HEAT SEALING Instruction Manual

LONGHILL
ELMSTONE HARDWICKE
CHELTENHAM
GLOS.
GL51 9TY
ENGLAND

Tel.: +44.(0)1242.680.680
Fax: +44.(0)1242.680.909
Email: sales@tbseng.co.uk

INSTRUCTION MANUAL
AUTOMATIC LID SEALING MACHINE TYPE LS4

LS4 - J17998

Issue 3
19/10/2007

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

Table of Contents

1. General Data......................................................................................................................... 1
2. Performance ......................................................................................................................... 2
3. 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 (1
st
time) .......................................................................................... 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

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/cm
2
)
Air Consumption ................. 0.43m/min free air compressed to 5 bar
Exhaust Ventilation
Required ............................. 0.8 m/s at 25mm H
2
O
Overall Machine
Dimensions ......................... Height ........... 2.55m
Length............. 3.3m (with lid loading)
Width............. 2.28m (with lid loading)
Machine Weight ..................

2. Performance

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

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

Length.. 180mm-540mm
Overall
Height... 175mm-295mm
Dimensions
Width.... 120mm-300mm

3. Installation

1. General

The machine will be received as one unit complete with one set of tooling as
standard. It should be securely mounted on a solid flat base and levelled by
adjustment of its four 16mm levelling screws. Adjacent gravity conveyors should
be 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 supply
of 5.6 - 6.8kg/cm
2
(80 - 100 psi).
Set the pressure regulator to 5.6kg/cm
2
.

3. Electrical Supply

Connect a 3 phase supply, neutral (where
appropriate) and earth to the electrical panel
situated at the side. Make the appropriate
electrical connections in accordance with the
wiring diagram.

4. Ventilation

Ventilation of suitable capacity should be connected to the machine through the
200mm connection.

Supply line

4. Setting Up Procedure

The following instructions are written as though new tooling is being offered for the first
time. 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 during
each 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 be
changed cold to avoid injury.

1. Lid Box Platen
a) If the quick change platen facility is not fitted then change the platens from the
front of the machine. Pull the platen forward and position the lid tooling over
the appropriate fixing holes. Bolt the tooling into position using new M8 x 20
long socket head cap screws and the special spring washer (LS 116). It is
important to use new screws smeared with anti-seize. Old screws are likely to
fracture. 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 the
clamp by hand with a lid fully in position. Make sure lid is clamped securely.

Fig. 1


Fig. 2
b) Use two people to position the lid holder onto the main head ram. Tighten the
two 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 correct
sensor is plugged into position 1. See Fig. 3.

Fig. 3

3. Box Positioning (1
st
time)
a) Open up the clamp and guide rails and position the container(s) roughly in
position on the conveyor.
b) Turn off panel isolator and open panel door. Select battery type as required,
i.e. single small battery, double small battery, single large battery. See Fig. 4.
Close panel door, lock and turn on isolator.

Fig. 4
c) Turn on power and air, but leave the platen heating off. Select manual control
with head up, platen back, cradle down, lid unclamp, battery stops in, box
clamp auto.
d) Using the gauge, adjust the cradle wheel until the gauge just slides between
the wheel and the setting block. See Fig. 5 and 6.
Note: If it is found that the amount of box melt requires adjustment, then slide
the setting block up or down as appropriate. This is a one-off adjustment.

Initial setting of the height setting block:
with the tooling cold, adjust the wheel until the box comes up to touch the
tooling. Then adjust the wheel so that it is 1mm from the bottom of the cradle.
This determines 1mm of melt. From then, put the setting gauge on top of the
box height adjusting wheel and position height setting block.

Fig. 5
Height adjusting wheel
Height setting block


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 ball
valve 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. Make
a note of the position used for the battery type so that future setting requires
only 3(d) and (g) to be carried out with the stops and front rail being positioned
on 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.

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 the
battery. Close guards.
c) Bring platen forward then select cradle up for approximately 4 seconds
allowing 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 adjusting
screw on top of the head assembly. The amount of melt is equal to the gap
between the compensating block and adjusting screw.

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 positioned
lids enter the machine or damage to the heater platen and lid clamping
assembly will result.

a) Set heating platen controller to required temperature 350C nominal and switch on
heater.
Note: The heating platen takes approximately 20-30 minutes to attain 350C. The
machine will not run until the temperature is within the lower limit set on the
temperature 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, cradle
down, 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 to
occur.
After sealing, check alignment of box to lid and adjust the stops and front rail as
necessary.
Cut up a seal and check it is secure.
The machine is now ready to run.

