R24 rimmer User Manual-3

• MILACRON® Muller UK & Ireland Group LLP UR Series Reciprocating Screw Blow Molding System R24 Rotary Trimmer 02/19 E 2016 Milacron LLC All Rights Reserved

Trimmer Start Up and Operation This section describes the procedures for starting and operating the Rotary Trimmer 24 (RT24). ! WARNING Do not attempt to set up or operate this machine, or perform maintenance on it, until you read, know and practice all the safety instructions in this manual. Know and practice safety rules set forth by your company. Failure to follow these instructions may result in serious personal injury and/or machine damage. Sequence of Operation The typical sequence of operation is as follows: a. A conveyor transports the blowmolded product from the blowmolding machine to the trimmer. Side rails on the conveyor guide the parts in the desired orientation. b. As the products enter the trimmer unit an infeed screw receives the them, timing and spacing their movement into the nest tool carousel. c. The nest tool carousel receives and captures the products from the infeed screw. It rotates them through the meshpoint of the trim tool carousel where the trim tooling removes flash. d. A conveyor transports the deflashed containers from the trim unit. 10839794_2 Trimmer Start Up and Oper - 1 02/2019

Starting and Operating the Machine ! WARNING Ensure proper operation of all safety doors and interlocks. Do not defeat their purpose by attempting to override them. Keep all fixed guards secured and in place. Maintenance and operating personnel must always check for proper operation of these devices prior to operating the machine. Under no circumstances should they ever be removed, bypassed, or modified. Failure to follow these instructions may result in serious personal injury and/or machine damage. Perform the following tasks before starting or cycling the machine: a. Make sure the trimmer has been properly installed according to the instructions in the Machine Installation section. b. Make sure all guards and doors are closed and secured. c. Turn the machine's main power disconnect switch to the ON position. Use the following steps to start and run the machine: a. Press the SAFETY RESET push button. b. Turn the keyed switch to RUN mode. c. Press the CYCLE ON/OF for Rotary Carousels button. d. Press the CYCLE ON/OF for Conveyor button. Trimmer Start Up and Oper - 2 10839794_2 02/2019

Cycle On/Off for Cycle On/Off Setup Safety Reset Rotary Carousels for Conveyor Emergency Stop Touchscreen Display Terminal Operator Control Panel Operator Control Panel Buttons and Functions Button Function CYCLE ON/OFF For Rotary Carousels This switch activates the rotation of the rotary carousels and CYCLE ON/OFF For Conveyor turns off the carousel rotation. SETUP This switch turns the conveyor On or Off SAFETY RESET This keyed switch allows the operator to choose between run COUNTER mode (clutch is engaged and the trimmer cycles continuously) EMERGENCY STOP and setup mode (the clutch is disengaged so the operator can turn the carousels freely). TOUCHSCREEN DISPLAY TERMINAL Press this lighted button to reset the safety system relays when all safety doors are closed. This display shows the number of parts trimmed. Press Emergency Stop to stop all machine functions. Pull out to reset the button. Emergency Stop shuts down all power except to the microprocessor. Use this touchscreen display panel to view the status of all safety doors. The red lighted buttons indicate a safety door is open. 10839794_2 Trimmer Start Up and Oper - 3 02/2019

Part Accumulation Timer Setup for Rotary Trimmer Trimmers with Logo PLC Control Note: For additional information, refer to the Rotary Trimmer Electrical Schematic Drawings supplied with the machine. Timer Setup Information B40: 2.0 Sec Delays brake from engaging when the stop button is used or a safety gate is B02: 1.0 Sec opened. B38: 3.0 Sec B04: 3.0 Sec Delays brake from engaging when the stop safety gate is opened. This works in B36: 1.0 Sec addition to B40. B31: 2.0 Sec B42: 2.0 Sec When an exit jam is detected from PE-5, this timer runs and delays the drive run B20-ON: 2.0 Sec signal from dropping out. B20-OFF: 3.0 Sec B46: 3.0 Sec This timers runs after B38 times out. When an exit jam has been detected the timer delays the brake from engaging after the drive run command has dropped out. This is an ON-delay timer to delay the drive run command from turning on before the brake disengages. After the last bottle has cleared PE-4, the delay timer times out and stops the drive run command. Delay timer runs when bottles have backed up to PE-2. This delays the drive run command from turning on and works with B36. When the bottles have backed up to PE-3, the ON-delay timer runs. This delays the trimmer high speed command until the ON-delay time has timed out. After the bottles have cleared PE-3, the OFF-delay timer runs. This allows time for the bottles to clear PE-2 before the trimmer high speed command drops out. When the bottles have cleared PE-2 this delay timer runs. This will delay the trim- mer high speed command from dropping out. This works with B20 OFF-delay. Trimmer Start Up and Oper - 4 10839794_2 02/2019

