Contiform Maintenance

1.

Blowing Wheel, Infeed/Discharge Starwheel /

Clamp Transfer to the Blow Mould
To adjust the blowing wheel at the infeed/discharge starwheel, remove the clamp from one arm and replace it using the adjusting device (3). / 3 The mould, to which this arm transferred, and the blowing nozzle of this station must be removed as well. Instead of the blowing nozzle, the adjusting tip (2) must be screwed into the blowing piston. Then, jog the starwheel to the transfer position. 2 As a rule, the zero reference arm according to the test record should be used here. Usually, arm number 1 is the zero reference arm (1). 1 1 Marks At the transfer position, the adjusting tip (2) should be set to allow for an admission at the mark (3) of one graduation (approx. 1 mm) up to Contiform S 16 and two graduations (approx. 2 mm) as of Contiform S 20, to compensate for the belt backlash at maximum machine speed. 231 1Contiform S 162 2Contiform S 20

T r a i n i n g M a n u a l

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Firstly loosen the 6 hexagon head screws (4) and turn the starwheel manually in machine operating direction past the correct position. The starwheel must then be turned back in the opposite direction until the correct position is reached. This is necessary to exclude any possible play from the transfer arm. If the position is correct, retighten the screws (4) with a torque of 45 Nm and check the position again. 64 45 Nm

Contiform Maintenance

Height Adjustment, Infeed/Discharge StarWheel /

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First, loosen the hexagon head screws on the tightener (1). 1

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Then loosen the hexagon socket screw (2). By turning the brass disk (3), you can move the complete infeed/discharge starwheel up or down, thus enabling the height to be adjusted precisely. Please make sure that, after height adjustment, the brass disk will be turned back 1/2 revolution, so that it does not closely fit the starwheel. 3 1/2

Training Manual

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The topmost mould carrier is the zero reference mould, and the arm identified with position 1 is the reference arm (measured in the factory)used for adjustment. Move the reference arm above the reference mould. Make sure that the preform is in the clamp. It should be adjusted in such a way that the distance between the lower edge of the perform neck ring and the upper edge of the mould shell amounts to 0.3 mm (using a feeler gauge) for the infeed starwheel and 0 mm for the discharge starwheel. 1 0.3mm 0mm Infeed/discharge starwheel: lowest arm, highest mould /

Contiform Maintenance

2.

Adjustment of the Heating Chain in Relation to the Infeed Starwheel of the Blowing Wheel
The heating chain must be adjusted at the transfer position to the infeed starwheel of the blowing wheel as follows.

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Check whether the position of the heating mandrel is centred to the clamp. If the heating mandrel is not positioned above the centre of the clamp, the position of the heating chain must be readjusted.

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Training Manual

Contiform Maintenance

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First, remove the cover plate (1) above the belt drive to allow for access to the oven drive unit. 1

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Then, loosen all inner screws (2) at the pulley. This will disengage the heating chain from the rest of the machine. Turn the main drive using the handwheel to exactly centre the clamp of the infeed starwheel above the heating mandrel of the oven. 2 Then, lock the hexagon socket screws (2) with a torque of 42 Nm and check the optimum state of the oven in relation to the machine. 42 Nm To test, jog some preforms through the machine.

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Contiform Maintenance

3.

Infeed Starwheel

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The infeed starwheel (otherwise known as the starwheel with chamfered pockets) must be readjusted if the heating mandrel fails to meet the centre of the preform neck finish. They are readjusted by means of the clamping set (6) provided in the centre of the infeed starwheel. To do so, a preform is jogged through the starwheel as far as the transfer position. If this position is not correct, this unit will need to be readjusted. 6

To do so, loosen all hexagon socket screws (1) and unscrew them a little. Now, completely remove three of the screws and screw them into the forcing-off thread (2), until there is a resistance. Now, turn these screws, one after the other, half a rotation each and repeat this procedure until the clamping set springs apart. Then return the screws to the position shown in (1). 1 32 1

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The infeed starwheel can now be turned manually until the transfer position is correct. It may be better to remove the centre guide (3). To do so, loosen the clip (4) and lift off the guide. In this way, the transfer position (5) is better visible. Slightly tighten the screws of the clamping set, check the transfer by jogging some preforms through the passage and readjust if necessary. If the transfer position is correct, evenly retighten the screws of the clamping set (1) in a diagonal order using a torque of 17 Nm. Refit the centre guide (3), if it has been removed, and lock with the clip (4). 34 5 17 Nm 34

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Contiform Maintenance

4.

