MACHINE SENSORS CONTROL PANEL CONVEYOR SYSTEM SYSTEM SENSORS...

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1 TABLE OF CONTENTS TABLE OF CONTENTS... 1 CONTROL PANEL MACHINE SENSORS... 5 CONVEYOR SYSTEM... 6 SYSTEM SENSORS... 6 INFEED BACKUP... 6 OUTFEED BACKUP... 6 CHANGEOVERS... 6 CONVEYOR GUIDES ADJUSTMENTS... 6 DETECTION SYSTEM-SENSOR ADJUSTMENT... 7 DETECTION SYSTEM-SENSOR ORIENTATION... 7 DIVERTER GUIDES ADJUSTMENTS... 7 CONVEYOR GUIDES ADJUSTMENTS... 8 MAINTENANCE... 9 TROUBLESHOOTING... 9 STARWHEEL SYSTEM SENSORS BOTTLE DETECTION LID ON BOTTLE REJECT ACKNOWLEDGE REJECT TRAY FULL STARWHEEL CLUTCH.. 10 CAP ON BOTTLE CAP HIGH REED SWITCH OUTFEED ACTUATOR REED SWITCH OUTFEED GATE REED SWITCH REJECT ACTUATOR CHANGEOVERS ANTI SPIN GRIPPER REMOVAL STARWHEEL PLATE STARWHEEL REMOVAL STARWHEEL GUIDE REMOVAL REJECT GUIDE REMOVAL INFEED GUIDE REMOVAL STARWHEEL ALIGNMENT Rebel PPC-111 Section 7 Page 1 / 33 - Rev.0

2 MAINTENANCE.. 13 MAINTENANCE.. 14 TROUBLESHOOTING LID APPLICATION SYSTEM SYSTEM SENSORS LID LOADED-VACUUM DETECTION CHANGEOVERS MAINTENANCE.. 18 TROUBLESHOOTING CAP FEEDER SYSTEM SYSTEM SENSORS TRAY LOADER SAFETY DOOR LOW CAP IN TRACK CAP CLEAR RELEASE POSITION TRAY IN POSITION CAP PICKUP DOWN POSITION CAP PICKUP UP POSITION TRAY EJECTOR REJECT/LOAD POSITION (REEDSWITCH) CHANGEOVERS SUCTION CUP SPACING ADJUSTMENT OVERHEAD SYSTEM CHANGEOVER TRAY EJECTOR POSITION CAP CONVEYOR SAFETY GUARD REMOVAL CAP CONVEYOR WIDTH ADJUSTMENT MAINTENANCE.. 22 TROUBLESHOOTING CAP FEEDING STARWHEEL CHANGEOVERS CAP FEEDING STARWHEEL HEIGHT ADJUSTMENT CAP FEEDING STARWHEEL REMOVAL MAINTENANCE.. 25 TROUBLESHOOTING TURRET SYSTEM SENSORS CAP IN PRETIGHT CHUCK PICK UP TURRET CHANGEOVERS TURRET HEIGHT ADJUSTMENT Rebel PPC-111 Section 7 Page 2 / 33 - Rev.0

3 CHUCK REMOVAL MAINTENANCE TROUBLESHOOTING FINAL TORQUE CHANGEOVERS HEIGHT ADJUSTMENT PRESSURE ADJUSTMENT CHUCK REPLACEMENT TORQUE LIMITER REMOVAL TROUBLESHOOTING EUROGUARD SYSTEM SENSORS SAFETY DOOR Rebel PPC-111 Section 7 Page 3 / 33 - Rev.0

4 CONTROL PANEL The control panel controls every system available on the equipment. From the control panel the user can adjust the various settings of each individual system as well as receive information and feedback on the machine status such as alarms, bottle count, and so forth. Some systems come equipped with a vision system, and the vision system output can be seen in a separate screen on the back of the control panel. (For more information about the vision system, see the manufacturer documentation). Rebel PPC-111 Section 7 Page 4 / 33 - Rev.0

