2 TRAINING MANUAL Soest SFR EVO - 157 LEVEL —— SYSTEMS GENERALITY AND DEFINITIONS NoTE The information contained i Systane: pation contained inthis module refer toa TYPICAL configuration ofthe machine and ofthe related - For information more detailed refer tothe drawings suppiled with the Mechanical Manual, ‘The systems connected wi the SFR Evo machine are generally: + Water system ~ Pneumatic system “The water system supplies the water supply to the folowing functional groups: + Dlowing/stretching unit + ovens unt ‘The cooling (and thermoregulation where necessary) ofthe stretchinglblowing unit (blow mould and mould bottom) is. Necessary for a good success of the container (see chapter regarding the process) while the cooling of the ovens Unit is necessary to avoid the overheating and the damage ofthe preform holder and of the threads ofthe preform with consequent deformation ‘The water system utiizes water coming from system availabe inthe place of installation of the machine or from a centralized system of refrigeration (chile ‘The pneumatic system ofthe blowing machine is composed of two separated circuits (non lubricated air) = auniliaies circuit or service air (forthe movement of the various devices pneumatically controlled) = blowing circuit (forthe blowing ofthe preforms, max 40 bar) “The two circuits are usually supplied by two distinct compressors (one of high and one of low pressure) supplied together with the machine or else, regarding the service air, itis possible obtaining itn at least 2 manners: - directly from the airline available in the place of installation (compressor of low pressure ai already existent) - through the air recovery system called ARS ‘The pneumatic and water supplies coming from the auxiliaries (chiler and compressors) are connected to the machine through a suitable manifold group called external manifold and from here distributed to the machine ‘according toa layout that willbe analyzed in next paragraphs, 2. SYSTEMS Pope of 26 SIPA rramine (@ Scanned with OKEN ScannerSIDA TRAINING MANUAL SFR EVO ~ 49 LeveL EXTERNAL MANIFOLD Page 20120 si IPA teaming (@ Scanned with OKEN Scanneri] Sip TRAINING MANUAL — SFR EVO - 1°" LEVEL ROTARY MANIFOLD The rotar ry mat supply (service, ered MAIER is located at the center of the blowing wheel and provides the water and pneumatic jing) tothe presses and tothe blowing moulds as well ast the stretching rod. 1 The rotary manifold comprises the following principal components: = ting block support = fing block; = rotary fitting “The fitting block suppot (1) is fixed, using screws, to the lower base frame of the machine, “The fitting block support (1) disposes ofthe housing forthe fiting block (2). “The fiting block (2) consents the connection, using sutable hoses, between the extemal manifold and the rotary fiting (2) tis fixed, using the intermediate plate (4), to the fiting block suppor (1) and is therefore fixed withthe ‘machine frame ‘The rotary fiting (3 ved withthe screws (5) tothe fiting Bock (2), free to rotate (movement 4) round its own verical avs by means of intemal bal bearings and therefore in synchronous mode in respect othe blowing wheel “The rotary fiting (3) sin fact pulled in rotation by two drag bars (6) and (7). “The rotary fiting (3) is atts turn subdivided in two units = Upper rotary fiting = Lower rotary fiting ‘The upper rotary fing disposes of outputs, ite pressed air at a6 ba forthe moverent ofthe seals (8), of ces bar (11) fr the primary blowing and compensation ard a at 40 bar 1d with suitable fitings that guarantee the distribution of the the stretching rods (10) and for some valves plots, of (12) for the secondary blowing and ‘compensation. “The loner rotary fing is divided in two sectors: __Thermoregulated water sector Cooling water sector ane Page 3.0126 ra a ‘SUPA rraininc (@ Scanned with OKEN ScannerTRAINING MANUAL SFR Evo - 4 necemreeau saings fo the distinc ut24 Water sector deposes of ble su the deletes (13) and tho retuns (14) fed wth Suto TT ing ion Dresses, "te Memerepused water pesen} oral ccony pore rural ad © The coking water aay water or the nee ep ae HROBE the devin (15) and te (1) ha coset he dain te SS rm ek (na rt cnn ts The water stro feted hile the a aston ScNeve INoUgh a sealing system beatae he chanbars rade wih bbe Po 1oused ‘achieved through a sea eramic disks table sols in thorn ugh @ sealing system between the chambers made with Housed in sutabe sits inthe wlayoe oe 1 system between the chamber des ==22¢8 THERMOREGULATED NOT THERMOREGULATED Page dol an. 2- SYSTEMS IPA rramine @ (@ Scanned with OKEN Scanner; t A TRAINING MANUAL i SFR EVO - 187 LEVEL WATER SYSTEM - EXTERNAL MANIFOLD @ nee omg {rom chiller (typically 4.5 bar at 12 °C) crosses the buttery valve (1) and enters the cartridge fiter (3) to read treeaurations, upstream and downstream the fiter there aa te pressure gauges equipped with cock Brevious one Desture drop inthe filer. Aer thal the war crosses another butlery valve which together wth the Sere eee Closed allows the maintenance operations of the fie. A thermometer (4) and an optional ressure ga Eecta” ©9086 eauipped with cock (3) pert Io ead the water parameters emparture ard presse) nthe 2 From vote Deals ‘THERMOREGULATOR | (OPTIONAL) . ‘Ss Page 6 01 26 Cihies SIPA rnamino oo (@ Scanned with OKEN ScannerP1100 (8) re ature value. A ball vave (©) Pe ET 100 (5) reads and sends o eh ter temperatu 7 a -C and therefore to Supervisor the wal Penis to drain the water fom the reas oe blow a. one tothe DOW After the ball vat the vay mee ways: one to th ovens themoremuaon oft Ty nal mode a a ted te ee ours) and one eta and ener carries (athe rotary fit well this last way, in ease of mou hot water isaad ote counsesn se wey a ay 'n fact, in the delivery rita 1 the moulds, there isa three-way vale (8) that n case oft eater coming fom the thermo remit ess ‘well has a similar wachine ‘moulds during mact {alves is therefore to impede the cold water circulation in the mol ‘would cause condensation, 1 the anti-condensation Vana te rum ns, tha one fos the outs has check va hat mpd, when te ( Vanes oe actvaed the slater credaton inthe mous recone ey Going on, one PT100 ¢ 10 Supervisor) (5) and a fom switch (7) send the relative measurements to PLC (ond therfore 7 cane of theme erences the consequent slams. To note thal the 160 seesuerea themo regulation, 1 same function described 2 Se vate (10) andthe fw such 2) onthe maul bot ru ne have the seme above meter (4) measure the global water Last, a ball valve (6) its to drain the circuit, one PT100 (6) and a thermometer iG nipped temperature on. te rane ipe (typically 2°C higher than the delivery), one optional scpedt of fre delivery) and With cock (3) measures the etum water pressure (ypcaly a pressure dop of 1.6 barn respect one buttery valve (1) permits io close completly the retun to chile Feverens SIPA traning (@ Scanned with OKEN Scannery Si TRAINING MANUAL Sein SFR EVO - 157 LEVEL 2. OVENS ciRcUIT During the oval machine operations in production, it is necessary lo force the water circulation in sutable pipes fed inside the neck rings an oe ogee rerio ved tho overhang ath ofthe preform hldere and ofthe preforms Typical 6 ji, coana water temperature inside the ovens is 17°C and can be set on Superisor To btn his dre a Hee constant conseng hale water coring for tech as alert abot 2° ne nating epee of helps vars neon fo the process, hs recess fo opeate a mira rough 2, waler turing fom the ovens ad the od water coming fom the cil. Such ming ahve relator ee ertene! three-way valve (1) that automaticaly and properly modulates the ming to operate in set temperlure and othe real emperatre ofthe water nthe delvery ne read by the PT 100 (4), 7 11 ‘The pump (3) permits to realize the water recirculation, while the pressure gauge (6) and the thermometer (6) permit to rend directly the water pressure and temperature on the delivery ine. The water reaches then the manifold (9) and from here is sent o the ovens cooling pipes both loading side (14 and 15) and biowing side (12 and 13), “The water retuming from the ovens is conveyed in the manifold (10) and one flow switch (7) permis to very its Thealation. The manifolds (9) and (10) ae equipped wih cocks (11) to drain the water from the ovens pings. Last, one buttery valve (6) permits to break the waler supply to ovens, Depending onthe machine operative condos, onthe process and onthe emperature set, three operating modes re possible: mixing made, no mixing mode and otal mixing mode 7: BYSTEMS Pogo 7 0120 SIPA rraininc (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 457 LEVEL 19 Mode, the depends (on the ope sores %, theeways vahe (1) a water quota (tat Pibe (2) gor PetCeniage ofthe wean Paty open (modulation) periting toa wae & flow throught mi the valve) to retum . ing 2) f0 Feta to chiler and tothe remaining quot "nthe devery ofcald water como terranes as MIXING MODE tochiller —fromechiller In the extreme case of total mixing mode (100%) the tree-vays vale impedes the water returning from the ovens {o come back to chiller obging it to pass enely through the bypass pipe (2) ands tis sucked by the pump (2) ‘And putin ecculaton. The cold wate, athe way the system s designed, cant be putin celaon inthe ovens and therefore is obiged to come backs eile through he va se (1) TOTAL MIXING MODE (100%) to chiller from chiller (@ Scanned with OKEN ScannerSiPA TRAINING MANUAL Seton tere SFR EVO - 157 LEVEL Last, i Whole et ther extreme case of no mixing mode (0%), the three-ways valve opens completely, permiting the 'e water retuming from the ovens to flow to chiller, while the cold water is totally delvered in the ovens pipings, being closed the way through (1) NO MIXING MODE (0%) tochiller _fromehiller SUPA 180 3. SYSTEMS, (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO ~ 457 LEVEL ion ar having passec andar sa tes ey (Cn se oe hata at aor ae 2 ‘manifold (6), Indeed, the external half-collet (2) is cooled ‘only in case of thermoregt coteratn e hea a hak hay, thea ute are external (4) half-moulds, A\ ress, tO of the successive pi The telum ofthe extemal hal.cole, when connected, ‘belongs tothe junction manifold (6) v0 interferences between the hases dunng the preseos pote Page 100128 2- SYSTEMS (@ Scanned with OKEN ScannerSiPA tRaininG manuaL ee Pn ae SFR EVO - 187 LEVEL Cooling circuit without thermoregulation Cooling circuit with thermoregulation a Ms Pogo 11 of 20 es sal SIPA reatnine (@ Scanned with OKEN ScanneriD P/N = TRAINING MANUAL ( 2.1 - SYSTEMS Abyu: STMENT AND FUNCTIONALITY PRESSURE SWITCH Tum um the machine in mania no of the mold vet area and enter inside © "2" Sich the brakes bypass brakes on, and open the doors 2ay w lf the pressure switch is set at 5 Sbars with in picture below, atthe threshold of §2 bars Circuit; and, til pressure dont rise up to 5 5 ive signal tothe PLC to reset the alarm, ‘The picture shows the PLC states relate to pressure variations 033 bars of hysteresis when the system has a fuctuaton of pressure lke the PLC wil receive the signal of lacking of pressure on the main service bars the machine won't work cause of tat alarm, After 55. the switch wall 2a SYSTEMS ag ol28 SIPA tranane x (@ Scanned with OKEN Scanner4 TRAINING MANUAL SiPA SFR EVO - 2"° LEVEL ‘GENERAL SERVICE AiR PRESSURE ‘SWITCH Adiusiment: Acton sew (2) puting level (8) 106.0 8ARS re ina roc Aust serie ai pressure to 60 bars acing on the pressura regia (1) ofthe extol manifold * Accede the electicel box REO (6) and find the PLC input (7) ofr to the pressure swt (2) (ake as ‘elerence the electrical diagrams ofthe machine) *+ Loosen the sew (5) unt the PLC inputted othe pressure sitch in subjet tums on *+ Gradually reduce the air pressure acting on the pressure regulator (1) and noe when the PLC input rated to the pressure switch in subject ums of, This valve shoul ot wer than 6:7 bar. Hii, means tat he hysteresis too high, therefore repeat he steps fom 1 to 4 unilobaring the requested contion ‘+ _Ifit wouldn't be possible fo obtain the requested concltion after several attempts, provide to replace pressure ‘switch (3) because it means that it doesn't work properly. bien norco at wien | preseuro | SIPA rraininc 2a SYSTEMS Resi (@ Scanned with OKEN Scannery SiPA TRAINING MANUAL SFR EVO - 2" LeveL BRaxe ci IRCUTT Al Pp ESSU Adiustnen: RE SWATCH Acton screw (4 . puting (5) at 6.5 bars Adjust sence “aatowaey "065 bar sing one presi raguate(Hofteenemal mantel cal box Re ay take 08 Het dope nega t= PLC HoH step Sen fhe screw (4) uni nite PL input eed one presse sich in sujet uns Gradually reduc th ‘aed tothe pressure swichin su input rated 10 the pressure che BF pressure cing onto pressure regu (1) andre when ne PLE FP 8. Verh rare cieh eet so a. rele rope ee erat er ha 60 bar tis means tat testes 9 HM 8 tiwwon Necker bereqeses cnn 7 nt be possible to obtain the reques several attempts, provide to replace pressur Macon Sas tears tacos wekpepey nee eT MACHINES WITH MULTIPLE on MORE s, TWO contro. estan BREAKING SYSTEM (TWO OR MORE CONTROL. VALVE: ‘SWITCHES) ‘Access the breaking cuit one 1. Bridge a pressure switches except the one to be aus. 2 Revove eas) ow be enh 2. Use as rch @ mn ose conga en campy em (5 Tenuate te peace snp weselte penare sms ewes oasat en Bese nen snes nae ve ane a ‘iene mest beige Replace the i (2), Use a screwdriver to fully tighten the adjustment screw (4) uni reaching the end stroke ‘Adjust service air pressure 1 45 bar, actng onthe pressure regiator (1) ofthe extemal manifold. ‘Accede the electrical box R50 and find the PLC input (7) referred tothe pressure switch (31 take as reference the electrical diagrams ofthe machine), Loosen the screve (4 unl the PLC input related tothe pressure switch in subject tums on. «1. Reering 1 the preumatc breaking yom dag, ae ou he Fes check vas (coe 508174, [Dnt epson athe moro sor ves Fs coe 031057 410. Gradually reduce the air pressure acting on the pressie regulator (1) end note when the PLC input related to the pressure switch in subject tums of stan 4506 Uh Reins fat te heres toh he esi at hs ina ot ve an 11, Vey ha te Ppa fom 2 eee be easton 42, Wit wouldnt be poset bln te requsiadcndon flr sveral temps, provide to replace pressure * Switch (1) because it means that dest work Property. Brig the pressure sich js asd andro te brio Fe nex one acs 1 Repeat the steps from 3 to 16 fra he pressure swches ofthe breskng system, 14, Re Install the check valves (8) (@ Scanned with OKEN ScannerMs 24-SYSTE! Page 4 of 28 SiPA TRAINING MANUAL Serena SFR EVO - 2° LEVEL ‘ADJUSTMENT OF THE GENERAL MOTION AIR PRESSURE ‘Agustmentisperfomed ating on ext manifold. Tho prossixes mus bo eet as flows © the pressure shown on the pressure gogo o! akon a (2) aqua fo 10.0 # 02ba acting on pressure reves (1). NOTE: in case of ARS configuration tho poston of (1) and (2) iforent. © the pressure gauge of supply a (4) equal fo 95 0.2 bar, ating on pressure reduce (2). © the pressure shown on the pressure gauge of er supply of OFC pross coms (6) equa othe pressure shawn €n the gauge of ai supply (4), I the coniion requested does not occur, replace te fiters (6). NOTE: The pressure check shown onthe pressure gauge of ar supply of OIC pross cams (6) is normaly performed vit the machine notin production. Ihe checks performed wih the machine in production itis admits reading Variations unt 05 bar. (© the pressure shown on the pressure gauge of brakes (12) equal io 7.5 + O2bar, acting on the reducer (11). ‘© the pressure shown on the pressure gauge of general (standard mactine) or 9.002 bar (machine with ARS), ac Con the pressure gauge of safety ccult air supply (10) equalto 250 pressure | movement air supply (B) equal to 7.0 # 0.2 bar ing on pressure reducer (7). he pressure shown 2 bar, acting on pressure reducer (2) SIDA TRAINING (@ Scanned with OKEN ScannerSiPA TRAINING MANUAL SFR EVo — 2"> LEVEL OUVONVLS pa - SYSTEMS (@ Scanned with OKEN Scanner“ A TRAINING MANUAL SFR EVO - 2"° LEVEL Aduus *TMENT OF STRETCH RODS MOTION AIR PRESSURE The agjus ‘ustment has to be performed with the auxiliaries enabled and air ava wre able into the general motion circuit al the pressure of circuit press is, eneral pressure, adjust aso the solely ce safety pressure is astvateg) See wih doors opened the With mov 7 ‘ovement air availabe, act ‘ods pressure . act on the knob of the stretching Tegulator and set the tis pressure val OZ biinon soe cerieunsonesags” nh : ADJUSTMENT OF THE STRETCHING RODS CIRCUIT MUFFLERS ‘Adjustable discharges (mufflers), located on the upper stretch cylinder coupling pipe must be first fully closed and then opened Stuns, Make sure, after about 1 hour of operations, that the stretch cylinder sleeve temperatures do not exceed 40°-45°C. Otherwise, use the adjustable flow regulators, opening them one extra tum, untl the indicated temperature is not exceeding, This ‘check should be repeated monthly since the flow regulators tend to clog and therefore limit ar circulation drastically, CYLINDERS FLOW REGULATORS which works during the seal lifting must be fully opened. Vice sjusted so that when lowering and iting, the seals time movement, is reached. (ADJUSTMENT OF BLOWING Jained in chapter 9, the upper flow regulator As ext fower fw regulator that works dung the seal lowering Tas oo versa atve time of 0,06-008, read in the Supervisor page referred 10 artminerly very that the movement pressureis 7 Par ith seal seal lowering speed, set the machine in simulation wi pe lorking angle, function of speed. If there are caviles at he werichine and proceed as required on these caviles fo regustors Re arity is found. tim movement at a speed ‘of 1000-1300 bot. To op ‘greatly deviate from the average working ansainch to gel ws operating regu —aveTews - ae oye 128 SIPA TRAINING (@ Scanned with OKEN ScannerT RAINING MANUAL REVO — 2"> LeveL "ween 3 and § bar, acting on the pagina the pressure on Ie below," He valve could. fp ADJUSTMENT OF PILOTING AIR OF BLOWING VALVES WARNING ‘After taking the pressure ofthe safety circuit o 7.0 £ 0.2 bar, is forbidden to use the seal down manual conto 1. Work on the pressure regulator (2) unti reaching a pressure equaling 7.0 + 0.2 bar on the safety circuit supply pressure gauge (3). 2. Using the manual rotation crank (1), tum the blowing wheel uni making the plot creuit loading pressure gauge (4) reachable. 3, Check that the pressure shown onthe pot cuit loading pressure gauge (4) equals 6.0 0.2 bar. Using the manual rotaon crank, tum the Blowing wheel uni making tne valve pilot pressure gauge (5) reachable. Check that Work on the safety circuit. ressure gauge (5) equals 7.5 + 0.2bar. the pressure shown on the valve pot P the normal working pressure equaling 2.5 0.2 bar on the pressure regulator (2) unt reaching Supply pressure gauge (3) (@ Scanned with OKEN Scanner‘o SIDA TRAINING MANUAL SFR EVO - 2"° LEVEL Fa SYSTEMS 9 Page 80128 SIPA traINinc (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVo - 2"> LEVEL REPLACEMENT OF 40 © Access the BARS FILTER CARTRIDGE lever (2) mani i shuter vale by tung and oper snr ee ad lose the high pressure air shutter valve by counter-clockwise (8). 4 comple eaak. inute for the pneumate circuit tobe automaticaly discharo™ PProKiMately one mi ine. rly from the Machi © Disconnect the electical or nectar (5) from the solenoid valve (4) Routt. CAUTION: MAKE SURE THAT THERE Is No RESIDUAL PRESSURE INTHE pvaTé oP ahs Unscrew the nut (3) ‘Connecting the block (7) to the fitering cartridge body (1), then rem NOTE: Owing to the Id be wor, body (1) ou Pressure and possible dit, the O-ring seal of the fitering cartidge bocY ‘herefore considerabe effort might be nosted ev eaca Jer access. 