Pyrometer Adjustment
1 Pyrometer

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Mandrel chain

A
Laser beam
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As shown on the drawing, the pyrometer should measure the temperature profile of at least 3 preforms! 3 The laser beam should be directed to the central preform of 5 preforms (A) in the heating zone, and should be set at such an angle that it meets all of the 3 preforms. If a preform is missing, it should not detect any gap with this setting. The 3rd layer of the heating tubes is the optimum height adjustment position for the pyrometer . 5A 3

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Training Manual

Contiform Maintenance

5.

Stretching Module to the Stretching Cam

Adjust the joint head (1) at the piston rod to set a gap (2) of 0.1-0.2 mm between the cam roller and the highest point of the stretch -ing cam, which is provided with a mark HP (highest point). To do so, check with the feeler gauge and readjust if required. 0.1-0.2 mmHP

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Contiform Maintenance

6.

Blowing Nozzle
The blowing nozzle must be adjusted as follows: there must be a distance of 0.7 mm between the blowing nozzle (1) and the blow mould. 1 0.7 mm

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Adjusting the Height of the Blowing Nozzle

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First remove the castle nut (1). Raise the blowing nozzle slide by hand (bottom picture) (2) and place a spacer (approx. 50 mm) underneath it (3) so that the setscrew (4) can be accessed. Then loosen the setscrew and, as shown in the bottom picture on the right, the blowing nozzle piston can be moved upwards or downwards by turning it using the spanner (5). When doing so, please make sure that the wrench stays in position to prevent the sleeve from also being turned, as can be seen in the picture. 12 350 mm 4 5

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Contiform Maintenance

7.
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Stretching Rod

To check or adjust the stretching rod, use the adjustment device (1) for base moulds. 1 At first, the appropriate base mould must be jogged to the adjustment device. Loosen the two threaded pins with hexagon socket at the side of the device (2), it is then possible to shift toward the inside. Exactly position the base mould roller (3) above the value (4) indicated on the horizontal part of the adjusting device and insert a feeler gauge between roller and adjusting device. The mould can now be opened and the base mould will remain exactly in the production position. 2 2 Machines of more recent design are adjusted using another adjusting device (1). It must be removed again after each checking or adjustment. The principle, however, is the same as in the illustration shown above. 1

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Then, insert a preform (5) and manually pull the stretching rod downwards until the stretching stopper completely butts against the counterpart (6). (See the picture on the next page). 5 The stretching rod height is correctly adjusted if the preform cannot be moved upwards or downwards but can easily be rotated. Otherwise, the height of the stretching rod must be readjusted, as shown in the following illustration.

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Contiform Maintenance

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Adjusting the Height of the Stretching Rod in Relation to the Base Mould

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Loosen the lock nut (8) at the stretching rod and turn the stretching rod upwards or downwards, by means of an openend wrench applied to the wrench side (9) of the stretching rod. Then, retighten the lock nut (8). Check this preset adjustment and repeat until the abovementioned criteria are met. 8 9 8

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Contiform Maintenance

8.

Adjustment of the Opening and Closing Movement at the Mould Carrier/

Checking the Proximity Switch Adjustment
Pressurize the pneumatic cylinder with 8-10 bar of compressed air. Use a filler gauge to adjust a distance of 2.2-0.5 mm (1) between the proximity switch and switching device.

