heat sealing instruction manual

8/12/2019 HEAT SEALING Instruction Manual

1/24

LONGHILLELMSTONE HARDWICKECHELTENHAMGLOS.GL51 9TYENGLAND

Tel.: +44.(0)1242.680.680Fax: +44.(0)1242.680.909

Email: [email protected]

INSTRUCTION MANUALAUTOMATIC LID SEALING MACHINE TYPE LS4

LS4 - J17998

Issue 3

19/10/2007

T.B.S. ENGINEERING LTD


2/24

INSTRUCTION MANUAL

T.B.S. AUTOMATIC LID SEALING MACHINE

TYPE L.S.4.

(Right to Left)

Supplied to : EXIDE INDUSTRIES LTD.

HALDIA - INDIA

Machine No. : J17998

Electrical Supply : 415V 3 phase 50 Hz

Neutral & Earth


3/24

T.B.S. Automatic Lid Sealing Machine, Type L.S.4.

Table of Contents

1. General Data ......................................................................................................................... 1

2. Performance ......................................................................................................................... 23. Installation ............................................................................................................................ 3

1. General ..................................................................................................................... 3

2. Air Supply.................................................................................................................. 3

3. Electrical Supply ....................................................................................................... 3

4. Ventilation ................................................................................................................. 3

4. Setting Up Procedure .......................................................................................................... 4

1. Lid Box Platen........................................................................................................... 4

2. Lid Holder.................................................................................................................. 4

3. Box Positioning(1sttime) .......................................................................................... 6

4. Check Box Melt......................................................................................................... 8

5. Running the Machine........................................................................................................... 9

6. Quick Change Platen Facility............................................................................................ 10

7. Automatic Lid Loading ...................................................................................................... 13

1. Setting Up Procedure.............................................................................................. 13

2. Running the Lid Loader........................................................................................... 13

8. Maintenance ....................................................................................................................... 14

1. Daily ........................................................................................................................ 14

2. Air Cylinder Adjustments......................................................................................... 14

3. Automatic Grease Pump......................................................................................... 14

9. Standard Spares and Tools............................................................................................... 15

10. Long Term Spares............................................................................................................ 16


4/24

T.B.S. Automatic Lid Sealing Machine, Type L.S.4. Page 1

1. General Data

Machine Type ..................... L.S.4.

Machine N ......................... J17998

Electrical Supply ................. 415V 3 phase 50 Hz - Neutral & Earth

Air Pressure........................ 80 - 100 psi (5.6 - 6.8kg/cm2)

Air Consumption ................. 0.43m/min free air compressed to 5 bar

Exhaust VentilationRequired ............................. 0.8 m/s at 25mm H2O

Overall MachineDimensions......................... Height ........... 2.55m

Length............. 3.3m (with lid loading)

Width............. 2.28m (with lid loading)

Machine Weight..................


5/24


2. Performance

Cycle Time ............................. Depending upon box characteristics,up to 180 cycles / hour

Machine Capacity ................... Battery sizes falling within the following dimensionsmay be processed:

Length..180mm-540mmOverall

Height...175mm-295mmDimensions

Width....120mm-300mm


6/24


3. Installation

1. General

The machine will be received as one unit complete with one set of tooling asstandard. It should be securely mounted on a solid flat base and levelled byadjustment of its four 16mm levelling screws. Adjacent gravity conveyors shouldbe adjustable in height to 800mm to enable the battery supply to flow smoothly.Bolt the machine in position using 4 off M16 fixing bolts.

If supplied with Auto Lid Loading, use the jacking feet to support its weight.

2. Air Supply

Connect a clean, dry, compressed air supplyof 5.6 - 6.8kg/cm

2(80 - 100 psi).

Set the pressure regulator to 5.6kg/cm2.

3. Electrical Supply

Connect a 3 phase supply, neutral (whereappropriate) and earth to the electrical panelsituated at the side. Make the appropriateelectrical connections in accordance with thewiring diagram.

4. Ventilation

Ventilation of suitable capacity should be connected to the machine through the200mm connection.

Supply line


7/24


4. Setting Up Procedure

The following instructions are written as though new tooling is being offered for the firsttime. The machine is equipped with a number of devices to allow rapid changeover

after initial setting, these are pointed out in the text.

Similarly, the procedure is the same whether one or two batteries are processed duringeach cycle.