Trimmer Pinch Points The conveyors, infeed screw, and rotating carousels are all potential pinch points for parts as they move through the system. Parts may become pinched, snagged, or jammed in these areas as they are processed. ! WARNING Keep hands free of moving parts and pinch points. The gears, belt, chain, conveyors, infeed screw and rotating carousels are all potential pinch points. Use extreme care when working in or around these areas. Failure to follow these instructions may result in serious personal injury and/or machine damage. Note: If a jam is detected on the infeed, the trimmer will automatically shut down. Use the following steps to clear obstructions: a. Push the CYCLE ON/OFF to OFF position. b. Turn the SETUP (keyed) switch to the Set Up position. c. Open the safety doors. d. Use a plastic or wooden implement (not metal) to clear the jam. The carousels may be rotated manually if needed. e. Close the safety doors and push the SAFETY RESET button to reset the safety relays. f. Turn the SETUP (keyed) switch to the Run position. g. Push the Rotary Carousels and Conveyor CYCLE ON/OFF switches to the ON position. 10839794_2 Trimmer Start Up and Oper - 5 02/2019

Control Screens Primary Screen Traditionally the HMI application PRIMARY screen shares primary functionality with the MONITOR screen. It is used to login/logout of the screen application. The open book button on the bottom of all screens takes user to this screen. Primary Screen Trimmer Start Up and Oper - 6 10839794_2 02/2019

Monitor Screen The MONITOR screen is the primary screen for the RT24. It is the default door alarm screen when the DOOR ALARMS OFF is selected on the MACHINE SETUP SCREEN screen. It opens when a trimmer door is not safe. It is accessible from most screens by pressing the Information button “i” at the top of the screen. Open doors are indicated by a grey pilot light and red when closed. Line Control photo eye status are shown in green when on and grey when off. The bottles per minute field (BPM) is calculated using trimmer drive RPM versus turret gear reduction and represents the number of containers that can pass through the trimmer at any given moment when trimmer is in AUTO CYCLE. The information button on the MONITOR screen toggles user to the TRIMMER STATISTICS screen. The directional arrow buttons at the top of the screen toggle user thru the TRIMMER DIAGNOSTICS screens. The SYSTEM LOG at the top of all screens takes user to a SYSTEMS DIAGNOSTICS screen. The buttons on the bottom of this and all other screens, allow user to access the remainder of the RT24 trimmer controls. RECIPE screen access is limited to administrator users. Monitor Screen 10839794_2 Trimmer Start Up and Oper - 7 02/2019

Drive Control Screen The DRIVE CONTROL screen is used to set Trimmer Speed / Trimmer HI Speed setpoints. Drive RPM, drive load in AMPS and drive AMPS Alarm Setpoint are also diplayed. With the appropriate user access, user can write to a setpoint field and is displayed in white. When a setpoint is displayed in lite blue user only has read access to setpoint fields. DRIVE SETUP is accessed by pressing the DRIVE SETUP button at the top of the screen. The DRIVE CONTROL screen is accessed by pressing the Motor button on the bottom of all screens. Drive Control Screen Trimmer Start Up and Oper - 8 10839794_2 02/2019