6. Quick Change Platen Facility

This feature is an optional extra and allows very rapid type change by allowing the
heater 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 within
the main panel.
d) When ready to change the tooling, ensure that proper heat resistant clothing is worn
including 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.

g) Turn off the platen heating and disconnect the heater and thermocouple plugs and
sockets.
h) Use the valve shown in Fig. 10 to raise or lower the carriage to present the spare
rail to the machine. Note: When lowering from the raised position, it is necessary to
release the safety catch.

Fig. 10
i) Unlatch the platen inside the machine from its drive as shown in Fig. 11 and pull out
onto the spare rails. Note: Be careful not to catch the platen heater cables.

Fig. 11

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

IMPORTANT NOTE

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

Failure to observe this instruction will result in the tooling being out of register with
the 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 switch
rollers are correctly aligned.
l) The spare platen can be allowed to cool for changeover.

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 the
sticks 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 is
located in the groove on the cassette cross bar. Lock into position.
d) Repeat this operation 4 times by closing all guard doors, selecting manual and
pressing the index button. This will index the cassette system to the next station
ready 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 by
selecting lid feed up switch. The cams should just go flat with the operating
bar. Adjust the operating bar if necessary. See Fig. 4.
f) Position the cassette at the loading angle using the support wedge as shown in
Fig. 3. Slide up into position a stack of lids, pushing up on the sticks to ensure
they fully engage in the top catch assembly. See Fig. 6. The fingers are held
apart 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 the
skirt of the lid. Once the fingers have been set, remove the lid retaining clips
from 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 out
Lid feed down
Lid placing auto

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

If small batches of a special lid type are to be run, it will probably be easier to run
the machine conventionally by isolating the lid loader (select lid placing manual)
and feeding the machine with boxes and loose covers.

8. Maintenance

The machine has been designed for a lower maintenance requirement. However, the
following planned maintenance should be carried out diligently, in order to maintain
optimum working conditions.

1. Daily

1. Check oil level in air lubricator Shell Tellus 23

2. Check air filter / water trap.
Drain and clean when required
Use liquid detergent or
paraffin only

3. Lightly grease slide rods and pillars
(not main platen slides)
Shell Darina R2

2. Air Cylinder Adjustments

All cylinders, with the exception of the lid clamp cylinder, have an end of stroke
damping facility. The control valves located in the end flanges of each cylinder are
screwed clockwise to increase dampening and anti-clockwise to decrease.

3. Automatic Grease Pump

If the grease pump is allowed to run low of grease, the machine will stop at the
end of cycle. Top up using a grease gun via the nipple provided. Do not take off
top and fill using another method as this tends to trap air.

Use Shell E.T. grease.

9. Standard Spares and Tools

MACHINE SPARES PACKING LIST (BO ITEMS)
Customer EXIDE INDUSTRIES LIMITED
Ref: J17998
Related M/Cs
Project: 4250
LID SEALING MACHINE
Iss.: B 02/07/2007
J17998 LS4B
J18040 LT3
J18035 SCT4
J18036 SW6
BO 010 LS4 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

10. Long Term Spares

SPARES IDENTIFICATION LIST
LS4B
Customer:
J17998
EXIDE INDUSTRIES LIMITED
IC1
Issue 05/10/2007
Job number J17998
Part number Schedule Item Qty Description
BO 082 25 211 40 000 1 003 0 - LOCKNUT
BO 082 8 231 10 000 1 005 0 - FORM A PLAIN STEEL WASHER
BO 082 12 231 10 000 1 006 0 - FORM A PLAIN STEEL WASHER
BO 082 10 410 10 102 1 135 0 - BUSH
BO 082 11 440 10 102 1 005 0 - THRUST WASHER
BO 082 24 470 30 000 1 004 0 - M6 STRAIGHT GREASE NIPPLE
BO 082 18 500 20 000 1 001 0 - 08B1#
BO 082 1 500 22 000 1 001 0 - SPRING CLIP
BO 082 21 511 10 292 1 023 0 - CHAIN GUIDE/CHANNEL
BO 014 3 560 20 000 1 021 0 - T/LOCK BUSH
BO 082 27 575 15 318 1 083 0 - GEARMOTOR 0.37Kw 87,5rpm
BO 082 26 580 10 203 0 001 0 - TENSIONER SPAN BOX
BO 082 15 810 10 320 1 011 0 - FRICTION ACCUMULATION ROLLER
Page 1 of 6 Printed 05/10/2007

