Mo02 SFR20 B

SFR 20
Operating Manual
LIST OF VALID PAGE
ENTER THE NEW UPDATED PAGES, DESTROY THE OBSOLETE PAGES
The issue dates of the original and updated pages are:
Original . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . 31 January 2002
Update . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . 25 July 2002
Page Update Page Update Page Update

No No No No No No
Title page 0 2-1 to 2-102 0
A to B 0 3-1 toto 3-62 0
i to x 0 4-1 to 4-16 0
I to XII 0 5-1 to 5-24 0
1-1 to 1-2 0 6-1 to 6-8 0
1-3 0 7-1 to 7-4
1-4 to 1-8 0 8-1 to 8-4
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THIS PAGE LEFT BLANK INTENTIONALLY
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SFR 20
Operating Manual
TABLE OF CONTENTS
INTRODUCTION
GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I
PURPOSE AND CONTENT OF THE MANUAL - - - - - - - - - - - - - - - - - - - - - I
REFERENCE PUBLICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I
REFERENCE MANUALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
APPLICABLE DIAGRAMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
EXTERNAL AUXILIARY SYSTEM MANUALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - II
INFORMATION ON USING THE MANUAL - - - - - - - - - - - - - - - - - - - - - - - - III
AIMS AND LIMITS OF THE OPERATING MANUAL - - - - - - - - - - - - - - - - - - - - - - - III
KEEPING THE MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IV
UPDATING THE MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IV
CO-OPERATION WITH USERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IV
DEFINITIONS AND TERMINOLOGY USED IN THIS MANUAL - - - - - - - - - - V
SPECIFIC TERMS USED IN THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - V
GENERAL DEFINITIONS CONCERNING SAFETY - - - - - - - - - - - - - - - - - - - - - - - - V
TECHNICAL DEFINITIONS CONCERNING THE MACHINES - - - - - - - - - - - - - - - - VI
DESCRIPTION AND ENVISAGED USE OF THE MACHINE - - - - - - - - - - - - VII
TECHNICAL SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII
AFTER-SALES SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII
MACHINE IDENTIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII
SPARE PARTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - X
DOCUMENTATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - X
CE MARKING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - X
SECTION 1
General information and safety rules
1.1 GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
1.2 REFERENCE STANDARDS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
1.3 AMBIENT CONDITIONS OF USE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.3.1. TEMPERATURE AND HUMIDITY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.3.2. OPERATING ENVIRONMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.3.3 LIGHTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.3.4. VIBRATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
1.3.5. RESIDUES AND ENVIRONMENTAL POLLUTION - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
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1.4 GENERAL SAFETY RULES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
1.4.1. CLOTHING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
1.4.2. ACCESS TO THE WORK AREA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
1.4.3. ENVISAGED, IMPROPER AND INCORRECT USE - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.4.4. WORK AND CONTROL AREAS - SAFETY AREAS - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.5 RISK ASSESSMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7
1.5.1. INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7
1.5.2. RISKS CONNECTED WITH THE INSTALLATION ENVIRONMENT - - - - - - - - - - - - - - - 1-7
1.5.3. RISKS CONNECTED WITH THE MACHINE'S FEATURES - - - - - - - - - - - - - - - - - - - - - 1-8
1.5.4. REMAINING RISKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
SECTION 2
Description and technical specifications
2.1 MACHINE DESCRIPTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2.1.1 PURPOSE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2.1.2 GENERAL DESCRIPTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2.2 PROCESS PHASES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
2.2.1 PHASE 1 - FEEDING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
2.2.2 PHASE 2 - PREFORM LOADING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
2.2.3 PHASE 3 - CONDITIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2.2.4 PHASE 4 - PREFORM TRANSFER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
2.2.5 PHASE 5 - STRETCHING/BLOWING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
2.2.6 PHASE 6 - BOTTLE TRANSFER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9
2.3 FUNCTIONAL UNITS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10
2.3.1 MACHINE FRAME FUNCTIONAL UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-13
2.3.2 DRIVES UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-15
2.3.3 PREFORM FEEDING FUNCTION UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-17
2.3.4 LOADING AND UNLOADING FUNCTIONAL UNIT - - - - - - - - - - - - - - - - - - - - - - - - - 2-20
2.3.5 OVEN FUNCTIONAL UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-23
2.3.6 TRANSFER FUNCTIONAL UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-29
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SFR 20
Operating Manual
2.3.7 STRETCHING/BLOWING UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-33

2.3.7.1 Blowing wheel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-33
2.3.7.2 Mold opening/closing cam - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-33
2.3.7.3 Rotating fitting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-34
2.3.7.4 Blowing press - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-35
2.3.7.5 Blowing mold - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-36
2.3.7.6 Stretching cam - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-36
2.3.7.7 Stretching/blowing system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-37
2.3.8 BOTTLE EJECTION FUNCTION UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-48
2.3.9 CABIN FUNCTIONAL UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-50
2.3.10 AUXILIARY UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-52
2.3.10.1 Main manifold (standard supply) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-52
2.3.10.2 Hopper (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-52
2.3.10.3 Bottle conveyor (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-52
2.3.10.4 Chiller (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-53
2.3.10.5 Compressor (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-53
2.3.10.6 Temperature adjuster (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-53
2.3.10.7 Mold holder carriage (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-53
2.3.10.8 Preform tipping device (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-53
2.4 SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-55
2.4.1 PNEUMATIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-55
2.4.1.1 Pneumatic system - Service air line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-56
2.4.1.2 Pneumatic system - Process air line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-59
2.4.2 WATER SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-61
2.4.3 ELECTRIC/ELECTRONIC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-63
2.4.3.1 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-63
2.4.3.2 Electronic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-64
2.5 DESCRIPTION OF CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-70
2.5.1 MASTER ELECTRIC PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-70
2.5.2 OPERATOR INTERFACE PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-73
2.5.3 MACHINE PUSH-BUTTON PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-76
2.5.4 HAND-HELD PANEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-78
2.5.4.1 Hand-held panel code list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-82
2.6 SAFETY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-88
2.7 AREAS AT RISK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-88
2.8 AREAS WITH A RESIDUAL RISK - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-90
2.9 SAFETY DEVICES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-92
2.9.1 GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-92
2.9.2 CABIN SAFETY DEVICES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-92
2.9.3 EMERGENCY STOP BUTTONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-96
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2.9.4 ELECTRIC PANEL SAFETY DEVICES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-98
2.9.4.1 Electric cabinet door safety devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-98
2.9.4.2 Flashing voltage indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-98
2.9.4.3 Main disconnecting switch with door lock - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-98
2.9.4.4 Key-operated control selectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-98
2.9.4.5 Column lamp and buzzers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-98
2.9.5 MISCELLANEOUS SAFETY DEVICES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-98
2.9.6 PLATES WARNING OF DANGER, PROHIBITION AND OBLIGATION - - - - - - - - - - - - 2-99
2.9.6.1 Plates warning of danger - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-99
2.9.6.2 Plates warning of prohibition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-99
2.9.6.3 Plates warning of obligation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-100
2.10 TECHNICAL SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-101
2.10.1 OVERALL DIMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-101
2.11 MAIN SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-101
SECTION 3
Supervisor description and use
3.1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3.2 GENERAL DESCRIPTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3.2.1 MAIN ELEMENTS OF THE SUPERVISOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
3.2.1.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
3.2.1.2 Standard tool bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
3.2.1.3 Operative tool bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3.2.1.4 Upper status bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3.2.1.5 Lower status bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
3.2.2 SUPERVISOR NAVIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-9
3.2.2.1 Selecting an active graphic element - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-9
3.2.2.2 Selecting a command - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-10
3.2.2.3 Selecting an alphanumeric box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-10
3.2.2.4 Selecting a disabled element - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-11
3.3 SUPERVISOR PAGE DESCRIPTION - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
3.3.1 HOME PAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
3.3.1.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-14
3.3.1.2 Operative commands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-14
3.3.2 AUXILIARIES PAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-15
3.3.2.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-16
3.3.2.2 Operative commands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-16
3.3.3 HOPPER PAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-17
3.3.3.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-18
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Operating Manual

3.3.4 DRIVE PAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-20
3.3.4.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-21
3.3.5 OVEN PAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-23
3.3.5.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-24
3.3.6 UNLOADING PAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-26
3.3.6.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-27
3.3.7 BLOWING PAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-28
3.3.7.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-29
3.3.8 PRODUCTION PAGE (STANDARD TOOL BAR) - - - - - - - - - - - - - - - - - - - - - - - - - - -3-31
3.3.8.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-32
3.3.9 CONFIGURATION PAGE (STANDARD TOOL BAR) - - - - - - - - - - - - - - - - - - - - - - - - -3-36
3.3.9.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-36
3.3.9.2 Operative commands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-38
3.3.9.3 Linked pages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-38
3.3.9.4 Select language page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-39
3.3.9.5 Set SUPERVISOR level set page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-39
3.3.10 PRODUCTION DATA PAGE (STANDARD TOOL BAR) - - - - - - - - - - - - - - - - - - - - - - -3-41
3.3.10.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-41
3.3.11 ARCHIVES PAGE (STANDARD TOOL BAR) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-44
3.3.11.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-45
3.3.11.3 Linked pages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-45
3.3.11.4 Explore diskette page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-45
3.3.11.5 Select recipe page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-46
3.3.12 HELP PAGE (STANDARD TOOL BAR) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-49
3.3.12.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-50
3.3.12.2 Operative Commands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-50
3.3.13 ALARMS PAGE (STANDARD TOOL BAR) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-51
3.3.13.1 Working area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-53
3.3.13.2 Operative commands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-54
3.3.13.3 Linked pages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-55
3.3.13.4 Alarm help page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-55
3.3.13.5 Display alarm history page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-57
3.3.13.6 Stop history page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-59
v
SECTION 4
Installing, moving and
dismantling (decommissioning)
4.1 GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
4.2 GENERAL INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2
4.3 REQUIREMENTS FOR INSTALLING THE MACHINE - - - - - - - - - - - - - - - 4-2
4.3.1 PREREQUISITES OF THE SITE OF INSTALLATION OF THE MACHINE - - - - - - - - - - - 4-2
4.3.2 EXTERNAL SYSTEM PREREQUISITES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
4.3.2.1 Electrical power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4
4.3.2.2 Earthing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
4.3.2.3 Compressed air supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
4.3.2.4 Water supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
4.4 UNPACKING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
4.5 HANDLING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
4.5.1 HANDLING AND POSITIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
4.6 CONNECTING FUNCTIONAL SYSTEMS - - - - - - - - - - - - - - - - - - - - - - 4-12
4.7 ELECTRICAL SYSTEM HOOK-UP - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
4.7.1 GROUNDING HOOK-UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-12
4.8 COMPRESSED-AIR SYSTEM HOOK-UP - - - - - - - - - - - - - - - - - - - - - - - 4-13
4.9 WATER SYSTEM HOOK-UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
4.10 LEVELLING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16
4.11 DISMANTLING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16
vi
SFR 20
Operating Manual
SECTION 5
Procedures for using the machine
5.1 GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
5.2 FIRST MACHINE START-UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
5.2.1 PRELIMINARY CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
5.2.2 PREPARATION AND REGULATION OF THE MACHINE - - - - - - - - - - - - - - - - - - - - - - 5-2
5.2.2.1 Powering the machines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
5.2.2.2 Manual machine control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
5.2.2.3 Loading recipes and machine data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
5.2.2.4 Start Cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
5.3 ALARM WARNINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
5.3.1 MEANING OF THE ALARMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-14
5.3.1.1 ALARM HELP page - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15
5.4 NORMAL OPERATING PROCEDURES - - - - - - - - - - - - - - - - - - - - - - - - 5-18
5.5 STOPPING THE MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-19
5.5.1 EMERGENCY STOP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-20
5.5.2 CYCLE STOP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-20
5.5.3 MACHINE STOP AND END OF CYCLE STOP - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-20
5.6 RESETTING WORKING CONDITIONS - - - - - - - - - - - - - - - - - - - - - - - - 5-22
5.6.1 RESETTING WORKING CONDITIONS AFTER AN EMERGENCY STOP - - - - - - - - - - -5-22
5.6.2 RESETTING WORKING CONDITIONS AFTER A CYCLE STOP - - - - - - - - - - - - - - - - -5-23
vii
SECTION 6
Operating control
6.1 GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
6.2 CYCLE CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
6.3 PRODUCTION CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
6.3.1 GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
6.3.2 CONTAINER CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-3
6.3.2.1 Empirical check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-3
6.3.2.2 Instrument check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-7
SECTION 7
Service operation
7.1 GENERAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
7.2 LIST OF SERVICE OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
SECTION 8
Glossary
8.1 VOCABULARY LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
viii
SFR 20
Operating Manual
INTRODUCTION
GENERAL
This manual provides the necessary information to install and use the SFR20 blowing machine to
manufacture containers made of PET (Polyethylene Terephthalate).
The information contained in this publication is property of SIPA S.p.A.; no part of it may be divulged
or reproduced without prior authorization.
This machine has been designed in conformity with the Machine Directive issued by the Council of
the European Communities (law 89/392 and subsequent amendments) to ensure safe use, provided
that the instructions given in this manual are always followed.
PURPOSE AND CONTENT OF THE MANUAL

The purpose of this manual is to provide the necessary information and instructions for the assigned
personnel to install and operate the machine safely.
In compliance with the Machine Directive, it contains all the general information to use the SFR20
blowing machine.
The necessary information and instructions for installation (understood as a set of several machines),
the description of the controls, the procedures for starting and running the machine safely and the
operations for routine service.
The subjects are split up into Sections, which in their turn are divided into progressively numbered
paragraphs and subparagraphs. The Sections have summary tables and illustrations making it easier
to understand the information given.
NOTE
This manual contains no information on servicing the machine
except for routine service operations that the Operator can carry
out himself. For any further information, please refer to the Main-
tenance Manual of SFR20 blowing machine.
REFERENCE PUBLICATIONS
In addition to this manual, the following publications on the machine and its components are availa-
MO-A0395_02.fm
ble.
The reference publications are divided into three distinct groups:
Reference manuals
Applicable diagrams
External auxiliary system manuals.
Introduction
I
Edition 31 January 2002
Reference manuals
This group contains all the publications concerning components used in the machine that have a sep-
arate manual:
Maintenance Manual, which describes the main routine and special maintenance work to be car-
ried out on the machine.
Mechanical Manual, which contains the illustrated spare parts catalogue of the components
forming the machine.
The booklet "Safety System Control" listing all the checks on all the machine's safety systems
to be carried out at the end of the installation procedures.
Applicable diagrams
This group contains a collection of all the diagrams applicable to the machine.
External auxiliary system manuals

This group contains all the publications on the auxiliary assemblies that are not part of the machine
but whose presence is essential for it to operate correctly.
Introduction
II
SFR 20
Operating Manual
REF TITLE DATA DATE OF

BASE LAST EDITION
Reference manuals
MM02-SFR20-A SFR Maintenance Manual 01/09/00 31/01/02
-- -- --
-- -- --
-- -- --
-- Machine Manual 2002 --
--
Applicable diagrams
-- Wiring diagrams --
-- Compressed air system diagrams --
-- Water system diagrams
External auxiliary system manuals

MO-A0395_02.fm
INFORMATION ON USING THE MANUAL
AIMS AND LIMITS OF THE OPERATING MANUAL

This manual (also the additional publications on assemblies and systems installed on the SFR20
blowing machine has been written for all operators interested in using and supervising the machine
Introduction
III
throughout its service life.
The purpose of this manual is to provide information on:
1. The technical specifications of the SFR20 blowing machine.
2. The preparation of the place of work as regards ambient features and power sources.
3. Safety regulations and information on the safety devices installed on the machine.
4. Use of the machine as envisaged in the project.
5. Availability of spare parts.
This manual can in no way replace specific training that operators must have received on similar
equipment or that they can receive on this machine under the guidance of personnel who have al-
ready been trained.
KEEPING THE MANUAL

The operating manual is considered an integral part of the machine and must be kept for future ref-
erence until the machine is finally demolished.
This manual must always be available for reference and must be kept with care, protected against
dust and moisture, in a safe place; in the event of it getting damaged such as to even partially impair
its reference, the user must request a new copy from the manufacturer.
UPDATING THE MANUAL

This manual has been written at the same time as preparing the machine it refers to and it cannot be
considered inadequate only because it has been updated at a later date (also for similar machines)
on the basis of new experience.
SIPA reserves the right to modify the manuals together with its production without being obliged to
update what has been supplied beforehand. Any supplements sent to users must be kept together
with this manual.
CO-OPERATION WITH USERS

SIPA is at the disposal of its customers to provide additional information on using and servicing its
machines, as well as to take into consideration proposals for improving the manual in order to make
it increasingly more compliant with the requirements it has been written for.
Introduction
IV
SFR 20
Operating Manual
DEFINITIONS AND TERMINOLOGY USED IN THIS MANUAL
SPECIFIC TERMS USED IN THIS MANUAL
CAUTION
THIS TERM IDENTIFIES A SITUATION FOR WHICH FAILURE
TO COMPLY WITH THE RULES GIVEN COULD BE A CAUSE
OF RISKS FOR THE SAFETY OF THE OPERATOR OR OF EX-
POSED PERSONS, WITH THE DANGER OF INJURY OR
DEATH.
WARNING
This term identifies a situation for which failure to comply
with the rules given could be a cause of damage to the ma-
chine or its components.
NOTE
This term draws the reader's attention to particular aspects of the
procedure described.
GENERAL DEFINITIONS CONCERNING SAFETY
OPERATOR
The operator is understood to be a person authorized by the plant safety manager to operate the ma-
chine, including the job of recognizing any potential danger to himself and others and avoiding the
associated risks. The authorization to run one or more machines is normally given after the operator's
capabilities have been proven, deriving from training (experience and instruction).
TECHNICIAN
See skilled personnel.
MAINTENANCE MAN
See skilled personnel.
SKILLED PERSONNEL
Person(s) with specific technical skills in one or more sectors, capable of carrying out maintenance
MO-A0395_02.fm
work other than normal service operations. Skilled personnel may be employees of the manufacturer
or his principal, of the user, or of outside companies.
EXPOSED PERSON
An exposed person is understood to be anyone who, for any reason whatsoever, is entirely or partly
in a dangerous area.
Introduction
V
DANGEROUS AREA
A dangerous area is the entire area in and/or around a machine within which the presence of an ex-
posed person could be a risk for his or her safety and health.
DANGER
Danger is understood to be a situation associated with one or more elements that can cause the
death or serious injury of the operator or exposed persons.
RISK
The term 'risk' in these manuals defines potential danger and, consequently, the possibility of the op-
erator or exposed persons suffering damage.
TECHNICAL DEFINITIONS CONCERNING THE MACHINES
OPERATING CYCLE
The operating cycle is understood to be the set of the various process phases carried out by the var-
ious appliances forming the machine that produce the finished product.
PRODUCTION
The action accomplished by one or more machines considered in relation to achieving an end result
(finished product).
FINISHED PRODUCT
A finished product is understood to be the final outcome (PET container) obtained at the end of the
entire operating cycle performed by the machine.
PREFORM
A preform is understood to be the semi-finished PET product, normally cylindrical in shape, with the
collet and ring nut for screwing the cap on already formed, from which, with additional machine proc-
ess phases, the finished product is obtained.
FUNCTIONAL UNIT
A functional unit is understood to be a device or a set of devices installed on a machine that is capa-
ble, alone or with others, of carrying out a production process phase accomplished by the machine
itself.
TOOL
The term 'tool' in these manuals defines an implement installed in a mechanism that is suitable in its
shape, features and size to manufacture a particular article.
Introduction
VI
SFR 20
Operating Manual
AUXILIARY TOOLS
The term 'auxiliary tools' defines one or more implements, not of SIPA manufacture, installed in a
mechanism that is suitable, in its shape, features and size, to perform a complementary function in
the various machine process phases.
PROCESS PHASES
The process phases are understood to be the middle stages of the continuous process of product
manufacture, where the article is itself processed by one or more functional units installed in a certain
position on the machine; the set of process phases constitutes the operating cycle of the machine to
make the finished product.
FIRST STARTING
Starting after installation, including the functional tests.
SERVICE OPERATIONS
Simple repairs or supplies to be made occasionally or at regular intervals that do not require skilled
personnel. Service operations can then be carried out by the operator.
SERIES
The term 'series' (SFR20 blowing machine, in full) identifies the type of line of machines capable of
making the finished product, with specific features and quantities.
TYPICAL INFORMATION
The term 'typical' identifies the features or operations that hold good for basic machines in their stand-
ard version. These features may vary in relation to the configuration of the single machines.
DESCRIPTION AND ENVISAGED USE OF THE MACHINE

The machine this publication refers to has been designed to manufacture PET (polyethylene tereph-
thalate) containers by heating and continuous stretching/blowing.
The entire machine is fitted for full automation of the production cycle and for being integrated in ex-
isting systems for finishing the article.
This machine must not be used to manufacture other articles than the ones it has been designed to
make.
MO-A0395_02.fm
Introduction
VII
TECHNICAL SERVICE
This manual provides the necessary information for using and running the machine it refers to. All
technical service work requested is therefore governed by the conditions of use and terms of warran-
ty of the plant.
SIPA After-Sales Service is at the disposal of our customers for any further information, explanations
or technical service in general.
NOTE
When requesting technical service or ordering spare parts it is al-
ways necessary to quote the machine's identification data (see
the relative paragraph below).
AFTER-SALES SERVICE
SIPA Plastic Packaging Systems
Via Caduti del Lavoro, 3
31029 Vittorio Veneto (TV) - Italy
Telephone 0039 - 0438 - 91.15.11
Telefax 0339 - 0438 - 91.22.73
E-mail: sipa@zoppas-industries.it
SIPA ON LINE SERVICE

E-mail: sol.sipa@zoppas-industries.it
MACHINE IDENTIFICATION
The main machine identification data are stamped on the plate on the machine ( figura 1).
The plate gives the main data of most interest for operators:
Machine type
Serial No.
Introduction
VIII
MO-A0395_02.fm SFR 20
Operating Manual
Figure 1. Machine identification
Introduction
IX
SPARE PARTS
It is recommended to use genuine SIPA spare parts only.
Spare parts should be ordered from SIPA After-Sales Service, always quoting the following data:
all the machine identification data (see identification data plate)
code number, description and technical description of the part to be replaced
NOTE
An identification code is printed on each part. Simply quote the
code shown on the part.
destination of the part requested.
NOTE
For more detailed information on the manner of ordering spare
parts, please refer to the Maintenance Manual enclosed with this
publication.
DOCUMENTATION
The documentation supplied with the SFR20 blowing machine comprises:
1. CE DECLARATION OF CONFORMITY
2. OPERATING MANUAL
3. MAINTENANCE MANUAL
4. DOCUMENTATION CONCERNING PURCHASED EQUIPMENT (Motors, Thermoregulator,
etc.).
CE MARKING
The SFR20 blowing machine is provided with CE marking in conformity with the directive of the Coun-
cil of the European Communities 89/392 and its subsequent amendments; the marking is made on
the machine's identification plate.
The machine is supplied together with the "CE Declaration of Conformity" with the Directive, signed
in an original copy; this document MUST BE CAREFULLY KEPT by the owner of the machine to be
Introduction
X
SFR 20
Operating Manual
shown whenever requested by the authorities.

The "CE Declaration of Conformity" is considered an integral part of the line and if the machine is
sold this document must be handed over to the new owner.
MO-A0395_02.fm
Introduction
XI
Introduction
XII
SFR 20
Operating Manual
SECTION 1 1
GENERAL INFORMATION AND SAFETY RULES
1.1 GENERAL
CAUTION
THE INFORMATION CONTAINED IN THIS SECTION REFERS
TO THE SFR MACHINE ONLY. THIS INFORMATION MUST
BE INTEGRATED WITH THE SAFETY REGULATIONS OF THE
SYSTEM WHERE THE MACHINE IS INSTALLED.
This Section contains the essential information, required by the Machine Directive, for compliance
with and observation of the safety rules generally, the evaluation of the risks deriving from using the
machine and the ambient conditions of use.
Failure to observe the information given in this section and the additional instructions contained in
this manual may make the conditions of safety envisaged at the design stage ineffective and be a
cause of injury for machine operators.
1.2 REFERENCE STANDARDS

The soffiatrice SFR as a whole and its single components have been designed taking the current har-
monized EC standards into account as well as other European and national standards that are ap-
plicable in accordance with the Machine Directive issued by the Council of the European
Communities (law 89/392 and subsequent amendments).
The main harmonized standards considered are the following:
EN 292-1 - Safety of machinery - Basic concepts, general principles of design. Part 1: terminology,
basic methods.
EN 292-2 - Safety of machinery - Basic concepts, general principles of design. Part 2: specifica-
tions and technical principles.
EEC Directive 73/23 - Directive concerning the reconciliation of the legislation of member states
on ELECTRIC MATERIAL DESIGNED TO BE USED WITHIN CERTAIN LIMITS OF VOLTAGE
("LOW VOLTAGE").
EN 60204-1 / CEI 44-5 - Safety of machinery - Electrical equipment of machines. Part 1: general
MO-A0396_02.fm
rules.
EN 422 - Machine safety for blowing hollow bodies - Requirements for design and manufacture.

1-1
Machine Directive.
89/336/EEC - Electromagnetic compatibility.