Drive Setup Screen The DRIVE SETUP screen allows the user to set the Turret Drive Accel and Drive Decel Duration Times by modifying the Drive Accel Time / Drive Decel Time setpoints. Timers Actuals indicate the timers running and completing. Drive accel/decel timers are adjusted to control container behavior when starting and stopping turret drive with containers in the trimmer while maintaining optimal trimmer throughput. The turret drive motor RPM and AMP load display values are calibrated by properly setting the span and scale for each item using motor name plate data. The drive motor AMPs span is typically the 125-150 percent of the drive motor FLA stripped of any decimal places (ie: 1.0 amps = 100 for span, 2.5 amps = 250 etc). Speed Data Scaling is used to adjust drive speed frequency scale in HZ and drive speed range scale in percent. Drive speed in HZ is typically copied from drive motor name plate data but can be adjusted to meet specific trimmer performance demands. Drive speed percent can also be adjusted to limit or enhanced turret drive performance. Drive Speed Scaling values shown are typical. The DRIVE SETUP screen is only accessible from the DRIVE CONTROL and MACHINE SETUP screens. User access to Drive Setup Setpoints is limited to administrator access. 10839794_2 Drive Setup Screen 02/2019 Trimmer Start Up and Oper - 9

Timers Screen The TIMERS screen allows users access to any one of the timer groups used for RT24 trimmer control. TIMERS 1 and TIMERS 2 are used for line control photo eyes time on/time off delay timers. TIMERS 3 is used for turret drive motor brake and drive motor start/stop performance as well as scrap blow off delay and duration at the trim tooling exit inside the trimmer. TIMERS 4 is used to control trimmed bottle blow off on/off delays for bottles that have fallen over on trimmer exit conveyor or have untrimmed neck flash on containers when leaving trimmer. TIMERS 5 is used for trimmed bottle blow off on/off delays for bottles that have fallen over on trimmer exit conveyor prior to entering container leak detector. The TIMERS screen is accessible by pressing the TIMERS icon at the bottom of all screens. Timers Screen Trimmer Start Up and Oper - 10 10839794_2 02/2019

Line Control Timers 1 (2, 3, 4, & 5) Screens Use these screens to adjust the amount of time for each process shown. Each timer is activated by other timers or processes. The setpoints are preset, but can be adjusted to correct problems or as required by changed specifications. The Actual column displays the current timer status. Access this screen by touching Timers & Counters Menu button on the menu bar, then touching “TIMERS #1 (2, 3, 4, or 5)” on the Timers & Counters Menu screen. 10839794_2 Line Control Timers #1 (2, 3, 4 & 5) Screen 02/2019 Trimmer Start Up and Oper - 11

LINE CONTROL TIMER 1 allows user to adjust line control photo eye on/off delay timers. These timers adjust trimmer infeed start, stop and hi speed characteristics necessary for optimum trimmer performance. PE4 INFEED CLR on/off delay timers control when conveyor line control senses containers backing up at trimmer infeed screw at rest and when containers clear the infeed section of the trimmer bringing the turret drive to a zero speed condition. PE3 LINE PRESSURE on/off delay timers control when infeed line pressure is present starting the turret drive and when the trimmer infeed conveyor hi speed condition no longer exists bringing the turret drive back to normal speed. PE2 HI SPEED on/off delay timers control when a trimmer entrance conveyor backup is sensed by the controller increasing the turret drive speed and when the controller senses that the trimmer entrance conveyor backup is beginning to clear. During normal operations containers must backup between PE4 and PE3 creating line pressure at the infeed screw entrance before turret drive starts and runs at normal speed. When containers back up between PE3 and PE2 the turret drive hi speed condition exists and the control increases turret drive speed. Once containers clear PE2 and PE3 turret drive resumes normal speed. If containers clear PE4 the turret drive stops and remains stopped until the line pressure condition exists between PE4 and PE3 at which time the turret drive resumes normal speed operation. If the trimmer entrance conveyor is backed up to PE4, PE3 and PE2 the trimmer will start at hi speed. Ideally distances on the trimmer entrance conveyor between PE4, PE3 and PE2, their associated on/off delay timers and turret drive speeds are set to allow the trimmer to cycle between normal speed and hi speed during trimmer auto cycle operation. This helps ensure that containers never back up to the blow molder and trimmer line pressure is always maintained. PE4 should always be positioned at the infeed screw entrance. The trimmer turret drive should never run unless infeed line pressure is present at the trimmer infeed screw entry point. PE5 EXIT JAM on/off delay timers control how the trimmer responds to containers passing thru and/or backing up at the trimmer exit. On delay allows containers to pass thru trimmer exit without causing a trimmer exit jam alarm to occur. Off delay is an exit jam alarm hold time that allows trimmer control and/or user intervention to clear the exit jam before resuming normal operation. PE6 EXIT DIVERT and PE7 EXIT BACKUP on/off delay timers are used to control container backup conditions on the trimmer exit conveyor. PE7 EXIT BACKUP on/off delay timers are used to detect when an exit conveyor backup is present and when the exit conveyor backup condition no longer exits. PE6 EXIT DIVERT on/off delay timers are used to trigger an exit conveyor backup control event and to signal when the exit conveyor backup is beginning to clear. During normal operations containers backing up between PE7 and PE6 trigger a trimmer not ready Trimmer Start Up and Oper - 12 10839794_2 02/2019

