SIDEL Blower MC SR 2-1 User Manual B&R 2016

PET STRETCH BLOW MOULDING MACHINE
Operating Manual
Sidel India Pvt. Ltd.

Sidel India Pvt. Ltd.
Manufacturing Plant
Plot No. B‐19, MIDC, Chakan Industrial Area, Near Mahalunge Village, Tal: Khed,
Dist: Pune‐410501‐India
Tel: +91‐2135‐664600 Fax: +91‐2135‐259033
You have made the right choice in buying your machine from SIDEL.
Take care to read & follow the enclosed instructions & we assure you quick & hassle free
commissioning & many years of trouble free running & a profitable experience with your
“SYNERGY” Machine.
DO NOT COMPROMISE ON THE UTILITIES AND

ROOM CONDITIONS MENTIONED HEREIN.
In case you require any assistance or information, you can contact or email:
Name Email address Designation Contact No.

Mr. P Hada Pradeep.Hada@sidel.com Sr. Mktg. Manager 9819444927
Mr. D Shelar Dnyaneshwar.shelar@sidel.com PGPM 9822087519
Mr. R Akkannavar Ramesh.Akkannavar@sidel.com CSM 8888834690
Mr. Azad M Azad.madhathil@sidel.com Manager – I & C 9890107092
Sales Office:
4th Floor, Tower A, Bldg. No.9
DLF Cyber City – Phase III, Gurgaon-122002
Tel:+91-124-2567781/2/3/4/5 Fax: 2567786
SR 2/1
INDEX OF CONTENTS
Section 1: PREFACE 3
1.1 Purpose of This User Manual: 3
1.2 Method of Consult: 3
1.3 Manual Keeping 3
SECTION 2: GENERAL INFORMATION 4
2.1 Manufacturers identification data 4
2.2 Machine identification data 4
2.3 After sales service 5
2.4 Warranty 5
2.5 Regulations and declaration of conformity 6
2.6 Operators qualifications and training required 6
2.7 Workshop Regulations 7
2.8 Temporary Workers 7
2.9 Responsibilities of the Operating Personnel 7
SECTION 3: GENERAL SAFETY ADVICE 8
3.1 About this section 8
3.2 Glossary Used 8
3.3 Symbols and signal words used 9
3.4 Responsibilities of the operating Personnel 9
3.5 Safety advice and precautions to be followed 10
3.6 Safety Precautions to be followed during operation 11
3.7 Safety precautions to be followed during maintenance 12
3.8 Protective Earthing 12
3.9 Owners’ Responsibilities 12
SECTION 4: INFORMATION ON THE MACHINE 14
4.1 General description 14
4.2 Prohibitive Use 14
4.3 Principle of Operation 14
4.4 Main units of the machine 18
4.5 Technical specification 27
4.6 Dimensions 28
4.7 Electrical Requirements 29
4.8 Environmental conditions 35
4.9 Lighting 35
4.10 Air Recovery (Optional) 35
SECTION 5: TRANSPORT AND HANDLING 37
5.1 Packing 37
5.2 Handling 37
5.3 Unpacking 38
SECTION 6: INSTALLATION 39
6.1 General warning 39
6.2 Environment requirements 39
6.3 Space necessary for use and maintenance 40
6.4 Requirements of foundation 40
6.5 Input Output Water Connections 42
SECTION 7: PREPARATION FOR OPERATIONS 43
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7.1 General warning 43
7.2 Operation Modes 44
7.3 Emergency stop provided 46
7.4 Stop modes 47
7.5 Description of actuators 47
7.6 Machine safety and protective devices installed 48
7.7 Checking of Safety Devices 49
7.8 Loading of raw material 49
7.9 Information on data storage, printout or other 49
SECTION 8: MACHINE OPERATION 50
8.1 General warnings 50
8.2 Getting the machine ready for starting 51
8.3 Starting the machine 52
8.4 B&R HMI User Interface 54
8.5 Generating Operator Password 73
8.6 Information on Data Storage & Printout 73
8.7 Electrical Trouble shooting 74
8.8 Process Trouble Shooting 81
8.9 PLC & Servo Drive Error List 85
SECTION 9: MAINTENANCE 88
9.1 General warnings 88
9.2 Daily maintenance procedures 89
9.3 Weekly maintenance procedures: 90
9.4 Monthly maintenance procedures: 90
SECTION 10: CHECK LISTS 91
10.1 Training Program 91
10.2 Check List before Commissioning of machine 92
10.3 Machine Commissioning – Site Status Report 94
SECTION 11: REFERENCES 96
11.1 Pneumatics 96
11.2 PLC Input / Output List 102
12.1 Bill of Material 106
12.2 Circuit Diagrams 106
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Section 1: PREFACE
1.1 Purpose of This User Manual:

This manual provides detail information on following topics in a structured way.
General information
General Safety Advice
Information on the machine
Transport and Handling
Installation
Preparation for Operation
Machine Operation
Maintenance
Check Lists
Circuit Diagrams
1.2 Method of Consult:

First time user must read it completely before operating the machine.
For maintenance: Refer Section 9
For general Safety advice and precautions, refer section 3 & 7
1.3 Manual Keeping
Manual must be kept carefully and must follow machine at every change of
ownership.
Handle with clean and dry hand. Do not keep in high humid environment
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SECTION 2: GENERAL INFORMATION
2.1 Manufacturers identification data
Address
Sidel India Pvt. Ltd.,

Plot No. B-19, MIDC, Chakan Industrial Area, Mahalunge Village,
Taluka Khed, Dist. Pune-410501
Phone : 91-(02135)-259133, 259144, 280003

Fax 91-(02135)-259033
2.2 Machine identification data

The machine is marked with following marking plate:
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2.3 After sales service

Every product of SIDEL INDIA has an After-Sales facility made available to
customer. Every machine has warranty coverage for 1 year as per Company’s
warranty policy.
Contact Person : Mr. Ramesh Akkannavar

Manager- Customer Services (Synergy)
Cell No. 8888834690
2.4 Warranty
The machine is guaranteed against manufacturing defects only for a period of
twelve months from the day of Technical Acceptance Certificate (or deemed
acceptance) or a period of eighteen (18) months from the date of dispatch,
whichever is shorter. However, warranty will come into force within 6 months
from the date of dispatch, irrespective of installation & commissioning of the
machine.
Warranty excludes the following:

- Consumable parts
- IR Lamps, Cards, Seals, Electrical/Electronic Parts.
- Any damage on account of mishandling of the machine.
The warranty clauses are subject to warranty documents to be mutually signed

on finalization of the order. In event of any dispute in respect of guarantee the
manufacturer’s decision would be treated as final. In event of dispute, all
matters will be subject to jurisdiction of Mumbai, INDIA.
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2.5 Regulations and declaration of conformity
The operating instructions contain all regulation and necessary information for
a safe operation of the machine. It is particularly useful to introduce new
personnel to handle the machine according to all safety instructions. We
recommend that all your employees read this instructions and confirm that
they have completely understood. Furthermore, General safety advice will
support you in your efforts to supplement your own safety regulations.
This chapter is directed to the user of this machine and its operating and
maintenance personnel.
This machine is in accordance with the latest state of engineering. Where
efficiency, material, operation and security is concerned, a sound knowledge
of the machine and responsible attitude towards safety by its user and its
operating and maintenance personnel are required to ensure a safe running
of the machine.
Declaration of conformity
The machine has been manufactured in accordance with the latest state of
engineering. There are, however, certain requirements, which you will have to
meet, because the machine has to be operated safely with specific safety
installations.
2.6 Operators qualifications and training required

Any personnel operating the machine shall possess a minimum technical
background of mechanics / electrical / plastic machinery or process and have
fair knowledge of English language.
Also any person operating the machine shall be a person trained by SIDEL
and this shall be mandatory.
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2.7 Workshop Regulations
The user is responsible for observing, performing and controlling the

necessary regulations for accident prevention. Without observing this accident
prevention regulation and strictly following them and the additional safety
instructions as laid down in this instruction manual, dangers to life as well as
the machine are unavoidable.
2.8 Temporary Workers
Be careful with temporary workers, because they must also be trained

according to the work they shall perform. No temporary worker, shall operate
the machine unless he has been trained by SIDEL.
2.9 Responsibilities of the Operating Personnel
Only trained and instructed personnel are allowed to perform works at the
machine.
As soon as an operator observes malfunctions during operation, he must

inform his senior or seniors and if necessary stop the machine.
They are not allowed to drink alcohol, endangering themselves and others.
When they are unable to perform their work without endangering themselves
or others after having had too much alcohol or due to any other reason, they
must not continue to work with the machine.
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SECTION 3: GENERAL SAFETY ADVICE
3.1 About this section
Your must read this chapter carefully and follow all recommendations and
instructions for your own safety. Should you not do this, you endanger your life
and could cause damage to the machine.
3.2 Glossary Used
Following terms are invariably used in the instruction manual.
Danger area: An area inside and or near the machine where the presence of
an exposed person implies a risk for safety and health of the exposed person
him/herself
Exposed person:
Any person entirely or partly inside a danger area
Operator: a person authorized for installing, operating, adjusting, performing
maintenance, cleaning, & troubleshooting the machine.
Operator’s qualification:
Any personnel operating the machine shall possess a minimum technical
background of mechanics / electrical / plastic machinery or process and have
fair knowledge of English language.
Also any person operating the machine shall be a personnel trained by SIDEL
and this shall be mandatory.
.
Residual hazards:
A kind of danger which has not been possible to eliminate or reduce sufficiently
when designing the machine, and which the protections are not or are not
completely effective against such danger.
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Safety components:
A component used to ensure a safety function. Fault or failure of such a
component will compromise the safety and or the health of exposed persons.
3.3 Symbols and signal words used
The following symbols and signal words have been

used in the operating instructions. The symbols and
signal words underline danger spots or important
information within the operating instructions.
Warning!
Paragraph marked with this word denotes
operating procedures and practices that
may result in severe injury or loss of life if
not correctly followed
Caution!
Paragraph marked with this word denotes

operating procedures and practices that, if
not strictly observed, may result in personal
injury or damage to the equipment
3.4 Responsibilities of the operating Personnel
Only trained and instructed personnel is allowed to perform works at the

machine.

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Follow the general, national or intra-company safety instructions. You must

lay down and observe strict rules for responsibilities concerning the operation
of the machine in order to avoid unclear competences regarding safety.
3.5 Safety advice and precautions to be followed
This section informs you about the machines safety installations.
When doing maintenance works ensure that machine is kept off or isolated
from the mains supply, unless you are working online with supply.
Ensure the 40 bar reservoir is emptied using the Drain Valve provided at the
bottom of the tank.
Before starting up the machine read all the instructions in this manual
carefully and follows the same with equal care.
We as manufacturer have taken great care, when designing this machine to

make as INSTRINSICALLY SAFE as possible. It incorporates every
protection and safety components considered to be necessary and have also
provided enough information to allow you to use it in a proper and safe
manner.
It is absolutely forbidden to inhibit the safety components installed on the

machine.
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Low-safety operations must be carried out complying strictly with the

instructions provided in the description of each of such operations. After such
operations, responsible persons must restore the protections to its highest
level immediately.
Washing or cleaning operations must be carried out with the electrical and
pneumatic systems cut off.
Do not modify any part of the machine for any reason, incase of any hazard
arise due to non-compliance with this, we will not be responsible for any
consequences. You must contact us for any modifications. Any change part
shall be in line with our specification. However, parts not procured from SIDEL
as spares shall not carry any warranty and also the warranty of the machine
does not apply for damages caused by use of such parts.
Installation and putting machine in use has to be performed by our technicians

and engineers unless an agreement exists between the user and Sidel.
The machine incorporates non-linear current consuming devices, which have

tendency to create noise in mains system. Although adequate care and
precautions have been taken by way of proper filtering, stabilization and
grounding, it may interfere in some way or other to a very sensitive device
when corrected to the same distribution point. If you observe any interference,
we recommend connecting such disturbing device to different distribution
points other than the one where this machine is connected
3.6 Safety Precautions to be followed during operation
The safety features incorporated have been designed keeping in view that the
machine is operated by a single operator. The personnel aiding the operator
must refrain from operating the machine.
No tools of any sort should be kept on the machine or in the vicinity of moving
parts when the machine is powered and supplied with compressed air.
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3.7 Safety precautions to be followed during maintenance
Any maintenance on the machine must be carried out with the electric power
and pneumatic pressure withdrawn completely. A period of about 5 minutes
should elapse after the power OFF before any maintenance can be carried out.
Technicians who have been trained and certified by SIDEL can only carry out
maintenance of the machine.
3.8 Protective Earthing

A dedicated Earthing not shared by any other electronic gadget/device should
be provided. The external Earthing pit must follow applicable standards in the
respective countries where the machine is in use.
3.9 Owners’ Responsibilities