1-2
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Operating Manual
1.3 AMBIENT CONDITIONS OF USE

1
1.3.1. TEMPERATURE AND HUMIDITY
The machine must be used in environments at an ambient temperature in the range from 15 to 35C,
maximum relative humidity of 50%.
SIPA S.p.A.must be informed if the ambient conditions are different to conduct the necessary tech-
nical evaluations.
1.3.2. OPERATING ENVIRONMENT
This machine must be used sheltered from atmospheric agents (rain, hail, snow, fog, etc.) and can
only be used inside industrial environments.
WARNING
If the machine is used in corrosive environments, it is neces-
sary to adapt maintenance times and methods suitable so as
to prevent excessive wear of components.
This machine has not been designed for use in an explosive or partially explosive atmosphere: it must
therefore not be used in these conditions.
Installation, settings, tryouts and maintenance of this machine must be carried out exclusively by
skilled and adequately trained personnel.
1.3.3 LIGHTING
The machine is provided with a specific lighting system inside the enclosure and the electrical panels.
Despite this, the room housing the machine must have adequate lighting to enable easy identification
of the control and emergency-stop devices and push-buttons.
The lighting provided is sufficient for normal inspection and maintenance operations. For other, spe-
cific or particular interventions the user is responsible for compliance with current standards on the
provision of lighting.
1.3.4. VIBRATION
In conditions of normal use, following the instructions given in this manual, vibration is not such as to
create dangerous situations. If you detect any abnormal vibration, stop the machine immediately and
call the after-sales service.
1.3.5. RESIDUES AND ENVIRONMENTAL POLLUTION

MO-A0396_02.fm
Users must comply with current laws, directives and standards for the treatment of the hydraulic oil,
lubricants and fluids used in the country of use of the machine.
Update 1

1-3
1.4 GENERAL SAFETY RULES
CAUTION
The machine's configuration and respective safety devices correspond to the requirements of the
Machine Directive issued by the Council of the European Communities (89/392 and subsequent
amendments).
Section 2 of this manual describes the safety devices; all the other sections give a detailed descrip-
tion of all the safety rules that need to be observed when installing and operating the machine.
Failure to apply these rules could make the safety conditions envisaged at the design stage ineffec-
tive.
Personnel assigned to operating and supervising the machine must be trained by their employer on
the risks of injury, the safety devices installed on the machine and the general safety rules envisaged
by the Community Directives E/O by the legislation in force of the country of destination of the ma-
chine.
SIPA disclaims all responsibility for damage to the machine or for the physical safety of the operator
or of third parties deriving from failure to observe the safety standards given in the technical docu-
mentation supplied with the machine
WARNING 1
Before starting work, the operator must have a thorough
knowledge of the features of the machine, the position and
operation of all the controls; in addition, he must have fully
read the operating and maintenance manuals and have ex-
amined the drawings and diagrams enclosed.
WARNING 2
The machine must be used solely by operators who have
been trained on site by SIPA personnel (if envisaged by the
supply contract) and who have understood the instructions
given in the accompanying manuals.
WARNING 3
The instructions, notices and general safety rules contained
in the manuals and/or shown on boards applied to the ma-
chine must be fully complied with.
WARNING 4
Unauthorized replacement or tampering with one or more
parts of the machines, use of accessories, tools, consum-

1-4
SFR 20
Operating Manual
ables other than the ones recommended by the manufactur-

er may be an accident risk and release the manufacturer 1
from civil and criminal responsibility.
1.4.1. CLOTHING
The clothing of anyone operating or carrying out maintenance on the machine must be suited to the
type of operation at all times. Furthermore, clothing must comply with the safety rules envisaged by
the legislation in force of the country of destination of the machine.
Generally speaking, operators must wear safety shoes with non-slip soles and it is not permitted to
wear moccasins, clogs, slippers or other footwear that might impair the wearer's mobility.
The clothes worn must be suitable for the work to carry on: overalls and aprons must be of natural
fibres (cotton for instance), not very inflammable and clean of traces of lubricant.
When operating in areas with heat emissions (see Section 2) wear appropriate fireproof, heatproof
gloves and, if there is a danger of splintering or material coming out, you must wear protective eye-
wear.
During installation, the operator must moreover always wear ear-plugs and a safety helmet.
CAUTION
WHEN OPERATING ON THE MACHINE NEVER WEAR
BRACELETS, WATCHES, RINGS OR CHAINS THAT CAN
DANGLE OR HINDER MOVEMENT. PAY THE UTMOST AT-
TENTION WHEN WORKING CLOSE TO MOVING PARTS OF
THE MACHINE THAT YOUR CLOTHING IS SUITABLE TO
MO-A0396_02.fm

1-5
AVOID GETTING HOOKED ON THESE DEVICES (SLEEVES,
FOLDS IN OVERALLS, LONG HAIR, ETC.).
ALWAYS WEAR THE SPECIAL SAFETY NEVER WEAR ANY BRACELETS

GLOVESI
Figure1-1. Clothing - safety rules
1.4.2. ACCESS TO THE WORK AREA
The work area (and especially the areas where the control panels and emergency stop are installed)
must never be occupied by material or other things so that nothing interferes with the operator's free-
dom of movement. In an emergency, immediate access to the machines must be ensured for the as-
signed personnel.
Access to the work area should be prohibited, with warning signs, for persons who are not directly
assigned to machine operation.
CAUTION 1
DURING SERVICE OPERATIONS, ESPECIALLY WHEN OP-
ERATING WITH OPEN GUARDS OR DISCONNECTED SAFE-
TY DEVICES, IT IS NECESSARY TO PAY THE UTMOST
ATTENTION SO THAT THE WORK AREA IS INACCESSIBLE
FOR PERSONS NOT DIRECTLY INVOLVED IN THESE OPER-
ATIONS.
CAUTION 2
AT THE END OF SERVICE OPERATIONS, CHECK THAT NO
TOOLS HAVE BEEN LEFT INSIDE THE SAFETY GUARDS OR
IN THE WORK AREA.

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SFR 20
Operating Manual
Figure1-2. Access to work area - general requirements

MO-A0396_02.fm

1-7
1.4.3. ENVISAGED, IMPROPER AND INCORRECT USE
The machine must be used to manufacture PET articles with exactly defined features (see the "De-
scription and Envisaged Use of the Machine" section of the "Introduction") and within the limits of the
supply contract stipulated between the purchaser and SIPA.
Using the machine to achieve higher production rates, or other than as prescribed, is considered im-
proper, therefore the manufacturer disclaims all responsibility for any damage caused to property or
persons, and considers forfeit all warranty on the machine.
1.4.4. WORK AND CONTROL AREAS - SAFETY AREAS
A description of the work and control areas, of the inaccessible areas and of the areas in which op-
eration requires activating special safety procedures (for instance, due to moving masses or high
temperatures) is given in Section 2 of this manual under the heading "Safety Devices".

1-8
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Operating Manual
1.5 RISK ASSESSMENT

1
CAUTION
1.5.1. INTRODUCTION
Assessment of risks deriving from using the machine is made on the basis of methods described in
the harmonized standards and in the relevant European Directives. The results of this analysis and
the safety precautions taken to eliminate or reduce risks for users are given in this section as regards
their general aspects and in Section 2 as regards a detailed description.
1.5.2. RISKS CONNECTED WITH THE INSTALLATION ENVIRONMENT
The environment where the machine is installed may contain hazardous situations that could prevent
it from operating correctly and could injure machine operators and maintenance personnel.
FLOOR
The surface the machine stands on must ensure proper support and levelling over time.
TEMPERATURE
The required ambient temperature must be assured; high, positive or negative, peaks in temperature
or humidity could cause operating trouble for the machinery constituting the machine (for instance,
difficulty in cooling the motors).
POLLUTING MATERIALS
It is necessary, in advance, to assess the potential damage deriving from using materials considered
to be polluting in the work environment, for instance:
POWDERS that can make the gaskets of pneumatic and hydraulic cylinders wear out quicker.
MAGNETIC FIELDS, caused by electricity lines passing close to the electronic equipment in-
stalled on the machine, can cause interference and malfunctioning.
TOXIC SUBSTANCES (gas, vapor and precipitate) in the work environment.
WARNING
The user is responsible for ensuring that the machine is in-
stalled in a location guaranteed to safeguard its integrity
MO-A0396_02.fm
over time.

1-9
1.5.3. RISKS CONNECTED WITH THE MACHINE'S FEATURES
In conformity with EEC Directive 89/392, an analysis has been made of all the machine's areas char-
acterized by risks inherent in the nature of the working process or in the structure forming the ma-
chine.
Whenever possible, the most appropriate precautions have been taken to decrease, or eliminate, po-
tential risks for exposed persons, equipping each machine with a set of regular, fixed and mobile
guards that prevent access to hazardous areas during work.
It should anyhow be borne in mind that the best protection for the operator's safety is the operator's
own caution and common sense, and that the greater experience he acquires over time by using the
machine can help improve the safety margins of his work.
NOTE
Please refer to Section 2 of this manual for a full description of
the safety devices installed on the machine.
1.5.4. REMAINING RISKS
Remaining risks in the areas of the machine or in the procedures are defined as being risks that, in
spite of the safety measures taken, still have a high degree of hazard, for instance due to high volt-
age, temperature, pressure, or moving parts. All the areas of the machine with remaining risks are
marked by warning signs to ISO standards; please refer to Section 2 of this manual for further details.

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SFR 20
Operating Manual
SECTION 2
DESCRIPTION AND TECHNICAL SPECIFICATIONS
2
2.1 MACHINE DESCRIPTION
2.1.1 PURPOSE
This manual describes a blowing machine which runs an automatic process to manufacture PET con-
tainers of various shapes and sizes (depending on the type of mold used) by continuous extrusion,
injection and stretching/blowing.
2.1.2 GENERAL DESCRIPTION
The SFR20 blowing machine is a flexible system ( figure 2-1). It is flexible since it offers considerable
versatility in the production of containers from semi finished preforms which are transformed into con-
tainers of various shapes and sizes by stretching/blowing.
The SFR20 blowing machine is composed of a structure of steel sections in which are installed the
various FUNCTIONAL UNITS (stretching/blowing, oven, etc. figure 2-1) that come into operation ei-
ther singly or at the same time in the entire production process.
NOTE
For a detailed description of the single functional units of the ma-
chine, please refer to paragraph 2.3.
Each functional unit performs a specific operation referring to a single PROCESS PHASE of the en-
tire product manufacturing cycle.
The set of process phases (feeding, stretching/blowing, etc. figure 2-1) forms the machine's oper-
ating cycle that produces the finished product. The individual process phases are described in
paragraph 2.2
The entire production process is fully automatic and managed by the operation and control program,
called SUPERVISOR, described in Section 3.
Each process phase is detected by a set of sensors, limit switches and transducers, which transmit
the relative signals to the PLC that interprets and re-processes them; solenoid valves, proportional
valves and other control devices make the commands received from the SUPERVISOR active by
acting on the various circuits (hydraulic and pneumatic) and on the electric motors.
The machine's self-diagnosis program provides synoptic diagrams and detailed information for each
operating fault or breakdown. An optoelectronic control system is provided for monitoring the pre-
MO-A0397_02.fm
forms loaded in the machine.

In addition, the machine is protected on the inside by a special cabin to ensure the required active
and passive safety with doors and hatches for scheduled and unscheduled maintenance operations.

2-1
The cabin soundproofs the machine with respect to the surrounding environment.
Partial air circulation is allowed inside the cabin to limit the hazardous effects of condense (dew).
The machine is equipped with a complete accident-prevention safety system, made in compliance
with current standards, which has the task of supervising and actively operating in the areas consid-
ered at risk so as to avoid all possible access by the operator to these areas during operation.

2-2
SFR 20
Operating Manual
2
MO-A0397_02.fm
Figure 2-1. General machine view - Process phases and functional units

2-3
2.2 PROCESS PHASES
The entire operative process for the production of containers is described in the following para-
graphs.
2.2.1 PHASE 1 - FEEDING
The feeding phase ensures a continuous, correct flow of preforms into the machine ( figure 2-2). The
preforms are taken from the hopper and conveyed to the directing device by means of a step con-
veyor. The directing device arranges the preforms correctly before they are conveyed to the feeding
chute. The preforms slide by gravity from the feeding chute to the machine. They are arranged in the
correct pitch by the screw conveyor and sent to the preform feeding wheel.
Figure 2-2. Feeding phase
Process phases
2-4
SFR 20
Operating Manual
2.2.2 PHASE 2 - PREFORM LOADING
The preforms on the feeding wheel are turned by approximately 180 clockwise and are collected by
the preform loading carriage forks. They are additionally turned by approximately 90 anti-clockwise
onto the preform holder chain ( figure 2-3).
2
Figure 2-3. preform loading phase

MO-A0398_02.fm
Process phases
2-5
2.2.3 PHASE 3 - CONDITIONING
The preform holder chain carries the preforms arranged at a 45 mm pitch through the thermal condi-
tioning oven to prepare for the next stretching/blowing phase ( figure 2-4).
The preforms move forwards and turn on the chain. The forwards movement allows the progressive
advancement of preforms in the ovens arranged in series along the perimeter of the oven frame,
while the rotary movement of the preforms around their axis ensures even warming. This is also fa-
cilitated by the action of fans.
The preforms reach the ideal thermal profile after being suitably left to cool down. This method is
known as "thermal inversion stabilization" in open air. To allow cooling, the preforms are carried out
of the ovens on the preform holder chain before the stretching/blowing phase.
Figure 2-4. Conditioning phase
Process phases
2-6
SFR 20
Operating Manual
2.2.4 PHASE 4 - PREFORM TRANSFER
In this phase, the preforms are transferred from the preform holder chain to the blowing mold ( figure
2-5). A preform transfer wheel is used for this purpose. The preforms on the preform holder chain
are taken from the transfer wheel grippers, turned by approximately 180 and arranged inside the
blowing mold. 2
Figure 2-5. preform transfer phase

MO-A0398_02.fm
Process phases
2-7
2.2.5 PHASE 5 - STRETCHING/BLOWING
Containers (bottles) are made from the preforms during the stretching/blowing phase ( figure 2-6).
The preforms are arranged in the blowing mold (which is fully open) during the transfer phase and
are vertically stretched (mold fully closed) by the pneumatically actuatored, adjustable stroke stretch-
ing rods. The stretching operation is completed in two separate stages by blowing low pressure air
(approximately 10 bars) and high pressure air (40 bar). A fully mechanical system (press opening/
closing cam) closes the blowing molds installed on the outer diameter of the blowing wheel during
the air blowing phase. The stretching/blowing phase is carried out while the presses and stretching
units (one for each press) are turning. The phase is controlled by a fully mechanical cam. A number
of containers equal to the number of installed presses are made for each complete turn of the blowing
wheel.
Figure 2-6. Stretching/blowing phase
Process phases
2-8
SFR 20
Operating Manual
2.2.6 PHASE 6 - BOTTLE TRANSFER
The containers are removed (transferred) from the molds and conveyed out of the machine (to the
aligning system, storage line, filling line, etc.) at the end of the stretching/blowing phase.
The containers are transferred by means of the bottle transfer wheel grippers similarly to the pre-
forms. 2
The bottles are taken from the blowing molds and conveyed out of the machine during this phase
( figure 2-7).
.
Figure 2-7. Bottle transfer phase

MO-A0398_02.fm
Process phases
2-9
2.3 FUNCTIONAL UNITS
The functional units forming the machine are described in the following paragraphs in logical order
according to the various process phases. Refer to figure 2-8 for location.
Unit 01 - MACHINE FRAME
Unit 02 - DRIVES
Unit 03 - PREFORM FEEDING
Unit 04 - LOADING AND UNLOADING
Unit 05 - OVEN
Unit 06 - TRANSFERS
Unit 07 - STRETCHING/BLOWING
Unit 08 - BOTTLE EJECTION
Unit 09 - CABIN
Unit 10 - AUXILIARY PARTS
NOTE 1
The following paragraphs contain a overview of the functional as-
pects (not constructive) for the machine. For a detailed descrip-
tion of the components forming the various functional units, refer
to the Maintenance Manual which is attached to this publication.
NOTE 2
The information contained in this chapter refer to a TYPICAL ma-
chine configuration. For a detailed description of the compo-
nents forming the various functional units, refer to the
Maintenance Manual which is attached to this publication.
Functional units
2-10
MO-A0399_02.fm SFR 20
Operating Manual
Figure 2-8. Functional unit identification (Sheet 1 of 2)
Functional units
2-11
Figure 2-8. Functional unit identification (Sheet 2)
Functional units
2-12
SFR 20
Operating Manual
2.3.1 MACHINE FRAME FUNCTIONAL UNIT
The machine frame functional unit is involved in all parts of the process by supporting and ensure
perfect coupling between the various functional units.
The machine frame functional unit includes the following main components ( figure 2-9): lower frame
(7), upper frame (3), oven frame (12) and electric manifold intake (20).
The lower frame (7) consists of a stiff crosspiece structure where the housings and the supports of
the various functional units are connected. The lower frame (7) has adjustable bases (9) to support
and level the machine. The upper part of the frame houses the blowing press brake supports (11),
the drive unit bases (8), the electric junction panel supports (6) and the upper frame bases (10). The
fifth wheel support (5) and the respective blowing press units are housed in the suitably reinforced
lower frame (7).
The upper frame (3) consists of a stiff crosspiece and interconnected pillar structure housing the
stretching cam plate (1), the upper oven plate (4) and the connection plates (2) for the oven frame
(12).
The oven frame (12) consists of an interconnected sidebar structure which is supported on one side
by legs (16) and adjustable feet (15) and on the other side it is connected to the upper frame (3) by
means of connection plates (13). The oven frame (12) houses the upper cabin supports (14) and the
oven lamp supports (17). The electric enclosures are housed under the oven frame (12).
The electric manifold intake (20) is a structure formed by three C-crosspieces fastened to top of the
upper frame (3). The electric manifold intake supports the stretching unit electric distribution panel
wiring and distributes power by means of a rotating manifold (19). Furthermore, the part supports the
upper part of the machine cabin. The rotating manifold (19) is located in the exact middle of the upper
intake crosspiece (20). It is fastened to the crosspiece by means of a coupling (18) which allows it to
turn.
MO-A0399_02.fm
Functional units
2-13
1. Stretching cam plate 8. Supporting base 15.Adjustable feet
2. Connection plates 9. Adjustable bases 16.Legs
3. Upper frame 10.Supporting base 17.Oven lamp supports
4. Oven upper plate 11.Brake supports 18.Joint
5. Fifth wheel support 12.Oven frame 19.Rotarty manifold
6. Supports 13.Connection plates 20.Electric manifold inlet
7. Lower frame 14.Upper cabin supports
Figure 2-9. Machine frame unit
Functional units
2-14
SFR 20
Operating Manual
2.3.2 DRIVES UNIT
The drives functional unit is involved in all process stages because it drives all the functional units
( figure 2-10).
The drives functional unit includes the following main components:
gear motors (9) and (10);
drive plate (5);
transmission gear (13);
propeller shaft (17);
manual actuator shaft (31);
The gear motor consists of an electric motor (10) and a gear unit (9) attached to the drive plate by
means of flange (8) and spacers (7). Pinion (2) and torque limiter (3) are fastened to the gear motor
shaft (4) by means of spline (1) (movement ). Pinion (2) transmits movement to the transmission
gear (13) while the torque limiter (where operated) protects the mechanical parts of the machine from
damage in the event of seizure. The gear unit (9) also features a de-multiplier (12) to couple the shaft
for manual operation (31).
The drive plate (5) is fastened to the lower frame of the machine by means of bolts (6) and washers.
The drive plate (5) houses the gear motor, the propeller shaft (11), the transmission gear (13) and
the timing belt (15) take-up roller (14).
The transmission gear (13) conveys movement from the gear motor propeller shaft (4) to the blowing
wheel via pinion (2) (movement ) and to propeller shaft (17) via pulley (16) (movement ) and
timing belt (15) (movement ).
The propeller shaft (17) conveys movement from the gear motor to the loading/unloading and trans-
fer functional units (movement ). The propeller shaft (17) consists of a lower shaft (22), an inter-
mediate shaft (20) and an upper shaft (18). The lower shaft (22) is fastened to the drive plate and
received movement from the gear motor via pulley (16) and timing belt (15). The intermediate shaft
(20) is fastened to the lower shaft by means of joint (21) and to the upper shaft via flange (19). The
upper shaft is fastened to the upper oven plate and transmits movement, via gear (25) to the loading/
unloading unit and via the transfer wheels to the transfer unit (movements and ).
Transfer wheel transmission consists of two timing belts (26), three gears (23), (24), (25) and two
take-up rollers (27) and (28). Gear (25) is connected to the propeller shaft (17), gear (24) turns the
preform transfer wheel, while gear (23) turns the bottle transfer wheel.
The manual operation shaft (31) is fastened to the gear motor de-multiplier (12) and machine frame
by means of flange (29). A handwheel (30) is connected to the end of the shaft to turn the shaft and
the de-multiplier (12).
MO-A0399_02.fm
Functional units
2-15
1 Spline 12 De-multiplier 23 Gear
2 Pinion 13 Transmission gear 24 Gear
3 Torque limiting device 14 Take-up roller 25 Gear
4 Gear motor shaft 15 Timing belt 26 Timing belts
5 Drive plate 16 Pulley 27 Take-up roller
6 Screws 17 Propeller shaft 28 Take-up roller
7 Spacers 18 Upper shaft 29 Flange
8 Flange 19 Flange 30 Handwheel
9 Gears 20 Intermediate shaft 31 Operating shaft (manual)
10 Electric motor 21 Coupling
11 Propeller shaft housing 22 Lower shaft
Figure 2-10. Drive unit
Functional units
2-16
SFR 20
Operating Manual
2.3.3 PREFORM FEEDING FUNCTION UNIT
The preform feeding function unit is involved in the feeding process ( figure 2-11). It feeds the pre-
forms required for production and consists of the following main parts (figure 3-2):
feeding screw tailstock (10);
preform feeding screw (11);
preform feeding wheel (26);
customized guides (PRS);
preform counter check;
screw drive.
The top of the feeding screw tailstock (10) is fastened to the machine frame by means of bolts and
centring pins. The lower part houses the slanted guides (2) which continue the hopper unit feeding
chute. The height of tailstock (10) can be adjusted and houses one end of the preform feeding screw
(11). The screw (11) only rests on the tailstock (10) to allow rapid release and fastening.
The plastic preform feeding screw (11) has a helicoid cross-section with a constant pitch to ensure
continuous preform feeding. A spindle (18) is provided on the base of the screw (11) for coupling a
respective shaft (17) with quick coupling device (20). The opposite side of the screw (11) is equipped
with an insert (19) and housing for the feeding screw tailstock (10). The preform feeding screw (11)
turns clockwise (movement ) and it held in position by the spring (21) which acts between hub (22)
and quick coupling (20).
The preform feeding wheel (26), has two coupled metallic wheels and is equipped with contoured
housings required for fastening and advancing the preforms, transporting the preforms in the correct
position without rocking from the feeding screw to the oven wheel and turning them by approximately
90 degrees. The preform feeding wheel (26) is fastened to the machine frame by means of a flanged
shaft (31) and a hub (24). A gear (23) for transmitting motion is fastened to the opposite end of the
flanged shaft (31). The hub (24) houses wheel (26) synchronization sensor (25). This sensor detects
if wheel (26) stops turning and stops the machine. The preform feeding wheel (26) motion (movement
) is guaranteed by the gear (23) and is synchronized with the oven control wheel. Synchronization
sensor (25) and fibre optics counter (29) which detect working problems are installed near and on the
preform feeding wheel (26).
The slanted guides (2) allow a first dimensional check of the preforms. The flat guides (7) are suitably
adjusted so to touch the preform collet by means of spacers (4) and adjustable spacers (5). Further-
more, the guides are equipped with a hinged drop-down safety cam (3) for ejecting preforms being
rejected and/or which were squeezed by the feeding screw (11) due to the low number of preforms
(lack of weigh in the preform hopper column), oval preforms or crushed preforms. Preform input is
regulated by gears (9) whose rotation can be stopped by the pneumatic cylinder (7) fastened to the
shim (5) by means of the bracket (8). The preform feeding wheel (30) guide can be also be adjusted
in height by means of spacers (28) and adjustable spacers (27) and is coupled to the flat guides (6)
MO-A0399_02.fm
to form a single surface. This guide (30) is contoured so to follow the profile of the preform feeding
wheel (26) to facilitate entry of preforms in the wheel.
Preforms are checked by the fibre optics counter (29) which counts the preforms let into the feeding
Functional units
2-17
wheel (26).
The preform feeding screw (11) is driven by timing belt (14) and gears (16). Gears (16) is operated
via pinion (12) directly on gear (23) (movement ). The gears (16) transfer movement to timing belt
(14) which is held taut by means of a specific take-up device (15). The shaft (17) is connected to one
end of the pulley (13) with internal clutch. The other end is fastened to the preform feeding screw (11)
by means of a quick coupling device (20).
Functional units
2-18
SFR 20
Operating Manual
1 Support 13 Pulley 25 Synchronization sensor

2 Slanted guides 14 Timing belt 26 Preform feeding wheel
3 Safety cam ball bearing 15 Take-up device 27 Adjustable spacers
4 Adjustable spacers 16 Gears 28 Spacer
5 Spacer 17 Shaft 29 Fibre optics counter
6 Flat guides 18 Spindles 30 Preform feeding wheel guide
7 Pneumatic cilinder 19 Insert 31 Flanged shaft
8 Bracket 20 Quick coupling device
9 Gears 21 Spring
10 Feeding screw tailstock 22 Hub
MO-A0399_02.fm
11 Preform feeding screw 23 Gear

