Plastic Caps Moulding Machine Production & Maintenance

USERS MANUAL
002AZ019A
ROTARY COMPRESSION MOLDING PRESS
CCM32M
T E C H N I C A L
D O C U M E N T A T I O N
E
N
G
L
I
S
H
Translation of original instructions
002AZ019A
USERS MANUAL
ROTARY COMPRESSION MOLDING PRESS
CCM32M
MANUFACTURER
S.C.
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
www.sacmi.com
PUBLISHED ON
30.07.2008 - 15.09.2010
VERSIONS
CCM32MA
002AZ019A
002AZ019A
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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 .................................................................................................... 1-2
1.4 USERS OF THE MANUAL ......................................................................................................... 1-2
1.5 WARRANTY ...............................................................................................................................1-3
1.6 SUPPLEMENTS .........................................................................................................................1-3
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR
IN THE MANUAL .......................................................................................................................1-4
1.8 MACHINE IDENTIFICATION PLATE ..........................................................................................1-6
1.9 DECLARATION OF CONFORMITY ........................................................................................... 1-7
2 MACHINE FEATURES ..................................................................................................................................2-1
2.1 MACHINE DESCRIPTION .......................................................................................................... 2-1
2.1.1 MAIN DEVICES ..........................................................................................................................2-2
2.1.1.1 Plasticization unit .......................................................................................................................2-2
2.1.1.1.1 Extruder .....................................................................................................................................2-3
2.1.1.1.2 Metering pump (optional) ..........................................................................................................2-4
2.1.1.1.3 Feed tube ...................................................................................................................................2-5
2.1.1.1.4 By-pass system ......................................................................................................................... 2-7
2.1.1.2 Drive unit ....................................................................................................................................2-8
2.1.1.3 Insertion turret ...........................................................................................................................2-9
2.1.1.4 Molding unit ............................................................................................................................. 2-12
2.1.1.5 Exit conveyor belt .................................................................................................................... 2-15
2.1.1.6 Pneumatic system ................................................................................................................... 2-15
2.1.1.7 Hydraulic system ..................................................................................................................... 2-15
2.1.1.8 Cooling system ........................................................................................................................ 2-15
2.1.1.9 Electric system: control board ................................................................................................ 2-15
2.1.1.10 Molds ....................................................................................................................................... 2-15
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE .................................................. 2-16
2.2 OVERALL DIMENSIONS ......................................................................................................... 2-17
2.3 TECHNICAL DATA ................................................................................................................... 2-18
2.3.1 SPECIFICATIONS .................................................................................................................... 2-18
2.3.2 ALLOWABLE FLUCTUATIONS ................................................................................................ 2-19
2.3.3 RATING PLATE ........................................................................................................................ 2-19
2.3.4 OPERATIONAL CHARACTERISTICS ......................................................................................2-20
2.3.5 AIRBORNE NOISE EMISSION LEVELS ..................................................................................2-22
2.3.5.1 Sound pressure level ..............................................................................................................2-22
2.3.5.2 Acoustic power level ...............................................................................................................2-23
2.3.6 DATA SHEET ............................................................................................................................ 2-24
2.4 DIAGRAMS ..............................................................................................................................2-26
2.4.1 PNEUMATIC SYSTEM DIAGRAM............................................................................................2-26
2.4.2 HYDRAULIC SYSTEM DIAGRAM............................................................................................2-29
2.4.3 COOLING SYSTEM DIAGRAM ................................................................................................2-32
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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
3.1.1.1 Required environmental conditions for correct machine operation ........................................ 3-1
3.1.2 SAFETY DEVICES INSTALLED .................................................................................................3-2
3.1.2.1 Shutdown devices .....................................................................................................................3-2
3.1.2.2 Indicating a shutdown ...............................................................................................................3-2
3.1.2.3 Devices to safeguard the operators ..........................................................................................3-2
3.1.2.4 Emergency stop buttons ...........................................................................................................3-2
3.2 SAFETY RULES FOR HANDLING .............................................................................................3-4
3.2.1 SLINGING THE LOADS .............................................................................................................3-4
3.2.2 HOISTING ..................................................................................................................................3-4
3.2.3 PLACEMENT .............................................................................................................................3-4
3.2.4 GUIDE LINES FOR USING THE LIFT EQUIPMENT ..................................................................3-5
3.3 INSTALLATION ......................................................................................................................... 3-6
3.3.1 GUIDELINES ............................................................................................................................. 3-6
3.4 OPERATOR TRAINING ..............................................................................................................3-7
3.4.1 END-USER ................................................................................................................................3-7
3.4.2 OPERATORS .............................................................................................................................3-7
3.4.3 MAINTENANCE STAFF..............................................................................................................3-8
3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THE MACHINE ..3-9
3.5.1 GENERAL SAFETY RULES .......................................................................................................3-9
3.5.2 NOTES REGARDING USE AND MAINTENANCE ................................................................... 3-12
3.5.2.1 Risks deriving from high temperatures ................................................................................... 3-12
3.5.2.2 Risk of explosion ..................................................................................................................... 3-12
3.5.2.3 Accessing the machine ........................................................................................................... 3-13
3.5.2.3.1 Accessing the waste container compartment ........................................................................ 3-14
3.5.2.3.2 Safety guards with mechanical lock ....................................................................................... 3-15
3.5.2.4 Accessing the extruder outlet ................................................................................................ 3-16
3.5.2.5 Risks from excessive air pressure ........................................................................................... 3-17
3.5.2.6 Cut hazards ............................................................................................................................. 3-18
3.6 MACHINE DECOMMISSIONING AND DISASSEMBLY ........................................................... 3-19
3.6.1 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED ................................................. 3-19
3.6.2 DISASSEMBLING THE MACHINE ...........................................................................................3-20
4 INSTALLATION .............................................................................................................................................4-1
4.1 SHIPPING, HANDLING AND POSITIONING THE MACHINE .................................................... 4-1
4.1.1 MACHINE DIVISION ..................................................................................................................4-3
4.1.2 DIMENSION AND WEIGHTS .....................................................................................................4-3
4.1.3 SYSTEMS FOR LIFTING INDIVIDUAL PARTS ..........................................................................4-3
4.2 INSTALLATION ..........................................................................................................................4-4
4.3 CONNECTIONS AND HOOK UPS.............................................................................................4-6
4.3.1 CONNECTING THE HYDRAULIC SYSTEM...............................................................................4-6
4.3.2 HOOKING UP THE COOLANT SYSTEM ...................................................................................4-8
4.3.3 HOOKING UP THE PNEUMATIC SYSTEM ............................................................................. 4-10
4.3.4 CONNECTING THE VACUUM SYSTEM .................................................................................. 4-11
4.3.5 ELECTRIC HOOK UP .............................................................................................................. 4-12
4.3.5.1 Connecting the electric cables ................................................................................................ 4-13
4.3.5.2 Earth connection ..................................................................................................................... 4-15
4.3.5.3 Connecting the power cable ................................................................................................... 4-16
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TABLE OF CONTENTS
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5 START UP ...................................................................................................................................................5-1
5.1 INTRODUCTION ........................................................................................................................ 5-1
5.2 FIRST TIME START UP ..............................................................................................................5-2
5.2.1 PRELIMINARY CHECKS............................................................................................................5-2
5.2.2 CHECKING OPERATION ...........................................................................................................5-3
5.2.3 PRELIMINARY OPERATIONS....................................................................................................5-4
5.2.4 STARTING THE AUTOMATIC CYCLE ........................................................................................5-5
5.3 SUBSEQUENT START UPS ......................................................................................................5-5
6 OPERATING INSTRUCTIONS .....................................................................................................................6-1
6.1 OPERATOR INTERFACE ...........................................................................................................6-1
6.2 WORK CYCLES ........................................................................................................................ 6-4
6.2.1 WORK CYCLES IN MANUAL/SET UP MODE .......................................................................... 6-4
6.2.1.1 Draining the nozzle ................................................................................................................... 6-4
6.2.1.2 Actuator upstroke to install/remove tools ............................................................................... 6-5
6.2.2 AUTOMATIC CYCLE ..................................................................................................................6-7
6.2.2.1 Preheating .................................................................................................................................6-7
6.2.2.2 Running the machine ................................................................................................................ 6-8
6.2.2.3 Stopping the machine .............................................................................................................. 6-8
6.3 PRODUCTION CYCLE ...............................................................................................................6-9
6.4 SHUTDOWN CYCLES AND RESET OPERATIONS ................................................................. 6-12
6.4.1 EMERGENCY SHUTDOWN WITH FAULT MESSAGE 1... ....................................................... 6-12
6.4.2 EMERGENCY SHUTDOWN WITH FAULT MESSAGE 3 ...................................................... 6-13
6.5 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 ADJUSTMENTS .......................................................................................... 7-2
7.1.3 FEED TUBE, MIXER (IF PRESENT), NOZZLE CASING, NOZZLE ............................................. 7-3
7.2 INSERTION TURRET ................................................................................................................. 7-4
7.2.1 ADJUSTING THE TURRETS CONNECTING ROD ................................................................... 7-4
7.2.1.1 Adjusting turrets connecting rod precharge ............................................................................7-6
7.2.1.2 Checking turret connecting rod precharge ............................................................................... 7-7
7.2.2 ADJUSTING THE CUTTER ........................................................................................................ 7-8
7.2.3 ADJUSTING PELLET INSERTION TIMING................................................................................ 7-9
7.2.3.1 Resetting the encoder ............................................................................................................. 7-10
7.2.3.2 Adjusting the pellet insertion stage ......................................................................................... 7-10
7.2.3.3 Adjusting the position and length of insertion .........................................................................7-11
7.2.3.4 Adjusting the stripper wheels .................................................................................................. 7-12
7.2.3.5 Adjusting the transfer wheel with vacuum ............................................................................. 7-12
7.3 ADJUSTING THE MOLDING TURRET .................................................................................... 7-13
7.3.1 ADJUSTING THE PRODUCT STRIPPER CAMS ..................................................................... 7-13
7.3.2 ADJUSTING THE QUALITY CONTROL UNIT ......................................................................... 7-13
7.3.2.1 Transducer BQ2 mechanical adjustments .............................................................................. 7-13
7.3.2.2 Setting / saving the reference distance .................................................................................. 7-14
7.3.2.3 Adjusting sensitivity ................................................................................................................. 7-15
7.4 PNEUMATIC SYSTEM ADJUSTMENTS .................................................................................. 7-16
7.4.1 PRESSURE SWITCH SP1 ........................................................................................................ 7-16
7.4.2 PRESSURE SWITCH SP7 ........................................................................................................ 7-17
7.5 HYDRAULIC SYSTEM ADJUSTMENTS .................................................................................. 7-18
7.5.1 ADJUSTING THE APPROACH STAGE (LOW PRESSURE) ..................................................... 7-20
7.5.2 ADJUSTING THE MOLDING STAGE (HIGH PRESSURE) ....................................................... 7-20
7.5.3 ADJUSTING THE ACTUATOR DOWNSTROKE ....................................................................... 7-20
7.6 ADJUSTING THE TEMPERATURE CONTROLLER ................................................................. 7-21
7.7 ADJUSTING THE MOLDS ....................................................................................................... 7-21
7.8 ADJUSTING THE EXIT CONVEYOR BELT .............................................................................. 7-22
7.8.1 ADJUSTING THE HEIGHT OF THE EXIT CONVEYOR BELT .................................................. 7-23
7.8.2 TENSIONING THE CONVEYOR BELT .................................................................................... 7-23
7.8.3 ADJUSTING THE GUIDES ....................................................................................................... 7-23
7.9 REPLACING THE SENSORS ................................................................................................... 7-24
7.10 ADJUSTING THE EMERGENCY BRAKING SYSTEM ............................................................. 7-28
7.10.1 BRAKING ANGLE WIDER THAN NORMAL BUT IN ANY CASE ACCEPTABLE ..................... 7-28
7.10.2 BRAKING ANGLE TOO WIDE ................................................................................................. 7-28
7.10.3 EMERGENCY BRAKING SYSTEM ADJUSTMENT PROCEDURE .......................................... 7-29
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8 MAINTENANCE ............................................................................................................................................8-1
8.1 ROUTINE MAINTENANCE .......................................................................................................8-2
8.1.1 SCHEDULED MAINTENANCE CHART .....................................................................................8-2
8.1.2 PERIODIC MAINTENANCE OPERATIONS ................................................................................8-9
8.1.2.1 Drive unit ....................................................................................................................................8-9
8.1.2.1.1 Checking the condition of the drive belts .............................................................................. 8-10
8.1.2.1.2 Tensioning the molding turret transmission belts .................................................................. 8-10
8.1.2.1.3 Replacing the molding turret transmission belts ................................................................... 8-10
8.1.2.1.4 Tensioning the insertion unit transmission belt ...................................................................... 8-10
8.1.2.1.5 Replacing the insertion unit transmission belt ....................................................................... 8-11
8.1.2.1.6 Checking the oil level in the molding turret gear motor ......................................................... 8-11
8.1.2.1.7 Changing the oil in the molding turret gear motor ................................................................. 8-11
8.1.2.2 Plasticization unit ..................................................................................................................... 8-12
8.1.2.2.1 Overhauling the extruder auger ............................................................................................... 8-13
8.1.2.2.2 Checking the oil level and adding oil in the extruder gearbox ................................................ 8-15
8.1.2.2.3 Changing the oil in the extruder gearbox ................................................................................ 8-16
8.1.2.2.4 Cleaning the polymer metering pump ..................................................................................... 8-16
8.1.2.2.5 Replacing/overhauling the polymer metering pump ............................................................... 8-16
8.1.2.2.6 Lubricating the universal joint ................................................................................................. 8-18
8.1.2.2.7 Cleaning the nozzle ................................................................................................................. 8-19
8.1.2.2.8 Checking and setting pressure transducers BP1 and BP2 .................................................... 8-19
8.1.2.2.9 Lubricating the extruder motor bearings ................................................................................8-21
8.1.2.3 Insertion turret .........................................................................................................................8-22
8.1.2.3.1 Cutters with insertion blower ..................................................................................................8-24
8.1.2.3.1.1 Sharpening the blades ............................................................................................................8-24
8.1.2.3.1.2 Replacing the blades ...............................................................................................................8-24
8.1.2.3.1.3 Cleaning the cutters ...............................................................................................................8-24
8.1.2.3.1.4 Replacing the blades ..............................................................................................................8-24
8.1.2.3.1.5 Cleaning or replacing the nozzles ...........................................................................................8-25
8.1.2.3.2 Cutters with insertion piston ...................................................................................................8-26
8.1.2.3.2.1 Rotating the blades .................................................................................................................8-26
8.1.2.3.2.2 Sharpening the blades ............................................................................................................8-26
8.1.2.3.2.3 Replacing the blades ...............................................................................................................8-26
8.1.2.3.2.4 Cleaning the cutters with insertion piston...............................................................................8-26
8.1.2.3.2.5 Replacing the cutters .............................................................................................................8-26
8.1.2.3.3 Cleaning the compressed air distributor .................................................................................8-27
8.1.2.3.4 Replacing the compressed air distributor ...............................................................................8-27
8.1.2.3.5 Checking precharge of the turret connecting rod ...................................................................8-27
8.1.2.3.6 Adjusting precharge of the turret connecting rod ...................................................................8-27
8.1.2.3.7 Tensioning the insertion turret drive belt .................................................................................8-28
8.1.2.3.8 Replacing the insertion turret drive belt ..................................................................................8-28
8.1.2.3.9 Replacing the pulley (item 10) .................................................................................................8-29
8.1.2.3.10 Replacing the toothed wheel (item 5) ......................................................................................8-29
8.1.2.3.11 Replacing the toothed wheel (item 7) ......................................................................................8-30
8.1.2.3.12 Replacing the pulley (item 8) ...................................................................................................8-30
8.1.2.3.13 Checking wear and tear and lubricating the gears .................................................................8-30
8.1.2.4 Molding turret .........................................................................................................................8-31
8.1.2.4.1 Cleaning ...................................................................................................................................8-32
8.1.2.4.2 Overhauling the actuator valve ................................................................................................8-32
8.1.2.4.3 Greasing the actuator valve rollers ..........................................................................................8-32
8.1.2.4.4 Greasing the stripper rod rollers .............................................................................................8-32
8.1.2.4.5 Replacing the hydraulic actuator gasket .................................................................................8-33
8.1.2.4.6 Replacing the upper flange gaskets ........................................................................................8-34
8.1.2.4.7 Replacing the lower flange gaskets ........................................................................................8-34
8.1.2.4.8 Lubricating the stripper rod guide bushes ..............................................................................8-35
8.1.2.4.9 Greasing the central tool wheel (optional) ...............................................................................8-35
8.1.2.4.10 Greasing the turret bearings ...................................................................................................8-35
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8.1.2.4.11 Replacing the gaskets and rotary distributor bearings ...........................................................8-35
8.1.2.4.12 Checking tightness of the lower flange ring nuts ....................................................................8-39
8.1.2.5 Cams .......................................................................................................................................8-40
8.1.2.5.1 Greasing and checking ...........................................................................................................8-41
8.1.2.5.2 Replacing the stripper cams (central movement) (optional) ..................................................8-41
8.1.2.5.3 Replacing the stripper cams (side movement) .......................................................................8-41
8.1.2.5.4 Replacing the actuator control cams .....................................................................................8-41
8.1.2.5.5 Replacing the cams for injecting air in the punches ..............................................................8-41
8.1.2.6 Hydraulic system .....................................................................................................................8-42
8.1.2.6.1 Checking the accumulators precharge ..................................................................................8-42
8.1.2.6.2 Checking the oil level in the hydraulic power unit .................................................................. 8-44
8.1.2.6.3 Changing the oil in the hydraulic power unit .......................................................................... 8-45
8.1.2.6.4 Replacing the filter in the hydraulic power unit ...................................................................... 8-45
8.1.2.6.5 Replacing the hydraulic power unit couplings and suction filter ........................................... 8-45
8.1.2.6.6 Checking for condensate on the bottom of the tank ............................................................. 8-45
8.1.2.6.7 Cleaning the solenoid valves .................................................................................................. 8-46
8.1.2.7 Cooling system ........................................................................................................................8-47
8.1.2.7.1 Cleaning/changing the filters ...................................................................................................8-47
8.1.2.7.2 Checking the coolant level/topping up .................................................................................. 8-48
8.1.2.7.3 Changing the coolant ............................................................................................................. 8-48
8.1.2.8 Pneumatic system ...................................................................................................................8-49
8.1.2.8.1 Air injection device ..................................................................................................................8-49
8.1.2.8.1.1 Checking the valves ................................................................................................................8-49
8.1.2.8.1.2 Replacing the valves ................................................................................................................8-49
8.1.2.9 Product exit conveyor belt ......................................................................................................8-50
8.1.2.9.1 Replacing the conveyor belt ....................................................................................................8-51
8.1.2.9.2 Cleaning the slots in the exit conveyor belt slide surface .......................................................8-51
8.1.2.10 Vacuum systems ....................................................................................................................8-52
8.1.2.11 Safety devices ........................................................................................................................ 8-53
8.1.2.11.1 Checking operation of the emergency stop buttons ............................................................. 8-53
8.1.2.11.2 Checking the door interlocking devices ................................................................................. 8-53
8.1.2.11.3 Checking the visual/audible indicators .................................................................................. 8-53
8.1.2.12 Electrical system..................................................................................................................... 8-54
8.1.2.12.1 Cleaning and servicing the electrical cabinets ...................................................................... 8-54
8.1.2.12.2 Checking cabinet and electrical box closure ......................................................................... 8-54
8.1.2.12.3 Air conditioner maintenance (if present) ................................................................................ 8-54
8.2 EXTRAORDINARY MAINTENANCE OPERATIONS ................................................................8-55
8.3 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS .........................................................8-56
8.4 TROUBLESHOOTING GUIDE .................................................................................................8-57
8.4.1 TROUBLESHOOTING THE MACHINE ....................................................................................8-57
9 DECOMMISSIONING ...................................................................................................................................9-1
9.1 MACHINE DECOMMISSIONING ............................................................................................... 9-1
9.2 DISASSEMBLY ..........................................................................................................................9-2
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GENERAL INFORMATION
1
1 GENERAL INFORMATION
1.1 INTRODUCTION
E0004

WARNING!
Carefully read the entire Users 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.
The company using the machine must always assure all operators have completely read and become familiar with
the operating instructions.
Notwithstanding the machine is equipped with active and passive safety devices, all risks resulting from incorrect
use cannot be avoided.
SACMI shall not be held responsible for failure to heed to the safety and accident prevention rules and standards
underlined in this manual and property damage and personal injury resulting from unintended, inappropriate and
erroneous use of the machine.
Any changes to the machine must be duly authorized by SACMI in advance.
All work done on the machine (maintenance, adjustments, repairs, cleaning) must be carried out by properly
trained personnel following the directions contained in this manual.
SACMI reserves the right to make technical changes to the machine and this manual without giving prior notice.
Additional copies of this manual can be obtained by contacting SACMIs Customer Service Department.
Copyright. All rights reserved. This publication or parts of it are valuable trade secrets and must not be copied,
stored, reproduced, disclosed, transferred or translated into any language, spoken or computer, in any form or by
any means without the express written consent of SACMI.
Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI
SACMI guarantees the contents of this publication. It is severely forbidden to use this publication for other purposes,
whatever they may be, that are extraneous to operation of the machine for which this publication has been drawn
up.
The information contained herein is guaranteed as being correct only if the user carefully follows all the guidelines
and instructions provided in this publication.
1.2 WHERE TO KEEP THE MANUAL
E0004