5 MACHINE SENSORS # PART NUMBER DESCRIPTION # PART NUMBER DESCRIPTION 1 EPH191 Infeed Backup 14 EPH800 Cap High 2 EPH217 Bottle Detection 15 EPH801 Cap on Bottle 3 PAC377 Lid Loaded-Vacuum Detection 16 EPH802 Cap Low 4 EPH217 Lid on Bottle 17 EPH172 Safety Door EPH217 Cap in Pretight Chuck 18 EPH172 Tray Loader Safety Door EPH217 Reject Acknowledge 19 EPH532 Low Cap in Track 7 EPH217R Reject Tray Full 20 EPH532 Cap Clear Release Position 8 EPH191 Outfeed Backup 21 EPH217 Tray in Position 9 EPH651 Starwheel Clutch 22 PAC856 Cap Pickup Up Position 10 PAC880 Reed Switch Outfeed Actuator 23 PAC856 Cap Pickup Down Position 11 PAC1127 Reed Switch Outfeed Gate 24 CYL1046 Tray Ejector Reject Position (Reed Switch) 12 PAC1132 Reed Switch Reject Actuator 25 CYL1046 Tray Ejector Load Position (Reed Switch) 13 EPH651 Pick Up Turret Rebel PPC-111 Section 7 Page 5 / 33 - Rev.0

6 CONVEYOR SYSTEM The conveyor system s task is to move the bottles through the equipment and link up the various machines in a production line. SYSTEM SENSORS INFEED BACKUP This sensor detects bottles at the infeed of the equipment. If no bottles are detected for a set amount of time, the machine will go in standby. OUTFEED BACKUP This sensor detects bottles at the outfeed of the equipment. If no bottles are detected for a set amount of time, the machine will go in standby. CHANGEOVERS CONVEYOR GUIDES ADJUSTMENTS The conveyor guides can be adjusted both vertically and horizontally. In either case loosen the fastener and slide the guide to the desired position and retighten the adjustment to complete the change. There is no precise numerical adjustment for the guide spacing, the bottle should be able to travel freely on the conveyor but be constrained enough that it does not fall off the conveyor usually a ~3mm clearance is best. Rebel PPC-111 Section 7 Page 6 / 33 - Rev.0

7 DETECTION SYSTEM-SENSOR ADJUSTMENT The sensor can be adjusted both vertically and horizontally. In either case loosen the fastener and slide the guide to the desired position and retighten the adjustment to complete the change. DETECTION SYSTEM-SENSOR ORIENTATION Adjust the angle of the sensor so that the beam deflects perpendicularly off of the reflector. DIVERTER GUIDES ADJUSTMENTS To accommodate a different format the diverter guides may need to be widened or narrowed. Loosen the fasteners holding the diverter guides in place and slide them to the desired position in order to accommodate the new format. The gap needs to be wide enough for the bottle to pass unhindered but narrow enough so that the bottle does not fall. A ~3mm clearance is best. Rebel PPC-111 Section 7 Page 7 / 33 - Rev.0

8 CONVEYOR GUIDES ADJUSTMENTS The infeed sensor should detect the top of the bottle and verify that the guide rails do not interfere with the detection of the bottle. This will detect a lack of or fallen bottles at the infeed of the machine and will switch the machine mode to Stand-By until bottles are detected anew. The outfeed sensor should detect the bottom of the bottle and verify that the guide rails do not interfere with the detection of the bottle. This will detect bottle accumulation and will switch the machine mode to Stand-By until the accumulation dissipates. Rebel PPC-111 Section 7 Page 8 / 33 - Rev.0

9 MAINTENANCE 1 1 # DESCRIPTION LUBRICANTS INTERVAL 1 Lubrication of the conveyor chains and sprockets. Synco-Superlube 960Hrs TROUBLESHOOTING The conveyor does not work. Cause Solution The conveyor is not connected. Verify the connection. The fuse on the DC drive is burned out. Change the fuse (s) (there are 2 fuses on the drive). The switch on the control panel is not on. The speed dial is at 0. An emergency was activated. Belt is broken. Bearings seized. Turn the switch on. Increase the speed dial. Correct the problem, release the emergency and reset the machine. Remove and replace belt with new one. Remove and replace bearings. Rebel PPC-111 Section 7 Page 9 / 33 - Rev.0