1 for easier 3 © Remove the four bli (6) unscrewing them, case remove the protective meta sheet © Remove the fiter cartridge inside the fitering cartridge body (1) unscrewing it an he whole working 08 © Use a clean, lint-free cloth and alcohol to clean the fitering carvidge body (1) Make sure no residues are left, then ft a new filter cartridge. ving seems distort (Check the cover O-ring seal of the fitering cartridge body (1). If the shape of the material wor, replace it wth a new one. removed, then the bloc Temoved previously, then i our bolts (6) previously Install the fitering cartridge body (1) previously, than instal and then the previo i Jock (7) and the nut 2), Lat reconnect the electrical connector (5) tothe solenoid valve (4). turing lever (2) clockwise. © Close the shutter valve (8) and open the high pressure air shutter valve by turing ted or the ° . (@ Scanned with OKEN ScannerPA TRAINING MANUAL SFR EVO ~ 2" LEVEL PNEUMATIC SYSTEM — BLOWING CIRCUIT EXTERNAL STANDARD MANIFOLD Tho bi oe oe Creult Is mainly dodicatod to tho blowing procenn ofthe proforms in tha outs circuit is su Sap iad city Wy a ok ra eae he elt le (yey by rane of igh prozac tne withthe SFR), A roll valve (11) 9a 1 42 bar and a prossure gauge (1) tat aloes 0 rssra ana taconite sab) et sn asin from the con {are compro. Tho prot ath} para dl io onagh ona, fri ‘nit (2) detect a possible er cogaing Onn al av (7) pata oman dhe wo ch oe Consonant hah emai (we nade moda sean ‘manage by th send valve (9) 2nd be mule (10), Les an arlene () pms ee ost high resus Wat is sont otha When the unit is su 1ppliod, the high prossure, onco paosod tho filer, ooo to tho Input ofthe valwan (12) (14 a , ho for, yt of the valves (12), (14), (19), and (17) which represen the softer lok ad eh oo ‘normally cloged lting the prosouro Inca the block ge through tho muffs (21). Tho sof-alart cysiom allows tho rotary manifold 19 go Under presaura in 2 gradual way. In working conditions, the solenoid valvo (12) ls enorgizod alowin ; . vol on 19 tho piloting and tho opaning ofthe vata (14) which let Tow the 40 bar pressure propor adjusted through tho flow rogulator (12) towards tha black C and the rotary manifold filing it gradually. ‘Once the operating pressure fs reached, dolcted by the prossuroovch (15), alone vale (16) open hod Peeing ne wave (17 al opens and ting he hgh proseure coming rom ho iler pass nour MPa ying avalie tho 40 bor bypassing te softs. Curing tho Bowing phaso Is eacsasan Wot the ‘solenoid valves (12) and (16) romain energized In ordor to hove tho ful alr capaci. itis not necessery to provide he pressure oth olary mailed, tho solo vats (12) snd(1) oe do-energized Siting he pressure bol ofthe plots and the cpealng ono trough fo mlloe (21) Last the high pressure drected 1 the block C is reduead by the manaue e (18) equipped with pressure Gauge (19) rom 40 bar to 10 bar iypiealy and chockod by fo Peer ‘wich (20), blaining tho primary air forthe Bievang, and sont, trough a dedicated and soparated pipe, ote roary. ‘manifold FROM [COMPRESSOR (40 TOROTARY, JOINT (10 BARD SIPA rnainino Pago 100120 (@ Scanned with OKEN ScannerTRAINING MANUAL na SFR EVo ~ 2 LEVEL ASU ARS The ars ‘Standard dlowir ‘S¥SIeM (Air Reco) lowing air, which imei "Y Syslam - ARS) has boon designed to recover part of he th 7 Stechng ving pone aston WUllbe depot oth enonment athe ond of ir recovered i ; 's used for Pre-blowing ofthe containers {SPP bing the machines sence ar airlines * SuppIying any us Y 82° tw pressure i (@pprox. 10 bar) located in the plant, To enable the ARS system on SFR machine, just push the button above. ARS MECHANICS “The 40bar air is filtered (A), taken at 1Sbar through the group (B). To avoid damages to pipes a relief valve has been added set at 42 bar (8) Group (C) supplies the ARS manifold (E) providing pressure tothe blowing when the ARS tank isnot sil fl. The pressure in this reducer, which can be seen by the pressure gauge (1), is set toa pressure value greater than the primary air pressure, in order fo guarantee enough process pressure inal the operative conions. To the primary air pressure reducer (D), displayed on pressure gauge (2), wich fs equal othe primary air blowing pressure (recipe data), are connected ~The reducer (C) (through the ARS manifol), from the toroidal tank of ARS. = The retum pipe valve (7) and to reste rt, goss to the ite (10), passes trough is displayed on press we Jve (7) and last goes 5 ate i When the auxiliaries are not dst | the pneumatic vale (9) is auge (3) week fn jiaries 2 rad ed, he pe : = a (9) allows aT ns airinto the ARS manor, (Obar (5) reduced by (F} at aw, a t! is air int iol e valve (9) 2! ab a inthe ARS tank pases The recreation ean The ARS age 110128 SIPA traminc (@ Scanned with OKEN ScannerSiPA TRAINING MANUAL Porte Reckeoma Baten SFR EVO - 2%? LEVEL During the doors bypass (fr instance uring the mould changeover) the whole service air is reduced to 2.6 bar in all bid Machine tank to the reducer (4), letting operators work in safety, allowing to move seals and compensation but only with low pressure GENES (12) are used to permit the whole system i properly discharged when the ausiaies are cut of (machine shut ‘own, emergency mushroom pressed, etc) FROM ARS TANK (@ Scanned with OKEN Scanner(Yellow) through another pipe ie 210 BLS) SSP re pressure ot as tank and to this one is connected F ne Sr the checking ofthe toroid tere pressure displayed in the ARS S Wtion startup, un the "OUGN @ dedicated pipe fron et? ARS lank is no comply chargod in possi, sated pe from the pipe (6) teu nt fino roto ety ot Ph Cis Airtowards ARS = Air trom ARS —— Air from group 8 — Primary air Vice air tient tine urn tine ait Pago 19020 (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 2"° LEVEL RECO! hs weeny PARAMETERS OPTIMIZATION ON ARS 8 Well yee ase 88 possible ARS sellings to manage are_ Ys - Pressure threshold to enable recovery valve; 5 * Pressure threshold to disable recovery valve; Ses aemmaaa x X must be the smal . llest possible in order to oblain a really litle curve on the graph, during decompression time (letter IF it has been set too bi i decompression ig time of recovery the graph wil show a big it affects negatively the minimum time of Ifitfhas been set too s - ‘short graph will not show trouble on decompression time but machine will not recover foo much ‘The graph below shows you the differences between [ARS (ight blue) and ‘Standard blow process gure 2, Grafice-curve-di Goffieagio-con-ARS-STD-artivato-(TIRIGA) risa, rao cue sofingyo con AHS-STD sativa (HHA) Y and Z set use to be regulated al: ‘y= recovery pressure -1,6 Bar ‘z= recovery prossure 1,6 Bar (maximum threshold at 46 bar) 1 good trado off must bo found in orr to fet tho ‘machine work in production into the In order to optimiza the systom two thresholds with no need to close and open recovery ' ‘valves. © scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 2"> LEVEL ASU ARS PLUS * Primary air blowing * Secondary air pata blowing: * Supplying the machine service ai ine * Supplying any users of low press air (approx. 10 bar) located in the ant oe To enable the mi Itiple fun uliple functions we an choose to use: on ARS plus ° ‘A Second recovery timing enable, 8B Seals movement pressure check enable C Intermediate blowing timing enable, First recovery timing enable To Activate ARS PLUS low pressure system just push the button red When he ARS-PLUS syste is deachates the stinging poss cared tn anda mae, Hat the ante cays dschargedin he emvonmer trough he sewers Incas of ARS PLUS cnfgrton re jt smd alow hea recovery in presse, rng te exhaust those, foe bmesetin Soper towng pope (Fa, bo When he ARS-PLUS system is erbledy sper are bow vate (19, fg soe) opens the cut and freon using or ing fo 0 eth as ates oer (sands) changes and that represent th presse vr (bite cv 88 aris oe te Seczds) The rer re rece fon aya ecrery tar The vue seconds can be set (6, below.) (@ Scanned with OKEN Scanner4 TRAINING MANUAL SIPA SFR EVO - 2"° LEVEL ARS PLUS MECHANIC ‘A. When the blowing stage has frished, te fist recovery valve (4 above) pus the cay in communication with the tank (6, figure above.) - second recovery stage or recovery of cavity air into service air line and any uses ‘equited by the cient. The value in seconds can be set (6, figure below) 8. ‘The first recovery valve (4 figure above.) closes. ©. Second recovery stage slats this eoincdes wih second recovery valve ‘opening (3, figure above) The air is sent to the service lines and client; - real degassing stage The value in seconds can be set (4, figure below), D. Second recovery valve (3, figure above) closes. E. _Degassing valve (5, figure above.) opens and discharges air into the environment. aia Bem ee aed a nag E NG 24 - SYSTEMS aaa SIPA tran (@ Scanned with OKEN Scannerprimary a Button 2. is an ransducer'g* (or set © correct primary 1d valve fOr (beloy by the pilte it Value to correct the output given Mensducer“4" (ostow imary air value to re onthe png) Button 3s the offset on cavity ‘Pressure transducer (made when there is no pressur Button 4, ‘display of current Pressure just over the piloted pressure valve But tondisal3wotnnones ee ma Button 6 is an Alarm for high pressure. sen enpccousnone ant SIPA rramnine ee (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 2"° LEVEL ARS PLUS SETTING ARS plus setings or 1 = Set value (bar) for tank HER RCUFERO AB ressure below whi ich the ial deactivates the diate blowing (value ingicated, can be set), 2 ~ Set value (bar) for tank Bressure above which the system deactivates the intermediate blowing 3. Ofeet vale (of send line transducer a || 4 - Real value (bar) of pressure during second recovery. The value is detected by the pressure transducer on ‘second recovery line. '5- Offset value (bar) for seals movement pressure 6 - Real value (bar) fr seals movement pressure. The value detected bythe pressure transducer on seas movement line. 7 - Seals movement pressure (bar) below which the machine enters a waming state 4 - Seals movernent pressure (bar) above which the machine enters a warring sate {9 - Set value (bar) for pressure below which sending air fo centis disabled 410 Set value (bar) for pressure above which ting is enabled fr sending air to cient 1L3). Represents the limit for the value 414 - Second recovery interupion pressure (bar) (valve indicated, can be seta that can be set for the field 10. 412. Marimum pressure (bat or activating intermedia blowing (value indicated, can be set at L3). Represents iit for the value that can be set forthe field 2. a), Represents iit for he value that ean be set or 412.- First reoovery pressure (bar) (value indicated, can be set at the field 14 -Set value (t indicated, can be sel), +45 -Set value (bar) for first recovery bar for fst recoverytankprossure above wich first recovery timing is disabled (value tank prosoure below which frst racovery igs enabled again (value indicated, can be 26!) 