WARNING!
This manual and supplements:
- are to be considered an essential part of the machine and must be kept along with it even if the machine is
sold;
- must always be kept in an easy-to-reach place near the machine protected against environmental agents that
may ruin them;
- must always be available and close by so that operators are able to consult them rapidly at any time.
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1
GENERAL INFORMATION
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.
Notes fundamental for the safety or health of operators are given inside a block pointed out by alert, warning and/or
danger symbols and written in italics, as shown below.
E0004

IMPORTANT!
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.
E0004

IMPORTANT!
The term operator is also generically used to identify a person who has to work on the machine: operator,
maintenance worker, etc..
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GENERAL INFORMATION
1
1.5 WARRANTY
As set forth in the assumed warranty, SACMI shall be held responsible only for the machine in its original configuration
and towards the individual who stipulated the sales contract with SACMI or, in the case of leased machinery, the
user named by the leasing company.
Any operations that alter the configuration of the machine or work cycle must be carried out or duly authorized by
SACMI.
SACMI shall not be held responsible for any consequences deriving from installation or use of non-original spare
parts, operations performed by the purchasers technicians or in the case of leased machinery, the user named by
the leasing company and/or technicians not duly authorized by SACMI and not described in this manual and/or for
whom supervision by SACMI is required and/or whom have not been expressly authorized by SACMI.
The warranty is contingent on proper use of the machine in accordance with the instructions provided by the
manufacturer.
The warranty does not cover parts subject to wear and tear.
The warranty is void in the following cases:
- required maintenance jobs not performed;
- altering, tampering or misuse of the machine;
- if spare parts different from the ones originally installed in the machine are used;
- if modifications are made
SACMI shall not be held liable for machine damage caused by misuse or malfunctioning of other equipment
connected to the machine.
The warranty covers only machine damage and/or malfunctions with explicit exclusion of compensation for any
additional damage. In any case, the seller shall not be held responsible for loss due to lack of or reduced production,
as well as any special, indirect or consequential loss of any nature whatsoever.
As regards any annexes or modifications to the above, in any case the general terms and conditions set forth in
the contract shall be abided.
In any case, any other warranty other than that assumed by contract by SACMI towards the machine purchaser or,
in the case of leased machinery, the user named by the leasing company, is excluded.
E0004

IMPORTANT INFORMATION!
The machine operators and maintenance staff are not responsible for carrying out operations under warranty
or extraordinary maintenance and repairs. These operations are to be performed only by the manufacturers
properly trained technicians and/or technicians who have been duly appointed. For this reason, these types
of operations are not dealt with in this manual and the machine purchaser or, in the case of leased machinery,
the user named by the leasing company, should contact SACMI to schedule service or receive the necessary
instructions.
1.6 SUPPLEMENTS
The following documents supplement this Instructions manual.
- INSTRUCTIONS B
(This document may be split into several handbooks containing instructions on how to use the control system
and the electric and electronic machine components).
- WIRING DIAGRAMS
- COOLING MIXES, ADHESIVES AND LUBRICANTS DATA SHEET
- VISION SYSTEM INSTRUCTIONS MANUAL (if present)
- INSTRUCTIONS MANUAL FOR METERING UNIT/MIXER (if present)
- FEEDER'S USER MANUAL (if provided)
- DEHUMIDIFIER INSTRUCTION MANUAL (if present).
- AIR CONDITIONER DOCUMENTATION (if present)
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1
GENERAL INFORMATION
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE
MANUAL
DANGER SYMBOLS
E0004

General hazard.
E0137

Danger of being burnt on hot surfaces.
E0003

Danger of hands being crushed.
E0007

High tension. Risk of electrical shock.
E0011

Risk of entanglement, amputation.
E0010

Risk of entanglement in moving parts.
E0134

Risk of falling.
E0035

Risk of explosion.
002AZ019A
1-5
GENERAL INFORMATION
1
WARNING SIGNS
E0001

Do not lubricate or work on moving parts under any circumstances.
E0034
O2

Do not use oxygen to recharge the accumulators.
E0136 Do not put arms in the openings.
ALERT SYMBOLS
E0138
Always wear heavy duty work gloves.
E0006

Machine must be connected to an effectively grounded power point.
E0038
Lift point.
ADDITIONAL SIGNALS
E0133

Dispose of carefully in accordance with current environmental regulations.

002AZ019A
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1
GENERAL INFORMATION
FIGURE 1.8 - MACHINE IDENTIFICATION PLATE
1.8 MACHINE IDENTIFICATION PLATE
E0004

IMPORTANT!
The CE mark is affixed only in the European Economic Community or in cases where foreseen.
002AZ019A
1-7
GENERAL INFORMATION
1
1.9 DECLARATION OF CONFORMITY
(only within the European Community or cases in which it is foreseen)
The declaration of conformity, when provided, accompanies the machine.
Drawn up in accordance with Annex II letter A of Directive 2006/42/EC and any subsequent amendments and/or
supplements. Fixed installation in accordance with Directive 2004/108/EC.
S.C. declares:
this machine is defined as machinery in conformity with the provisions of Council Directive 2006/42/EC and any
subsequent amendments and/or supplements and that the CE mark has been affixed;
this machine complies with the provisions of the following European Directives (references to standards are
also extended to any subsequent amendments and/or supplements):
- 2006/42/EC;
- 97/23/EC.
S.C. is authorized to hold the technical file.
002AZ019A
1-8

1
GENERAL INFORMATION
002AZ019A
2-1
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 a plasticization unit,
cut into suitably gauged pellets and then inserted inside the molds.
A hydraulic system is employed to close the molds 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 molding turret runs.
The main machine parts are illustrated in the figure.
FIGURE 2.1 - OVERALL VIEW
1 Plasticization unit
2 Drive unit
3 Insertion turret
4 Molding turret
5 Pneumatic system
6 Hydraulic system
7 Cooling system
8 Electrical cabinet
9 Control panel
10 Exit conveyor belt
2
8
9
7
6
4
10
5 3
1
T4723
002AZ019A
2-2

2
MACHINE FEATURES
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, a link unit 3 (that may vary according to the type of plastic compound and delivery
rate used) and a by-pass system 2.
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 By-pass system
3A* Feed flange
3B* Metering pump and feed pipe
(*) As an alternative between each other
1
3B 3A
2
T4724
2
4
3
5
1B
1A
002AZ019A
2-3
MACHINE FEATURES
2
2.1.1.1.1 Extruder
Extruder
The extruder melts down the plastic compound and homogenizes it with any colorings and lubricants that may
have been added.
The granular material, picked up by feeder 5 (Refer to the manufacturer's manual), is let in through a hopper 1A
or, as an alternative a metering unit/mixer 1B (see the instructions manual provided by the manufacturer) and is
pushed into the cylinder 2 by the auger 3 through the various heat 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.
E0004

E0003

WARNING!
Never start the machine and/or extruder without the hopper or metering unit/mixer, danger of shearing.
If the hopper or metering unit/mixer need to be removed for maintenance/replacement, firmly secure in place
before attempting to start the machine and/or extruder.
FIGURE 2.1.1.1.1 - EXTRUDER
1A Hopper (*)
1B Metering unit/mixer (*)
2 Cylinder
3 Auger
4 Extruder gearbox
5 Feeder
(*) The hopper and metering unit/mixer
are alternatives to one another
T4551
A
B
A
B
002AZ019A
2-4

2
MACHINE FEATURES
2.1.1.1.2 Metering pump (optional)
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.
A cooling circuit is installed at the ends of the shaft to prevent the plastic compound from flowing out abruptly.
The pressures of the suction and delivery lines are measured by transducers BP1 and BP2 respectively. The pump
temperature is controlled by thermocouple BT7.
FIGURE 2.1.1.1.2 - METERING PUMP
1 Pump casing
2 Gears
6 Suction flange
7 Delivery flange
BP1 Sensor for suction line pressure
BP2 Sensor for delivery line pressure
BT7 Thermocouple
EH7 Heating element
M8 Geared motor
BP1
1
7
2
M8
6
BP2
BT7
EH7
T4725
002AZ019A
2-5
MACHINE FEATURES
2
2.1.1.1.3 Feed tube
This carries the melt from the metering pump to the by-pass unit.
It consists of a tube and a static mixer (optional), which is used to ensure that the characteristics and temperature
of the plastic compound are even throughout.
While traveling along the path from the tube to the mixer, the material is kept at a constant temperature by heating
elements EH8 and EH9.
The temperature is measured by thermocouples BT8 and BT9 respectively.
FIGURE 2.1.1.1.3/A - FLANGE AND FEED TUBE WITHOUT MIXER
BP2 Delivery pressure sensor
BT6 Thermocouple
BT8 Thermocouple
EH6 Heating element
EH8 Heating element
BT6 BT8
BP2
EH6
EH8
T4726
002AZ019A
2-6

2
MACHINE FEATURES
FIGURE 2.1.1.1.3/B - FLANGE AND FEED TUBE WITH MIXER AND METERING PUMP
BT8 Thermocouple
BT9 Thermocouple
EH8 Heating element
EH9 Heating element
BT8 BT9
EH8 EH9
T3964
EH15
6
BT15
5
1
BT16
3
4
EH16
BT17
002AZ019A
2-7
MACHINE FEATURES
2
2.1.1.1.4 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 2.1.1.1.4 - 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
EH15 Heating element
EH16 Heating element
T1495
T2964
002AZ019A
2-8

2
MACHINE FEATURES
2.1.1.2 Drive unit
The drive unit transmits motion to the entire machine.
This unit includes an epicyclic geared motor with self-braking motor M9 mounted on the vertical axis, a handwheel
16 to carry out operations in manual mode, a toothed belt 4 that drives the molding turret and a tensioning unit 17
used to tension the belt.
An oil drain cock 13, filler and bleeder plug 14 and level indicator 15 are also provided.
FIGURE 2.1.1.2 - DRIVE UNIT
1 Screw
2 Nut
3 Screw
4 Belt
5 Belt
6 Nut
7 Screw
8 Pulley
9 Counter-device
10 Screw
11 Nut
12 Screw
13 Cock
14 Filler plug
15 Level indicator
16 Manual handwheel
17 Tensioner
M9 Epicyclic gear motor
7
15
14
9
11
12
3
8 5 6
10
3 1 2
13
4
M9
16
17
002AZ019A
2-9
MACHINE FEATURES
2
2.1.1.3 Insertion turret
The insertion turret has the dual function of cutting and placing the plastic pellets in the cavities of the molding
turret and transferring the finished product onto the exit conveyor belt.
The insertion turret is driven by the drive unit through a toothed belt 9 and pulley 1.
A torque limiter 2 and encoder 3 are mounted on the drive shaft. The encoder sends information about the machines
work position to the microprocessor based control system.
The mount 4, that sustains the insertion turret, is installed on the machine base.
The drive shaft that transmits motion from the pulley 2 to the toothed wheel 5 operates inside the mount.
The insertion turret moves in and out of the work position in the molding turret as pneumatic cylinder 6 turns it
around the pivot 5. The toothed wheel 5 transmits motion to toothed wheel 7 and pulley 10 through pulley 8 and
toothed belt 9.
Toothed belt 9 is kept tight by tensioner 11.
The cutters 12 cut the plastic material flowing out of the extruder nozzle into pellets and place them in the molding
turret cavities through a mechanical/pneumatic action.
The finished product is placed on the disk 13, equipped with a vacuum hold down system, and carried to the exit
conveyor belt by the stripper wheels 14 and 15.
002AZ019A
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2
MACHINE FEATURES
FIGURE 2.1.1.3 - INSERTION TURRET
YV33 Solenoid valve
1 Pulley
2 Torque limiter
3 Encoder
4 Mount
5 Toothed wheel
7 Toothed wheel
8 Pulley
9 Toothed wheel
10 Pulley
11 Tensioner
12.1 Cutter without insertion piston
12.2 Cutter with insertion piston
12A Disk
12B Piston
12C Gasket
12D Sleeve
12E Knife
12F Screw
12G Cutter
12H Screw
12L Nozzle
12M Gasket
13 Disk
14 Wheel
15 Wheel
16 Screw
17 Spacer
18 Distributor
19 Flange
20 Screw
21 Nut
22 Pin
23 Nut
24 Pin
25 Counter-device
26 Screw
27 Connecting rod
28 Screw
29 Screw
30 Screw
31 Disk
32 Screw
33 Spring
34 Pin
38 Cover
39 Screw
40 Screw
41 Spacer
42 Ring nut
43 Flange
44 Nut
45 Screw
46 Screw
49 Shaft
50 Screw
51 Flange
52 Nut
53 Washer
54 Spring
55 Spacer
56 Screw
57 Pin
58 Ring nut
59 Spacer
60 Snap ring
61 Screw
62 Snap ring
63 Cover
T4817
002AZ019A
2-11
MACHINE FEATURES
2
1
2
3
55
54
52
53
12F
12G
12H
12E
12D
12C
12B
12A
12.2
12.1
12G
12L
12M
12E
12F
12H
30 20
21
23
22
24
38
40 8 9
34 28 16 51 15
11 39
32
45
46
29
50
26
43
7 57
42 14
YV33
13 41 33
58
59
44 10
6
4
49
5 61
62 60
31 18 19 17 27
56
12.1
12.2
25
63
002AZ019A
2-12

2
MACHINE FEATURES
2.1.1.4 Molding unit
The hydraulic actuators and molds are located in the molding unit. They are used to form, cool down and remove
the pellets of molten plastic that are sent to them from the insertion turret. The finished product is then placed on
the stripper wheel.
Motion is transmitted from the drive unit to the molding unit through a pulley 14 and belt 13.
The distributor 11 delivers the cooling fluid to the upper and lower tools, oil under pressure to the hydraulic actuators
and compressed air to the molds. The hydraulic actuators 8 are mounted on the lower body of the turret 9.
A mold 7 (lower) is provided with each of the actuators. The mold receives 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 12, for the molds 7 coolant, passes through the actuators rod. The upper molds are mounted on the upper
turret body 3.
The relative rods 16, that drive the devices used for stripping the product, are mounted on the circumference further
inside compared to that of the upper molds. A fork 6, whose task is to act on the stripper, is keyed to the rod.
The stripper rods 16 are controlled by a fixed cam 4 that acts on rollers 15 secured to the same rods.
In addition, the machine is equipped with a number of pneumatic valves 1 so that the product can be removed by
blowing air into the upper molds.
These valves send air under pressure to each mold. 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 the valves 1. The
air then reaches the flow controls found near the molds.
The upper molds are cooled down by the coolant that runs through the duct 5.
Two drive systems may be performed to remove the product when certain tools (fig. 2.1.1.4/B) are used. The upper
mold 2 is driven both by the stripper rod 16 and cam 17 that acts on a wheel found in the middle of the mold.
FIGURE 2.1.1.4/A - MOLDING TURRET
1 Valve
2 Upper mold
3 Turrets upper body
4 Fixed cam
5 Coolant duct (upper molds)
6 Fork
7 Lower mold
8 Hydraulic actuators
9 Turrets lower body
10 Actuator control valve
11 Distributor
12 Coolant duct (lower molds)
13 Belt
14 Pulley
15 Wheel
16 Stripper drive rod
17 Cam
T3004
A
A
002AZ019A
2-13
MACHINE FEATURES
2
FIGURE 2.1.1.4/A - MOLDING TURRET
2
6
7
8
10
11
12
14
13
16
15
3
4
5
9
1
T3891
A
A
002AZ019A
2-14

2
MACHINE FEATURES
FIGURE 2.1.1.4/B - MOLDING TURRET WITH TOOLS WITH CENTRAL DRIVE SYSTEM
4
6
7
8
10
11
12
14
13
2
3
5
9
1
17
16
15
002AZ019A
2-15
MACHINE FEATURES
2
2.1.1.5 Exit conveyor belt
The exit channel receives the product from the stripper wheels and brings it in an orderly manner to the area where
it is fed to the next machine in the production line.
The belt has devices that reject any defective caps or pick up sample caps.
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 molding turret.
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.
- A unit that controls the oil flow rate (mounted on the press). Two manual control valves to adjust the flow rate
and actuator return pressure are also provided in this unit.
- A rotary distributor.
- Ball control valves with relative actuators.
- Ducts that run from the rotary distributor to the valves and related actuators inside the molding turret.
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 units water/oil exchanger
- extruder
- upper molds
- lower molds
The system includes a cooling unit (optional) which delivers the fluid at a low temperature to a thermal control
unit 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 chapter 6 - OPERATING INSTRUCTIONS and the
Instructions B manual.
2.1.1.10 Molds
The molds are strictly related to the kind of product being handled as they include 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.
002AZ019A
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2
MACHINE FEATURES
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.
E0004

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
SACMI shall not be held responsible for malfunctions or personal injury or property damage deriving from incorrect
and erroneous use of the machine.
Generally speaking, the most common causes of incorrect use are listed below:
- failure to observe the safety standards, rules and guidelines given in this manual;
- unintended and inappropriate use of the machine;
- personnel not adequately trained;
- 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!
E0004

IMPORTANT!
The machine must never be used under the conditions given below and, in any case, the following operations must
never be carried out:
- never remove, lock out or disable any safety devices or guards;
- never lubricate or in any case perform maintenance jobs while the machine is running;
- never climb and/or get on the machine or any parts of it;
- never take out the waste container while the plasticization unit is running if the production cycle is not in
progress and no products are clearly seen being carried on the exit conveyor belt;
- never access the waste container while the plasticization unit and/or machine is running, danger of burns and
amputation.
2
7
0
0
2
2
0
0
2
5
0
0
5
7
0
6
8
0
3
0
0
1
6
9
0
7
4
0
2
1
7
5
2
9
4
0
3
4
0
0
2
6
9
0
8280
7580 600
6880
2400 1000 1610 455 630 785
(700)
3460
X
Y
6310 1970
2210
520
4
7
7
0
1
5
0
0
8
0
0
8
7
0
8
0
0
8
0
0
1
3
5
0

0
-
5
0
2
9
0
HI T HO
C
E
A
T4727
002AZ019A
2-17
MACHINE FEATURES
2
2.2 OVERALL DIMENSIONS
FIGURE 2.2/A - OVERALL DIMENSIONS WITH 60 MM EXTRUDER
A Pneumatic connection
C Material supply
E Electrical connection
HI Cooling system connection (inlet)
HO Cooling system connection (outlet)
T Cooling system connection (leaks)
X Minimum connecting height for lifting
Y Maximum height for maintenance
002AZ019A
2-18

2
MACHINE FEATURES
2.3 TECHNICAL DATA
2.3.1 SPECIFICATIONS
EXTRUDER
PRESS 60 mm
Maximum production output pieces/min 800 800
Maximum rpm rpm 25 25
Number of cavities 32 32
Molding cylinder stroke mm 115 115
Maximum molding force kN 21 21
EXTRUDER
Type of plastic compound PP PE
Extruder delivery rate Kg/h 100 150
Temperature of molten plastic C 280 280
ELECTRICAL WIRING
Power requirements kVA (50Hz) 189 189
Power for cable sizing kVA (50Hz) 104 104
Maximum power absorbed kW (50Hz) 60 60
Average power absorbed kW (50Hz) 49 49
PNEUMATIC SYSTEM
Required delivery rate (at 0.5 Mpa) Nl/min 600 600
Average consumption (at 0.5 Mpa) Nl/min 500 500
Minimum required pressure MPa 0.5 0.5
Maximum allowable pressure MPa 1.0 1.0
Air cleanliness class (ISO 8573-1) 644 644
Connecting hose mm 17 17
COOLING SYSTEM
Thermal power to be dissipated kcal/h 39000 42000
Required flow rate l/min 130 140
Pressure drop MPa 0.1 0.1
Maximum allowable pressure MPa 1.0 1.0
Temperature C 10 10
System hose mm 40 40
Un In
04076369
c
c
I
Matr.Nr.
Serial No.
Te
Cert.
Cert.
fn
Cod.
Mat.
M A D E I N I T A L Y
Anno
Year
O.d.V.
Order No.
E0146
SACMI IMOLA S.C. VIA SELICE PROVINCIALE 17/A IMOLA - ITALIA
2.3.2 ALLOWABLE FLUCTUATIONS
ELECTRIC
Voltage = 400 V 10%
Voltage 400 V 5%
Frequency 2%
PNEUMATIC
Delivery rate 15%
COOLING FLUID
Delivery rate 10%
2.3.3 RATING PLATE
E0004

IMPORTANT!
The CE mark is affixed only in the European Economic Community or in cases where foreseen.
FIGURE 2.3.3 - RATING PLATE
002AZ019A
2-19
MACHINE FEATURES
2
002AZ019A
2-20

2
MACHINE FEATURES
2.3.4 OPERATIONAL CHARACTERISTICS
TYPE OF PRODUCT
The machine can produce thermoplastic products whose dimensions have been previously agreed upon with
SACMIs 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.
E0004

ATTENTION!
If material that is not included on the data sheet (facsimile given below) is used, contact SACMIs laboratory
before starting processing.
E0004

WARNING!
Never use any material that may be hazardous in the event of skin or eye contact, ingestion, inhalation or that
may produce fumes and/or toxic or dangerous phenomena during 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.
T1498
Min
Max
43
25
20
5
002AZ019A
2-21
MACHINE FEATURES
2
FIGURE 2.3.4 - PRODUCT CHARACTERISTICS
The dimensions given in the figure are for reference purposes only and are not binding in any way.
MAX 800 Pieces/min
MAX 6 g/piece
T4729
002AZ019A
2-22

2
MACHINE FEATURES
.
2.3.5 AIRBORNE NOISE EMISSION LEVELS
2.3.5.1 Sound pressure level
(EN ISO 11202)
Test conditions
- Operating conditions: trial run with 60 mm extruder
- Type of operation: plastic cap production (600 caps/min.).
- Operating cycle: material feed and cap formation
- Test environment: factory with reflecting flooring.
Instruments employed
Class 1 instruments (IEC 804)
Values measured
L
pA
L
pC peak
dB(A) dB(C)
P1 84.0 102.5