signal back to the blowmolder. The blowmolder in turn enables a bottle blowoff on the trimer entrance conveyor preventing containers from entering the trimmer while the trimmer continues to run. When the exit conveyor backup clears the the trimmer issues a ready signal to the blowmolder disabling the entrance conveyor blowoff allowing normal trimmer operations to resume. BRAKE ON/OFF DELAY timers are used on RT systems that have a brake motor. The timers are set to allow the motor brake to release before starting the turret drive and to allow the turret drive to stop before engaging the motor brake. DRIVE ON/OFF DELAY timers are used with the brake delay timers to ensure the motor is not trying to run while the motor brake is engaged. SCRAP BLOFF ON/OFF DELAY timers are used to control the bottle trim coming off of the trim nest tooling while the trimmer is trimming containers. TRIM BTL BLOW ON/OFF DLY timers are used to detect and remove containers before exiting the trimmer at the trimmer exit turret that have either fallen over onto the exit conveyor or have not properly trimmed. BTL DWN TOP ON/OFF DLY timers are set to allow trimmed containers to pass without activating the bottle down blowoff. BTL DOW BTM ON/OFF DLY controls how long the bottle down blowoff is enabled. During normal operations two photo-eyes, top down and bottom down, determine if a container has passed the bottle down station. If both photo-eyes see the container the bottle passes the bottle down station. If both photo-eyes do not see the container, the container is blown off the trimmer exit conveyor. NECK FLASH BLO ON/OFF DLY timers control how container top flash detection and container blow off at the neck flash detection station. A single photo-eye determines the pressence of container neck flash. Timer delay on allows time for a container to come into view of the photo- eye while the delay off timer determines how long the container blowoff is enabled. CONVEYOR BTL BLOW ON/OFF DLY timers are used to detect and remove containers from the trimmer exit conveyor that have fallen over prior to entering the inline leak detector. BTL DWN TOP ON/OFF DLY timers are set to allow trimmed containers to pass without activating the bottle down blowoff. BTL DOW BTM ON/OFF DLY controls how long the bottle down blowoff is enabled. During normal operations two photo-eyes, top down and bottom down, determine if a container has passed the bottle down station. If both photo-eyes see the container the bottle passes the bottle down station. If both photo-eyes do not see the container, the container is blown off the trimmer exit conveyor. 10839794_2 Trimmer Start Up and Oper - 13 02/2019

Machine Setup Screen AUTO EXIT DIVERT/BLOW OFF: Currently a development option, the AUTO EXIT DIVERT/BLOW OFF enable can be used to prevent containers backing up into the trimmer if the trimmer is equipped with a divert gate or blowoff solenoid. TRIMMER ALARM on/off: Enables or disables trimmer alarms from triggering the alarm screen. DOOR ALARMS on/off: Enables or disables trimmer door alarms. EXIT JAM: If EXIT JAM is enabled the trimmer will stop when an exit jam alarm is active but will resume normal operation when the exit jam is cleared. Exit jams typically occur when containers backup into trimmer or containers are not exiting trimmer while the trimmer continues to run. If EXIT JAM is disabled the trimmer will run regardless of trimmer exit conditions. TRIMMER DIAGNOSTICS: Takes user to TRIMMER I/O screen. DRIVE SETUP: Takes user to trimmer DRIVE SETUP screen. CLEAR ALARM HISTORY: Clears all alarms from alarm history screen. TIME SET: Takes user to trimmer TIME SET popup screen. USER MAINTAINANCE: Takes use user maintenance screen. SHUT DOWN: Shuts down screen application and returns user to Factory Talk View ME Station screen. For further information call Milacron Uniloy for assistance. Machine Setup Screen 10839794_2 02/2019 Trimmer Start Up and Oper - 14