46- Real value (bar) of proseuro In tank. 47 -offet value (bar) of pressure wonder “Tho valuo Is dotocted by pressure tansducar on the tank 1 first racoveryitank tino oS (@ Scanned with OKEN Scanneryu IPA TRAINING MANUAL SFR EVo — 2"> LEVEL Our Goals to in picure 1 peor N Oscilloscope (one in picture above. ‘raph like the one in pct a Optimizing the process we vl each condition C2, F2, G2, ition C2, F2, cH, iW Cis influenced by parameter 2 ofthe blow ing page, tts low pressure i a canons eget cl met muerte eee the time litle by litte;you wil lt the greph become smoother ike C2. = F Is influenced by parameter 5 of the blowing page, fits too long the low pressure recovery time (2) you will SEE in the osciloscope a graph F1 like, reducing the time litle by litle;you wil let the graph become smoother ike F2. recovery time (2) you wil, SEE eerteseope 2 graph Gt ike, reducng he time lite By kitesyou wil tthe gr@ph Become oie Bent asaosse Page 19828 a eySTEMS SIPA TRamine (@ Scanned with OKEN ScannerTRAINING MANUAL Ss IPA SFR EVO - 2™> LEVEL PNEUMATIC SCHEME « in case of ARS STD Recovery — 18-24 bar — rimary (@ Scanned with OKEN Scannerent pipe the secondary § Pair (air at 10-15 ‘at 40 bar for numberof bi at forthe primary blowing and ait {or te oa bowing Every blowing ble auiles leaves the rotary fiting carying the air to each INEST sing of 19 Cavities thoy boy ing block is re img 20% responsible of the primary blowing, secondary Blowing 2 |_- Secondary al ‘pilot © Primary alt eainder ( Primary Alt -ompensa(ion Ti or ee iow requiat (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 2"? LEVEL ‘The blowing occurs according to the following sequence: © Press closing and successive descent of the seal (15) operated by the service ar. © de-energizing ofthe three-ways two positions solenoid valve (10) which supplies in advance with respect to the primary air blow in the cavity the compensation cylinder (11). The compensation cyinder contrasts the ction of the pressure in the blow mold cavily. The speed of the cylinder movement supplied in tis phase ough the lines (17) and (18) is adjustable by means of the flow regulator (9) © enabling of the solenoid vave (1) with consequent plating of the valve (6) the primary ait i sent ito the wing cylinder (14) and from here into the cavity (12). The capacity of primary air is adjustable through the flow regulator (2). (primary phase) © enabling of the solenoid valve (10) and direct compensation with the same primary air present in the cavity which goes to the cylinder (11) through the line (16). © de-energizing of the solenoid valve (1) and contemporary enabling of the solenoid valve (3) with consequent piloting of the valve (6): the secondary air is sent into the blowing cylinder (14) and from here into the cavity (12). Moreover, direct compensation with the same secondary air present in the cavity which goes to the cylinder (11) through the line (16). (secondary phase) © de-energizing of the solenoid valve (3) and contemporary enabling of the solenoid valve (4) with consequent piloting of the valve (7): the air present in the cavity, in the block Eugen-Seitz and in the compensation cylinder (11) is discharged through the muffler (8). (degassing phase). © seal ascent (15) and successive press opening. One pressure transducer fitted in each press group (13) permits to detect and read the real pressure in the cavity during the entire blowing process. (@ Scanned with OKEN Scanneryy SiPA TRAINING MANUAL cae SFR EVO - 2"> LEVEL REPLACEMENT oF LUBRICATION DISPENSER © Enter the LUBRICATION video page of the Supendsor. © Identify among the elements dispensers. splayed on vic representing the empty 5 recogrizable by ye ‘on video page the onels which 9 replace into the acne by Yellow color, then proceed to recogrize the positon ofthe empty di © Accede the empty dispenser. WARNING: make sure that the electrical connector (4) plugged to the electromechanical unit (3) is not too much rotated or pulled in order to avoid further wire breaking, © Remove (loosen) the electromechanical unit (3) from the lubricant dispenser (2) ‘© Remove (loosen) the dispenser (2) from the manifold (1). Provide to clean the manifold (1) using @ clean ragged cloth without rps. Fil all the tbricant pipes and cocks wit a suficent amount of grease using a manual pump, before instaling the new dispenser. ; Provide to install (screw) the new dispenser in a(t instal (sre) the elecromecharical unit (3) ofthe spencer corridge ito the new one, «Repeat the operation forall the eventual empty sponses. its seat in the manifold (1). (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 2"? LEVEL ‘The icon on Supervisor page representing the dispenser will tum to red color whenever @ malfunction of the ‘automatic lubricant system would happened (breaking, electical wires troubles, etc.) Despite the frequency of lubrication is a fixed value set on Supervisor, in the most upgraded versions of SFR is possible to force the greasing turing the machine in manual mode and pushing the button located on the bottom of the relative greaser on the video page. In this way the icon will tum on green color for a couple of minutes (together vith its button) and the system wil provide to dispense the grease during his tme, finaly stopping automatically at ‘completed operation. If you want to stop ths lubrication process in advance, push the automatic cycle button then the manual one. “TRAINING 24 - SYSTEMS Poge 24 0f28 ait (@ Scanned with OKEN ScannerTRAINING MANUAL SFR Evo _ 2"> LEVEL RESET oF s; TARC The roceaye wen ONTROL DRIVE OF A MOTORIZED LUBRICATOR ded at ie 28 the rules fo re mochines, need happening ofthe folowing," FeSeing the ve of a motorized hibricator of SFR mactines. . the cartdge c theca ae SPREE before the dive gives hesgnal of empty cage Ghee sonascanridge empty but tia eetaty wre 1 wo intend 19 modliy the poe lispensed,, "MY he Seting ofthe cp-swiiches to modi the type of operation or of the quankiy ofS © Partially used carvidge is mounted Functional description of automatic lubricator The system is fumished of a « cen 7 a8 v Oe rive unit equipped with a motor criven by an integrated electronic unit and by rc rons Canister unt wit changeable Kent Th a eet et, "isn oto minutes to guarantee the correct supply during the functioning, The system is Ui sutomatc Pressure liter ined to 8 bar once tis ae eae ecg. The 3 attempts of activation orkng K cvalable 2 diferent kinds dipswiches: TIME and VOL, TIME modifes the quanty supplied during 100 working hours, VOL. sets the capacity of LC unto he males acd with LC M120 only it supplies the settled quantity of grease only at once, and the voltage nutes atleast. To stant another lubrication cycle, the vollage supply has to be interupled bar: once this value will be reached the system stops automaticaly after several The impulse mode is used has to be available for 2 mi for 5 seconds at least, then reactivated, The range of suitable temperature varies from-10 °C to 60°C. A Semperature of 20°C is suggested for correct storage of product with expiration time not longer than one year maximum, The lubrication cartridges are electronically driven by PLC. During automatic cycle, the PLO gives an impulse to the the appropriate Supervisor video page, (in the figure of page 1 this time cartridges at every time interval set in corresponds to 160 minutes). This function do not considers the stand by condition. The cartridges have to be cleaned with a clean humid rag, trying to avoid the Contact of liquids (water or detergents) with the internal part, 1 Connector with wired plug 2—Led status indicator ‘3 Serial Number (ex.0035495) 4— Drive Unit (cover + drive) 5 —LC unit (ex. M120 = 120 cm3) 1g data (ex. SFO1 00/12 where 6 -Lubricant technical information and filin SF01 =universal grease; 00/12 = 12" week, year 2000) i (@ Scanned with OKEN ScannerSIDA TRAINING MANUAL eens SFR EVO — 2" LEVEL tion of the motorized lubrication To better understand such operating instruction, following is explained the operat C. there starts the motor of the device. Wh i sation device and the red LED tums on. eee 1e motor completes release insta eo on ot t errs on the number of tums completed by the motor. ae eee ne corre revoluions completed corresponds to the number of i otherwise the red LED should remain on, this means that the lubrication device is broken; if instead both the LED re on, this means that the cartridge is empty. At every impulse therefore the motor completes a certain number ‘of revolutions and adds them to those carried out Until that point. When the number of otal turns completed corresponds 10 a precise seth ‘of the lubrication device (the setting is set with the Dip Switches and ‘depends on the volume of the cartridge, used), a impulse will advise that the cartridge is empty. Therefore, if for example We replace the cartridge before the lubrication device has accomplished the number of revolutions set, the lubrication device itself ‘will proceed with the ‘counting and will give the signaling of empty cartridge before the new cartridge really is. Note: in the cases b), ¢) and d) the counter of the lubrication device is zeroed and 2 ge installed, therefore the signaling of Wor eoinede wit te effective eve fg avaiable the Dip Switches present on .ctvation depends turns expected, the red LED will switch off and fi the output of PLC is held to 1, signaling the ‘empty cartridge will no lon ary ro ofthe state ofthe caridge wi Ne tobe cared 0 he lubrication device. in the cartridge. As a consequence in tosling of 2 new cartridge, when there wil be necessary anew reset oft LED indicators “The LED located on the drive have tne folowing meaning Green continuous signal > OK i KEN Red continuous signal > ERROR, BRO! SLC UNIT EMPTY, NEED TO BE REPLACED LYING IN PROGRESS red continuous signal — tinuous signal (while te motors running) -> LUBRICANT SUPP Green Red cont Dip-Switches tubrificante of lubricant per ogni impulse 1 Ateach pulse “VOL” IPA TRAINING (@ Scanned with OKEN ScannerSiPA TRAINING MANUAL Seen caer SFR EVO - 2"? LEVEL RESET OF THE DRIVE Introduction: All jth code i 1 the ones with 5037900 and code wy eon dispensers have to be setled on the same way: in partoular he 1e 80027236 have to be sel has reported on beside figure. ‘© Unplug the connector from the device, Unscrew the dispenser from the point of lubrication, Unscrew and remove the LC unit from the dtive, ‘Adjust the lever "VOL" has reported on the previous figure (manual reset), ‘A white pin rises from the base ofthe drive: push it and keep itpushed. Connect the drive to the voltage supply inserting the Connector, then enable the lubrication from Supervisor. ‘AS soon as the motor starts to operate, release the pin ‘and unplug the connector from the dive. © Adjust the quantity of grease to dispense, as much as necessary, acting onthe levers “TIME” and “VOL” Push and keep pushed once again the white pin located on the base of the ive. ‘Connect the drive o the supply voltage inserting the plug and enabling the lubricating device from Supervisor video page. Release the pin after 3 seconds, then unplug once again the connector form the drive. PERNO DIRESET RESET PIN In the