12 Pinion 24 Hub
Figure 2-11. Preform feeding unit
Functional units
2-19
2.3.4 LOADING AND UNLOADING FUNCTIONAL UNIT
The loading and unloading functional unit is involved in the loading/unloaded process phase ( figure
2-12).
The loading/unloading function unit loads the preforms supplied by the preform functional unit and
conveys them after conditioning to the transfer functional unit.
The loading and unloading function unit includes the following main components:
oven control wheel;
preform loading/unloading;
preform holder chain;
oven control wheel;
preform check contour;
optical pyrometer.
The oven control wheel assembly consists of oven control wheel (2), crown support (12), crown (13)
and oven control wheel support (1). The oven control wheel assembly is housed on the upper oven
plate (7) fastened to the upper frame. Crown support (12) is a sliding bearing which allows crown (13)
to turn. Crown support (12) is lubricated by a dedicated lubrication device. Crown (13) bolted to sup-
port (12) and turns the oven control wheel (2). The oven control wheel support (1) fastens the oven
control wheel (2) to the crown (13) and is driven by the latter.
Preform loading/unloading is ensured by preform loading/unloading carriages (16) and loading/un-
loading cams (8), (10) and (9). The preform loading/unloading carriage consists of a guide pin (17),
a slide (20) and rollers (19) and (18). The top of the guide pin (17) is fastened to the oven control
wheel (2), while the lower part is fastened to the support (21) allowing angular movements of the car-
riage (16). The vertical movement of slide (20) occurs along the guide (22) with built-in return spring
(23). The slide (20) is held in home position (upwards) by spring (23) and moves downwards for load-
ing and unloading the preforms by effect of the roller (19) along the cam profile (9). While loading,
the preform is fastened to the slide (20) by means of fork (15). It is inserted in the preform holder by
the upwards movement of slide 20, movement ). During unloading, it is released from the preform
holder by the downwards movement of slide 20, movement ) and passed onto the fork (15). Cams
(8), (10) and (9) are fastened by means of screws to follow the oven wheel profile. The upper cam
(8) prevents violent upper rebound of the slide (20) and the safety counter cam (10) lifts the slide up
(20) if it seizes. A micro limit switch fastened to the base plate by means of a support detects pre-
forms not transferred by the loading/unloading unit to the preform transfer wheel. The micro limit
switch is equipped with a rod so to touch the preform holder chain. If a preform is inserted in the
preform holder, the limit switch rod will knock into it the next time round and will be moved to home
position. The tripped limit switch stops the machine immediately.
The preform holder chain (24) consists of a set of plastic material double links assembled by means
of steel pins (25) with roller guides (26) fastened to the ends allowing the chain to the driven by the
oven control wheel (2) and housings for the rollers. Furthermore, the rollers (26) allow the chain to
slide in the specific guides arranged along the route. The preform holder chain joints (24) let the
chain move on the vertical axis and on the horizontal axis (movement and ). Each joint is formed
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Operating Manual
by two links. Each link has an bored arm (26) housing a spindle (28) which can turn on its axis by
means of two bushings. Pinion (27) and the preform holder to which the preform is attached are fas-
tened to the two ends of the spindle (28). In each link, the section of spindle (28) equipped with pinion
(27) has a different length with respect to one next to it, to keep the pinions (27) from interfering with
each other on preform holder chain (24) bends. This is because pinions (27) engage a double chain
fastened to the machine structure which turns it allowing the preform to turn on its axis.
The oven control wheel (2) consists of a cast iron, machined, nickel-coated, specifically contoured
part (14) which central part houses the roller guides (26) of the preform holder chain (24). Holes for
housing the upper end of the guide pin (17) fastened the preform loading/unloading carriages (16)
are provided in the same area. The oven control wheel (2) turns in sync with the preform feeding units
and preform transfer units (movement ).
The preform check contour (6) consists of a suitably contoured sheet (5) and a rocker (4) fitted on a
support base. It is positioned on the base plate (11) where the preform holder chain (24) leaves the
oven control wheel (2). The preform check contour (6) ensures that no deformed preform or badly
inserted preform can reach the oven inlet and damage it. Preforms presenting a very curved body
knock in to the contoured sheet (5) moving it. This movement is detected by a sensor which operates
the ejection cylinder which removes the faulty preform from the respective preform holder.
Optical pyrometer (31) consists of one sensor montabile which can be fitted in three positions so to
encompass the entire body of the preforms conveyed by the preform holder chain into the oven. It
is housed on a support (30) which is fastened to the upper frame immediately before the transfer
wheel. It is angled to "see" three consecutive preform sections. Optical pyrometer (31) controls and
authorizes preform blowing only when optimal temperature is reached. The control operated by the
optical pyrometer (31) also effects the preform conditioning process with the possibility of adjusting
the oven temperature (power output by the lamps).
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1 Oven control wheel support 12 Crown support 22 Guide
2 Oven control wheel 13 Crown 23 Spring
3 Pitch change cam 14 Contours 24 Preform holder chain
4 Rocker 15 Fork 25 Pins
5 Contoured sheet 16 Preform loading/unloading 26 Guide rollers
6 Preform check contour carriages 27 Pinion
7 Upper oven plate 17 Guide pin 28 Spindle
8 Upper roller cam 18 Guide roller 29 Bored arm
9 Roller cam 19 Roller 30 Support
10 Safety counter cam 20 Slide 31 Optical pyrometer
11 Base plate 21 Support
Figure 2-12. Loading and unloading unit
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2.3.5 OVEN FUNCTIONAL UNIT
The oven functional unit is involved in the conditioning process ( figure 2-13).
The oven functional unit conditions the preforms from the preform loading and unloading functional
unit.
The oven functional unit includes the following main components:
oven lamp support joints;
preform holder chain guide (11);
preform holder chain take-up system (14);
preform collet cooling;
preform holder rotation system;
Inversion stabilizer system;
oven lamp support (45);
optoelectronic system (49) (OPTIONAL);
oven fan.
The oven lamp support joints consists of a joint support (7), an upper slide (5), a hinge (3) and an
upper bracket (1). The joint support (7) is fastened to the oven frame (16) by means of bolts. It height
can be adjusted. It supports the oven lamp support section (43) allowing partial tipping individually or
in pair (according to the number of lamp supports in the section). The upper slide (5), coupled to the
upper bracket (1),rests on the joint support (7). The oven lamp support section (43), fastened to the
upper slide (5) on supports (6), can be moved slightly lengthwise by means of the adjustment knob
(4). The upper bracket (1) houses the jointed hinge (3) for tipping the oven lamp support (43) and is
actuated by handle (2). The upper slide (5) is equipped with an arm (8) for fastening the gas shock
absorber (9) which assists tipping of oven lamp support section (43). The upper bracket (1) is the
component in contact with the support profile (29) of the oven lamp support section (43). It is
equipped with an arm (10) for housing the other end of the gas shock absorber (9) for tipping the oven
lamp support section (43).
The upper bracket (1) is in contact with the supporting section (29) of the oven lamp support section
(43).
The preform holder chain guide is split into two separate parts. An inner chain guide (11) is arranged
along the entire length of the oven lamp units (43), from the oven frame end (16) to near the preform
holder chain take-up system (14). An outer chain guide (26) is arranged on the top of the upper frame
(28). The inner chain guide (11) consists of two anodized aluminium metal profiles (20) which upper
parts are fastened to the oven frame (16) arranged on both sides of the frame. The metal profiles (20)
are C-shaped and consequently force the preform holder chain rollers (22) to run on along a fixed,
MO-A0399_02.fm
obliged route. Two plastic profiles (21) supporting the double preform holder drive chain (32) are fas-
tened to the oven frame (16) immediately under the metal profiles (20). The outer chain guide (26)
consisting of two support arms (27), a C-support base (25) and a plastic profile (24), is the actual
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guide. The outer chain (26) is symmetric with respect to the upper frame (28) at oven frame outlet
(16) before the inversion stabilization system.
The preform holder chain take-up system (14) is housed in the ends of the oven lamp support sec-
tions (43) and is fastened to the connection crosspiece (18) between the two oven frame main beams
(16). The preform holder chain take-up system (14) consists of two semi-circular guides (12) fastened
centrally to a mechanical piston (13) by means of bolts. A plastic flange (15) which profile is similar
to the two guides described above is fastened under the two guides (12) and has a central groove
for guiding the preform holder pinions. The preform holder chain take-up system is actuated by a me-
chanical piston (13) which has a spring (17) and can be adjusted by means of a nut and lock nut (19)
on the side opposite to the connection crosspiece (18). An emergency limit switch is housed on the
top of the crosspiece which purpose is to stop the machine if the preform holder chain is too taut.
The preform collect cooling system consists of a hollow metal section (30) in which cooled water from
the auxiliary functional unit chiller flows. The section (30) touches the preform collet while they move
along the oven keeping the temperature in this area lower with respect to the body of the preform.
The section (30) is installed on the oven frame (16) along the inner chain guide (11) and is equipped
with quick coupling fittings on the two ends to connect to the water system by means of hoses. Sec-
tion (30) of the oven lamp support sections (43) is fitted on the support frame (29) by means of spac-
ers (31) ensuring an optimal distance from preform collets. The oven lamp support section (43)
section (30) cavities are connected by means of quick coupling fittings and hoses.
The preform holder system is turned by the double chain (32) which develops along the right and left
hand side of the oven frame (16). The double chain (32) engages the pinions on the opposite end of
the preform holder chain (22) turning the system and consequently the preforms. The double chain
(32) is fastened to the oven frame (16) by one end and is pulled by a spring (34) and a tie-rod (33)
on the opposite side. The tie-rod (33) consists of a threaded bar (37), a nut (35) and a lock nut (36).
Careful management of the preform body temperature is achieved by means of the inversion stabili-
zation system. This system allows to change (increase or decrease) the time of permanence of pre-
forms from the oven in the open air before reaching the stretching/blowing unit to obtain the perfect
temperature conditions for blowing. The inversion stabilization system consists of two semicircular
guides (38), which are similar to those of the preform holder chain take-up system (22), can advance
or retract along the crosspieces opposite to the upper frame (28). The movement of the two guides
(38) is ensured by two wormscrews (40) controlled by a handwheel (42) and by a motion transmission
system (41) inside the upper frame beams (28). Furthermore, two sliding guides (39) ensure the ap-
propriate structural stiffness for the guides (38) regardless of their position.
The oven lamp support (45) consists of an aluminium sheet box. The lamps (46) are housed in the
upper part. The opposite side of the oven lamp support (45) has a sleeve (48) for electrical wires lead-
ing to an inner terminal board. It also contains a baffle (47) for cooling air from oven fans (50) which
crosses lamps (46) and is let out from grid (44) on the top. Several oven lamp supports are fastened
to the supporting section (29) to form the oven lamp support section (43).
The optoelectronic system (preform monitoring camera) (49) (OPTIONAL) is located on top of the
outer chain guide (11) outside the upper frame (28) before the preform oven unit entry. The system
compares the preforms being let into the oven against a sample of perfect preforms from dimensional
and qualitative points of view (clarity, inclusions and blow holes). The passage of a faulty preform
generates an alarm signal. All identified preforms are unloaded if the problem effects quality. The ma-
chine is immediately stopped to safeguard the oven lamps if, on the other hand, the problem is relat-
ed to dimensions ("big banana" excessively bent preform alarm).
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Operating Manual
The oven fans (50) have two functions: to make the heat flow in the oven even and to cool the oven
frame (46). The fans are arranged in central position on the oven frame (16). Each fan cools a single
oven lamp support (45) on each side. Each oven fan (50) consists of an electric motor (54) arranged
in central position, an impeller (55) and tangent air flow distribution system, an air vent (52) which is
protected by a large link mesh (56) on the top and two vents (51) fitted on the two opposite sides near
the respective oven lamps (46). Two C-shaped sheets (53) are provided for partially insolating the
area between the oven lamps (46) and the oven fans (50) to prevent heat dispersion, optimize heat-
ing and re-address the heat flow of the last lamp in the support (45) towards the upper part of the
preform.
.
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Figure 2-13. Oven unit (Sheet 1 of 3)
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Operating Manual
Figure 2-13. Oven unit (Sheet 2)
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1 Upper bracket 21 Section 40 Wormscrew
2 Handle 22 Preform holder chain 41 Transmission system
3 Hinge 23 Connection 42 Handwheel
4 Knob 24 Section 43 Oven lamp support section
5 Upper slide 25 C-base 44 Grid
6 Support 26 Outer chain guide 45 Oven lamp support
7 Joint support 27 Support arms 46 Lamp
8 Arm 28 Upper frame 47 Baffle
9 Gas shock absorber 29 Support section 48 Sleeve
10 Arm 30 Section 49 Optoelectronic system
11 Inner chain guide 31 Spacer blocks 50 Oven fans
12 Guide 32 Chain double 51 Vents
13 Mechanical piston 33 Tie-rod 52 Air vents
14 Platorelli chain take-up system 34 Spring 53 Sections
15 Flange 35 Nut 54 Electric motor
16 Oven frame 36 Lock nut 55 Impeller
17 Spring 37 Threaded bar 56 Mesh
18 Connection crosspiece 38 Guide
19 Nut and lock nut 39 Sliding guide
20 Metal sections
Figure 2-13. Oven unit (Sheet 3)
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Operating Manual
2.3.6 TRANSFER FUNCTIONAL UNIT
The transfer functional unit is involved in the preform transfer and bottle transfer process phase
( figure 2-14).
The transfer functional unit transfers the preforms from the loading and unloading unit to the stretch-
ing/blowing unit and transfers the bottle from the latter unit to the bottle ejection unit.
The transfer functional unit comprises the following main components:
preform and bottle detection and ejection;
preform transfer wheel (16);
bottle transfer wheel (28).
The bottles which are not transferred from the stretching/blowing unit to the bottle transfer wheel are
detected by a micro limit switch (4) which is fastened to the top of the upper frame by means of the
support (1). A plate (3) with rod (2) is fastened to the front of the micro limit switch (4). The rod is
adjusted to touch the area corresponding to the bottle collet in the blowing molds of the stretching/
blowing unit. If a molded bottle is not fastened to the bottle transfer wheel (28) grippers (29) it knocks
into the rod (2) turning the wheel (3) and consequently tripping the limit switch (4) which immediately
stops the machine. The grippers (17) and (29) of the preform transfer wheel (16) and the bottle trans-
fer wheel (28), if forced, can turn on themselves to prevent missing position. In this case, grippers
(17) and (29) respectively trip the preform ejection limit switch and limit switch (8) which stop the ma-
chine preventing the gripper from reaching the preform or bottle transfer point. Preform ejection is
actuated by the ejector (10) (movement ) on bracket (9) fastened to the plate on the top of the up-
per frame. The ejector (10) works near the tangent of the preform transfer wheel (16) by means of
rod (11). If tripped, it ejects the preforms on the wheel, releasing the respective grippers (17). It is
controlled either by the optical pyrometer (preform temperature unsuitable for blowing), by the pre-
form monitoring camera (faulty preform) or manually, when required. This same operation is carried
out by the ejector (7) (movement ) on the bottles before reaching the bottle ejection system. The
ejector (7) is fastened to the bracket (6) positioned on the crosspiece (5) connecting the bottle ejec-
tion system and the upper frame. It is controlled either by the blowing chamber pressure switches
(low pressure or exploded bottles), by the bottling line (overload, jamming) or manually, when re-
quired. When started up after a machine stop, both ejectors are worked to unload all preforms and
bottles from the machine.
The preform transfer wheel (16) (movement ) is fitted on the flanged shaft (12) installed in the hub
(13) on the plate on top of the upper frame in the most suitable position to be tangent to the oven
control wheel and to the stretching/blowing wheel. The flanged shaft (12) turns on two ball bearings
on the end of the hub (13). The preform transfer wheel (16) is equipped with a fork (19) which engag-
es the lower part of the flanged shaft (12) spline (18) for adjusting the wheel. Housings for the transfer
levers (15) are arranged around the preform transfer wheel. The transfer lever has an arm (24) hous-
ing the gripper (17) and a pin (23) turning in the sleeve (22) by means of a ball bearing. A second
arm (20) is fitted on the opposite end of the pin (23). It forms a 90 angle with respect to the arm (24).
A roller (21) assisted by spring (26) follows the profile of the cam (14) installed on the flanged hub
(13) over the preform transfer wheel (16) to synchronize the various functional units. The sleeve (22)
MO-A0399_02.fm
allow arm (24) to turn is fastened to the preform transfer wheel (16) by means of flange (25) and bolts.
The bottle transfer wheel (28) (movement ) is positioned on the upper frame beam facing the bottle
ejection auxiliary unit. From a construction point of view, the bottle transfer wheel (28) is similar to
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the preform transfer wheel (16), with the exception of the cam (27).
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Operating Manual
Figure 2-14. Transfer unit (Sheet 1 of 2)
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1 Support 11 Rod 21 Roller
2 Rod 12 Flanged shaft 22 Sleeve
3 Plate 13 Hub 23 Pin
4 Limit switch 14 Cam 24 Arm
5 Crosspiece 15 Transfer lever housings 25 Flange
6 Support 16 Preform transfer wheel 26 Spring
7 Ejector 17 Gripper 27 Cam
8 Limit switch 18 Pin 28 Bottle transfer wheel
9 Bracket 19 Fork 29 Gripper
10 Ejector 20 Arm
Figure 2-14. Transfer unit (Sheet 2)
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Operating Manual
2.3.7 STRETCHING/BLOWING UNIT
The stretching/blowing unit is involved in the stretching/blowing process.

The stretching/blowing functional unit mechanically stretches and blows the preforms in the blowing
molds into their final shape (container).
The stretching/blowing functional unit includes the following main components:
blowing wheel;
mold opening/closing cam;
rotating fitting;
blowing press;
blowing mold;
stretching cam;
stretching/blowing system.
2.3.7.1 Blowing wheel
The blowing wheel (1) ( figure 2-15) is housed in the upper part of the blowing press housing. The
blowing wheel is fastened to the brake disc (2) and to the fifth wheel (3). The fifth wheel (3) is fastened
to the lower part of the machine frame by means of screws. The fifth wheel (3) has a dedicated lubri-
cation system consisting of a lubrication block (9) with lubrication cartridge (10). The lubricators ar-
ranged along the inner diameter of the fifth wheel (3) are feed by the lubrication block by means of
fittings (11) and (13) and suitable shaped plastic and copper tubes (12). The blowing wheel (1) is
turned (movement ) by the gear motor via the fifth wheel coupling (3) which is fastened to the blow-
ing wheel (1) and the intermediate crown wheel (4) on the drive plate (5). The blowing wheel (1) has
pneumatic brakes arranged on the diameter of the wheel near the brake disc (2).The brakes (6) are
fitted on suitable supporting bases (7) and can be adjusted in height by means of spacers. The
brakes (6) are operated by a pneumatic actuator (8) and feed by the machine pneumatic system via
a safety pressure switch.
2.3.7.2 Mold opening/closing cam
The mold opening/closing cam (1) consists of ( figure 2-16) an outer output cam (20), an inner output
cam (18), an inner central cam (22), a mobile outer input cam (21) and an outer input cam (23). Glo-
bally, the five cams guide the roller (10) allowing the correct opening and subsequent closing of the
press (24) in the preform and bottle transfer sector of the blowing wheel. The mold opening/closing
cam (1) is fitted on the cam plate (11) by means of spacers (13) allowing the cam (1) to correctly en-
gage the rollers (10) and the joints (12) which allows a certain mobility to the mobile outer input cam
(21), the outer output cam (20) and the inner output cam (18). In particular, la outer output cam (23)
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is the first guide which the roller (10) engages (movement ) after leaving the safety cam (2) due
to the blowing wheel turn. The roller (10) is obliged to travel along the corridor between the outer out-
put cam (23) and the inner central cam (22), sliding gradually (movement ) towards the middle of
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the blowing wheel because it is obliged by the mobile outer output cam (21) to reach the point of the
inner central cam (22) in which the press (24) is fully open. Over this point, the inner central cam (22)
guides the roller (10) gradually back (movement ) and closes the press (24). The roller runs along
the corridor between the outer output cam (20) and the inner output cam (18) until it is finally released
from the mold opening/closing cam (1) to be engaged by the safety cam (2) again (2). The mobile
outer output cam (21) turns on a joint (12) by means of a pneumatic actuator (17) which normally
holds it closed against a stop with limit switch (14). The pneumatic actuator (17) in particular circum-
stances can turn the mobile outer output cam mobile (21) opening it and preventing damaging the
press (24). Also the inner (18) and outer (20) output cams can turn slightly on their joints (12). They
are kept into position respectively by a gas spring (16) and a spring guide (15). Both cams normally
rest on stops with limit switches (14). The outer output cam (20) avoid shock caused by the press
closing (24) and protects the roller (10). The same effect and solution is found at mold opening/clos-
ing cam output (1) when the roller (10) passes into the inner output cam (18). The mobile outer output
cam (21), the inner central cam (22) and the outer output cam (20) are lubricated by means of grease
dispensers (19) arranged either on or near the respective cams. The safety cam (2) is arranged
around the blowing wheel, outside the sector occupied by the mold opening/closing cam (1). It is fas-
tened to the lower frame (3) by means of spacers (8) and to the cam plate (11) by means of two sup-
ports (9). The safety cam (2) consists of a tubular steel element which is bent to follow the profile of
the blowing wheel and is closed on the back of the machine into two mobile sectors which allow to
open and close the presses (24) for maintenance and to replace the molds. The mobile input sector
(4) is controlled by a pneumatic actuator (7) while the mobile output sector (5) is held in position by
a spring tie-rod (6) which bends when the roller passes (10).
2.3.7.3 Rotating fitting
The rotating fitting feeds water and air to the presses and to the blowing molds. The rotating fitting
includes the following main components ( figure 2-17):
fitting block support;
fitting block;
rotating fitting.
The fitting block support (4) is fastened by means of screws to the lower machine frame basement.
The fitting block (3) is housed in the fitting block support (4).
The fitting block (3) connects the manifold on the machine frame lower base (feed by the main man-
ifold) to the rotating fitting (1) by means of hoses. It is fastened to the fitting block support (4) by the
intermediate plate (5) and is consequently fastened to the machine frame. The rotating fitting (1) is
fastened by means of screws (2) to the fitting block (3) and is free to turn (movement ) on its vertical
axis (thanks to an inner bearing) in sync with the blowing wheel. The rotating fitting (1) is turned by
two drives (6) and (7). The rotating fitting (1) has inputs and outputs with suitable fittings to distribute
compressed air at a pressure of 6 bar (9) and (10), 15 bar (11) and 40 bar (8), cooling water to molds
(14), cooling water to bottoms (13) and controlled temperature water of external mold (12) and inner
mold (15).
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Operating Manual
2.3.7.4 Blowing press
The blowing press includes the following main parts ( figure 2-18):
press frame;
compensation cylinder;
bottom holder carriage;
bottom quick change.
PRESS FRAME
The press frame (5) is fastened to the upper base of the blowing wheel by means of screws (22), (24)
and centring pin (23). The press frame consists of a fixed part. The upper part of the press frame (5)
has housings for the press closing fixed pin (4) and preform holder lock plate (3). The central part has
housings (2) for the compensation cylinder (31) and the inner half mold (fixed). The lower part has
housings for the upper fork (6) and the lower fork (8) for fastening the mobile part of the press. The
mobile part of the press consists of a connecting rod and double joint mechanism. The mechanism
consists of an outer mold holder (12), an upper connecting rod (15), a control connecting rod (17)
and a carriage (9). The outer mold holder (12) (movement ) is fastened to the upper fork (6) of the
press frame (5) by means of pins (14). The outer mold holder (12) is equipped with an upper pin (1)
which is required with the mold closing fixed pin (4) to clamp the press during preform blowing (seal
down). Furthermore, the outer mold holder (12) has housings for the outer half mold (mobile) and for
fastening the upper part of the upper connecting rod (15). Fastening is obtained by means of an offset
knuckle pin (7) and an offset knuckle pin block (11). The upper part of the upper connecting rod (15)
is fastened to the outer mold holder (12) by means of fork and offset knuckle pin (13). The lower part
is connected to the control connecting rod (17) by means of the two knuckle pins (16). The control
connecting rod (17) is fastened in three points, on the top, the middle and the bottom. The top is con-
nected to the upper connecting rod (15), the middle is connected to the press frame (5) by means of
sleeves and pins (21) and the bottom is connected to the roller holder pin (19) of the carriage (21) by
means of rods (20). The carriage (9) is equipped with shoes (26) and (29) which can slide (move-
ment ) along the guides (25) and (30) fastened to the lower part of the press frame (5). The central
part of the carriage (9) has a housing for the roller holder pin (19). The upper roller holder pin (19) is
fastened to the control connecting rod (17) by means of fork and pin (18), while the lower part has
two rollers (27) and (28). The travel of carriage (9) is limited by the blowing wheel at the back and by
the limit switch at the front (10).
COMPENSATION CYLINDER
The compensation cylinder (31) is housed in the respective housing in the middle part of the press
frame (5) and is fastened by means of two mold holder blocks (38) and the respective screws (37).
It compensates the effects (mold opening) due to the primary and secondary action of the air inside
the blowing mold. This is because the cylinder exerts a pressure to cancel the minimum play of the
mold closing seal by pushing the inner half mold against the outer half mold (mobile) (movement ).
The compensation cylinder (31) consists of a liner (35), a cylinder (33), a spring (34), a rear washer
MO-A0399_02.fm
(40) and a front plate (36). The cylinder (33) with suitable o-rings and seals is housed inside the liner
(35). The rear washer (40) and the front plate (36) close cylinder (33), spring (34) and liner (35) by
means of screw (32). The rear washer (40), the cylinder (35) and the front plate have two channels
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(39) and two conduits (41) to ensure the passage of coolant into the inner half mold water circuit.
BOTTOM HOLDER CARRIAGE

The bottom holder carriage consists of a bottom support (48), a shoe (55) and a guide (49).
The guide (49) is fastened by means of screws to the press frame (5) in the part under the compen-
sation cylinder (31) housing (2). The guide (49) allows vertical movement of the shoe (55) which is
fastened by means of screws (57) to the bottom support (48) via plate (56). The front part of the bot-
tom support (48) is equipped with a roller (53) fastened to it by means of the a pin and a nut (52). The
roller (53) is arranged to slide insider the cam on the control connecting rod (17). This arrangement
allows the vertical movement of the bottom holder carriage (downwards) when the press is opening
(movement ).
BOTTOM QUICK CHANGE

The bottom quick change consists of a manifold (42), a button (43) with return spring and two quick
coupling fittings (46). The upper part of the manifold (42) has a housing for mold bottom and the lower
part has a housing for button (43) and housings for fittings (46). The two fittings (46) are linked up to
the water system and consequently ensure mold cooling via the conduits inside manifold (42). Button
(43), with return spring (44), is fastened to the manifold (42) by means of a guide and pin (47). The
button and return spring system allows to rapidly connect/disconnect the manifold (42) and the return
of the mold bottom to the bottom holder carriage centring device (50).
2.3.7.5 Blowing mold
The blowing mold (15) consists of ( figure 2-19) an inner mold (4), an outer mold (1), a inner mold
holder (8), and outer mold holder (5) and a bottom (3). The inner (4) and outer molds (1) are fastened
by means of screws to the inner mold holder (8) and to the outer mold holder (5) respective to form
the inner half mold (14) and outer half mold (16). The inner half mold (14) is fastened by means of
screws (13) to the press frame (9), while the outer half mold (16) is fastened to the outer mold holder.
The lower part of the mold consists of the bottom (3) which is fastened to the bottom quick change
by means of screws. When the mold is closed (press closed), the outer half mold (16), fastened to
the outer mold holder, approaches the inner half mold (14) (movement ) to close it completely. At
the same time, the bottom (3) moves upwards (movement ), being fastened to the bottom and to
the bottom quick change, ensuring the prefect closure of the lower part of the mold. The upper part
of the mold is closed by the downwards movement of the seal (mold close plate) (movement )
which, at the same time, prevents the press from opening. The preform transferred from the mold is
fastened into position by the fork (6). The fork (6), fastened to the inner half mold (14) by means of
the guide (7) and the lock plate (11), is equipped with a slot for quick release/fastening by means of
a spring piston (10). The outer half mold (16) also has a coolant inlet and outlet (12). The outer mold
(1) and inner mold (4) have coolant inlets and outlet (2) on the top (symmetric arrangement).
2.3.7.6 Stretching cam
The stretching cam (1) ( figure 2-20) consists of a rod raising cam (12), an upper cam (10) and a rod
descent cam (11). The three cams are connected by the two upper supports (2) and (7). The stretch-
ing cam (1) consists of two nitrated steel bars which are bent to follow the profile of the blowing wheel.
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SFR 20
Operating Manual
The stretching cam (1) is fastened to the plate (6) on the top of the upper frame by means of two
lower supports (5) and (9), two upper supports (2) and (7) and an intermediate support (8). It guides
the stretching rollers allowing accurate engagement or extracting the stretching rod from the pre-
forms/bottles before the press closing/opening sector. The stretching rod thus gradually stretches the
preform while it is being molded and retracts rapidly before the press opens. The lower end of the
rod raising cam (12) is fastened to the lower support (9) by means of bolts and centring pins. The
opposite end of the rod raising cam (12) is fastened to the upper support (2) and is topped by a stretch
of the upper cam (10) forming a single part and reducing the coupling step. The rod raising cam (12)
has upper holes on nearly its entire length. These holes allow fitting of the rod quick raising section
(4) according to the dimensions of the bottle to be molded in suitable position along the cam (12).
Guiding the stretching roller, the rod rapid raising section (4) ensures a rapid initial detachment of the
stretching rod from the bottom of the bottle. This profile (4) is equipped with a grease dispenser (3)
for lubricating the stretching cam (1) roller race. The ends of the upper cam (10) are fastened to the
two upper supports (2) and (7). The middle is connected to the intermediate support (8). It guides the
roller and, consequently, the stretching rod which is in all removed position, avoiding any form of in-
terference with the collet of the recently molded bottle. In central position, the upper cam (10) has a
step of a few millimeters to additionally raising the stretching rod, preventing any interference with
the mechanical units for the preform/bottle transfer unit. The rod descent cam (11) allows the pro-
gressive descent of the stretching rod by guiding the respective roller to reach the bottom of the mold.
One end is fastened to the lower support (5) and the opposite end is fastened to the upper support
(7) topped by the upper cam (10) with which it combines to reduce the coupling step.
2.3.7.7 Stretching/blowing system
The stretching/blowing system ( figure 2-21) includes the stretching and blowing assembly.
The stretching assembly consists of a stretching structure (3), fastened to the upper part of the press
by means of screws. A pneumatic cylinder (1) is fitted to the top. A sliding carriage (2) sliding guide
(4) is connected by means of screws to the stretching structure on the longitudinal axis. The sliding
carriage (2) is fastened by means of screws to the shoe (14) and is free to slide along the guide (4).
The sliding carriage is driven by the pneumatic cylinder rod (1) on roller (7) (vertical downwards
movement) (movement ). The roller is fastened to the sliding carriage (2) by means of the roller
holder pin (12) and lock ring (6). It follows the stretching cam profile operating the sliding carriage (2)
during the raising phase (vertical upwards movement) (movement ). The sliding carriage move-
ment is limited at the bottom by a mechanical stop (13), on which the decelerator operates (11), and
at the top by the stretching structure (3). It has a resting cylinder (17) with compression spring (15)
and elastomer spring (16) for slowing the carriage down. The sliding carriage also has a housing (8)
for the stretching rod (5), fastened to it by means of the mechanical stop (10) and the two lock plates
(9). This arrangement allows to centre the rod with respect to the blowing assembly.
The blowing assembly is fastened to the lower part of the stretching structure (3). The blowing as-
sembly comprises a blowing cylinder (19) and a press closing plate (seal) (18). The blowing cylinder
(19) consists of an upper block (22), a lower block (24), a liner (27) and tie-rods (23). The upper block
(22) and the lower block (24) close the liner (27) by means of the tie-rods (23). The upper part of the
upper block (22) has an inlet hole (21) for the stretching rod (5) and inputs and outputs (20) for the
blowing air. Sleeve (29) is housed inside the piston liner (27). The central part of the sleeve has a
MO-A0399_02.fm
housing for the piston (31), which is fastened to it by means of the lock ring (30). The lower part has
a housing for the press closing plate (18), which is fastened to its by means of a collet holder plate
(32) and screws. The sleeve movement (29) (movement ) is fastened to that of the press closing
Functional units
2-37
plate (18). The press closing plate (18) has three holes, one central (25) for housing the collet holder
plate (32) and for fastening the sleeve (29) and two side holes (26) with bushings (28). During the
stretching/blowing phase, the piston (31) lowers the sleeve and the press closing plate engages the
two pins on the press ensuring press closure and sealing of blowing mold.
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2-38
SFR 20
Operating Manual
1 Blowing wheel 8 Pneumatic actuator