10 STARWHEEL The center starwheel indexes the bottles in order for them to be processed by each of the stations. The starwheel has two anti-spin grippers at both the cap application turret and the final torque station. They are actuated by pneumatic cylinders and hold the bottle in place while the cap is applied. At the outfeed there are two possible scenarios: 1: A bottle is tagged as good 2: A bottle is tagged as a reject Good bottles, once they reach the outfeed are simply bumped by the outfeed actuator onto the outfeed conveyor. Tagged rejects on the other hand need to travel to the reject station. To ensure that the tagged rejects do not travel onto the outfeed conveyor a gate is actuated that blocks the path to the outfeed conveyor. After the strawheel indexes once more the gate is retracted and the reject actuator bumps the tagged reject into the reject station. SYSTEM SENSORS BOTTLE DETECTION This fiber-optic sensor detects bottles entering the infeed starwheel. The fiber-optic acts as a tracking sensor for the systems on the machine. If no bottles are detected the machine will not activate the systems when the empty starwheel pocket arrive at these same stations preventing any product loss. LID ON BOTTLE This sensor will detect if a lid is located on the bottle. If no lid is detected the station preceding the faulty detection will not be activated. The bottle will then be rejected. REJECT ACKNOWLEDGE This will indicate that a rejected vial traveled to the reject tray. REJECT TRAY FULL This sensor will detect if the reject tray is full. When the tray is full the machine will stop. STARWHEEL CLUTCH This photocell detects an excessive amount of torque on the system created by an object preventing the starwheel from indexing. A LED on the control panel will light up indicating a problem, correct the problem and reset the machine by pressing on RESET button and then the START button to restart the machine. CAP ON BOTTLE This fiber-optic sensor detects the presence of caps on bottles. If no caps are detected the bottle will then be rejected. Rebel PPC-111 Section 7 Page 10 / 33 - Rev.0

11 CAP HIGH This fiber-optic sensor detects the presence of caps on bottles that are too low. If too low caps are detected the bottle will then be rejected. REED SWITCH OUTFEED ACTUATOR This sensor monitors that position of the outfeed actuator that directs bottles onto the outfeed track. REED SWITCH OUTFEED GATE This sensor monitors the presence of the outfeed gate, which prevents tagged rejects from entering the outfeed track. REED SWITCH REJECT ACTUATOR This sensor monitors that position of the reject actuator that directs bottles onto the reject track. CHANGEOVERS ANTI SPIN GRIPPER REMOVAL Unscrew the thumbscrews and carefully remove the grippers. STARWHEEL PLATE Unscrew the starknobs indicated and lift the starwheel hub and plate carefully to remove them. STARWHEEL REMOVAL With the starwheel plate and hub removed lift the starwheel to remove it. Rebel PPC-111 Section 7 Page 11 / 33 - Rev.0

12 STARWHEEL GUIDE REMOVAL Remove the indicated starknobs and carefully lift the guide to remove it. REJECT GUIDE REMOVAL Unscrew the indicated starknobs and carefully lift the guides to remove them. INFEED GUIDE REMOVAL Unscrew the indicated starknobs and carefully lift the guide to remove it. Rebel PPC-111 Section 7 Page 12 / 33 - Rev.0

13 STARWHEEL ALIGNMENT To correctly be aligned the key starwheel positions are 2 and 4, which are below the cap turret pickup pocket and the final torque. 1 2 Once 2 is correctly aligned below the turret chuck, position 1 should be aligned with the cap infeed. Once 4 is correctly placed position 5 will be correctly aligned with the bottle infeed. Position 3 at the end of the adjustments should line up below the turret chuck that will place the cap on the bottle SENSOR HEIGHT ADJUSTMENT To adjust the height of the sensors, loosen the ratchet handle locking the adjustment in place and use the adjustment dial to modify the height of the sensor. MAINTENANCE 1 1 # DESCRIPTION LUBRICANTS INTERVALS 1 Lubricate up and down shaft and height adjustment screw Synco - SuperLube 960 Hrs Rebel PPC-111 Section 7 Page 13 / 33 - Rev.0

