belt and secure it in place with nut (7).
- Check and time the stripper wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph
in chapter 7.

8.1.2.5.18 Tensioning belt B

- Loosen the nut (4).
- Wait until the spring inside block (42) moves the tensioner’s (43) pin forward.
- Fully tighten the nut (4).
- Check and time the wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph in chapter
7.

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MAINTENANCE 8
8.1.2.5.19 Replacing the toothed belt B
- Loosen the nut (4).
- Loosen the screws (40) that secure the tensioner so that the belt can be slackened.
- Loosen the self-locking nut (7) and pull out the cap exit conveyor belt.
- Loosen the screws (10) and remove the plate.
- Loosen the screws (8 and 6) and remove the connecting rod from the support shaft.
- Loosen the screws (3) that secure the guard to the connecting rod.
- Loosen the ring nut (9) and remove the flange (12).
- Loosen the ring nut (5) and remove the toothed wheel (D).
- Replace the belt (B).
- Install the wheel (D) by tightening the ring nut (5).
- Center the drive belt with the pulleys. Tighten screws (40) that secure the tensioner and tighten the nut (4).
- Install the wheel (D) and tighten with ring nut (5).
- Install the safety guard by tightening the screws (3).
- Install the connecting rod on the drive support making sure the wheel teeth mesh properly and tighten the screw
(6).
- Install the flange (12) and tighten screws (8).
- Install the exit conveyor belt plate and tighten with screws (10).
- Install the spacer and rack and tighten with ring nut (9).
- Install the exit conveyor belt and secure it in place with nut (7).
- Check and time the stripper wheel as directed in the ADJUSTING THE PELLET INSERTION STAGE paragraph
in chapter 7.

8.1.2.5.20 Lubricating the gears

- Remove the screws (3) and take off the cover.
- Lubricate the coupling between gears (C and D).
- Put the cover back on securing it in place with the screws (3).

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8 MAINTENANCE
8.1.2.6 Forming unit

Figure 8.1.2.6 - FORMING UNIT

14

15
T2537

13

12

11
10

5
6

T2553

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MAINTENANCE 8
8.1.2.6.1 Cleaning
- Remove any extraneous matter, paying special attention to the following parts:
• Check and remove any caps or waste material found on the machine base.
• Clean the cavities (5) inside and outside as well as the surrounding area, removing any plastic compound or caps
present.
• Clean the outside of the tools and the surrounding area, removing any plastic material present.
• Remove any oil present on the surfaces of the drum.

8.1.2.6.2 Overhauling the actuator valve

- Shut off electricity to the machine with the main switch located on the cabinet.

E0004P
ATTENTION!
The actuators must not be in position for forming.

- Loosen the screws (3).

- Remove the control for valve (1).
- Remove the element (2) using the two threaded holes present at the top of the valve.
- Carry out the following operations to overhaul the valve:
• Remove any oil present on the valve.
• Replace the gaskets and springs found inside and outside the valve.
- Put the valve parts back in place.
- Install part (2) being careful not to cut the gaskets.
- Install part (1) by tightening the screws (3).

8.1.2.6.3 Greasing the roller

- Grease the valve roller with grease fittings (4). Use the grease gun provided.
- Clean up any extra grease present on the valve.

8.1.2.6.4 Replacing the hydraulic actuator gasket

- Shut off electricity to the machine with the main switch located on the cabinet.

E0004P
ATTENTION!
The actuators must not be in position for forming.

- Turn the forming unit manually with the handwheel found over the motor until the actuator corresponds to the hole
in the base.
- Disconnect the tubes (9) from the coupling mounted on the drum manifold. Pour the coolant that flows out of the
tube into a container to avoid getting the machine dirty.
- Remove the cavity (5).
- Loosen the two head screws and remove the flange (6).
- Loosen the screw (7) and remove the clamp that prevents rotation.
- Loosen the screws (8) and remove the lower flange.

E0004P
ATTENTION!
The oil in the drum cavity flows out when the lower flange is unscrewed.

- Remove the hydraulic actuator and replace the gasket.

- Carry out the operations in reverse order to put the parts back in place.

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8 MAINTENANCE

E0004P
ATTENTION!
Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself.

8.1.2.6.5 Replacing the upper flange gaskets

- Shut off electricity to the machine with the main switch located on the cabinet.

E0004P
ATTENTION!
The actuators must not be in position for forming.