The system being very complex, adequate care and precautions have been
taken while designing and erecting the machine. It has operational flexibility for
maintenance purpose and product process refinement. It is the owner’s duty to
ensure by way of proper trainings/control or watch that the operational
flexibilities are not mis-utilized intentionally by a highly qualified maintenance
person.
It is the end users duty to impart the training to new operators or request the
manufacturer when trained operators and service personnel leave the user or
transfer of duty takes place.
Various levels of password protections are provided for access in to operation

of the machine. High-risk operations, where higher levels of hazards exist, are
strictly protected for supervisors and senior managers. Owner must ensure
proper custody of these password protections for the safety of the machine.
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The machine incorporates non-linear current consuming devices, which have

tendency to create noise in mains system. Although adequate care and
precautions have been taken by way of proper filtering, stabilization and
grounding, it may interfere in some way or other to a very sensitive device
when corrected to the same distribution point. If you observe any interference,
we recommend connecting such disturbing device to different distribution
points other than the one where this machine is connected
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SECTION 4: INFORMATION ON THE MACHINE
4.1 General description
Correct nomenclature of the machine
PET STRETCH-BLOW MOULDING MACHINE
Intended use
This machine is intended to produce PET bottles, within the rated minimum &
maximum volume, by use of premoulded Polyethylene Terephthalate (PET)
preforms as raw material.
Prohibitive use
This machine is intended to produce PET bottles, within the rated minimum &
maximum volume, by use of premoulded Polyethylene Terephthalate (PET)
preforms as raw material.
This machine can be used for stand-alone production only or can also be
integrated into a complete bottle filling line.
4.2 Prohibitive Use

This machine should not be used for any purpose other then its intended use and
within the parameters specified in Section 3 & 4.
4.3 Principle of Operation
The preforms are stored / dumped mechanically or manually into a low level
hopper from which they are conveyed upwards by means of a conveyor belt into
an orientation unit. The orientation unit ensures that the preforms are correctly
oriented and spaced and as they are oriented with the collar of the preform, they
slide onto the sliding rails to the shuttle unit where they are gated and continue
their descent where the Preform Feeder pick them with the gripper jaws and
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mounts them on spindles embedded onto a preform carrier (Pallets), which take
them thru the infra heating oven.
As the preforms mounted on spindles move into the heating oven they start
rotating and pass between the heating oven consisting of infra-red heaters &
reflector plates facing them to provide even & controlled heating (around 95ºC to
110ºC) of the different zones for stretching and blowing. It is of particular
importance to note here that, although
7 the whole preform other than the neck
6
area must be heated, different
5
Fig. 3
temperatures are desirable in different
areas to ensure a perfect bottle. The
4
size and shape of the bottle to be
blown, as well as the weight and
ZONE 7
3
ZONE 6 material of the preform are all factors
ZONE 5 determining the so-called temperature
ZONE 4
2 profile which has to be established
ZONE 3
ZONE 2
along the length of the preform.
1
ZONE 1
Neck cooling
To be able to vary the temperature

profile as required every Oven has
separate infra-red heaters arranged horizontally above each other at a pitch of
18/14mm (depending on the model), and which heat different parts of the
preform. Each row/zone can be individually regulated from the control panel,
allowing the operator not only to adjust
the temperature profile but also to apply
heat progressively as the preforms pass
through the oven. The zone around the
shoulder of the bottle often requires
more heat applied to ensure that it can
be blown to the correct profile. The
precision moulded neck of the bottle,
which is already fully formed at the
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preform injection moulding stage, is protected from the heaters by a water-cooled

shield called the cooling rail. The number of ovens and the speed of passage
through the oven will depend on the number of bottle moulds in the machine and
the weight of the preforms being heated. Because PET is a poor conductor of
heat it is necessary to cool the outer surface of the preform. If this were not done
it would be possible to overheat the surface of the material, leading to
undesirable crystallization. This cooling is carried out using air-blowers which
blow air thru the slots of the reflector.
Upon exiting from the oven, the preforms are transferred to a Blowing station.
The heated preforms are now carried to the blow mould section. The time taken
to heat the preforms is considerably longer than the time taken to stretch/blow the
bottles. This means that there are a much greater number of preforms in the oven
than the blowing stations.
The typical PET bottle mould is a three-piece design

with two side walls opening in the vertical plane and
a base which moves up and down. As soon as
the preform is in place the mould closes. The sliding
base moves into position and the two sides close around
it, all in one smooth movement, with all three elements
being clamped firmly together.
At the same time as the mould is closing,

the stretching rod starts to move up (Fig.) so
that it is in position to begin stretching the
preform as soon as the mould is clamped.
This is the low pressure point. Their must be
a gap of 2 to 2.5 mm between the stretch
rod and the base of the preform (if the
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stretch lift the preform the neck collar will get damage ).
The preform is stretched in a vertical direction and preblown at a pressure of about

4-12 bar giving the bottle approximately 80 to 90 percent of its final volume (Fig ).
A second high pressure air (30-40 bar) is introduced to give it the final shape and
finer details engraved in the mould. The air pressure in the bottle is exhausted
before the mould opens, to avoid distortion. Since the preform is stretched
longitudinally, by the stretch rod & usually by means of air pressure, the
molecules are bi-axially oriented, giving PET the required strength.
After a small cooling period, the blown bottles are ejected from the machine or
conveyed directly to an air conveyor for further process like filling/capping /
labeling etc.
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4.4 Main units of the machine

(Illustration shown herein may vary for different SYNERGY machine models)
FRAME
A unitized frame fully fabricated with Co2 welding process. Members of the
frame are strategically reinforced to adequately support the various units that
are assembled over the frame. In simple word the frame is similar to a chassis
of an automobile.
LOADING UNIT (Optional with some models)
The loading unit consists of the storage system for preforms, conveying of
preform, orientation, distribution and finally loading of the preform on to the
machine.
Storage system is a hopper (A) with a

capacity to take about 5000 preforms B
for 1 liter application. Conveying C
consists of a conveyor belt (B) with

D
pleats to carry preform in between and
delivering the preforms on to the top A
into the orientation hopper (C).
Orientation Hopper consists of 2 roller

rotating and the gap is maintained to
orient the preform based on the size of the preform; during orientation process
the preform also slides down due to the natural slope and rotation. A fan in
the orientation hopper throws off the excessive preforms and allows only the
oriented preform to go through the rails.
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Preforms slides over the rails (D) and are distributed by the distribution unit
that is mounted on the machine frame.
In conjunction with the distribution unit is mounted the

loader with gripper unit which physically loads the
preform onto the spindle on the preform carrier.
PREFORM CARRIER / PALLETS

(May vary for different SYNERGY machine models)
Preform Carrier/Pallet carries the preform

from the loading station to the blowing station
through the oven. It also further carries the
bottle on to the out feed unit. Pallet is a
housing that holds the bearing and the
sprocket pin. Spindles are threaded on to the sprocket pin.
PREFORM PRESSING UNIT
Function of this unit is to ensure that the preforms

are fully in contact with the spindle. It consists of
one cylinder with nylon cups which presses the
preform on to the spindle after being loaded,
which ensures that the perform is located
thoroughly onto the spindle.
GUIDED RAILS
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These are the guides that carry the pallets from in feed to out feed and for
cycle completion. These are steel strips with chrome plating and
mounted/welded on the frame with definite reference to the blowing station.
NECK COOLING RAILS
This is to ensure that the neck & the

threaded portion below the neck
does not get heated up during the
process of heating the preforms
before it is stretched & blown.
OVEN
A two cavity machine consists of two

ovens. Each oven has 3 banks for
mounting the heaters. Each bank has
provision for mounting 8 heaters stacked
one above the other & each such stack is
known as Zone. In all, a single oven with
3 banks can house 24 heaters maximum.
Each oven has a duct through which air is blown continuously to ensure that
the temperature at the tip of the heater does not rise above & damage the
heaters. Heat intensity of each zone of the oven is precisely controlled
through the PLC.
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REFLECTOR UNIT.
This unit provides cooling of the

preform surface all through its
travel in the oven.
It consists of blowers and louvers with reflecting medium on the surface.
CLAMP UNIT (Blowing Station)
This is in the heart of the

mechanical system of the machine.
Clamping unit houses the moulds
for the bottle to be blown and has a
mechanism to open & close the
die/moulds during the cycle of
blowing.
Clamp unit is designed and

analyzed for the large forces that
are encountered during the blowing process. The system used in this
machines is purely a mechanical locking system, wherein pneumatics is used
only for movement of the plates for closing & opening.
The mould opening and closing operation of the machine is based on

pneumatic operation and mechanical locking. Pneumatic cylinders do the
movement of each individual clamping/moving plate. The cylinders are
mounted on the thrust plates and the movements of the cylinder pistons,
which are coupled on to the moving plates, do the movement of the moving
plates. So when the four cylinders, two mounted on each side move the
opening and closing operation of the mould takes place. Synchronous
movement takes place with the help of the rack pinion mechanism. The
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internal side of the moving plates is fitted with wedge blocks (stationary). The
thrust plates - house the sliding plate, on which the moving wedges blocks
and wear plates are mounted - have a block, which accommodates a wedge
block plate or the wedge plate. A cylinder mounted to a base plate of clamp
unit moves the sliding plate up and down.
In auto cycle when the mould is closed upward movement of the wedge plate
takes place. The wedges in upward position mesh exactly with the wedges in
the moving plate and therefore a mechanical locking takes place.
The inner side moving plate has an extra plate known as the compensation
plate. This plate is coupled to the moving plate with the help of four ‘C’
clamps. In between the compensation plate and the moving plate is an
annular space and rubber ‘O’ ring. When the blowing operation takes place a
separate tapping is taken from the blowing circuit and provided to the center
of the moving plate and compensation plate. The ‘O’ ring acts as a seal for
this air, which is blown in between the plates. So when the mould clamping
takes place with the help of wedges and blowing operation takes place the
compensation provides a clamping force continuing the blowing force. i.e. the
projected area of the air trapped in between the ‘O’ ring being higher than the
mould projected area.
WARNING: Compensation pressure is adjusted through a pressure regulator.
The pressure for compensation should never exceed more than 28 kg/cm².
The air compensation can switched ON or OFF through the MMI keyboard.
The Air compensation valve cannot be checked through the Test mode
Output. NEVER OPERATE THE AIR COMPENSATION VALVE, AS IT WILL
RESULT IN A SEVERE DAMAGE TO THE CLAMP UNIT, WHEN THE
MOLD IS IN OPEN CONDITION. The machine is interlocked such that when
the mould is in open condition the wedges cannot be taken in. When the
wedges are in UP condition the mould cannot be opened.
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The Compensation Circuit
Wedge Block Mounting Plate

Additional Locking Tie-bar (Sliding Plate)
Force, is available on
your wedge lock
Wedge Mounting Block Thrust Plate
machine by use of high
pressure air (which is
used for blowing) a
small amount of which is
diverted to an annular
gap between the moving
Moving Plate (a)
platen (a) & a floating
compensation (b) plate, Floating Compensation Plate (b)
on which one half of the mould is mounted. The annual gap is sealed by a
special sealing ring (503mm ID x 487 OD). The plate a & b are held together
by ‘C’ clamps, so that in mould open condition, the gap between the two
plates is 0.7 to 0.9mm. This gap will reduce 0 to 0.2mm or so, when mould is
closed & wedges in locked position.
High Pressure air is given to the annular gap within the inside dia. of the
sealing ring causing the Floating plate to firmly hold the one half of the mould
against the blowing force during blowing.
Supply is given to the coil of the normally closed solenoid valve of the
compensation circuit, simultaneously with the start of low pressure blow and
the supply cut off at end of blowing time, simultaneously with the start of
exhaust. Connection from compensation valve to compensation platen is thru
a ¾" x 1600 high pressure flexible hose pipe.
CAUTION
In no case should compensation valve be energized when mould is not
mounted on the machine & the clamp unit not in closed position & wedges not
in locked position. This can cause serious damage to the clamp unit.
Compensation pressure must never be set to more than 28kg/cm2. This may
cause breakage.
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BOTTOM FORMING UNIT
On this unit the base moulds of the

bottle to be blown is suspended. It
consists of a pneumatic cylinder,
with a provision to mount the base
mould .
Entire system in is built to enable ease of handling the base assembly during
change of molds for any given volume of bottle.
EJECTION UNIT
This ensures that the bottle that are blown, once

removed from the machine are either passed on
to the conveyor for further operation or dropped
down for collection in a bin.
This unit consists of a mechanism to pick up the

bottles, rotate by 180 deg. & eject them on a
conveyor for further operation like rinsing, filling, capping etc. or just drop
them in a bin below.
BOTTLE TRANSFER/TAKE OFF UNIT

(Optional for some models)
If the bottle is to be transferred directly on to the air conveyor for cleaning or
filling, then this unit serves as the intermediate unit for the same.
This is mounted on the frame and is guarded externally.
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STRETCH UNIT
This unit is mounted just below the blowing station. It houses a

pneumatic cylinders assembly for the stretching operation.
The stretch rods/pins are mounted on the sliding plate which
slides over the ground, hard chrome plated guide rods and
self-lubricating bushes.
The stroke of the stretching is set by stoppers, depending on

the size of the bottle to be blown.
HMI Touch Screen

The power panel interface panel of the system is very important because all
the interaction with the controller and the machine is done through it. It is used
for setting different parameters, to observe machine parameters (such as
temperatures, timers etc.), to observe collected information, to conduct test
programs and many more. The power panel is designed to facilitate easy
setting of all the parameters and easy operation of the machine. At the same
time effort has been made to provide maximum amount of information on the
power panel.
Feather touch membrane keypad is provided on the door panel to facilitate

easy setting of different parameters. Keypad is divided into 3 parts.
1. Machine operation keys.