2 Brake disc 9 Lubrication block
3 Fifth wheel 10 Lubrication cartridge
4 Drive intermediate crown 11 Fitting
5 Drive plate 12 Tube (plastic or copper)
MO-A0399_02.fm
6 Brake 13 Fitting
7 Supporting base
Figure 2-15. Stretching/blowing system - Blowing wheel
Functional units
2-39
1 Mold opening/closing cam 10 Roller 19 Grease dispenser
2 Safety cam 11 Cam plate 20 Outer output cam
3 Lower frame 12 Joints 21 Mobile outer output cam
4 Mobile input sector 13 Spacers 22 Inner central cam
5 Mobile output sector 14 Limit switch 23 Outer output cam
6 Spring tie-rods 15 Spring guide 24 Press
7 Pneumatic actuator 16 Gas shock absorbers
8 Spacers 17 Pneumatic actuator
9 Supports 18 Inner output cam
Figure 2-16. Stretching/blowing system - Mold opening/closing cam
Functional units
2-40
SFR 20
Operating Manual
1 Rotating fitting 7 Drive ant feed (external mold)

2 Screws 8 40 bar air feed 13 Bottom coolant feed
3 Fitting block 9 6 bar air feed (stretching rod) 14 Mold coolant feed
4 Fitting block support 10 6 bar air feed (seals) 15 Temperature controlled cool-
ant feed (inner mold)
MO-A0399_02.fm
5 Intermediate plate 11 15 bar air feed

6 Drive 12 Temperature controlled cool-
Figure 2-17. Stretching/blowing system - Rotating fitting
Functional units
2-41
1 Pin 11 Offset pin block 21 Sleeves and pins
2 Housing 12 Outer mold holder 22 Screw
3 Preform holder clamp 13 Offset knuckle pin 23 Pin
4 Press closing fixed pin 14 Pins 24 Screw
5 Press frame 15 Upper connecting rod 25 Guide
6 Upper fork 16 Knuckle pins 26 Shoe
7 Offset knuckle pin 17 Control connecting rod 27 Roller
8 Lower fork 18 Pin 28 Roller
9 Carriage 19 Roller pin 29 Shoe
10 Limit switch bracket 20 Rods 30 Guide
Figure 2-18. Stretching/blowing system - Press (Sheet 1 of 2)
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SFR 20
Operating Manual
31 Compensation cylinder 40 Rear washer 49 Guide

32 Screw 41 Conduits 50 Centring device
33 Cylinder 42 Manifold 51 Screws
34 Spring 43 Button 52 Pin and nut
35 Liner 44 Spring 53 Roller
36 Front plate 45 Centring device housing 54 Pin
37 Screws 46 Quick couplings 55 Shoe
MO-A0399_02.fm
38 Mold holder blocks 47 Pin 56 Plate

39 Ducts 48 Bottom support 57 Screws
Figure 2-18. Stretching/blowing system - Press (Sheet 2)
Functional units
2-43
1 Outer mold 7 Guide 13 Screws
2 Coolant inlets/outlets 8 Inner mold holder 14 Inner half mold
3 Bottom 9 Press frame 15 Blowing mold
4 Inner mold 10 Spring piston 16 Outer half mold
5 Outer mold holder 11 Lock plate
6 Fork 12 Coolant inlet/outlet
Figure 2-19. Stretching/blowing system - Blowing mold
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SFR 20
Operating Manual
1 Stretching cam 5 Lower support 9 Lower support

2 Upper support 6 Plate 10 Upper cam
MO-A0399_02.fm
3 Grease dispenser 7 Upper support 11 Rod descent cam

4 Rod rapid raising section 8 Intermediate support 12 Rod raising cam
Figure 2-20. Stretching/blowing unit - Stretching cam
Functional units
2-45
1 Pneumatic cylinder 7 Roller 13 Mechanical stop
2 Sliding carriage 8 Stretching rod housing 14 Shoe
3 Stretching structure 9 Lock plates 15 Spring
4 Sliding guide 10 Mechanical stop 16 Elastomer spring
5 Stretching rod 11 Decelerator 17 Spring resting cylinder
6 Ring 12 Roller holder pin
Figure 2-21. Stretching/blowing unit - Stretching/blowing (Sheet 1 of 2)
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SFR 20
Operating Manual
18 Press closing plate 23 Tie-rods 28 Bushing

19 Blowing cylinder 24 Lower block 29 Sleeve
20 Air input/output 25 Central hole 30 Lock ring
MO-A0399_02.fm
21 Stretching rod hole 26 Side holes 31 Piston

22 Upper block 27 Liner 32 Collet holder plate
Figure 2-21. Stretching/blowing unit - Stretching/blowing (Sheet 2)
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2.3.8 BOTTLE EJECTION FUNCTION UNIT
The bottle ejection functional unit ( figure 2-22) releases and conveys the bottles produced in an or-
derly, sequenced way. The bottle ejection functional unit comprises the following main components:
release cam (2);
conveyor (1).
The release cam (2) is fastened to the machine frame by means of a suitable support. The cam (2)
is arranged to touch the lower part of the gripper (4) on the bottle transfer wheel (5). This ensures
that all produced bottles are released. The released bottles are sent to the conveyor (1) by means of
a sliding guide (6). The released bottle movement is facilitated by means of a jet of compressed air
from a conduit (3).
NOTE
The conveyor is an optional device. For this reason, it is not de-
scribed in this manual. Refer to paragraph 2.3.10.3 for general in-
formation.
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SFR 20
Operating Manual
1 Bottle conveyor 4 Gripper

2 Bottle release cam 5 Bottle transfer wheel
MO-A0399_02.fm
3 Compressed air conduit 6 Sliding guide
Figure 2-22. Bottle ejection unit
Functional units
2-49
2.3.9 CABIN FUNCTIONAL UNIT
The cabin functional unit is involved in all process phases. It isolates the machine from the surround-
ing environment and contains noise levels and vibrations.
The cabin functional unit ( figure 2-23) consists of a metal structure which completely encases the
machine. It is a protection system which protects the operator and other exposed persons from risk
and hazard of any sort, in addition to preventing indiscriminate access to moving parts inside the ma-
chine during the normal working process. Each machine flap has specific limit switches which are
monitored by the system to report "door open" condition which cuts of the electric circuit and imme-
diately stops the machine.
The cabin functional unit is equipped with the following parts:
Hinged doors (2) and (5) - for accessing the inside of the cabin (stretching/blowing area).
Tipping upper cover (8) - for accessing the upper part of the machine.
Fixed windows (7) and (11) - for visual inspection on behalf of the machine operator, from both
sides.
Sliding doors (10) - for accessing the transfer area and the preform loading and unloading rear
area.
Opening windows (1) - for accessing the preform loading areas.
Rejected preform flap (3) - for accessing the rejected preform collection compartment (carriage).
Rejected preform carriage (4) - for removing rejected preforms.
Oven unit flaps (6) and (9) - for accessing the oven unit.
Functional units
2-50
MO-A0399_02.fm SFR 20
Operating Manual
Figure 2-23. Cabin functional unit
Functional units
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2.3.10 AUXILIARY UNIT
The unit includes the following auxiliaries:

Main manifold (standard supply);
Hopper (indispensable, optional);
Bottle conveyor (optional);
Chiller (optional);
Compressor (optional);
Temperature adjuster (optional);
Mold holder carriage (optional);
Preform tipping device (optional).
2.3.10.1 Main manifold (standard supply)
Functions:
- Filtering the air and water from the chiller and the plan line compressor.
- Line air reduction from 38-40 bar to 15 bar (process air);
- Feeding supply at 6-8 bar (service air);
- Mixing of coolant from molds and ovens by means of specific valve, to eliminate dew (condensa-
tion).
2.3.10.2 Hopper (optional)
The hopper is essential for the good operation of the machine and may also not be supplied by SIPA.
The hopper orders the preforms and feeds the machine at a suitable frequency.
The hopper includes the following main components:
- collection reservoir;
- elevator;
- ordering rollers;
- chute.
2.3.10.3 Bottle conveyor (optional)
The bottle conveyor (mechanical or pneumatic pallet conveyor) transports the recently produced bot-
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2-52
SFR 20
Operating Manual
tles towards the filling line in an orderly, sequenced fashion.
2.3.10.4 Chiller (optional)
The chiller is used for conditioning (cooling) the machine water.
2.3.10.5 Compressor (optional)
The compressor feeds compressed air at 40 bar to the main manifold.
2.3.10.6 Temperature adjuster (optional)
The temperature adjuster is only required for the production of certain types of bottles (critical pro-
ductions). It adjusts the coolant temperature (by warming it) in the mold cooling circuit (bottle body
area).
2.3.10.7 Mold holder carriage (optional)
The mold holder carriage is used to carry customizations and mold into the machine.
2.3.10.8 Preform tipping device (optional)
The preform tipping device is used to facilitate unloading operations inside the hopper collection res-
ervoir of an "OCTABIN" contents (preform octagonal container).
MO-A0399_02.fm
Functional units
2-53
Functional units
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SFR 20
Operating Manual
2.4 SYSTEMS
The movements of the various units forming the machine are essentially controlled by the following
systems:
pneumatic system;
2
hydraulic system;
electric/electronic system.+
The following paragraphs list the various systems in relation to the different process phases of the
machine in order to provide useful information for a global vision and rapid identification of the func-
tion of each system.
NOTE
For further information and a detailed description of the single
systems, please refer to the Maintenance Manual and the relative
diagrams enclosed herewith.
2.4.1 PNEUMATIC SYSTEM
The system is supplied directly from the air line available at the place of installation of the machine
and is essentially composed of:
- compressor (on request)
- distribution lines.
The compressed air from the compressor (if installed) or from the centralized system, is sent to the
manifold (see installation layout) and from here to the various units of the machine.
The compressed air distribution line comprises:
- service air line (conveyor);
- process air line (15 e 40 bar).
WARNING
The information given in the following paragraphs relate to a
TYPICAL configuration of the machine; they have merely a
descriptive purpose, associated with the accompanying fig-
ures, and so it is always necessary to refer to the relative
system diagrams for certain, unambiguous component iden-
tification.
2.4.1.1 Pneumatic system - Service air line

MO-A0400_02.fm
The service line ( figure 2-24) uses dry, not lubricated air at a minimum pressure of 6 bars.
Systems
2-55
The typical components are solenoid valves (or solenoid valve blocks) controlling the various pneu-
matic cylinders (actuators) to which rods the mechanisms to be operated are attached. Each actuator
has a flow regulator for adjusting the air let in and out of the cylinder in the two directions.
The system is fitted for handling the following components.
Table 2-1I Pneumatic system - Service air
PROCESS PHASES UNITS SUPPLIED COMPONENTS
FEEDING Preform feeding Preform stop loading wheels (2).
PREFORM LOADING Loading/unloading Preform ejection cylinder (contour

check) (3).
CONDITIONING None None.
PREFORM TRANSFER Transfer Preform ejection rocking pneumatic

motor (8).
STRETCHING/BLOW- Blowing Stretch cylinder (1).

ING
Seal cylinder (4).
Blowing wheel brake cylinders (5).
Mold opening/closing cam control cylin-

der (6).
BOTTLE TRANSFER Transfer Bottle ejection rocking pneumatic motor

(7).
Systems
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SFR 20
Operating Manual
2
MO-A0400_02.fm
Figure 2-24. Pneumatic system - Service air (Sheet 1 of 2)
Systems
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Figure 2-24. Pneumatic system - Service air (Sheet 2)
Systems
2-58
SFR 20
Operating Manual
2.4.1.2 Pneumatic system - Process air line
The process air line is designed to carry out the preform blowing process exclusively.
The system ( figure 2-25) receives air directly from the manifold air line.
- PRIMARY AIR (15 bar) used for the first phase of blowing
2
- SECONDARY AIR (40 bar) used to complete blowing.
The blowing air delivery can be adjusted by means of the knobs installed at each blowing mold cavity.
The system is set up to feed the following components by means of the solenoid valves controlling
the various utilities, namely blowing molds (1) and compensation cylinder (2).
Table 2-2Pneumatic system - Process air
FEEDING None None
PREFORM LOADING None None
CONDITIONING None None
PREFORM TRANSFER None None
STRETCHING/BLOW- Blowing Blowing mold figures.

ING
Compensation cylinder.
BOTTLE TRANSFER None None

MO-A0400_02.fm
Systems
2-59
Figure 2-25. Pneumatic system - Process air
Systems
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SFR 20
Operating Manual
2.4.2 WATER SYSTEM
The water system is used to condition the temperature of the parts which for operating are exposed
to heat or which required a specific temperature in order to work.
Temperature conditioning of these parts is indispensable to ensure mechanical part integrity (cool-
ing) and to maintain the optimal temperatures conditions required by the process (heat regulation). 2
WARNING
The description of the water system refers to a TYPICAL con-
figuration of the machine which is useful for a general over-
view. For a more detailed picture of the system and definite,
unambiguous identification of components, it is always nec-
essary to refer to the relative system diagrams and the Main-
tenance Manual.
The water system ( figure 2-26) employs water from the chiller and/or heat regulator. The delivery
and return line feeding the fitting block, the rotating joint (1) and the water circuits listed in table 2-3
(processes) via manifolds (6 and 7).
Each line (delivery and return) have cut-off ball valves to cut off feed to the line.
Table 2-3I Water cooling system
FEEDING None None.
PREFORM LOADING None None.
CONDITIONING Oven Preform collet cooling circuit (8).
PREFORM TRANSFER None None.
STRETCHING/BLOW- Blowing Bottom cooling circuit (2).

ING
Inner/outer half mold cooling circuit
(collet area) (3).
Inner half mold heat regulating circuit

(body area, via compensation cylinder)
(4).
Outer half mold heat regulating circuit

(body area, via outer mold holder (5).
MO-A0400_02.fm
BOTTLE TRANSFER None None.
Systems
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Figure 2-26. Water system
Systems
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SFR 20
Operating Manual
2.4.3 ELECTRIC/ELECTRONIC SYSTEM
2.4.3.1 Electrical system
NOTE
For more detailed information on the contents of the different 2
electric panels and boxes, please refer to the applicable Wiring
diagrams.
All the components of the electrical system are located in the electric panels (master e slave) and in
the box.The arrangement of the electric panels and of the boxes is illustrated in the figure 2-27.
Figure 2-27. Electrical system - Location of main components

MO-A0400_02.fm
Systems
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2.4.3.2 Electronic system
The electronic system performs the function of commanding, controlling and monitoring the machine.
To perform these functions the electronic system is equipped with the following main components:
programmable controller (PLC)
industrial computer (PC)
electronic cards
input and output modules
serial lines
sensors
actuators
user (operator) interface.
The main components are located in the electric panel (master) and in the boxes, according to a plan,
that may vary from one machine to another, but which essentially mirrors what is shown in the figure
2-28.
PROGRAMMABLE CONTROLLER (PLC)

The programmable controller (PLC) (Simatic - Siemens S7 400) performs the function of reading the
sensors, activating the outputs and counts.
The PLC (10) is modular and is housed in the master panel.
INDUSTRIAL COMPUTER
The industrial computer XYCOM 3515 (1) performs the function of acquiring and processing the sig-
nals from the PLC and from the electronic cards.
The industrial computer uses software, called "SUPERVISOR", that makes it possible to control the
machine at every stage of production.
The industrial computer is equipped with a "touch-screen" user (operator) interface (3).
The "touch-screen" (3) lets the operator monitor and control machine operation moment by moment,
while it allows the maintenance man to perform some setting functions as a consequence of mainte-
nance work.
The industrial computer is housed as shown in figure 2-28.
ELECTRONIC CARDS
The electronic system includes PWR8 electronic cards for controlling resistance loads and SP/V25
heat regulating cards (11).
The electronic cards are housed in the master panel.
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SFR 20
Operating Manual
INPUT AND OUTPUT DEVICES

The input and output devices ET 200 S (9) make it possible to connect the PLC to the sensors, ac-
tuators and manual controls with the field bus PROFIBUS-DP.
The input and output devices are seen by the PLC as slave units.
The ET 200 S devices are composed of:
2
- one modular quick coupling terminal base that carries the wiring and receives the electronic
block;
- an electronic block (digital inputs, digital or analog outputs).
SERIAL LINES
The architecture of the electronic system is the decentralized distributed type.
The different components are connected together with serial lines of three types:
- MPI serial line. This line is used for point-to-point connection between the PLC and industrial PC;
- RS422 serial line. This line is used to connect the industrial PC with the different electronic cards;
- PROFIBUS-DP serial line. This line is used to connect the PLC and the input and output modules
and to connect some cards with the input and output modules. In this case the "master" unit is
composed of the PLC while the input and output modules and cards are "slaves".
SENSORS
The sensors such as pressure switches, thermocouples, proximity switches, etc. installed on the ma-
chine in the different functional units or systems make it possible to detect changes in physical mag-
nitudes (pressure, temperature, etc.) and to convert them into an electrical magnitude that can be
interpreted, after conversion into a digital format, by the PLC management program.
The sensor conductors are generally connected to the terminal blocks with input and output devices
(ET 200 S).
ACTUATORS
Actuators such as pneumatic cylinders, electric motors, etc., installed on the machine, in the different
functional units or systems, make it possible to move components of the units and systems on re-
ceiving a command from the operator (manual command) or generated automatically by the PLC.
The actuators, like the sensors, are also connected via input and output devices to the PLC.
USER INTERFACES
The user (operator) interface (1) is composed of:
- industrial PC "touch-screen" (3);
- preform optoelectronic control screen (2);

MO-A0400_02.fm
- control panel and push button panel (4) and (5);
Systems
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- hand-held keypad (6).
The user interface consists of a "touch-screen" built into the industrial PC. The control panels on the
master panel and outside the cab are to all intents and purposes network "slaves" made with the
PROFIBUS-DP field bus.
The manual panel controls are connected to the input devices and to the ET 200 S output. Conse-
quently, the operators control signals are sent on the serial line (PROFIBUS-DP) to the PLC.
The hand-held keypad is connected to the push-button panel by means of a connector and allows
the operator to carry out some manual controls on the machine (for example opening and closing
molds, etc.).
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SFR 20
Operating Manual
2
MO-A0400_02.fm
Figure 2-28. Electronic system - Location of main components (Sheet 1 of 2)
Systems
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Figure 2-28. Electronic system - Location of main components (Sheet 2)
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SFR 20
Operating Manual

MO-A0400_02.fm
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2.5 DESCRIPTION OF CONTROLS
The controls located on electric panels and in other areas of the machine are described in the follow-
ing paragraphs.
2.5.1 MASTER ELECTRIC PANEL
The MASTER electric panel contains some of the main controls and respective indicators used for
controlling machine operation ( figure 2-30):
- circuit breaker;
- warning lights and buzzers;
- MASTER electric control panel.
A detailed description of the controls and indicators on the MASTER panel as illustrated in the fol-
lowing tables.
Table 2-4 Master electric panel indicators and controls
REFERENCE DESCRIPTION FUNCTION
1 Circuit breaker with mechanical Position I - To power the machine.

door lock open TRIP position - Intermediate position of
the switch between I and 0 following an
emergency stop or a blackout.
Position 0 - Electric power is cut off. The
electric cabinet doors can be opened.
RESET position - Position over 0 for
resetting electrical power following an
emergency stop or blackout (TRIP posi-
tion).
2 Beacon White flashing - Indicating a WARNING

alarm condition.
Orange flashing - Indicating a machine
alarm condition.
3 Buzzer Machine alarm buzzer
4 Buzzer Machine cycle start buzzer
5 Front door toggle safety key Horizontal position - The cabinet doors
switch can be opened without cutting off the elec-
tric power.
Vertical position - Electric power will be
cut off when a cabinet door is opened.
Description of controls
2-70
SFR 20
Operating Manual
Table 2-5 Master panel push-button panel
6 230 Vac white indicator Lights up to indicate the presence of 230 V

ac power.
On - Signals the presence of 230 Vac 2
power.
Off - No 230 V ac power.
7 EMERGENCY orange indicator On - Signals the presence of auxiliary

alarms.
Off - No auxiliary alarms.
8 RESET EMERGENCY blue light Press and release - Resets all auxiliary
button alarm signals.
9 AUXILIARY RUN white light but- Press and release (on) - Enables all aux-
ton iliary devices.
Auxiliary enabling is subordinated to the
position of the key switch (10) and to no
auxiliary alarm condition (orange indicator
off)(7).
10 AUXILIARY ENABLE key switch Turn the key clockwise to enable auxiliary
operation. Switch the auxiliaries on by
means of the light button (9).
11 Self-locking mushroom EMER- Press - Immediately stops the machine.

GENCY STOP button To reset normal operating conditions,
release the button by turning it in the direc-
tion shown by the arrow printed on the but-
ton (clockwise).
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2-71
Figure 2-29. MASTER electric panel controls
2-72
SFR 20
Operating Manual
2.5.2 OPERATOR INTERFACE PANEL
The operator interface panel contains the main controls for operating the machine ( figure 2-31).
The operator interface panel includes:
- preform optoelectronic control display (OPTIONAL);
2
- SUPERVISOR display interface touch screen;
- control panel.
A detailed description of the operator interface panel is illustrated in the following tables.
Table 2-6 Operator interface panel (PC)
1 SCREEN Color screen for displaying preform optical con-

trol.
2 SCREEN Color touch screen for displaying graphic inter-

face. Machine control and command supervisor.
3 DISKETTE DRIVE 3.5" diskette drive for loading and saving data
(e.g. recipe loading).
4 KEYBOARD CONNECTOR External keyboard connector (PS2).
5 CURSOR POINTER CONNECTOR Cursor pointer connector (mouse, trackball, etc.)

(PS2).
6 SERIAL PORT Serial port connector.
7 SERIAL PORT Parallel port connector (printer).
8 UNLOAD MACHINE button Press and release (green light on) - The
machine will completely unload (close preform
loading, complete blowing phase, unload all
blown bottles).
9 ALARM OFF button Press and release (green light off) - Immediately
silences all alarms (solved).
The alarm situation must be solved before the
alarm can be silenced (e.g. empty chute alarm:
the alarm will continue if loading remains
enabled).
Press and release (green light on and flashing) -
Immediately silences alarms (not yet solved).
MO-A0401_02.fm
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Table 2-6 Operator interface panel (PC)
10 CYCLE STOP button Press and release (green light on) - Enabled
cycle stop mode stop.
Start cycle warning light off.
Cycle stop disabled mode is subordinated to
cycle start (11).
11 CYCLE START button Press for 5 seconds and release (green light
on) - Start machine (start cycle).
Stop cycle warning light off.
Cycle start disabled mode is subordinated to
automatic mode. Any alarm situations must be
solved.
12 AUTOMATIC button Press and release (green light on) - Automatic

operation enabled.
Manual warning light (13) off.
Automatic disabled mode is subordinated to
manual mode (13) enabled.
13 MANUAL button Press and release (green light on) - Manual

operation enabled.
Manual mode disables automatic mode.
Automatic warning light(12) off.
Manual disabled mode is subordinated to auto-
matic mode (12) enabled.

GENCY STOP button To reset normal operating conditions, release the
button by turning it in the direction shown by the
arrow printed on the button.
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2
MO-A0401_02.fm
Figure 2-30. Operator interface panel controls
2-75
2.5.3 MACHINE PUSH-BUTTON PANEL
This push-button panel is located between the oven and the machine body on the cabin ( figure 2-31).
A detailed description of the controls on the push-button panel is illustrated in the following table.
Table 2-7 Machine push-button panel

GENCY STOP button To reset normal operating conditions, release the
button by turning it in the direction shown by the
arrow printed on the button.
2 PUSH-BUTTON PANEL BY-PASS Hand-held keyboard switch:

switch Turn clockwise to connect or disconnect the
push-button panel and release the white switch.
3 KEYBOARD CONNECTOR Hand-held keyboard connector.
4 BRAKE BYPASS switch Pneumatic brake circuit power (brakes open):

turn switch clockwise.
5 Cabin light switch Up - cabin lights on.