Shut Down Screen This screen appears when the SHUT DOWN button is pressed on the Machine Setup Screen. Shut Down Screen 10839794_2 Trimmer Start Up and Oper - 15 02/2019

Trimmer I/O Screen Trimmer I/O Screen Trimmer Start Up and Oper - 16 10839794_2 02/2019

Inputs A001-A016 (A017-A032) Screen INPUT CARD 1 (A001-A016) and INPUT CARD 2 (A016-A032) diagnostics screens. Inputs A001-A016 & A017-A032 Screens 10839794_2 Trimmer Start Up and Oper - 17 02/2019

Outputs E001-E016 Screens OUTPUT CARD 1 (E001-E016) diagnostic screen. Outputs E001-E016 Trimmer Start Up and Oper - 18 10839794_2 02/2019

User Mainenance Screen User Maintenance can be used to add, delete or restrict user access. There are four user groups. Modifying or deleting master user will impair administrator access to critical trimmer functions and will require reloading trimmer screen application. Default users have view only access to basic trimmer screens and are denied access to setup and system screens. Operators (users) have access to and can change values on basic trimmer screens but are denied access to setup and system screens. Maintenance (main) operators have access to and can change values on basic and setup trimmer screens but are denied access to system screens. Administrators (master) have access to and can change values on all trimmer screens. To return to the system screen use the title bar at the top of the screen.   User Maintenance Screen 10839794_2 Trimmer Start Up and Oper - 19 02/2019

Timeset Screen Timeset Screen Trimmer Start Up and Oper - 20 10839794_2 02/2019

Trimmer Statistics Screens TRIM CYCLES represents the number of containers passing through rotary trimmer. TRIM EXIT BTL SCRAL CNT represent the number of containers that did not pass through trimmer exit. BOTTLES TRIMMED represents the number of containers that successfully passed through trimmer exit. EXIT CONV BTL DWN CNT represents the number of containers that fell over on exit conveyor prior to entering leak detector. CYCLE TIME represents the trim time for a container passing through trimmer. BOTTLES PER MINUTE is the calculated bottles per minute speed of the trimmer. Press NUMBER OF TRIM STATIONS to enter the number of trim stations available on the trimmer. User can only enter 4 or 8 at this time. Press RESET ALL COUNTERS to clear trimmer statistics. 10839794_2 Trimmer Statistics Screens 02/2019 Trimmer Start Up and Oper - 21

Recipe Management Screen To save to existing recipe use direction keys to hilite recipe and select UPLOAD. To create new recipe by select UPLOAD & CREATE, type new recipe name and enter. To load recipe hilite recipe and select download. To delete recipe hilite recipe and select DELETE. Any recipe can be deleted except for recipe template (default). To rename recipe hilite recipe and select RENAME, then type new recipe name and enter. To enter or view recipe contents hilite recipe using direction keys, then touch bottom section of recipe screen and select RESTORE. Navigate to desired recipe data using direction keys and hit enter. Modify recipe date and enter. To save recipe data change select SAVE. To put recipe change into effect select DOWNLOAD. Recipe Management Screen Trimmer Start Up and Oper - 22 10839794_2 02/2019

System Log Screen SYSTEM LOG screen is the RT24 control health screen. It shows login/logout, screen changes, system function write/read operations and tag health information. The SYSTEM LOG is accessible from most screens and is useful for diagnosing screen and/or plc control issues when they occur. Pressing the screen tittle bar returns user to previous screen. System Log Screen 10839794_2 Trimmer Start Up and Oper - 23 02/2019

