Changeover

1. 1

   5-1

   Safety and flag adjustment

   p.39

   Remove all energy sources per plant policy. Rotate the safety block to the safe position. Punches and dies have sharp edges — wear PPE.

   When working on or around the machine table, always rotate the safety block to the safe position. The machine alarm sounds if it is unsafe.

   • Infeed flag adjustment (may not be required): loosen locking collars with an Allen key, adjust flags in the correct slots, leave a 1/16-inch gap between collar and flag, then tighten.
2. 2

   5-2

   Liner infeed setup

   p.40

   Loosen all machine screws. Adjust rail guides to the cap diameter + 1/8 in and tighten. Place caps in the guide rows so guides are centered in the lanes. Visually inspect meshing of each guide section at conveyor level — no overhang between sections.

3. 3

   5-3

   Set cover height

   p.41

   Quick-adjustment knobs are on the sides of the infeed and outfeed conveyors. Set top covering so it sits 1/8 in above the cap. Guide adjustment may not be required when switching similar cap heights.

4. 4

   5-4

   Upside-down cap sensor and machine access

   p.42

   Loosen the securing screw on each locate center, move to the proper centered position on each lane, then tighten. If the machine is powered on, put it in Manual mode and press the door-unlock button on the bottom of the HMI.

5. 5

   5-5

   Safety stop

   p.43

   When accessing the machine, always put the press safety stop in place on the machine table.

   Install the press safety stop before continuing inside the machine.

6. 6

   5-6

   Deactivate air

   p.44

   Deactivate the machine air supply by turning the air dump to the off position.

7. 7

   5-7

   Remove infeed rail cover

   p.45

   Lift and remove the infeed covers on the inside of the machine table. Different rail covers must be used for varying recipes.

8. 8

   5-8

   Punch outfeed conveyor removal

   p.46

   Unplug the outfeed conveyor, loosen and remove the hand knob, then move the conveyor away from the work area.

9. 9

   5-9

   Liner cover removal

   p.47

   Remove the liner cover from the machine table so the tooling plate can be accessed.

10. 10

    5-10

    Disconnect fiber optics

    p.48

    Disconnect fiber optics before the tooling plate leaves the machine.

    Disconnect fiber-optic cables from the power source on the side of the machine table. Secure the wires on top of the tooling plate so they are not damaged when the plate is removed.

11. 11

    5-11

    Tooling-plate vacuum lines

    p.49

    Remove the vacuum lines from the clock pneumatic cylinders on the tooling plate. Remove the push-to-disconnect fittings. Remove the air lines from the pneumatic cylinder.

12. 12

    5-12

    Tooling toe clamps

    p.50

    Loosen the clamps on the tooling plate.

13. 13

    5-13

    Vacuum lines

    p.51

    Remove the vacuum lines from the top of the punch assembly.

14. 14

    5-14

    Install support blocks

    p.52

    Install the plastic guides for tooling-plate removal. Pins on the machine table secure the plastic guides.

15. 15

    5-15

    Tooling cart and tool removal

    p.53

    Position the tooling cart. UHMW support blocks have slotted grooves that hold the cart against the table. (1) Lift tooling with a straight bar or pry bar. (2) Lift upwards and back toward the cart. (3) Place the tooling plate on the cart.

16. 16

    5-16

    Clean die plate

    p.54

    With the tooling plate removed, run the die plate with a fine stone. After deburring, wipe the surface with a clean rag.

17. 17

    5-17

    Install die plate

    p.55

    Install the tooling plate into the machine. Remove the tooling cart once the plate is in position. Hook up fiber optics from the tooling plate to the input plugs on the side of the table.

18. 18

    5-18

    Remove punches

    p.56

    Place a protective barrier between the punches and the tooling plate. Hold each punch so it cannot strike the tooling.

    When tamp bars are clear of the punches: (1) Loosen the bolts on punch #1. (2) Hold the punch before the bolts come free. (3) Angle the punch 45° to remove it from the upper pressure fixture. (4) Repeat for remaining punches.

19. 19

    5-19

    Reconnect air lines

    p.57

    Before new dies are installed, hook up the air lines on the pneumatic cylinders on the tooling plate.

20. 20

    5-20

    Install punches — Lexan cover

    p.58

    Place a Lexan cover on top of the tooling plate to protect the dies while punches are handled.

21. 21

    5-21

    Install punches I

    p.59

    Do NOT force a punch into the die — damage will occur. Tolerances are very close.

    While lifting the punch, remove the Lexan cover and lower the punch into the die. Lower the upper die-set plate to 3/8 in above the punch mounting plate. Start the bolts by a couple of threads.

22. 22

    5-22

    Install punches II

    p.60

    Keep the punch fully engaged in the die while the tamper top gate is held firmly against the upper press plate. Align and hand-tighten bolts in a cross pattern. Always use the ground washers. Release the brake and use the hand-wheel to verify alignment — no rubbing, ticking, or contact. Then tighten to 10 ft-lb in a cross pattern.

23. 23

    5-23

    Install punches III

    p.61

    Lower the punch so it is completely seated and tighten bolts to 25 ft-lb using a cross-pattern sequence. Verify the punch makes no contact with the tooling-plate die. Repeat until all punches are installed. Any contact will damage tooling or the punch.

24. 24

    5-24

    Main air

    p.62

    Turn the main air supply back on. Ensure all components have air and there are no leaks. Close all access doors and reset the machine on the console. Unlock the doors and re-access when air is restored.

25. 25

    5-25

    Reset tamp bars I

    p.63

    Place a cap right-side up in punch position 1. Verify the tamp spring has air and the spring roller contacts the end of the pneumatic cylinder.

26. 26

    5-26

    Reset tamp bars II

    p.64

    Use the foot pedal to move the punch to its lowest position at 180°. Hold the tamp down and tighten the tamp cam block. Repeat for each punch. Bring punches to top dead center / 360°. (1) Hold light pressure on the tamp spring cam blocks and press in on the rubber stop block while tightening. (2) At the top position the tamp plate should be flush or slightly recessed into the punch. Adjust tamp travel with the bolt on top of the pneumatic tamp cylinder.

27. 27

    5-27

    Secure liner guides and covers

    p.65

    Install part infeed guides and liner guides on the machine table. Make sure all red thumb screws are installed and properly seated.

28. 28

    5-28

    Install and plug in outfeed conveyor

    p.66

    Reinstall the outfeed conveyor to the machine table. Plug in the power cord on the side of the machine.

29. 29

    5-29

    Accumulator and vision guides

    p.67

    (1) Adjust accumulator guide rails to the accumulator outfeed conveyor. (2) Set accumulator height to the desired cap ± 1/8 in. (3) Adjust vision infeed conveyor guides to cap width ± 1/8 in. (4) Use the hand knobs to set guard height ± 1/8 in above the cap.

30. 30

    5-30

    Final steps

    p.68

    Do not start until the ten-point safety checklist is complete.

    Remove the safety stop, close all access doors, and clear all alarms. Change the recipe if needed. Safety checklist: (1) All safety guidelines have been followed. (2) The press safety stop is in place. (3) The machine interior is free of dirt and debris. (4) Material is properly fed through the machine. (5) Caps are being supplied to the infeed conveyor. (6) Air and pushbutton e-stops are in the ready position. (7) Access doors are closed and locked. (8) All guards are completely closed. (9) No warnings or alarms are present. (10) The machine is in Auto mode. Press and hold CYCLE START for three seconds to start.

After the last check, the machine starts with a three-second hold on Cycle Start.