14 MAINTENANCE # DESCRIPTION LUBRICANTS INTERVALS 1 Lubrication of the indexing plate. Lubrication of the indexing cam. Synco - SuperLube 960 Hrs 2 Verify the condition of the anti-spin inserts N.A. Daily 3 Clean the starwheel of debris N.A. Daily TROUBLESHOOTING Starwheel does not start. Cause Solution No power to starwheel. Verify main power connection. Emergency has been triggered. Alarm has been generated (See alarm for description). Reset button is illuminated. Speed is set to zero. The system is not enabled on the control panel. Starting conditions have not been met. Start button was not pressed. Stop button was pressed. Breaker is triggered (if installed) Verify fuses (if installed) Relay is defective (if installed) Drive is defective. Release emergency pushbutton and reset the starwheel. Clear alarm and reset the starwheel. Press the reset button. Verify / change the value. Enable the system on the control panel. Verify starting conditions. Press the start button. Press the start button. Verify and / or reset the breaker. Verify and / or replace fuse(s). Verify and / or replace the relay module. Verify and / or replace the drive. Rebel PPC-111 Section 7 Page 14 / 33 - Rev.0

15 LID APPLICATION SYSTEM S Lids are stacked on the system between the four rods. As the chuck comes up, it opens up the rods, and picks up a lid that drops. Once that it picks it up the chuck flips over and places the lid on the bottle. SYSTEM SENSORS LID LOADED-VACUUM DETECTION This vacuum switch verifies that a lid has been picked up by the lid application chuck. Rebel PPC-111 Section 7 Page 15 / 33 - Rev.0

16 CHANGEOVERS LID APPLICATION SYSTEM HEIGHT ADJUSTMENT To adjust the height of the lid application system, set the machine in JOG mode. Start slowly jogging the machine and pay careful attention to the lid application system, it may crash into the machine if it is not adequetly adjusted. Jog the machine to the lowest cam position of the lid application system with the bottle in place, but if the system gets to low modify the height adjustments indicated below as needed. Once that the cam has reached its lowest positions, the final adjustments can be made. (Note: The final position of the lid applicatin system should be such that the chuck drops the lid when it is roughly 1mm above the bottle. ) Loosen the thumb screw located on the front side of the lid application system. Then adjust the height of the lid application station by referring to the set up sheets and the new bottle format needed. To raise and lower the lid application chuck travel path loosen the thumbscrew and move the spline shaft as needed. Rebel PPC-111 Section 7 Page 16 / 33 - Rev.0

17 LID HOPPER CHANGE To change the lid hopper unscrew the thumbscrew holding it in place and carefully remove the lid hopper. LID APPLICATION CHUCK CHANGE To change the lid application chuck, unscrew its supporting thumbscrews and carefully remove the chuck. Rebel PPC-111 Section 7 Page 17 / 33 - Rev.0

18 MAINTENANCE # DESCRIPTION LUBRICANTS INTERVALS 1 Lubrication of the shaft. Synco - SuperLube 960 Hrs 2 Lubrication of the height adjustment screw. Synco - SuperLube 960 Hrs 3 Verify that the suction cup is free and clean of any debris and dirt. N.A. Daily TROUBLESHOOTING Lids application system does not function correctly Cause Rod guide are bent. The lids are not being grabbed by the chuck Solution Straighten out the rod guides, for better lid flow The lids are too staggered they should be a straight column as much as possible There is not enough vacuum generated by the chuck verify the suction cup for blockages and debris Rebel PPC-111 Section 7 Page 18 / 33 - Rev.0

19 CAP FEEDER SYSTEM The cap feeder system is supplied with lids in trays. The trays travel along the conveyor and stops at the end. The caps are picked by an overhead suction cup system that grabs individual rows of caps and places them on the machine feeding conveyor. Once that all of the rows in the tray are taken, the tray is bumped off into the reject bin and a subsequent tray is brought to the same place to allow the overhead suction cup system to grab more caps. SYSTEM SENSORS TRAY LOADER SAFETY DOOR 1-4 These sensors will detect the position of the Tray Loader safety doors. When a door is opened the equipment will trigger an alarm displayed on the equipment s control panel. Once the door is closed the equipment will have to be restarted by pressing on the control panels reset button. If the alarm was properly dealt with the reset button light will turn itself off, if the door stays opened the reset button light will stay illuminated. Once the problem corrected the operator will be able to restart the equipment by pressing the start button. LOW CAP IN TRACK This is the fiber optic sensor on the end of the cap conveyor. If this sensor fails to detect caps in this portion of the chute the machine will stop the infeed of bottles, this will prevent containers passing through the machine when there are no caps in the cap supply chute. CAP CLEAR RELEASE POSITION This sensor is used by the overhead cap suction cups to indicate the position at which it is safe to drop the lids onto the cap conveyor. TRAY IN POSITION This sensor is used by the overhead cap suction cups to indicate that a tray of caps is in position. Rebel PPC-111 Section 7 Page 19 / 33 - Rev.0