Trimmer Start Up and Oper - 24 10839794_2 02/2019

Trimmer Maintenance This section describes the procedures for maintaining and making adjustments to the Rotary Trimmer 24 (RT24). ! WARNING Do not attempt to set up or operate this machine or perform maintenance on it, until you read, know and practice all the safety instructions in this manual. Know and practice safety rules set forth by your company. Follow your company’s lockout/tagout procedure to ensure that the machine is safe to work on. Failure to follow these instructions may result in serious personal injury and/or machine damage. Mechanical maintenance for the machine consists of adjustments to the various components, such as the carousels, clutches, drive belt, drive chain and infeed screw. Proper lubrication is also required. Routine preventive maintenance on the Rotary Trimmer is imperative for longevity, efficiency and safety. Many warranty claims are a result of improper or non-existent maintenance. Maintenance logs should be developed and used for all routine maintenance, as well as unscheduled down time. It is recommended that prior to each shift, the operator looks for and removes any parts or flash that may have been left or stuck in the trimmer mechanism during the last shift. All safety interlocks must be checked at the start of each shift to ensure they are in safe operating condition. The operator should inspect the entire machine on a daily basis to assure that all components and assemblies are in good working order. Check for sprocket gear and carousel misalignment, a loose belt and chain, or worn parts. The operator should also visually inspect the trim tooling for damage or abnormal wear. 10839795_2 Trimmer Maintenance - 1 02/2019

Nest and Trim Tool Carousels The main assembly of the Rotary Trimmer is the trim station with a pair of counter-rotating carousels supported on a frame. The nest tool (or infeed) carousel carries a series of nest tools that receive the blowmolded parts from the infeed screw. The trim tool (or outfeed) carousel carries a series of trim tools that remove flash and eject the parts onto a conveyor. The number of tools on the carousels is determined by the rate at which parts are to be trimmed. The system can be set up with four or eight trim tools. ! WARNING If electrical power is connected to the machine, turn off and lock out the main disconnect switch before you begin any maintenance or repair procedures. Follow your company’s lockout/tagout procedure to ensure that the machine is safe to work on. Failure to follow these instructions may result in serious personal injury and/or machine damage. Note: The carousels, infeed screw and drive system will free-wheel when power to the machine is turned OFF, or when the SETUP (keyed) switch is set to the SETUP position. Aligning the Carousels Proper alignment of the carousels is critical to prevent damage to the machine, tooling and blowmolded parts. Use the carousel alignment fixture supplied with the trimmer. Use the following procedure to align the carousels: a. Turn the machine OFF. b. Remove trim tooling (if necessary) from the trim tooling mounting plates on one arm of the car- ousel. c. Loosen the carousel adjustment bolts on top of both of the carousels. d. Install carousel alignment fixture between the carousels. 1. Bolt alignment fixture blocks to the mounting plates. Tighten lightly. 2. Install alignment fixture rail between the blocks. Tighten lightly. Trimmer Maintenance - 2 10839795_2 02/2019

e. With fixture in position, tighten the carousel adjustment bolts. Adjustment Bolts Adjustment Fixture Rail Carousel Alignment Installing and Adjusting the Trim Tooling Trim nests and punches are attached to the trim tooling mounting plates. Bolts attach trim nests directly to the trim tooling mounting plates. Trim punches are bolted to riser blocks attached to a trim tooling mounting plate. Use the following procedure to install trim tooling: a. Turn the machine OFF. b. Check the platen and carousel alignment using the carousel alignment fixture. c. Mount the trim nest assembly onto the nest tool carousel. Check the alignment of the nests on the nest mounting plate using a trimmed sample part. The part should fit securely into the trim nests without binding or distortion. Minor adjustments are possible by loosening the nest mount- ing bolts. 10839795_2 Trimmer Maintenance - 3 02/2019