2. Direct page call keys.
3. Manual operation keys.
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Electrical Controls Panel
See Diagram
It houses all the main electrical control components such as PLC, SSRs,
MCBs, Contactors, Servo Drive etc.
The external view shows
1) Main Switch – 63 Amp mounted on the door. The machine will not Switch
ON until this door has properly locked.
3) Hooter – if any interlock or alarm comes the hooter sounds. To

acknowledge the hotter press standby key.
Page 26 of 106
SR 2/1
PLC (Programmable Logic Controller)
This unit is a custom designed PLC to operate SYNERGY Stretch blow

moulding machines. Its functions includes:
Control all machine valves to operate the machine in the desired sequence.
Control temperature of different heating zones.
Provide timer signals for different machine operations.
To enforce different interlocks in machine operation for operator and machine

safety.
To provide utility interlock in machine operation.
To detect and indicate different alarms. (such as thermocouple open circuit

etc.)
To perform supervisory functions (such as cycle timer, cycle counter etc.)
To provide permanent memory for different moulds parameters.
To provide test programs for easy fault finding and maintenance
4.5 Technical specification
Description SR 2/1
No. of cavities 1
Max. volume of bottle (ml) 2000
Min. volume of bottle (ml) 200
Max. dia. of bottle (mm) 105
Max. height of bottle (mm) 355
Neck ID Min – Max (mm) 28-46
Type of Stretching Pneu
Type of Locking Pneu WL
Max. Production (bph) 1.0 Lt x 1400
Page 27 of 106
SR 2/1
4.6 Dimensions
Top View
Page 28 of 106
SR 2/1
4.7 Elec
ctrical Re
equireme
ents
Machine iss wired forr 3 phases + Neutral + Earth.
A separate e main isolation switcch (63 Amps) should d be mountted on
the wall, alongside
a each
e machine. Prope er Earthing is most
important
Make sure e your Eartthing is efffective. Fo
ollowing po
oints to havve
Earthing:
a) Machinne
b) Loaderr
c) Electricc Cabinet
Make suree Voltage available
a iss 415V AC + 5% & NO SURGE
ES
Machine will
w give ala arm stop if voltage is beyond abbove limit.
Continuou
us voltage from
f Mainss or from Generator
G is necessaary,
because every
e start & stop willl cause wa
astage of preforms.
p
Model E
ELECTRIC
CAL LOAD
D
SR 2/1 (415V AC
C x 3 Phas
se + Neutral + Earth)
No. of Ove
en Heaterr/Oven Heating Loa ad Conne ected Load
(kW) (
(kW)
Bottle 3 8 x 1 Kw 24 26
Jar 3 8 x 1.5 36 38
Warning!
A dediicated earrthing not shared byy any otheer electronnic
gadge
et/device should
s be provided.. The eartth pit or bu
uilding ea
arthing
must be
b as per thet norms s followed
d in the res
spective country.
c
The machine incorpo

orates non
n-linear currrent consu
uming devices, which
h have
tendency to
t create noise
n in ma
ains system
m. Althoug
gh adequatte care and
d
precaution
ns have be
een taken by
b way of proper
p filtering, stabilization and
d
grounding, it may intterfere in some
s o other to a very sen
way or nsitive devvice
ected to th
when corre he same distribution point.
p If you observe any interfe
erence,
we recomm necting succh disturbing device to different distributio
mend conn on
points othe
er than the
e one wherre this macchine is con
nnected
Paage 29 of 1006
SR 2/1
Earthing Requirements
Proper earthing of the machine is necessary, not only for the safety of the
operating personnel, but also for proper working of the machine. The machine
electrical cabinet, loader etc. must each be separately connected to the
earthing at atleast 2 points each.
Obiective of Earthing or Groundling
To Provide surface under & around Machine & its parts at uniform zero
potential or absolute earth potential, by providing low impendence return path
for the fault current.
The machine, its accessories & the exposed non current carrying metal parts
should be earthed by two separate & distant connection with earth.
All Earth connections shall be visible for inspection. Each Earth system shall
be so devised that the testing of individual earth electrode is possible.
Equipments for Earthings;
Earth Electrode :
Typical Installation of Plate earth electrode are used for earthing procedure.
Care should be taken to select a material that is resistant to corrosion in the

type of soil in which it will be used.
The Earth Electrode can be of Copper or Copper clad electrode or Zinc

Coated (galvanized) iron Plates. A copper plate is preferable.
Plate earth electrodes shall be of the size at least 60cm x 60cm. plates are
generally 6.3 mm thick. The Plate electrodes of Copper shall be not less than
3.15mm in thickness.
The plate should be placed vertically in the ground in such a way that its top
edge is not less than 1.5 meters below ground level and surrounded by a
layer of charcoal, 300mm thick all around.
Adequate number of earth electrodes should be provided with interlinking

earth bus for getting an optimum value of the earth resistance. A minimum 2
earthing electrodes are recommended for each installation.
Earthing Conductor :
A protective conductor connecting the main Earthing Terminal to an Earth

Electrode or to other means of Earthing.
The connection of the Earthing conductor to the Earth electrode or other

means of earthing should be readily accessible and soundly made by the use
Page 30 of 106
SR 2/1
of soldered joints or substantial clamps of non ferrous material. Such joint

should be protected by heavy coat of bitumen.
Copper earthing conductors must be used & cross sectional area should be
atleast 25 sq.mm
Procedure of Earthing:
The Earthing Conductor connection should be joined to the Earth Electrode

plate at not less than two separate points.
The plate Electrode shall have a galvanized iron water pipe buried vertically
and adjacent to the Electrode. One end of pipe shall be at least 5cm. above
the surface of the ground. The internal diameter of the pipe shall be at least 5
cm. The length of pipe if under the earths surface shall be such that it should
be able to reach the center of the plate
Earthing Resistance:- The Earth Resistance should not exceed 4 Ohms when
measured with Earth Meggar ( typical is 1 ohm)
For full details, refer diagram below.
Note:- 3-4 Buckets of water should be poured thru the galvanized iron water
pipe every few days to keep the earthing plate permanently moist
6.30 mm M.S. ROD 12.7 mm Ø GI PIPE

12.5 cm
20 cm CI COVER HINGED TO CI FRAME
GROUND
CI FRAME
LEVEL
COPPER OR
30 cm GI WIRE
WIRE MESH
60 cm
15 cm FUNNEL
CEMENT CONCRETE
70 cm (1:4:8)
1.5 Mtr
(Min)
BOLT,NUT,CHECK NUT
19 mm Ø GI PIPE & WASHER TO BE OF
COPPER FOR PLATE
& GI FOR GI PLATE.
CHARCOAL
60 X 60 cm X 6.30
mm GI PLATE OR
A
60 X 60 cm X 3.15
60 cm 90 cm ENLARGED
mm COPPER NOTE: THREE OR FOUR BUCKETS OF WATER TO BE DETAIL A
PLATE POURED INTO SUMP EVERY FEW DAYS TO KEEP
THE SOIL SURROUNDING THE EARTH PLATE
15 cm
PERMENANTLY MOIST.
15 cm
THE RESISTANCE OF SUCH AN EARTH

ELECTRODE SYSTEM IS GENERALLY LESS
THAN 1 OHM.
Page 31 of 106
SR 2/1
The Pneumatic System

(See Pneumatic Circuit & Blowing Circuit diagrams)
AIR CONSUMPTION
Model System Air Requirement Blowing Air Requirement
calculated at 8 bar at 40 bar
SR 2/1 CFM Assumed Speed CFM
For Std. Machine 50
(w/o AR) 1400 bph x 1 lit. 60
With Air Recovery 27
option
* Values indicated above are for 1.0 litre x 1400 bph water application.
Important Note:
Please note all pipes must be perfectly cleaned internally by means of a wire bottle –
brush, with kerosene to remove all traces of rust/dirt before welding. Use proper
welding rods/procedure to prevent slag from going/forming inside the pipes. After
welding the pipe must then be flushed with high pressure air to remove any entrapped
impurities before connection to the system via the filter provided.
Clean filter element thoroughly with Petrol and refit before starting production run.
Failure to follow above procedure; could cause dirt to enter the system and damage
the valves & regulator. Regulator failure could lead to bursting of compensation “O”
ring.
The pneumatic system is divided into 2 parts:
a. Low Pressure (System Air)

At 7 bar for operating of machine. Clean dry air from the compressor is
connected to the FRL unit, which provides further filtration of 40 micron &
helps condense any residual moisture. It also provides a small quantity of oil
to lubricate the pneumatic system. Further a Distribution Block separates the
flow to banks of individual valves, located in position close to the moving
parts, to help reduce wastage of air in pipes. Flexible pipes of PU material are
used to convey the air to the valves & thereon to the cylinders etc. to provide
the different movements of closing/opening of moulds, indexing, loading of
preforms & ejection of bottles – all of which are operated pneumatically.
Page 32 of 106
SR 2/1
b. High Pressure System (Air for Blowing)
Clean dry air at 30-40 bar is connected to the machine thru a filter of @ 40
microns (not part of supply), thru a safety ball valve (to relieve air pressure in
the system when carrying out any work on the system).
The Blowing Circuit consists of 1 stainless Steel Tank mounted on the frame
of the machine.
The tank is for the High Pressure Blowing. It is fitted with a regulator which is
normally set to @ 30 kg/cm2 for water application & @ 38 bar for blowing
CSD bottles and a Safety valve.
Air from the pressure tank is taken to a Blowing manifold block, where it is
divided into 2 or 4 streams, depending on the no. of cavities to be blown on
the machine. From LP block Î LP blowing valve Î Non-return valve Î
Blowing manifold block.
The non-return valve (NRV) is to prevent high pressure air from reverse flow
into the LP valve & regulator. Failure of malfunction of NRV could result in
damage to the LP valve & regulator.
At the end of each blowing cycle, the air trapped in each bottle is exhausted to
atmosphere thru an exhaust solenoid valve thru a silencer.
Failure or malfunction or sluggishness of exhaust valve would result in bottle

bursting during mould open.
In addition to above pressurized air is also taken to a separate regulator Î

onto a high pressure solenoid valve Î Manifold Block Î the Floating (or
compensation) plate, near Index 1.
As soon as mould is closed, the compensation plate is pressurized by a

solenoid valve.
Page 33 of 106
SR 2/1
This provides the final locking pressure to keep mould halves firmly held
together during the blowing operations.
The bottles are first blown at low pressure for the initial forming of the shape
and then with a burst of high pressure, to complete the final shape & details.
At the end of the cycle the air filled in the bottles is exhausted before the
mould is opened.
Pneumatics Tanks details

Material SS 304 L
Shell Thickness 6.5 mm
Dish Thickness 8mm
Capacity 30 Litres
Working pressure 40 bar
Design pressure 44 bar
Test pressure 66 bar
PNEUMATIC PIPING
Polyurethane Tubing (for low pressure line)
Make: Legris
Diameter – O.D. =8, I.D.=6
Burst pressure – 24 kg/cm2
Working pressure – 8-10 bar
Max. temp. -20º +70ºC
LOW PRESSURE LINE (Aluminium)

Operating pressure ____ bar
Burst pressure ¾” ____ bar
Diameter – I.D. 10mm
HIGH PRESSURE LINES (Flexible, Food Grade)