Down - cabin lights off.
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2
MO-A0401_02.fm
Figure 2-31. Machine push-button panel
2-77
2.5.4 HAND-HELD PANEL
The machine has a special SP2000 hand-held panel ( figure 2-32) with display for manually operating
most of the machine mechanisms.
WARNIG 1
Keep the PUSH-BUTTON BYPASS switch (2, figure 2-31) in
horizontal position to connect (and disconnect) the hand-
held panel socket.
WARNIG 2
Switch the machine to manual to use the hand-held panel
(paragraph 2.5.2)
WARNIG 3
The hand-held push-button panel is only used by mainte-
nance or authorized personnel.
NOTE
The hand-held push-button panel is arranged to be used with
both hands (black man presence button) to prevent accidental
operation.
A detailed description of the controls on the push-button panel are illustrated in the following table.
Table 2-8 Hand-held panel controls
1 Display (split into areas) Used to display the items related to a certain
mechanism to be controlled.
A MOVEMENT DESCRIPTION dis- Displays a description of the enabled movement

play area (e.g. BLOWING WHEEL MOVEMENT).
B/C MOVEMENT TYPE display area Displays the type of movement related to the
mechanism to be controlled (e.g. OPEN-
CLOSE). The movement is controlled by means
of large buttons (6) and (7).
D MACHINE STATUS display area Displays a description of the active machine sta-
tus.
E WORKPLACE ID display area Displays the keyboard workplace ID.
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F SELECTED CODE display area Displays the code entered by means of the num-
ber keypad identifying the mechanism and the
respective movement to be controlled. 2
G ALARM CODE display area Displays the alarm code related to the item in
area (D).
H CONTROL ON display area OFF LINE - Indicating that the keyboard cannot
be used for controlling; MAN PRESENCE button
is not pressed.
ON LINE - Indicating that the keyboard controls
are enabled. MAN PRESENCE button is
pressed.
2 "MAN PRESENCE" black button Pressed - All movements can be controlled by

means of the keyboard. The button must be
pressed for the controls to be enabled.
Released - Current movement will be immedi-
ately disabled. No control will be enabled.
3 "SCROLL UP" button Press the button to scroll the various items in
sequence (movement, code, etc.) related to a
certain movement to be selected.
4 "SCROLL DOWN" button Press the button to scroll the various items in
sequence (movement, code, etc.) related to a
certain mechanism to be selected.
5 E (ENTER) button To confirm the selection made. Select the move-

ment to be made either by entering the code or
by means of buttons (3) and (4) and press the E
button to confirm.
6 + (plus) button Press the button to run the control enabled in

area (C) (e.g. OPEN).
7 - (minus button) Press the button to run the control enabled in

area (B) (e.g. CLOSE).
8 Self-locking mushroom EMER- To immediately stop the machine. To reset nor-

GENCY STOP button mal operating conditions, release the button by
turning it in the direction shown by the arrow
printed on the button and press the ALARM OFF
button (see tabella 2-6, reference 9).
9 C (cancel) button To cancel a code incorrectly entered in area F

related to a movement to be selected.
MO-A0401_02.fm
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10 NUMERIC keypad To enter the code in area F related to a move-

ment to be selected.
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2
MO-A0401_02.fm
Figure 2-32. Hand-held panel
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Operating Manual
2.6 SAFETY
The machine is equipped with safety devices capable of preventing injury to the operator and any
exposed persons as well as accidental damage to the machine.
In accordance with the EEC Directive 89/392 and its subsequent amendments, an analysis has
been made of all the machine areas forming the line with danger inherent in the nature of the process 2
or in the structure forming the machine; wherever possible, the most suitable precautions have been
taken to reduce, or eliminate, all possible risk for anyone operating on the machine.
All persons assigned to running the machine and all persons who may come into contact with it must
carefully read the following paragraphs that describe the so-called areas of the machine "at risk" and
the relative action taken in terms of safety, as well as the so-called areas of "residual risk" which are
areas where in spite of the action taken, present a certain degree of danger.
CAUTION 1
THE SAFETY DEVICES MUST BE KEPT FULLY EFFICIENT
AND PERIODICALLY INSPECTED.
CAUTION 2
THE SAFETY DEVICES MUST NOT BE REMOVED, DEACTI-
VATED OR BY-PASSED FOR ANY REASON WHATSOEVER;
ANY OPERATION CARRIED OUT ON THE MACHINE PURPO-
SELY DISABLING THE SAFETY DEVICES OR ANY TYPE OF
TAMPERING WITH THESE DEVICES IS AT THE RISK OF THE
PERSON SO DOING.
2.7 AREAS AT RISK

Running the machine during ordinary production is overall without risk since the panelling does not
allow indiscriminate access to the moving parts of the machine.
Having to carry out maintenance work requiring access inside the cabin and so directly on the ma-
chine's parts, it is necessary to pay special attention due to the presence of so-called areas "at risk"
listed by functional unit in the following table.
CAUTION
AREAS AT RISK ARE AREAS OF THE MACHINE WHERE
THERE IS THE DANGER OF INJURY, SEVERE LESIONS OR
DEATH OF THE OPERATOR OR EXPOSED PERSONS, IF
THE GUARDS AND SAFETY DEVICES USED HAVE BEEN RE-
MOVED OR MADE INACTIVE.
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Safety
2-83
Table 2-9 Areas at risk
FUNCTIONAL UNIT RISK AREA DESCRIPTION
DRIVES The entire drive transmission Risk of dragging or crushing by moving

area parts
PREFORM FEEDING Preform input area Risk of dragging or crushing by moving

parts.
LOADING AND Preform loading area Risk of dragging or crushing by moving

UNLOADING Preform unloading area parts
OVEN Preform heating area Risk of dragging or crushing by moving

parts.
Risk of electric shock for the presence

of live parts.
Risk of burning by contact with hot par-

ts.
TRANSFER Preform transfer wheel area Risk of dragging or crushing by moving

parts.
Bottle transfer wheel area
STRETCHING/ Blowing wheel area (presses Risk of dragging, crushing, cutting or

BLOWING and molds). knocking by moving parts and blowing
molds.
UNLOADING Bottle ejection area Risk of dragging or crushing by moving

parts.
ELECTRIC PANELS Area inside panels and electric Risk of electrocution or burning for the
boxes presence of live parts.
PNEUMATIC Area inside soundproofing Risk of crushing, cutting or knocking.

SYSTEM cabin
areas at risk
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Operating Manual
2.8 AREAS WITH A RESIDUAL RISK

The machine on the whole has no residual risks since the operations are automatic and, in manual
mode, they have effective safety devices and protection.
In any case, in spite of the safety measures taken, there is still a high degree of danger, which cannot
be completely eliminated so as not to compromise on the operation of the line. 2
In this regard, some general information follows that makes it possible to highlight the so-called areas
of "residual risk".
CAUTION
AREAS OF RESIDUAL RISK ARE THOSE WHERE THE OPE-
RATOR IS AT RISK OF INJURY, WOUNDING OR DEATH IF
ATTENTION IS NOT PAID TO DANGER SIGNS POSTED IN
THE AREA, OR TO THE INFORMATION PROVIDED IN SEC-
TION 1 AND THROUGHOUT PARAGRAPH 2.6, OR IF DUE
CAUTION AND COMMON SENSE ARE NOT EXERCISED DU-
RING OPERATION.
1. The control areas (operator interface panel and master panel) must be considered areas with a
residual risk since the operator cannot have a full view of the machine; before making any
movement it is necessary to make sure there is no one else operating on or near the machine.
2. The entire machine must be considered an area with a residual risk due to potential electric,
pneumatic and mechanical hazards and very hot parts.
3. The electric panels must be considered an area with a residual risk due to the high voltage in the
terminals linking the cabinet with the external mains even with the panel doors open and
therefore with the safety devices active: there is the danger of death by electrocution should
anyone touch the terminals.
CAUTION
SOME CIRCUITS, SUCH AS THE ENCLOSURE LIGHTS AND
ALL CIRCUITS WITH ORANGE WIRE, WILL REMAIN POW-
ERED WHEN THE CIRCUIT BREAKER IS AT POSITION "0".
CAUTION
ENCLOSURE AND ELECTRICAL PANEL DOORS MAY EX-
CLUSIVELY BE OPENED BY ELECTRICIANS.
MO-A0402_02.fm
Areas with a residual risk

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Areas with a residual risk

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2.9 SAFETY DEVICES
2.9.1 GENERAL
This machine is equipped with a set of integrated devices that protect the operator and any exposed 2
persons from the risks and hazards of any nature that may occur in normal conditions of the machine
working.
The devices installed on the machine can be distinguished in two types:
Passive safety devices - composed of devices that prevent the operator from coming into contact
with the moving parts of the machine and the impossibility of accessing certain areas during au-
tomatic operation of the machine (e.g. protection cabin, guards, grids, etc.).
Active safety devices - composed of all the protection devices that shut down the machine when
the safety conditions are not as required (e.g. limit switch, door safety unit, etc.).
The combined action of both types of safety device ensures compliance with the conditions of safety
protecting the operator and any exposed persons from risk and danger.
CAUTION
ANY TAMPERING BY THE USER (OR ANYONE APPOINTED
BY HIM) WITH A SAFETY DEVICE, FREES SIPA OF ALL RE-
SPONSIBILITY AND MAKES THE USER SOLELY RESPONSI-
BLE WITH REGARD TO THE COMPETENT BODIES FOR
ACCIDENT PREVENTION AT WORK.
2.9.2 CABIN SAFETY DEVICES
The following table lists the safety devices installed on the panelling, briefly describing their function
( figure 2-33).
WARNIG 1
Any tampering by the user with a safety device frees SIPA
from all responsibility and makes the user solely responsible
with regard to the competent bodies for accident prevention.
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safety devices
2-87
WARNIG 2
The machine goes into EMERGENCY STOP in the event of
the limit switches on the doors malfunctioning.
Table 2-10 Cabin safety devices
1 Sliding doors Sliding doors with safety limit switches
2 Opening windows Spoiler opening window to reach preform loading

area
3 Rejected preform flap Rejected preform collection compartment flap
4 Oven flap Oven unit access flaps
5 Hinged doors Hinged doors with safety limit switches (active

when door is closed)
WARNIG 3
The doors opening during the automatic cycle causes an im-
mediate EMERGENCY STOP of the machine.
safety devices
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Operating Manual
2
MO-A0402_02.fm
Figure 2-33. Cabin safety devices (Sheet 1 of 2)
safety devices
2-89
Figure 2-33. Cabin safety devices (Sheet 2)
safety devices
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Operating Manual
2.9.3 EMERGENCY STOP BUTTONS
The switches are installed in different areas of the machine ( figure 2-34) in order to stop operation
immediately.
Each of them is composed of a red safety push-button, with mushroom-head and detent, with the
function of emergency stop (pressing the button immediately stops operation of all the machine). 2
Generally speaking, the consequences of pressing an emergency stop button may be summed up
as follows:
Immediate stop of electric gear motor.
Application of pneumatic brakes.
Break in the motor power circuit.
Break in heating feeding circuit (general).
Break in the auxiliary device power circuit.
De-energizing of the solenoid valves controlling the various pneumatic mechanisms.
For all the time the emergency button stays pressed, it is not possible to carry out any operation; to
restore conditions of normal operation it is necessary to release the button by turning it in the direction
shown by the arrow stamped on it and reset the auxiliaries.
CAUTION
THE EMERGENCY STOP BUTTON MUST BE KEPT CLEAR
FROM OBJECTS, CLOTHES. ETC. WHICH COULD HINDER
OR DELAY OPERATION IN SOME WAY AT ALL TIMES.
WARNING
The emergency stop button must be used only in the case of
conditions occurring that are hazardous for the operator or
for the machine. Using this device for normal stoppage bre-
aks the safety rules and can cause damage to the machine.
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safety devices
2-91
Figure 2-34. Emergency stop button location
safety devices
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Operating Manual
2.9.4 ELECTRIC PANEL SAFETY DEVICES
2.9.4.1 Electric cabinet door safety devices
The safety devices installed on the electric cabinet doors have the function of cutting off electrical
power to the entire machine if any of the doors of the Master cabinet open. 2
This condition is obtained on the Master electrical cabinet with a limit switch and a hardware device
to automatically disconnect the main switch at the moment a door is opened.
2.9.4.2 Main disconnecting switch with door lock
The switch is inside the MASTER electrical cabinet and can be operated from the outside with a knob
on the door of the cabinet ( figure 2-29, detail 1).
The switch has two positions, "RESET", "0" (off), "TRIP" and "I" (on); opening the cabinet is only pos-
sible with the switch on position "0", i.e. with the power off.
NOTE
Refer to paragraph 2.5. for a more detailed description.
2.9.4.3 Key-operated control selectors
Some controls which change the machine safety level can only be operated by means of a specific
key. The purpose of these safety precautions is to allow access to the functions controlled by the abo-
ve-mentioned selectors only for authorized persons.
These persons are the only to whom the keys are assigned following specific authorization on behalf
of the employer.
NOTE
See paragraph 2.5 for a complete description of controls.
2.9.4.4 Column lamp and buzzers
Refer to paragraph 2.5.1 and the relative figures.
2.9.5 MISCELLANEOUS SAFETY DEVICES
There follows a list of the additional safety devices installed on the machine:
separating and soundproofing cabin;
protective guards for moving mechanical parts;

MO-A0402_02.fm
torque limiting devices on drive transmission units.
safety devices
2-93
2.9.6 PLATES WARNING OF DANGER, PROHIBITION AND OBLIGATION
In order to highlight the areas of the line where it is necessary to pay particular attention and the areas
with residual risks for the safety of the operator and exposed persons, warning plates have been af-
fixed indicating danger, prohibition and obligation to ISO standards.
CAUTION
REMOVING THE PLATES OR FAILING TO REPLACE THEM
SHOULD THEY DETERIORATE MAKES THE USER FULLY
RESPONSIBLE FOR ALL THE CONSEQUENCES THAT MAY
ARISE OR DERIVE FROM USING THE MACHINE WITHOUT
OBSERVING THE SAFETY CONDITIONS ENVISAGED BY
THE MANUFACTURER.
2.9.6.1 Plates warning of danger
The following danger warning signs are affixed on the machine ( figure 2-35):
- ELECTRIC CURRENT (7)
Danger of electrical shock, lesions or injury due to high voltage in the case of access inside the
marked areas; this sign can be completed with the value of the voltage present.
- MOVING PARTS (8)

Danger of injury or death due to moving parts if operating without the protection or safety devices
or if these are not fully efficient.
- CRUSHING HAZARD (9)

Crushing hazard due to moving mechanical parts.
2.9.6.2 Plates warning of prohibition
The following signs with prohibition warnings are affixed on the machine( figure 2-35):
- NEVER OIL OR CLEAN THE MECHANISMS DURING MOVEMENT (1)
Never clean or lubricate the various mechanisms during normal machine operation.
- NEVER USE WATER TO PUT OUT FIRES (2)

Never use water to put out fires on electric devices.
- NEVER REMOVE THE SAFETY DEVICES (4)

Never remove the accident-prevention safety devices installed on the machines.
- NEVER OPEN THE ELECTRIC PANELS (3)

Never open the electric panels. Only maintenance staff or authorized personnel are allowed to
open the panels (e.g. electricians).
2.9.6.3 Plates warning of obligation
The following signs with obligation warnings are affixed on the machine ( figure 2-35):
safety devices
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Operating Manual
- PERSONAL PROTECTION MEASURES MUST BE USED AT ALL TIMES (10)

Operators and all exposed persons must use the safety helmet, eyewear, hearing protection equi-
pment, and safety shoes.
Operators and anyone who has to operate in areas of the machine that are hazardous due to the
high temperatures must wear safety gloves.
2
Figure 2-35. Plates warning of danger, prohibition and obligation

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safety devices
2-95
2.10 TECHNICAL SPECIFICATIONS
2.10.1 OVERALL DIMENSIONS
The main overall dimensions of the machine, in conditions of normal operation, are given on the ma-
chine layout enclosed with this publication.
2.11 MAIN SPECIFICATIONS

The main technical specifications of the soffiatrice SFR are listed in the following table.
Table 2-11 Main specifications of machine
BLOWING MOLDS
Number of cavities per blowing mold N 1
Number of blowing molds N 20
MISCELLANEOUS SPECIFICATIONS
Machine dimensions (LxDxH) m 7.6X4.2X4

.4
Weight with no load kg 18500
Gear motor oil dm3 11.8
Total weight of machine in operation kg 24500
ELECTRICAL SPECIFICATIONS
Voltage 3Ph + N + E (standard) V 400
Frequency (standard) Hz 50
Power for mechanical movement kW 30
Power for heating kW 340
Total power installed kW 384
Mean power draw (Note 1) kW 265
min max
COMPRESSED AIR FOR MOVEMENT
Air pressure bar 6 8
Technical specifications
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Operating Manual
Table 2-11 Main specifications of machine
COMPRESSED AIR FOR BLOWING flat carbon- soft drink

ated
Air pressure bar 30 35 40 2

MOLD COOLING
Thermal power (Note 1) kcal/h 85000
Input water temperature C 10
Input/output temperature delta C 2
Coolant delivery m3/h 17.5
Input pressure bar 4.5
NOTE 1
Thermal power and average SFR blowing machine intake power
may vary according to the physical-geometric characteristics of
the bottles to be produced.
MO-A0402_02.fm
Main specifications
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Main specifications
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Operating Manual
SECTION 3
SUPERVISOR DESCRIPTION AND USE
3.1 INTRODUCTION
3
This section illustrates the information and the instructions required for using the SUPERVISOR (vid-
eo interface).
3.2 GENERAL DESCRIPTION

The SUPERVISOR is a complete, flexible program specifically created to control and operate the
SFR blowing machine production cycle.
The program is used to carry out all the control, setup and configuration operations of the various
mechanisms, transducers, sensors, etc. which are used in the various machine process phases.
Furthermore, the program is used to load the software parameters required to operate the machine
and to produce a certain bottle format. These parameters are called CONFIGURATION DATA and
RECIPES, respectively.
The SUPERVISOR is structured on four different access levels, as shown below:
Operator level
Maintenance level
Configuration level
Help Desk level.
The level which is running is identified by means of a graphic element (icon) in the lower left-hand
corner on the status bar ( table 3-2).
OPERATOR LEVEL
The operator level allows to use the program for operating the machine and displaying machine di-
agnostics by means of alarm signals on the display. The operator level is also the default level for
immediate SUPERVISOR use. Some SUPERVISOR functions will be deactivated when the operator
level is running (settings, configurations, etc.).
MAINTENANCE LEVEL
This level is protected by a password (paragraph 3.3.9.5). This level is for personnel (maintenance
MO-A0403_02.fm
staff) who have been specifically trained to carry out maintenance procedures on individual systems
or who have taken part in training courses organized by SIPA.

3-1
CONFIGURATION LEVEL
This level is protected by a password (paragraph 3.3.9.5). Configuration level operations are re-
served to authorized personnel.
HELP DESK LEVEL

This level is protected by a password (paragraph 3.3.9.5). Help Desk level operations are reserved
exclusively to SIPA personnel or other personnel, following prior authorization.
NOTE 1
Program function descriptions are limited to operator level only.
Contact SIPA Technical Assistance Service for operations involv-
ing the program at a higher level.
NOTE 2
This chapter does not contain machine maintenance informa-
tion, with the exception of normal service operations which can
be carried out directly by the machine operator. Refer to the SFR
blowing machine Maintenance Manual for additional informa-
tion.

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Operating Manual
3.2.1 MAIN ELEMENTS OF THE SUPERVISOR
The program is installed on a personal computer (industrial PC) and housed in the operator interface
panel. It implements a touch screen video interface.
The program consists of pages (paragraph 3.3); each page ( figure3-1) has a standard structure of
variable elements (according to the displayed page) and fixed elements (displayed on all pages):
Variable elements
3
- Working area
- Upper status bar
- Tool bar.
Fixed elements
- Lower status bar
- Standard tool bar.
Figure 3-1. Main SUPERVISOR elements

MO-A0403_02.fm

3-3
3.2.1.1 Working area
The working area ( figure3-2) is a portion of a page containing:

- Active graphic elements
- Passive graphic elements
- Alphanumeric boxes.
The active graphic elements are used to go to other pages or run specific functions. Select an ac-
tive graphic element to go to the SUPERVISOR page related to the selected graphic element or to
run a specific SUPERVISOR function. For example: select the ovens graphic element (bright blue
frame) to go to the ovens page or select the down arrow graphic element to scroll down a list.
The passive graphic elements are used to provide auxiliary information, e.g. to create environ-
ments (machine graphic representations) or to characterize alphanumeric data source.
The alphanumeric boxes are used to display different parameter values (temperature, speed, per-
centages, etc.) or data which cannot be replaced by passive graphic elements. The information pro-
vided in alphanumeric boxes must always be read with the information provided by passive elements.
The alphanumeric boxes are generally identified by a frame (red, blue or yellow):
- red frame - identifying data or parameters which can only be displayed (stated value, display val-
ues) and cannot be edited (setting values).
- blue frame - identifying data or parameters which can be displayed (stated value) and edited (set-
tings). To edit (set) the data or parameters, select the alphanumeric box corresponding to the data
or parameter. In most case, the data and parameters cannot be edited if the operator level is run-
ning.
- yellow frame - indicating configuration data or parameters. These data are always displayed (stat-
ed value) and can be edited (settings) only if the configuration level is running.

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Operating Manual
Figure 3-2. Working area
3.2.1.2 Standard tool bar
The standard tool bar ( table 3-1) is found horizontally in the lower part of the display. It contains the
commands which are always available on every SUPERVISOR page. These commands can be used
regardless of the SUPERVISOR page on which they appear and allow to go to specific pages which
cannot be reached in many cases by using the currently displayed working area.
Table 3-1 Standard commands
BUTTON NAME FUNCTION
PREVIOUS PAGE To go back to the previous page

MO-A0403_02.fm

3-5
HOME PAGE To go back to the home page
PRODUCTION To go to the production page
CONFIGURATION To go to the configuration page
PRODUCTION DATA To go to the data production page
GRAPHS Not enabled on operator level
ARCHIVES To go to the archives page
HELP To open the help on-line function
ALARMS To go to the alarm page

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Operating Manual
3.2.1.3 Operative tool bar
La operative tool bar located vertically on the right-hand side of the screen includes a set of com-
mands related to the displayed page. The commands are used access additional pages and/or use
specific functions. The number and the type of commands shown on the tool bar depend on displayed
page.
3.2.1.4 Upper status bar 3

The upper status bar ( figure3-8) appears on the home page only. It is split into two parts:
Upper row - identifying the recipe in use.
Lower row - operative status of the machine.
Upper row - contract production rate.
3.2.1.5 Lower status bar
The lower status bar (status bar) constantly provides information on SUPERVISOR status ( table 3-
2).
Table 3-2 Status bar symbols
SYMBOL MEANING
Telephone line status (connection to SIPA)

Red telephone: no telephone line.
Green telephone: telephone line present.
MO-A0403_02.fm

3-7
SYMBOL MEANING
SUPERVISOR level
Operator level
Maintenance level
Configuration level
Help Desk level
SUPERVISOR language - selectable languages:

English - automatically set when
SUPERVISOR is switched on .
Italian
Destination language - language

of the country of destination of the
machine (where relevant).
PLC connection status

Green symbol - connection on.
Red symbol - connection off.

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Operating Manual
3.2.2 SUPERVISOR NAVIGATION
Navigation in the SUPERVISOR is possible by means of a touch screen.

The functions which are normally carried out by moving a pointing device on the screen (mouse,
trackball) are made by touching the screen directly with a finger, an appropriate pen , etc.
Tap anywhere on the screen to move the cursor to that position.
Tap and move to drag the cursor on the screen. 3

Tap on a frame or active graphic element, a control or an alphanumeric box to select the respec-
tive element.
NOTE
Use a lintless soft cloth and mild detergent to clean the SUPER-
VISOR screen. You should switch the machine off to clean the
screen to prevent the SUPERVISOR from interpreting the move-
ment of the cloth as commands.
3.2.2.1 Selecting an active graphic element
Touch the screen on the active graphic element (frame or area) to select it.
MO-A0403_02.fm
Figure 3-3. Selecting an active graphic element
Select an active graphic element to display an additional page linked to the graphic representation of

3-9
the object. For example, select the active graphic element corresponding to the ovens to go to the
ovens page.
NOTE
Select two or more commands at the same time to display the
corresponding pages in rapid sequence without a pause be-
tween pages.
3.2.2.2 Selecting a command
Touch the screen at the command (frame or area) to select it (standard/operative tool bar)
Figure 3-4. Selecting a command
Select a command to:

display an extra page;
run a control associated to the command.
3.2.2.3 Selecting an alphanumeric box
Touch the screen at the alphanumeric box to select it (frame or area).

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Operating Manual
Figure 3-5. Selecting an alphanumeric box

Select an alphanumeric box to set the numeric value in the box by means of the keypad which will
appear on the screen after the selection ( figure3-6).
Parameter setup is enabled for the level which is being run. Consequently, only the blue framed al-
phanumeric boxes can be edited regardless from the level which is running.
Figure 3-6. Numeric keypad
3.2.2.4 Selecting a disabled element

MO-A0403_02.fm
A warning window will appear if you attempt to select an element (active graphic element, alphanu-
meric box or command) which is not enabled in the current level ( figure3-7).

3-11
In the warning window, the graphic symbol in the top left (A) shows the level required to edit/set the
currently disabled element, while the level which is running is shown by element (B). The required
level can be run by using command (D). Command (C), on the other hand, is used to close the win-
dow.
Figure 3-7. Selecting a disabled element
Select command (C) to restore normal SUPERVISOR operation.

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Operating Manual
3.3 SUPERVISOR PAGE DESCRIPTION
3.3.1 HOME PAGE
The home page is the starting point in SUPERVISOR navigation and use (it is the first page which
appears when the SUPERVISOR is switched on).
The home page working area shows a simplified drawing of the machine identifying the main func- 3
tional groups (hopper, drive, ovens, etc.).
The graphic elements are "active" and consequently can be selected to go to the page corresponding
to the assembly.
The right part of the working area shows a number of vital machine parameters (which need to be
checked frequently), e.g. preform temperature (at oven outlet or mold inlet), number of bottles pro-
duced in a unit of time (hour).
Figure 3-8. SUPERVISOR - Home page

MO-A0403_02.fm

3-13
ACTIVE GRAPHIC ELEMENTS
REF. NAME USE LINKED

PAGE
A HOPPER To go to the hopper page. figure3-10
B DRIVE To go to the drive page. figure3-11
C OVEN To go to the oven page. figure3-12
D UNLOADING To go to the unloading page. figure3-15
E BLOWING To go to the blowing page. figure3-14
ALPHANUMERIC BOXES
REF. DESCRIPTION
1 Contractual productivity rate (stated value, cannot be edited).
2 Preform temperature at blowing unit input (stated value, cannot be edited).
3 Number of bottles in ovens (stated value, cannot be edited).
4 Coolant temperature in ovens (stated value, cannot be edited).
5 Number of bottles produced per hour (stated value, cannot be edited).
3.3.1.2 Operative commands
AUXILIARIES To go to the auxiliaries page (PG4, figure3-9).