d. If the trim tooling includes a punch assembly for removing flash from the inside of a handle, mount the trim punch assembly on the trim tool carousel. Remove the shoulder and nest trim punches from the riser blocks, leaving the handle punch on the assembly. e. Manually rotate the carousels forward to the trimming position to check the alignment of the han- dle punch with the body nest. Clearance around all sides of the handle punch should be equal. f. Adjust the handle punch by loosening the handle punch riser mounting bolts, if needed. g. Manually rotate the carousels backwards so the trim nests are at the infeed position. h. Insert a trimmed part into the trim nests. i. Manually rotate the carousels forward to the trimming position, adjusting the blowmolded part guide rails during rotation. When properly adjusted, the rails should make light contact with the part. j. Check the handle punch to part alignment at the trimming position. The handle punch should pass through the blowmolded part without interference or distortion. k. Manually rotate the carousels forward to the outfeed position, continuing the adjustment of the blowmolded part guide rails. At the outfeed position, the rails should remove the part from the trim tooling and place it onto the takeout conveyor (or other takeout device, as applicable). l. In applications using a spring puncher to assist in container removal, adjust the puncher so the impact does not distort the blowmolded part. m. Install the shoulder and neck trim punches. The trim punches should pass within 0.5 mm (0.020 in.) of the blowmolded part. n. Mark the trim tooling mounting plates to correspond with the appropriate carousel arm. The trim tooling nest and punch assemblies should be placed at these same positions during future installa- tions. Trimmer Maintenance - 4 10839795_2 02/2019

Mounting Bolts Nest Assembly Infeed Screw Nest Tool Carousel 10839795_2 Trimmer Maintenance - 5 02/2019

Guide Rail Platen Nest Handle Punch Trim Tooling Trim Tool Carousel Trimmer Maintenance - 6 10839795_2 02/2019

Infeed Screw As the blowmolded parts are moved by conveyor to the Rotary Trimmer, they are directed to an Infeed Screw with flights sized to capture the container. The screw threads capture, space, and move the parts through guide rails into the rotating nest and trim tool carousels. Screw flights are variable, increasing cyclically along the screw such that the speed of the containers accelerates and spacing increases. ! WARNING If electrical power is connected to the machine, turn off and lock out the main disconnect switch before you begin any maintenance or repair procedures. Follow your company’s lockout/tagout procedure to ensure that the machine is safe to work on. Failure to follow these instructions may result in serious personal injury and/or machine damage. Adjusting and Synchronizing the Infeed Screw Use the following procedure to adjust the synchronization of the infeed screw to the nest tool carousel: a. Turn the machine OFF. b. Loosen the two set screws on the drive end of the infeed screw. c. Place a blowmolded part in the thread of the infeed screw. d. Rotate the infeed screw until the part is close to the nest tool carousel. e. Rotate both the nest tool carousel and the infeed screw to synchronize them so the part can exit the infeed screw and be properly positioned on the nest tool carousel. f. When the nest tool carousel and infeed screw are properly synchronized, tighten the set screws on the infeed screw. If adjustments need to be made, repeat the above steps. 10839795_2 Trimmer Maintenance - 7 02/2019

Infeed Screw Set Screw Infeed Screw Infeed Screw Overload Release Clutch The Infeed Screw drive system is equipped with a Cabot brand, Roto-Fuse Model 1.5 overload release clutch for safety purposes. The clutch will automatically release if the Infeed Screw becomes jammed, at which point it instantly disengages allowing free rotation. When a torque overload occurs, the spring-loaded balls inside the clutch unit retract into the rotor, allowing the rotor to rotate relative to the housing. With about 15° relative rotation, the single drive key escapes into a recess in the housing outer wall, allowing the hub to rotate freely without ratcheting. Re-engagement is accomplished by reversing the relative rotation for one revolution or less by rotating the Infeed Screw. The clutch will re-engage at the same angular relationship between input and output automatically. No additional adjustments should be required. Trimmer Maintenance - 8 10839795_2 02/2019

Use the following procedure to reset the Infeed Screw Overload Release Clutch: a. Make sure the machine is turned OFF or the SETUP (keyed switch) is set to SETUP mode. b. Rotate the Infeed Screw one revolution in the opposite direction of standard operation. The clutch should re-engage and no additional adjustments should be necessary. 10839795_2 Overload 02/2019 Release Clutch Infeed Screw Overload Release Clutch Trimmer Maintenance - 9

Replacing the Infeed Screw The infeed screw assembly is designed to be easily removed for product changes or machine service. Use the following procedure to remove or replace the infeed screw: a. Turn the machine OFF. b. Support the Infeed Screw so it does not drop. c. Remove the four screws from the rear feedscrew bearing and slide it off the Infeed Screw shaft. d. Push the Infeed Screw towards the drive chain and rotate it clockwise until the unit releases from the housing. e. Pull the Infeed Screw away from the spindle block. Push In Spindle and Block Rotate Infeed Infeed Screw Screw Shaft Support Bracket Feedscrew Screws (4) Bearing Infeed Screw Removal Trimmer Maintenance - 10 10839795_2 02/2019