- Disconnect the tubes (9) from the coupling mounted on the drum manifold. Pour the coolant that flows out of the
tube into a container to avoid getting the machine dirty.
- Remove the cavity (5).
- Loosen the two head screws and remove the flange (6).
- Replace the gaskets.
- Carry out the operations in reverse order to put the parts back in place.

E0004P
ATTENTION!
Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself.

8.1.2.6.6 Replacing the lower flange gaskets

- Shut off electricity to the machine with the main switch located on the cabinet.

E0004P
ATTENTION!
The actuators must not be in position for forming.

- Disconnect the tubes (9) from the coupling mounted on the drum manifold. Pour the coolant that flows out of the
tube into a container to avoid getting the machine dirty.
- Loosen the screw (7) and remove the clamp that prevents rotation.
- Loosen the screws (8) and remove the lower flange.

E0004P
ATTENTION!
The oil in the drum cavity flows out when the lower flange is unscrewed.

- Replace the gaskets.

- Carry out the operations in reverse order to put the parts back in place.

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MAINTENANCE 8

E0004P
ATTENTION!
Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself.

8.1.2.6.7 Greasing the roller and stripper rod pin

- Grease the rod wheel with grease fitting (15) found on the support pin for the wheel. Use the grease gun provided.

8.1.2.6.8 Lubricating the stripper rod guide bushes

- Loosen the nut (10) and take out the spacer.
- Loosen the pin (12).
- Take out the fork (11) and stripper (13) at the same time.
- Raise the rod and grease the cylindrical surface that has just been exposed. Push the rod inside the unit so that the
grease lubricates the bushes. Repeat this operation several times to assure the lubricant penetrates.
- Carry out the operations in reverse order to put the parts back in place.

8.1.2.6.9 Greasing the central tool wheel (optional)

- Grease the central tool wheel with grease fitting (14) found on the support pin for the wheel. Use the grease gun
provided.

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8 MAINTENANCE
8.1.2.7 Cams

Figure 8.1.2.7 - CAMS

10

14
12

20 11
19 16 15 13 18 17

T2538

1 T2539
2

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 002AZ001A
MAINTENANCE 8
8.1.2.7.1 Greasing and checking
- Check the condition of the cam raceway. If the raceway is worn, replace it without delay.
- Grease the cam raceway. To grease the actuator control cams, take off the covers (8) using the mounting screws
provided.

8.1.2.7.2 Replacing the stripper cams (central movement) (optional)

- Loosen the screws (9).
- Replace the cam (3).
- Position the cam as indicated on the “Data sheet”.
- Fully tighten the screws (9).
- Check the position of the cam.
- Grease the cam raceway.

8.1.2.7.3 Replacing the stripper cams (side movement)

- Remove seven stripper rods from the forming drum from the side opposite the operator, as indicated below.
Loosen the nut (10) (see figure 8.1.2.6 - FORMING DRUM).
- Pull out the stripper rod being careful not the damage the stripper (13) (see figure 8.1.2.6 - FORMING DRUM).
- Remove the stripper ring with the fork installed (see figure 8.1.2.6 - FORMING DRUM).
- Turn the drum manually until the part of the drum without any rods corresponds to the stripper cam.
- Loosen the screws (10).
- Replace the cam (4).
- Position the cam as indicated on the “Data sheet”.
- Fully tighten the screws (10).
- Check the position of the cam.
- Grease the cam raceway.
- Turn the drum manually until the part of the drum without any rods is on the side opposite the operator.
- Install the stripper rods.
- Install the ring (13) by inserting the fork (11) in the stripper rod and fully tightening the nut (10) (see figure 8.1.2.6
- FORMING DRUM) for all the rods.

8.1.2.7.4 Replacing the actuator control cams

- Loosen the screws (11 and 17).
- Take off the covers (12 and 18).
- Remove the pins (13).
- Loosen the screws (16).
- Remove the cam mount (15).
- Loosen the screws (14) and replace the cams.
- Carry out the operations in reverse order to put the parts back in place.
- Grease the cam raceway.

8.1.2.7.5 Replacing the cams for injecting air in the punches

- Loosen the screws (19 and/or 20) depending on the cam section to be replaced.
- Replace the cam and position it as indicated on the “Data sheet”.
- Fully tighten screws (19 and/or 20).
- Grease the cam raceway.

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8 MAINTENANCE
8.1.2.8 Rotary distributor

8.1.2.8.1 Replacing the gaskets

- Contact SACMI’S CUSTOMER SERVICE DEPARTMENT when carrying out this operation.