Customer:
J17998
LS4
Issue 05/10/2007
Job number J17998
BO 001g 2E 105 10 111 1 005 0 - HEAD, SPRING RETURN
BO 001i 2E 0 -
BO 001g 2E 105 10 111 1 006 0 - FIXED BODY/CONTACT ASSY
BO 001i 2E 0 -
BO 001g 2E 105 10 111 1 010 0 - ROLLER LEVER STEEL
BO 001i 2E 0 -
BO 001i 2E 105 40 107 1 001 0 - GUARD SWITCH
BO 001f 1E 105 70 321 1 006 0 - LONG RANGE IND SENSOR (7mm)
BO 001b 11 110 10 321 1 001 0 - MAGNETIC CYL. SENSOR
BO 001h 2E 110 50 321 1 003 0 - M18 DIFFUSE PHOTOCELL
BO 001g 2E 112 10 144 1 005 0 - MINIATURE PLUG
BO 001g 2E 112 10 144 1 006 0 - INSULATING BOOT
BO 003 17 112 10 204 1 003 0 - 40A MODULE, TURNED CRIMP MALE
BO 001g 2E 112 10 204 1 004 0 - 40A MODULE, TURNED CRIMP FEM
BO 003 18 112 10 204 1 005 0 - 4.0mm TURNED CRIMP MALE PINS
BO 001g 2E 112 10 204 1 006 0 - 4.0mm TURNED CRIMP FEMALE PIN
BO 001g 2E 112 10 204 1 021 0 - HBE 6 PANEL BASE WITH LID
BO 003 14 112 10 204 1 022 0 - HBE 6 SIDE ENTRY HOOD (PG16)
BO 003 16 112 10 204 1 030 0 - 2 WAY FEMALE FRAME
BO 001g 2E 112 10 204 1 031 0 - 2 WAY MALE FRAME
BO 001b 29 115 10 321 1 003 0 - 5M 90 DEG CONNECTOR, M12 4 PIN
BO 001f 2E 115 10 321 1 005 0 - 10M 90 DEG CONNECTOR, M12 4PIN
BO 001h 2E 0 -
BO 003 11 130 10 120 1 004 0 - THERMOCOUPLE
BO 001g 2E 130 15 120 1 003 0 - THERMOCOUPLE SOCKET
BO 003 8 160 10 147 3 017 0 - HEATER 1200W 230V 12.625"lg 24"tails HEATING ELEMENT
BO 003 12 160 10 147 3 018 0 - HEATER 1600W 230V 13"long 24"tails HEATING ELEMENT
BO 003 5 190 10 000 1 006 0 - NEUTRAL LINK
BO 001e 95 210 60 164 1 003 0 - M10 TEE NUT
BO 001b 23 211 40 000 1 005 0 - LOCKNUT
BO 001e 90 0 -
BO 001h 2E 0 -
BO 001b 12 211 40 000 1 011 0 - LOCKNUT
BO 010 3 225 10 228 3 001 0 - SET OF STUD STOP ADJUSTERS
BO 001e 94 231 20 164 1 002 0 - JIG WASHER
BO 010 4 232 11 000 3 001 0 - S/COIL RECT/SEC SPRING WASHER
BO 001b 17 260 10 164 1 001 0 - LOCATION PIN
BO 001b 18 260 10 164 1 003 0 - LOCATION PIN
BO 001f 2E 260 20 164 1 002 0 - SPRING PLUNGER
BO 001c 39 260 20 164 1 007 0 - INDEX PLUNGER
BO 001i 2E 270 10 000 1 001 0 - 606SA CHROME HANDLE
BO 001f 2E 270 10 164 1 033 0 - CLAMPING HANDLE
BO 001f 1E 270 10 164 1 034 0 - CLAMPING HANDLE
BO 001e 92 270 10 164 1 035 0 - CLAMPING HANDLE