Drive System Maintenance The Rotary Trimmer is powered by a single Variable Frequency Alternating Current (VFAC) electric motor connected to a gear reducer and a DODGE brand IEC Series electric clutch mechanism. This motor gear directly drives a large spur gear that is underneath the trim tool carousel making it rotate in a counter-clockwise direction. The trim tool spur gear meshes with a matching spur gear underneath the nest tool carousel making it rotate in a clockwise direction. The nest tool spur gear has a shaft underneath it that drives a belt that runs through a tensioner and over to the gear box located under the input end of the infeed screw. There is a chain drive from the gear box up to the infeed screw that makes the screw rotate. This chain drive has a tensioner and an Overload Release Clutch for safety purposes. Drive Motor Electric Clutch Overload Release Clutch Clutch Locations ! WARNING If electrical power is connected to the machine, turn off and lock out the main disconnect switch before you begin any maintenance or repair procedures. Follow your company’s lockout/tagout procedure to ensure that the machine is safe to work on. Failure to follow these instructions may result in serious personal injury and/or machine damage. 10839795_2 Trimmer Maintenance - 11 02/2019

Drive Motor Electric Clutch Adjustment The DODGE IEC Series electric clutch is pre-burnished at the factory and should not require any air gap adjustments prior to operation. The clutch has a self-adjusting feature that will automatically compensate for friction surface wear. Armature air gaps should range from .030 to .050 inches, which have been pre-set at the factory. If clutch sensitivity needs to be adjusted, this is accomplished by adjusting the voltage to the clutch unit. Use the following procedure to adjust he clutch: a. Remove the cap from the control module located inside the operator panel. This will expose a slotted adjustment screw. b. Insert a screwdriver into the adjustment screw slot and rotate it counterclockwise to set the voltage to 0. c. Start the machine to engage the clutch. d. Rotate the screwdriver clockwise to increase the voltage. Increase the clutch voltage until the trimmer runs without hesitation. Trimmer Maintenance - 12 10839795_2 02/2019

Operator Panel Clutch Control Module Overview Motor Electric Clutch Gear 10839795_2 Electric Clutch Adjustment 02/2019 Trimmer Maintenance - 13

Infeed Screw Overload Release Clutch Adjustment A wide range of torque settings are possible by adding, subtracting, or changing springs in the Cabot brand, Roto-Fuse Model 1.5 Overload Release Clutch. Please contact the manufacturer or Uniloy for additional information. Overload Release Clutch Overload Release Clutch Drive Belt Adjustment The drive belt will only need tension adjustment if it becomes loose. Replace the belt as needed. Use the following steps to adjust the drive belt tension: a. Turn the machine OFF. b. Loosen the Adjustment Bolt. c. Slightly loosen the Pivot Bolt d. Move the Tensioner Pulley outwards to tighten and inwards the machine to loosen the belt. Trimmer Maintenance - 14 10839795_2 02/2019

e. Tighten both Bolts. f. Realign the Carousels and Infeed Screw, if necessary. Drive Belt Pivot Tensioner Adjustment Bolt Pulley Bolt Drive Belt Adjustment Infeed Screw Chain Drive Adjustment The infeed screw drive chain will only need tension adjustment if it becomes loose. Replace the chain as needed. The chain drive is equipped with a Cabot brand, Roto-Fuse model 1.5 overload release clutch. See “Infeed Screw Overload Release Clutch” on page 8. 10839795_2 Trimmer Maintenance - 15 02/2019

Use the following steps to adjust the chain tension: a. Loosen the two screws for the chain tensioner slide block. b. Loosen the locknut on the adjustment bolt. c. Using the adjustment bolt, slide the tensioner arm toward the chain to tighten, or away from the chain to loosen. d. Tighten the adjustment bolt locking nut and two slide block screws when desired tension is set. e. Check the Infeed Screw for proper rotation. Adjustment Bolt Clutch Tensioner Slide Idler Gear Chain Infeed Screw Chain Drive Trimmer Maintenance - 16 10839795_2 02/2019