Operating pressure 40 bar
Burst pressure 1” – 352 bar
¾” – 420 bar
Diameter – I.D. 19-25
Page 34 of 106
SR 2/1
4.8 Environmental conditions
Enclosure where machine is installed would have to be kept dust free

and air-conditioned to a temperature of approximately 30-35oC.
4.9 Lighting
The machine does not need any special lighting arrangement for its
intended operation. Illumination as per local factory laws is sufficient for
safe operation of the machine.
4.10 Air Recovery (Optional)
For more efficient running & saving on energy, some machine have
been fitted with the optional air-recovery unit.
Working:
Normally the high pressure used for blowing the bottles is exhausted to
the atmosphere. Thus the remaining energy spent in generating the
high pressure air is wasted, thru the exhaust. With the ‘SYNERGY’, Air
Recovery System, part of this air is scavenged & pushed back into the
low pressure system, thereby dramatically reducing the requirement of
air in this system; resulting in possibility of using a smaller compressor
for the purpose and consequently saving on electric power.
The amount of air recycled depends on the volume of the bottles blown
and the speed of the machine. On an average, the savings in system
air requirements is @ 25-40% and compressors can be downsized
accordingly.
Page 35 of 106
SR 2/1
The recovery unit has been perfected after much R & D and mounted
in a Black Box behind the blowing valve block of the machine. The box
is sealed using a numbered seal and the seal number recorded. There
are no user serviceable parts inside and is not to be opened by other
than a Sidel service engineer.
CAUTION
Please note in case box is opened by any person/persons other
than an authorized Sidel engineer, the warranty of the full machine
will cease.
Page 36 of 106
SR 2/1
SECTION 5: TRANSPORT AND HANDLING
5.1 Packing
The packing is carried out in wooden cases. The table herebelow give
an indicative list. Please refer to the packing list which is provided
alongwith the consignment
Case
No. Description of Goods Unit Qty
Main Machine with No. 1
1. accessories
2. Loader Unit No. 1
Preform Unit No. 1
3.
Conveyor
4. Preform Feeding System No. 1
5. Loader Stand No. 1
6. Loader Support Stand No. 1
7. IR Lamps No. 1
5.2 Handling
Machine Model Crane or Forklift capacity required
SR 2/1 Min. 5 ton capacity
Page 37 of 106
SR 2/1
5.3
3 Unpacking
You will need cra

ane or fork lift for unlo
oading the machine ffrom the tru
uck as
detailed in table 5.1 above
e.
After unloading re
emove
top cov
ver & side covers of
the paccking case
e.
Unscre
ew all the 4
Bolts/S
Studs at the
e bottom
to unclamp the machine
m
from th
he platform
m.
Use prroper slingss for lifting the machiine
Paage 38 of 1006
SR 2/1
SECTION 6: INSTALLATION
6.1 General warning
Warning!
You are advised to go through General Safety advice provided at
section 3 & 7. For the correct installation, operation, maintenance and
repairs it is utmost important that the operators or personnel working
with the machine for any purpose understand safety precautions to be
followed.
6.2 Environment requirements
Ambient light:
The machine does not need any special lighting arrangement for its
intended operation. Illumination as per local factory laws is sufficient for
safe operation of the machine.
Temperature and humidity:
Enclosure where seaming machine is installed would have to be kept

dust free and air-conditioned to a temperature of approximately 30-
35ºC, 80% Humidity
Ventilation requirements:
The room where the machine is installed should be kept air-conditioned

to a temperature of approximately 30-35ºC and should be kept
reasonably clean and dust free.
Page 39 of 106
SR 2/1
6.3 Space necessary for use and maintenance

Please refer to the Machine Layout diagram .
6.4 Requirements of foundation
FLOORING
1. Make sure a level reinforced concrete floor, (weight carrying capacity 2
tons/sq. meter min.) is available, duly tiled.
2. RCC layer not less than 100mm.
3. Tiles must not be slippery
4. Slope not more than 2 mm per meter under any circumstances.
LEVELLING PROCEDURE
1. Remove the preform carriers near and around the positions where the
parallel block to be placed.
2. Take any one point as the reference by placing the spirit level on the
parallel block.
3. Drive in the wedges, so as to bring the bubble in the spirit level close to
the middle position. Establish this as the reference (see Fig.A)
Page 40 of 106
SR 2/1
4. Repeat the above procedure at all four corners of the rails in any taken
direction.
5. Repeat point no. 4 in the other direction too.
6. Make sure at any given point and given direction the bubble in the level
is close to the middle position.
7. Drive in expandable foundation bolts, for which provision is made in the
frame.
8. Grout all the four bolts and allow to cure.
9. Check once again the levels and clamp the frame on to the bolts.
Sprit level
FIG. A
LEVELLING ALONG THE

WIDTH OF THE MACHINE
Wedges
FIG. B
LEVELLING ALONG THE

WIDTH OF THE MACHINE
Sprit level
Wedge
Details “A”
Page 41 of 106
SR 2/1
Overall variation of 0.3-0.5mm per meter is permissible.
Equipment Required
1. Sprit level with 0.1mm/meter accuracy.

2. Parallel block – 4 Nos.
3. Tapered wedges – 16 Nos.
6.5 Input Output Water Connections
WATER
It is necessary to provide clean, soft, chilled water for cooling of the moulds
and the cooling rails on the machine for protecting the neck of the preform in
the oven area.
Chilled water at 8º-12ºC at 4 bar pressure & 30 lpm is recommended in most

cases.
A typical illustration is shown hereunder.
A B C D
A. ¾" BSP for chilled water inlet for Cooling Ramp & Mould
B. ¾" BSP for chilled water outlet for Cooling Ramp & Mould
C. ¾” BSP (Tested at 60 kg/cm ²) for Low pressure inlet.
D. 1" BSP (Tested at 60 kg/cm²) for High pressure inlet.
Your machine has separate inlets/outlets for cooling rail/Base mould cooling.
Please refer to the Machine Layout diagram.
NOTE:
It is advisable to have isolation valves at the entry points before the machine on the
water inlet. Pressure gauges would be an added advantage for the operator during
process.
Page 42 of 106
SR 2/1
SECTION 7: PREPARATION FOR OPERATIONS
7.1 General warning

Warning!
You are advised to go through General Safety advice provided at
section 3. For correct operation, maintenance and repairs it is utmost
important that the operators or personnel working with the machine for
any work understand safety precautions to be followed.
Any maintenance on the machine must be carried out with the electric
power and pneumatic pressure withdrawn completely. A period of
about 5 minutes should elapse after the power OFF before any
maintenance can be carried out.
Technicians who have been trained and certified by SIDEL can only
carry out maintenance of the machine.
Only trained and instructed personnel is allowed to perform works at

the machine.
As soon as an operator observes malfunctions during operation, he

must inform his senior or seniors and if necessary stop the machine.
They are not allowed to drink alcohol, endangering themselves and

others.
When they are unable to perform their work without endangering

themselves or others after having had too much alcohol or due to any
other reason, they must not continue to work with the machine.
Page 43 of 106
SR 2/1
Follow the general, national or intra-company safety instructions. You

must lay down and observe strict rules for responsibilities concerning
the operation of the machine in order to avoid unclear competences
regarding safety.
7.2 Operation Modes
The machine operates in the following two modes: -

Manual mode:
The following operations can be carried out in the manual mode by use
of these keys on the MMI keyboard: -
Mould Open Moving platen moves back

Mould Close Moving platen moves forward
Indexing Index 1 cylinder is activated and then Index 2
cylinder pushes the preform carrier
Wedge In The wedges move up to lock the platen for
blowing
Wedge Out Wedges move downwards allowing the platen to
move back and open the mould.
Blow Pin Blow pin moves upwards into the mould
High Pressure High pressure air is thrust into the mould
Blowing
Index 1 Index 1 cylinder stroke pushes the preform
carrier in the forward direction (into the mold)
Index 2 Index 2 cylinder stroke pushes the preform
carrier towards the preform loading unit.
Preform Loading The loader unit is activated to start loading the
preforms on the spindles
Preform Conveyor The conveyor belt motor is switched on, which
enables the preforms to be elevated into the
distribution unit from the loader hopper
Loader Roller This switches on the fan motor & roller motor of
the orientation unit .
Preform Gate This enables the gating cylinder to be activated,
which controls the flow of preforms into the
distribution unit.
Preform Grip This activates the preform loader unit which
picks up the preforms by gripping it from the
distribution unit .
Preform Lift The preforms gripped are lifted.
Preform Rotate The preforms lifted are rotated for placing them
Page 44 of 106
SR 2/1
on the spindles/preform carrier

Bottle Grip The ejector unit grips the blown bottle
Bottle Lift The blown bottle which is gripped by the ejector
unit is lifted
Bottle Rotate The blown bottle is rotate and placed out of the
machine for ejection.
Bottle Eject This function does all the function in 1, it grips
the blown bottle, lifts, rotate and a cylinder
pushes it out of the machine into a bin or air
conveyor for further processing like filling,
labeling, capping etc.
Vacuum On N.A.
Bottle Take-Off The take-off unit moves in the forward direction
enables the blown bottles to be pushed forward
for further processing
Air Compensation The air compensation is energized (Only in Auto
ON Mode)
Stop To reset the emergency switch to rotate the
emergency switch clockwise.
Stretch Pin IN 2 The stretching cylinder stroke retracts pulling
with it the stretch pin in the downwards direction
& out of the mould.
Base Mould The base moulds cylinders stroke retracts
pulling up the base moulds suspended to it out
from the mould body.
Low Pressure Low pressure air is thrust into the mould
Blowing
Preform Loading The loader unit is activated to start loading the
preforms on the spindles
Preform Conveyor The conveyor belt motor is switched on, which
enables the preforms to be elevated into the
distribution unit from the loader hopper
Bottle Grip The ejector unit grips the blown bottle
Bottle Lift The blown bottle which is gripped by the ejector
unit is lifted
Bottle Rotate The blown bottle is rotate and placed out of the
machine for ejection.
Bottle Eject This function does all the function in 1, it grips
the blown bottle, lifts, rotate and ejects it out of
the machine into a bin or air conveyor for further
processing like filling, labeling, capping etc.
Emergency Stop To reset the emergency switch to rotate the
emergency switch clockwise.
Page 45 of 106
SR 2/1
Automatic mode:
This mode is used for continuous production . After the machine has been set
manually in all respects such as Stretch Pin is out, Blow Pin is out, Indexing
Cylinder retracted, Base mould is in IN position, Mold is in open position etc.
Press the “Auto” key on the keyboard to start continuous production.
7.3 Emergency stop provided

2 Emergency stop knobs are provided
i. Emergency Stop Knob below the HMI Keypad

When machine is running and if any serious
damage of any type has happened or seems to
happen, push the knob inside. Once operated,
machine needs to reset the control manually by
turning it clockwise and then starting the
machine as usual.
ii. Emergency Stop Knob near

preform feeder
This switch is provided near the preform
feeder as shown in the adjacent fig.
When machine is running and if any
serious damage of any type has
happened or seems to happen, push the
knob inside. Once operated, machine
needs to reset the control manually by
turning it clockwise and then starting the
machine as usual
Page 46 of 106
SR 2/1
7.4 Stop modes

In addition to the 2 Emergency Stops provided (as mentioned in
Section 7.3) on the machine, the machine is also provided with another
stop:
i. Manual Mode – When machine is running in “Auto” mode, and if

for some reason the machine has to be stopped, press the
“HAND” key to stop the machine. This will stop the machine
cycle, but keep the POWER “ON”. This key is located on the
HMI keyboard.
ii. Main Switch – This is a handle type hand operated switch

mounted on the main electrical panel to switch “OFF” the power
rotate it to the “OFF” position.
7.5 Description of actuators
Servo Motor – This is dedicated single axis servo motion controller for stretching
unit of machine. The servo system provides ease in setting of the stretching
operation such as Point “0” setting point & “10” setting bring it to the easy touch
of your fingers.
Page 47 of 106
SR 2/1
Chain Motor – It is used to rotate the spindles along with the preforms in the
oven so that the preforms are uniformly heated.
7.6 Machine safety and protective devices installed
Machine is provided with following safety / protective devices:
1. Door Interlocks – The machine is provided with 9 door interlocks

also. If when the machine is running in “AUTO” mode and if any
door is opened by anybody, knowingly and unknowingly, then this
interlocks gets activated and stops the machine cycle immediately.
Electrical devices and components are protected either by fuses and /or
miniature circuit breakers and or motors are protected by motor protective
circuit breakers. Any overload or insulation failure or component breakdown
results into operation of such protective devices.
Page 48 of 106
SR 2/1
7.7 Checking of Safety Devices
Safety checks must be performed weekly to ensure that the machine Safety
Devices are operational and to detect a failure in advance, if any
Door Safety Limit Switch

Emergency Stop
Safety Pressure Relief Valves
7.8 Loading of raw material
The preforms can be loaded into the hopper manually or by a preform

dumper.
7.9 Information on data storage, printout or other
The PLC has inbuilt data storage. A printer can be connected to the Printer
Port of the PLC by an IEEE-1284 parallel printer cable.
It is useful to get machine data like Heating, Timers, Servo settings etc. as
specified in 8.5 herein.
Page 49 of 106
SR 2/1
SECTION 8: MACHINE OPERATION
8.1 General warnings
Warning!
You are advised to go through General Safety advice provided at section 3.

For correct operation, maintenance and repairs it is utmost important that the
operators or personnel working with the machine for any work understand
safety precautions to be followed.
and pneumatic connections withdrawn completely. A period of about 5
minutes should elapse after the power OFF before any maintenance can be
carried out.
Technicians who have been trained and certified by the manufacturer can
only carry out maintenance of the machine.

machine.