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Operating Manual
3.3.2 AUXILIARIES PAGE
The auxiliaries page provides important information on auxiliary status (electric panel, conditioners,
filling line).
The working area shows a simplified drawing of the machine (passive graphic element) and a sim-
plified drawing of the connected auxiliaries (active graphic elements).
The information provided in the alphanumeric boxes relate to fundamental auxiliary parameters, e.g.
temperature of the electric panels, coolant temperature at conditioner input and output. 3
Figure 3-9. SUPERVISOR - Auxiliaries page

MO-A0403_02.fm

3-15

PAGE
A ELECTRIC PANELS Not enabled on operator level --
B FILLING LINE OK Not enabled on operator level --
C CONDITIONER Not enabled on operator level --
ALPHANUMERIC BOXES
REF. DESCRIPTION
1 Temperature inside electric panel (stated value, cannot be edited).
2 Coolant temperature at chiller input (stated value, cannot be edited).
3 Coolant temperature at chiller output (stated value, cannot be edited).
4 Chiller coolant delivery (stated value, cannot be edited).
Not present.

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Operating Manual
3.3.3 HOPPER PAGE
The hopper page provided information related to preform feeding unit operation.
The working area shows a drawing of the hopper (passive graphic element) and of the elevator and
extractor drives (active graphic elements).
The information provided concerns electrical drive fundamental parameters (rotation speed) and a
rough estimate of the number of preform on the chute.
If the hopper is not directly supplied by SIPA, the working area is replaced by a similar representation
3
without active graphic elements or numeric indications (F).
Figure 3-10. SUPERVISOR - Hopper page

MO-A0403_02.fm

3-17
REF. NAME USE LIKED

PAGE
A ELEVATOR DRIVE Not enabled on operator level --
C EXTRACTOR DRIVE Not enabled on operator level --
PASSIVE GRAPHIC ELEMENTS
REF. INFORMATION
B Electric drive status.

Off On
D Feeding chute preform loading status.

0% - Empty 50% 100% - Full
E Customer hopper working area
F As B
ALPHANUMERIC BOXES
REF. DESCRIPTION
1 Extractor drive rotation speed percentage (stated value, cannot be edited).

3-18
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Operating Manual
REF. DESCRIPTION
2 Extractor drive rotation speed (stated value, cannot be edited).
3 Elevator drive rotation speed percentage (stated value, cannot be edited).
4 Elevator drive rotation speed (stated value, cannot be edited). 3

Not enabled on operator level.

MO-A0403_02.fm

3-19
3.3.4 DRIVE PAGE
The drive page provides information on the parameters strictly related to the drives.
The working area shows a graphic drawing of the drive unit (active graphic element) and drive trans-
mission units (passive graphic elements).
The indications provided concern parameters effected by the electric gear motor rotation speed, e.g.
bottles per hour, rotation speed (expressed in bottles per hour) when the machine is in manual mode,
speed (expressed in bottles per hour) during synchronization phase, etc.
Figure 3-11. SUPERVISOR - Drive page

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Operating Manual

PAGE
A DRIVE Not enabled on operator level -- 3
ALPHANUMERIC BOXES
REF. DESCRIPTION
1 Preform body temperature.
2 Current speed - bottles per hour (stated value, cannot be edited).
3 Manual mode speed - bottles per hour (stated value, can be edited).
Cannot be edited on operator level.
4 Synchronization phase speed - bottles per hour (stated value, can be edited).
5 Rod descent phase speed - bottles per hour (stated value, can be edited).
6 Simulation mode speed - bottles per hour (stated value, can be edited).
7 Operative mode speed - bottles per hour (stated value, can be edited).
8 Warning threshold value (stated value, cannot be edited).

The machine is set up for one or more warnings if the current value of one of the parameters
(values) 1, 3, 4, 5, 6 or 7 is higher than the corresponding threshold value (expressed as a
percentage respect to the set value).
For example, if the manual mode speed setting value is equal to 100 bph and the threshold
value is equal to 10%, the SUPERVISOR will report a warning as soon as the recorded speed
in manual mode reaches and exceeds 110 bph.
MO-A0403_02.fm

3-21
REF. DESCRIPTION
9 Alarm threshold value (stated value, cannot Be edited).

The machine is set up for one or more alarms (stopping the machine) if the current value of
one of the parameters (values) 1, 3, 4, 5, 6 or 7 is higher than the corresponding threshold
value (expressed as a percentage respect to the set value).
For example, if the manual mode speed setting value is equal to 100 bph and the threshold
value is equal to 10%, the SUPERVISOR will report an alarm whereby stopping the machine
as soon as the recorded speed in manual mode reaches and exceeds 110 bph.

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Operating Manual
3.3.5 OVEN PAGE
The oven page provides information on parameters strictly related to preform conditioning unit set-
tings.
The working area shows a graphic drawing of the oven unit (active graphic elements) and some main
components (active and passive graphic elements).
Indications provided concern the main oven unit component parameters, e.g. fans, individual oven
status, power output by each lamp, etc. 3
Figure 3-12. SUPERVISOR - Oven page

MO-A0403_02.fm

3-23
REF. NAME INDICATIONS/USE LINKED

PAGE
A OVEN SETTINGS Indicating the percentage power output by each --

lamp (blowing side).
Oven off Oven on Oven on
(working) (faulty)
B FAN SETTINGS Not enabled on operator level. --
C OVEN LAMP SET- Not enabled on operator level. --

TINGS
E OVEN TREND Not enabled on operator level. --

GRAPH
F OVEN SETTINGS Indicating the percentage power output by each --

lamp (loading side).
Oven off Oven on Oven on
(working) (faulty)
REF. INFORMATION
G Fan status:
Turning - graphic element simulating turning.
Stopped - stationary graphic element.

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Operating Manual
ALPHANUMERIC BOXES
REF. DESCRIPTION
1 Number of preforms at oven inlet.
2 Coolant temperature. 3
3 Coolant flow percentage from modulating valve.
4 Oven temperature.
5 Mold preform input temperature.
6 Fan rotation speed.
7 Fan rotation speed percentage.
3.3.5.2 OVEN GRAPH PAGE
The OVEN GRAPH page is used to display temperature patterns in a 2-D (time/temperature) chart
related to the following:
- oven air temperature (blue graph);
- preform temperautre (red graph);
- preform set temperature (purple graph);
- oven air set temperature (green graph).
The working area includes the following commands:

Left arrow (A) - Press (select) to move the graph leftwards.
Right arrow (B) - Press (select) to move the graph rightwards.

MO-A0403_02.fm

3-25
Figure 3-13. SUPERVISORE - Pagina GRAFICO FORNI
The page includes the following operative commands:
PULSANTE NOME FUNZIONE
PRINT Press (select) to print selected graphics (if a connected

printer is present).
ZOOM Press (select) to activate zoom tool.

Zoom tool operates dragging the cursor in a selected
zone (rectangle).

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Operating Manual
PULSANTE NOME FUNZIONE
PAGE Press (select) to active the instrument blowup to width

WIDTH page.
It returns the blowup to the maximum concurred from
the width page.
3
SAMPLING Press (select) to disactive data sampling.
STOP Graphics are not updated in real time.
SAMPLING Press (select) to restart data sampling.

RESTART Graphics are updated in real time.
TEMPORAL AXIS Press (select) to set up unit of measure of the temporal

1 MINUTE axis on a minute.
TEMPORAL AXIS Press (select) to set up unit of measure of the temporal

5 MINUTES axis on five minute.

MO-A0403_02.fm

3-27
3.3.6 UNLOADING PAGE
The unloading page provides information related to the bottle aligner.

The working area shows a graphic drawing of the unloading unit and the aligners, with the respective
electric drive (active graphic element).
The indications provided concern aligner electric drive rotation speed.
The working area will show a similar drawing without active graphic elements or numbers if the align-
er is not supplied directly by SIPA (C).
Figure 3-14. SUPERVISOR - Unloading page

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Operating Manual
REF. NAME INFORMATION/USE LINKED

PAGE
A ALIGNER ELECTRIC Not enabled on operator level. --

3
DRIVE SETTINGS
REF. INFORMATION
B Electric drive status.

Off On
C Customer aligner working area.
ALPHANUMERIC BOXES
REF. DESCRIPTION
1 Electric motor rotation speed percentage.
2 Electric drive rotation speed.

MO-A0403_02.fm

3-29
3.3.7 BLOWING PAGE
The blowing provides information on the stretching/blowing system.

The working area shows a simplified graphic drawing of the stretching/blowing system (passive
graphic elements). A colored sector (blue, violet, green, yellow, red, etc.) and a numeric value asso-
ciated to the angular position at the beginning of the specific phase corresponds to a stretching/blow-
ing phase (seal descent, primary air blowing start, secondary air blowing start, decompression start,
etc.).
The information provide in the alphanumeric boxes relate to the main parameters of the stretching/
blowing phase, such as, for example, the angular position of the reference press (press number one),
the angular position at primary air blowing start, etc.
Figure 3-15. SUPERVISOR - Blowing page

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Operating Manual

PAGE
L ENABLE/DISABLE To enable/disable the secondary air blow. --

3
SECONDARY AIR Press (select) central green light on - secondary air
enabled.
Press (select) central green light off - secondary air
disabled.
REF. INFORMATION
A SEAL DESCENT START (blue sector) - The displayed data indicates the angular position cor-
responding to the start of seal descent.
B SEAL CLOSURE CHECK (violet sector) - The displayed data indicates the angular position
corresponding to the seal closure check.
C PRIMARY AIR START (green sector) - The displayed data indicates the angular position cor-
responding to the primary air blowing start.
D SECONDARY AIR START (yellow sector) - The displayed data indicates the angular position
corresponding to the secondary air blowing start.
E DECOMPRESSION START (red sector) - The displayed data indicates the angular position
corresponding to decompression phase start.
F SEAL RISING (light blue sector) - The displayed data indicates the angular position corre-
sponding to seal rising.
G MOLD CLOSURE (violet sector) - The displayed data indicates the angular position corre-
sponding to the mold closure.
H SEAL OPEN CHECK (yellow sector) - The displayed data indicates the angular position corre-
sponding to the seal opening check.
MO-A0403_02.fm

3-31
ALPHANUMERIC BOXES
REF. DESCRIPTION
1 Press number one angular position (stated value, cannot be edited).
2 Bottles per hour (stated value, cannot be edited).
3 Compensation valve advance (stated value, can be edited).

Cannot be edited on OPERATOR level.
4 Primary air blow start angular position (stated value, can be edited).
5 Secondary air blow start angular position (stated value, can be edited).
6 Decompression phase duration time (stated value, can be edited).


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Operating Manual
3.3.8 PRODUCTION PAGE (STANDARD TOOL BAR)
This page provides information on machine operation (production).

The left side of the working area contains a set of commands for enabling/disabling the main opera-
tive modes of the machine: simulation and production. Simulation mode allows to enable/disable ma-
chine operative functions, such as:
rotation only, the machine can only turn with all parts in sync;
3
rotation enabled to seal closure and primary air blow functions;
rotation enabled for preform loading, seal closure and primary air blowing functions only (only the
heating function is disabled).
Enabling production mode implies enabling all the operative functions of the machine (rotation, load-
ing and conditioning). The right side of the working area contains some commands for enabling/dis-
abling unloading and preform ejection at certain points of the production cycle: i.e. after preform
shape check, after conditioning (the so-called "cold preforms" which are actually preform which do
not satisfy blowing requirements), after stretching/blowing (bottles).
MO-A0403_02.fm
Figure 3-16. SUPERVISOR - Production page (standard tool bar)

3-33

PAGE
A DISABLE ALL To disable all machine production functions (allowing --

machine rotation only).
Press (select), central green light on, to disable
loading, conditioning and stretching/blowing.
Select one of the other production functions (B, C
and D) to automatically disable this command.
B ENABLE ROTATION To enable blowing machine production functions. --

ONLY Press (select), central green light on, to enable
(simulation mode) blowing wheel rotation.
Select one of the other production functions (A, C
C ENABLE LOADING To enable machine production related to preform --

ONLY loading from hopper.
(simulation mode) Press (select), central green light on, to enable pre-
form loading from hopper.
Select one of the other production functions (A, B
D ENABLE ALL To enable all machine production functions (preform --

(production) loading from hopper, conditioning, stretching/blow-
ing).
Press (select), central green light on, all machine
production functions.
Select one of the other production functions (A, B
and C) to automatically disable this command.
NOTE 1
The functions related to commands B and D combined with
command E allow other functions.
NOTE 2
Actual bottle blowing is subordinated to command D (ENABLE
ALL) combined with command E (LOAD PREFORMS).

3-34
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Operating Manual

PAGE
F EJECT PREFORMS To eject preforms after shape check. --

(after shape check) Press (select), central green light on, manual func-
tion disabled. To eject all loaded preforms. 3
Press (select), central green light off, manual func-

tion disabled, automatic function enabled. To eject
all preforms which do not pass the shape check
(misshapen, bent or badly loaded).
G EJECT COLD PRE- To eject preforms before they are loaded in molds. --
FORMS Press (select), central green light on, manual func-
tion enabled. To eject all loaded preforms from the
machine (conditioned or not conditioned).
Press (select), central green light off, manual func-

preforms which do not satisfy the temperature val-
ues set for blowing ("cold" preforms).
MO-A0403_02.fm

3-35
PAGE
H EJECT BOTTLES To eject the bottles output from molds to allow pro- --
duction inspection.
Press (select), central green light on, manual func-
tion enabled.
Press (select), central green light on, manual func-

misshapen bottles only, i.e. the bottles which are
punctured. Punctured bottle detection is possible
thanks to a pressure switch in the blowing cavity; the
puncturing value can be set in "maintenance" mode
only.
NOTE
The ejected preforms following the shape check or which do not
satisfy set temperature values ("cold" preforms) are unloaded in
two compartments of the same container arranged in the front
part of the cabin. Preforms are conveyed into the container by
means of chutes.
ALPHANUMERIC BOXES
Not present.

3-36
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Operating Manual
LOAD PREFORMS Press (select), central green light on, to load preforms
on feeding chute.
Press (select), central green light off, to prevent loading
preforms on feeding chute. 3
REJECT NOT ENABLED ON OPERATOR LEVEL
MANAGEMENT
PREFORM NOT ENABLED ON OPERATOR LEVEL

SAMPLING
NOTE
In ENABLE ROTATION ONLY mode (simulation), command
(B) selected (enabled), the LOAD PREFORMS command will
run seal and compression cylinder simulation (primary air cir-
cuit).
MO-A0403_02.fm

3-37
3.3.9 CONFIGURATION PAGE (STANDARD TOOL BAR)
The configuration page provides information on configuration (hardware and software) of boards
which control and manage conditioning, the PLC (software version) and the industrial PC (memory,
loaded software, connected printed, where relevant).
Figure 3-17. SUPERVISOR - Configuration page (standard tool bar)

Not present.

3-38
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Operating Manual
REF. INFORMATION
A Oven heating board software version, for example:

V25 - motherboard
TC48 - optional board
DP - profibus 3
MC4 - axis control
B PLC software version.
C PC name.
D RAM, free storage capacity (KB).
E Current time (HH:MM:SS) and date (MM/DD/YY).
F Software licence code.
G Connected printer path (identification), where relevant.
H Hard disk, free capacity (KB).
L Software application identification.
ALPHANUMERIC BOXES
Not present.
MO-A0403_02.fm

3-39
Not enabled on operator level
SELECT LANGUAGE Press (select), to access the language selection func-

tion.
Link to page PG18 ( figure3-18).
SET SUPERVISOR Press (select), to access the SUPERVISOR level set-

LEVEL ting function.
Link to page PG19 ( figure3-19).
3.3.9.3 Linked pages
Select one of the following commands:

- SELECT LANGUAGE;
- SET SUPERVISOR LEVEL;
to access other configuration pages.

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Operating Manual
3.3.9.4 Select language page
The Select language page is used to change the SUPERVISOR operator interface language.
Three possible languages may be available. The first two are standard (English and Italian), the third
depends on the country where the machine will be used (country of destination of the machine).
Figure 3-18. SUPERVISOR -Select language page (standard tool bar)
The following commands are found in the working area:

Available languages (A) - the languages which can be selected (English, Italian and language of
destination of the machine, if relevant). Press (select) the required language to select and set the
SUPERVISOR interface language.
The status bar provides indications on the language in use (B).

The graphic symbol (B) corresponds to the selection made by means of command (A).
3.3.9.5 Set SUPERVISOR level set page
The SUPERVISOR level page allows to set the SUPERVISOR level.

Switching from the operative level to the maintenance level is only allowed by inserting the level
MO-A0403_02.fm
switching floppy disk in the drive. A double key password on the other hand will be required to switch
to the configuration and help desk levels.

3-41
Figure 3-19. SUPERVISOR - Set SUPERVISOR level page (standard tool bar)

Available levels (A) - the SUPERVISOR levels which can be selected (operator, maintenance,
configuration and help desk). Press (select) the required level to select and set the SUPERVISOR
level.
The status bar provides indications on the language in use (B).

The graphic symbol (B) corresponds to the selection made by means of command (A).

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Operating Manual
3.3.10 PRODUCTION DATA PAGE (STANDARD TOOL BAR)
The production data page provides information on machine production.

Production data are split into total data (counting from first machine start-up) and partial data (count-
ing from last reset).
The working area only shows production data (passive graphic elements).
Figure 3-20. SUPERVISOR - Production data page (standard tool bar)

Not present.
MO-A0403_02.fm

3-43
REF. INFORMATION
A Partial time/quantity column.
B Total time/quantity column.
C Total machine power up time (machine powered).
D Total machine stops (machine powered by not running).
E Total time before operator intervention (during an alarm).
F Total machine downtime.
G Total machine production.
H Total machine simulation.
L Total preforms loaded in machine.
M Total preforms ejected after shape check.
N Total quantity of preforms rejected after optoelectronic check.
P Total quantity of rejected cold preforms.
Q Total quantity of rejected bottled for following baga check.
R Total quantity of rejected bottles.
S Total quantity of bottles (incorrectly produced).
ALPHANUMERIC BOXES
Not present.

3-44
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Operating Manual
RESET COUNTER Press (select) to reset the partial times and quantities
columns (e.g. at the beginning of each shift).
3
EFFICIENCY AND Not enabled on operator level.
PRODUCTIVITY
GRAPHICS
TRANSFER ACTUAL Press (select) to transfer the actual page data in files
DATA (.TXT)
TRANSFER Press (select) to transfer efficiency data in files (.ZIP)

EFFICIENCY AND for processing by SIPA technics.
PRODUCTIVITY DATA
PRINT Press (select) to print the actual page.

MO-A0403_02.fm

3-45
3.3.11 ARCHIVES PAGE (STANDARD TOOL BAR)
The archives page is used to access functions related to configuration data, recipes and alarm map
archive management.
The working area has three active graphic elements for accessing the pages corresponding to these
functions.
Only Select recipe (B) can be selected on operator level.
Figure 3-21. SUPERVISOR - Recipe page (standard tool bar)

3-46
SFR 20
Operating Manual

PAGE
A LOAD CONFIGURA- Not enabled on operator level --

3
TION DATA
B SELECT RECIPE To access the recipe loading function. figure3-23
C LOAD ALARM MAP Not enabled on operator level --

Not present.
ALPHANUMERIC BOXES
Not present.
EXPLORE DISKETTE Press (select) to access an additional page displaying

diskette contents without quitting SUPERVISOR.
No error message will be displayed and no window will
be opened if there is no diskette in the drive.
Select EXPLORE DISKETTE to access the EXPLORE DISKETTE page.

The SELECT RECIPE page is used to access the SELECT RECIPE page.
3.3.11.4 Explore diskette page
The Explore diskette page is used to display the contents of a diskette in the respective drive without
MO-A0403_02.fm
quitting SUPERVISOR.

3-47
Figure 3-22. SUPERVISOR - Explore diskette page
A list showing diskette contents will appear in window (A) when the page is opened.
Arrow up (B) - Press (select) to scroll the list upwards.
Down down (C) - Press (select) to scroll the list downwards.
Close (C) - Press (select) to close the window and go back to the ARCHIVES page.
No error message will be displayed and no window will be opened if there is no diskette in the drive
when the EXPLORE DISKETTE command is used.
3.3.11.5 Select recipe page
The Select recipe page is used to select the recipe used by the PLC.
The recipe includes machine parameters, i.e. process data combined with rotation speed, etc.
Saving or setting a new recipe will change the general machine operating conditions.
The operator level is used to select only the recipes which are available (loaded) in the recipe archive.

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Operating Manual
Figure 3-23. SUPERVISOR - Select recipe page (standard tool bar)
The DEFAULT recipe will be displayed when the text window (A) is opened regardless of the number
of stored recipes. The default recipe cannot be deleted because it is the basic format for the variables
contained in the various recipes.
NOTE
The available commands are enabled only when the text in the
window (A) turns black (bold print) after grey.
Arrow up (C) - Press (select) to scroll the available recipe list (A) upwards one row at a time.
Arrow down (B) - Press (select) to scroll the available recipe list (B) downwards one row at a
time.
Print (D) - Press (select) to print the data related to the recipe shown in the window (A).
The recipe will be printed out in table form (make sure the printer is connected). The printout will
show the list of variables and the respective settings.
MO-A0403_02.fm

3-49
There is only one command on the page:
CONFIRM SELEC- Press (select) to confirm, i.e. to activate the recipe

TION selected by means of the commands in the working
area.
A sand clock symbol will appear when the data is being
loaded to screen to indicate that the system is busy and
that all other commands will be temporarily disabled.

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Operating Manual
3.3.12 HELP PAGE (STANDARD TOOL BAR)
The Help page is used to access help on-line functions, such as:
filmed footage;
documentation.
There are two active graphic elements in the working area allowing to access the same number of
pages referred to each of the previously listed functions. 3
Figure 3-24. SUPERVISOR - Help page (standard tool bar)

MO-A0403_02.fm

3-51

PAGE
A DISPLAY FILMS To view films (AVI format) on maintenance proce- --

dures, etc.
B DISPLAY DOCUMEN- To display machine documentation (wiring diagrams, --

TATION mechanical manual, etc.).
This function is constantly updated. Consequently, a
detailed list of the documents which can actually be
accessed cannot be provided at this time.

Not present.
ALPHANUMERIC BOXES
Not present.
3.3.12.2 Operative Commands
Not present.

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Operating Manual
3.3.13 ALARMS PAGE (STANDARD TOOL BAR)
The Alarms page displays the list of warnings generated by faulty machine operation. The list of
alarm signals is sorted in order of time. The last alarm in the list is the most recent (causing the ma-
chine to stop).
The alarms are split into two categories:
ALARMS (red) stop the machine;
3
WARNINGS (yellow) do not stop the machine.
The presence of two or more warnings can generate an alarm and, consequently, stop the ma-
chine.
NOTE
An alarm which stops the machine may not appear as the last
alarm in the list because, in most cases, an alarm will cause a
cascade of other alarms. In order to discriminate the real cause
of the stop, use the STOP HISTORY command (see paragraph
3.3.13.4).
The following information is provided for each alarm (row in the list):
- numeric code - the numeric code univocally identifying the alarm signal correlated to the signal
which generated by alarm;
- brief description - the brief description provides indications on the alarm;
- date and time - this is the date (DD/MM/YY) and time (HH:MM:SS) of the alarm.
MO-A0403_02.fm

3-53
Figure 3-25. SUPERVISOR - Alarms page (standard tool bar)

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PAGE
A SELECT ALARM/ Tap on the screen on any of the rows in the alarm/ --
3
WARNING warning list to select the corresponding alarm or
warning (the entire row will turn blue).
B SCROLL UP Press (select) to scroll the list up (one row at a time). --
C SCROLL DOWN Press (select) to scroll the list down (one row at a --
time).
D RESET ALARMS Press (select) to eliminate the row(s) corresponding --

to solved alarms.
REF. INFORMATION
E Alarm in - date and time when the alarm occurred.
F Description - Brief description of the alarm.
ALPHANUMERIC BOXES
Not present.
ALARM HELP Press (select) to access the selected alarm/warning

description page (help) (PG15 - figure3-26).
The description page (help) provides information on the
possible causes generating the alarm/warning and the
possible solutions.
MO-A0403_02.fm

3-55
DISPLAY ALARMS Press (select) to display alarms and warnings at the

AND WARNINGS same time.
The DISPLAY ALARMS and DISPLAY WARNINGS
commands will disable this command.
DISPLAY ALARMS Press (select) to display only the alarms only (red).
The DISPLAY ALARMS AND WARNINGS and DIS-
PLAY WARNINGS commands will disable this com-
mand.
DISPLAY WARNINGS Press (select) to display the warnings only (yellow).

The DISPLAY ALARMS AND WARNINGS and the DIS-
PLAY ALARMS command will disable this command.
-- Not used
DISPLAY ALARM HIS- Press (select) to access the page displaying the alarms
TORY (PG 17 - figure3-27).
STOP HISTORY Press (select) to access the page display all the alarms
causing machine stops (PG 18 - figure3-27).
This information is essential to understand why the
machine stopped.

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SFR 20
Operating Manual
Select one of the following commands:

- ALARM HELP;
- DISPLAY ALARM HISTORY;
- DISPLAY STOP HISTORY

3
to access additional pages linked to the alarm page.
3.3.13.4 Alarm help page
The Alarm help page provides additional information on alarm signals display on the Alarms page
(PG14 - figure3-25).
Figure 3-26. SUPERVISOR - Alarm help page (standard tool bar)
The following five fields are provided in the working area:

Alarm code (1) - univocally identifying the alarm;
MO-A0403_02.fm
Alarm description (2) - providing a brief description of the alarm;

3-57
Area of concern (3) - information for physically locating the area or part of the machine which
generated the alarm;
Causes (4) - information on the possible causes of the alarm. Each cause is identified by means
of a number;
Solutions (5) - information on the operations to be carried out to eliminate the alarm. Each solu-
tion is identified by means of a number which corresponds to the correlated cause.
The following commands are included in the lower part of the working area:
Arrow down (A) - Press (select) to move the cursor downwards.
This same function can be obtained by directly touching the screen in the point where you want
to position the cursor (touch screen function).
Arrow up (B) - Press (select) to move the cursor upwards.

to position the cursor.
Arrow right (C) - Press (select) to move the cursor to the right.
Arrow left (D) - Press (select) to move the arrow to the left.
Print (E) - Press (select) to print the displayed page (only if a printer is connected).
Quit (F) - Press (select) to quit the Alarms help page.
NOTE
The information on alarms and possible solutions acquire when
this manual was printed may not be sufficient to re-establish reg-
ular machine working conditions. If the information on screen is
not sufficient to restore normal working conditions, call the SIPA
Telephone Help Desk.