P1 - Control post, measured at a height of 1.55 m from the floor.
L
pA
- Continuous A-weighted sound pressure level.
L
pC peak
- Peak C-weighted instantaneous sound pressure level.
FIGURE 2.3.5.1 - SOUND PRESSURE LEVEL
P1
002AZ019A
2-23
MACHINE FEATURES
2
2.3.5.2 Acoustic power level
(EN ISO 3746)
Test conditions
- Operating conditions: trial run with 60 mm extruder
- Type of operation: plastic cap production (600 caps/min.).
- Operating cycle: material feed and cap molding
- Test environment: factory with reflecting flooring.
Instruments employed
Class 1 instruments (IEC 804)
Results
L
wA
= 104.0 dB(A)
L
wA
= A-weighted sound power level in dB.
002AZ019A
2-24

2
MACHINE FEATURES
T4380
Sales order: Position:
Customer: Equipment
CCM ACQUISITION PROFILE
Operator Type of operation Date / /
Type of pressing PLC program Output per minute
[pieces/min]
Number pieces
produced
Work hours
G
e
n
e
r
a
l

i
n
f
o
Cap name Cap code Tooling code Tooling mounted in machine
Thickness of cap
bottom
Type of compound
Nominal D [mm]
Compound manufacturer
Maximum D [mm] Shell H [mm] Bottom Temperature
[C]
Wall Temperature
[C]
Master type Master manufacturer % mixed
P
r
o
d
u
c
t
PLC indicated melt temperature
[C]
Actual melt temperature
[C]
Extruder Temperature 1
[C]
Temperature 2
[C]
Temperature 3
[C]
Temperature 4
[C]
Temperature 5
[C]
Flange temperature
[C]
Manual speed
[%]
Automatic Speed
[%]
Manual speed
[%]
Automatic Speed
[%]
Metering
pump
Temperature
[C]
Set pressure 1
[Bar]
Actual pressure 1 [Bar]
Min. value
Max. value
Actual pressure 2 [Bar]
Min. value
Max. value
P
l
a
s
t
i
f
i
c
a
t
i
o
n
Pipe temperature
[C]
Mixer temperature
[C]
Nozzle temperature
[C]
Nozzle body temperature
[C]
Hydraulic system preheat temperature
[C]
Hydraulic system operating temperature
[C]
Accumulator precharge High
[Bar]
Accumulator precharge Low
[Bar]
Accumulator precharge Return
[Bar]
Oil pressure High
[Bar] (average value)
Oil pressure Low
Oil pressure Return
Actuator height under low pressure
[mm]
H
y
d
r
a
u
l
i
c
s
y
s
t
e
m
Flow regulation High Flow regulation Low
Cavity (zone 1) PLC tempera -
ture [C]
Real temperature
[C]
Pressure
[Bar]
Flow rate
Punches (zone 2) PLC tempera -
ture [C]
Real temperature
[C]
Pressure
[Bar]
Flow rate
Distributor cooling capacity Auxiliary equip. (zone 3) PLC tempera -
ture [C]
Real temperature
[C]
Pressure
[Bar]
Control unit flow rate
Chiller temperature
[C]
Chiller model
C
o
o
l
i
n
g
s
y
s
t
e
m
Tool holder stripper height
[mm]
Disk-wheel height
[mm]
Actuator downstroke cam
Cutter code Cutter width
[mm]
Cutter height
[mm]
Mechanical phase [mm]
Insertion blower code Insertion air jet time Insertion air jet delay Insertion air jet pressure
[bar]
Fast upstroke pressure
[bar]
Cooling pressure
[bar]
Degree of vacuum
[cmHg]
Cylinder/cavity distance
[mm]
Side stripper cam code Position Central stripper cam code Position
Tooling code Extruder auger code Upper coupler Lower coupler
Inner guide code Stripper code Wheel code
C
C
M
6
4
M
/
3
2
M
/
4
8
S
/
2
4
S
/
2
4
L

t
o
o
l
i
n
g
Blade code Blade height
[mm]
Nozzle end diameter
[mm]
no.
2.3.6 DATA SHEET
002AZ019A
2-25
MACHINE FEATURES
2
C
C
M
3
2
M
Air injection cam code Air injection pressure
[Bar]
Position 1
st
cam
(lh)
Position 2
nd
cam
(rh)
C
C
M
6
4
M
/
4
8
S
/
2
4
L
/
2
4
S
Punch injection cam
(long/short side)
Air injection pressure
[Bar]
Punch injection cam position
C
C
M
2
4
L
D
i
v
i
s
i
o
n

n
o
t
e
s
Cavity injection cam
Main motor serial number
Hydraulic power unit motor serial number
Recirculation control unit serial number
Extruder drive motor serial number
Belt blower serial number
Burr suction blower serial number
Air injection pressure
[Bar]
Position
T4381
T4730
SP7 YV17
SP1
5
5
5
YV6
YV50
YV41
YV44
17
16
T
E
J
2
1
YV3
YV25/26
YV23P/23B
4
7
15
13
3
11
12
13
9
YV9
11
5
YV33
YV13
YV31 YV35
14
PA
EV
YV101
002AZ019A
2-26

2
MACHINE FEATURES
2.4 DIAGRAMS
2.4.1 PNEUMATIC SYSTEM DIAGRAM
FIGURE 2.4.1/A - PNEUMATIC SYSTEM DIAGRAM
E Plasticization unit
EV Solenoid valves
J Jet stream
PA Air preparation unit
T Temperature controller
1 Filter
2 Pressure regulator
3 Pressure regulator, Pellet insertion
5 Throttle
7 Cylinder, By-pass unit drive
9 Pressure regulator, Air injection in molds
11 Accumulator
12 Injection valve, Molds
13 Pressure gauge
14 Pressure regulator, Piston
15 Pressure regulator, Piston pellet rejection
16 Pressure regulator, Piston cleaning
17 Pressure regulator, Heater
SP1 Pressure switch, Mains pressure
SP7 Pressure switch, Machine air supply
YV3 Solenoid valve, Pellet rejection
YV6 Solenoid valve, Insertion turret adjustments
YV9 Solenoid valve, Air injection in molds
YV13 Solenoid valve, Insertion accumulator
discharge
YV17 Solenoid valve, Compressed air mains
YV23B/P Solenoid valve, By-pass air drive
YV25 Solenoid valve, Insertion turret connecting
rod piston drive
YV26 Solenoid valve, Connecting rod piston,
Insertion turret drive
YV31 Solenoid valve, Storage unit
YV33 Solenoid valve, Pellet insertion
YV35 Solenoid valve, Product rejection
YV41 Solenoid valve, Piston cleaning
YV44 Solenoid valve, Heater
YV50 Solenoid valve, Piston safety
YV101 Solenoid valve, CVS reject
002AZ019A
2-27
MACHINE FEATURES
2
FIGURE 2.4.1/B - LAYOUT OF ELEMENTS IN AIR SUPPLY SYSTEM
2
15 14
YV6
YV23P
YV17 SP1 SP7 YV3 YV41 YV44
1
3
9
YV26
YV23B YV25 16-17
YV50
002AZ019A
2-28

2
MACHINE FEATURES
FIGURE 2.4.1/C - LAYOUT OF ELEMENTS IN AIR SUPPLY SYSTEM
YV13 11
11
YV35
YV9
YV33 YV31
002AZ019A
2-29
MACHINE FEATURES
2
2.4.2 HYDRAULIC SYSTEM DIAGRAM
The hydraulic schematic is described in functional units, 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
SP12/SP13 Pressure switches, Low pressure present
SP14/SP15 Pressure switches, High pressure present
YV21 Solenoid valve, Drain closure, High pressure circuit
YV27 Solenoid valve, Drain closure, Low pressure circuit
C Flow control assembly
15 Control valve, Actuator return circuit pressure
16 Restrictor, Drain circuit
17 Pressure gauge, Actuator return circuit pressure
18 Accumulator, Actuator return circuit
19 Flow regulator, Low pressure circuit
20 Diaphragm
21 Rotary joint
23 Hydraulic actuator
SP115 Pressure switch, Dampener
YV30 Solenoid valve, Actuator approach circuit shut off
T3961
A
B
C
SP4
1
5 4
3
13
10
11 12
15
17
16
19
20
21
A
B
T
R
SP115
23
22
YV30
18
9
SP14/SP15 SP12/SP13
8 7
6
YV27
2
M M
M1
BT10
YV21
SL2
T
M4
002AZ019A
2-30

2
MACHINE FEATURES
FIGURE 2.4.2/A - HYDRAULIC SYSTEM SCHEMATIC
002AZ019A
2-31
MACHINE FEATURES
2
FIGURE 2.4.2/B - LAYOUT OF ELEMENTS IN HYDRAULIC SYSTEM
18 16 21
17 15 19 YV30
23
22
SL2
5
BT10
SP4
4
SP15
SP14
SP13
SP12
12
YV21
YV27
14
11 13 M4 M1
6
9
10
002AZ019A
2-32

2
MACHINE FEATURES
2.4.3 COOLING SYSTEM DIAGRAM
A Cooling unit
B Temperature regulator
C Press
D Hydraulic power unit
E Plasticization unit
DS Distributor
M Delivery line
R Return line
UI Lower tools
US Upper tools
6 Heat-exchanger
8 Non-return valve
9 Flow meter, Upper tools
10 Flow meter, Lower tools
13 Metering pump
14 Extruder gearbox
15 Extruder supply
16 By-pass valves
17 Reservoir
BT18 Thermocouple, Temperature control for lower tools
BT19 Thermocouple, Temperature control for upper tools
BT20 Thermocouple, Temperature control for extruder and hydraulic power unit
EH18 Heating element, Temperature control circuit, Lower tools
EH19 Heating element, Temperature control circuit, Upper tools
EH20 Heating element, Temperature control circuit, Extruder and hydraulic power unit
M18 Motor, Temperature control pump, Lower tools
M19 Motor, Temperature control pump, Upper tools
M20 Motor, Temperature control pump, Extruder and hydraulic power unit
SP18 Differential pressure switch, Lower tool temperature control
SP19 Differential pressure switch, Upper tool temperature control
SP20 Differential pressure switch, Extruder and hydraulic power unit temperature control
YV10 Solenoid valve, Manifold bypass, Cooling 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
YV38 Solenoid valve, Heat exchanger water
T4739
YV38
A
E D
DS
15 14 13
C
UI
6
10
8
8
9
US
B
R M R M R M
T
M18
M19 M20
17
EH20
BT20
YV20
YV19
EH19
BT19
YV18
SP18 SP19 SP20
YV10
EH18
BT18
T T
002AZ019A
2-33
MACHINE FEATURES
2
FIGURE 2.4.3/A - COOLING SYSTEM SCHEMATIC
002AZ019A
2-34

2
MACHINE FEATURES
FIGURE 2.4.3/B - LAYOUT OF PARTS IN COOLING SYSTEM
6
11
8
9
10
YV38
002AZ019A
2-35
MACHINE FEATURES
2
FIGURE 2.4.3/C - LAYOUT OF PARTS IN COOLING SYSTEM
YV18
YV10
BT18
SP18
YV19 YV20
M18
EH19
BT19
BT18
EH18
SP18
17
M20
M19
BT20
EH20
SP20
SP19
002AZ019A
2-36

2
MACHINE FEATURES
002AZ019A
3-1
SAFETY EQUIPMENT AND PRECAUTIONS
3
3 SAFETY EQUIPMENT AND PRECAUTIONS
3.1 SAFETY DEVICES AND GUARDS
E0004

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.
The presence of safety devices does not exempt the operators from exercising extreme caution during work,
avoiding actions that may endanger him/herself or damage the machine at all times. In particular, the operators
must never touch rotating machine parts.
3.1.1.1 Required environmental conditions for correct machine operation
The conditions required are those commonly found in an industrial environment:
The machine foundations must be constructed on solid ground, with no water seepage and suitable to withstand
the indicated loads.
The environment must be adequately ventilated with openings that admit fresh air to replace stale air.
The user must assure that the lighting in the work areas allows the operations and all machine parts to be clearly
seen. The lighting must meet standard EN 12464-1. In particular, it must be free of shadows, bothersome glaring
and stroboscopic effects.
Some environmental conditions such as sea level, high relative humidity and high temperatures may affect the
motors selected therefore these particular conditions should be specified at the time of order.
- The machine is designed to work only indoors.
- The machine is designed to work at a temperature ranging from +5C to +40C.
- The machine is designed to work at a maximum temperature of 40 C with relative humidity <50%; higher
relative humidity may be permitted at lower temperatures (for example 90% at 20 C).
- The machine is designed to work at altitudes < 1000 m above sea level.
- The machine is designed to be stored in ambients whose temperature ranges from -25 C to 55 C (only for
periods < 24 hours the maximum temperature may reach 70 C).
E0004

IMPORTANT!
Carefully empty the cooling circuit if the machine is operated at room temperatures below 2 C.
002AZ019A
3-2

3
- The machine is not designed to work in a potentially explosive atmosphere.
- The machine is not designed to work in areas where fires may break out
- The machine is not designed to work in dusty environments.
- The machine is not designed to work in the presence of acids, corrosive agents, and salt.
- The machine is not designed to work in the presence of ionizing and non-ionizing radiation (X-rays, lasers,
microwaves, ultraviolet rays).
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 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 operators
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.
3.1.2.4 Emergency stop buttons
Emergency stop buttons are provided.
When pressed, the machine immediately shuts down.
E0004

IMPORTANT!
If SACMI does not supply the entire assembly which the machine is to be incorporated in, the end user is
responsible for connecting the emergency shutdown circuit of the machine dealt with in this manual to the
emergency shutdown circuit of the line in which it is installed.
002AZ019A
3-3
3
FIGURE 3.1.2 - SAFETY DEVICES INSTALLED
1 Emergency stop button on electrical cabinet control panel
2 Emergency stop buttons on-board machine
3 Electrically interlocked mechanical guards
4 Fixed mechanical barriers
5 Indicator tower
QS1 Main switch
QS1
1
5
2
2
3
2
4 3 4
4
SB1A SB1B SB1C
2
SB1D
002AZ019A
3-4

3
3.2 SAFETY RULES FOR HANDLING
E0004

WARNING!
Only specially trained authorized personnel may lift and handle the machine. No one should be near the hanging
load or within the range of action of the lift equipment while the machine is being lifted and handled.
The loads may be handled manual, where possible, only by personnel properly trained on how to lift and
handle, observing all current safety standards and laws.
The manufacturer shall not be held responsible for any personal injury or property damage caused by failure to
heed current safety standards regarding lifting and handling materials in the users facility.
3.2.1 SLINGING THE LOADS
To safely and correctly lift and handle the machine always:
- use equipment which best suits the characteristics and has an adequate lift capacity;
- cover all sharp edges;
- 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
- gradually lift to avoid sway or irregular movements
3.2.2 HOISTING
While being moved, the load must always remain perfectly horizontal regardless of the type of lift equipment
used.
To facilitate the lifting and handling operations use bars, levers and ramps. Never use your hands. The person in
charge must:
- know the path to be followed and be able to clearly see it;
- give information to the crane operator from a position where he/she can be clearly see;
- stop immediately if dangerous conditions arise;
3.2.3 PLACEMENT
Before placing the machine make sure the floor is perfectly level and its load bearing capacity is suitable for the
weight of the machine.
Do not place the loads in areas where they may create potential dangers or prevent access to equipment and/or
emergency exits.
The machine must be placed on the cross-bars provided so that it is stable and the slings can be easily removed.
Do not place worn containers or those with protruding material on top of it.
Do not stack material at a dangerous height.
002AZ019A
3-5
3
3.2.4 GUIDE LINES FOR USING THE LIFT EQUIPMENT
Use the lift equipment only as shown in this manual.
Hooking or lifting in different ways may compromise attachment of the lift equipment and holding of hook up points
creating extremely dangerous conditions for the operators.
E0004

WARNING!
Risk of being crushed in the areas where the equipment is attached when the load is hoisted.
E0004

WARNING!
It is severely forbidden to use the lift equipment for purposes or applications different from those specified in
this Users Manual.
The lift equipment and slings, once used to install the machinery, must be put away and stored in a dry place
protected against atmospheric agents. Take all the precautionary measures needed to keep the materials used to
construct the equipment in good condition.
Steel ropes are to be covered with protective oil or grease and must be hung up vertically with their eyebolts to
prevent them from bending or curling up.
Synthetic slings are to be stored away from heat sources, acids and preferably in a dry area.
The equipment and lugs are to be stored in a dry area protected against humidity and corrosion with specifically
formulated products or oil or grease.
E0004

WARNING!
If the lift equipment is to be used another time after being put away and stored in a store room, its surface is to
be thoroughly checked to identify any damage or torn strands, for example on the ropes. Never use damaged
equipment or ropes.
E0004

ATTENTION!
If the lift equipment is broken or damaged, contact Sacmi Customer Service Department.
002AZ019A
3-6

3
3.3 INSTALLATION
3.3.1 GUIDELINES
E0004

ATTENTION!
Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations
in force in your country.
Make sure there is enough space around the machine so that it can be operated and serviced easily. It is important to
take into consideration the dimensions of the machine in all the positions moving parts may reach, in particular:
- the minimum distance to allow people to pass to use the machinery and perform maintenance must be 500
mm.
- the minimum distance between moving parts and fixed obstacles must meet the requirements of standard
EN349; to prevent total body crushing the minimum distance must be 500 mm.
The area surrounding the machine must always be kept free of obstacles, clean, dry and well-lit.
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.
E0007
WARNING!
It is extremely important that the machine is properly connected to adequate earth electrodes.
E0007
WARNING!
The electric system does not come with a differential protective device unless expressly requested.
E0007
WARNING!
If electronic converters are present in the electrical control cabinet, the differential protective devices installed on
the cabinets power supply line must provide ground leakage current protection with continuous component.
E0004

WARNING!
SACMI shall not be held responsible for any property damage or personal injury resulting from improper
installation.
T4729
002AZ019A
3-7
3
3.4 OPERATOR TRAINING
E0004

WARNING!
3.4.1 END-USER
The machine is designed for professional use.
The company using the machine must prevent access by unauthorized personnel.
The company using this equipment must see that their personnel:
- 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;
- wear work gloves, safety shoes and all the personal protective equipment set forth by work place safety and
health laws taking into consideration the type of chemical substances used;
- do not wear any loose or hanging clothes, rings, necklaces, bracelets, watches ties or other items that may be
caught in moving machine parts;
- receive specific training on how to face emergency situations resulting from operator injuries.
Supplemental training courses are available on request to become more familiar with the machine.
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 to use the controls and instruments provided on the machines control panel.
FIGURE 3.4.2 - OPERATOR CONTROL STATION
002AZ019A
3-8

3
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.).
002AZ019A
3-9
3
3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING THE
MACHINE
3.5.1 GENERAL SAFETY RULES
E0001
WARNING!
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
WARNING!
Before performing any operations on the machine, all the operators who work on the machine must:
- make sure the machine cannot be accidentally started up by shutting off electrical power with personal locks
(for example padlocks) stamped with the name of the operator who put it on;
- remove and hold on to the keys for the locks.
E0007
WARNING!
The electrical cabinets and junction boxes installed on-board the machine contain live parts.
As laid down by the EN 60204-1 directive, access to the electrical cabinet should only be possible with a special
tool. This tool 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.
E0007
WARNING!
Wherever plug-outlet connections are present, whether they are in the electrical control cabinets or junction
boxes on-board the machine, they are to be disconnected only with the machine stopped and after shutting off
power from the supply mains.
E0007
WARNING!
Specific tools are to be used to connect and disconnect the conductors inserted in spring terminals.
E0134
WARNING!
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 personal injury and equipment damage.
002AZ019A
3-10

3
E0004

WARNING!
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.
E0137

E0138
WARNING!
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.
E0004

WARNING!
In order to ensure that the machine operates efficiently, safely and in a trouble-free manner always follow SACMIs
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 (replacing them, if necessary) and efficiency of the earth-ground connection.
E0004

WARNING!
Do not remove any nameplates and stickers provided on the machine.
The user must restore the markings (conductors, terminals, devices, etc..), monitor signals and nameplates when
no longer legible or if removed for any reason.
E0004

WARNING!
SACMI shall not be held responsible for any personal injury or property damage if:
- non-genuine spare parts are used;
- spare parts are incorrectly installed;
- jobs or modifications not authorized by SACMI are carried out;
- tampering or altering the machine.
002AZ019A
3-11
3
E0004

WARNING!
Never use the machine if any of the safety devices are malfunctioning under any circumstances. Immediately
shutdown the machine cutting off all the power sources. Turn the machine back on only when all the safety devices
work efficiently.
E0004

WARNING!
Dispose lubricants and coolants according to local laws in force in the country the machine is installed in.

002AZ019A
3-12

3
3.5.2 NOTES REGARDING USE 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 plasticization unit guards.
Never touch the external surfaces provided with warnings indicating danger of being burnt.
Mobile and/or fixed safety guards may have to be opened to clean the machine or make checks when the machine
is shut down under emergency conditions.
E0004

E0137

E0138
WARNING!
When the plasticization unit 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 PLASTICIZATION UNIT, RISK OF BEING SCORCHED AND BURNT
The molten material flowing out of the nozzle or plasticization unit by-pass may reach temperatures up to 280 C.
Wait for the material to cool down or take adequate precautions (use grippers, gloves, etc.).
E0004

E0137

E0138
WARNING!
Exercise extreme caution whenever it is necessary to work on the plasticization unit nozzle while molten plastic
is exiting the nozzle. Wear adequate personal protective equipment to avoid burns (heavy duty work gloves,
grippers, etc..).
HYDRAULIC CONTROL ASSEMBLIES, RISK OF BEING SCORCHED AND BURNT
While operating, the hydraulic control assemblies may reach temperatures capable of causing slight burns.