It is assumed that there is no tooling fitted to the machine.

Before commencing, isolate both air and electrical supplies. The platen tooling must bechanged cold to avoid injury.

1. Lid Box Platen

a) If the quick change platen facility is not fitted then change the platens from thefront of the machine. Pull the platen forward and position the lid tooling overthe appropriate fixing holes. Bolt the tooling into position using new M8 x 20long socket head cap screws and the special spring washer (LS 116). It isimportant to use new screws smeared with anti-seize. Old screws are likely tofracture. Do not over-tighten the screws.

b) Repeat the operation for the box tooling.

c) Push the platen to the back of the machine.

2. Lid Holder

a) With the lid holder on the bench, first check the operation of the lid clamp.Place lid in position using locating guides, see Fig. 1 and 2. Operate theclamp by hand with a lid fully in position. Make sure lid is clamped securely.

Fig. 1


8/24


Fig. 2

b) Use two people to position the lid holder onto the main head ram. Tighten thetwo swing bolt retainers.

c) Connect the pneumatic pipes using the quick-release couplings.

d) Plug in the lid sensors. Note: If single lids, only one is powered. The correctsensor is plugged into position 1. See Fig. 3.

Fig. 3


9/24


10/24


Fig. 6

e) Place the lid(s) on the lid holder and clamp up.

f) Lower the head by venting the air to the head cylinder by means of the ballvalve located on the head cylinder. Move the boxes to align with the lids.Select battery stop auto, position the front rail and finger stops to box.

g) Adjust the clamp rail to give approximately 2mm of clearance on the box.

h) Operate the box clamp to check alignment.

i) Set the screwed rods as a position reference for both stop and front rail. Makea note of the position used for the battery type so that future setting requiresonly 3(d) and (g) to be carried out with the stops and front rail being positionedon the screwed rods. See Fig. 7.

Fig. 7

j) Close the guards and raise the head by means of the head cylinder ball valve.Remove the guard override switch so that automatic operation is obtainable.


11/24


4. Check Box Melt

a) Select manual head up, cradle down, platen back.

b) Place a box or boxes with loose lids against the front rail and stops. Clamp thebattery. Close guards.

c) Bring platen forward then select cradle up for approximately 4 secondsallowing the box sealing face to melt. Lower cradle.

d) Unclamp the box and check the melt. Adjust as per 3(g).

e) Repeat the same procedure for the lid. The melt is adjusted by the adjustingscrew on top of the head assembly. The amount of melt is equal to the gapbetween the compensating block and adjusting screw.


12/24


5. Running the Machine

Note: No attempt should be made to operate the machine without:-a) all guards in position.

b) ensuring that no other object other than battery boxes with loosely positionedlids enter the machine or damage to the heater platen and lid clampingassembly will result.

a) Set heating platen controller to required temperature 350C nominal and switch onheater.

Note: The heating platen takes approximately 20-30 minutes to attain 350C. Themachine will not run until the temperature is within the lower limit set on thetemperature controller.

b) Set heating time (4 seconds nominal).

c) Set cooling time (6 seconds nominal).

d) Check air supply 5.6 kg/cm (80 psi).

e) Select box clamp auto, head up, platen back, cycle auto, battery stops auto, cradledown, lid clamp.

f) Select automatic.

g) Press start button.

h) Allow one or two boxes and lids into the machine and allow a full automatic cycle tooccur.

After sealing, check alignment of box to lid and adjust the stops and front rail asnecessary.

Cut up a seal and check it is secure.

The machine is now ready to run.


13/24


6. Quick Change Platen Facility

This feature is an optional extra and allows very rapid type change by allowing theheater platens to be changed for the next product type whilst the machine is running.

a) Fit the new platens as per 1a, b and c. See Fig. 8.

Fig. 8

b) Connect the thermocouple probe and heater plug and close the guard.

c) The platen will attain the temperature set on the small temperature controller withinthe main panel.

d) When ready to change the tooling, ensure that proper heat resistant clothing is wornincluding gloves and apron.

e) Lift up and hook in position the rear guard panel. See Fig. 9.

Fig. 9

f) Lift up the hinged guard.


14/24


15/24


j) Position the new platen and slide forward onto the rails. Connect the drive latch andplug in the thermocouple and heating sockets. Replace guards and turn on theplaten heating.

IMPORTANT NOTE

When coupling up the platen drive link, it is essential that the flats on the platenhandle face towards the platen (see diagram).