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Operating Manual
3.3.13.5 Display alarm history page
The working area shows the complete list (in chronological order) of alarms recorded by the PLC dur-
ing the entire life of the machine.
Figure 3-27. SUPERVISOR - Display alarm history page (standard tool bar)
The following information is provided for each alarm (1) (row in the list):
- date and time - this is the date (DD/MM/YY) and time (HH:MM:SS) of the alarm.

MO-A0403_02.fm

3-59
The Display alarm history page has the following commands:

The DISPLAY ALARMS and DISPLAY WARNINGS
commands will disable this command.
DISPLAY ALARMS Press (select) to display only the alarms only (red).
The DISPLAY ALARMS AND WARNINGS and DIS-
PLAY WARNINGS commands will disable this com-
mand.
DISPLAY WARNINGS Press (select) to display the warnings only (yellow).

The DISPLAY ALARMS AND WARNINGS and the DIS-
PLAY ALARMS command will disable this command.
DISPLAY ALARMS Press (select) to display the alarm which occured during
LAST DAY the last day.
LAST WEEK the last week.
LAST MONTH the last month.
SAVE ALARMS Press (select) to export alarm log files to diskette (in
TXT format).

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Operating Manual
SAVE WARNINGS Press (select) to export warning log files to diskette (in
TXT format).
3
REF. INFORMATION
C Alarm out - date and time when the alarm was solved.
D Alarm in - date and time when the alarm occurred.
E Description - Brief description of the alarm.

MO-A0403_02.fm

3-61
3.3.13.6 Stop history page
The working area shows the complete list of alarms which stopped the machine recorded by the PLC.
Figure 3-28. SUPERVISOR - Display stop history page (standard tool bar)
The following information is provided for each alarm (1) (row in the list):
- in date and time - this is the date (DD/MM/YY) and time (HH:MM:SS) when the alarm occurred;
- out date and time - this is the date (DD/MM/YY) and time (HH:MM:SS) when the alarm was
solved.


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Operating Manual
The Display stop history page has the following commands:
DISPLAY STOP Press (select) to display the last alarm causing the
CAUSE machine to stop.
3
DISPLAY STOPS Press (select) to display the alarms causing the
LAST HOUR machine to stop which occurred during the last hour.

LAST DAY machine to stop which occurred during the last day.

LAST WEEK machine to stop which occurred during the last week.

LAST MONTH machine to stop which occurred during the last month.
DISPLAY ALL STOPS Press (select) to display all the alarms which made the
machine stop since start-up date.
SAVE STOPS Press (select) to export, on floppy disk, files (.TXT) con-
taining the list of the historical allarms that generated the
machine stop.
MO-A0403_02.fm

3-63
REF. INFORMATION
C Description - Brief description of the alarm.
D Alarm in - date and time when the alarm occurred.
E Alarm out - date and time when the alarm was solved.

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Operating Manual
SECTION 4
INSTALLING, MOVING AND
DISMANTLING (DECOMMISSIONING)
4.1 GENERAL
4
Installation, testing and starting up the machine for the first time are carried out by SIPA technicians
unless provided for otherwise in the purchase contract.
The buyer and anyone he appoints, is responsible for designing, making, installing and testing the
systems necessary for the machine to operate, such as: electric, air and water feeding and distribu-
tion systems, etc.
In addition, the buyer is responsible for defining the machine layout in relation to the features of the
place of work, meaning by this the location of the machine and auxiliary devices, taking into account
the information, recommendations and specifications contained in the relevant manuals, laws and
current regulations and international and national standards applicable.
WARNING 1
The layout of the machine prepared by SIPA is for informa-
tion purposes only since it cannot take into account all the
details, known only to the user, concerning details of the
building, other machines or systems at the site of installation
and work organization.
WARNING 2
The layouts have the sole purpose of providing overall di-
mensions and information for installation of the subject of
SIPA supply. The user is entirely responsible for the feasibil-
ity study, especially for aspects concerning safety.
To make it possible to install the machine correctly and comply with the safety standards, some in-
formation is provided of a general nature relating to the machine as a whole.
1. Examine the information contained in Section 1.
2. Check that the systems comply with the applicable standards for each one of them.
3. Check that the other systems, not of SIPA supply (if any), do not alter the safety of the machine.
4. Check that the systems not supplied by SIPA, but which can be connected to the machine
comply with the specifications stated in the contract.
5. If installation and handling are done by the Customer's personnel, the Customer must ensure
MO-A0404_02.fm
that these operations are carried out by skilled personnel who have been properly trained.
Installing, moving and dismantling (decommissioning)

4-1
CAUTION 1
THE MACHINE MUST ALWAYS BE INSTALLED AND
HOOKED UP IN COMPLIANCE WITH THE INSTRUCTIONS
PROVIDED IN THE OPERATING AND MAINTENANCE MAN-
UALS.
CAUTION 2
DISRESPECT OF THIS RULES MAY BE A HAZARD FOR MA-
CHINE OPERATORS.
4.2 GENERAL INFORMATION

On receiving the machine, check the integrity of the packing, if any; should you find any damage has
occurred during transit or any missing parts, call SIPA after-sales service. The machine is shipped
on an articulated truck, broken down into its main units which, if necessary, are further broken down
into subassemblies which are carefully and suitably packed.
4.3 REQUIREMENTS FOR INSTALLING THE MACHINE

4.3.1 PREREQUISITES OF THE SITE OF INSTALLATION OF THE MACHINE
The machine must be installed on a floor which is suitable for supporting the dynamic, concentrated
loads shown in the installation layout drawings. The dimensions of the foundations must then be such
as to comply with the above prerequisites and in any case in agreement with the current standards
in the country of installation. The dimensions of the foundations should then be such as to comply
with the above prerequisites and in any case in agreement with the current standards in the country
of installation.
In particular the space for the machine (according to the installation layout) must be calculated in re-
lation to:
- Total surface area of the floor
- Total height from the ground (machine and cabin)
- Clearance required to open the cabin doors (all inclusive)
- Space required to change the molds (ordinary movements)
- Space required for the auxiliary tools (hopper, manifold, etc.).
In addition, it is important for the site of installation of the machine to have adequate lighting and ven-
tilation.

4-2
SFR 20
Operating Manual
SEE THE INSTALLATION LAYOUTS

MO-A0404_02.fm
Figure 4-1. Installation layout

4-3
4.3.2 EXTERNAL SYSTEM PREREQUISITES
The site of installation of the machine must be fitted for hooking up to the external electricity mains,
earth system, compressed air and water systems.
All the systems of the installation site must be made to standard.
4.3.2.1 Electrical power
The electrical system of the installation site of the machine and of the different external auxiliary sys-
tems must be prepared for hooking up to the external mains and in compliance with the applicable
standards, especially with reference to the European standard EN 60204-1.
The main requirements are given in the following table and in the electrical system layout diagram
enclosed with this publication.
DESCRIPTION PARTICULARS
MASTER PANEL
Supply voltage 400 V 10% 50 Hz 3 FASI + T + N
Installed power 384 kW (SFR20)
Power cable (type) Variable according to line lenght

(es: 5 X 240 mm2)
Power cable (section) Variable according to line lenght

(es: 240 mm2)
EXTERNAL AUXILIARY SYSTEMS
Supply voltage 400 V 10% 50 Hz
Installed power
- Air compressor - kW (variable according to installation)
- kW (variable according to installation)

- Conditioner (chiller) - 24.4 kW
WARNING
An appropriate transformer is needed if the power supplier
is different from 400 V.

4-4
SFR 20
Operating Manual
4.3.2.2 Earthing
The machine and the relative external auxiliary systems must be earthed through the centralized cir-
cuit available on the site of installation.
NOTE
The earth system characteristics must comply with the standards
in force in the country where the machine is installed.
4.3.2.3 Compressed air supply 4

The centralized compressed-air supply system already at the site of installation of the machine must
comply with the terms set down in the contract agreements and must be designed, made and in-
stalled by expert technicians, in conformity both with the regulations of the law and with SIPA tech-
nical requirements; in this connection, please refer to the installation layouts.
In particular, the compressed air system of the SFR 20 blowing machine must have the following fea-
tures:
Each supply line to the machine must correspond to a branch of the centralized system.
The general supply pressure must always be within the established limits specified below, even
in the most severe load conditions (e.g. maximum machine speed, maximum load, maximum trav-
el of actuators).
CAUTION
OTHER COMPRESSED AIR SUPPLY PRESSURES (MEA-
SURED AT THE MACHINE INLET) THAN THE ONES INDI-
CATED CAN CAUSE SERIOUS MALFUNCTIONING OF THE
MACHINE AND BE DANGEROUS FOR THE SAFETY OF PER-
SONS.
The piping of the centralized system, to the machine air inlet, must be made of corrosion-proof
material, stainless steel for example.
The compressed air supplying the machine must be clean, dry, filtered and free of contaminants.
WARNING
Several devices installed on the line are controlled pneumat-
ically; it is therefore extremely important for these applianc-
es to be able to work at peak efficiency so as not to
jeopardize the duration, reliability and level of safety of the
system.
MO-A0404_02.fm

4-5
DESCRIPTION MOVEMENT AIR BLOW AIR
Piping 1 1/2" G 2" G
Operating pressure 7 bar 38 bar
Max/Min operating pressure 6 / 8 bar 35 / 40 bar
Typical consumption 125 Nm3/h da 774 a 2907 Nm3/h

(rate 1400 bottles/hour) (SFR20) (SFR20)
Air specifications Filtered, dry compressed air.
CAUTION
CONTINUE LUBRICATIONS
IF SERVICE AIR IS ACCIDEN-
TALLY LUBRICATED AND IN-
FORM SIPA TECHNICAL
ASSISTANCE IMMEDIATELY.
4.3.2.4 Water supply
The centralized water supply already at the site of installation of the machine must comply with the
terms set down in the contract agreements and be designed, made and installed by expert techni-
cians, in conformity both with the regulations of the law and with SIPA technical requirements.
The features of the water system for cooling the various systems are given in the following table.
WARNING
Failure to comply with the requirements, especially the tem-
perature of the water used, can cause serious damage to the
machine; it is recommended to avoid using long sections of
non-insulated pipe in areas at high temperature.
DESCRIPTION SFR
Type Low-density mains water
Operating pressure 4.5 bar
Piping 2"

4-6
SFR 20
Operating Manual
DESCRIPTION SFR
Typical consumption 21.60 m3/h

(SFR20)
Max temperature 25 C
Max hardness < 20 French

4
4.4 UNPACKING
The machine is shipped using special containers or suitable means of protection depending on the
means of transportation used; it is recommended to pay the utmost attention when unpacking in or-
der to avoid damage to persons or to the machine and to dispose of the packing materials in confor-
mity with current regulations in the country where the machine is installed and used.
WARNING
The packing containers must only be opened and the ma-
chine removed from the packing containers in the presence
of a technician appointed by SIPA.
Any tampering with the machine's original packing may be grounds for checking the integrity of the
various parts of the machine. The cost of this check is to the Customer's account and can only be
carried out by technicians appointed by SIPA.
After unpacking, inspect the machine and its parts for any signs of damage or breakage that may
have occurred in transit.
4.5 HANDLING
As already mentioned, the machine is installed by SIPA technicians. The instructions given in this
section are provided for information purposes and may be useful if the user intends to change the
machine's original position.
CAUTION 1
LIFTING OPERATIONS MUST BE CARRIED OUT BY PER-
SONNEL TRAINED FOR THIS FUNCTION (CRANE, FORK-
LIFT TRUCK OPERATORS, ETC.) AND WITH GROUND AS-
SISTANCE FROM A PERSON ASSIGNED TO SIGNALLING IF
THE OVERALL DIMENSIONS OF THE LOAD DO NOT GRANT
MO-A0404_02.fm
SUFFICIENT VISIBILITY; THE PERSONNEL MUST BE FIT-

TED OUT WITH THE NECESSARY INDIVIDUAL ACCIDENT-
PREVENTION GEAR.

4-7
CAUTION 2
IT IS PROHIBITED TO ACCESS THE AREA INVOLVED WITH
LIFTING FOR ALL PERSONNEL NOT DIRECTLY ENGAGED
IN THIS WORK, USING THE MOST SUITABLE EQUIPMENT
FOR THIS PURPOSE (RAILINGS, SIGNS, ETC.).
CAUTION 3
THE CAPACITY OF THE LIFTING EQUIPMENT USED MUST
BE ADEQUATE FOR THE WEIGHTS TO BE HANDLED; HAN-
DLING MUST BE DONE SLOWLY, WITH GOOD LIGHTING
AND SUFFICIENT CLEAR SPACE TO WORK SAFELY.
CAUTION 4
FOR NO REASON CAN PERSONNEL ASSIGNED TO THESE
OPERATIONS BE AUTHORIZED TO PASS UNDER THE LOAD
OR CLOSE TO IT, AND THIS HOLDS ALSO FOR THE PER-
SON ASSIGNED TO SIGNALLING FROM THE GROUND.
To permit handling the machine or any units separated from it, it is necessary to comply with the fol-
lowing instructions.
1. Have suitable equipment to lift the load, making sure it has sufficient capacity to ensure safe
handling. In this connection, refer to the documentation on the machine's technical
specifications.
CAUTION
THE ROPES AND/OR CHAINS USED TO SLING AND LIFT
THE LOAD MUST BE IN PERFECT CONDITION. THE
LENGTH OF THE ROPES AND/OR CHAINS MUST BE ADE-
QUATE; IT IS RECOMMENDED NOT TO USE ROPES THAT
ARE TOO SHORT THAT, BESIDES POSSIBLY INTERFERING
WITH PARTS OF THE MACHINE, WOULD INCREASE THE
LIFTING ANGLE AND CONSEQUENTLY INCREASE THE
TENSION ON THE ROPE.
2. For handling and/or unloading, use a crane.

3. The machine has special lifting points fitted for attaching connections. The methods of lifting are
described in the following sections.
4. Start lifting gradually, very slowly, to check the load is properly balanced; otherwise, where
possible, adapt the position of the ropes and/or chains appropriately.
4.5.1 HANDLING AND POSITIONING
The SFR 20 blowing machine must be lifted using steel slings and attaching them to the lifting points
( figure 4-2).

4-8
SFR 20
Operating Manual
It must be positioned on adjustable feet (1) - dimensions 100x150 mm - to be placed beforehand on

the floor by the machine base support points.
WARNING
The illustrations shown in figure 4-2 are only indicative. Refer
to the Mechanical Manual for more detailed information.
NOTE
Machine handling and positioning is normally done with it divid-
ed into three parts: machine body, oven and master panel. Re-
fer to the relative illustrations ( figure 4-2) to identify the special
4
lifting points on the single parts.
MO-A0404_02.fm

4-9
Figure 4-2. Machine handling and positioning (Sheet 1 of 2)

4-10
SFR 20
Operating Manual
4
MO-A0404_02.fm
Figure 4-2. Machine handling and positioning (Sheet 2)

4-11
4.6 CONNECTING FUNCTIONAL SYSTEMS
If, due to the overall dimensions during transit, the machine has been divided into several parts, in
the installation and positioning phase it is necessary to reconnect the parts.
4.7 ELECTRICAL SYSTEM HOOK-UP

The electrical system is hooked up by SIPA technicians when installing the machine. Here, all the
electrical devices dismantled for transit are installed back on the machines and connected to the con-
nection boxes and the hook-up is made to the Master panel, the interfacing made between the sys-
tems for commanding and controlling the machines, assembly of the raceways and all the testing
necessary to make the machine operative.
Because of the systems characteristics, it is not envisaged that the user would do these operations
independently.
CAUTION 1
HOOKING UP THE MACHINE TO THE ELECTRICAL LINE
MUST ONLY BE DONE BY SKILLED PERSONNEL IN COM-
PLIANCE WITH THE CURRENT SAFETY STANDARDS IN THE
COUNTRY WHERE THE MACHINE IS INSTALLED.
CAUTION 2
BEFORE MAKING THE ELECTRICAL HOOK-UP OF THE MA-
CHINE, DISCONNECT POWER TO THE MAIN LINE.
CAUTION 3
REFER TO THE APPLICABLE WIRING DIAGRAMS AND IN-
STALLATION LAYOUTS ENCLOSED WITH THIS MANUAL.
4.7.1 GROUNDING HOOK-UP
The machine's electrical system must be equipped with earthing in conformity with current standards,
for obvious reasons of safety.
For the hook-up, examine the information provided in paragrafo 4.3.2.2

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Operating Manual
4.8 COMPRESSED-AIR SYSTEM HOOK-UP
NOTE
The indications provided in the diagram shown in figure 4-3 are
only indicative. Refer to the installation and manifold layout at-
tached to this publication at all times.
The air system ( figure 4-3) to supply the SERVICE air (movement) must be connected separately
from that for the PROCESS air (blowing) in relation to the characteristics of each system and in com-
pliance with the instructions of paragrafo 4.3.2.3 4
Connect the flexible hoses from the main manifold to the machine, making reference to the informa-
tion and illustrations given on the installation layout enclosed with this publication.
WARNING 1
With a blast of dry, filtered compressed air, carefully clean all
the components of the supply lines (tanks, piping, fittings).
WARNING 2
Dirt in the supply circuits can cause the pneumatic mecha-
nisms to malfunction and jam, consequently being a risk of
damage and danger for persons.
4.9 WATER SYSTEM HOOK-UP
NOTE
The indications provided in the diagram shown in figure 4-4 are
only indicative. Refer to the installation and manifold layout at-
tached to this publication at all times.
The water system ( figure 4-4) must be connected bearing in mind the characteristics of each system
and in compliance with the instructions of paragrafo 4.3.2.4
1. Connect the flexible hoses from the main manifold to the machine, making reference to the
information and illustrations given on the installation layout enclosed with this publication.
2. Check that the features of the water supply line correspond to the indications of paragrafo 4.3.2.4
Check that, with the circuit open, there is no leakage of water from the inlet and outlet fittings of the
various cooling systems.
MO-A0404_02.fm

4-13
Figure 4-3. Air system hook-up - Diagram

4-14
SFR 20
Operating Manual
4
MO-A0404_02.fm
Figure 4-4. Water system hook-up - Diagram

4-15
4.10 LEVELLING
After installing the machine and before levelling it, carefully clean it, taking care to remove dust and
residues especially from the sliding surfaces and the cams.
Refer to Section 7 for a list of cleaning operations to be carried out on the machine.
The machine must work horizontally so as to ensure adequate alignment of the base, eliminating vi-
bration and excessive stress.
In this connection, before starting the machine, level it as instructed (sheet 01-41-1064) taking into
account that the adjustment must be made with the machines in conditions of normal operation, with
all the movement devices installed.
WARNING 1
Levelling is done by SIPA technicians after installing the ma-
chine. It is recommended to check the levelling at regular in-
tervals during normal machine operation (at least during the
first months of operation).
WARNING 2
The manufacturer disclaims all responsibility for damage or
malfunctioning of the machine deriving from poor levelling
or failure to make the envisaged periodical checks.
4.11 DISMANTLING
Demolition of the machine must be done by skilled personnel.
Current regulations in the various countries on this type of operation are different and so it is recom-
mended to analyze and implement the regulations of the law at the time when the machine needs to
be dismantled.
The machine has been made using non-hazardous materials (steel, plastics, rubber) that involve no
problems of recycling or disposal and it can be fully disassembled; however, thorough knowledge of
the machine's construction features is required along with specific technical knowledge for taking it
apart, as well as the appropriate tools.
It is therefore recommended to refer to the Sipa after-sales service to ensure this job is done in total
safety.

4-16
SFR 20
Operating Manual
SECTION 5
PROCEDURES FOR USING THE MACHINE
5.1 GENERAL
This section provides the necessary procedures for using the SFR blowing machine.
This machine is started up the first time by SIPA technicians after installation, when the adjustments
and settings of the various devices and mechanisms of the machine are also made in combination
to the required customizations.
5
The user cannot change the configuration settings in any way by operating on the various mechani-
cal, electric and pneumatic parts of the machine, except for the normal procedures related to the con-
tainer to be made or to maintenance operations (scheduled and unscheduled). Furthermore, the
machine management and control software (SUPERVISOR) implement various safety levels to pro-
tect machine configuration data from changes.
WARNING
The Manufacturer disclaims all responsibility for damage to
persons or property, breakage or malfunctioning that may
occur after actions of this type carried out by unauthorized
personnel.
5.2 FIRST MACHINE START-UP
5.2.1 PRELIMINARY CHECKS
The following operations are to be carried out before starting up the machine:
1. Check that the water, air and electrical power hook-ups are properly connected to the respective
main lines (refer to Section 4).
2. Make a general inspection of the machine, checking that no components have been removed or
modified during the installation and/or maintenance procedures.
3. Check that no one is working on or near the machine.
4. Check that the machine and the surrounding area are clear of rags, tools, spare parts and
miscellaneous objects so that they will not interfere during operation of the machine and do not
obstruct is safety devices.
5. Check that the floor and walkways of the machine are clear of oil, grease and water.
MO-A0405_02.fm

5-1

5.2.2 PREPARATION AND REGULATION OF THE MACHINE
The preparation and regulation of the machine for the first start-up as per the following phases:
Powering the systems
Operating manually;
Loading recipe and machine data
Start cycle.
5.2.2.1 Powering the machines ( figure 5-1)
NOTE
The coolant must reach the value set in machine configuration
data before starting the cycle. The time required to reach this val-
ue depends on the characteristics of the chiller (conditioner) and
on the environmental conditions (ambient temperature).
1. Check that all manifold sluices are open.

2. Check working pressure on respective pressure gauges:
- from 6 to 7 bars for movement air;
- from 37 to 40 bars for blowing air.
3. Master electric panel: main switch I / 0 in position I.

4. Master push button panel:
a. check that the indicator light (white) 230 Vac is on.
b. key selector ENABLE AUXILIARIES in horizontal position
c. blue AUXILIARY ALARM RESET button pressed and released.
d. check that the indicator light (orange) AUXILIARY ALARMS is off.
e. white luminous push button START AUXILIARIES pressed and released (light on).
5.2.2.2 Manual machine control
1. Operator interface panel: press and release MANUAL button (green light on).
2. Turn handwheel (1) for manual operation.
3. Machine push button panel: turn BRAKE BY-PASS clockwise and release (pneumatic brake
system feed).
4. Turn blowing wheel slowly by means of the handwheel (1) and check that:

5-2
SFR 20
Operating Manual
a. Machine movement is fully linear (smooth, no seizing);
b. Transfer and loading/unloading units are synchronized and aligned.
5. If the effort required to turn the handwheel increases considerably, stop immediately and check
for obstructions and/or interference.
6. Turn the blowing wheel at least twice completely.
7. Machine push button panel: turn PUSH BUTTON PANEL BY-PASS switch clockwise and hold
in position until the hand-held portable keypad is connected. Release the switch.
8. Hand-held portable keypad: turn the blowing wheel a few times to check (command code 18,
button +).
9. Hand-held portable keypad: perform the following operations for each mold: 5
WARNING
The following operations are indispensable to verify correct
operation of the control solenoid valves.
a. seals up and down (command code 48, button + and -);

b. compensation cylinder actuation (command code 49, button +);
c. primary air blow (command code 50, button +).
NOTE
The command codes of the hand-held portable keypad refer to
mold one only.
10. Check for the presence of preforms in the hopper reservoir.

11. Hand-held portable keypad: move hopper (command code 8, button + hold pressed).
12. Check that the preforms in the reservoir are extracted and lifted correctly and continuously.
13. Hand-held portable keypad: stop move hopper (command code 8, button + release).
14. Preform feeding unit: check that preforms slide correctly on chutes. If this is not so, carry out
maintenance operation xx-xx-xxxx (preform feeding chute adjustment).
15. Hand-held portable keypad:
a. Run convey preform (command code 20, button + held pressed to load 10, 20 preforms).
Check that this occurs smoothly and/or without interference.
NOTE
The convey preform command synchronizes preform feeding
flap opening and closing according to the angular position of the
feeding screw.
MO-A0405_02.fm
b. Enable eject rejected bottle (command code 15, button +);

5-3

NOTE
The eject rejected bottle function is used to unload the preforms
loaded in the previous stages.
c. Run move blowing wheel (command code 18, button + hold pressed) and check the preform
travel:
- movement should be linear;

- movement should be smooth and/or without interference;
- correct passage into oven.
d. When the last preform has been unloaded, release the + button on the hand-held portable
keypad;
e. Disable eject rejected bottle (command code 15, button -);
f. Check fan operation (command code 24, button + hold pressed for several seconds).
g. Check oven lamp operation (command code 25, button + hold pressed for several seconds).
16. Check complete loading of SUPERVISOR.

17. Check for presence of alarms.
18. Eliminate alarm, if any.
19. Go to the AUXILIARY page and wait until the set coolant temperature is reached.
20. Load recipe (paragraph 3.3.11.5).

5-4
SFR 20
Operating Manual
5
MO-A0405_02.fm
Figure 5-1. Machines powering phase

5-5

5.2.2.3 Loading recipes and machine data
In the beginning, all the production and cycle control values must be entered via software. This op-
eration is carried out by loading the appropriate RECIPE code and the machine DATA code.
For the operating procedures to load the recipe via software, refer to Section 3.
5.2.2.4 Start Cycle
1. Operator interface panel: press and release AUTOMATIC button (green light on).
2. SUPERVISOR: ALARM page, check for alarms and eliminate, if any (trash command).
3. SUPERVISOR: PRODUCTION page, select ENABLE ALL command (work area) (machine set
for production) and the OPEN FLAP operative command (green light on).
4. Operator interface panel: press START CYCLE button for five seconds and release when
machine starts turning when the acoustic warning goes out (green light on).
NOTE
The machine will start warming up (average time, approximately
2 min.) by turning all oven lamps on. At the end of the preheating
phase, the machine will slow down to allow the stretching rods
to move down and will accelerate after reaching production
speed loading the preforms and starting the production cycle.

5-6
SFR 20
Operating Manual
5
MO-A0405_02.fm
Figure 5-2. . Start cycle phase (Sheet 1 of 2).

5-7

Figure 5-2. Start cycle phase (Sheet 2).

5-8
SFR 20
Operating Manual
5.3 MACHINE OPERATING INSTRUCTIONS

The following machine operating instructions must be followed to the letter.
SIPA supervisor only must be used during normal operation.
Always only use UNLOAD MACHINE command to stop normal production. Never use the fol-
lowing methods:
- open the doors;
- press the emergency stop button;
- use the MANUAL control; 5

- use the STOP CYCLE command.
MO-A0405_02.fm

5-9

5.4 ALARM WARNINGS
The state of the machine is constantly monitored by sensors (thermocouples, pressure transducers,
limit switches, etc.). Each sensor sends a signal to the PLC which will be processed according to the
instructions resident in memory.
In the industrial PC, the SUPERVISOR command and control program signals any trouble or mal-
functioning of the machine through the user interface and generates the corresponding alarms.
The machine alarms can be divided into four types:
Type 1 - warning
Type 2 - unload machine
Type 3 - cycle stop
Type 4 - phase stop (immediate stop and emergency stop);
To deactivate the buzzer press and release the SILENCE ALARMS button on operator interface
panel.
WARNING Alarm warning that does not involve the machine stopping.
Machine state Operative.
Actions to carry out
Check cause of alarm (paragraph 5.4.1) and carry out the consequent maintenance operation, if re-
quired.