Page 50 of 106
SR 2/1

8.2 Getting the machine ready for starting
Make sure the following ball valves are provided on the pipelines, just before
the entry of the machine.
Note:
Make sure all the valves are identified and the piping color-coded.
Set compressor pressure. Set chilled water temp.
Fit and connect the heaters in position. Do not touch lamp body by bare
hands. Hold lamp near the ceramic caps.
Salts from bare hands devitrified quartz body reducing lamp life. Hold the
lamps with two hands (wearing cotton gloves) on body. If touched, wipe lamp
body with alcohol on clean cloth. Turn off power when removing or installing
lamp. Handle lamp very carefully through out as it can crack or break easily
on impact. Infrared radiation is an intense source of heat and may give burn
on human body if touched when the lamp is hot. However exposure from a
distance is not known to have any harmful effect on living organisms.
PLEASE DO NOT MOUNT LAMPS WITHOUT COTTON HAND GLOVES.
Page 51 of 106
SR 2/1
8.3 Starting the machine
Switch “ON” MCB for Oven, Lubrication & Air Conditioner in control panel.
Connect the 3 Phase, 415 V 50 Hz with Earthing of 16 mm2, Supply to Mains
Input Terminals.
R, Y & B indicators provided on the control panel will glow.
Put the Lever operated Main Switch on control panel to “ON”.position.
The HMI screen will lit after approx. 10 secs.
Press F9 key (Servo Home) for homing the servo drives.
Machine is ready in Manual mode.
Press Index 1 & Index 2 for moving of pallets. Repeat procedure 2 times.
Machine is ready in Auto mode.
Push the Auto button for starting the machine in Auto-mode.
When we put the machine in Auto mode the blower motor and the preform
rotor motor automatically get ON.
The conveyor motor gets ON automatically through the sensing of the

photocell present under the loader rollers. When preforms are not there on the
roller the proximities automatically trigger the conveyor Motor to ON and when
the preforms are sensed the conveyor motor gets OFF.
The electrical power for this machine other than that for the heater is given
through one MCB (40 Amp) located in the electrical panel. The power for the
heaters and all the motors is through a 63 Amp lever operated main switch.
This is also located on the door of the electrical panel.
The power for the rotor motor is through a (24VDC Coil) contactor. The motor
can be brought ON by operating a keypad located on the keyboard. An
auxiliary N.O. contact of this contactor is connected as an input to the PLC.
This provides an interlock, such that unless the rotor is ON, indexing and
heaters will not come ON.
The power for the blower is also likewise given through a (24VDC Coil)
contactor and the blower can be brought ON by operating a key pad. A similar
interlock is also provided, so that the heater can come ON only when the
blowers are ON.
Page 52 of 106
SR 2/1
The Loader conveyor motor is controlled by a contactor (24V DC coil), when

there are no preforms in front of the photo sensor devices, located under the
roller is brought ON when sufficient number of preforms collect in roller unit,
photocell switches off the conveyor motor.
In the event of any malfunctioning of the machine or any change in the

working, please refer to the below Programme Number. E.g. SIDELBO2 (The
Same is displayed on the screen of the MMI)
Every time oven temp reaches it limit timer loader delay is initiated. At the end
of loader delay lift output 23 (Q 2.6) is brought ON
Page 53 of 106
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8.4
8 B&R
R HMI Us
ser Interfface
1. Default Pa
age: Defau
ult page displays the HMI functtion key de
etails as be
elow:
unction keyys are loca

F1 to F4 fu ated on LH
HS & F5 to F8 on RHS
S of HMI.
Left Arrow
w & Right arrows are used for pa
age naviga
ations resp
pectively.
2. Main Page
e: Press Main
M tab whicch will displays as:
Press right side arrow to displa

ay manual mode – 2 as below:
Paage 54 of 1006
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3. Main Page: Press settings tab which will displays as:
Page displays following parameters:
a. Password Field – for entering passwords.

b. Programme Version: Displays current running Programme Number.
c. Last Download: Programme Download date.
d. Programme Error Unlock Code (PEUC): Enter PEUC to run machine.
4. Logic Setting: Press Logic settings tab which will displays as:
a. Preform Detect Logic – With Enable / Disable feature.
i. Enable the feature – Machine will run only with indexing cycle in auto
mode.
ii. Disable the feature – Machine will run in auto with clamping,
stretching, indexing, ejection operations.
Page 55 of 106
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b. Air Recovery: With Enable / Disable feature.
c. HR Process: To enable HR process with HR option.
d. Preferential Heating: To enable PH process with PH option.
5. Logic Setting: Press Set Timer tab which will displays as:
Enter Timer variable requires for operations.
6. Set Heating: Press Set Heating tab which will displays as:
Enter Main Oven variable requires for setting I. R. Lamps.
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Enter Preferential Oven variable requires for setting I. R. Lamps with PH.
Preferential Heating will be get “ON” only if the has pressed.
7. Set Heating: Press Mould Memory tab which will displays as:
Mould memory is used to save different recipes as per pack sizes.
a. New Settings.
b. View Settings.
c. Change Folder.
d. Delete Folder.
e. Load Setting – To load save process parameters w.r.t. pack sizes.
f. Save Settings – To save current process parameters.
g. Error Ack – To reset the errors.
Page 57 of 106
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8. M/C Status: Press Machine Status tab which will displays as:
a. Process Monitor.
b. Production Counter.
c. Utility.
d. User Log.
e. Close Loop.
f. Machine Counter.
g. Preform Diagnostics.
9. Process Monitor: Press Process Monitor tab which will displays as:
Page 58 of 106
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10. Production Counter: Press Production Counter tab which will

displays as:
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11. Daily Counter: Press daily Counter tab which will displays as:
Displays Day 01 to Day 15 Details:
Displays Day 15 to Day 28 Details by pressing right arrow
Displays Day 29 to Day31 Details by pressing right arrow:
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12. Hourly Counter: Press Hourly Counter tab which will displays as:
Displays 12 AM to 11 AM hourly production details.
Displays 12 PM to 11 PM hourly production details by pressing right arrow:
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13. Utility: Press Utility tab which will displays as:
14. User Log: Press User Log tab which will displays as:
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15. Close Loop: Press Close Loop tab which will displays as:
16. Machine Counter: Press Machine Counter tab which will displays
as:
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17. Machine Actual Times: Press Machine Actual Times tab which will
displays as:
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18. Machine Settings: Press Machine Settings tab which will displays
as:
19. Preform Diagnostics: Press Preform Diagnostics tab which will

displays as:
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20. Diagnose: Press Diagnose tab which will displays as:
21. DI Status: Press DI Status tab which will displays as:
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Press arrows to switch between pages
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22. DO Status: Press DO Status tab which will displays as:
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23. DO Force: Press DO Force tab which will displays as:
To force the Output, press Test Mode Tab on Manual Mode – 1.
24. AI / AO Status: Press AI Status tab which will displays as:
Page 70 of 106
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25. AT Status: Press AT Status tab which will displays as:
26. System Diagnose: Press AT Status tab which will displays as:
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TOUCH SCREEN CALIBRATION SCREEN:
27. Alarms / Interlock: Press which will displays as:
a) Alarms History – by pressing Alarms Tab.

b) Interlocks History – by pressing Interlocks Tab.
c) Utility Locks – by pressing Utility Lock Tab.
d) All Alarms – All Alarms History – by Pressing All Alarms Tab.
e) Reset Hooter – to reset hooter.
f) Reset Alarms – to reset Alarms.
Page 72 of 106
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8.5 Generating Operator Password

To generate an operator password add the current date as follows:
For e.g. if today’s date is 5th July 2011 then add 05+07+2011=2023
if today’s date is 25th Oct. 2011 then add 25+10+2011=2046 is the
password..
8.6 Information on Data Storage & Printout

The PLC has inbuilt data storage. A printer can be connected to the Printer
Port of the PLC by an IEEE-1284 parallel printer cable. It is useful to get
machine data like Heating, Timers, Servo settings etc.
1. On the back of the power panel insert TRANSCEND [D33193] or B&R make
USB pen drive [BLANK, without data].
2. Go to the MOULD MEMORY page.
3. Select CHANGE FOLDER.
4. After that select any page for copy e.g. go to the timer page and press on the
power panel left side of the upper corner on the Sidel Logo and wait for 20-25
sec to copy the data. Suppose you want to copy heating page then go to the
heating page and press on the Sidel Logo on left side of the upper corner of
power panel and wait for 20-25 sec to copy the data.
5. Automatically all the above two page will copy on USB drive. [after coping all
the pages.]
6. Remove the USB drive from the power panel.
7. Connect the USB drive to your P.C and take the print out of copied pages.
Page 73 of 106
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8.7 Electrical Trouble shooting
Problem Causes Remedy

Check Reed Switch Replace Reed Switch
Check Input wiring
Faulty input card Replace Input Card
MOULDS NOT Check output card fuse Replace O/Put Card Fuse
1. OPEN. Faulty output card Replace Output Card
Check output wiring
Check wedge out Replace Fuse
Check pneumatic valve Replace Pneumatic Valve
Check cylinder Replace Cylinder
Check reed switch Replace Reed switch
Check input wiring
BLOW PIN Faulty input card Replace input card
NOT OUT. Check output card fuse Replace output card fuse
2.
Faulty output card Replace o/put card
Check output wiring
Check pneumatic valve Replace pneumatic valve
Check cylinder Replace cylinder
Check proximity switch Replace proximity switch
Check PLC input (ON/OFF)
STRETCH PIN Faulty input card Replace input card
3. NOT OUT. Faulty output card Replace o/Put card
Check output fuse Replace o/put Card fuse
Check reed switch Replace reed switch
Check input wiring
Faulty input card Replace input card
Check output card fuse Replace output card fuse
INDEX-2 NOT Check output wiring
4. FORWARD
Faulty output card Replace output card
Check pneumatic cylinder Replace cylinder
Page 74 of 106
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Check input wiring
INDEX – 1 Faulty input card Replace input card
NOT Check output card fuse Replace output card fuse
5. FORWARD
Check output wiring
Check input wiring
MOULDS NOT Faulty input card Replace input card
CLOSED Check output card fuse Replace output card fuse
6.
Check output wiring
Check input wiring
BOTTOM NOT Faulty input card Replace input card
IN Check output card fuse Replace output card fuse
7.
Check output wiring
Check input wiring
INDEX 2 NOT Faulty input card Replace input card
BACK Check output card fuse Replace output card fuse
8.
Check output wiring
LOW Check PLC input card Replace input card
PRESSURE Check input wiring
BLOW START Check output card fuse Replace o/put card fuse
9.
NOT SENSED
Check output card Replace output card
Check valve replace valve
Page 75 of 106
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HIGH Check PLC input card Replace input card

PRESSURE Check input wiring
BLOW START Check output card fuse Replace o/put card fuse
10.
NOT SENSED.
Check output card Replace output card
Check valve replace valve
Check Emergency push replace push button
EMERGENCY button
STOP CHECK Check Emergency push replace emergency switch
11. PUSH button Element element
BUTTON. Check Input wiring
Faulty Input card Replace input card
Check input wiring
Faulty input card replace input card
PREFORM Check motor contactor replace motor contactor
ROTATE Check 3 phase supply of the
MOTOR NOT motor
12.
ON. Faulty motor replace motor
Check output wiring
Check output card FUSE Replace o/put card fuse
Faulty output card replace output card
check reed switch replace reed switch
check input wiring
INDEX 1 NOT faulty input card replace input card
BACK. check output wiring
13.
check output card fuse replace output card fuse
faulty output card replace output card
check pneumatic valves replace pneumatic valve
check pneumatic cylinder replace pneumatic cylinder
check reed switch Replace reed switch
check input wiring
EJECTOR faulty input card Replace input card
GRIPPER NOT check output wiring Replace output card fuse
14. OPEN
check output card fuse
faulty output card Replace output card
check pneumatic valves Replace pneumatic valve
check pneumatic cylinder Replace cylinder
Page 76 of 106
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check input wiring

faulty input card Replace input card
EJECTOR NOT check output wiring
LIFTING. check output card fuse Replace output card fuse
15.
faulty output card Replace output card
check input wiring
input card faulty replace input card
MOULD OPEN check output wiring
16. HELD UP DUE
TO INDEXING
Faulty Output Card replace output card
CYCLE TIME Check timing of blowing & it is within limit ( not less
17. exhaust than 3.55 sec. cycle time)
NOT OVER
check proximity switch replace proximity switch
check input wiring
LOADER faulty input card replace input card
ROTATE NOT
check output wiring
18. SENSED
check output card fuse Replace o/put card fuse
faulty output card replace output card
check pneumatic valve replace pneumatic valve
check rotary actuator replace rotary actuator
SAFETY check limit switch (All Doors) Close all doors properly.
GUARD NOT faulty limit switch replace limit switch
19. CLOSE check input wiring
faulty input card replace input card
check input wiring
INDEX-1A NOT input card faulty replace input card
FORWARD check output wiring
20.
faulty output card replace output card fuse
check output card fuse replace output card
LOADER check input wiring
GRIPPER NOT input card faulty replace input card
21. OPENS.
check output wiring
Faulty Output card replace output card
Page 77 of 106
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Check gripper cylinder
faulty gripper cylinder Replace Gripper cyl.
check input wiring
input card faulty replace input card
LOADER GRIP check output wiring
NOT LIFT Faulty output card replace output card
22.
Check gripper cylinder
check reed switch Replace Reed switch
check input wiring
PREFORM faulty input card Replace input card
BLOWER NOT check output wiring
23. ON
check output card fuse Replace output card fuse
faulty output card Replace o/put card
LOADER NOT Check timing of blowing & it is within limit ( not less
24. exhaust than 3.55 sec. cycle time)
BACK
Check input wiring
LOADER Faulty input card Replace input card
LOWERING Check output card fuse Replace output card FUSE
25. NOT SENSED
Check output wiring
Check input wiring
INDEX 1A NOT Faulty input card Replace input card
FORWARD Check output card fuse Replace output card fuse
26.
Check output wiring
Page 78 of 106
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after ejecting bottle,