case a) assemble a new cartridge on the drive In the cases b) and c) assemble once again the intial certidge. In the case d) assemble the partially used cartridge. lace the cover on the drive ‘Screw the cover locking it manually. LC unit and cover have to mate perfect. “Take the safety cap out from the new LC unl. ‘Screw down the lubricating device on the polnt of lubrication Finally, connect the plug once again. ‘21 SYSTEMS: 27 of 28 Pee SIPA traning (@ Scanned with OKEN ScannerSIPA (CENTRALIZED LUBRICATION (OPTIONAL) TRAINING MANUAL SFR EVO - 2"° LEVEL Centralized Lubrication replaces all the 4 singles lubricator using @ 4 point of injection. One electric pump inject ‘grease in the dispenser and from here to =fith gear 0,4 colsec oven Wheel 0,2 celsec. mould cam 0,2 celsec. rod cam 0.2 celsec. Lubrication time interval for 100 MIN PER SFR 20 E SFR 24 E 140 MIN PER SFR 6, SFR 8, SFR 12, SFR 16. is limited to 100 minutes Each one lasts for 20 seconds. Progressive distributor has a micro switch to check the real spool stroke by an electric, signal, This checks that all the piping proper functionality To refi the dispenser just pump some grease on the refill point (PARALIQ GA 351 0 equivalent) To force the lubrication just push the button on the page below. ze: ame 34. SYSTEMS Motor Pump Lworieaton LUBRICATION PIPING INLET ‘GREASE LEVEL s06016 WUBRICATION FINISHED PROGRESSIVE DISTRIBUTOR Pago 28 of 28 SIPA trainin (@ Scanned with OKEN ScannerTRAINING MANUAL ALARMS 1. GENERAL INFORM, ATION —— ION AND DEFINITIONS sends a sonareenaetine hic tant Menlored by sensors (pressure transducers, mit switches, etc). Each sensor '¢ PLC which will be processed according to the instructions resident in memory. In the Pe through the teSUPERVBOR, commands and conten rogram signals any trouble or maltunctioning of the machine * Inlerace and generates the comtesporciny wae The machine ‘alams can be. ‘divided in two types: ~ Waring (yetow colon ~ Alarms (ed colour WaRNING pronase, 22 that does nt nvlve the stooping ofthe mechne ypicalit wars a stuation that may stop the hoped emp, PrOPer situation. tis signalzed by a monotone eaind of the buzzer and the lightening of the white To silence the buzzer press and release the ‘ALARMS CUT-OFF button on the HMI panel ALARM Indicates an alarm that involves the stopping the machine. Every time an alam occurs the acoustic signal ith {Sen} emits a btonal sound with the ightenire ote oe on it ight on the emergency lamp on top of the cabin and {he lightening ofthe ed ofthe button ALARMS CUT ORE wesc on panel the acoustic signal ~ the lightening and the blinking of the emergency light on top of the cabin ~ the blinking of the led of the button ALARMS CUT-OFF on the HMI panel - _ the blinking of the led of the button ‘STOP CYCLE on the HMI Panel, ~__ the appearance of the cause ofthe machine stoppage on the ALARMS page on Supervisor Note: tis possible to silence the acoustic signal pressing the button ALARMS CUT-OFF on the HMI panel, ‘Stop Stare Once the machine has stopped the following conditions occur. ~ led of the button STOP CYCLE on the HMI panel ON - led of the button ALARMS CUT-OFF on the HMI panel ON acoustic signal (unt the pressure ofthe button ALARMS CUT-OFF on the HMl panel ~ blinking of the emergency light on top of the cabin the appearance of other possible alarms connected tothe actual slate of the machine on the ALARMS page ‘on Supervisor For an optimal management of the machine Is suggested to frequently check forthe presence of alarms on the ALARMS page on Supervisor. (@ Scanned with OKEN ScannerSiPA TRAINING MANUAL ieee SFR EVO - 1°" LEVEL i TYPES OF STOPPAGES DUE TO ALARMS, ring 8 the automatic eye Type eae pentose, ho eloppage ol he machine duet lame can cer in diferent ways depending on he = Machine untoading Cycle stop Phase stop Emergency stop MACHINE UNLOADING Certain types of alarm: ‘worki ; 36 cause the stoppage of he machine ar the competi ‘ therefore, besides of the conditions of the STOPPING PHASE, also occurs: ine eedentaa et > stopping of the preforms loading discharging of all preforms inside the machine by blowing them; ‘The machine goes then in the Sto Stare. Note: during the preforms dischar ischarge the green led of the button STOP CYCLE on the HMI panel is biinkr the light becomes fixed (StoP STATE) before starting any operation, Lament Stop CYCLE Sl |ypes of las cause the stoppage ofthe mactine ate a tne ag eal the time needed for the 1e cycle in progress (blowing of the preforms insid¢ i tic Geompltion cf the cyl in Pr gress (blowing pI inside the moulds); besides of the conditions of the. stopping of the preforms loading completion of the cycle in progress; The machine goes then in the STOP STATE. Notet: during the Stop Cycle the green led of the button STOP CYCLE on the HMll panel is blinking. Wait for the light becomes fixed (STOP STATE) before starting any operation. Note2: after the stoppage of the production working cycle (whether for Machine Unloading or for Stop Cycle), wait for the ovens fans stop and then further 5 minules before disabling the machine auxiiary devices and cutting-of the main electric supply ‘STOP PHASE Certain types of alarms cause the immediate stoppage of the machine in whichever state the machine is, setting the machine directly in the StoP STATE. The green led of the button STOP CYCLE on the HMI panel becomes fixed immediately. NOTE: although the machine is in the Stop Stare, opening one cabin door without the proper safety Conditions are suited (manual state and key switch BraKes BYPass in horizontal position) causes the immediate auxiliary devices shut-off. NOTE: The stopping in Stop PHASE of the machine implies the ‘whole and immediate stop of all the units in movement, therefore there could be partially blown bottles even ‘stuck on the stretching rods. EMERGENCY STOP it i ‘Stop PHASE He pressure of one mushroom button or the opening of @ cabin door causes the machine stoppage in Toe ‘with the exclusion of the pneumatic supplies and of the electric drives (AUXILIARY DEVICES SHUT-OFF), Refer to chapter 10 - SAFETIES for further detalis. t of all the units "The stopping in EMERGENCY of the machine implies the whole and immediate stop peony Saves) therefore Troe could be partially blown bottles even stuck on the stretching rods. —————————————— (@ Scanned with OKEN Scanner4 TRAINING MANUAL SIPA SFR EVO - 187 LEVEL 3. INTERPRETING ALARMS he ALARMS page of Supervisor permits to see the cause ofthe machine sop and the presence of eer alarms in ‘occurrence or in consequence tothe stoppage. The cause that stopped the machine i displayed inthe bottom eld in green coor 1) Many other alarms normally Drabom Foe atm Page but is tke an avalanche effect. Therefore not al alam displayed mena tet Inoe or, ‘problem. For example, after a stop, the alarm that there is @ fault in the heater or in a power devices cut-off and therefore the heatings a isto understand what caused the auxiliary devices cut-off. The suggestion isto reset the alarms fist, in order to alarms. Everytime the operaior thinks to have solved one cause isa good rue to test ‘again the alarms and see if the relative alarm disappears and doesn't come back, The information provided by the alarm page is: + machine stoppage cause (3); ~ type of alarm (yellow or red cover); + alarm code; + brief description; + date and time, The alarms are identified by the red color while the warnin ae identfid by the yelow colo. Each alam, independent of is level and ype, sidentied witha code number (6 cgis) Itis a good rule to take note of the alarm code, communication with Sipa, ‘The code number is folowed by a brief description ofthe alarm that allows the pera to dently at east esonere agro a Tn stn s wey ay gh ee, cured especially Hf envisaging maintenance work and for a direct The description page (HELP) provides information about the Bossble c@Uses that generated the alarm and the possible solutions, "ALARMS Page 308 SIPA reaninn (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 187 LEVEL Once sel Selected the alarm, pressing the HELP bulton its possible to view: the alam code (1) the alann description (2); the z he zone concemed wit the relative inputfouput signals (3) the possible causes (4 ‘he possible retative solutions (6) 4, RESTARTING Refers also to chapter 8 (Machine star-up and stoppage procedures) for futher details, a. Machine in the Stop STATE with no need to enter inside the cabin: 4. Check the cause ofthe alarm in the ALARMS page of Supervisor. 2. Solve the cause of the alarm and carry out the required maintenance operation if needed. Ifthe maintenance opereion requires the machine in manuel state, press and release the bution MANUAL on the HMI panel (green led on) and in case operate with manual commands, WARNING :if the maintenance operation requires a manual intervention inside the cabin, oto step b). Inthe ALARMS page of Supervisor eliminate the alarms presert (trash icon command). (Check for addtional alarms (repeat the step 2), nce al alarms are solved (ALARMS page of Superior without red alarms) check the green fed ofthe button ALARMS CUT-OFF on the HMI panels off, otherwise repeat fom step 1. Ifthe machine has been set in manual stale, press and release the button AUTOMATIC on the HMM panel (green led on), otherwise ALARMS Page 4 of 8 ‘SUPA Trainin (@ Scanned with OKEN ScannerSIDA TRAINING MANUAL ‘Res rectsone Same SFR EVO - 197 LEVEL sec, and release it after Press and keep pressed the bullon START CYCLE on the HMI panel for about § the machine has started-up, NOTE: The machine will automaticalh nl by the stop, 199 . will automaticaly complete the phases which were interrupts {operating} conditions and resume the noma production oye. ore original b. Machine in the Stop State and need to operate inside the cabin: ited Press and release the button MANUAL on the Hil panel (green led on) an operate according fo the Se maintenance level > operations L1 or L2 with no need of movements (pneumatic, electric): 1. Check the cause of the alarm in the ALARMS page of Supervisor. 2. Open the cabin doors. The auaiiary devices will shut down. Note: In this condition no movement is allowed except the one with the manual crank Pressure is discharged, heatings are disabled. However be careful to ovens that are stil hot. 3. Salve the cause of the alarm and cary out the required maintenance operation f needed and the checks ‘Needed to solve the causes) that brought the possible stop in Siop Phase |i the ALARMS page of Supervisor eliminate the alarms present (rash icon command). 