E0004

E0137

E0138
WARNING!
Wait for the components to cool down or take adequate precautions (use grippers, gloves, etc.) before working
on the assemblies.
3.5.2.2 Risk of explosion

E0004

E0034
O2

E0035

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

002AZ019A
3-13
3
3.5.2.3 Accessing the machine
The machine is equipped with interblocked safety devices. Guards protected with these devices can be opened
only if the following conditions are satisfied:
- No parts are moving.
- No residual hydraulic pressure is present.
The safety guards are released automatically when fault messages CHECK AJ102, CHECK AJ104 and CHECK
AJ105 are no longer displayed.

E0004
ATTENTION!
Do not force the safety guards to open.
E0004
WARNING!
Use the key releases present on the individual interlocked safety devices to access the machine when power
is not present.
The release keys should be given only to personnel authorized to access and service the machine.

002AZ019A
3-14

3
3.5.2.3.1 Accessing the waste container compartment
E0004

E0137
WARNING!
Do not take out the waste container while the plasticization unit is running of the machine is not performing the
production cycle and no products are seen being carried on the exit conveyor belt, risk of burns.
E0004

E0137

E0003

E0010
WARNING!
Never access the waste container compartment while the plasticization unit and/or machine is running, risk of
burns and shearing.

FIGURE 3.5.2.3.1 - ACCESSING THE WASTE CONTAINER COMPARTMENT
1 Waste container
1

002AZ019A
3-15
3
3.5.2.3.2 Safety guards with mechanical lock
A number of safety guards with mechanical locks may stay in place even without the fixing screws, for example the
top covers of the plasticization unit.
E0004
WARNING!
Always secure all the safety guards in place before attempting to start up the machine.

002AZ019A
3-16

3
3.5.2.4 Accessing the extruder outlet
The machine works under safe conditions only when the hopper or metering unit/mixer is mounted on the extruder
outlet.
E0004

E0003

WARNING!

FIGURE 3.5.2.4 - ACCESSING THE EXTRUDER OUTLET
1A Hopper (*)
1B Metering unit/mixer (*)
2 Extruder outlet
(*) The hopper and metering unit/mixer are in alternative to each other.
1A 2
1B

002AZ019A
3-17
3
3.5.2.5 Risks from excessive air pressure
E0004

WARNING!
It is severely forbidden to modify the pressure relief devices that protect the air system.
Incorrectly adjusting these devices may cause malfunctions or break down of parts in the pneumatic system
creating dangerous conditions for the operators.

FIGURE 3.5.2.5 - RISKS FROM EXCESSIVE AIR PRESSURES
1 Pressure regulator
SP1 Pressure regulator, Mains
SP7 Pressure switch, Machine supply
SP1 SP7 1
002AZ019A
3-18

3
3.5.2.6 Cut hazards
INSERTION TURRET CUTTING BLADES
E0004

E0138

WARNING!
Cut hazard at the insertion turret cutting blades; adequate personal protective equipment must be worn
(grippers, protective gloves, etc).
002AZ019A
3-19
3
3.6 MACHINE DECOMMISSIONING AND DISASSEMBLY
3.6.1 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED
E0004

WARNING!
Carefully follow the instructions given in chapter 9 - DECOMMISSIONING, paragraph WHAT TO DO WHEN THE
MACHINE IS NO LONGER USED in compliance with current standards.
E0004

WARNING!
Only skilled personnel specially trained in servicing and handling may work on the machine.
Use only adequate lift equipment and means and operate in compliance with current laws and standards.
E0004

WARNING!
Release any pressurized gas contained in the accumulators with the tester / inflator supplied with the machine
as directed in the CHECKING ACCUMULATOR PRECHARGE paragraph in chapter 8 - MAINTENANCE.
E0004

WARNING!
Contact Sacmi Technical Assistance to obtain packaging and transport instructions if the machine has to be
moved from one facility to another.
002AZ019A
3-20

3
3.6.2 DISASSEMBLING THE MACHINE
E0004

WARNING!
Follow the instructions given in Chapter 9 - DECOMMISSIONING paragraph DISASSEMBLING THE MACHINE
and observe current standards and safety regulations.
E0004

WARNING!
Only skilled personnel specially trained in servicing and handling may disassemble the machine.
Use only adequate lift equipment and means and operate in compliance with current laws and standards.
E0004

WARNING!
Release any pressurized gas contained in the accumulators with the tester / inflator supplied with the machine
as directed in the CHECKING ACCUMULATOR PRECHARGE paragraph in chapter 8 - MAINTENANCE.
E0004

WARNING!
Remove the machine parts observing current safety standards and the instructions given in chapter 4 -
INSTALLATION and the safety guidelines given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS,
paragraphs SAFETY RULES FOR HANDLING and MACHINE DECOMMISSIONING AND DISASSEMBLY.
E0004

WARNING!
Dispose lubricants and coolants according to local laws in force in the country the machine is installed in.
E0004

E0133
WARNING!
When the machine is disposed, the materials should be recycled to the greatest extent possible in compliance
with laws in force in the country in which the machine is installed.
002AZ019A
4-1
INSTALLATION
4
4 INSTALLATION
4.1 SHIPPING, HANDLING AND POSITIONING THE MACHINE
25 mm
2
2
0
0
2
3
2
0
2
1
5
0
1
Kg 4600
3
Kg 320
4
Kg 1200
A
( 60 mm)
2
5
0
0

m
m
2
5
0
0

m
m
2
8
0
0

m
m
16 mm
16 mm
B
C
1
2
6
0
m
m
6
3
0
m
m
1
5
5
0
m
m
2
5
2
0
m
m
7
0
0
m
m
1
4
5
0
m
m
16 mm
B
8
0
0
12 mm
1
0
0
0
6
8
0
m
m
7
4
0
m
m
1
4
5
0
m
m
2
4
2
0
2
7
0
0
8
0
0
B
16 mm
5
Kg 450
6
Kg 120
2
Kg 1500
T4816
002AZ019A
4-2

4
INSTALLATION
FIGURE 4.1 - SHIPPING, HANDLING AND POSITIONING THE MACHINE
1 Press
2 Extruder
3 Temperature controller
5 Hydraulic power unit
A CCM00125002 tool
B CCM00125003 tool
C CCM00402030 tool
002AZ019A
4-3
INSTALLATION
4
4.1.1 MACHINE DIVISION
The machine is divided into groups depending on the shipping and installation requirements.
4.1.2 DIMENSION AND WEIGHTS
The dimensions and weights given in this manual are approximate therefore they are given for reference purposes
only.
4.1.3 SYSTEMS FOR LIFTING INDIVIDUAL PARTS
When the crates arrive on site, they must be handled with extreme care and transported both inside and outside
the factory, with means that are able to support the weight indicated on the packing and shipping documents.
It is fundamental that the user weighs all the parts when they arrive to verify their exact weight.
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.
E0004

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.
E0004

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.
002AZ019A
4-4

4
INSTALLATION
4.2 INSTALLATION
- Position the press 1
- Lay down the tracks 5 of the extruder
- Place the extruder 2 on the tracks.
- Install the extruder connecting tube 3 joining it to extruder 2 making sure the coupling flange is clean. Tighten
nuts 15 with a 6 Kgm torque wrench.
- Level press 1 with the adjustable height legs.
- Secure the press 1 with the mounting brackets 6.
- Level extruder 2 with press 1, adjusting the threaded supports of the extruders wheels.
- Connect extruder feed tube 3 to press flange 13 with screws 14 making certain the parts are clean and the
tubes ball is aligned with the nozzle body.
- Put cover 12 on tube 3.
- Take the lift equipment off the extruder and put the top covers on the extruder.
E0004

WARNING!
Do not damage the heaters cables.
- Position the hydraulic power unit 8.
- Position temperature controller 11.
- Put electric cabinet 4 in its correct position.
- Install plastic compound feed hopper 10 on the extruder (or, as an alternative, the optional metering unit/
mixer).
E0004

E0003

WARNING!
Do not attempt to start up the extruder without the hopper or metering unit/mixer, risk of amputation.
- Put trunks 7 that protect the tubes and electric wires in place
- Put the operator interface cabinet 9 in place.
T2953
T4746
002AZ019A
4-5
INSTALLATION
4
FIGURE 4.2 - PUTTING THE PARTS IN PLACE
1 Press
2 Extruder
3 Feed tube
4 Electric cabinet
5 Extruder tracks
6 Press brackets
7 Trunks
9 Operator interface
10 Feed hopper
12 Cover
13 Flange
14 Screw
15 Nut
3
15
13
14
12
7
11 8 1
10 5 2
9 6
4
002AZ019A
4-6

4
INSTALLATION
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 HYDRAULIC SYSTEM
Connect as shown in the figure below:
FIGURE 4.3.1/A - CONNECTING THE HYDRAULIC SYSTEM
3 2 1
2
1
3
002AZ019A
4-7
INSTALLATION
4
FIGURE 4.3.1/B - CONNECTING THE HYDRAULIC SYSTEM
4
6 (Y)
5 (OIL)
4 7 (X)
002AZ019A
4-8

4
INSTALLATION
4.3.2 HOOKING UP THE COOLANT SYSTEM
Connect as shown in the figure below:
FIGURE 4.3.2/A - HOOKING UP THE COOLANT SYSTEM
1 Cavity delivery tube
2 Cavity return tube
3 Punch delivery tube
4 Punch return tube
5 Ancillary delivery tube
6 Ancillary return tube
7 Extruder delivery tube
8 Extruder return tube
6
2
3
1
4
8
7
5
7
8
002AZ019A
4-9
INSTALLATION
4
FIGURE 4.3.2/B - HOOKING UP THE COOLANT SYSTEM
1 Cavity delivery tube
2 Cavity return tube
3 Punch delivery tube
4 Punch return tube
5 Ancillary delivery tube
6 Ancillary return tube
9 Connecting tube to cooling system
10 Connecting tube arriving from cooling system
1 2 3 4 5 6 9 10
002AZ019A
4-10

4
INSTALLATION

4.3.3 HOOKING UP THE PNEUMATIC SYSTEM
PNEUMATIC CONTROL UNIT
- Attach a hose whose inside diameter is as stated in the specifications to the fitting A from the compressed air
supply.
E0004
WARNING!
The machines 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.
- Connect the air hose between the machine and plasticization unit to fitting B.
FIGURE 4.3.3 - HOOKING UP THE PNEUMATIC SYSTEM
A Compressed air system fitting
B Machine/plasticization unit fitting
A B
002AZ019A
4-11
INSTALLATION
4

4.3.4 CONNECTING THE VACUUM SYSTEM
Connect the tubes arriving from the machine to the couplers present on block 1. There may be one or two tubes,
depending on whether cutters with insertion piston are installed in the machine.
FIGURE 4.3.4 - CONNECTING THE VACUUM SYSTEM
1
002AZ019A
4-12

4
INSTALLATION
4.3.5 ELECTRIC HOOK UP
The customer must assure the machine is connected to an electrical system equipped with a device that protects
against surges. The cut off current must be suitable to protect the supply wires.
E0004
WARNING!
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.
002AZ019A
4-13
INSTALLATION
4
4.3.5.1 Connecting the electric cables
Make the electrical connections between the various parts of the machine as indicated in the figure below.
The identification numbers used in the diagram are those marked on the points to be connected and wires.
E0004
WARNING!
Seal the conduit for the electric cables with polyurethane foam or similar products to assure they remain clean
and in good condition.
FIGURE 4.3.5.1 - CONNECTING THE ELECTRIC CABLES
2 Press base
5 Operator interface cabinet
BQ1 Encoder
BQ2 Thickness transducer
BT10 Thermocouple
EH22 Heater heating element (*)
M1 Hydraulic power unit motor
M2 Extruder auger motor
M4 Recirculatory motor, Hydraulic power unit
M5 Motor, Vacuum line for holding caps in place and vacuum for pistons
M8 Volumetric pump motor (*)
M9 Molding unit motor (main drive unit)
M9F Motor M9 brake control
M17 Exit conveyor belt motor
M18 Motor, Temperature controller, Zone 1
M21 Waste and burr suction motor (*)
M31 Suction motor, Exit conveyor belt
M35 Auxiliary motor, Mold maintenance circuit (*)
CE.OL Hydraulic power unit box
CE.PN Pneumatic control unit box
EXTR. RES Extruder heating element box
INF.SX Left lower Profibus box
INF.RX Right lower Profibus box
EXTR. POT Extruder power box
EXTR. SEG Extruder Profibus box
TERM.POT Temperature controller box
TERM.SEG Temperature controller Profibus box
TU.P Tube power box
TU.S Tube signal box
UGEL. Nozzle box
BY-PASS Extruder by-pass control panel
(*) Optional
T
U
.
S
T
U
.
P
U
G
E
L
.
B
Y
-
P
A
S
S
C
E
.
P
N
I N F . S X
I N F . D X
C E . O L
T
E
R
M
.
P
O
T
.
T
E
R
M
.
S
E
G
.
E
X
T
R
.
S
E
G
E
X
T
R
.
R
E
S
E
X
T
R
.
P
O
T
M
2
M
5
M
8
M
3
1
M
1
7
M
2
1
M
9
M
1
M
3
5
M
4
M
2
0
M
1
9
M
1
8
M
9
F
1
4
3
6
5
2
X
B
2
4
X
B
2
6
X
T
3
1
W
1
2
X
B
3
2
X
B
3
3
X
B
5
X
B
4
X
T
3
5
X
T
8
X
B
1
8
X
T
4
0
X
B
2
0
X
B
2
3
X
B
1
2
X
B
2
9
B
Q
2
X
B
1
0
B
T
1
0
B
Q
1
E
H
2
2
X
B
7
X
B
1
4
S
B
3
W
1
2
X
B
2
2
T
4
8
1
9
X
B
2
7
X
B
1
2
X
B
1
7
X
T
3
0
X
B
3
A
X
B
3
X
B
2
X
T
1
1
1
002AZ019A
4-14

4
INSTALLATION
FIGURE 4.3.5.1 - CONNECTING THE ELECTRIC CABLES
002AZ019A
4-15
INSTALLATION
4
4.3.5.2 Earth connection
Connect the parts marked with symbol
E0006
(417-IEC-5019) present on:
- machine body
- hydraulic power unit
- plasticization unit
- temperature controller
to the bar 1.
Connect the bar 1 directly to an effective earth-ground system.
Specially trained personnel should make the connections in the areas indicated on the relative plates.
Any paint present should be removed before the relative screws are tightened in order to ensure perfect electrical
continuity.
E0004
Only in the event that it is not possible to connect the bar 1 directly to an earth-grounding system, connect
the cable 2 to the earth bar found inside the main electrical cabinet.
E0004
WARNING!
Failure to earth/ground the indicated parts may cause serious personal injury as well as equipment damage.
Unless otherwise specified, the installation worker assigned by the customer is responsible for earth
connections.
FIGURE 4.3.5.2 - EARTH CONNECTION
1 Earth bar
2 Ground system connecting cable
3 Machine connecting cable
4 Plastification unit connecting cable
5 Temperature controller connecting cable
6 Hydraulic power unit connecting cable
2 3 4 5 6 1
002AZ019A
4-16

4
INSTALLATION
4.3.5.3 Connecting the power cable
Connect the power cable to the terminals marked R, S and T of the main switch located inside the main electrical
cabinet.
E0004
Connect the grounding cable to the terminal marked PE (EN60445) of the main switch located inside the main
electrical cabinet.
E0004
WARNING!
Failure to earth/ground the indicated parts may cause serious personal injury as well as equipment damage.
Unless otherwise specified, the installation worker assigned by the customer is responsible for earth
connections.
The power and earth cables must be constructed and have a cross-section suitable for the specific electrical
wiring. Information about the size of the cables is given on the installation plans supplied with the machine at
the time of purchase.
FIGURE 4.3.5.3 - CONNECTING THE POWER CABLE
002AZ019A
5-1
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.
E0004
WARNING!
Solely the manufacturers 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.
The customers 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.
E0004
As regards machines equipped with components that fall into the scope of Directive 97/23/EC, the customer
must test them before starting them up in accordance with regulations in force in the country in which the
machines are installed.
002AZ019A
5-2

5
START-UP
5.2 FIRST TIME START UP
5.2.1 PRELIMINARY CHECKS
- Verify that the machine and/or equipment incurred not damage during shipment, handling and installation.
- Make sure all the retainers and fasteners employed for shipment have been removed.
- Make certain all the materials and equipment used for machine installation have been removed.
- Check the oil level in the hydraulic power unit.
- Check the coolant level in the temperature controller.
- Make sure the power supply is as indicated on the machine nameplate.
- Make sure the air mains pressure is as required (see paragraph 2.3 SPECIFICATIONS).
- Make certain the cooling system supply is as indicated on the machine nameplate (see paragraph 2.3
SPECIFICATIONS).
- Verify the cables and/or tubes are properly attached and not damaged or twisted.
- Check to see whether all the shut off valves are open.
- Make sure the safety guards have been correctly and completely installed.
- Verify the sequence of the phases is correct by checking the direction in which all motors run.
- Check all the safety devices for efficiency.
- Check operation of the audible/visual indicator devices.
- Check the emergency brake by performing an emergency braking cycle as directed in chapter 7 - ADJUSTMENTS,
paragraph ADJUSTING THE EMERGENCY BRAKE.
E0004
WARNING!
002AZ019A
5-3
START-UP
5
5.2.2 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
- Make sure all the parameters given on the data sheet have been properly set for the machine. Some of the
parameters can be set with the operator interface while others need to be set directly on the equipment.
PROCEDURE
- Turn the mode selector on the keyboard to MAN.
- Press key 0 to reset the machine.
- Open the guards turn the handwheel for manual movements.
- Make sure there are no obstructions by allowing the molding turret to complete at least one full turn.
- Close the guards.
- Press button 2-28 to start the temperature regulator for the extruder
- Press key 17-28 to start the temperature regulator for the molds and auxiliary circuits.
- Make sure the coolant does not leak in any part of the machine.
- Press key 8-28 to start the hydraulic power unit.
- Activate the low pressure circuit with key 11-28.
- Activate the high pressure circuit with key 10-28. All the actuators will move up except for those found near the
control cams for the hydraulic valves.
- Make sure there are no oil leaks.
- Set the speed of the main motor to about 10% (see INSTRUCTIONS B).
- Start the main motor with key 3-28 and make sure the actuators run correctly while the turret is turning.
- Stop the molding turret (key 7).
- Set the rpm suitable for the selected production output (pieces/min).
- Use key 3-28 to start the main motor.
- Activate the low pressure shut off circuit (key 16-28).
- Make sure the actuators operate properly by referring to the control unit display (see INSTRUCTIONS B
Manual).
- Inactivate the high pressure (key 10) and low pressure shut off (key 16) circuits.
- Wait until all the actuators have moved down and stop the molding 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 9-28.
- Make sure the extruder and metering pump can turn freely (if provided).
- Inactivate the plasticization unit by using key 13.
002AZ019A
5-4

5
START-UP
5.2.3 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.
CONDITIONS
- OPERATIONAL CHECKS described in previous paragraph successfully completed.
PROCEDURE
- Turn the mode selector 19-23 on the keyboard to MAN.
- Press button 2-28 to start the temperature regulator for the extruder
- Press key 17-28 to start the temperature regulator for the molds and auxiliary circuits.
- Press key 8-28 to start the hydraulic power unit.
- Activate the low pressure circuit with key 11-28.
- If the machine remains inoperative for an extended period, proceed as directed below or go to the next step.
PROCEDURE FOR EXTENDED SHUTDOWN
- Activate the high pressure circuit with key 10-28.
All the actuators will move up except for those found near the control cams for the hydraulic valves.
- Set the speed of the main motor to about 10% (see Instructions B).
- Start the main motor with key 3-28 and wait at least 10 minutes.
- Inactivate the high pressure circuit (key 10).
- Wait until all the actuators have moved down and stop the molding turret with key 7.
- 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.
- 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.
- Press key 12 to shut off the hydraulic power unit.
- Press key 9-28 to 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).
- Open the guards on the operators side.
- Press key SB23B to empty.