Failure to observe this instruction will result in the tooling being out of register withthe box and lid when the platen moves forward to the melt position.

k) Operate the platen forward / back in manual once or twice so that the limit switchrollers are correctly aligned.

l) The spare platen can be allowed to cool for changeover.


16/24


7. Automatic Lid Loading

1. Setting Up Procedure

a) Select the correct lid sticks for the lid type to be run. Thread the lids onto thesticks and retain into position using the retaining clips provided. See Fig. 1.

b) Fit the correct positioning plate. See Fig. 2.

c) Load the four cassettes onto the central hub location ensuring the dowel islocated in the groove on the cassette cross bar. Lock into position.

d) Repeat this operation 4 times by closing all guard doors, selecting manual andpressing the index button. This will index the cassette system to the next stationready for changing. It is easier to change cassettes one at a time rather than

removing all four at once and then loading four new cassettes.

e) With the four cassettes in position, check the operation of each one byselecting lid feed up switch. The cams should just go flat with the operatingbar. Adjust the operating bar if necessary. See Fig. 4.

f) Position the cassette at the loading angle using the support wedge as shown inFig. 3. Slide up into position a stack of lids, pushing up on the sticks to ensurethey fully engage in the top catch assembly. See Fig. 6. The fingers are heldapart using special tool C19366 as shown.

Release the fingers and lower the cassette into its normal position. Set the lid

place fingers by slackening the clamp screw and pushing them against theskirt of the lid. Once the fingers have been set, remove the lid retaining clipsfrom the sticks. See Fig. 7.

g) Repeat (f) for the three remaining cassettes.

h) Check the manual operation of each cassette by repeating (e) for each station.

2. Running the Lid Loader

Clear any lids from the lid place trolley.

Select: Lid trolley outLid feed downLid placing auto

The lid loader will function as part of the main machine sequence. Should themachine be stopped when lids are in position on the trolley, it will be necessary toclear these before pressing the start button.

If small batches of a special lid type are to be run, it will probably be easier to runthe machine conventionally by isolating the lid loader (select lid placing manual)

and feeding the machine with boxes and loose covers.


17/24


18/24


9. Standard Spares and Tools

MACHINE SPARES PACKING LIST (BO ITEMS)

Customer EXIDE INDUSTRIES LIMITEDRef: J17998

Related M/Cs

Project: 4250

LID SEALING MACHINE

Iss.: B 02/07/2007

J17998LS4BJ18040LT3

J18035SCT4

J18036SW6

BO 010LS4 STANDARD SPARES

Part Number Qty Description

Iss: 1 26/03/2007

220 20 000 1 047 25 SOC HEAD CAP SCREW

220 20 000 1 052 25 SOC HEAD CAP SCREW

225 10 228 3 001 1 SET OF STUD STOP ADJUSTERS

232 11 000 3 001 12 S/COIL RECT/SEC SPRING WASHER

910 10 000 1 013 1 COMBINATION SPANNER 13 A/F

910 20 000 1 001 1 OPEN-ENDED SPANNER 08-10 A/F



910 30 000 1 001 1 RING SPANNER 17-19 A/F

920 10 000 1 001 1 ALLEN KEYS 02-10 A/F

950 40 139 1 001 1 HIGH TEMPERATURE GREASE

950 40 140 1 001 1 ANTI-SIEZE COMPOUND

950 40 142 1 001 1 COTTON GLOVES

950 40 286 1 001 1 AIR FILTER


19/24

10. Long Term Spares

SPARES IDENTIFICATION LIST

LS4BCustomer:

J17998

EXIDE INDUSTRIES LIMITED

IC1 Issue 05/10/2007

Job number J17998

Part number Schedule Item Qty Description

BO 082 25211 40 000 1 003 0- LOCKNUT

BO 082 8231 10 000 1 005 0- FORM A PLAIN STEEL WASHER

BO 082 12231 10 000 1 006 0- FORM A PLAIN STEEL WASHER

BO 082 10410 10 102 1 135 0- BUSH

BO 082 11440 10 102 1 005 0- THRUST WASHER

BO 082 24470 30 000 1 004 0- M6 STRAIGHT GREASE NIPPLE

BO 082 18500 20 000 1 001 0- 08B1#

BO 082 1500 22 000 1 001 0- SPRING CLIP

BO 082 21511 10 292 1 023 0- CHAIN GUIDE/CHANNEL

BO 014 3560 20 000 1 021 0- T/LOCK BUSH

BO 082 27575 15 318 1 083 0- GEARMOTOR 0.37Kw 87,5rpm

BO 082 26580 10 203 0 001 0- TENSIONER SPAN BOX

BO 082 15810 10 320 1 011 0- FRICTION ACCUMULATION ROLLER

Page 1 of 6 Printed 05/10/2007


20/24

Customer:

J17998


LS4 Issue 05/10/2007

Job number J17998


BO 001g 2E105 10 111 1 005 0- HEAD, SPRING RETURN

BO 001i 2E 0-

BO 001g 2E105 10 111 1 006 0- FIXED BODY/CONTACT ASSY

BO 001i 2E 0-

BO 001g 2E105 10 111 1 010 0- ROLLER LEVER STEEL

BO 001i 2E 0-

BO 001i 2E105 40 107 1 001 0- GUARD SWITCH

BO 001f 1E105 70 321 1 006 0- LONG RANGE IND SENSOR (7mm)

BO 001b 11110 10 321 1 001 0- MAGNETIC CYL. SENSOR

BO 001h 2E110 50 321 1 003 0- M18 DIFFUSE PHOTOCELL

BO 001g 2E112 10 144 1 005 0- MINIATURE PLUG

BO 001g 2E112 10 144 1 006 0- INSULATING BOOT

BO 003 17112 10 204 1 003 0- 40A MODULE, TURNED CRIMP MALE

BO 001g 2E112 10 204 1 004 0- 40A MODULE, TURNED CRIMP FEM

BO 003 18112 10 204 1 005 0- 4.0mm TURNED CRIMP MALE PINS

BO 001g 2E112 10 204 1 006 0- 4.0mm TURNED CRIMP FEMALE PIN

BO 001g 2E112 10 204 1 021 0- HBE 6 PANEL BASE WITH LID

BO 003 14112 10 204 1 022 0- HBE 6 SIDE ENTRY HOOD (PG16)

BO 003 16112 10 204 1 030 0- 2 WAY FEMALE FRAME

BO 001g 2E112 10 204 1 031 0- 2 WAY MALE FRAME

BO 001b 29115 10 321 1 003 0- 5M 90 DEG CONNECTOR, M12 4 PIN

BO 001f 2E115 10 321 1 005 0- 10M 90 DEG CONNECTOR, M12 4PIN

BO 001h 2E 0-

BO 003 11130 10 120 1 004 0- THERMOCOUPLE

BO 001g 2E130 15 120 1 003 0- THERMOCOUPLE SOCKET

BO 003 8160 10 147 3 017 0- HEATER 1200W 230V 12.625"lg 24"tails HEATING ELEMENT

BO 003 12160 10 147 3 018 0- HEATER 1600W 230V 13"long 24"tails HEATING ELEMENT

BO 003 5190 10 000 1 006 0- NEUTRAL LINK

BO 001e 95210 60 164 1 003 0- M10 TEE NUT

BO 001b 23211 40 000 1 005 0- LOCKNUT

BO 001e 90 0-

BO 001h 2E 0-

BO 001b 12211 40 000 1 011 0- LOCKNUT

BO 010 3225 10 228 3 001 0- SET OF STUD STOP ADJUSTERS

BO 001e 94231 20 164 1 002 0- JIG WASHER

BO 010 4232 11 000 3 001 0- S/COIL RECT/SEC SPRING WASHER

BO 001b 17260 10 164 1 001 0- LOCATION PIN

BO 001b 18260 10 164 1 003 0- LOCATION PIN

BO 001f 2E260 20 164 1 002 0- SPRING PLUNGER

BO 001c 39260 20 164 1 007 0- INDEX PLUNGER

BO 001i 2E270 10 000 1 001 0- 606SA CHROME HANDLE

BO 001f 2E270 10 164 1 033 0- CLAMPING HANDLE

BO 001f 1E270 10 164 1 034 0- CLAMPING HANDLE

BO 001e 92270 10 164 1 035 0- CLAMPING HANDLE



21/24

Customer:

J17998


LS4 Issue 05/10/2007

Job number J17998


BO 001c 48270 10 164 1 043 0- CLAMPING HANDLE

BO 001f 2E295 10 118 1 004 0- COMPRESSION SPRING

BO 001d 65295 10 118 1 015 0- COMPRESSION SPRING

BO 001i 2E297 30 000 1 001 0- 13 BRASS BULLET CATCH

BO 001i 2E297 30 000 1 002 0- 3" x 1" ALUMINIUM BARREL BOLT

BO 001i 2E297 40 304 1 001 0- CABINET BARREL LOCK

BO 001b 13300 00 105 1 022 0- 32x80 STROKE CYLINDER

BO 001d 54300 00 105 1 043 0- 80x150 STROKE CYLINDER

BO 001c 34300 00 105 1 052 0- 100x200 STROKE C/TRUNNION CYLINDER

BO 001c 44300 00 105 1 087 0- 32x050 STROKE CYLINDER

BO 001e 89300 00 105 1 089 0- 32x25 STROKE CYLINDER

BO 001h 2E 0-

BO 001b 10300 01 105 1 016 0- 80x250 STROKE MAG.CYLINDER WITH VITON SEALS

BO 001f 1E300 15 117 1 002 0- 20x25 STROKE CYLINDER

BO 001d 55305 00 105 1 015 0- 80/100 PISTON ROD CLEVIS

BO 001d 56305 00 105 1 019 0- 80 REAR MALE TRUNNION

BO 001d 57305 00 105 1 022 0- 80 REAR TRUNNION

BO 011 6360 10 117 1 007 0- BANJO FLOW REGULATOR

BO 011 3365 10 221 1 002 0- CHECK UNIT 1/8" BSP

BO 011 4365 10 221 1 003 0- CHECK UNIT ADAPTOR 1/8" BSP

BO 011 2370 30 109 1 003 0- 1/2" BALL VALVE, VENTED

BO 011 5385 40 116 1 002 0- NON RETURN CHECK VALVE

BO 011 7385 50 116 1 003 0- POPPET VALVE

BO 003 2400 40 110 1 007 0- DRAWN CUP NEEDLE ROLLER BEARIN

BO 001d 60400 40 110 1 008 0- DRAWN CUP NEEDLE ROLLER BEARIN

BO 001d 61400 40 110 1 015 0- INNER RING FOR NEEDLE BEARING

BO 001c 30405 10 168 1 001 0- LINEAR BEARING WITH SEAL

BO 001b 14405 10 168 1 003 0- LINEAR BEARING WITH SEAL

BO 001c 47410 10 102 1 002 0- BUSH

BO 001f 2E410 10 102 1 019 0- BUSH

BO 001f 2E410 10 102 1 034 0- BUSH

BO 001f 1E410 10 102 1 044 0- BUSH

BO 001h 2E410 10 102 1 045 0- BUSH

BO 001e 91410 10 102 1 051 0- BUSH

BO 001d 59425 10 103 1 030 0- SELF LUBE BEARING UNIT

BO 001f 2E440 10 102 1 004 0- THRUST WASHER

BO 001d 62440 10 110 1 002 0- BEARING WASHER

BO 001d 63470 30 000 1 004 0- M6 STRAIGHT GREASE NIPPLE

BO 001c 41730 10 000 1 002 0- 'O' RING

BO 001d 73750 10 134 1 015 0- HEX JAM NUT

BO 001d 72750 10 134 1 026 0- SHOCK ABSORBER

BO 001d 58750 10 161 1 001 0- SHOCK ABSORBER

BO 001b 28750 10 161 1 003 0- SHOCK ABSORBER



22/24

Customer:

J17998


LS4 Issue 05/10/2007

Job number J17998


BO 001l 2E950 40 286 1 001 0- AIR FILTER

BO 001i 2E950 46 000 1 002 0- PERSPEX SHEET 940x412x8 THICK



23/24

Customer:

J17998


LS4B Issue 05/10/2007

Job number J17998


D65803310 00 121 1 059 0- ISO 1 5/2 SOL/SOL VALVE

D65803310 00 121 1 061 0- ISO 2 5/2 SOL/SOL VALVE

D65803355 10 121 1 006 0- FILTER

D65803360 20 121 1 019 0- PRESSURE REGULATOR 3/8"

D65803360 20 121 1 026 0- PRESSURE REGULATOR 1/4"

D65803360 20 121 1 034 0- REGULATOR

D65803363 10 121 1 003 0- LUBRICATOR



24/24

heat sealing instruction manual

Documents