5. Check for the presence of further alarms not regarding the doors, the safeties and the auxiiary devices (repeat the step 3 if any), Close the cabin doors and eliminate the alarms (rash con command) in the ALARMS page of Supervisor. ‘Be sure that all cabin doors are closed. Enable and run the auxiliary devices. its not possible check ifthe ‘machine is in MANUAL mode or the presence of other alarms, Reset them and camry out the required ‘Maintenance operation f needed. 8. Take a general look if any component is in right positon or needs @ further intervention. Ifit is necessary 10 ‘move some devices, operate with manual commands, 9. Inthe ALARMS page of Supervisor eliminate the alarms present (trash icon command). 10. Once al alarms are solved (ALARMS page of Supenisor without red alarms) check the green led of the button ALARMS CUT-OFF on the HMI panelis of, otherwise repeat fom step 1 or fom case a 111, Press and release the button AUTOMATIC on the HMM panel (green led on. 12. Press and keep pressed the button START CYCLE on the HMI panel for about § sec. and release it after the machine has started-up > operations L2 with need of low pressure air: 4. Check the cause of the alarm in the ALARMS page of Supervisor, 2. Call a maintenance worker who will operate a BRAKES BYPASS and wil alow to open the cabin doors without shutting down the pneumatic supp. 2. Open the cabin doors. The auxiliary devices won't shut down. Note: In this condition are enabled some pneumatic commands. 14, Solve the cause of the alarm and carryout the required maintenance operation if needed and the checks needed to solve the cause(s) that brought the possible stop in Stop Phase. 5. Inthe ALARMS page of Supervisor eliminate the alarms present (rash icon command). 6. Check forthe presence of futher alarms no regarting the door othe safeties (repeat the step 4 if any) 7. Close the cabin doors and turn the BRAKES BYPASS in vertical poston. 8. Reset the alarms (trash icon command) in the ALARMS page of Supervisor. 3 ALARMS os age - SIPA traning (@ Scanned with OKEN Scanner ATRAINING MANUAL SFR EVO - 187 LEVEL 8. Tekea genera ook itary component iin ht poston or neds einer move some devies, peta wth manvol commends See eee 10, Once at alams ae soled (ALARMS poge of Supevrwihou fd ars) check baton ALARIIS CUT-OFF on Ml pane va hence opal tom sup fotoncesea) 1 1. Press andreas the bton AUTOMATIC onthe HM panel (een on) 12 Press and eo 7 P pressed the button START CYCLE on the HM panel for about 5 sec. and release it after Ye machine has started-up. ¢, Machine in Stop PHASE: 1. Ghecktne cause ofthe arin the ALARMS poge of Sipe 2 Press and lease the btn MANUAL on he HM panel (ren so) 3. Toke a genera lok it any component in bad poston and needs a prrinterenon. Hts neessry o move some devices, operate with manual commands or crank. 7 ‘a a? ‘ Solve the cause ofthe alarm and ca i ea ry Out the required maintenance operation and the needed checks to Sole te problem tha caused ine stoppage in Stop Phase movements ise he cat ae nessa. ca maintenance worker who wil operate @ BRAKES B 7 ‘movements withthe auraitonance wr op% PASS and will alow the pneumatic is wth the Note: In this condition are enabled some pneumatic commands. 5 Shes er nove (if needed) the possible partially blown preforms from the blowing moulds and form the 6. Close the cabin doors; turn (in vertical postion) if not yet, the key switch BRAKES BYPASS, 7. Inthe ALARMS page of Supervisor eliminate the alarms present (rash icon command) 8 Take a general look if any component isin right position oF needs a further intervention. If it is necessary to move some devices, operate with manual commands, a Once all alarms are solved (ALARMS page of Supervisor without red alarms) check the green led of the button ALARMS CUT-OFF on the HMI panel sof, otherwise repeat from step 1 or from case a). 410. Press and release the button AUTOMATIC on the HMI panel (green led on). 411. Press and keep pressed the button START CYCLE on the HMI panel for about 5 sec. and release it after the machine has started-up. d. Machine in the Emergency Stop state: 4. Press and release the button MANUAL on the HMI panel (green led on). Check what mushroom button has been pressed (or what dor has been opened). Restore the mushroom button and press the blue button EMERGENCY RESET (or close the door and RESET the doors safety unt) The orange light on Master cabinet must ight of Inthe ALARMS page of Supervisor efminat the alarms present (rash icon command). jing the auxiiany reneral look i any component isin bad postion and needs intervention before enabling 5. Take a et open the cabin doors and carry out the requfed maintenance operation. Then cose ine a ql ible check if th li ot possible check ifthe that all cabin doors are closed. Enable and run the auxiliary devices. fits ch Foe one R MANUAL mode or the presence of ober alms. Reset them and cary ou Ihe requited maintenance operation needed, 7. Proceed as from step 3 of the case ¢) Page 6 of 8 ‘SEPA TRAINING (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 157 LEVEL WARNING Before starting the machine automaticall i refully inspect ly (START CYCLE) you are advised to cai ‘while manually unloading the blowing wheel, The fat thatthe power supplies are cut may ca Problems (e.g. sticking of preforms on the stretching rods). e Norma Sxety festa in automatic mode, fo athe time the buton START CYCLE is pressed tis also present th intermittent acoustic signal that wams the machine is stating up. Preah machine has statedup in automatic eco, aranges automaticaly ( necessary) tothe completion of the interupted phases due tothe previous stoppage, discharging the preforms or the botlles ff they are yet present in the machine and reset the orginal operative conditions for the production. This station is signaled by the blinking of the Seem the button START CYCLE on the HMI panel and is called Reset PHASE. Once the reset phase is Completed, the machine runs in automatic cycle in the selected mode (green led ofthe button START CYCLE on), the machine use severe (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 187 LEVEL WHAT TO DO IN CASE OF ALARM GUIDE TO POSSIBLE ACTIONS. [ER see teaem SGD esemanresnsin am Reset the alarm and restart in automatic mode oa SALAS x — Page Bot 8 SIPA trawwins (@ Scanned with OKEN ScannerSiPA TRAINING MANUAL See ee SFR EVO - 4°" LEVEL ELECTRIC LAYOUT led ‘momen oven mie mel fr to 9 TYPICAL seu fhe lect ytem, For more dtl informatio, refer tothe applicable Wing Diagrams Irina ol he eecicetectoni tem ar cated inthe Maser cabin nd inthe Boxes rpreserted inthe following picture: VO PROFIBUS 10 ETHERCAT INVERTERS IRAZ24 IRAZ24 (PWRCO08) (PWRCO8) BUTTON PANEL PANEL PC. EK1100 BRIDGE BOX R70 A and B INVERTERS MASTER ETHERCAT INTELLIGENT fg, SOCKETS \ ae BOX R50 lio ETHERCAT INVERTER ROFIBUS VO PROFIBUS 4- ELECTRIC LAYOUT Poge tof 14 SIPAsnanne Q (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 187 LEVEL SIDA BOX 55 BOX R70A ROTARY JOINT se MASTER CABINET RTD = | [] BOX R70 B | 7 i remote socket PO%*! BOX 53 SLAVE C TILTER 7 ‘Tho MASTER electric cabinet houses mainly: =the main power switch breaker tne inverter that conto the gearmotor for genre! movement the inverter that contro’ the ovens fans motors ~ the lees over oards PWRCOS (or in some mactine configurations, RAZ24) that manage the ovens lamps = the input/output modules Se | the stabilzed power supplies 24V and 230V the emergency unit and the cabin doors safety unt to the enabing of the heatings, fans and safeties status referring mainly = the UPS = the Panal PC BECKHOF the module K1100 with Bridge functions Page 2014 SIPA rrainino rd To evecTRIc LAYOUT (@ Scanned with OKEN ScannerSIPA ‘The SLAVE C electric cabinet houses main! the hopper main power switch breaker {he inverter that controls the gearmotor ofthe extractorelevaor preforms the safeties regarding the titing unit The electric BOX R50 houses mainly: Sensor of the blowing wheel and the preform loading cylinder The electric BOX R70 A and B house mainly: Of the blowing and related controls included pressure transducers Finally any blowing press houses an INTELLIGENT SOCKET 1P2001 Ethercat, EtHeRcaT EK1100 for the managing of stretching rods, seals, compensations, ARS. Let's see now the architecture and the main components in the electic panels. TRAINING MANUAL SFR EVO - 157 LEVEL ‘he InputYoutput modules Stevens refering mainly tothe hopper and titing unit controls ‘modules l]O Stewens that manage the whole machine, incuded brakes control, aiwater external manifold ~ Modules WO EtHeRcAT EK1100, that manage the enabling signals of the expelles, of the synchronization Modules YO EtweRCAT E1100 that manage together with INTELUGENT SOCKET 12001 ETHERCeT, the enabling In case of Hot Fill configuration The electric BOX R70 AIB are replaced with a single box. It houses Modules VO ETHeRcAT EK1100 that manage together with INTELLIGENT SOCKET P2001 ETHERCAT, the enabling Of the blowing and related controls included pressure transducers and the boards controls. the electronic power boards PWRCO8 (or in some machine configurations, IRAZ24) that manage the heaters for the moulds heating bets that sends outputs coming from VO primary air, secondary air, degassing, (@ Scanned with OKEN Scanner$ 4 TRAINING MANUAL iPA SFR EVO - 187 LEVEL ARONTECTURE ‘The electicelectronic architecture is decentralized rast elect boards there are NODES, hal i looic blocks thal perform fad functions in earn zones of the machine ree Can Be realized by one oF more components even of diferent Kind (ex dgtaVanleque VO modules Fe poeta acto cards) bu ti however characterized by an addtess thal Wentfes unambiguous snd logical ' positon along the electric serial line (us SFB Evo the nodes are connected each other inthis way. PC is connected via ErMERCAT fo a moda EK 100 ‘with the function of Bridge for the serial lines CANopen (for the managing of heating signals), Ethercat (for the part Contling blowing signals and expelrs), and Profbus that manages the est ofthe signals contin hs eachine tre AE. Conaurations with 1RAZ24 modules instead of PWRRCOB, the ne CANopen isnot used and is replaced by ketal tne RS422 which has not the nodes even # the boards are sil addressed through cokes thes aaRresses of Profious and CANopen tines ate general set by means