20 CAP PICKUP DOWN POSITION This sensor will detect when the cap pickup system has reached its lowest position. CAP PICKUP UP POSITION This sensor will detect when the cap pickup system has reached its highest position. TRAY EJECTOR REJECT/LOAD POSITION (REEDSWITCH) This sensor is used by the tray feeding conveyor to only bring forth new trays when the tray ejector has returned to its load position after having ejected an empty tray. CHANGEOVERS SUCTION CUP SPACING ADJUSTMENT To adjust the spacing of the suction cups loosen the ratchet handle and slide the suction cup to the desired position. OVERHEAD SYSTEM CHANGEOVER To change the overhead for a different format remove the screws and carefully pull down the overhead. Rebel PPC-111 Section 7 Page 20 / 33 - Rev.0

21 TRAY EJECTOR POSITION To adjust the position of the tray ejector, loosen the ratchet and slide the ejector to the desired position. CAP CONVEYOR SAFETY GUARD REMOVAL To remove the cap conveyor safety guard unscrew all of the indicated thumbscrews and carefully lift the guard to remove it. CAP CONVEYOR WIDTH ADJUSTMENT To adjust the width of the conveyor loosen the thumbscrews locking the guide rails in place and slide the guide rails to the desired position. Rebel PPC-111 Section 7 Page 21 / 33 - Rev.0

22 MAINTENANCE # DESCRIPTION LUBRICANTS INTERVALS 1 Lubrication of the shaft. Synco - SuperLube 960 Hrs 2 Verify that the suction cups are clear of and dirt and debris. N.A. Daily 3 Verify that the conveyor is clear of and dirt and debris. N.A. Daily TROUBLESHOOTING Caps are not being picked up Cause Suction is not sufficient Solution Verify that there is no debris or dirt clogging the suction cups. Rebel PPC-111 Section 7 Page 22 / 33 - Rev.0

23 CAP FEEDING STARWHEEL The cap feeding starwheel takes caps from the cap feeding conveyor and prepares them for the turret to grab them and place them on bottles. CHANGEOVERS CAP FEEDING STARWHEEL HEIGHT ADJUSTMENT To adjust the height of the starwheel loosen the ratchet handle and raise or lower the starwheel to the desired height. Rebel PPC-111 Section 7 Page 23 / 33 - Rev.0

24 CAP FEEDING STARWHEEL REMOVAL To remove the capping starwheel remove the center starknob and carefully lift the starwheel hub and starwheel to remove it. CAP FEEDING STARWHEEL GUIDE REMOVAL To remove the cap feeding starwheel guides remove the indicated thumbscrews and lift up the guides to remove them. Rebel PPC-111 Section 7 Page 24 / 33 - Rev.0

25 MAINTENANCE 1 # DESCRIPTION LUBRICANTS INTERVALS 1 Clean the starwheel of debris N.A. Daily Rebel PPC-111 Section 7 Page 25 / 33 - Rev.0

26 TROUBLESHOOTING Starwheel does not start. No power to starwheel. Cause Solution Verify main power connection. Emergency has been triggered. Alarm has been generated (See alarm for description). Reset button is illuminated. Speed is set to zero. The system is not enabled on the control panel. Starting conditions have not been met. Start button was not pressed. Stop button was pressed. Release emergency pushbutton and reset the starwheel. Clear alarm and reset the starwheel. Press the reset button. Verify / change the value. Enable the system on the control panel. Verify starting conditions. Press the start button. Press the start button. Breaker is triggered (if installed) Verify fuses (if installed) Relay is defective (if installed) Drive is defective. Verify and / or reset the breaker. Verify and / or replace fuse(s). Verify and / or replace the relay module. Verify and / or replace the drive. Rebel PPC-111 Section 7 Page 26 / 33 - Rev.0