8.1.2.9 Hydraulic system

Figure 8.1.2.9/A - HYDRAULIC SYSTEM

23 23 20

17
19

21

22

16
7
18 29
30
10

5 12

11 1

3
4

13
8

6
14

T2542

8 - 42
 002AZ001A
MAINTENANCE 8

39
Figure 8.1.2.9/B - HYDRAULIC SYSTEM

41

42
T2543

40
31 32
38

T2555

37 33

36

T2565

36 35 34

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8 MAINTENANCE
8.1.2.9.1 Checking the oil level in the hydraulic power unit
- Make sure the oil level falls within the full and low level marks indicated on gauge (1). If the level is below minimum
pour in oil through the hole under the cap (7).

8.1.2.9.2 Changing the oil in the hydraulic power unit

- Unscrew the cap (7)
- Place a container for collecting the oil under the valve (8).
- Open the valve (8) and let the oil flow out until the tank in the hydraulic power unit is empty.
- Close the valve (8).
- Add oil until the level falls within the full and low level marks indicated on gauge (1).
- Put the cap (7) back in place.

8.1.2.9.3 Replacing the flexible coupling in the hydraulic power unit

- Disconnect the electrical cables from the boxes for motors (9 or 10).
- Loosen the screws (11 or 12) that secure the two motors to the hydraulic power unit control assembly.
- Lift the motor.
- Replace the connecting wheel found on one of the two half-flanges of the flexible coupling.
- Carry out the operations in reverse order to put the parts back in place.

8.1.2.9.4 Replacing the filter in the hydraulic power unit

- Disconnect the electrical cables from the boxes for motors (9 and 10).
- Loosen the screws (11 and 12) that secure the two motors to the hydraulic power unit control assembly.
- Lift the motors.
- Disconnect tubes (3, 4 and 5).
- Loosen the screws (2).
- Lift the control assembly.
- Loosen the clamp (13) and replace the wire filter (14). Once this has been done, tighten the clamp (13).
- Loosen the cartridge type filter (6) and replace it with a new one.
- Carry out the operations in reverse order to put the parts back in place.

8.1.2.9.5 Checking the oil level in the hydraulic power unit for 150/200 kg/h extruders
- Make sure the oil level falls within the full and low level marks indicated on gauge (31). If the level is below minimum
pour in oil through the hole under the cap (32).

8.1.2.9.6 Changing the oil in the hydraulic power unit for 150/200 kg/h extruders
- Remove the guards around the hydraulic power unit for the extruder.
- Unscrew the cap (32)
- Attach a hose to the cock (33) to collect the oil in a container.
- Open the valve (33) and let the oil flow out until the tank in the hydraulic power unit is empty.
- Close the valve (33) and remove the hose previously installed.
- Add oil until the level falls within the full and low level marks indicated on gauge (31).
- Put the cap (32) back in place.
- Put the guards back in place.

8.1.2.9.7 Replacing the flexible coupling for the 150/200 kg/h extruder motor-pump unit
- Detach the hoses (34) (use a container to collect the oil present in the hoses).
- Loosen the screws (36) and remove the pump (35).
- Replace the connecting wheel found on one of the two half-flanges of the flexible coupling.
- Carry out the operations in reverse order to put the parts back in place.

8.1.2.9.8 Replacing the filter in the hydraulic power unit for the 150/200 kg/h extruder
- Put a container under filter (37) to collect the oil.
- Loosen the filter (37).
- Replace the cartridge.
- Carry out the operations in reverse order to put the parts back in place.

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MAINTENANCE 8
8.1.2.9.9 Cleaning control valve Pb
- Unscrew the control valve (21).
- Loosen the screws (20) and lift up the block.
- Remove the part (30) by hand.
- Clean the regulator, block and part using compressed air.
- Carry out the operations in reverse order to put the parts back in place.

8.1.2.9.10 Cleaning control valve Ph

- Unscrew the control valve (22).
- Loosen the screws (19) and lift up the block.
- Remove the part (29) by hand.
- Clean the regulator, block and part using compressed air.
- Carry out the operations in reverse order to put the parts back in place.

8.1.2.9.11 Cleaning solenoid control valves Pb and Ph

- Before attempting to perform these operations, write down how the valve is directed as its position cannot be
changed when re-installed.
- Loosen the screws (23).
- Remove the solenoid valve.
- Divide bodies (16 and 17).
- Remove the cylinder (18) and thoroughly clean.
- Carry out the operations in reverse order to put the parts back in place. Be careful not to change the direction of the
valve.