check bottle is not Ejecting manually press auto key To
27. BOTTLE NOT properly reset the alarm
EJECTED.
check whisker switch replace whisker switch
check input wiring
EJECTOR Check timing of blowing & it is within limit ( not less
28. ROTATE NOT exhaust than 3.55 sec. cycle time)
END.
INSIDE Check input wiring
WEDGE Faulty input card Replace input card
LOCKS NOT Check output card fuse Replace output card fuse
29.
IN. Faulty output card Replace o/put card
Check output wiring
Check input wiring
WEDGE Check output card fuse Replace output card fuse
30. LOCKS NOT
OUT.
Check output wiring
Check input wiring
OUTER Check output card fuse Replace output card fuse
31. WEDGE LOCK
NOT IN.
Check output wiring
Check input wiring
INDEX-2A NOT Check output card fuse Replace output card fuse
32.
FORWARD . Faulty output card Replace o/put card
Check output wiring
INDEX-2A NOT Check input wiring
33.
RETURNED Faulty input card Replace input card
Check output card fuse Replace output card fuse
Page 79 of 106
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Check output wiring
Check input wiring
INDEX 1A NOT Check output card fuse Replace output card fuse
34.
RETURNED Faulty output card Replace o/put card
Check output wiring
remove the bottle if the
AIR Check air conveyor conveyor is full
CONVEYOR Check photocell
35. FULL faulty photo cell replace photocell
LOADING Check input wiring
STOPPER, Check input card
INVALID Check on the keyboard page
36. EPROM No. 17/18 Contact Sidel Engineer
ERROR Serial ID number of EPROM Replace the EPROM
PROGRAMME
37.
ERROR Contact Sidel Engineer Replace the EPROM
Check preform temp. Increase the heating
Check IR camera & wiring
PREFORM-1 faulty IR camera replace IR camera
TEMP.
45. Check T/C wiring
OUTSIDE
LIMIT Faulty T/C card replace T/C card
Check RTD wiring
faulty RTD card replace RTD card
Page 80 of 106
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8.8
8 Pro
ocess Trrouble Sh
hooting
Zone 1 2 3 4
NO. PROCES SS ZONE • CAU

USES • SOLUTIONS
PROBLE EM
1. Pearlesceence, silve
er 3 • Prefoorm tempeerature • Increasee
Colour in the side too lo
ow at blow
wing tempera ature of
part the ovenn or of
the invollved
zone
2. Opalesce ence, 2,3,4 • Prefo
orm tempe erature • Reduce
crystalliza
ation too h
high at blow
wing tempera ature of
commenc ces the ovenn or of
the invollved
zone
3. External folding of 4 • Prefo
orm base not
n • Increasee
the base (button) corre
ectly heate
ed tempera ature of
• Pre-b
blowing the ovenn or of
pressure too lo
ow the invollved
• Pre-b
blowing tooo late zone
• Increasee pre-
blowing
pressuree
• Pre-bloww
earlier
4. Internal fo
olding of 4 • Bad heat profiling, • Reduce
the base • Prefo
orm base not
n tempera ature of
corre
ectly heate
ed the ovenn or of
• Prefo
orm base not
n the invollved
corre
ectly heate
ed zone
• Pre-b
blowing • Pre-bloww
pressure too lo
ow earlier
• Increasee pre-
blowing
pressuree
5. Too much material 4 • Prefo
orm base not
n • Increasee
on the ba
ase corre
ectly heate
ed tempera ature of
• Pre-b
blowing tooo late the ovenn or of
• Pre-b
blowing the invollved
pressure too lo
ow zone
Paage 81 of 1006
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• Pre-blow
earlier
• Increase pre-
blowing
pressure
6. Base off-centered 4 • Pre-blowing • Reduce pre-
pressure too high blowing
• Pre-blowing too early pressure
• Stretching rod not • Pre-blow later
correctly adjusted • Adjust the gap
between
stretching rod
and base
mould
7. Internal folding in 2 • Pre-blowing • Increase pre-
the neck area pressure too low blowing
• Pre-blowing too late pressure
• Bad heat profiling • Pre-blow
earlier
• Increase
temperature of
the oven or of
the involved
zone
• Reduce
temperature of
the oven or of
the involved
zone
8. Neck deformed 1 • Abnormal heating of • Check spindle
spindles or spindles water circuit
protection and spindle
• Air does not circulate safety
correctly in the oven • Check that the
• Blow nozzles oven
bearing too much ventilators
operate
correctly and
check
adjustment of
air admission
• Adjust blow
nozzle position
(adjust spring
pressure)
• Adjust the
height of
spindles
safety-neck (2
Page 82 of 106
SR 2/1
or 3 mm above
the neck ring)
9. Marks on bottle 2,3,4 • Preform quality bad • Check preform
body quality
(impacts,
scratches,
sticking, full
filling) _
10. Flats on split line 2,3 • Pre-blowing • Reduce pre-
pressure too high blowing
pressure
• Remove the
beginning of
high pressure
blowing of
stretching end.
11. Distinct split line 2 or 3 • Mould locking loose • Retighten
mould locking
12. Not correctly shaped 2,3,4 • Mould temperature • Increase
too low mould
temperature
13. Petaloid base not 4 • Blowing pressure too • Increase
correctly shaped low blowing
• Blowing pressure too pressure
late • Blow earlier
• Bad heat profiling • Adjust heat
profiling
14. Local deformation of 2 or 4 • Blowing pressure too • Reduce mould
the bottle when off late temperature
the machine
15. Excess thickness in 2 or 3 • Pre-blowing • Increase
the form of rings pressure too low preblowing
• Bad heat profiling pressure.
• Set Heating
Profile
16. Defective 2 or 3 • Irregular rotation of • Check Chain
circumferential preforms rotate.
thickness • Incorrect preform • Check preform
distribution geometry geometry
17. Defective 2,3,4 • Bad heat profiling • Adjust heat
longitudinal • Pre-blowing profiling
thickness pressure too low • Increase pre-
distribution • Pre-blowing blowing
pressure too high pressure
• Pre-blowing too early • Reduce pre-
• Pre-blowing too late blowing
pressure
• Pre-blow
earlier
Page 83 of 106
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• Pre-blow later
18. Bottle volume 2,3,4 • Blowing pressure too • Increase
changes when low blowing
ageing • Blowing pressure too pressure
late • Blow earlier
19. Bottle busting when 4 • Base not correctly bi- • Check
dropped oriented injection point
• Preform base not • Adjust the
correctly heated height of
• Pre-blowing spindles
pressure too low safety-neck (2
• Pre-blowing too late or 3 mm above
the neck ring)
• Increase pre-
blowing press.
• Increase
temp.of the
oven or of the
involved zone
• Pre-blow
earlier
20. Bottle busting under 3 or 4 • Base not correctly bi- • Increase
abnormally low oriented temp.of the
pressure • Preform base not oven or of the
correctly heated involved zone
• Pre-blowing • Increase pre-
pressure too low blowing press.
• Pre-blowing too late • Pre-blow
• Weak at injection earlier
point • Check preform
injection point
21. Opalescent lines at 3 or 4 • Preform • Check quality
the bottom of the manufacturing mould (impacts,
bottles too cold. scratches,
sticking, full
filling) _
Page 84 of 106
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8.9 PLC & Servo Drive Error List

B & R Servo Drive
09SEL000424 8V1090.001 - 2 (Servo Drive)
09SEL000425 8AC110.60 - 2 (CAN Interface Module)
09SEL000426 8AC122.60 - 2 (Resolver Interface Module)
09SEL000427 8CM007.12-1 (Motor Cable 7 Mtr.)
09SEL000428 8CR007.12-1 (Resolver Cable 7 Mtr.)
09SEL000434 8LSA55.R0030D300-0 (Stretch Unit Motor)
09SEL000436 8CM010.12-1 (Motor Cable 10 Mtr.)
09SEL000437 8CR010.12-1 (Resolver Cable 10 Mtr.)
09SEL000438 7AC911.9 (Bus Connector)
09SEL000445 8CM005.12-1 (Motor Cable 5 Mtr)
09SEL000446 8CR005.12-1 (Resolver Cable 5 Mtr)
09SEL000453 8LSA44.R0022D100-0 (Indexer & Preform Distributor Motor)
B & R PLC
09SEL000408 4PP480.1043 - 75 (Power Panel)
09SEL000409 5CFCRD.0064 - 03 (Compact Flash)
09SEL000411 0TB704.9 (Accessory Terminal Block)
09SEL000412 X20BR9300 (X20 Bus Receiver)
09SEL000413 X20BM01(X20 Supply Bus Module)
09SEL000414 X20TB12 (Terminal Block)
09SEL000415 X20AT4222 (X20 Analog Temperature Input Module)
09SEL000417 X20BM11 (X20 Bus Module)
09SEL000419 X20AI4622 (X20 Analog Input Module)
09SEL000420 X20DI9371 (X20 Digital Input Module)
09SEL000421 X20DO8332 (X20 Digital Output Module)
09SEL000422 0PS1100.1 (10A, 24VDC Power Supply)
09SEL000429 0TB103.9 (Accessory Terminal Block)
09SEL000430 3IF797.9 - 1 (aPCI Interface Module)
09SEL000432 X67CA0X99.1000 (X2X Cable)
09SEL000491 X20DO9322 (X20 Digital Output Module)
09SEL000492 X20AO4622 (X20 Analog Output Module)
Tritek PLC for Heating Module
TPHAC440V9Z PHASE ANGLE CARD (415V, 9ZONE)
Page 85 of 106
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Error No. Causes

4005 Controller cannot be switched on; Drive in error state
4007 Lag error stop limit exceeded
4008 Positive limit switch reached
4009 Negative limit switch reached
5022 Second limit switch signal received; Reference switch not found
5023 Incorrect limit switch signal received for current movement direction
6015 CAN controller: CAN bus disturbance (receive error counter greater
96)
6016 CAN controller: CAN bus disturbance (transmit error counter greater
96)
6019 ACOPOS: Over current
6020 Hardware: 24V power supply fail
6021 Low level at controller enable input
7200 DC bus: Overvoltage
7210 DC bus: Voltage unstable
7211 DC bus: Voltage drop - check the power line
7212 DC bus: Voltage drop - Emergency-Stop interrupted
7214 DC bus: Charging resistor hot (too many power line fails)
7215 DC bus: At least one phase of the power line failed
7217 DC bus: Voltage too high - Check power supply
7218 DC bus: Voltage too low - Nominal voltage detection not possible
7219 DC bus: Voltage too low - Check power supply
7220 Nominal voltage detection: Voltage not allowed
7221 Line: Frequency not allowed
7222 Connection X5 (Motor/Choke): Ground leakage
7223 DC bus: Overvoltage DC-GND
Page 86 of 106
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7224 DC bus: Tighten all lower module fixing screws

7225 DC bus: Over voltage
9030 Junction temperature model: Over temperature -
Movement stopped
9050 ACOPOS peak current: Overload - Movement stopped
9070 Motor temperature model: Overload - Movement
stopped
32001 Error calling CAN_xopen()
32002 Error defining Write COB for Broadcast Command
32003 Error defining Write COB for Parameter Read Request
32004 Error defining Write COB for Parameter Write Request
32005 Error defining Read COB for Parameter Read Response
32006 Error defining Read COB for Parameter Write Response
32007 Error defining Read COB for Monitor Data from the
drive
32008 Error sending Read Request (network error ?)
32009 Error sending Write Request (network error ?)
32060 Timeout for cyclic data from drive - Indications invalid
(network error ?)
32061 Timeout sending a Read Request telegram (network
error ?)
32062 Timeout sending a Write Request telegram (network
error ?)
41031 Junction temperature model: Overtemperature
41051 ACOPOS peak current: Overload
41061 ACOPOS continuous current: Overload
41070 Motor temperature model: Overtemperature
Page 87 of 106
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SECTION 9: MAINTENANCE
9.1 General warnings
Warning!
You are advised to go through General Safety advice provided at section 3.

For correct operation, maintenance and repairs it is utmost important that the
operators or personnel working with the machine for any work understand
safety precautions to be followed.
and pneumatic connections withdrawn completely. A period of about 5
minutes should elapse after the power OFF before any maintenance can be
carried out.
Technicians who have been trained and certified by the manufacturer can
only carry out maintenance of the machine.

machine.

Page 88 of 106
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9.2 Daily maintenance procedures
Check oil levels in the FRL.