E0004

E0137

E0003
WARNING!
Heed to all safety rules and standards - risk of burns and crushing.
- Press key 13 to stop the plasticization unit.
- Close the safety guards.
- Turn the mode selector switch 19-23 on the keyboard to AUT.
002AZ019A
5-5
START-UP
5
5.2.4 STARTING THE AUTOMATIC CYCLE
(References given in figure 6.1)
CONDITIONS
- Machine on and at the correct temperature
- Guards closed
PROCEDURE
- Turn the mode selector 19-23 on the keyboard to AUT.
- Start the automatic cycle by using key 1-28.
5.3 SUBSEQUENT START UPS
- Perform only the operations described in the PRELIMINARY OPERATIONS and STARTING THE AUTOMATIC
CYCLE paragraphs.
002AZ019A
5-6

5
START-UP
002AZ019A
6-1
OPERATING INSTRUCTIONS
6
6 OPERATING INSTRUCTIONS
6.1 OPERATOR INTERFACE
The operator interface allows the operators to run or control machine operation.
The following operations can be performed from the user interface:
- the work cycle can be set.
- the operating data can be entered or changed even when the work-cycle is in progress.
- messages and settings can be displayed.
- the operating data for the selected work-cycle can be stored and retrieved.
- self-diagnosis.
- maintenance checks.
E0004
IMPORTANT!
All information about how to program and use the controller are given in INSTRUCTIONS Manual B - Use of
the microprocessor control system.
The illustration of the keyboard is not binding.
The background colors and colors and shapes of the keys may vary according to the electric codes in force in
the country of installation and color of the machine.
However, the number and functions of the keys do not vary even if the colors are different.
T4842
1 2 3 8 9 0 10
24
11 16 17 18
5 6 7 12 13 4 14 15 20 21 22
30 30 31
25 25 26
29 27 28
19-23
002AZ019A
6-2

6
FIGURE 6.1 - OPERATOR INTERFACE CABINET KEYBOARD
002AZ019A
6-3
6
OPERATION 1
st
key 2
nd
Key
KEY
Safety module alarm/Reset 0
Automatic cycle start 28 1 AUT.
Extruder heating start 28 2
Machine start, Forward operation 28 3 SETUP/MAN.
Machine start, Reverse operation 30 3 SETUP/MAN.
Automatic cycle stop 5 AUT.
Extruder heating stop 6
Machine stop 7 SETUP/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 SETUP/MAN.
Hydraulic power unit stop 12 SETUP/MAN.
Extruder by-pass stop 13 SETUP/MAN.
Insertion turret in on/off 28 14 SETUP/MAN.
Insertion turret out on/off 28 15 SETUP/MAN.
Low pressure switch on/off 28 16 SETUP/MAN.
Temperature regulators start/stop 28 17
Jog start 28 18 SETUP/MAN.
Plastic compound feeder start/stop 28 21 SETUP/MAN.
Preheating 28 22 AUT.
E0004
WARNING!
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.
002AZ019A
6-4

6
6.2 WORK CYCLES
E0004

E0003

WARNING!
6.2.1 WORK CYCLES IN MANUAL/SET UP MODE
All the operations whereby the user has to access the machine directly (i.e. with the safety guards open) are
considered manual and set-up operations.
The operators must pay special attention when performing these operations.
The mode selector 19-23 on the keyboard must be turned to either position MANUAL or SET UP.
6.2.1.1 Draining the nozzle
E0004

E0137

E0003
WARNING!
- Start the plasticization unit by using key 9-28.
- Press and hold down button SB23B until some pieces of molten material are ejected. The material will be
gathered and thrown into the by-pass collection tray.
- Thoroughly clean the top of the nozzle.
FIGURE 6.2.1.1 - DRAINING THE NOZZLE
SB23B
002AZ019A
6-5
6
6.2.1.2 Actuator upstroke to install/remove tools
(only for machines equipped with auxiliary circuit for mold maintenance)
FIGURE 6.2.1.2 - ACTUATOR UPSTROKE TO INSTALL/REMOVE TOOLS
HL35A
SB35
SA4
002AZ019A
6-6

6
E0004
IMPORTANT!
This operation can be done only if the machine encoder has been correctly zeroed. Perform the steps given
below to reset.
- Turn mode selector 19-23 to MAN.
- Press key 0 to reset the machine
- Turn on the hydraulic power unit with button 8-28.
- Start the low pressure circuit with button 11-28.
- Set the rpm to 5%.
- Press key 3-28 to start the machine and allow the molding turret to complete at least two full turns.
- Press key 7 to stop the unit.
E0004
IMPORTANT!
This operation can be performed only if fault message MOLDS CANNOT BE SERVICED is not displayed.
With the safety guards closed:
1 - Turn mode selector 19-23 to SETUP and press key 0 to reset the machine.
2 - Turn on the hydraulic power unit with button 8-28.
3 - Start the high pressure circuit with button 10-28 allowing it to function until the molds are closed.
4 - Press button 12 to shut off the hydraulic power unit.
5 - Press and hold down button SB35 until it lights up and green indicator light HL35A is illuminated.
6 - Open the safety guards.
E0004
WARNING!
Some operations (for example turning the manual control handwheel or the pressure of a slide valve) cause the
auxiliary pump to shutdown immediately and the circuit to be drained.
In this case, proceed as directed below:
- Close the safety guards;
- Press key 0 to reset the machine;
- Repeat the procedure from step 5;
E0004
WARNING!
Once the tools reached from the back of the machine have been disassembled/installed (to install/remove the
remaining tools) proceed as directed below.
002AZ019A
6-7
6
7 - Close the safety guards.
8 - Turn the mode selector to MAN and press key 0 to reset the machine.
9 - Turn on the hydraulic power unit with button 8-28.
10 - Start the low pressure circuit with button 11-28.
11 - Press button 3-28 to run the machine until all the cavities have moved down.
12 - Press button 7 to stop the work unit.
13 - Press button 12 to shut off the hydraulic power unit.
14 - Turn the mode selector to SET-UP.
15 - Repeat the procedure (from steps 1 to 6) for the remaining molds.
E0004
WARNING!
Before attempting to lock/release the lower tools, make sure indicator light HL35A is illuminated (actuators
closed and under pressure).
If it is not, the molds may be seriously damaged.
6.2.2 AUTOMATIC CYCLE
- Turn selector 19-23 to AUT to set the machine for automatic operation.
E0004
WARNING!
Running the machine for prolonged periods without a mold or when pellets are not placed in a mold may cause
serious equipment damage.
6.2.2.1 Preheating
The machine can automatically be preheated by setting the date and time the system is to come on from the
operator interface.
For further information on how to enter data, refer to the INSTRUCTIONS B manual.
002AZ019A
6-8

6
6.2.2.2 Running the machine
Press key 1-28 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 Turret speeds up to reach required speed.
Insertion turret entry.
4 Start of pellet ejection.
5 Pellets inserted.
Start of product rejection.

6 End of product rejection.
Start of production.
E0004

E0137
WARNING!
Never take out the waste container if the machine is not running and no products are clearly seen being carried
on the exit conveyor belt; risk of burns.
E0004

E0137

E0003

E0010

WARNING!
Never access the waste container while the plasticization unit and/or machine is running, danger of burns and
amputation.
6.2.2.3 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 turret exit.
Actuators move down.
Rotation stops.
002AZ019A
6-9
6
6.3 PRODUCTION CYCLE
The production cycle for continuous molding by means of compression develops from a complete rotation of the
molding turret as illustrated in the figures below.
The work position of the actuators are shown in the figures. These correspond to the numbers actually marked on
the actuators.
E0004
ATTENTION!
A standard cycle is illustrated, it may vary depending on the type of caps that need to be produced.
PRODUCTION STAGE
1 PELLET INSERTION
The pellets of plastic compound (DM) are picked up by the nozzle through the insertion turret (GI) and are deposited
in the mold (MA) of the actuator.
32 ACTUATOR PAUSE
The mold (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 mold of the
actuator (MA) to move up until it reaches its molding start position.
29 MOLDING
The valve that controls the actuators when up (C) (with oil at high pressure) opens a second time thereby causing
the mold to move up until the pellets of plastic compound (DM) are completely formed.
28-6 PRODUCT COOLING
While the turret is turning, the formed product (PS) stays in its pressing position and cools down.
5 ACTUATOR DOWNWARD MOVEMENT
The valve that controls the actuators when down (A) is activated thereby causing the mold to move down while the
formed product remains attached to the upper punch (PU).
4-2 ACTUATOR PAUSE
The mold is empty and waits for another pellet (DM) to be inserted.
1 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.
PU
ES
PS
GI
DM
MA
T1550
SE
T1594 PC
002AZ019A
6-10

6
CONTROL STAGES
30 START OF MOLDING POSITION CONTROL
A sensor controls the correct position for the start of molding (see chapter 7 ADJUSTMENTS).
24 PRODUCT CONTROL
A sensor detects the position of the mold during pressing.
The formed product is classified as follows depending on the position reached by the mold:
- double weight (with double pellets)
- weight greater than nominal value
- weight corresponds to nominal value
- weight lower than nominal value
- no product (pellet not deposited)
DOUBLE THICKNESS
If a number of pieces whose thickness is double the nominal one are detected, the machine automatically carries
out the relative shutdown cycle.
PRODUCT WEIGHT HIGHER OR LOWER THAN STANDARD VALUE
If a number of pieces whose weight is higher or lower than the standard one are detected, the machine carries out
the relative shutdown cycle.
NO PRODUCT
If a number of empty molds (MA) are detected because the pellet was not inserted, the machine carries out the
relative shutdown cycle.
FIGURE 6.3/A - PRODUCTION CYCLE
DM Pellet
ES Stripper
GI Insertion turret
MA Mold
pc Central product panel
PS Formed product
PU Punch
SE Stripper wheel
PS
pc
1 32
31
30
29
28
27
26
25
24
23
22
21
20
19
18 17 16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
B B
A
30 17
C C C C C C C C C C C
A A A
C C C C C C C C C C C C
16 15 14 13 12 11 10 2 1 32 31 30 8 29 28 27 26 25 24 23 22 21 20 19 18 3 4 5 6 7 8 9
A
A A
GS
SQ39
SQ62
SQ62
SQ39
24 24
30
15 6 5 1
BQ21
BQ21
BQ2
BQ2
GI
A
B
C C C C
A
T4820
002AZ019A
6-11
6
FIGURE 6.3/B - PRODUCTION CYCLE
A Valve down: oil being drained
B Valve in first position upwards: oil at low pressure
C Valve in second position upwards: oil at high pressure
GI Insertion turret
GS Molding turret
1 Pellet insertion/product removal
32 Actuator pause
31/30 Approach
29 Molding
28 - 6 Product cooling
5 Actuator moves down
4-2 Actuator pause
24 Product checked
30 Start of molding position checked
002AZ019A
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6
6.4 SHUTDOWN 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 potentially problematic situations.
6.4.1 EMERGENCY SHUTDOWN WITH FAULT MESSAGE 1...
1 Fault detected.
2 Molding turret motor braked to stop.
Insertion turret inactivated.
By-pass opens.
Hydraulic power drained.
3 Plasticization unit stopped.
Hydraulic power unit stopped.
4 Fault message code 1..... displayed .
RESET
As seen in the flow chart, the above mentioned safety feature causes the machine to shutdown immediately. To
reset it, free the product from the molds.
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 8-28.
- Press key 11-28 for low pressure.
- Press jog key 18-28 until the product is removed from the molds.
- Shut off the hydraulic power unit with key 12.
- Wait until the safety guards can be opened.
- Open the safety guards.
- Locate and remedy the trouble.
E0004

E0137

E0003
WARNING!
Work in accordance with safety standards, hazard of burns and crushing
- Carefully remove the removed product from the molds making sure nothing remains inside.
E0004
ATTENTION!
Pay careful attention to the product and pellets located inside the lower tools or jammed in the upper mold.
- Turn the mode selector to AUT.
002AZ019A
6-13
6
6.4.2 EMERGENCY SHUTDOWN WITH FAULT MESSAGE 3
1 Fault detected.
2 Pellet insertion stops.
Extruder stops.
3 Insertion unit exits
Actuators move down.
Rotation stops.
RESET PROCEDURE
- Wait until the safety guards can be opened.
- Locate and remedy the trouble.
E0004

E0137

E0003
WARNING!
Work in accordance with safety standards, hazard of burns and crushing
002AZ019A
6-14

6
6.5 PRODUCT SAMPLING
Press button 1 to eject a sample (consisting of a complete set of formed pieces) by means of the conveyor.
In this way it is possible to check the formed product for defects.
FIGURE 6.5 - PRODUCT SAMPLING
1 Sample button
1
002AZ019A
7-1
ADJUSTMENTS
7
7 ADJUSTMENTS
7.1 PLASTICIZATION UNIT
7.1.1 EXTRUDER
The parameters that can be set are with the electronic control system are given below.
- Temperature of the heat treatment zones.
- Extruder motor speed % (available only for operations in manual mode if the metering pump is present).
- Coolant temperature
The values of these parameters are given on the Data sheet
E0004
ATTENTION!
- 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.
002AZ019A
7-2

7
ADJUSTMENTS
7.1.2 METERING PUMP ADJUSTMENTS
- Speed % of the pump motor.
- Pump intake pressure.
- Pump-casing temperature.
E0004
ATTENTION!
- 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.
002AZ019A
7-3
ADJUSTMENTS
7
7.1.3 FEED TUBE, MIXER (IF PRESENT), NOZZLE CASING, NOZZLE
- Temperature.
E0004
ATTENTION!
- Refer to the INSTRUCTIONS B manual for the control system for information on how to set the
parameters.
002AZ019A
7-4

7
ADJUSTMENTS
7.2 INSERTION TURRET
E0004

E0005

WARNING!
7.2.1 ADJUSTING THE TURRETS CONNECTING ROD
FIGURE 7.2.1 - ADJUSTING THE TURRETS CONNECTING ROD
YV33 Solenoid valve
1 Pulley
2 Torque limiter
3 Encoder
4 Support
5 Gear wheel
7 Gear wheel
8 Pulley
9 Toothed belt
10 Pulley
11 Tensioner
12.1 Cutter without insertion cylinder
12.2 Cutter with insertion cylinder
12A Disk
12B Piston
12C Gasket
12D Sleeve
12E Cutter
12F Screw
12G Cutter
12H Screw
12L Nozzle
12M Gasket
13 Disk
14 Turret
15 Turret
16 Screw
17 Spacer
18 Distributor
19 Flange
20 Screw
21 Nut
22 Pin
23 Nut
24 Pin
25 Bar
26 Screw
27 Connecting rod
28 Screw
29 Screw
30 Screw
31 Disk
32 Screw
33 Spring
34 Pin
38 Cover
39 Screw
40 Screw
41 Spacer
42 Ring nut
43 Flange
44 Nut
45 Screw
46 Screw
49 Shaft
50 Screw
51 Flange
52 Nut
53 Washer
54 Spring
55 Spacer
56 Screw
57 Pin
58 Ring nut
59 Spacer
60 Flexible ring
61 Screw
62 Flexible ring
63 Cover
T4817
002AZ019A
7-5
ADJUSTMENTS
7
FIGURE 7.2.1 - INSERTION TURRET ADJUSTMENT
1
2
3
55
54
52
53
12F
12G
12H
12E
12D
12C
12B
12A
12.2
12.1
12G
12L
12M
12E
12F
12H
30 20
21
23
22
24
38
40 8 9
34 28 16 51 15
11 39
32
45
46
29
50
26
43
7 57
42 14
YV33
13 41 33
58
59
44 10
6
4
49
5 61
62 60
31 18 19 17 27
56
12.1
12.2
25
63
002AZ019A
7-6

7
ADJUSTMENTS
7.2.1.1 Adjusting turrets connecting rod precharge
- Perform the following operations with the machine at its required operating temperature.
E0004

E0137

E0003
WARNING!
Work in compliance with all safety rules and standards, risk of burns and crushing
- Turn the mode selector switch to SETUP or MAN.
- Press the RESET button 0; the insertion unit is in its home position, i.e. away from the molding turret .
- Loosen nut 21.
- Loosen the nut that secures pin 22.
- Tighten pin 22 to move the bearing fully up.
- Loosen nut 23 half a turn.
- Put the insertion turret in its work position manually by pushing it towards the molding turret until the grub screw
comes into contact with it. As a result, pin 24 will be under bar 25.
- Make sure there is play between the two pins and bar 25. If there is not, work on screw 26.
- Place the magnetic strip with precision comparator (1/100) on the molding turret. The comparators feeler should
rest on the connecting rod 27.
- Reset the comparator.
- Work on screw 26 to bring pin 24 against bar 25 being careful not to precharge the turret (make sure the
comparator reads 0).
- Tighten pin 22 until it rests against bar 25 and then fully tighten the relative nut.
- Precharge the insertion turret. Tighten screw 26 (the comparator will detect vertical movement of the connecting
rod 27) until a value ranging from 0.2 to 0.35 mm is read).
- Bring the turret into the machine shutdown position and tighten screw 23.
- Tighten nut 21.
- Place the insertion unit in its work position again and check the value given on the comparator.
- If the value changed, take the unit out of its work position, loosen screw 23 half a turn, loosen nut 21 and turn
screw 26 until a value ranging between 0.2 to 0.35 mm is read.
- Put the unit in the position in which the machine shuts down and tighten screw 23 and then nut 21.
- Place the insertion turret in its work position and check the value given on the comparator.
- Remove the comparator.
- Move the insertion unit into its home position, i.e. away from the molding turret , manually.
002AZ019A
7-7
ADJUSTMENTS
7
7.2.1.2 Checking turret connecting rod precharge
- Perform the following operations with the machine at its required operating temperature.
E0004

E0137

E0003
WARNING!
- Turn the mode selector switch to SETUP or MAN.
- Press the RESET button 0; the insertion unit is in its home position, i.e. away from the molding turret .
- Push the insertion turret bringing pins 22 and 24 near bar 25 without inserting them.
- Place the magnetic strip with precision comparator on the molding turret. The comparators feeler should rest
on the connecting rod 27.
- Bring the insertion unit into its work position by hand. Push it towards the molding turret until the grub screw
comes into contact with it.
- Check the precharge by verifying the comparator reads a value ranging between 0.2 to 0.35 mm.
- Repeat the operation making sure pins 22 and 24 are near bar 25 and the comparator reads 0 (zero).
- Remove the comparator.
- Move the insertion unit into its home position, i.e. away from the molding unit, manually.
T4515
002AZ019A
7-8

7
ADJUSTMENTS
7.2.2 ADJUSTING THE CUTTER
Conditions:
- Turret connecting rod correctly precharged.
- Mode selector turned to SET-UP or MAN.
- Key 0 pressed to reset machine.
- Extruder nozzle at correct temperature and machine safety guards open. The temperature of the plasticization
unit will continue to be controlled.
- Machine at required operating temperature
Adjustments
E0004

E0137

E0003
WARNING!
- Bring the insertion unit into its work position by hand. Push it towards the molding turret until the grub screw
- Use the handwheel to turn the turrets clockwise until one of cutters is in the middle of the hole in nozzle 2.
- Loosen screws 3 which 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 with a
thickness Y of 0.02 - 0.05 mm) between the cutting edge of blade 1 and the upper edge of the nozzle.
- Put a screwdriver in the slot in cutter 1. Press on the blade until the cutting edge comes into contact with the
blade.
- Keep the blade in this position and tighten screws 3.
- Repeat this procedure for the remaining cutters.
E0004
ATTENTION!
This procedure is to be carried out for all the cutters.
FIGURE 7.2.2 - ADJUSTING THE CUTTER
1 Cutter
2 Nozzle
3 Screw
Y
1
3
2
T4516
002AZ019A
7-9
ADJUSTMENTS
7
7.2.3 ADJUSTING PELLET INSERTION TIMING
FIGURE 7.2.3 - ADJUSTING PELLET INSERTION TIMING
X
002AZ019A
7-10

7
ADJUSTMENTS
7.2.3.1 Resetting the encoder
E0004
ATTENTION!
The encoder is automatically reset whenever the machine is turned on while the turrets start running. It is
important to perform the reset procedure before timing or making any adjustments which require that the
encoders value is correct.
- Shut off electrical power to the machine.
- Wait for the operator interface computer (if provided) to shut off.
- Turn on the machine.
- Start the turrets in manual mode and wait until the molding turret has completed two full turns. The machine
automatically resets encoder 3.
7.2.3.2 Adjusting the pellet insertion stage
E0004
ATTENTION!
Molding turret and insertion turret timing is factory set prior to delivery. Changing this value may cause
malfunctions and/or machine damage. Whenever the toothed belts, that transmit motion from the molding
turret to the insertion turret are tensioned, check timing and make any corrections required.
Conditions
- Mode selector 19-23 on keyboard turned to SET-UP or MAN.
- Encoder reset.
- Machine at required operating temperature
Adjustments
- Open the safety guards on the operator side.
E0004

E0137

E0003
WARNING!
Work in compliance with all safety rules and standards, risk of burns and crushing.
002AZ019A
7-11
ADJUSTMENTS
7
- Turn the manual control handwheel clockwise until the encoder display reads 0 .
- Bring the insertion unit into its work position manually. Push it towards the molding turret until the grub screw
- Make sure value X corresponds to the value given on the data sheet.
If it does not, proceed as directed below:
- Loosen the screws 20.
- Rotate the insertion turret until the front edge of the end of the nozzle is at distance X, as indicated on the
data sheet, from the front edge of the cutter.
- Tighten screws 20 without altering the position obtained.
- Check the position and repeat the adjustment procedure.
7.2.3.3 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 from the control system. 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.
E0004
ATTENTION!
The insertion delay and length of insertion parameters and compressed air pressure are strictly related to
the type of material handled as well as other variables.
Therefore, observe the values given on the Data sheet.
002AZ019A
7-12

7
ADJUSTMENTS
7.2.3.4 Adjusting the stripper wheels
Conditions:
- Mode selector 19-23 on keyboard turned to SET-UP or MAN.
Adjustments:
E0004

E0137

E0003
WARNING!
- Turn the manual control handwheel until one of the upper molds near the cap stripping zone is fully down.
- Put the insertion turret in its work position in manual mode.
- Loosen screws 28 and turn wheel 14 to center a wheel cavity with the upper mold.
- Tighten screws 28 without changing the position.
- Put the insertion turret in its home position in manual mode.
- Turn the insertion turret clockwise, grasping the cutters, and turn to release the clutch.
E0004
ATTENTION!
Wear heavy duty work gloves and other personal protective equipment.
- Loosen the screws 29 and turn the turret and wheel 15 until the wheels 14 and 15 are timed.
- Tighten screws 29.
- Turn the insertion turret, grasping the cutters, to engage the clutch.
E0004
ATTENTION!
Wear heavy duty work gloves and other personal protective equipment.
7.2.3.5 Adjusting the transfer wheel with vacuum
- Loosen the hex. screws 30 that secure the disc 13. They are found between the wheel 14 and disc itself.
- Turn the disc 13 in manual mode to center the disc holes with the wheel cavities 14.
- Fully tighten the screws that secure the disc 13 without changing the position.