0.2 -0.5 mm

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2 Bottom cylinder: 9.5 bar pressure 3 Moveable cam segment 8-10 bar 0.2-0.5mm 2 9.5 bar 3

Adjusting the Mould Carrier Control Lever

To loosen the tightener (1), turn out the 6 hexagon head screws (2) and screw in each respective adjacent thread again. 162 Please note that three of these six screws are screwed in more deeply than the others. The reason for this is that this tightener is mounted on 2 rings which must be separated by force independently from one another.
632

This means that the longer three Please note that the longer screws screws must be repeatedly tightened one after another for approximately must be separated first. half a rota-

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tion until the top clamping mechanism has been released. This must then be repeated with the shorter screws until the bottom clamping mechanism has been released. Now the control lever (3) has been released and can be readjusted. The 7th screw is used for centring between the top and bottom clamping mechanism. 37

Adjust the Main Lever

Gap measurement Move the mould carrier to the start of the locking cam. Press the mould-carrier side parts together slightly using a screw clamp, as can be seen in the picture on the left. Check with a feeler gauge whether the gap between locking shaft and hammer is 0.1 mm. The edge of the locking shaft should have plunged approx. 2 5 mm into the locking hammer for checking. 0.1 mm 2 5 mm

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Contiform Maintenance
Turn the machine in the direction of operation until the gauge (1) starts jamming at 0.2mm between shaft and hammer. This is the exact locking moment which should be used for fixing the tightener. 0.21

Feeler gauge 0.2 mm

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Firstly remove 8-10 bar from the main cam and leave 0.3 mm between the fixed segment and the cam roller. Then pressurise the main cam to 8-10 bar again. 8-10 bar 0.3mm8-10 bar

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Place a 8 mm spacer (1) underneath and tighten the tighener to the specified 27 Nm. 8 mm27 Nm

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Contiform Maintenance
Remove the 8-10 bar pressure from the main cam. Remove the feeler gauge (0.1mm), screw clamp and spacer. Pressurise the main cam to 8-10 bar again and once again check the 0.1 mm gap between the locking shaft (1) and the locking hammer (2). The mould must be able to be locked easily. 8-10 bar(0.1mm) 8-10 bar12 0.1 mm

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Contiform Maintenance

9.

Adjusting the Mould Shells

Check the height difference with a dial gauge. When doing so, place the dial gauge on the left (moveable) and right (fixed) mould-carrier side part. The left mould-carrier side part must be lower than the right so that the pressure pad does not experience any friction. Tolerance: -0.05 mm. If necessary, place an adjustment plate (1) underneath.
-0.05 mm

Left Side of the Mould Carrier

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Right Side of the Mould Carrier

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The right side of the mould carrier is the fixed side. The left side is the side which can be moved. It should be 0-0.5 mm lower than the right side. You must be able to close the mould gap once the blowing nozzles have been sealed against the preform neck finish. 0-0.5 mm

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Contiform Maintenance

10.

Adjusting the Mould Carriers

Adjusting the Mould Gap

Tighten the hexagon socket screws using a torque wrench with 20 Nm. 2 Tighten the hexagon socket screws using a torque wrench with 25 Nm. 1 20 Nm 2 25 Nm

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If repairs or other tasks must be performed at the mould carrier, please make sure that the mould gap (3) is correctly adjusted to 0.25-0.35 mm. It is very important to always check this gap width at four points. For small cavity machines, this mould gap should range between 0.25 and 0.30 mm, in heatset machines, 0.15 mm. In "H" machines, measurements are always performed on hot moulds. The hexagonal socket screws (1, 2) are used to fix the pressure pad (4). This so-called component will close the mould gap as soon as the blowing pressure is provided. 3 0.25-0.35 mm4 0.25 0.30 mm 0.15 mm"H" 12 This mould gap can be changed and/or adjusted, when (5) presses on (1). Afterwards, it is necessary to secure the adjustment screw (5). To do so, lock (6) on (5). 51/ 565