Check oil level in the lubrication reservoir
Check Air pressure for blowing air / pneumatic system air
Check for all Air Regulators - Air pressure and reset if required.
Check the proximities of clamp unit/stretch unit and ensure their
position
Check the lock nuts on the clamping unit, and tighten, if required.
Check the base mould for its securedness.
Ensure that heater stopper clamps are in position.
Check for oil/air leakages in general.
Ensure that all flow controls are not tampered with.
Ensure greasing of Rack & Pinion.
Drain LP & HP tank. In case machine is being stopped for long
interval.
Check Stretch Rod clamp nuts
Check whether any heater mounting strips have loosened out
Apply grease to the servo drive ball screw nuts thru grease nipple
Page 89 of 106
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9.3 Weekly maintenance procedures:
Clean guide pin of the mould

Clean the machine thoroughly.
Lubricate chain on both sides for preform rotation with Silicon
grease spray
Check Chain tension / tightness.
Check Blow Pin seals, for its usability.
Check the peripherals – such as Chiller, Loader etc. for its
working.
Check shock absorbers on all units.
9.4 Monthly maintenance procedures:
Clean the mould/base mould with cotton buds for better finish of
bottle.
Check the moulds for any damages etc.
Check for the piston rod nuts of 3 & 1A indexing, Ejector unit,
loading unit, bottom
Forming unit and other index cylinders and ensure that they are
tight.
Check Roller Belt tension on the loader.
Ensure smoother rotation of the conveyor belt of the loader.
Check Oven bank alignment
Change water in the chiller
Page 90 of 106
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SECTION 10: CHECK LISTS
10.1 Training Program
DAY 1
Handing over training material.
Take group to the machine- show machine functions & identify the parts.
Showing them the flow from preform loading to bottle exit.
Explanation of each unit.
Briefing them regarding the lubrication and maintenance.
DAY 2
Mould mounting by the trainees, stretch rod setting and loader setting.
Machine startup and setting the process.
Tracking of process related problems.
DAY 3
(Electrical)
Panel wiring layout.
Explanation of the PLC.
Explanation of sensors wiring.
Explanation of electrical junction boxes and location.
Explanation of servo drives and servo motors.
Explanation of MMI.
Explanation of heater wiring circuit.
Practical demo of changing the Modules.
Practical demo of fixing the heaters.
Review of the session.
DAY 4
(Mechanical Assemblies)
Practical demo of sub-assemblies.
Compensation pin setting and its importance.
Location of Pneumatic valve junctions.
Practical demo of Blowing PET block and maintenance.
Practical demo of clapper assembly.
DAY 5
Trouble shooting on machine.
Review of entire training.
Farewell (Certificate).
Page 91 of 106
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10.2 Check List before Commissioning of machine
Ensure m/c parts are received without damage.

Ensure that all utilities are in within specification. (i.e. Air compressor, chiller
,ambient temperature, oven ducts, voltage etc.)
Ensure the blowing room neat and clean.
Check the m/c lay out as per instruction manual.
Assemble the m/c with loader and electric panel as per lay out drawing given
in the manual.
Assemble the loose parts with m/c, (i.e., index I cylinder, take off unit etc.)
Check leveling of the m/c.
Air line flushing to be done at least five times. (With a frequency of 10minutes
each.)After this air line connection can be done with filters
Ensure the chilled water quality (it should clear and without contaminants i.e.
for dissolved salts, chlorine.) and flush once.
Ensure the preform parameters are as per preform drawing.
Check the mould (if it is not mounted on the m/c.) parameters i.e. Thickness,
Height, parallelity and base mould stud height are within specification.
Mount the mould as per the procedure given the manual.
Stretch road setting to be done, ie-0 point and 10 point.
Ensure the cooling rail set as per preforms. (make sure all specifications i.e.
gap between preform neck and cooling rail as per manual.)
Ensure the heater bank is straight and perpendicular to the clapper rail.
IR lamps mounting and checking by each zone individually.
Ensure the tightness of all screws on the electrical junction boxes.
Greasing to be done on rack pinion and wedge plate.
Servo ball screw greasing to be done by lithium base grease.
Check the direction of rotation of chain motor is as per indication sticker
Check the direction of rotation of blowers are as per indication sticker
Check the loader conveyor rotation as per the indication.
Check the loader roller rotation as per indication.
Check the loader fan motor rotation as per indication.
Page 92 of 106
SR 2/1
Check the centering of ejector plate.(i.e. put preforms on the spindles and
ensure forward and reverse movement of ejector plate without air.)
Ensure the centering of the loader grippers.(i.e.-by put preforms on the
spindles check gripper jaws can hold preform neck without any disturbance.)
M/c put on dry run with heaters on without any interlock up to one hour.
Demonstration about m/c handling and process setting.
Process parameters setting, and ensure the bottle parameters are as per the
spec.
M/c put on continuous production. (Tune the process if it is required in auto
run.)
Ensure the over all m/c function and out put rate are as per the costumer
commitment.
Page 93 of 106
SR 2/1
10.3 Machine Commissioning – Site Status Report
The engineer will leave for commissioning only after all points mentioned below are certified as
“Done” by a responsible person, with his signature, designation and rubber stamp of company.
I, Mr. ________________________, Designation ______________________ hereby certify that all
above work has been carried out/kept ready to my satisfaction & now request you to send your
engineer at earliest.
I certify
following is Initials
REQUIREMENTS ready.
(Pls. tick 3)
1. BLOWING ROOM
a) Construction, plastering, painting etc. complete.
b) Ventilation provided.
c) Area is dust free
d) Air conditioning operative (room temp. above 30°C not
acceptable)
e) Flooring is complete as specified in Preinstallation Guidelines
booklet provided.
2. Machine & Loader placed in position (enough space for service
engineers to move around the machine)
3. ELECTRICAL (Note: proper earthing with minimum 16 mm2 x 1
core copper wire essential).
a) Stabilized power supply available. (415 V, +5%, 3 ph +
neutral + 2 separate earthings (1 Elect.Panel+1 Machine
Loader)
b) Backup generator connected.
c) Connection from main panel to machine panel provided.
d) Earthing to machine provided.
e) Separate earth to control panel provided.
f) Separate earth to Servo Stabilizer provided
g) Separate earth to loader unit provided.
h) Stabilizer installed as required for different models
4. AIR
a) High-pressure compressor commissioned.
b) High Pressure set to 40 kg/cm2 cut-off & 38.5 kg/cm2 cut-in.
c) Min. 38 bar high pressure continuously available at machine.
d) Low-pressure compressor commissioned.
e) Low-pressure compressor set to 8-9 kg/cm2.
f) Min. 7 bar low pressure continuously available at machine
inlet.
g) Pipes from compressor are min. 1½” dia. (End connection
Flexible type 1” BSP x length as required for HP & ¾” x
length as required for System pressure , Working pressure
60bar, Test Pressure 100bar )
h) Pipes from compressor are SS material.
i) Pressure gauges and isolation valves fitted at the end points
of the air piping near the machine (LP & HP both)
j) Filter is installed at the inlet of the machine (HP, LP) Line.
5 Air Conveyor length min. 18 mtrs from machine to filler. IMP.
6 Hood over heating area (as per drg provided)
Page 94 of 106
SR 2/1
7. Moulds are available and checked to be in accordance with

specifications in the preinstallation guidelines/manual.
8. Water cooling pipes etc. are ready
9. Electrical chain pulley block or wire hoists of 1000 kg capacity
over the clamp unit for loading/unloading of moulds.
10. Preforms –Min 10,000 Nos for each pack size (50% of rated bph
for Machine Testing and balance for CAV run)
11. Mosil Grease 1 Tube for wedges
12. Grease (THK AFB70) Min.400 gms. & Grease Gun for ball screw
is available.
13. Silicon spray for spraying onto the chain of the oven is available.
14. At least 10 liters–SAE32 grade lubricant for Auto Lubrication
15. Lubricant grade 22 Hyspin servo for FRL - 5.0 Liters (SAE-32)
Festo Special Lubricant –Aral Vitam GF-3, or BP Energol HLP –
32, or Esso Nuto H32, or Shell Tellus DO –32.
16. COOLING TOWER & PUMP
Electrical Connection to the Cooling Tower & Pump
Make up Water connected
Piping with/without insulation
Water Line connected to the machine
Cooling Tower & Pump Commissioning
17. CHILLER: chiller is commissioned and installed
Temp: 8 ~ 10 deg is achieved. Flow as required (mentioned in
preinstallation guidelines) is available
18. D. G. SET
Diesel Tank fitted & diesel available
Change Over Switch
Wiring from D. G. Set to the Machine
D. G. Set is Commissioned
19. 50 liter (Hythem 500) for Mould temp controller
(for HOTFILL Machines only)
20. Machine Equipped with all Utility Connections, Tools, lubricant, &
Manpower.
21. Personnel trained at Sidel Chakan Plant are available
2 Operators. Name:_________________ ________________
1 Engineer., Name:___________________
22. Photo of the Site attached with this report
As per the terms the engineers travel, lodging & boarding expenses will be borne by us.
Note:- In case site is found to be NOT COMPLETELY READY as per above report, our technician will be
recalled and next visit will be arranged as per availability of person on per day charges ,travel, lodging &
boarding expenses will borne by the customer.
________________________________
Signature & Rubber Stamp of Customer
To call for services of our engineer for commissioning, please remove the 2 pages ( Machine Commissioning-Site
Status Report) from this book only when all above 20 points are ready. Sign the same & forward to Sidel. Attn:
Mr.Adil on Fax No. 02135-259033 or email adil.adajania@sidel.com with cc to Mr. V. Kalbate at Fax No. 022-
28396107 or email vithal.kalbate@sidel.com
NOTE: All installation of utilities have to be done by customer. Only commissioning/startup will be
done by Sidel engineer.
adil.adajania@sidel.com with cc to Mr. V. Kalbate at Fax No. 022-28396107 or email vithal.kalbate@sidel.com
Page 95 of 106
SR 2/1
SECTION 11: REFERENCES

11.1 Pneumatics
VALVE
FERRUL NO. SR. 2/1 ( WL ) O/P NO.
NO
L 1 1,2 MOULD O/C 103
2 3,4 WEDGE I/O 305
3 NA
4 NA
5 NA
R NEAR CLAMP UNIT
L VALVE
NO
1 10 , 11 BOTTLE GRIP 202
2 12 , 13 BOTLE ROTATE 204
3 14 , 15 BOTTLE UP 203
CUSHIONING / INDEX2 / 2A /
4 20, 21 LOCKING / 106
PREFORM PRESSING
CUSHG. 1 / CLAP. LOCK /
5 18, 19 403
INDEX 1A
6 26, 27 BLOW PIN UP 105
7 16 , 17 BOTTOM UP 102
8 22, 23 STRETCHING STAGE 1 207
9 24, 25 STRETCHING STAGE 2 303
R
NEAR EJECTOR UNIT
L VALVE
NO
1 28, 29 PREFORM LIFT 307
2 30 , 31 LOADER ROTATE 104
3 32 , 33 LOADER GRIP 308
4 28 , 29 LOADER UP AND GATING 302
R
Page 96 of 106
SR 2/1
List of Valves
CYL. PIPE
OPERATES
NO FUNCTION FERRULE
CYLINDER
NO
MOULD OPEN CLOSE 1, 2 80 x 80
WEDGE IN / OUT 3, 4 80 x 80
1.
WEDGE UP/ DOWN &
26, 27 63 x 40
B.PIN
NA 7, 8 NA
EJECTOR PUSHER 10, 11 25 x 80
EJECTOR ROTATE 12, 13 DSR 40-180P
EJECTOR LIFT 14, 15 32 X 25
INDEX 2 20 , 21 40 x 95
2. CUSHIONING INDEX 1 / 18, 19
16 x 50
CLAPPER LOCK
INDEX 3 24 , 25 NA
BLOW PIN UP -DOWN 26 , 27 EP 125 X 12
3. BOTTOM UP DOWN 16, 17 50 X 30
CUSHIONING INDEX 2A 20, 21 16 X 50
INDEX 1 18, 19 32 X 165
INDEX 1A 18, 19 32 X 165
CUSHIONING INDEX 2 20, 21 16 X 50
PREFORM PRESS 20, 21 32 X 125
LOADER LIFT 28, 29 32 X 25
LOADER ROTATE 30, 31 DSR-32-180-P
LOADER GRIP 32, 33 HGR-25-A
4. GATING 28, 29 16 X 25
CUSHIONING INDEX 1A/ 16 X 50
18, 19
CLAPPER LOCK 16X 10
INDEX 2A 20, 21 40 X 95
STRETCH I 24, 25 50 x 225
5. STRETCH 22, 23 32 x
Page 97 of 106
SR 2/1
List of HP, LP & Exhaust Valves
SIZE /
NO FUNCTION MAKE LOCATION QTY. Type
DESCRIPTION
RIGHT SIDE
PROVIDE LOW PRESSURE 0.5 TO 10 BAR,
1. LEGRIS OF 1 NC
WHILE BLOWING 3/4 "
MACHINE
PROVIDE HIGH PRESSURE 0.5 TO 40 BAR,
2. LUCIFER ” 1 NC
WHILE BLOWING 3/4 "
PROVIDE EXHAUST TO
0.5 TO 40 BAR,
3. HIGH PRESSURE AIR LUCIFER “ 1 NC
3/4 "
AFTER BLOWING
PROVIDE HIGH PRESSURE
0.5 TO 40 BAR, CLAMP LEFT
4. WHILE CLAMPING TO LUCIFER 1 NC
3/4 " SIDE
COMPENSATION PLATE
TO PROVIDE EXHAUST
HIGH PRESSURE NC
0.5 TO 40 BAR, CLAMP LEFT
5. PROVIDED WHILE LUCIFER 1
3/4 " SIDE
CLAMPING TO
COMPENSATION PLATE
FRONT OF
6. NON-RETURN VALVE 3/4” E/PNEU. 1 -
MACHINE
List of Regulators
SIZE /
NO FUNCTION MAKE LOCATION QTY.
DESCRIPTION
LOW PRESSURE FRONT OF
1. LR ¾ -D MAXI FESTO 1
BLOW MACHINE
LOW PRESSURE
2. REGULATOR (PISTON 40 BAR RAICO ON TANK 1
TYPE)
HIGH PRESSURE
3. REGULATOR (PISTON 40 BAR RAICO ON TANK 1
TYPE)
HIGH PRESSURE
4. REGULATOR (PISTON 40 BAR RAICO CLAMP LEFT SIDE 1
TYPE)
Page 98 of 106
SR 2/1
List of Flow Controls
SIZE /
NO FUNCTION MAKE LOCATION QTY
DESCRIPTION
FLOW CONTROL OF LOADER
1. 1/8 BSP FESTO 2
LOADER LIFT CYLINDER UNIT
FLOW CONTROL OF
LOADER
2. LOADER ROTATE CYL. 1/8 BSP FESTO 2
UNIT
DSR32-180
FLOW CONTROL OF INDEX 2A
3. ¼ BSP FESTO 1
INDEX 2A FORWARD CYL
FLOW CONTROL OF
4. ¼ BSP FESTO INDEX 2 2
INDEX 2
FLOW CONTROL OF
5. 1/8 BSP FESTO INDEX 1A 1
INDEX 1A
TOP OF
FLOW CONTROL OF
6. 1/4 BSP FESTO CLAMP 2
BOTTOM FORM. CYLINDER
UNIT
FLOW CONTROL OF
EJECTOR
7. EJECTOR ROTATE 1/4 BSP FESTO 2
UNIT
ACTUATOR DSR40
FLOW CONTROL OF EJECTOR
8. 1/8 BSP FESTO 2
BOTTLE PUSHER CYLINDER UNIT
9. FLOW CONTROL INDEX I 1/8 BSP FESTO INDEX 1 1
FLOW CONTROL OF EJECTOR
10. 1/8 BSP FESTO 2
EJECTOR LIFT UNIT
Page 99 of 106
SR 2/1
List of Cylinders
NO. FUNCTION SIZE TYPE LOCATION QTY.