002AZ019A
7-13
ADJUSTMENTS
7
7.3 ADJUSTING THE MOLDING TURRET
7.3.1 ADJUSTING THE PRODUCT STRIPPER CAMS
The strippers are mechanically controlled by cams. The position of the cams is given on the Data sheet.
E0004
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.
7.3.2 ADJUSTING THE QUALITY CONTROL UNIT
7.3.2.1 Transducer BQ2 mechanical adjustments
- Turn mode selector switch 19-23 on the keyboard to SETUP or MAN.
- Press the reset button 0 to reset the machine.
- Open the guards on the side opposite the operators side.
- Remove an upper punch and relative stripper.
- Using the manual control handwheel, position the back-plate of the actuator that corresponds to the punch
removed so that the middle of the back-plate matched the transducers center-line.
- Start the hydraulic power unit with button 8-28.
- Activate the high pressure circuit with button 10-28.
- Wait for the actuators to move completely up.
- Shut off the hydraulic power unit with button 12.
- Use the nuts to bring transducer BQ2 to a height 2.75 mm (+/- 0.05 mm) away from the back-plate.
- Start the hydraulic power unit with button 8-28.
- Activate the cavity return circuit with button 11-28.
- Run the machine with key 3-28 until all the cavities have moved down
- Stop the unit with key 7.
- Shut off the hydraulic power unit with button 12.
- Put in the upper punch and stripper previously removed.
002AZ019A
7-14

7
ADJUSTMENTS
7.3.2.2 Setting / saving the reference distance
This is the distance between sensor BQ2 and the reference surface on the actuator, forming a cap whose nominal
thickness of the bottom is correct. To change this distance, set the speed of the metering pump, if present, or
extruder so that caps are produced whose bottom thickness corresponds to the nominal one.
E0004
The reference distance should be saved only after producing caps for a reasonable amount of time in order to
allow the machine to reach the correct operating temperature.
- Go to the CCM DATA page.
- Disable function QUALITY CTRL ENABLE or the quality control enable selector (condition NO).
- Take sample caps that correspond to a complete turret revolution, pressing the relative key found near the exit
channel.
E0004
The sample caps should be taken only after the machine has reached the correct operating temperature roughly
after running at least 15 minutes.
- Make sure the dimensions of the bottom of the caps are correct:
- if they are, enable function QUALITY CTRL ENABLE or the quality control enable selector (condition
YES);
- if they are not, proceed as directed below.
Plasticization unit with metering pump
- Disable FEEDBACK.
- Adjust the metering pump speed; the correct value is given on the Data sheet.
- Enable function QUALITY CTRL ENABLE (condition YES).
- Take sample caps that correspond to a complete turret revolution, pressing the relative key found near the
exit channel.
- Enable function QUALITY CTRL ENABLE or the quality control enable selector (condition YES).
Plasticization unit without metering pump
- Disable FEEDBACK.
- Adjust the extruder speed; the correct value is given on the Data sheet.
- Enable function THICKNESS ACQUISITION (condition YES).
- Take sample caps that correspond to a complete turret revolution, pressing the relative key found near the
exit channel.
- Enable FEEDBACK.
002AZ019A
7-15
ADJUSTMENTS
7
T3903
X X-(> 0,15) X+(> 0,15)
FIGURE 7.3.2.3 - SENSITIVITY ADJUSTMENT
7.3.2.3 Adjusting sensitivity
The sensitivity for quality checking can be adjusted by setting the low threshold, defective caps and the high
threshold, defective caps parameters in the control system. This allows the dimension field within which the
product is considered acceptable to be defined. The reference value is 0.15 mm.
This value is subject to changes depending on the type of caps produced.
002AZ019A
7-16

7
ADJUSTMENTS
7.4 PNEUMATIC SYSTEM ADJUSTMENTS
7.4.1 PRESSURE SWITCH SP1
Check and adjust the pressure that activates pressure switch SP1.
Conditions
- Machine energized and air supplied.
Adjustment
- Work on pressure regulator 1 until the pressure reaches 0.3 MPa, making certain led SP1 on the electronic
cards in the electrical cabinet or control system go out.
- On the contrary, work on the adjustment screws 2 located on the head of the pressure switch until the pressure
switch comes on once the pressure reaches 0.3 MPa.
FIGURE 7.4.1 - PRESSURE SWITCH SP1
1 Pressure controller
2 Adjustment screw
2
1
002AZ019A
7-17
ADJUSTMENTS
7
7.4.2 PRESSURE SWITCH SP7
Check and adjust the pressure that activates pressure switch SP7.
Conditions
- Machine energized and air supplied.
- Pressure switch SP1 correctly set.
Adjustment
- Work on pressure regulator 1 until the pressure reaches 0.4 MPa, making certain led SP7 on the electronic
cards in the electrical cabinet or control system go out.
- On the contrary, work on the adjustment screws 2 located on the head of the pressure switch until the pressure
switch comes on once the pressure reaches 0.4 MPa.
FIGURE 7.4.2 - PRESSURE SWITCH SP7
1 Pressure controller
2 Adjustment screw
1
2
002AZ019A
7-18

7
ADJUSTMENTS
7.5 HYDRAULIC SYSTEM ADJUSTMENTS
FIGURE 7.5 - HYDRAULIC SYSTEM ADJUSTMENTS
A Hydraulic power unit reservoir
1 Suction filter
2 High pressure pump
3 Low pressure pump
4 Oil filter
5 Heat exchanger
14 Oil drain valve
BT10 Thermocouple
M1 Electric motor
M4 Oil recirculation motor
SL2 Oil level sensor
SP4 Pressure switch, Filter clogged
B Hydraulic power unit
6 Low pressure control valve
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
SP12/SP13 Pressure switches, Low pressure detection
SP14/SP15 Pressure switches, High pressure detection
YV21 Solenoid valve, High pressure circuit discharge closure
YV27 Solenoid valve, Low pressure circuit discharge closure
C Flow control assembly
15 Control valve, Actuator return pressure
16 Restrictor, Discharge circuit
17 Pressure gauge, Actuator return circuit pressure
18 Accumulator, Actuator return circuit
19 Flow control, Low pressure circuit
20 Diaphragm
21 Rotary joint
SP115 Pressure switch, Restrictor
YV30 Solenoid valve, Actuator approach circuit cut off
002AZ019A
7-19
ADJUSTMENTS
7
FIGURE 7.5 - HYDRAULIC SYSTEM ADJUSTMENTS
18 16 21
17 15 19 YV30
23
22
SL2
5
BT10
SP4
4
SP15
SP14
SP13
SP12
12
YV21
YV27
14
11 13 M4 M1
6
9
10
002AZ019A
7-20

7
ADJUSTMENTS
E0004
WARNING!
The control valves are equipped with a ring nut to tighten the threaded control rod only to the value set for the
valve.
Do not remove the ring nut and fully tighten the control rod to avoid creating dangerously high pressures in the
hydraulic system.
Always monitor the pressure with the relative pressure gauge while making adjustments/performing
maintenance.
7.5.1 ADJUSTING THE APPROACH STAGE (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
molding turret . 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.
If the flow rate is incorrectly set, the products may have defects and the yellow warning light found on the electrical
cabinet comes on.
A sensor, located near the point where the valve is opened a second time (i.e., oil starts flowing under high pressure),
detects the path of the back-plates that stop the actuators from turning. If the sensor detects a number of back-
plates equal to the total number with a path different from the nominal one consecutively, the machine performs a
controlled shutdown procedure as described in chapter 6 - OPERATING INSTRUCTIONS. Adjust the flow rate of
the low pressure circuit with flow control 19.
Adjust the pressure of the low pressure circuit by working on adjustment valve 6 located.
The values are given on the Data sheet.
E0004
ATTENTION!
If the delivery rate of oil under low pressure is too high, the machine and molds may be seriously damaged.
7.5.2 ADJUSTING THE MOLDING STAGE (HIGH PRESSURE)
The pressure is regulated by working on valve 13 located in the hydraulic power unit.
The value is given on the Data sheet.
7.5.3 ADJUSTING THE ACTUATOR DOWNSTROKE
Work on valve 15 located in the hydraulic power unit to adjust the pressure.
The value is given on the Data sheet.
E0004
ATTENTION!
If the return pressure of the actuator is too high, the piston may violently bang its end-stop.
002AZ019A
7-21
ADJUSTMENTS
7
7.6 ADJUSTING THE TEMPERATURE CONTROLLER
E0004
ATTENTION!
Do not change the settings, given on the data sheet, of the thermostatic valve and temperatures set for the
upper and lower molds.
Set the temperature of the molds and auxiliary equipment from the control system
The values are given on the Data sheet.
7.7 ADJUSTING THE MOLDS
The molds are strictly related to the type of product handled.
The instructions concerning specific tooling are given during the training session attended by the customers
personnel.
002AZ019A
7-22

7
ADJUSTMENTS
7.8 ADJUSTING THE EXIT CONVEYOR BELT
FIGURE 7.8 - ADJUSTING THE EXIT CONVEYOR BELT
1 Conveyor belt
2 Screw
3 Guide
4 Nut
5 Screw
6 Nut
7 Screw
8 Nut
9 Guide
10 Screw
11 Cover
12 Screw
13 Screw
14 Screw
15 Plate
16 Cover
17 Screw
18 Conveyor
5
17
13
14
1
6 7 8
2
9
3
18
17
17 16 17
10
4 12 11
15
002AZ019A
7-23
ADJUSTMENTS
7
7.8.1 ADJUSTING THE HEIGHT OF THE EXIT CONVEYOR BELT
- Loosen fixing screws 6 and nut 8.
- Adjust the height of the belt with screw 7.
- Fully tighten fixing screws 6 and nut 8.
7.8.2 TENSIONING THE CONVEYOR BELT
- Loosen nuts 4.
- Tension the belt with screws 5.
- Make sure the clearance between the screw head and plate is the same for both adjustments screws.
- Fully tighten nuts 4.
7.8.3 ADJUSTING THE GUIDES
- Loosen screws 2 and 9.
- Adjust the guides 3 and 9.
- Tighten screws 2 and 9.
002AZ019A
7-24

7
ADJUSTMENTS
7.9 REPLACING THE SENSORS
When replacing the sensors consult the chart below as they must be placed the correct distance away in order to
read properly.
SENSOR REFERENCE OBJECT DISTANCE X
BQ2 See paragraph ADJUSTING THE QUALITY CONTROL UNIT
BQ21 See the procedure to set the sensor given in the INSTRUCTIONS B manual; adjust the position
of the sensor so that its reading surface is parallel with the surface to be detected.
SQ1 Block 1 mm
SQ2 Actuator clamp 2 mm
SQ11 Cap on turret 1 mm
SQ18 Limiter mobile ring, with limiter pick up 0.5 mm
SQ21 Cap on turret 1 mm
SQ39 Stripper rod head 8.5 mm
SQ59 Punch lower surface 8 mm (L=95 mm)
SQ62 Actuator clamp (down) 2 mm
SQ62C Cap on turret 2 mm
T2578
SQ39
SQ1
SQ11
SQ62C
SQ62
SQ59
SQ18
SQ21
BQ21
SQ2
BQ2
T4822
002AZ019A
7-25
ADJUSTMENTS
7
FIGURE 7.9/A - REPLACING THE SENSORS
1 Insertion
2 Cavity lift
3 Molding
4 Cooling
5 Cavity opening
6 Stripping
X
5
6
1
2
3
4
002AZ019A
7-26

7
ADJUSTMENTS
FIGURE 7.9/B - REPLACING THE SENSORS
X
SQ39
X
SQ21
SQ18
X
SQ1
SQ11
X
X
002AZ019A
7-27
ADJUSTMENTS
7
FIGURE 7.9/C - REPLACING THE SENSORS
X
SQ2
X
SQ62 SQ62C
X
SQ59
X
L
002AZ019A
7-28

7
ADJUSTMENTS
7.10 ADJUSTING THE EMERGENCY BRAKING SYSTEM
Purpose
This operation is performed to assure the emergency braking system works efficiently.
The emergency braking system is used in the event of an emergency to immediately shutdown the turrets and
prevent the molding turret from coming into contact with the insertion turret.
The machine is able to measure the braking angle at the time of emergency shutdown.
7.10.1 BRAKING ANGLE WIDER THAN NORMAL BUT IN ANY CASE ACCEPTABLE
The following message is displayed:
4011 CHECK BRAKING
The braking system has braking longer that the required value.
This message is displayed so that the machine can restart the automatic cycle.
E0004
ATTENTION!
Adjust the emergency braking system as instructed in paragraph EMERGENCY BRAKING SYSTEM
ADJUSTMENT PROCEDURE.
7.10.2 BRAKING ANGLE TOO WIDE
The following message is displayed:
3148 BRAKING SYSTEM FAILURE
The braking system has braked longer than the allowable value.
Under this condition, the machine CANNOT restart the automatic cycle. In fact, the safety conditions required for
the turrets and their parts are not guaranteed.
E0004
ATTENTION!
Immediately adjust the emergency braking system as instructed in paragraph EMERGENCY BRAKING SYSTEM
ADJUSTMENT PROCEDURE.
002AZ019A
7-29
ADJUSTMENTS
7
7.10.3 EMERGENCY BRAKING SYSTEM ADJUSTMENT PROCEDURE
Checking the emergency braking system
- Turn mode selector switch 19-23 on the keyboard to SETUP or MAN.
- Press the reset button 0 to reset the machine.
- Set the turret speed to 5%.
- Turn on the hydraulic power unit (keys 28-8).
- Turn on the lower mold downstroke circuit (keys 28-11).
- Turn on the molding turret (keys 28-3) and make sure all the caps present in the molds have been removed and
all the lower molds are down.
- Stop the turrets (key 7).
- Open the safety guards and verify that the molds, above all the cavities, are clean and that there are no pieces
of plastic or other objects present.
- Close the safety guards and reset the machine (keys 28-0).
- Open the lower safety guards on the operators side.
- Remove the cap of the self-braking motor.
- Loosen the nuts 2.
- Adjust air gap T with screws 1 bringing it down to the lowest value shown in the figure. Make sure the value is
the same around the entire circumference.
- Fully tighten nuts 2 keeping screws 1 in place.
- Make sure the value around the entire circumference has not been affected.
E0004
IMPORTANT!
Value X must be greater than or equal to the value given in the figure.
E0004
IMPORTANT!
Disengagement lever 3 should not be installed while the machine is operating to avoid affecting operation of
the brake system.
- Put the cap on the self-braking motor.
- Make sure the hydraulic accumulators are correctly precharged (see data sheet).
- Make sure the hydraulic system flow rate and pressures are correctly set (see data sheet).
- Press buttons 28-15 to bring the insertion turret to its home position, i.e. away from the molding turret.
- Set the machine rpm so that > 800 caps per minute are produced.
E0004
IMPORTANT!
In order to correctly finish the procedure, the production should never be below < 800 caps.
- Turn on the turrets (keys 28-3).
002AZ019A
7-30

7
ADJUSTMENTS
- Turn on the high pressure circuit (keys 28-10).
- Turn on the low pressure circuit (keys 28-16).
- Wait for the oil to reach the operating temperature (48-50 C) and in any case at least one minute. Depending on
the machine settings for the automatic cycle, during this stage the lower molds may not complete the upstroke
and therefore they do not come into contact with the upper molds. This is normal.
- Press one of the emergency stop buttons to simulated an emergency shutdown.
Three conditions may arise:
- Fault message 3148 BRAKING SYSTEM FAILURE is displayed: repeat the adjustment procedure.
- Message 4011 CHECK BRAKING is displayed; even though the machine can restart the automatic cycle,
the adjustment procedure should be repeated to assure the braking system works efficiently.
- Fault message 3148 BRAKING SYSTEM FAILURE is not longer displayed and other messages do not
appear, the adjustments have been correctly made.
- Reset the machine (keys 28-0).
- Set the machine speed to 10% of the production speed..
- Turn on the turrets (keys 28-3).
- Wait until all the lower molds have been lowered.
- Stop the turrets (key 7).
- Shut off the power unit (key 12).
- The braking system has been correctly adjusted.
T3965
3 2 1
1,5mm
1,5mm
T = 0,4 0,55mm
X 1,2mm
002AZ019A
7-31
ADJUSTMENTS
7
FIGURE 7.10.3 - EMERGENCY BRAKING SYSTEM ADJUSTMENT PROCEDURE
002AZ019A
7-32

7
ADJUSTMENTS
002AZ019A
8-1
MAINTENANCE
8

8 MAINTENANCE
GENERAL INFORMATION AND SAFETY PRECAUTIONS
E0004
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.
- isolate electrical power with personal devices (for example pad locks) stamped with the name of the operator
who put it on;
- remove the keys to the locks and personally hold on to them;
- post a maintenance in progress sign on the electrical cabinet;
Always keep in mind the potential risks and follow the safety rules given in chapter 3 - SAFETY EQUIPMENT
AND PRECAUTIONS.
E0004
IMPORTANT!
The pressure control valves have a ring nut that allow the threaded rod to be tightened only up to the valve
setting.
Do not take off the ring nut or fully tighten the rod to avoid creating excessively high pressures in the hydraulic
system.
Always monitor the pressure with the gauge provided when making adjustments/performing maintenance.
The maintenance operations are subdivided as follows:
- routine maintenance (to be carried out by the customers maintenance staff)
- special maintenance (to be carried out by the manufacturers properly trained technicians).
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.
E0004
WARNING!
002AZ019A
8-2

8
MAINTENANCE
8.1 ROUTINE MAINTENANCE
8.1.1 SCHEDULED MAINTENANCE CHART
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002AZ019A
8-8

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T1495
T2964
002AZ019A
8-9
MAINTENANCE
8
8.1.2 PERIODIC MAINTENANCE OPERATIONS
8.1.2.1 Drive unit
FIGURE 8.1.2.1 - DRIVE UNIT
1 Screw
2 Nut
3 Screw
4 Belt
5 Belt
6 Nut
7 Screw
8 Pulley
9 Back plate
10 Screw
11 Nut
12 Screw
13 Cock
14 Filler plug
15 Level gauge
16 Manual control handwheel
17 Tensioning unit
M9 Epicyclic gear motor
7
15
14
9
11
12
3
8 5 6
10
3 1 2
13
4
M9
16
17
002AZ019A
8-10

8
MAINTENANCE
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 molding turret transmission belts
- Take off the bottom covers to reach the transmission belts
- 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 molding turret 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 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 8.
- Tighten the screw 7 until the reference plate 9 is 0.1 mm (check the distance with a thickness gauge) from the
end of the support or transmission unit.
- Time the molding unit, insertion unit and stripper wheels (see chapter 7 - ADJUSTING PELLET INSERTION
TIMING).
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.
002AZ019A
8-11
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 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.
- Install the mount with encoder by tightening the nuts 11.
- Install the mount with sensor by tightening the screw 12.
- Make sure the sensor is activated.
- Time the molding unit, insertion unit and stripper wheels (see chapter 7 - ADJUSTING PELLET INSERTION
TIMING).
8.1.2.1.6 Checking the oil level in the molding turret gear motor
- Make certain the oil level does not fall below the collar fixed to the level indicators tube 15. If it does, add oil
through the filler plug 14.
8.1.2.1.7 Changing the oil in the molding turret gear 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.
T4558
002AZ019A
8-12

8
MAINTENANCE
FIGURE 8.1.2.2 - PLASTICIZATION UNIT
8.1.2.2 Plasticization unit
9 11 2
18
1
7 14 10 7
5
17 16
15
13
A
4
3 8 12 19
6
A
002AZ019A
8-13
MAINTENANCE
8
8.1.2.2.1 Overhauling the extruder auger
E0004

ATTENTION!
To ease cleaning, use polypropylene when by-passing and increase the extruders operating temperature so
that it does not cool down excessively when disassembling.
E0004

E0137

E0003
WARNING!
- 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.
E0004

ATTENTION!
Stop feeding plastic compound to the extruder when cleaning.
- Install the guide extensions 1 provided.
- Shut off the machine with the main switch located on the electrical cabinet.
- Take the safety guards off the extruder.
- Take off the cover 4 on the extruder connecting tube.
- Disconnect the pressure transducers 2 loosening the quick-connect coupler located under the mounting
bracket joined to the extruder. Unscrew the probe attached to the pump being careful not to twist or bend the
transducer cable.
- Disconnect the cable connectors 3 from the electrical boxes.
- Disconnect the thermocouple mounted on the nozzle case.
- Remove screws 5.
- Back up the extruder with the connecting tube attached to the end of the guides longitudinal stroke. Clean up
the plastic compound that flows out of the tube and nozzle as soon as possible.
E0004

ATTENTION!
Move the electrical cables away from under the extruder to avoid cutting them.
- Loosen the nuts 18 and turn the extruders wheels 90.
- Move the extruder outwards cross-wise.
- Loosen the nuts 6 and remove the connecting tube. Clean up the plastic compound that flows out of the tube
and volumetric pump as soon as possible.
- Pull out the heating elements 7 removing the relative mounting screws.
- Disconnect the connectors of the thermocouples 8.
- Loosen the heating elements 9 loosening the fixing screws.
- Loosen the two screws 10 from the top of the volumetric pump and replace them with two longer screws to
secure the two eyebolts used to lift the pump.
002AZ019A
8-14

8
MAINTENANCE
- Loosen grub screw 19.
- Loosen nuts 11 and remove volumetric pump 12 keeping it raised with the chains fitted with hooks secured to
the eyebolts previously put in.
- Remove extruder filter 13 using the screws to be tightened in the threaded holes.
- Remove screws 14 and take off the cover that protects the threaded fitting for the fixture used to remove the
auger.
- Put in fixture 15 supplied with the machine. Tighten it to the threaded fitting and screw on the threaded extensions
until the extruder auger 16 is removed.
- Take out the fixture 15 used to remove the extruder auger.
- Clean auger 16, filter 13 and extruder chamber as directed below.
E0004