27 TURRET The turret is a system that is in continuous motion and is powered by air motors driven by a gear system. As the turret moves in a circular motion driven by the large gear beneath the machine, it picks up caps from the cap feeding starwheel and places them on bottles in the main starwheel. The chucks pick up the caps and as they place them on the bottle they spin such as to pre-tighten the cap on the bottle. SYSTEM SENSORS CAP IN PRETIGHT CHUCK This sensor will detect if the chuck is holding a cap. PICK UP TURRET This sensor calculates and keeps track of the turret height displacement. Rebel PPC-111 Section 7 Page 27 / 33 - Rev.0

28 CHANGEOVERS TURRET HEIGHT ADJUSTMENT To adjust the height of the turret, loosen the ratchet handle locking the adjustment in place and turn the handwheel to the desired height. CHUCK REMOVAL To remove the chucks carefully use a wrench to remove the fasteners keeping it in place. Rebel PPC-111 Section 7 Page 28 / 33 - Rev.0

29 MAINTENANCE # DESCRIPTION LUBRICANTS INTERVAL 1 Lubrication of the height adjustment screw Synco-Superlube 960 Hrs. 2 Lubrication of the up and down shaft Synco-Superlube 960 Hrs. 2 Verify the condition of the chucks and replace as necessary N/A Daily TROUBLESHOOTING The turret does not work. Cause Solution The air motors are not working Caps are not being picked up Check air is sufficient Verify air motor oil, after long standing time Verify that there is no debris or dirt clogging the suction cups. Rebel PPC-111 Section 7 Page 29 / 33 - Rev.0

30 FINAL TORQUE This system finalizes the cap application with the right amount of torque onto the bottles. CHANGEOVERS HEIGHT ADJUSTMENT Move the final torque system up or down until the desired height is reached. The numbers on the counter should correspond with the setup sheet. Rebel PPC-111 Section 7 Page 30 / 33 - Rev.0

31 PRESSURE ADJUSTMENT To adjust the pressure of the system, simply turn the knob clockwise to add pressure to the system to counter clockwise to remove. CHUCK REPLACEMENT Unscrew the chuck and remove it. TORQUE LIMITER REMOVAL Put a wrench on the shaft of the motor and a second one at the bottom of the chuck and turn them the opposite way until it gets loose enough for you to pull it out. Rebel PPC-111 Section 7 Page 31 / 33 - Rev.0

32 MAINTENANCE NCE # DESCRIPTION 1 Lubrication of the up / down shafts and height adjustment screw. LUBRICANTS Synco-Superlube INTERVAL 2 Verify the condition of the timing belts N.A. Daily 3 960Hrs 3 Lubrication of the cam and cam follower Synco-Superlube 960Hrs 4 Verify the condition of the chuck N.A. Daily TROUBLESHOOTING Caps are not completely tightened. Cause Height of the head is too high. The speed of the chuck is not fast enough. Caps break during operation. Cause Height of the torqueing system is too low. Bottles break during operation. Cause Height of the torqueing system is too low. Solution Adjust the height of the torqueing system. Adjust the speed of the torqueing chuck. Solution Adjust the height of the torqueing system. Solution Adjust the height of the torqueing system. Rebel PPC-111 Section 7 Page 32 / 33 - Rev.0

33 EUROGUARD The Euroguard is there to protect the machine s operator from any injuries. If a door on the Euroguard is opened while the machine is operating it will automatically stop the machine or if the machine is not in function it will not start because of the interlock switches mounted on the doors. This will prevent any injuries to the personnel and damages to the machine and its components. SYSTEM SENSORS SAFETY DOOR 1-6 These sensors will detect the position of the Euroguard doors. When a door is opened the equipment will trigger an alarm displayed on the equipments control panel. Once the door is closed the equipment will have to be restarted by pressing on the control panels reset button. If the alarm was properly dealt with the reset button light will turn itself off, if the door stays opened the reset button light will stay illuminated. Once the problem corrected the operator will be able to restart the equipment by pressing the start button. Rebel PPC-111 Section 7 Page 33 / 33 - Rev.0

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