of selectors of tipsurtches, tho siden {eINE an Now to set tis described inthe elecriceiagrams andlor in the documentation in attached to tha electrons boards. ETMERCAT recognizes instead automaticaly the address according to the connection realized, so i the wiring is correct the machine will self address properly ‘The following picture shows the serial lines layout just described with a R422 instead of CANopen Boe DEVICE STATE MENU | | | AT ail J i _<. x (@ Scanned with OKEN ScannerSdPA TRAINING maNuAL Pee eer SFR EVO - 457 LEVEL ‘SERIAL CONNECTIONS Profibus ‘The PROFBUS-DP serial in isa field bus a i both directions we isa field bus and is realized by a twisted pair in which the signals go in ihe nose Sr neie 6 each noe by means of connectors cuppa selector (ee leat agra) tal sts 1, codes terminal (ist or ast) or through (intermediate Rode). To the PROFIBUS serial line is assigned the task to transmit the inputioutput signals between the PC (Soft PLC) and the modules (ET) from the sensors, to the actuators where Maas ome the crives of the gear motors and of the evens fans, the protocols Master Save YPC, te et the Profious module of EK1100 and the nodes (Slaves) are he UO meres E2008, the Safely nit inverters. In the Picture below is outined the PRoFisus layout and the nodes connected tot BOX R70 A&B ROTARY JOINT MASTER CABINET SLAVE C iu (@ Scanned with OKEN ScannerSip, TRAINING MANUAL Peete Reckeowe Brees SFR EVO - 157 LEVEL CANBus phe serial line CANBus based on CANopen protocol connects through the Bridge EK1100 the PC withthe power poards PWRCO8 for lamps heating. Again, each board has an address that identifies is poston along the serial line, In figure ate shown one or more additional PWRCOB boards located in the Box R70 for molds bodies heating present ‘only in case of Hot Fill configuration. Master is the CANopen module of the EK1100 while each boards is seen as Slave. CANopen is used instead of RS422. Rs422 The serial line RS422 connects through the Bridge EK1100 the PC with the power boards IRAZ24 for lamps heating Again, each board has an address that identifies its position along the serial line. In figure are shown one or more additional IRAZ24 boards located in the Box R70 for molds bodies heating present only in case of Hot Fill Configuration. Rs422 is used instead of CANopen. Rs422 is a “pure” serial ine therefore we cannot speak in this case about Master, Slaves and nodes. Anyway we can identify the RS422 module of the bridge EK1100 as the starting point. ROTARY JOINT COLLETTORE ROTANTE MASTER CABINET (@ Scanned with OKEN ScannerSPA TRAINING MANUAL Pree SFR EVO - 157 LEVEL Ethercat d nds) EtherCAT (Ethernet Control Automation Technology) is a fieldbus Ethernet based high speed (250 microsecor rk card and the pe 3 oetiuous few of information tis used fr coectng the PC (Master) hanks tof netWor the modules EK1100 and the inteligent sockets (Slaves) re00g the Fesres Tcognizes automaticaly each node according othe conneations realzed, soi the wing is corect jcture Deena Sef adress propery all the nodes ofthe seri Ine without doing t manvaly. The flowing Pi Shows the typical layout with also the Hot Fill option, BOX R70 A&B INTELLIGENT ‘SOCKETS ROTARY MASTER CABINET ‘4 ELECTRIC LAYOUT Page 7 of 14 (@ Scanned with OKEN ScannerSIiPA TRAINING MANUAL ‘Ptenic Packaging Syaterns SFR EVO - 157 LEVEL (MAIN ELECTRICAL COMPONENTS INouSTRIAL compuTER The industrial computer BECKHOFF in configuration Panel PC integrated in the screen performs the function of Anulning and processing signals from the electronic boards andlor processed by the PLC emulation software INCAT), The industrial computer uses a graphical human machine interface software program (HMI) called SUPERVISOR that ‘uns under Windows and that allows to control the machine during any production phase, The PC has moreover the function of generating electronic virtual cams which, together with encoder, permit 10 choose precisely the angle in which to enable each operation related to the blowing of each mold generating the Corresponding output signals (compensation, primary air, secondary ai, decompression, seals, etc) ‘An UPS is connected to the PC, that guarantees about one minute of auxiliary supply in event of black-out of the main power. ‘The industrial computer Beckhoff is a genuine PC equipped with a number of additional dedicated boards such as: a etwork card through which is interfaced with the module EK1100, USB and DVI Port to interface PC with the screen, a USB port for the Dongle Hardware license key and a USB port for modem connection. In the following picture is outined the layout of the PC. DONGLE ZENON (USB) (@ Scanned with OKEN ScannerSiIPA TRAINING MANUAL Raat Pct SFR EVO st LEVEL ind transducers rial PC, sensors 2 i strat pneumatic cyinders, Cet Input/Output modules sil {ink up the indus ‘The input and ouput modules ET 200 § (1) make it possible to (oreceur switches, thermocouples, proximiy svaches, otc) and actuators (va ‘motos. ec) via the id bus PRoFiGUS-DP managing the relative electric So aie Jed with the | ‘The ET 200 S modules can manage digital or analogue inputs (signals from eae ee oards, 500mA Tax.) cond to the PC via PROFS, and eigial or analogue oulputs (signals to actu teceved fom he PC. va rid tate Le aortas labeled withthe llr T.. [9 .. kacaaneeon acta aan SAWN | Ls Uy A MCT . In the picture below are represented the connection with the Proreus (2), the dip- i switches for setting the address (@), the leds that point out the signal state (4), the wiring with the sensors or the actuators (5) ‘Among the signals managed by these dls we meion also ‘the DROK (Drive ok — input signal recened form @.boart tal means the board i ead 10 Operate) and the DAN (rhe Grebe-ountsgraioaad 62g 45 that enables the board itself). ‘The input/output modules are located in the Master cabinet, in the Box R50, and in Slave C. Ethercat modules They are V/Os modules called EK1100 for managing input and output signals (right picture), the interface between Panel PC and the other serial ines such as CANopen (or RS422), Profibus and Ethercat (see EK1100 Bridge described below) and finally the IP2001 inteligent sockets to manage the output signals related to each press (left picture), There is no need give them an address since Ethercat is a self addressing fieldbus and it does it at any machine reset ‘AIIIO modules are linked by RJ-45 based cable. ‘ELECTRIC LAYOUT Page 8 of 14 SIPA traming (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 197 LEVEL MODULE EK1100 (Broce) isd Modile EK1100 has the function to interface the Panel PC connected only through Ethernet ine with the rest of 'zchine. For this purpose the module EK1100 has a bridge function. In fact i is equipped with dedicated Trestles able to transform the signals and relative communication protocols in order to be Used by the different ronic components of the machine. In particular is so composed: > Supply module 24 > Base module Ethercat module (interface between PC and drives) CANopen module (interface between PC and modules PWRC 08); allematively can be present the module RS422 (interface between PC and modules IRAZ24) Profious module (interface between PC and modules E2005) ‘The following picture show the functions and connections of EK1100 module. ETHERCAT £K1100 BRIDGE MASTER SLAVE ETHERCAT satin WASTER 2av canonen Pe SUPPLY aster eIwERCAN BASE MODULE. E1100 DRIVES vO MODULE ETHERCAT SIPA TRAINING J- ELECTRIC LAYOUT Page 10 of 14 (@ Scanned with OKEN ScannerNG MANUAL NI SiPA oe _ 4st LEVEL (rene rochoom Stes HEATING MANAGEMENT PWRCO8 boards .c08 modules depends on the final coriguration ofthe machine: “The number of PWR ‘The PWRCOS board is a P ronic driving of 8 resistive loads Wt fe each channel dedicated to infrared lamps 0 115A for ather resistive loads with a single Phase © ae ae aia fast eect um power of 2KWV per channel and has in each Shanna! a short circuits protection perform fuses. since each PRC can contol independently up fo 8 ani the machine. PIVRICOS modules depends on the final configuration of rene of & lamps each, the possible futher modules. of dedicated to differentiated Ovens: oven ot cules are dedicated to the possible adtional Pe (ninth and tenth), if present, of each oven, For further esnsidenng a SFR12 EVO that has 14 ovens ith 8 each, you wil ind 16 PWRCOS boards: to 14 for each set of eight lamps of the 14 ovens, the 16" and 16" module for the 14 additional lamps. low is represented the relative video page that shows Me ciagnostc both of PWRCOB 2nd of lamps PROCESS for further information about that). 1y phase (1), the temperature of the ‘and each standard oven simaly the frst modules ave 4 iit present), the possible over In the picture be (Resides of the lamps enabing; see the chapter 14- frequency of the supp! ard (3). heat sinker (2) of In particular, there is the voltage and the the board, the referring oven (4) driven by the bos Inthe picture below is highlighted also the lamps dlagnostc; in etal: = Lamps ON = highlighted by the light green color (lamps n. 7 and 8 are off) (@ Scanned with OKEN ScannerGiPA TRAINING MANUAL ‘reate Packaging Sater SFR EVO - 1°" LEVEL + Channel in saturation - highlighted by the yellow color (channel of the lamp 2). Channel in e in saturation ‘means that the board, in some periods, is driving at the maximum rate because is not able to reach the value of temperature set Open circuit alarm (broken lamp, disconnected cable, etc.) — highlighted by red color (lamp n.2). ~ Fuse alarm - highlighted by red color (lamp n.4). > SCR alarm (that drives the power percentage) - highlighted by red color (lamp n.5). In case of Hot Fill configuration, there will be additional PWRCO8 modules for driving the heaters ofthe blowing ™oulds, in particular one heater forthe internal ha-mould and one for the extemal haf mould. Below the detailed picture and connection scheme of the PWRCO8, OS 1 SIPA rraminc Da* ELECTRIC LAYOUT Page 1201 14 f (@ Scanned with OKEN Scanner4 TRAINING MANUAL SPA SFR EVO ~- 45" LEVEL IRAZ 26 boards ‘The number of raz 24 modules depends on th The Itz 24 board is a power board lamps) with a rated current of 13 ‘equipped with microproces ‘and has in each channel ¥ final configuration of the machine, {or the electronic driving of 24 resistive loads (infrared A for each channel at the rated voltage of 230 Vac, $801 conto. Each iRaz 24 can contol unt 24 tamps independently @ shor circuits protection