ATTENTION!
This operation is to be performed with the plastic compound at room temperature.
- Thoroughly clean the auger with soft metal hand tools (for example bronze or copper), removing the resin
sheath.
- Clean the inside of the cylinder with a brush, removing any material stuck to the cylinder.
- Thoroughly clean filter 13. Replace it if worn. To open the filter holes, use a drill bit whose diameter is slightly
smaller than the holes in the filer.
- Make certain cover 17 on the extruder head (that may have different shapes) is completely tightened.
- Lubricate the grooved profile of the auger (use type G.10 grease, see ADHESIVES AND LUBRICANTS DATA
SHEET).
- Install the auger on the extruder mating the extruders grooved profile correctly with the auger, making sure the
auger is fully in.
- Install filter 13.
- Install heating elements 9.
- Install the volumetric pump by fully tightening nuts 11 (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 original mounting screws 10 for the pump cover.
- Fully tighten the fixing screws for heaters 9.
- Reconnect the connectors for thermocouples 8.
- Install the heating elements 7 fully tightening the relative screws.
- Mount the extruders connecting tube fully tightening nuts 6 with a 6 kgm torque.
- Move the extruder crosswise towards the machine.
- Turn the extruders wheels 90 and tighten nuts 18.
- Bring the tube near the nozzle body and connect it tightening screws 5 being careful to align the ball of the
connecting tube with the nozzle body.
- Connect the nozzle bodys thermocouple.
- Connect the connectors 3 of the electric cables to the relative boxes.
- Install the pressure transducers 2, screwing the probe attached to the pump and quick-connect coupler. Be
careful not to twist or bend the transducer cable.
- Put the safety guard 4 on the extruders connecting tube.
- Put the cover on the extruder augers fitting securing with screws 14.
- Remove the extensions for guides 1.
- Install the extruder safety guards.
- Turn on the machine with the main switch.
002AZ019A
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MAINTENANCE
8
8.1.2.2.2 Checking the oil level and adding oil in the extruder gearbox
- Make sure the oil level, shown by the gauge 2, is correct. If it is not, top up as follows:
- Take off cap 1.
- Add oil until sight glass 2 shows the correct level has been reached.
- Screw the cap 1 back on.
FIGURE 8.1.2.2.2 - CHECKING THE OIL LEVEL AND ADDING OIL IN THE EXTRUDER GEARBOX
3
2
1
002AZ019A
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8
MAINTENANCE
8.1.2.2.3 Changing the oil in the extruder gearbox
(See figure 8.1.2.2)
- Take off cap 1.
- Take off cap 3 and drain the oil from the gearbox.
- Add oil until sight glass 2 shows the correct level has been reached.
8.1.2.2.4 Cleaning the polymer metering pump
E0004

E0137

E0003
WARNING!
- Remove all the plastic that flows out of the pump 12 being careful not to cut the pressure transducer and
heating element cables.
8.1.2.2.5 Replacing/overhauling the polymer metering pump
E0004

ATTENTION!
To ease cleaning, use polypropylene when by-passing and increase the extruders operating temperature so
that it does not cool down excessively when disassembling.
E0004

E0137

E0003
WARNING!
- 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.
E0004

ATTENTION!
Stop feeding plastic compound to the extruder when cleaning.
- Shut off the machine with the main switch located on the electrical cabinet.
- Take the safety guards off the extruder.
- Take the cover 4 off the extruder connecting tube.
- Disconnect the pressure transducers 2, unscrewing the quick-connect coupler found under the extruders
mounting bracket and loosen the probe attached to the pump being careful not to twist or bend the transducer
cable.
002AZ019A
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MAINTENANCE
8
- Disconnect the cable connectors 3 from the electrical boxes.
- Disconnect the thermocouple mounted on the nozzle body.
- Remove screws 5.
- Back up the extruder with the connecting tube attached to the end of the guides longitudinal stroke. Clean up
the plastic compound that flows out of the tube and volumetric pump as soon as possible.
E0004

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 7 removing the mounting screws.
- Disconnect the connectors of thermocouples 8.
- Loosen the screws to loosen heating elements 9.
- Remove the two screws 10 from the top of the volumetric pump and put in two longer screws to secure the two
eyebolts used to lift the pump.
- Loosen grub screw 19.
- Loosen nuts 11 and remove volumetric pump 12. Keep it up with the chains that have hooks attached to the
eyebolts previously installed.
- 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.
002AZ019A
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8
MAINTENANCE
8.1.2.2.6 Lubricating the universal joint
- Take off the side covers in the area where the universal joint is found.
- Clean the universal joint and surrounding areas removing any extruded plastic material.
- Grease with the grease fittings 1 until grease runs out from between the parts of the universal joint.
- Put the side covers back on.
FIGURE 8.1.2.2.6 - LUBRICATING THE UNIVERSAL JOINT
1
002AZ019A
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MAINTENANCE
8
8.1.2.2.7 Cleaning the nozzle
- Remove the plastic compound that has deposited on the nozzle during operation. Be careful not to ruin the top
part where the cutters that cut the pellets pass by.
E0004

E0137

E0003
WARNING!
8.1.2.2.8 Checking and setting pressure transducers BP1 and BP2
E0004

E0137

E0003
WARNING!
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
transducers probe inside the pump can be completely tightened, when a new transducer is installed.
E0004
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 XB98;
BP2 (outlet pressure) cable XB99.
C - First of all adjust transducer BP1.
D - Call up the DATA page on the display.
E - Remove the protective screw 1 on the transducer casing and press button 2, located inside with the extruder
stopped (this means that pressure does not reached the pump).
F - Adjust transducer BP2 repeating the operations given for step E.
G - Verify that the pressure values (pump input and output) shown on the display screen read zero.
002AZ019A
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8
MAINTENANCE
FIGURE 8.1.2.2.8 - CHECKING AND SETTING PRESSURE TRANSDUCERS BP1 AND BP2
1
2
002AZ019A
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MAINTENANCE
8
8.1.2.2.9 Lubricating the extruder motor bearings
- Take off the side covers in the area where the motor is found.
- Grease the motor bearings with grease fittings 1 until grease runs out from under the motor shaft.
- Put the side covers back on.
FIGURE 8.1.2.2.9 - LUBRICATING THE EXTRUDER MOTOR BEARINGS
1
002AZ019A
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8
MAINTENANCE
8.1.2.3 Insertion turret
E0004

E0137

E0003
WARNING!
E0004

E0138

WARNING!
YV33 Solenoid valve
1 Pulley
2 Torque limiter
3 Encoder
4 Mount
5 Toothed wheel
7 Toothed wheel
8 Pulley
9 Toothed wheel
10 Pulley
11 Tensioner
12.1 Cutter without insertion piston
12.2 Cutter with insertion piston
12A Disk
12B Piston
12C Gasket
12D Sleeve
12E Knife
12F Screw
12G Cutter
12H Screw
12L Nozzle
12M Gasket
13 Disk
14 Wheel
15 Wheel
16 Screw
17 Spacer
18 Distributor
19 Flange
20 Screw
21 Nut
22 Pin
23 Nut
24 Pin
25 Counter-device
26 Screw
27 Connecting rod
28 Screw
29 Screw
30 Screw
31 Disk
32 Screw
33 Spring
34 Pin
38 Cover
39 Screw
40 Screw
41 Spacer
42 Ring nut
43 Flange
44 Nut
45 Screw
46 Screw
49 Shaft
50 Screw
51 Flange
52 Nut
53 Washer
54 Spring
55 Spacer
56 Screw
57 Pin
58 Ring nut
59 Spacer
60 Snap ring
61 Screw
62 Snap ring
63 Cover
T4817
002AZ019A
8-23
MAINTENANCE
8
1
2
3
55
54
52
53
12F
12G
12H
12E
12D
12C
12B
12A
12.2
12.1
12G
12L
12M
12E
12F
12H
30 20
21
23
22
24
38
40 8 9
34 28 16 51 15
11 39
32
45
46
29
50
26
43
7 57
42 14
YV33
13 41 33
58
59
44 10
6
4
49
5 61
62 60
31 18 19 17 27
56
12.1
12.2
25
63
002AZ019A
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8
MAINTENANCE
8.1.2.3.1 Cutters with insertion blower
8.1.2.3.1.1 Sharpening the blades
- Loosen screws 12F and take out the blades 12E.
- Sharpen the blades at a work bench with vice with a grinding stone.
- Install the blades 12E by tightening the screws 12F.
- Adjust the height of the blades as instructed in chapter 7 - paragraph ADJUSTING THE CUTTER.
8.1.2.3.1.2 Replacing the blades
- Put in the new blades.
8.1.2.3.1.3 Cleaning the cutters
- Remove the guides mounted on top of wheels 14 and 15.
- Remove the screws 29.
- Remove the flange 51 that the wheel 15 is mounted on.
- Remove the wheel 14.
- Remove the disk 13.
- Loosen the screws 12H and remove the cutter 12G.
- Clean the cutter to remove any burrs of plastic compound and degrease the part with diluent.
- Install the cutter 12G and tighten the screws 12H.
- Install the disk 13 by tightening the screws 30.
- Install the wheel 14 by tightening the screws 28.
- Install the flange 51 with the wheel 15 by tightening the screws 29.
- Install the guides over the wheels 14 and 15.
- Adjust the cutters, pellet insertion and the wheels as directed in the ADJUSTING THE CUTTER and ADJUSTING
PELLET INSERTION TIMING paragraphs in chapter 7.
- Loosen the screws 12H and remove the cutter 12G.
- Install the blade 12F, taken off the old cutter, on the new one 12G.
- Install the cutter 12G and tighten the screws 12H.
002AZ019A
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MAINTENANCE
8
8.1.2.3.1.5 Cleaning or replacing the nozzles
- Loosen the screws 12H and remove the cutter 12G and nozzle 12L.
- Clean the nozzle 12L with diluent. Blow compressed air in the holes to remove any dirt; replace the nozzle if
damaged.
- Check the condition of gasket 12M. Replace it if worn.
- Install the nozzle 12L on the cutter 12G.
- Install the cutter 12G by tightening the screws 12H.
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8
MAINTENANCE
8.1.2.3.2 Cutters with insertion piston
8.1.2.3.2.1 Rotating the blades
- Loosen screw 12F and take out the blades 12E.
- Turn the blades 12E 180 to use the other edge.
8.1.2.3.2.2 Sharpening the blades
- Sharpen the blades at a work bench with vice with a grinding stone.
- Put in the new blades.
8.1.2.3.2.4 Cleaning the cutters with insertion piston
- Loosen screws 12H.
- Remove cutter 12G paying attention to disc 12A as it is free inside the housing.
- Remove the piston 12B.
- Remove the sleeve 12D.
- Clean the cutter 12G of any plastic burrs and degrease the part with a thinner.
- Blow compressed air in the holes to remove the thinner and any dirt.
- Clean the sleeve 12D and piston 12B with alcohol.
- Install the sleeve 12D in the cutter 12G without using any grease or oil.
- Install the piston 12B without using any grease or oil, making sure gasket 12C is present.
- Make sure the piston 12B and sleeve 12D are able to move freely without any seizure. If this is not the case,
clean the parts again.
- Install the cutter 12G and disc 12A in the disc housing 31.
8.1.2.3.2.5 Replacing the cutters
- Loosen screws 12H.
- Remove cutter 12G paying attention to disc 12A as it is free inside the housing.
002AZ019A
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MAINTENANCE
8
- Mount the sleeve 12D, previously removed from the old cutter, in the new cutter 12G without using any grease
or oil.
- Mount the piston 12B, previously removed from the old cutter, in the new cutter 18C without using any grease
or oil, making sure gasket 12C is present.
- Make sure the piston 12B and sleeve 12D are able to move freely without any seizure. If this is not the case,
clean the parts with alcohol.
- Install the blade 12E, removed from the old cutter, on the new body 12G.
- Install the cutter 12G and disc 12A in the disc housing 31.
8.1.2.3.3 Cleaning the compressed air distributor
- Remove the spacer 17.
- Raise the distributor 18 and flange 19.
- Blow compressed air in the holes in the distributor 18 and remove any dust present both on the distributor and
nearby parts.
- Perform the steps in reverse to reinstall the parts.
8.1.2.3.4 Replacing the compressed air distributor
- Remove the spacer 17.
- Raise the distributor 18 and flange 19.
- Remove the flange 19.
- Remove the springs 33.
- Detach the air lines from the distributor.
- Remove solenoid valve YV33.
- Remove the pneumatic fittings.
- Remove the dowel 34.
- Replace the distributor 18.
- Perform the steps in reverse to reinstall the parts.
8.1.2.3.5 Checking precharge of the turret connecting rod
- Verify that the connecting rod is charged while it engages itself with the nozzle cases insert as indicated in
chapter 7 - ADJUSTMENTS, paragraph ADJUSTING TURRETS CONNECTING ROD PRECHARGE.
8.1.2.3.6 Adjusting precharge of the turret connecting rod
- Verify that the connecting rod is charged while it engages itself with the nozzle cases insert as indicated in
chapter 7 - ADJUSTMENTS, paragraph ADJUSTING TURRETS CONNECTING ROD PRECHARGE.
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8
MAINTENANCE
8.1.2.3.7 Tensioning the insertion turret drive belt
- Tighten the nut 52 so that the washer 53 rests against spacer 55 found inside the spring 54.
8.1.2.3.8 Replacing the insertion turret drive belt
- Remove the cover 63.
- Loosen the ring nut 42 and remove the flange 43.
- Loosen the screws 39 and take off the cover 38.
- Loosen the nut 52 of the tensioner to slacken the belt.
- Make sure the belt 9 is slack enough to remove the connecting rod 27.
- Remove the pin 11 with the toothed wheel 7 and pulley 8 mounted.
- Remove the screw 45.
- Raise the connecting rod 27.
- Change the belt 9.
- Put the connecting rod 27 back in place being careful to put the toothed belt in the pulley 10.
- Put in the pin 11 of the toothed wheel 7 and pulley 8 being careful to insert the toothed belt in the pulley without
damaging it.
- Tighten the screw 56.
- Install the flange 43 and tighten the ring nut 42.
- Install the flange 51 with wheel 15 tightening the screws 29.
- Put in and tighten the screw 45.
- Tighten the belt 9 as directed In paragraph TENSIONING THE INSERTION TURRET DRIVE BELT.
- Put the cover 38 back in place and secure with screws 39.
- Put on the cover 63.
002AZ019A
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MAINTENANCE
8
8.1.2.3.9 Replacing the pulley (item 10)
- Remove the cover 63.
- Loosen the ring nut 42 and remove the flange 43.
- Loosen the nut 52 of the tensioner to slacken the belt.
- Make sure the belt 9 is slack enough to remove the connecting rod 27.
- Raise the connecting rod 27.
- Loosen the ring nut 58 and remove the spacer 59.
- Change the pulley 10.
- Put in the spacer 59 and tighten the ring nut 58.
- Put the connecting rod 27 back in place being careful to put the toothed belt in the pulley 10.
- Install the flange 43 and tighten the ring nut 42.
- Install the flange 51 with wheel 15 tightening the screws 29.
- Put in and tighten the screw 45.
- Tighten the belt 9 as directed in paragraph TENSIONING THE INSERTION TURRET DRIVE BELT.
- Put the cover 38 back in place and secure with screws 39.
- Put on the cover for the waste conveyor.
8.1.2.3.10 Replacing the toothed wheel (item 5)
- Take off the cover 63.
- Take off the toothed wheel 5 and replace it.
- Perform the operations in reverse order to put the parts back in place.
- Check pellet insertion timing and how the turrets are adjusted as directed in chapter 7 ADJUSTMENTS -
paragraph ADJUSTING PELLET INSERTION TIMING.
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8
MAINTENANCE
8.1.2.3.11 Replacing the toothed wheel (item 7)
- Loosen the nut 52 from the tensioner to slacken the belt.
- Pull out the pin 57 with the toothed wheel installed.
- Remove the snap ring 60 at the work bench.
- Replace the toothed wheel 7.
- Perform the operations in reverse order to put the parts back in place. Be careful not to damage the toothed belt
when putting it in the pulley 8.
- Check timing and how the stripper turrets are adjusted as directed in chapter 7 ADJUSTMENTS - paragraph
ADJUSTING PELLET INSERTION TIMING.
8.1.2.3.12 Replacing the pulley (item 8)
- Loosen the nut 52 from the tensioner to slacken the belt.
- Pull out the pin 57 with the toothed wheel installed.
- Remove the snap ring 60 at the work bench.
- Replace the toothed wheel 7.
- Remove the snap rings 62 that secure the pulley 8.
- Replace the pulley 8.
- Perform the operations in reverse order to put the parts back in place. Be careful not to damage the toothed belt
when putting it in the pulley 8.
- Check timing and how the stripper turrets are adjusted as directed in chapter 7 ADJUSTMENTS - paragraph
ADJUSTING PELLET INSERTION TIMING.
8.1.2.3.13 Checking wear and tear and lubricating the gears
- Loosen the screws 39 and remove the guard 38.
- Grease the gear teeth 5 and 7.
- Turn the handwheel to grease all the teeth.
E0004

E0003

WARNING!
- Install the guard 38 tightening the relative screws 39.
T4824
T4825
002AZ019A
8-31
MAINTENANCE
8
8.1.2.4 Molding turret
FIGURE 8.1.2.4 - MOLDING TURRET
1 Turret lower section
3 Lower mold
4 Actuator drive valve
4A Valve control
4B Valve
5 Coolant ducts (lower molds)
6 Upper mold
7 Turret upper section
8 Stripper drive rod
9 Fork
11 Wheel
14 Grease fitting
15 Grease fitting
16 Screw
17 Cover
18 Upper flange
19 Nut
20 Lower flange
21 Nut
22 Grease fitting
23 Grease fitting
24 Screw
T4827
4
4B
4A
16
15
11
17
22
5
22
19
20
18
6
24
7
8
23
14 9 21
3
1
2
4
002AZ019A
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8
MAINTENANCE
8.1.2.4.1 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 3 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 turret.
8.1.2.4.2 Overhauling the actuator valve
- Shut off electricity to the machine with the main switch located on the cabinet.
E0004
ATTENTION!
The actuators must not be in the molding position.
- Remove the control for valve 4A.
- Remove the valve 4B 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 valve 4B being careful not to cut the gaskets.
- Install the control for valve 4A by tightening the screws 16.
8.1.2.4.3 Greasing the actuator valve rollers
- Grease the valve roller with grease fitting 15. Use the grease gun provided.
- Clean up any extra grease present on the valve.
8.1.2.4.4 Greasing the stripper rod rollers
- Grease the rod roller with grease fitting 14. Use the grease gun provided.
002AZ019A
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MAINTENANCE
8
8.1.2.4.5 Replacing the hydraulic actuator gasket
E0004
ATTENTION!
- Turn the molding turret manually with the handwheel found over the motor until the actuator corresponds to the
hole in the base.
- Disconnect the tubes 5 from the coupling mounted on the turret manifold. Pour the coolant that flows out of the
tube into a container to avoid getting the machine dirty.
- Remove the cavity 3.
- Loosen the fixing screws and remove the flange 18.
- Loosen the nut 19 and remove the clamp that prevents rotation.
- Loosen the screws and remove the lower flange 20.
E0004
ATTENTION!
The oil in the turret 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.
E0004
ATTENTION!
Be careful not to ruin the gaskets when installing the flange on the actuator or the actuator itself.
002AZ019A
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8
MAINTENANCE
8.1.2.4.6 Replacing the upper flange gaskets
E0004
ATTENTION!
- Remove the cavity 3.
- Loosen the fixing screws and remove the flange 18.
- Replace the gaskets.
E0004
ATTENTION!
8.1.2.4.7 Replacing the lower flange gaskets
E0004
ATTENTION!
- Loosen the nut 19 and remove the clamp that prevents rotation.
- Loosen the fixing screws and remove the lower flange 20.
E0004
ATTENTION!
The oil in the turret cavity flows out when the lower flange is unscrewed.
- Replace the gaskets.
E0004
ATTENTION!
002AZ019A
8-35
MAINTENANCE
8
8.1.2.4.8 Lubricating the stripper rod guide bushes
- Loosen the nut 21 and take out the spacer, fork 9 and stripper 6.
- 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.
8.1.2.4.9 Greasing the central tool wheel (optional)
- Grease the central tool wheel with grease fitting 23 found on the support pin for the wheel. Use the grease gun
provided.
8.1.2.4.10 Greasing the turret bearings
- Grease the turret bearings with grease fittings 22.
8.1.2.4.11 Replacing the gaskets and rotary distributor bearings
E0004

E0003

WARNING!
Exercise extreme caution when handling the parts: danger of being crushed.
E0004
IMPORTANT!
Discharge the pressurized gas in the accumulators with the tester/inflator provided as directed in chapter 8 -
MAINTENANCE, paragraph CHECKING ACCUMULATOR PRECHARGE.
E0004
IMPORTANT!
Use a container to collect the oil and one to collect the coolant contained in the hoses and components which
will be removed.
- Detach the tubes that connect the rotary joint 1, spring accumulator 39 and distributor 14 to the machine.
- Remove the accumulator 38.
- Remove the spring accumulator 39 by loosening the screws 40.
- Detach the hoses that join the distributor 21 to the machine.
- Loosen the screws 41 and remove all the manifolds 42.
- Remove all the tubes 43.
- Loosen the antirotation screws 2.
- Remove the rotary joint 1 using the attachment at its base.
- Remove parts 3 and 4 by loosening the fixing screws with tool 5 (item A).
- Install tool 6 and eyebolt 7 on the distributor 8 (item B).