8.1.2.9.12 Checking for condensate on the bottom of the tank

- See if there is any condensate on the bottom of the hydraulic power unit tank. If condensate is found, dry the damp
parts with a rag.

8.1.2.9.13 Checking the accumulator precharge

- Make sure there is no pressure in the hydraulic circuit.
- Unscrew the cap found on the side where the inflation valve (38) is installed.
- Unscrew the regulator (39).
- Open the bleeder (40).
- Screw the inflation tester found on the inflation valve manually.
- Secure the connector manually positioning the pressure gauge as required.
- Screw the regulator (39) observing the pressure gauge’s needle. When the needle moves from 0 continue turning
(1/2 a turn is enough; there is no need to fully tighten).
- Read the inflation pressure given on the gauge (to check the values, consult the DATA SHEET).
• To reduce the pressure.
- Slowly open the bleeder (40) until the desired pressure is reached.
• To increase the pressure.
- Take off the knurled cap (41).
- Attach the end of the hose (1/4" BSO at 60°) to connector (42).
- Attach the other end of the hose to the nitrogen source and pressurize (it is fundamental to wait until heat
exchanging caused by the pressures has stabilized before checking or precharging).

O2

WARNING!
E0035P E0034D

Only use dry nitrogen, in cylinders provided with a pressure reducer, in order to pre-charge the accumulators.
Never, under any circumstances, use air compressors and/or oxygen.

- To disassemble carry out the operations in reverse order.

- Make sure the inflator valve on the accumulator is well sealed.
- Screw the cap on the inflator valve side.

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8 MAINTENANCE
8.1.2.10 Air supply system

8.1.2.10.1 Cleaning the filter

- Loosen the screw (4), found under the filter (1), to let out any extraneous matter (for example: water created by the
condensate).

8.1.2.10.2 Cleaning and replacing the silencers

- Unscrew the silencers (3) and/or silencer (2).
- Blow compressed air to clean or replace, if necessary.
- Screw on the silencer (3) and/or (2).

Figure 8.1.2.10 - AIR SUPPLY SYSTEM

T2512

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8.1.2.11 Cooling system

8.1.2.11.1 Checking the coolant level

- Make sure the coolant level does not fall below the low level mark indicated on gauge (1). If the level is near or below
minimum add coolant as directed below.

8.1.2.11.2 Adding coolant

- Unscrew the cap (2).
- Add coolant (see paragraph 2.3.1 - SPECIFICATIONS) until the full level mark is reached.
- Screw on cap (2).

8.1.2.11.3 Cleaning the filters

- Close the valve (4).
- Remove the thermocouple (5).
- Loosen the filter (3) and place a container on the underlying parts to protect them from the fluid that may flow out.
- Remove the filter cartridge and blow air to clean.
- Carry out the operations in reverse order to put the parts back in place.

8.1.2.11.4 Changing the coolant

- Unscrew the cap (2).
- Detach the hoses from the fittings (6) and open the cock to let the coolant out. Collect the coolant in a container.
- Close the cock and attach the hose to the fitting.
- Pour in oil through the hole in the cap (2) in the percentages indicated in paragraph 2.3.1 - SPECIFICATIONS.
- Close the cap (2).

Figure 8.1.2.11 - COOLING SYSTEM

T2545

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8.1.2.12 Safety devices

8.1.2.12.1 Checking the efficiency of the safety devices

- With the machine set to automatic or manual mode, open one of the two protective panels (1).

E0004P
WARNING!
The machine must not be running.

- Make sure the “GUARDS OPEN” fault message appears on the control panel display.
- Close the panels.
- Carry out a RESET procedure to set the machine back to the correct work conditions.
- Repeat the same operations for the other panel.

Figure 8.1.2.12 - SAFETY GUARDS

T2546

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8.1.2.13 Air injection device

8.1.2.13.1 Checking the valves

- See if air flows out of the valve (22) when it is not activated by cams (1 and 2).

8.1.2.13.2 Replacing the valves

- Loosen the screws (21) when the valve is not activated (to be carried out on the side opposite the operator).
- Detach the air hose from valve (22).
- Replace the valve (22).
- Tighten the screws (21).
- Connect the air hose to the connector on the valve.

Figure 8.1.2.13 - AIR INJECTION DEVICE

22

21

T2540

T2538

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8.1.2.14 Product exit conveyor belt

8.1.2.14.1 Checking the condition of the belt

- Check the condition of the belt (33). Make sure the teeth are not excessively rounded or broken. Make sure the
paddles that convey the caps are not broken or damaged in any way. If problems are found, replace the belt as
directed below.