performed by ultra fas fuses. Parposing that the SFR E has 16 ovens wth 8 lamps each (128 in toa), 6 Inez 24 boards Wil Pe needed, whose § totally used (5 x 24 = 120) ara! cea Partially (8 channels, the Temsining 16 wil be fee) In the picture below is represented the relativ \ia2 24 and of lamps (besides ofthe lamps e video page that shows the diagnostic both of that), ‘enabling; see the chapter 14 - PROCESS for further information about Particularly, are represented the vok 'Raz 24 boards must have the sa Hiages ofthe three supply phases (1), the software version (2) ofthe board (all the the naz 24 at issue (4), the relat Te version!) . the temperature ofthe internal heat dissipaters (3) inside the board, ive oven driven by the board (5), Inthe picture below is highighted also the lamps diagnostic; ndetalln the example {Lamps ON ~ highlighted by the ight green color (6); lamps n. 7 and 8 are oft Chane in saturation - highlighted by the yelow color (channel ofthe lamp 2). Channel in e in saturation Talus of tare Boar, in some periods, is criving atthe maximum rate because is it sble reach the value of temperature set ‘Open circuit alarm (broken lamp, disconnected cable, etc) — highl ighted by red color (lamp n.3), Fuse alarm - highlighted by red color (lamp n.4) SCR alarm (that dves the power percentage) - highlighted by red color (amp 1.5), tn case of Ht Fill configuration, there willbe addtional 2 24 WODULES for diving the heaters of the blowing moulds 4-ELECTRIC LAYOUT Page 13.14 SIPA traning \ (@ Scanned with OKEN ScannerTRAINING MANUAL SFR EVO - 1°" LEVEL Drives ‘The drives present in the SFR Evo are CONTROL TECHNIQUES: UNIDRIVE SP drives the gearmotor forthe main general movement ofthe machine (located inthe Master cabinet), COMMANDER SI: three drives for driving the ovens fans motors and the unloading blower (located on the Master Comat the gear motor that moves the extractor and elevator preforms belts of the hopper (located in the Slave ‘abi = Programming of those inverters is reserved to specialized and authorized technicians, and therefore isnot here fescri (@ Scanned with OKEN ScannerGiDA TRAINING MANUAL ‘Pente Peckeaive Syetome SFR EVO - 187 LEVEL ELECTRONIC MANAGEMENT In this chapter wil be analyzed how is managed the rotation ofthe blowing wheel and the relative management of the signals regarding the blowing unt to this connected. There will be moreover introduced other concepts that regard the general management of the machine. Al of the main movements of the machine are mechanically connected by means of two toothed wheels and transmission belts. There is present a single gear motor operated by an inverter that permits the general handling. In the following figures are illustrated some examples of how are constrained the various handling wheels. GEAR MOTOR REFORMS: TRANSFER (@ Scanned with OKEN ScannerSiDA TRAINING maNuaL See SFR EVO - 187 LEVEL The contol of th ¢ SFR, in ‘sim reread ee ha spl wad cared oon ag ofan, nce he Hong hei We must reason parame ron he ales because, since we can vary he seed of producon of he machin. he reference toed sm more logical, Such as speed and time, become too variable to be controlled and moreover ing the angular ae Positions constant and involving all of the wheels of the machine, are used as preference the Its then defined the MACHINE STEP a in (eprocend oe nai: STEP AWOL, hat cori in he angle formed by thease of we aacet mais ‘Such angle is will be _ 3 arene oe round angle divided by the number of moulds present in machine, therefore for a SFR12 it Hadid kode RI fl Ibe 25% an sero ‘of 18° and so on, This signifies that every successive Sey bunm sche ice camjeencaer as neem mats ts 't remains to define which fi is th ) Seeman stating pont a ae The ze10 vas chosen Colimalors posiioned one on the machine fame onthe dy) ‘moulds closing and the other oo 0 Fon the mould n. 1 well defined When the mould 1 is in this postion, the encoder must provide a reading of 0° (or 360"), and the grip of the preforms transfer wheel is perfectly in phase withthe mould 1 of he Bowing veel that # wm ed 3m on the grip this would be perfectly in brefor perfectly inserted in the These fundamental principles of the machine permit us ‘now to understand how the SFR *reasons" { ‘To every preform loaded in machine, the PLC assigns a label giving ithe value 1, that corresponds to the stating postion, This “baptism is realzed by means of a photoelectric cel postoned on the preforms feeding star. As the preform advances this number will increment and the PLC compiles a logical register on which i wrtes step by step the state of the preform (prefom presence, preforn absence, defects, detections, etc.) communicated by various sensors. Every time the oven chain makes an ulterior step forward, the register ‘sides’ forward of one postion, therfore in practice the logical register advances withthe preform. chine of knowing the history ofthe preform in object: therefore as example, when the preform (step) 13, ithe preform has a dimensional defect noticed by the sensor, the the station of rejected preforms (step 20) the This permits to the ms arrives to shape control thatis in position PLC memonzes it in the logical register and when this preform arrives att PLC, after therefore 7 machine steps, will command the ejection. step and the successive one, the poston ofthe preform is determined by the valve To we consider a SFR12 whose machine pitch anges given by 360°: 12= 30°. ere are 30° of difference. ‘cell of oven inlet (positioned at step 74 in the sion inthe box called “relative postion” (See p angle” are 0°. Moreover, between one machine ofthe angle. Les make an examoh “Therefore between a machine step and the successive th rm is exacly in front of the photoelectric crample represented by the figure below), verifying the value of ths pos gure) that wil be hence 74 and that the degrees readin the Dox caled ‘machine st slowly (uth the crank) the blowing wheel, we can notice that he valu of he cess the box called Meving vr so oso reve nang 200887 ce ave a Me a Frc wa estar incrementing unt 30° and so on, Ever tm het resiars the counting of the degrees, the value in Pie tos called “eltive poston’ will inrease of one unt indeatog that the preform has accomplished an entre are ie atepIn our example, accomplished 30" the preform wi Pe now! 9 postion 75 and the preform that folews ‘will be now in position 74. Let's suppose now that a preto ~FLECTRONIG MANAGEMENT aise Page 2016 SIPA rramninc (@ Scanned with OKEN Scanner4 TRAINING MANUAL SiPA SFR EVO - 1°" LEVEL MANUFACTURING POSITIONS. ‘Thanks to these position and angle counters, the PLC knows perfectly at every moment where each preform is and therefore is able to act on every preform according to the program pre-set and to the choices of the operator. ‘Neturally the different sensors and actuators are located in precise and fixed positions and angles obviously known by the PLC. ‘The synchronization and the mechanical phasing of the different wheels of the SFR is not matter of this manual. tis enough to know that exist some sensors that observe problems of synchronization causing the immediate stop of the machine and that the mechanical zero of the machine is determined (as said previously) when the mould 4 isin axis with the collimator, From these considerations we can understand how the blowing wheel is considered the principal wheel of all the ‘machine, and that therefore is the reference for all the other wheels, (@ Scanned with OKEN ScannerSiPA TRAINING MANUAL Packooing Syatene SFR EVO - 187 LEVEL ‘i Setting of the speed of the blowing wheel is realized using an INVERTER (at present a CONTROL TECHNIQUES TNDRNE SP located in the Master cabinet) whose programming is reserved to Sipa or authorized technicians (L3). 1 Setting of the speed (of production, simulation, synchronism, manual mode) can be set by Supervisor in the video page following displayed (cfr. chap. 7 - Video pages). We remember that the speed is expressed in bph, thats botles per hour for each caviy. Inthe fgureis set 9 value ‘of 1400, that corresponds for an SFR 12 for example, al a total productivity of 1400 x 12 = 16800 bottles per hour. MAIN WHEEL (@ Scanned with OKEN Scannerq TRAINING MANUAL SiPA SFR EVO - 1°" LEVEL mit the management of the bl Lets analyze now the other main components that pe "one ABSOLUTE ENCODER is mounted on the elec rotating joint for the determi! ory moment of the mould 1 (2nd as @ consecec also of the ere Mower but it requests a setup procedure [or the collimation ff encoder is not able to carry out direct ‘measurements of speed, PEC. The signals ofthe encoder are inputs ofthe VO module Ethercat ‘A SENSOR OF SYNGHRONSM consents of verfVing at EAT revol Cenween the mechanical zero and the electronic 2.16 ‘sine mould 1, that is if every Ym mou passes in front of the collimator (mechanical We), the encoder reveals a readied of 0° (electronic 2610 Basblems to the encoder, breaks or loosening of the ‘ransmission belt or erred configurations are revealed by eo sersor wth the immediate stop of the machine, The ‘ignals of the sensor are inputs ‘of the VO module Ethercat EK1100 in Box 50 ‘The PC has the function, by means of an intemal implementation of a CAM GENERATOR. of generating virtual electronic cams function is a et th mechanical cams with the diferenes that the ‘cams send intelligent electronic cams are programmal .e blowing wheel, these sockets, through the Ethercat line, fixed (but programmable) angular positions of the blowing wheel ‘Atthe inside of the electric box R70 A and B a ‘Signals to send each inteligent socket for each Press. (seals, bl Signals fom sensors and transducers of each press. The exPS Ethercat EK1100 in Box 50. (On every blowing press is assembled Ethercat EK1100 modules which function is to en ‘compensation, et). Inthe following picture is roughly represented what said it Tr pe calculated by means wheel the synchronis™ that the mould 7 le At every revolution of the the enabling signals in precise 2! re housed the VO MODULES ETHERCAT EK1100 thal mance the Towing, compensation, etc.) and receive the haw re instead managed by @ VO module fan INTELUGENT SOCKET IP2001 that receives the signals form VO ssble the valves related to blowing (seals, blowing valves, sofar: BOX 50 a Ivo ETHERCAT| PCIPLC GER [ vist cams |__inveRTER}=} joror pROFBUS ETHERCAT | —— wsnms Power sicnats. vo SIGHALG ETHERCAT (@ Scanned with OKEN Scanner