5-10
SFR 20
Operating Manual
UNLOADING MACHINE alarm warning that involves completion of the work cycle:
- close preform inlet flap;
- complete blowing phase of all loaded preforms;
- unload all blow bottles;
- stop machine.
Machine state Unloading machine.
Action to carry out

5
1. Check the cause of alarm (paragraph 5.4.1) and if necessary carry out the required
maintenance.
2. After eliminating the alarm:
a. SUPERVISOR: ALARM page, eliminate alarms (trash command).
b. Check for any additional alarms.
3. On operator interface panel:
a. CYCLE STOP button on (green light on flashing), SILENCE ALARMS button on (green
light on flashing).
b. Check that the SILENCE ALARM button goes out, otherwise repeat points 1 and 2.
c. Press START CYCLE button for 5 sec. and release when you hear the alarm (green light
on).
NOTE
The machine will start up again automatically, warm up and
start the normal production cycle.
MO-A0405_02.fm

5-11

CYCLE STOP Alarm will stop the machine after a period of time equal to the
machine time required to complete the cycle.
The machine will slow down gradually to a full stop.
Machine state cycle stop.
Action to carry out
1. Check cause of alarm (paragraph 5.4.1) and carry out the consequent maintenance operation, if
required.
2. Eliminate cause of alarm:
b. Check for other alarms.

a. CYCLE STOP button on (green light on flashing), SILENCE ALARMS button on (green
light on flashing).
on).
NOTE
The machine will automatically complete the interrupted phas-
es, unload the bottles and the preform in the machine and start
the normal production cycle.

5-12
SFR 20
Operating Manual
PHASE STOP Alarm entailing immediate machine stop (emergency stop

(immediate stop) brakes are applied).
In any case, the machine blows air to prevent the preforms in
the molds from sticking to stretching rods.
Machine state Phase stop.
Action to carry out
1. Check cause of alarm (paragraph 5.4.1) and carry out the consequent maintenance operation, if 5
required.
2. Restore main torque limiter fitting by turning by hand.

a. CYCLE STOP button on (green light on flashing), SILENCE ALARMS buttons on (green
light on flashing).
on).
NOTE
MO-A0405_02.fm

5-13

PHASE STOP Alarm entailing immediate machine stop. Emergency brakes
(emergency stop) are applied and all power is cut off.
Machine state Phase stop.
Action to carry out
1. Locate which mushroom button was pressed (paragraph 5.4.1). Check whether the button was
pressed accidentally or voluntarily.
2. Reset the mushroom button.
3. Restore main torque limiter fitting by turning by hand.

a. CYCLE STOP button on (green light on flashing), SILENCE ALARMS buttons on (green
light on flashing).
on).
NOTE

5-14
SFR 20
Operating Manual
5.4.1 MEANING OF THE ALARMS
The following will occur if one or more alarms are tripped during normal machine operation:
- an acoustic alarm will sound;
- the SILENCE ALARMS button will flash.
Recall the page by selecting the ALARMS command in SUPERVISOR (standard command bar,
figure 5-3) to check the cause of alarm.
NOTE
The screen page shown in figure 5-3 is indicative only. Some items
may change according to the characteristics of the machine. 5
WARNING
For optimal machine operation, frequently check for alarm
by selecting ALARMS in SUPERVISOR.
The ALARM page includes the following commands:
ALARM HELP Press (select) to access the description page (help) of

the select alarm/warning (paragraph 5.4.1.1).
The description page (help) provides indications on the
possible causes which generated the alarm/warning and
the solutions.
DISPLAY ALARM Press (select) to open the page displaying all the
HISTORY alarms/warnings recorded by the SUPERVISOR.

The DISPLAY ALARMS or DISPLAY WARNINGS
command will disable this command.
DISPLAY ALARMS Press (select) to display alarms only (red).

MO-A0405_02.fm

5-15

DISPLAY WARNINGS Press (select) to display warnings only (yellow).

The following information is provided on the ALARM page:

- type of alarm (alarm color);
- alarm code;
- brief description;
- date and time.
ALARMS are red and WARNINGS are yellow.

Each alarm, regardless of level and type, is identified by means of a numeric code (five digits). You
are recommended to take note of the alarm code, especially in view of maintenance operations. The
code is followed by a short description of the alarm allowing to identify the component generating the
alarm, in principle. The description is followed by the date (day and time) when the alarm occurred.
5.4.1.1 ALARM HELP page
The following information is provided in the ALARM HELP page ( figure 5-4):
NOTE
The screen page shown in figure 5-4 is indicative only. Some items
may change according to the characteristics of the machine.
- alarm code;
- alarm description;
- concerned area;
- possible causes;
- solutions.
This information completes and integrates the information provided by the alarm indicating the pos-
sible causes of the alarm and the respective solutions, in all or in part.

5-16
SFR 20
Operating Manual
5
MO-A0405_02.fm
Figure 5-3. ALARM page

5-17

Figure 5-4. ALARM HELP page

5-18
SFR 20
Operating Manual
5.5 NORMAL OPERATING PROCEDURES

The following is a list of the operating procedures the operator must keep to during normal machine
operation.
1. Run the production cycle and production check according to the instructions provided in Section
6 and at regular intervals of 60 min.
2. Every hour, refer to the Supervisor screens to check the temperatures of the heated parts,
paying close attention to high differences between the set and real values.
3. Every hour, check the temperature and pressure of the cooling water manifolds.
4. Inspect the movements of the various functional units, mechanisms and single components
acting throughout the machines production cycle. 5
5. Every hour and when arising, check for alarm messages by referring to the Supervisor interface.
6. Keep the machine work area and the cabin windows clean to allow frequent inspection of the
machine during operation.
7. Regularly inspect the external auxiliary system state (chiller, conditioner, etc.).
8. Write up the required production reports according to company standards and production needs.
9. Note all machine stops, highlighting the cause of the stop, its duration and the action (or
solutions) taken that made it possible to eliminate the reason for the machine stop.
MO-A0405_02.fm

5-19

5.6 STOPPING THE MACHINE
The machine can be stopped in either of the following ways (see diagram in figure 5-5):
emergency stop (operator);
cycle stop (operator or alarm);
machine stop or end of cycle stop (operator).
Figure 5-5. General diagram

5-20
SFR 20
Operating Manual
5.6.1 EMERGENCY STOP
CAUTION
ONLY USE THE EMERGENCY STOP PROCEDURE IN THE
EVENT OF GENUINE, EXTREME DANGER.
1. Press any one of the self-locking mushroom buttons in the points shown in figure 5-6.
5.6.2 CYCLE STOP
To stop the machine cycle, press and release the CYCLE STOP button on the operator interface
panel. 5
When the cycle is stopped, the phases in progress are ended but the preforms and the bottles are
not unloaded. In this condition, the functional units are taken to predetermined positions which cor-
respond to the recently completed production cycle phase.
5.6.3 MACHINE STOP AND END OF CYCLE STOP
Operator interface panel: press and release UNLOAD MACHINE button to fully unload the machine.
Proceed as follows when the machine has finished unloading:
1. Master electric panel push button panel: ENABLE AUXILIARY key switch in vertical position.
2. Master electric panel:
a. Circuit breaker I / 0 switched to 0.
b. Check that 230 VAC light (white) is off.
3. Distribution manifold: close the four/six input sluices.

MO-A0405_02.fm

5-21

Figure 5-6. EMERGENCY stop

5-22
SFR 20
Operating Manual
5.7 RESETTING WORKING CONDITIONS

The procedures required to reset the machine working conditions are illustrated in the following para-
graph (also see figure 5-5).
5.7.1 RESETTING WORKING CONDITIONS AFTER AN EMERGENCY STOP
WARNING 1
Reset working conditions as soon as possible compatible
with the causes which led to the stop.
WARNING 2
5
An emergency stop will immediately power down all sup-
plies (water, air and electricity). In such conditions, the pre-
forms may stick to the stretching rods if timely action is not
taken.
1. Release the self-locking mushroom button pressed to stop the machine by turning it in the
direction of the printed arrow.
2. SUPERVISOR: ALARM page, check alarm cause(s).
3. Operator interface panel:
a. Press and release SILENCE ALARMS buttons to stop the acoustic alarm (flashing green).
b. Press and release MANUAL button (green light on).
4. Hand-held portable push button panel:

a. Lift all mold seals (command 40, button +);
b. Lift all mold stretching rod (command 30, button +).
5. Fit the handwheel for manual operation.

6. Machine push button panel: turn BRAKE BY-PASS switch clockwise (brake air system delivery)
and release.
7. Turn the blowing wheel by turning the handwheel anticlockwise to reset the main torque limiter.
8. Carry out the maintenance operations required to eliminate the cause(s) generating the
EMERGENCY STOP.

MO-A0405_02.fm
10. Operator interface panel: check that the SILENCE ALARMS button goes out; otherwise repeat
points 4 and 5.

5-23

a. Press and release the AUTOMATIC button (green light on).
b. Press START CYCLE button for 5 sec. and release when you hear the alarm (green light on).
5.7.2 RESETTING WORKING CONDITIONS AFTER A CYCLE STOP
Proceed as follows:
1. Proceed as follows if the cycle was stopped by an alarm; otherwise go to point 7.
a. CYCLE STOP button on (flashing green), SILENCE ALARMS button on (flashing).
b. Press and release SILENCE ALARMS to stop the acoustic alarm (flashing green).
3. SUPERVISOR: ALARM page, check cause of alarm.

4. Carry out the required maintains operations to eliminate the cause of "cycle stop".
5. After eliminating the cause of the alarm:
6. Operator interface panel: check that the SILENCE ALARMS button goes out; otherwise repeat
points 4 and 5.
7. Check that the cabin doors are closed.
8. Operator interface panel: press START CYCLE button for 5 sec. and release when you hear the
alarm (green light on).
NOTE
The machine will automatically complete the interrupted phases,
unload the bottles and the preform in the machine and start the
normal production cycle.

5-24
SFR 20
Operating Manual
SECTION 6
OPERATING CONTROL
6.1 GENERAL
Machine operation is monitored moment by moment and throughout production.
It is the operator's job to check the production and machine work cycle.
Checking the machine work cycle consists of responding to the alarm warnings.
Checking the production consists of checking the shape and appearance of the subproduct (pre-
form) and finished product (container) to modify the machine work parameter settings if necessary. 6
6.2 CYCLE CONTROL

As mentioned above, checking the production cycle consists of interpreting and responding ade-
quately to the various alarm warnings the machine generates during operation.
In this connection, refer to the description of the alarm warnings given in Section 5.
NOTE
During the machine's normal production cycle, it is advisable to
check frequently for any alarm warnings by enabling the relative
diagnostics pages from the Supervisor.
6.3 PRODUCTION CONTROL

6.3.1 GENERAL
Production control is made on bottles and takes place according to two criteria:
- random check
- statistical check.
MO-A0406_02.fm
Operating control
6-1
Making a random check means:
1. taking any bottle at any time in production;
2. running the checks described in the paragraphs (paragraph 6.3.2).
Making a statistical check means:
1. taking a numerically substantial sample of bottles (at least one cast per mold)
2. running the checks described in the paragraphs (paragraph 6.3.2).
TYPES OF CHECKS
The checks are divided into two types:
empirical check
instrument check.
The empirical check consists of a visual/tactile examination of the container (expert operators).
The instrument check consists of an examination with dedicated instruments in accordance with the
defined technical specifications of the preform and container.
The checks are made to prevent and eliminate unsuitable containers due to:
- defects in shape
- defects in appearance
- defects in firmness.
Operating control
6-2
SFR 20
Operating Manual
6.3.2 CONTAINER CONTROL
6.3.2.1 Empirical check
DEFECTS CAUSE SOLUTIONS
APPEARANCE
White petals -- Check perform quality
Problem concern- Wrong recipe data config- Change the recipe

ing all bottles uration
Preform temperature too
low
Check and change the oven unit settings (recipe) if
required.
6
Problem concern-
Decompression valve(s) Check the decompression valve(s) work prop-
ing some bottles faulty erly.
only
Check the static relay.
Thoroughly check the pneumatic system.
Total opacity -- Check preform quality
Wrong recipe data config- Change the recipe

Problem concern- uration
ing all bottles Preform temperature too Check and change the oven unit settings (recipe) if
high required.
Crystallized preform Check preform quality and temperature.

material
Problem concern-
ing some bottles Decompression valve(s) Check the decompression valve(s) work
only faulty properly.
Check the static relay.
Thoroughly check the pneumatic system.
Partial opacity Check that preform holder chain is turning freely.

MO-A0406_02.fm
Operating control
6-3
Porosity Dirty blow air Check quality of blow air.

(dimpled)
Moisture in the air Check air dryer operation and condensation dis-
charge.
Mold cavities dirty Clean mold cavities as described in the Mainte-

nance Manual.
Dirt in the PET during the Check preform quality.

process
SHAPE
Corrugation No primary air in the blow Check for primary air and pressure.
(rings in hollow) phase Check the primary air gate valves open correctly.
Check the primary air solenoid valve power.
Check the check valve works properly.
Local deforma- High pressure activated Decrease the secondary air blow delay.
tion too late
Longitudinal mal- Dirty blow cavity air out- Clean blower mold air outlets.
formation of the lets
container profile
Secondary air delay Vary the secondary air delay.
Low preform temperature Check and change the oven unit settings (recipe) if
required.
Mold opens during blow- Check mold closure adjustment and compensa-
ing tion cylinder
Insufficient secondary air Increase the blow or holding time.

Check pressure setting.
Marking vertical Mold closure not correct Check mold closure adjustment and compensa-
joint tion cylinder.
Press parallelism not cor- Check press parallelism and figure coupling.
rect
Impurities in the mold Clean any residues in the mold.
Operating control
6-4
SFR 20
Operating Manual
Ovalization High pressure delay too Increase the secondary air holding time.
low
No low pressure air (pri- Check primary air valve (static relay).
mary)
Poor mold outlet Clean mold outlets.
Decompression delay Anticipate decompression. The bottle could remain

attached to the internal mold and get misshapen.
Perpendicularity Too much material on the Check the cavity cooling and chiller operation for
6
bottom making it more water temperature.
difficult to cool the mate- Lower the temperature in the top area.
rial
Increase the secondary air holding time.
Misalignment on the neck Advance primary air inlet.

after molding Check primary air valve operation.
Check semi-flange diameter of the blow mold.
Rods not straight Check that the stretching rods are perpendicular
and straight.
Thickness not Check preform quality.

uniform
Unsuitable recipe Change bulb power.
External corruga- Poor preform condition- Increase the temperature of the area defined.
tion ing
Low pressure blow delay Decrease primary air blow delay time.
time too long
Primary air pressure too Increase the primary air pressure.

low
MO-A0406_02.fm
Operating control
6-5
Internal corruga- Poor conditioning profile Decrease the temperature.

tion
Poor heating of preform Decrease the bottom temperature.

bottom
Secondary air blow delay Vary secondary air delay time.

time too long

low
Petal formation Secondary air blow too Advance the secondary air blow.
(none or partial) late or too low Increase the holding time.
Decompression valve Check the decompression valve(s) and static relay

faulty work properly.
Dirty mold bottom Clean the air outlet holes.
Lenticular Primary air blow delay Decrease primary air delay time.
(too much mate- time too long
rial)

low
Off centre Primary air activated too Increase the primary air delay time.
(see Container soon Thoroughly check the primary air pneumatic sys-
perpendicularity tem.
as well)
Mold bottom rod dis- Check the distance between the mold bottom and
tance too great the rod.
Stretching rod not Check that the stretching rod is straight.

straight
Operating control
6-6
SFR 20
Operating Manual
FIRMNESS
Breakage due to Bottom oriented wrongly Check the preform injection point.
falling
Poor heating of preform Check the quality of the preform or resin (PET).
bottom Check set temperature (recipe).
Primary air pressure too Increase primary air pressure.

low
6
Low pressure delay time Decrease primary air blow time.
too high
Fragility of preform at the Check the preform injection point.

point of injection Check the cooling water temperature.
Check primary air inlet time.
Poor quality of resin Check preform and resin (PET) quality.

(PET)
Change in vol- Secondary air pressure Increase the secondary air pressure.
ume after a cer- too low Increase the holding time.
tain time
High pressure activated Vary primary air time.

too late
6.3.2.2 Instrument check
Not applicable.
MO-A0406_02.fm
Operating control
6-7
Operating control
6-8
SFR 20
Operating Manual
SECTION 7
SERVICE OPERATION
7.1 GENERAL
This section contains the list of all the simple work of topping up and filling to be done occasionally
or at regular intervals that does not require assistance from skilled personnel.
7.2 LIST OF SERVICE OPERATION

A detailed description of each of the operations listed below is shown in the maintenance manual
attached to this publication. 7
OPERATION OPERATION
FREQUENCY
CODE
LEVEL
Assembly 03 - Preform feeding
Clean fibre optics 03-60-2009 L1

Clean guides 03-60-2010 L1
New shift
Assembly 05 - Oven
Clean illuminator 05-60-2054 L1

Visually inspect 05-51-2016 L1
Assembly 06 - Transfer
Clean fibre optics 06-60-2017 L1

-- -- --
Every day
24 hours
MO-A0407_02.fm
Service operation
7-1
OPERATION OPERATION
FREQUENCY
CODE
LEVEL
-- -- --
48 hours
-- -- --
Every week
170 hours
Assembly 04 - Loading/unloading
Every fortnight
340 hours
Clean optic pyrometer lens 04-60-2014 L1

Assembly 05 - Oven
Clean camera lens 05-60-2015 L1

-- -- --
Every month
670 hours
Assembly 02 - Drives
Check drive belt play and overall conditions 02-51-2005

L1
1000 hours
Check integrity of transmission wheel teeth 02-51-2006 L1

Lubricate manual drive shaft 02-23-2007 L1
Check manual drive shaft 02-51-2026 L1
Assembly 03 - Preform feeding
Check belt play 03-51-2011 L1
Service operation
7-2
SFR 20
Operating Manual
OPERATION OPERATION
FREQUENCY
CODE
LEVEL
Assembly 01 - Frame

Check gear motor oil level 02-51-2004 L1

Assembly 04 - Loading/unloading
Lubricate pitch change rollers 04-23-2013 L1

7
Replace oven wheel lubrication cartridge 04-81-2012 L1
Every three months
Assembly 06 - Transfer
2000 hours
Lubricate transfer wheel arm direction cam

06-23-2018 L1
Lubricate transfer wheel arm torsion springs
06-23-2001 L1
Assembly 07 - Stretching/blowing

Replace mold opening/closing cam cartridge
07-81-2020 L1
Assembly 09 - Cabin

MO-A0407_02.fm
Service operation
7-3
OPERATION OPERATION
FREQUENCY
CODE
LEVEL
Replace transmission wheel cartridge 02-81-2008 L1

Every six months
Assembly 07 - Stretching/blowing
4000 hours
Replace fifth wheel lubrication cartridge 07-81-2019 L1

Replace stretching cam lubrication cartridge L1
07-81-2021
Visually inspect brakes 07-51-2022 L1
Replace turning fitting lubrication cartridge L1
07-81-2023
8000 hours
Every year
Change gear motor oil 02-81-2002 L1
Service operation
7-4
SFR 20
Operating Manual
SECTION 8
GLOSSARY
8.1 VOCABULARY LIST

Tabella 8-1
TOOLS The term 'tool' in these manuals defines an implement installed

in a mechanism that is suitable in its shape, features and size
to manufacture a particular article.
AUXILIARY TOOLS The term 'auxiliary tool' defines one or more implements, not of
SIPA manufacture, installed in a mechanism that is suitable in
its shape, features and size to fulfil a complementary function
in the various process phases of the machine.
OPERATING CYCLE The operating cycle is understood to be the set of the various
8
process phases carried out by the various appliances forming
the machine that produce the finished product.
MACHINE DATA The set of parameters permitting electro-mechanical configura-

tion of the machine irrespective of the production of a certain
container format.
PROCESS PHASES Process phases are understood to be the intermediate stages

of the continuous process of manufacturing the product, where
the article is worked on by one or more functional unit installed
in a certain position of the machine; the set of process phases
constitutes the operating cycle of the machine to make the fin-
ished product; the set of process phases makes up the
machine's operating cycle to make the finished product.
LIMIT SWITCH A pneumatic, electric, electronic sensor that notifies the

machine's operating unit (PLC) of the passage of a moving
mechanical part by the movement itself generating a break in
the signal.
FUNCTIONAL UNIT A functional unit is understood to be a device or a set of

devices, installed on a machine, that is capable, alone or with
others, of carrying out a phase in the production process made
by the machine.
TYPICAL INFORMATION The term 'typical' identifies the features or operations that hold
for the basic machine in its standard version. These features
MO-A0408_02.fm
may vary in relation to the configuration of the single machines.
Glossary
8-1
Tabella 8-1
MAINTENANCE MAN See skilled personnel.
OPERATOR The operator is understood to be a person authorised by the

plant safety manager to operate the machine, including the job
of recognizing any potential danger for himself and for others
and avoiding the associated risks. Authorization to operate one
or more machines is normally given after proof of the operator's
capabilities, deriving from his training (experience and instruc-
tion).
SERVICE OPERATIONS Simple operations of restoring or refilling to be done occasion-

ally or at regular intervals that do not require any assistance
from skilled personnel. Service operations can then be carried
out by the operator.
DANGER Danger is understood to be a situation associated with one or

more elements that can cause the death or serious injury of the
operator or exposed persons.
EXPOSED PERSON An exposed person is understood to be anyone who, for any

reason whatsoever, is entirely or partially in a dangerous area.
SKILLED PERSONNEL Person(s) with specific technical skills in one or more sectors,
capable of carrying out maintenance work other than normal
service operations. Skilled personnel may be employees of the
manufacturer or his principal, of the user or of external firms.
PET Polyethylene Terephthalate. A granular semi-crystalline resin

that is used to produce preforms through the work stations.
PLC The machine's operating unit (programmable controller) that

presides over all the process phases, assimilates and applies
the settings, controls all the cycle phases and sends the rela-
tive alarms and any malfunctioning.
PREFORM A preform is understood to be a semi-finished product of PET,

normally cylindrical in shape, with collet and ring nut of the cap
already formed, from which, through additional machine pro-
cess phases, the finished product is obtained.
FIRST START-UP Starting up after installation, including functional tests.
FINISHED PRODUCT A finished product is understood to be the final result (PET con-
tainer) obtained at the end of the entire operating cycle carried
on by the machine.
Glossary
8-2
SFR 20
Operating Manual
Tabella 8-1
PRODUCTION The action carried on by one or more machines considered in

relation to achieving an end result (finished product).
RECIPES The set of parameters contributing to produce a certain con-

tainer format.
RISK The term 'risk' in these manuals defines potential danger and,
consequently, the possibility of the operator or exposed per-
sons suffering damage.
HALF-MOULDS Each of the two cast iron shells in which the forms of the body
of the container are obtained; mounted on the mould plates, at
the time of blowing they are closed pneumatically, integrally
incorporating the mould bottom in the seat obtained in the base
of each half-mould.
SENSOR Apparatus signaling movement of the machine's mechanical
8
parts, similar to a limit switch.
SERIES The term 'series' identifies the type of line of machines capable
of making the finished product, with specific quantities and fea-
tures.
SEAL An airtight metal ring that, at the time of blowing the primary
and secondary air, moves down to hermetically close the pre-
form opening.
EXTERNAL AUXILIARY SYS- The set of all the equipment outside the machine body that are
TEMS connected to it and are an aid for its correct operation (condi-
tioners, chillers, thermoregulators, etc.).
STRETCHING/BLOWING An operation by which the container is formed out of a PET

preform.
TECHNICIAN See skilled personnel.
DANGEROUS AREA A dangerous area is the entire area inside and/or around a
machine within which the presence of an exposed person is
cause for potential risks for their safety and health.
MO-A0408_02.fm
Glossary
8-3
Glossary
8-4

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ENTER THE NEW UPDATED PAGES, DESTROY THE OBSOLETE PAGES

The issue dates of the original and updated pages are:

Original . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . 31 January 2002

Update . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . 25 July 2002

Page Update Page Update Page Update

Title page 0 2-1 to 2-102 0

A to B 0 3-1 toto 3-62 0

I to XII 0 5-1 to 5-24 0

1-1 to 1-2 0 6-1 to 6-8 0

1-3 0 7-1 to 7-4

1-4 to 1-8 0 8-1 to 8-4

2.3.7 STRETCHING/BLOWING UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-33

3.3.3.2 Operative commands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19

PURPOSE AND CONTENT OF THE MANUAL

External auxiliary system manuals.

External auxiliary system manuals

REF TITLE DATA DATE OF

MM02-SFR20-A SFR Maintenance Manual 01/09/00 31/01/02

-- Machine Manual 2002 --

-- Compressed air system diagrams --

-- Water system diagrams

External auxiliary system manuals

INFORMATION ON USING THE MANUAL

AIMS AND LIMITS OF THE OPERATING MANUAL

KEEPING THE MANUAL

UPDATING THE MANUAL

CO-OPERATION WITH USERS

DEFINITIONS AND TERMINOLOGY USED IN THIS MANUAL

SPECIFIC TERMS USED IN THIS MANUAL

GENERAL DEFINITIONS CONCERNING SAFETY

TECHNICAL DEFINITIONS CONCERNING THE MACHINES

DESCRIPTION AND ENVISAGED USE OF THE MACHINE

SIPA ON LINE SERVICE

Figure 1. Machine identification

code number, description and technical description of the part to be replaced

destination of the part requested.

shown whenever requested by the authorities.

1.2 REFERENCE STANDARDS

General information and safety rules

89/336/EEC - Electromagnetic compatibility.

General information and safety rules

1.3 AMBIENT CONDITIONS OF USE

1.3.2. OPERATING ENVIRONMENT

1.3.5. RESIDUES AND ENVIRONMENTAL POLLUTION

General information and safety rules

General information and safety rules

ables other than the ones recommended by the manufactur-

General information and safety rules

ALWAYS WEAR THE SPECIAL SAFETY NEVER WEAR ANY BRACELETS

Figure1-1. Clothing - safety rules

1.4.2. ACCESS TO THE WORK AREA

General information and safety rules

Figure1-2. Access to work area - general requirements

General information and safety rules

1.4.4. WORK AND CONTROL AREAS - SAFETY AREAS

General information and safety rules

1.5 RISK ASSESSMENT