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Contiform Maintenance
At the interior of the mobile mould-carrier side part, the gasket must be tightly pressed into the recess during assembly. To do so, apply some silicone grease to the gasket. Afterwards, make sure that the pressure compensation remains mobile at a pressure of 0.5 bar, and the pressure is allowed escape. This is to make sure that the pressure compensation device does not jam and remains mobile. Afterwards, apply a pressure of 2 bar to the pad. Now the pressure must no longer escape (listen to check). 0.5 bar 2 bar

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6 mm Set the shock absorber (7) to 6 mm with the mould-carrier side parts being closed. The mould-carrier side parts should also be closed for adjusting the distance between the pressure component (8) and the mould carrier stop to 0.15 mm using a feeler gauge. 76 mm 0.15 mm

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Contiform Maintenance

11.

Replacement of the Mandrel

The mandrel should be replaced at the rear of the oven.

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This is the best possible assembly position. When doing so, you must make sure that the two cylinders (1) which keep the oven chain tight, are always held without pressure during assembly. 21

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Remove the plastic bearings (1). 1

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Loosen the screw (1) using a hexagon socket screw key. Remove the lock washer (2) and pull off the pin. 12

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Contiform Maintenance

12.

Belt Tension Frequencies

The belt tension frequencies must always be set at the side of the belt without the tension roller. When a belt is disassembled, it must be assembled again in the same running direction! If the original direction of operation is not known, a new belt must be used! If a used belt is fitted, the belt must be adjusted according to the tension frequency indicated in the "used" column (see below). Belts must not be retightened! A 20% loss of tension is normal! 120%

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Belt tensioning frequencies, 8-10 mould posiTions8-10

Belt 11
Belt 22 Belt 33 Belt 44

New 17.3 -18.1Hz 30.1 -31.6Hz 42.1 -44.2Hz 19.3 -20.3Hz

Used 14.5 -15.5Hz 25.2 -26.9Hz 35.2 -37.7Hz 16.2 -17.3Hz

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Contiform Maintenance

Belt tensioning frequencies, 12-14 mould Positions12-14

Belt 11 Belt 22 Belt 33 Belt 44 New 15.8 -16.6Hz 49.3 -51.7Hz 37.7 -39.1Hz 20.3 -21.2Hz used 13.2 -14.1Hz 41.3 -44.1Hz 31.2 -33.4Hz 17.0 -18.1Hz

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Belt tensioning frequencies, 16-18 mould positions16-18

Belt 11 Belt 22 Belt 33 Belt 44 New 14.4 -15.1Hz 35.6 -37.3Hz 30.6 -32.1Hz 20.7 -21.7Hz used 12.0 -12.8Hz 29.8 -31.8Hz 25.6 -27.4Hz 17.3 -18.5Hz

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Contiform Maintenance

Belt tensioning frequencies, 20-24 mould positions20-24

Belt 11 Belt 2*2* Belt 2**2** Belt 33 new 13.8 -14.5 Hz 35.3 -37.0 Hz 37.4 -39.2 Hz 23.2 -24.4 Hz used 11.5 -12.3 Hz 29.5 -31.6 Hz 31.3 -33.4 Hz 19.4 -20.8 Hz

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2*

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Contiform Maintenance

13.

Overview of the Torques

Oven Infeed Starwheel, Cone Tightener

17 Nm 17 Nm

Blowing Wheel Infeed/Discharge Starwheels

/ 45 Nm: M10 hexagon head 41 Nm: tightener 45 Nm: M10 41 Nm:

Control Lever for Opening/Closing

/ 27 Nm

Blowing Slide and Stretching Slide

30 Nm

Blowing Nozzle Block

50 Nm

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Mould Compensation in the Mould Carrier

1 4x20 Nm 2 8x25 Nm

Flange for Stretching Rod

30 Nm

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Contiform Maintenance

Securing the Base Mould

1 M6 = 7 Nm

Securing the Mould and Mould Holder

1 Mould secured at: M8 = 12 Nm 1 M8 = 12 Nm 2 Mould holder secured at: M6 = 10 Nm 2 M6 = 10 Nm

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