8.1.2.14.2 Checking belt tension

- Make certain the belt has not slackened as it will no longer be properly timed with the exit wheel . In addition, make
sure the side play is not excessive which would cause the belt to vibrate to a greater extent. To tension the belt, see
the ADJUSTING THE EXIT CHANNEL
paragraph in chapter 7.

8.1.2.14.3 Replacing the belt

- Loosen the nut (29).
- Loosen the screws that secure the guard (31) and take off the guard.
- Loosen the screw (30) until the belt can be removed from the pulleys.
- Replace the belt (33).
- Tension the belt as directed in the ADJUSTING THE EXIT CHANNEL
paragraph in chapter 7.
- Adjust the exit channel as directed in the ADJUSTING THE EXIT CHANNEL paragraph in chapter 7.
- Put the guard (31) back on.

8.1.2.14.4 Cleaning and centering the photocell

- Remove any plastic found in the hole in the photocell mount (32) as well as on the cap slide surface so that the
photocell can read properly.

8.1.2.14.5 Cleaning the cap slide surface

- Remove any plastic that has deposited on the cap slide surface as well as on the guides along the exit channel so
that the caps are not obstructed while traveling.

Figure 8.1.2.14 - PRODUCT EXIT CONVEYOR BELT

29
31

30

T2550

32 34 33

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8.1.3 LUBRICATION

8.1.3.1 Lubricant specifications

OIL

A 23°E - 50°C ISO 3498 - CC 320 (320 cSt. - 40°C)

B OIL HLP DIN 51524-2 VG46

F OIL PRESS 3000 ISO 46

GREASE

D Dropping point 200 °C - Worked penetration (DIN 51804) 300 dmm - Dynamic toughness 7000 mPas

G Density at 20 °C 0.92 - Dropping point (DIN ISO 2176) > 250 °C

Worked penetration (DIN ISO 2137) 310 - 340 dmm - Dynamic toughness 2000 - 4000 mPas
Approved for food and pharmaceutical industries in compliance with USDA-H1 standards.

When selecting the lubricants, consult the LUBRICANT HANDBOOK supplied under separate cover.

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8.1.4 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS

S.R. = Resisting section (mm2)

MS = Tightening torque (kgm)
V = Pre-load (corresponding to the tightening torque) (Kg).

NORMAL THREAD SCREWS

DIAMETER mm 4 5 6 8 9 10 12 14 16 18 20 22 24

THREAD mm 0.70 0.80 1.00 1.25 1.25 1.50 1.75 2.00 2.00 2.50 2.50 2.50 3

S.R. mm2 8.11 13.31 18.68 34.57 45.77 55.28 79.92 110.16 150.49 185.16 236.52 294.16 338

5S MS = kgm 0.22 0.43 0.73 1.81 2.33 3.23 5.46 8.33 12.72 16.02 24.88 33.10 44.00