Customer:
J17998
LS4
Issue 05/10/2007
Job number J17998
BO 001c 48 270 10 164 1 043 0 - CLAMPING HANDLE
BO 001f 2E 295 10 118 1 004 0 - COMPRESSION SPRING
BO 001d 65 295 10 118 1 015 0 - COMPRESSION SPRING
BO 001i 2E 297 30 000 1 001 0 - 13 BRASS BULLET CATCH
BO 001i 2E 297 30 000 1 002 0 - 3" x 1" ALUMINIUM BARREL BOLT
BO 001i 2E 297 40 304 1 001 0 - CABINET BARREL LOCK
BO 001b 13 300 00 105 1 022 0 - 32x80 STROKE CYLINDER
BO 001d 54 300 00 105 1 043 0 - 80x150 STROKE CYLINDER
BO 001c 34 300 00 105 1 052 0 - 100x200 STROKE C/TRUNNION CYLINDER
BO 001c 44 300 00 105 1 087 0 - 32x050 STROKE CYLINDER
BO 001e 89 300 00 105 1 089 0 - 32x25 STROKE CYLINDER
BO 001h 2E 0 -
BO 001b 10 300 01 105 1 016 0 - 80x250 STROKE MAG.CYLINDER WITH VITON SEALS
BO 001f 1E 300 15 117 1 002 0 - 20x25 STROKE CYLINDER
BO 001d 55 305 00 105 1 015 0 - 80/100 PISTON ROD CLEVIS
BO 001d 56 305 00 105 1 019 0 - 80 REAR MALE TRUNNION
BO 001d 57 305 00 105 1 022 0 - 80 REAR TRUNNION
BO 011 6 360 10 117 1 007 0 - BANJO FLOW REGULATOR
BO 011 3 365 10 221 1 002 0 - CHECK UNIT 1/8" BSP
BO 011 4 365 10 221 1 003 0 - CHECK UNIT ADAPTOR 1/8" BSP
BO 011 2 370 30 109 1 003 0 - 1/2" BALL VALVE, VENTED
BO 011 5 385 40 116 1 002 0 - NON RETURN CHECK VALVE
BO 011 7 385 50 116 1 003 0 - POPPET VALVE
BO 003 2 400 40 110 1 007 0 - DRAWN CUP NEEDLE ROLLER BEARIN
BO 001d 60 400 40 110 1 008 0 - DRAWN CUP NEEDLE ROLLER BEARIN
BO 001d 61 400 40 110 1 015 0 - INNER RING FOR NEEDLE BEARING
BO 001c 30 405 10 168 1 001 0 - LINEAR BEARING WITH SEAL
BO 001b 14 405 10 168 1 003 0 - LINEAR BEARING WITH SEAL
BO 001c 47 410 10 102 1 002 0 - BUSH
BO 001f 2E 410 10 102 1 019 0 - BUSH
BO 001f 2E 410 10 102 1 034 0 - BUSH
BO 001f 1E 410 10 102 1 044 0 - BUSH
BO 001h 2E 410 10 102 1 045 0 - BUSH
BO 001e 91 410 10 102 1 051 0 - BUSH
BO 001d 59 425 10 103 1 030 0 - SELF LUBE BEARING UNIT
BO 001f 2E 440 10 102 1 004 0 - THRUST WASHER
BO 001d 62 440 10 110 1 002 0 - BEARING WASHER
BO 001d 63 470 30 000 1 004 0 - M6 STRAIGHT GREASE NIPPLE
BO 001c 41 730 10 000 1 002 0 - 'O' RING
BO 001d 73 750 10 134 1 015 0 - HEX JAM NUT
BO 001d 72 750 10 134 1 026 0 - SHOCK ABSORBER
BO 001d 58 750 10 161 1 001 0 - SHOCK ABSORBER
BO 001b 28 750 10 161 1 003 0 - SHOCK ABSORBER

Customer:
J17998
LS4
Issue 05/10/2007
Job number J17998
BO 001l 2E 950 40 286 1 001 0 - AIR FILTER
BO 001i 2E 950 46 000 1 002 0 - PERSPEX SHEET 940x412x8 THICK

Customer:
J17998
LS4B
Issue 05/10/2007
Job number J17998
D65803 310 00 121 1 059 0 - ISO 1 5/2 SOL/SOL VALVE
D65803 310 00 121 1 061 0 - ISO 2 5/2 SOL/SOL VALVE
D65803 355 10 121 1 006 0 - FILTER
D65803 360 20 121 1 019 0 - PRESSURE REGULATOR 3/8"
D65803 360 20 121 1 026 0 - PRESSURE REGULATOR 1/4"
D65803 360 20 121 1 034 0 - REGULATOR
D65803 363 10 121 1 003 0 - LUBRICATOR

Customer:
J18038
LS4T
Issue 05/10/2007
Job number J17998
BO 202 11 105 70 321 1 006 0 - LONG RANGE IND SENSOR (7mm)
BO 202 12 115 10 321 1 001 0 - 2M 90 DEG CONNECTOR, M12 4PIN
BO 202 14 210 30 164 1 002 0 - COLLAR NUT
BO 202 4 232 11 000 3 001 0 - S/COIL RECT/SEC SPRING WASHER
BO 202 13 240 20 164 1 002 0 - SWING BOLT
BO 202 22 250 31 000 1 001 0 - CLEVIS PIN - 8 x 20 HEADED
BO 202 1 300 14 121 1 012 0 - 25x10 STROKE COMPACT CYLINDER
BO 202 5 410 10 102 1 015 0 - BUSH
BO 202 6 410 10 102 1 019 0 - BUSH
BO 202 3 410 10 102 1 112 0 - BUSH
TO PLACE FURTHER ORDERS CONTACT
T.B.S. ENGINEERING LTD
LONGHILL,
ELMSTONE HARDWICKE,
CHELTENHAM,
GLOS.
GL51 9TY
ENGLAND

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