002AZ019A
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8
MAINTENANCE
- Loosen the screws 9 with tool 37 (item C). Raise the distributor using the eyebolt 7 previously installed.
- Place the distributor on a stable support.
- Loosen the eyebolt 7.
- Loosen the ring nut 10.
- Loosen four of the six screws 11 and install tool 12 on distributor 14 using the four threaded holes that contained
the screws 11.
- Screw the threaded bar of tool 12 onto tool 6 and secure with nut 13.
- Remove the distributor 14 with nuts 24 of tool 12 (item D).
- Replace the gaskets 15.
- To replace the bearings, follow the directions given below:
- Remove tool 12.
- Loosen the last two screws 11 of the flange 27.
- Replace the bearing 28. Use tool 29 to remove as shown in the figure (item G).
- Remove the snap ring 30.
- Tighten the eyebolts 17 (item E).
- Raise the distributor 18 using the eyebolts previously installed.
- Place the distributor on a stable support.
- Loosen the eyebolts 17.
- Install the tool 20 as shown in the figure (item F). Screw the threaded bars to the distributor 18 and secure with
nuts 22.
- Remove the distributor 21 with nuts 23 of tool 20.
- Replace the gaskets 25.
- To replace the bearings, follow the directions given below:
- Remove tool 20.
- Replace the bearing 37.
- Perform the operations in reverse order to put the parts back into place paying special attention while handling
the parts.
T4836
T4837
002AZ019A
8-37
MAINTENANCE
8
FIGURE 8.1.2.4.11/A - REPLACING THE ROTARY DISTRIBUTOR BEARINGS AND/OR GASKETS
41
42
43
4
40
2
38
1
39
3
16
T4838
A B C
D
E
G
F
002AZ019A
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8
MAINTENANCE
FIGURE 8.1.2.4.11/B - REPLACING THE ROTARY DISTRIBUTOR BEARINGS AND/OR GASKETS
5
8
10
6
11
9
7
24
27
28
14
31
30
12
15
13
6
29
20
37
18
19
17
32
26
37
22
33
21
18
35
34
36
25
23
002AZ019A
8-39
MAINTENANCE
8
T5935
80 Nm
1
2
A.03
8.1.2.4.12 Checking tightness of the lower flange ring nuts
- Verify the ring nuts 2 are tight by hand.
- Only in the event that the ring nuts are loose, tighten the ring nuts 2, using the torque indicated in the figure
and A.03 adhesive (see the COOLANT MIXES, ADHESIVES AND LUBRICANTS DATA SHEET supplied under
separate cover). Use tool 1.
FIGURE 8.1.2.4.12 - CHECKING TIGHTNESS OF THE LOWER FLANGE RING NUTS
T2970
T2969
T2538
T2538
002AZ019A
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8
MAINTENANCE
8.1.2.5 Cams
FIGURE 8.1.2.5 - CAMS
20
1
2
19
9
3
4
10
8
18
15
11
12
16
13
17
14
002AZ019A
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MAINTENANCE
8
8.1.2.5.1 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.
8.1.2.5.2 Replacing the stripper cams (central movement) (optional)
- Replace the cam 3.
- Position the cam as indicated on the Data sheet.
- Check the position of the cam.
8.1.2.5.3 Replacing the stripper cams (side movement)
- Remove seven stripper rods from the molding turret from the side opposite the operator, as indicated below
(refer to figure 8.1.2.4).
- Loosen the nut 21.
- Remove the stripper ring 6 with the fork 9 installed.
- Remove the stripper rod 8.
- Turn the turret manually until the part of the turret without any rods corresponds to the stripper cam.
- Replace the cam 4.
- Position the cam as indicated on the Data sheet.
- Check the position of the cam.
- Turn the turret manually until the part of the turret without any rods is on the side opposite the operator.
- Install the stripper rods (refer to figure 8.1.2.4).
- Install the ring 6 by inserting the fork 9 in the stripper rod 8, mount the spacer and fully tightening the nut 21
for all the rods.
8.1.2.5.4 Replacing the actuator control cams
- Loosen the screws 11 and 17.
- Take off the covers 12 and 18.
- Remove the pins 13.
- Remove the cam mount 15.
- Loosen the screws 14 and replace the cams.
8.1.2.5.5 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.
002AZ019A
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8
MAINTENANCE
8.1.2.6 Hydraulic system
8.1.2.6.1 Checking the accumulators precharge
- Turn mode selector 19-23 to MAN
- Make sure there is no pressure in the hydraulic circuit.
E0004

E0034
O2

E0035

ATTENTION!
Wait for heat exchange caused by movement of the pressures has stabilized before attempting to check or
precharge the accumulators.
- Unscrew regulator 1.
- Make sure bleeder valve 5 is closed.
- Unscrew the cap on the accumulators inflation valve.
- Screw the inflation tester on the accumulators inflation valve manually, screwing fitting 4.
- Secure fitting 4 manually positioning the pressure gauge as required.
- Screw regulator 1 observing the pressure gauges 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 bleeder valve 5 until the desired pressure is reached.
- Close bleeder valve 5.
- Loosen regulator 1 completely.
- Open bleeder valve 5.
- Remove the inflation tester by loosening fitting 4.
To increase the pressure.
- Take off knurled cap 2.
- Attach the end of the hose (1/4 BSO at 60) to fitting 3.
- Attach the other end of the hose to the nitrogen source and let it in.
- Close the nitrogen source valve.
- Completely loosen regulator 1.
- Open bleeder valve 5.
- Remove the inflation tester by loosening fitting 4.
E0004

E0034
O2

E0035

ATTENTION!
The accumulators must be precharged with only dry nitrogen in tanks fitted with a reducer. Oxygen and/or air
compressors must never be used under any circumstances.
- Make sure the inflator valve on the accumulator is well sealed.
- Screw the cap on the accumulator inflator valve.
T3910
5
1
2
3
4
002AZ019A
8-43
MAINTENANCE
8
FIGURE 8.1.2.6.1 - CHECKING THE ACCUMULATORS PRECHARGE
T4826
10
9
5
11
7
1
8
4
3
YV27
YV21
12
6
2
13
14
002AZ019A
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8
MAINTENANCE
8.1.2.6.2 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,
take off the cap 7 and pour in oil.
FIGURE 8.1.2.6.2 - CHECKING THE OIL LEVEL IN THE HYDRAULIC POWER UNIT
002AZ019A
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MAINTENANCE
8
8.1.2.6.3 Changing the oil in the hydraulic power unit
(See figure 8.1.2.6.2)
- Unscrew the cap 7.
- Place a container for collecting the oil under the valve 8.
- Open the valve 9 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.
- Close cap 7.
8.1.2.6.4 Replacing the filter in the hydraulic power unit
- Replace the filter element 11.
8.1.2.6.5 Replacing the hydraulic power unit couplings and suction filter
E0004

E0003

WARNING!
- Detach the electrical cables from the boxes of motors 9 and 10.
- Detach tubes 3, 4 and 5.
- Raise the plate 12 complete with motors and pumps.
- Replace the filters 6.
- Place the plate 12 on a secure support and remove the motors 9 and 10 by loosening the screws that secure
the motors to the flanges, being careful not to drop the pumps, to reach the flexible coupling.
- Replace the link wheels 13 and 14 of the motors flexible coupling.
8.1.2.6.6 Checking for condensate on the bottom of the tank
- See if there is any condensate on the bottom of the hydraulic power as instructed below:
- Place a container under the valve 8.
- Open the valve 8 and make sure water does not leak out and deposit on the bottom of the tank.
- Wait until oil starts to flow out and then close the valve.
- Restore the correct oil level as directed in paragraph CHECKING THE OIL LEVEL IN THE HYDRAULIC POWER
UNIT.
T4510
002AZ019A
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8
MAINTENANCE
FIGURE 8.1.2.6.7 - CLEANING THE SOLENOID VALVES
8.1.2.6.7 Cleaning the solenoid valves
E0004
IMPORTANT!
Before attempting to perform these operations, write down how the valve is directed as its position cannot be
changed when re-installed.
- Loosen screws 1.
- Remove the solenoid valve.
- Divide bodies 2 and 3.
- Remove the piston 4 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.
1
2
4
3
T2545
002AZ019A
8-47
MAINTENANCE
8
8.1.2.7 Cooling system
FIGURE 8.1.2.7 - COOLING UNIT
8.1.2.7.1 Cleaning/changing the filters
- Shut off the temperature controller.
- Close the valves 4.
- Protect the parts under filter 3 with a container to protect them from the fluid that may flow out.
- Remove the filter cartridge 3 and blow compressed air to clean or replace it according to the frequency stated
in the SCHEDULED MAINTENANCE CHART.
- Clean or change the other filters.
E0004
After CLEANING/CHANGING THE FILTERS, always check the coolant level present.
4
3
2
1
6
002AZ019A
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8
MAINTENANCE
8.1.2.7.2 Checking the coolant level/topping up
- Check the gauge 1 to verify the coolant is nearly at the maximum allowable level.
- If the coolant level shown on the gauge 1 is close to or below the minimum allowable level, top up as directed
below:
- Add the coolant mix, indicated in the SCHEDULED MAINTENANCE CHART, until the maximum allowable level
is reached.
E0004
Use only the coolant mix indicated in the SCHEDULED MAINTENANCE CHART.
- Tighten the cap 2.
8.1.2.7.3 Changing the coolant
- Place a container under the fittings 6 and detach the relative hoses.
- Open the fitting valves 6 and drain all the coolant present in the temperature controller.
- Close the fitting valves 6 and put the hoses back on.
- Take the top guard off the temperature controller and the cover off the coolant tank.
- Thoroughly clean the tank.
- Put the cover on the tank and the top guard on the temperature controller.
- Add the coolant mix, indicated in the SCHEDULED MAINTENANCE CHART, until the maximum allowable level
is reached.
E0004
Use only the coolant mix indicated in the SCHEDULED MAINTENANCE CHART.
- Tighten the cap 2.
T3968
4
5
T3967
2
1
002AZ019A
8-49
MAINTENANCE
8
8.1.2.8 Pneumatic system
8.1.2.8.1 Air injection device
8.1.2.8.1.1 Checking the valves
- Verify that no air leaks out of valve 4 when it is not actuated by cam 1 and 2.
8.1.2.8.1.2 Replacing the valves
- When the valve is not operating and the air system is not running (operation to be performed from the side of
the machine opposite the operator), loosen screws 5.
- Remove the air hose connected to valve 4.
- Replace valve 4.
- Tighten screws 5.
- Connect the air hose to the fitting mounted in the valve.
FIGURE 8.1.2.8.1 - AIR INJECTION DEVICE
002AZ019A
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8
MAINTENANCE
8.1.2.9 Product exit conveyor belt
FIGURE 8.1.2.9 -PRODUCT EXIT CONVEYOR BELT
1 Belt
2 Screw
3 Guide
4 Nut
5 Screw
6 Nut
7 Screw
8 Nut
9 Guide
10 Screw
11 Cover
12 Screw
13 Screw
14 Screw
15 Plate
16 Guard
17 Screw
18 Conveyor
5
17
13
14
1
6 7 8
2
9
3
18
17
17 16 17
10
4 12 11
15
002AZ019A
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MAINTENANCE
8
8.1.2.9.1 Replacing the conveyor belt
- Open the cover 16.
- Loosen the screws 17 and remove the conveyor 18.
- Loosen the screws 12 and remove the cover 11.
- Loosen the nuts 4 and screws 5 so that the belt 1 can be easily removed.
- Loosen the screws 14 and remove the plate 15.
- Replace the belt 1.
- To put back all the parts perform the above operations in reverse order taking care to tension the conveyor belt
again as indicated in the ADJUSTING THE EXIT CONVEYOR BELT paragraph in Chapter 7 - ADJUSTMENTS.
8.1.2.9.2 Cleaning the slots in the exit conveyor belt slide surface
- Clean the slots in the slide surface located under the exit conveyor belt 1 to remove any plastic compound
deposits which could block the suction channel.
002AZ019A
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8
MAINTENANCE
FIGURE 8.1.2.10 - VACUUM SYSTEMS
1 Main system filter
2 Auxiliary system filter
3 Vacuum pump
4 Blower
8.1.2.10 Vacuum systems
4
3
2
1
002AZ019A
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MAINTENANCE
8
8.1.2.11 Safety devices
8.1.2.11.1 Checking operation of the emergency stop buttons
- Turn the mode selector on the keyboard to position MAN.
- With the machine stopped, press one of the emergency stop buttons and make sure the relative fault message
appears on the screen.
- Press key 0 to reset the machine (the fault message should be cleared).
- Proceed in the same manner for the other emergency stop buttons.
8.1.2.11.2 Checking the door interlocking devices
- Close both doors.
- Turn the mode selector on the keyboard to position MAN.
- With the machine stopped, open one of the two doors and make sure the relative fault message appears on the
screen.
- Close the door.
- Open the other door and make sure the relative fault message appears on the screen.
- Close the door.
- Start the machine with key 3-28.
- Try to open the two doors without forcing them to avoid damage to assure they are locked.
- Press key 7 to shutdown the machine.
8.1.2.11.3 Checking the visual/audible indicators
- When the cabinet comes on, the light tower and led indicators on the control panel light up and the audible alert
signal on the indicator tower sounds during the first 3 seconds.
002AZ019A
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8
MAINTENANCE
8.1.2.12 Electrical system
8.1.2.12.1 Cleaning and servicing the electrical cabinets
- Clean the components inside the electrical cabinets with an aspirator.
E0004
WARNING!
Do not blow compressed air.
- Check and tighten the terminal blocks, bolts and connectors.
8.1.2.12.2 Checking cabinet and electrical box closure
- Make sure the cabinet doors and covers of the electrical boxes close correctly and that the seals are in place
and not worn to avoid compromising the degree of protection.
8.1.2.12.3 Air conditioner maintenance (if present)
- Consult the specific documentation enclosed with the air conditioners to perform the maintenance jobs
recommended by the manufacturer.
002AZ019A
8-55
MAINTENANCE
8
8.2 EXTRAORDINARY MAINTENANCE OPERATIONS
The machine operators and maintenance staff are not responsible for carrying out extraordinary maintenance
work. 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.
002AZ019A
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8
MAINTENANCE
8.3 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS
S.R. = Resisting section (mm
2
)
MS = Tightening torque (Kg)
V = Pre-load (corresponding to the tightening torque) (Kg)
E0004
WARNING!
12.9 class screws must be tightened with a torque wrench. The operation must be done as if they were of the
10.9K class.
Example: A 12 mm dia. screw with a 1.75 pitch (class 12.9) must be tightened to 120.46 Nm instead of 144.59 Nm.
STANDARD THREAD SCREWS
DIAMETER mm 4 5 6 8 9 10 12 14 16 18 20 22 24
PITCH 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. mm
2
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
5.8 MS = Nm 2,15 4,21 7,16 17,75 22,85 31,68 53,56 81,71 124,78 157,15 244,07 324,71 431,64
V = N 2226 3659 5130 9594 12576 15185 21954 30254 41339 50855 66933 82757 96922
8.8 MS = Nm 3,33 6,76 11,37 28,44 36,59 50,81 85,73 1 30,66 199,73 251,43 351,29 425,36 593,50
V = N 3561 5846 8210 15195 20110 24299 35119 48412 66139 81373 103946 129276 54998
10.9 MS = N m 4,80 9,41 16,08 32,92 51,50 71,41 120,46 183,83 280,86 353,55 494,03 598,11 834,14
V = N 5012 8230 11546 21366 28292 34168 49393 68081 93008 114433 146169 181798 213269
12.9 MS = Nm 5,68 11,37 19,22 47,97 61,80 85,64 144,59 220,62 337,07 424,28 592,81 717,69 989,82
V = N 6013 9868 13851 25633 33942 40995 59272 81697 111608 137320 174912 218154 255060
FINE THREAD SCREWS
DIAMETER mm - - - 8 - 10 12 14 16 18 20 22 24
PITCH mm - - - 1,00 - 1,00 1,50 1,50 1,50 1,50 1,50 1,50 2
S.R. mm
2
- - - 37.14 - 61,87 83,83 119,42 161,29 209,44 263,86 324,58 374,5
5.8 MS = Nm - - - 18,83 - 34,53 55,72 86,62 131,15 171,47 266,43 351,29 448,31
V = N - - - 10202 - 16990 23024 32804 44301 57525 75419 92096 105948
8.8 MS = Nm - - - 30,21 - 55,23 89,17 138,51 209,83 274,28 379,15 511,10 647,46
V = N - - - 16323 - 27193 3 6846 52483 70887 92047 115964 141904 168732
10.9 MS = Nm - - - 42,47 - 77,59 125,37 194,82 295,08 385,72 533,27 724,17 892,71
V = N - - - 22955 - 38239 51806 73800 99679 129442 163071 208452 238383
12.9 MS = Nm - - - 50,91 - 93,19 150,48 233,77 354,04 462,83 639,90 871,02 1079,10
V = N - - - 27546 - 45881 62175 88339 119623 155331 195689 211287 286452
002AZ019A
8-57
MAINTENANCE
8
8.4 TROUBLESHOOTING GUIDE
8.4.1 TROUBLESHOOTING THE MACHINE
TROUBLE CAUSE REMEDY
1 Irregular pellet insertion;
some pellets are rejected or
lost; cutting burrs
Operating parameters
incorrectly set: operating
pressure, length of insertion,
insertion delay
Set the parameters as specified
on the Data sheet
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)
Mechanical phase in wrong
position
ADJUSTMENTS)
Improper adjustment of
insertion turret precharge
ADJUSTMENTS)
Malfunctioning of solenoid valve
YV33 for pellet insertion
Replace
2 Incomplete caps. Rpm of polymer metering pump
incorrectly set (too low)
Set the parameter as specified
on the Data sheet
Incorrect rpm of the molding
turret (too high)
on 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
incorrectly set (too high)
on the Data sheet
Insertion turret transmission
worn
Contact the Customer Service
Department
4 Machine rejects caps even
though their weight is
correct
Incorrect reject threshold Set the parameter as
required (see chapter 7 -
ADJUSTMENTS)
002AZ019A
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8
MAINTENANCE
TROUBLE CAUSE REMEDY
5 An actuator does not move
up.
Relative hydraulic valve fails to
operate properly
Remove and clean the valve,
replace the return spring if
necessary
6 Actuators do not operate
properly: the molds do not
close correctly.
Incorrect low pressure flow rate Set the parameter as required
(see Data sheet)
Hydraulic accumulator
precharge decreased
Charge the accumulators with
nitrogen until the correct value is
reached
7 Oil temperature too high.
Coolant temperature incorrect Restore the correct values (see
Data sheet)
8 Actuators do not move down
at the end of the production
run.
Hydraulic valve used to move
the actuators up is stuck in the
open position
Clean the valve
9 Melt pressure high/low. Plastic compound incorrectly
fed
Check
002AZ019A
9-1
DECOMMISSIONING
9
9 DECOMMISSIONING
9.1 MACHINE DECOMMISSIONING
E0004
WARNING!
Only skilled personnel specially trained on operating and handling procedure may work on the machine.
Use only suitable lift equipment and means that meet current laws and standards.
If the machine is no longer used or in the case of prolonged inactivity, first of all, perform the operations given
below:
- Turn off the machines power supply by using the factorys main switch.
- Unplug the power cable from the electrical cabinets terminal block.
- Disconnect the cables that join the cabinet to the machine, detaching the connectors.
- Disconnect the line between the factorys compressed air mains and the control unit.
- Disconnect the lines that join the cooling system to the water mains and factory drain line.
E0004
WARNING!
Release the gas under pressure inside the accumulators with the tester / inflator supplied with the machine as
directed in the CHECKING ACCUMULATOR PRECHARGE paragraph in chapter 8.
- Activate all the safety devices provided.
- 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.
E0004
IMPORTANT!
If the machine has to be transferred from one facility to another, contact Sacmi Technical Support to obtain
information regarding packaging and handling.

002AZ019A
9-2

9
DECOMMISSIONING
9.2 DISASSEMBLY
E0004
WARNING!
Only skilled personnel specially trained on operating and handling procedure may work on the machine.
Use only suitable lift equipment and means that meet current laws and standards.
If the machine is to be dismantled, first of all, perform the operations given below:
The operations given below need to be carried out when the machine is no longer used:
- Turn off the machines power supply by using the factorys main switch.
- Unplug the power cable from the electrical cabinets terminal block.
- Disconnect the cables that join the cabinet to the machine, detaching the connectors.
- Disconnect the line between the factorys compressed air mains and the control unit.
- Disconnect the lines that join the cooling system to the water mains and factory drain line.
E0004
WARNING!
Release the gas under pressure inside the accumulators with the tester / inflator supplied with the machine as
directed in the CHECKING ACCUMULATOR PRECHARGE paragraph in chapter 8.
- Engage all the safety devices provided.
- Drain the oil from the hydraulic system.
- Empty the coolant from the cooling system.
E0004
IMPORTANT!
Remove the various parts of the machine observing all the safety precautions in force and following the
instructions given in chapter 4 - INSTALLATION. Pay close attention to the safety precautions and warnings
given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS, paragraphs SAFETY RULES FOR HANDLING
and MACHINE DECOMMISSIONING AND DISASSEMBLY.
002AZ019A
9-3
DECOMMISSIONING
9
E0004
ATTENTION!
Dispose the lubricants and coolants used in compliance with environmental protection laws in force in the
country the machine is installed in.
E0004

E0133
WARNING!
When the machine is disposed, the materials should be recycled to the greatest extent possible in compliance
with laws in force in the country in which the machine is installed.
002AZ019A
9-4

9
DECOMMISSIONING

Plastic Caps Moulding Machine Production & Maintenance

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