V = kg 227 373 523 978 1282 1548 2238 3084 4214 5184 6823 8436 9880

8G-A4.80 MS 0.34 0.69 1.16 2.90 3.73 5.18 8.74 13.32 20.36 25.63 35.81 43.36 60.5

V 363 596 837 1549 2050 2477 3580 4935 6742 8295 10596 13178 15800

10K MS 0.49 0.96 1.64 4.07 5.25 7.28 12.28 18.74 28.63 36.04 50.36 60.97 85.3

V 511 839 1177 2178 2884 3483 5035 6940 9481 11665 14900 18532 21740

12K MS 0.58 1.16 1.96 4.89 6.30 8.73 14.74 22.49 34.36 43.25 60.43 73.16 100.9

V 613 1006 1412 2613 3460 4179 6042 8328 11377 13998 17830 22238 26000

FINE THREAD SCREWS

DIAMETER mm - - - 8 - 10 12 14 16 18 20 22 24

THREAD mm - - - 1.00 - 1.00 1.50 1.50 1.50 1.50 1.50 1.50 2

S.R. mm2 - - - 37.14 - 61.87 83.83 119.42 161.29 209.44 263.86 324.58 374.5

5S MS = kgm - - - 1.92 - 3.52 5.68 8.83 13.37 17.48 27.16 35.81 45.7

V = kg - - - 1040 - 1732 2347 3344 4516 5864 7688 9388 10800

8G MS - - - 3.08 - 5.63 9.09 14.12 21.39 27.96 38.65 52.10 66.00

V - - - 1664 - 2772 3756 5350 7226 9383 11821 11541 17200

10K MS - - - 4.33 - 7.91 12.78 19.86 30.08 39.32 54.36 73.82 91.00

V - - - 2340 - 3898 5281 7523 10161 13195 16623 21249 24300

12K MS - - - 5.19 - 9.50 15.34 23.83 36.09 47.18 65.23 88.79 110.0

V - - - 2808 - 4677 6338 9005 12194 15834 19948 21538 29200

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8.2 TROUBLESHOOTING

Whenever the machine shuts down, an error code along with a brief description appear on the control unit display.
Refer to the Instructions B manual for information on how to locate and clear the trouble. If safety devices come into
action, reset the machine as described in chapter 6 - OPERATING INSTRUCTIONS.

However, the following may cause malfunctioning:

- faults during the forming cycle
- defects in the formed product
The troubles, causes and actions to be taken are described on the following pages.

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TROUBLE CAUSE REMEDY

1 Irregular pellet insertion; some Operating parameters incorrectly set: Set the parameters as specified on
pellets are rejected or lost; cutting operating pressure, length of the “Data sheet”
burrs insertion, insertion delay

Cutter blades worn Sharpen or replace

Cutter body dirty Clean or replace

Cutter body not the right size Replace (see “Data sheet”)

Incorrect pellet insertion nozzle Replace (see “Data sheet”)

Cutter blades improperly adjusted Adjust (see chapter 7 -

ADJUSTMENTS)
Improper adjustment of insertion Adjust (see chapter 7 -
drum precharge ADJUSTMENTS)
Malfunctioning of solenoid valve Replace
YV33 for pellet insertion

2 Incomplete caps Rpm of polymer metering pump Set the parameter as specified on
incorrectly set (too low) the “Data sheet”

Incorrect rpm of the forming drum Set the parameter as specified on

(too high) the “Data sheet”
Incorrect high pressure flow rate Set the parameter as specified on
the “Data sheet”
Actuator gasket worn Contact the Customer Service Department
Coupling gasket worn Contact the Customer Service Department

3 Caps too heavy Rpm of polymer metering pump Set the parameter as specified on
incorrectly set (too high) the “Data sheet”

Insertion drum transmission worn Contact the Customer Service

Department

4 The machine rejects the caps even Incorrect reject threshold Set the parameter as required (see
though their weight is correct chapter 7 - ADJUSTMENTS)

5 An actuator does not move up The related hydraulic valve fails to Remove and clean the valve, replace
operate properly the return spring if necessary

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TROUBLE CAUSE REMEDY

6 Actuators do not operate Incorrect low pressure flow rate Set the parameter as required (see
properly: the dies do not close “Data sheet”)
correctly Hydraulic accumulator precharge Charge the accumulators with
decreased nitrogen until the correct value is
reached

7 Oil temperature too high Thermostatic valve incorrectly set Restore the correct values (see “Data
sheet”)
Coolant temperature incorrect Restore the correct values (see “Data
sheet”)

8 Actuators do not move down at The hydraulic valve used to move the Clean the valve
the end of the production run actuators up is stuck in the “open”
position

9 Melt pressure high/low Plastic compound incorrectly fed Check

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9 DECOMMISSIONING
MAKING THE MACHINE INOPERATIVE WHEN NO LONGER USED
The operations given below need to be carried out when the machine is no longer used:
- Turn off the machine’s power supply by using the factory’s main switch.
- Unplug the power cable from the electrical cabinet’s terminal block.
- Disconnect the cables that join the cabinet to the machine, detaching the connectors.
- Disconnect the line between the factory’s compressed air mains and the control unit.
- Disconnect the lines that join the cooling system to the water mains and factory drain line.

WARNING!
E0035P

Discharge the gas under pressure from the accumulators by using the tester/inflator provided. Follow the
instructions given in Chapter 8 in the CHECKING THE ACCUMULATOR PRE-CHARGE paragraph.

- Thoroughly clean the machine paying particular attention to the moving parts. Lubricate as a protective measure,
if necessary.
- Close the doors of the electrical cabinet and machine to prevent the parts from being tampered with, dust from
building up, etc.
- Activate all the safety devices provided.

DISMANTLING THE MACHINE

Remove the various parts of the machine by carefully observing all current safety regulations as well as following
the directions given in chapter 4 - INSTALLATION in this manual. Special attention must be given to the
procedures for lifting and handling the machine as well as the warnings and precautions given in paragraph 3.3 -
SAFETY RULES FOR HANDLING.

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