1. INDEX 1 32 x 165 PNEU INDEXING UNIT 1
2. INDEX 2 40 x 95 PNEU INDEXING UNIT 1
3. INDEX 2A 40 x 95 PNEU INDEXING UNIT 1
4. INDEX 1A 32 x 165 PNEU INDEXING UNIT 1
PNEU CLAMP UNIT MOVING
5. INDEX 3 N.A. 1
PLATE (INNER SIDE )
PREFROM DNC-32-125- PNEU LOADER SIDE OF THE
6. 1
PRESS PPV-A MACHINE
7. BOTTOM UNIT 50 X 30 PNEU ABOVE CLAMP UNIT 1
MOULD PNEU CLAMP UNIT THRUST
8. 80 x 80 2
OPEN CLOSE PLATE
WEDGE PNEU BELOW CLAMP UNIT
9. 63 x 40 2
IN OUT BASE PLATE
PNEU NEXT TO CLAMP
10. EJEC LIFT 32 x 25 1
UNIT
11. EJEC PUSHER 25 x 80 PNEU EJECTOR UNIT 1
12. EJEC ROTATE DSR 40-180-P PNEU EJECTOR UNIT 1
CLAPPER PNEU
13. 16 x 10 INDEXING UNIT 3
LOCKING
14. CUSHIONING 16 x 50 PNEU INDEXING UNIT 4
15. LOADER LIFT 32 x 25 PNEU LOADER UNIT 1
16. LOADER ROTATE DSR 32-180-P PNEU LOADER UNIT 1
LOADER PNEU
17. HGR- 25A LOADER UNIT 1
GRIPPER
18. GATING 16 x 25 PNEU SHUTTLE UNIT 2
BLOW PIN PNEU
19. 125 x 12 STRETCH UNIT 2
UP-DOWN
20. STRETCH 1 50 x 225 PNEU STRETCH UNIT 1
21. STRETCH 2 40 x 200 PNEU STRETCH UNIT 2
Page 100 of 106

SR 2/1
List of Quick Exhaust Valves
SIZE /
NO FUNCTION MAKE LOCATION QTY
DESCRIPTION
QUICKLY RELEASE THE CUSHIONING CYL.OF
1. 1/8 BSP FESTO 1
AIR WHILE RETRACTING INDEX 2A SIDE
QUICKLY RELEASE THE CUSHIONING CYL.OF
2. 1/8 BSP FESTO 1
AIR WHILE RETRACTING INDEX 1A SIDE
QUICKLY RELEASE THE
3. 1/8 BSP FESTO INDEX 1 CUSHIONING 1
AIR WHILE RETRACTING
QUICKLY RELEASE THE
4. 1/8 BSP FESTO INDEX 2 CUSHIONING 1
QUICKLY RELEASE THE
5. 1/8 BSP FESTO INDEX 1 / 1A 1+1
QUICKLY RELEASE THE
6. 1/8 BSP FESTO INDEX 2A 1
7. WEDGE IN-OUT 1/4" BSP FESTO UNDER CLAMP UNIT 2
8. BLOW PIN 1/8” BSP FESTO NEAR BLOW PIN 1
Page 101 of 106

SR 2/1
11.2 PLC Input / Output List
PLC Unit
1 2 3 4 5 6 7 8
Power Supply card 1.

Thermocouple Card 1 2.
CPU Card 3.
Input Card – 1 4.
Input Card – 2 5.
Output Card – 1 & 2 6.
Output Card – 3 & 4 7.
Triac Card – 1 8.
THERMOCOUPLE CARD
Description Corr. Wire No.
Oven Thermocouple TC-1
Mains Voltage Red TC-2
Mains Voltage Yellow TC-3
Main Voltage Blue TC-4
IR Camera TC-5
Page 102 of 106

SR 2/1
Input List
INPUT MODULE X20 – DI 9371

DESCRIPTION INPUT WIRE SR. NO’s.
NO.
Mould Open Reed Switch I 0.0 1.
Blow Pin Out Proximity Switch I 0.1 2.
Stretch Pin Out Proximity Switch I 0.2 3.
Index 2 Front Reed Switch I 0.3 4.
Index 1 Front Reed Switch I 0.4 5.
Mould Close Reed Switch I 0.5 6.
Bottom In Proximity Switch I 0.6 7.
Index 2 Rear Reed Switch I 0.7 8.
Low Pressure Blow Proximity Switch I 1.0 9.
High Pressure Blow Proximity Switch I 1.1 10.
Emergency Stop Push Button I 1.2 11.
Photo Cell on Loader Side – 1 I 1.3 12.
Index 1 Rear Reed Switch I 1.4 13.

Ejector Gripper Open Reed Switch I 1.5 14.
Ejector Lift Reed Switch I 1.6 15.
Photo Cell on Loader Side – 2 (Low Level) I 1.7 16.
Loader Gripper Open Reed Switch I 2.0 17.
Index 2 Return Reed Switch I 2.1 18.
Mandrels side Gripper ON Proximity Switch I 2.2 19.
Input that comes On when the Rotor Motor is ON I 2.3 20.
Input that comes ON when the Blowers are ON I 2.4 21.
Loader Side Gripper ON Proximity Switch I 2.5 22.
Loader Down Reed Switch I 2.6 23.
Ejector IN Proximity Switch I 2.7 24.
INPUT MODULE X20 – DI 9371

Index 2A Forward Reed Switch I 3.0 25.
Inner Side Wedge Lock In Reed Switch I 3.1 26.
Outer Side Wedge Lock In Reed Switch I 3.2 27.
Wedge Lock Out Reed Switch I 3.3 28.
Photocell for Preform Logic 1 I 3.4 29.
Loader Lift Reed Switch I 3.5 30.
Guard Limit Switch I 3.6 31.
Index 2A Return Reed Switch I 3.7 32.
Index 1A Forward Reed Switch I 4.0 33.
Spare(Preform Gating Forward (Jar Loading) I 4.1 34.
Index 1A Return Reed Switch I 4.2 35.
Ejector OUT Proximity Switch I 4.3 36.
Page 103 of 106

SR 2/1
Output List
OUTPUT MODULE X 20 – DO – 8332

DESCRIPTION OUTPUT WIRE NO. SR. NO’s.
Index Cylinder 1 & 1A / Cushioning / Clapper Lock Q 0.0 1.
Bottom Out Q 0.1 2.
Mould Close Q 0.2 3.
Loader Rotate Q 0.3 4.
Blow Pin Q 0.4 5.
Index Cylinder 2 & 2A / Cushioning / Clapper Lock Q 0.5 6.
Low Pressure Blow Left (1 Station) Q 0.6 7.
High Pressure Blow Left (1 Station) Q 0.7 8.
Mould Open Q 1.0 9.

Ejector Grip Q 1.1 10.
Ejector Lift Q 1.2 11.
Ejector Rotate Q 1.3 12.
Main Exhaust Valve Q 1.4 13.
Fan Motor & Roller Motor Contactor Q 1.5 14.
Stretch Pin IN 1 Q 1.6 15.
Loader Conveyor Motor Q 1.7 16.
Mould Cylinder – 1 Q 2.0 17.

Preform Gating – 1 Q 2.1 18.
Stretch Pin IN 2 Q 2.2 19.
Chain Motor Contactor Q 2.3 20.
Blower Motor Contactor Q 2.4 21.
Mould Cylinder – 2 Q 2.5 22.
Loader Gripper Lifting Cylinder Q 2.6 23.
Gripper for Loader Q 2.7 24.
OUTPUT MODULE X 20 – DO – 8332
DESCRIPTION OUTPUT WIRE NO. SR. NO’s.
Preform Press Q 3.0 25.
Hooter Q 3.1 26.
Compensation ON Q 3.2 27.
Compensation Exhaust Valve Q 3.3 28.
Wedge Lock Close Q 3.4 29.
Wedge Lock Open Q 3.5 30.
Preform Gating – 2 Q 3.6 31.
Air Recovery Valve – 1 Q 3.7 32.
Cooling H.P Exhaust – 1 Q 4.0 33.

Cooling H.P Exhaust – 2 Q 4.1 34.
Cooling H.P Timer (Stretch Rod) – 1 Q 4.2 35.
Cooling H.P Timer (Stretch Rod) – 2 Q 4.3 36.
N.A. Q 4.4 37.
N.A. Q 4.5 38.
N.A. Q 4.6 39.
N.A. Q 4.7 40.
Page 104 of 106

SR 2/1
RTD LIST
ANALOG MODULE AT 4222

DESCRIPTION RTD WIRE NO.
Main Voltage R Phase RTD - 1
Main Voltage Y Phase RTD – 2
Main Voltage B Phase RTD – 3
Oven Temperature RTD – 4
ANALOG MODULE X20 – AO – 4622 (For Reflector Fan)

DESCRIPTION RTD WIRE NO.
Inner Oven Fan AO – 1
Spare AO – 2
ANALOG MODULE X20 – DO – 9322 – 1 (Main Heater Bank)

DESCRIPTION RTD WIRE NO. SR. NO’s.
Zone – 1 R1 41.
Zone – 2 R2 42.
Zone – 3 R3 43.
Zone – 4 R4 44.
Zone – 5 R5 45.
Zone – 6 R6 46.
Zone – 7 R7 47.
Zone – 8 R8 48.
Zone – 9 R9 49.
ANALOG MODULE X20 – DO – 9322 – 2 (Preferential Heater Bank)

DESCRIPTION RTD WIRE NO. SR. NO’s.
Pref. Zone – 1 R10 50.
Spare R15 55.
Spare R16 56.
Spare R17 57.
Spare R18 58.
Page 105 of 106

SR 2/1
12.1 Bill of Material
12.2 Circuit Diagrams
Page 106 of 106

1 2 3 4 5 6 7 8
A 8 x 11 A
2
150 THRU.
=
175
OPEN
440
4
87.50
=
3
B B
20
140 300 300 300 300 200
10 X 11
THRU.
200
40
300
1 OPEN
C C
1400 40 400 40
1480
100
480
8 X 11 175 100 120 +6'/01 2#4607/$'4 &'5%4+26+10 36;

D THRU. 60 D
*11&5/#.. 5*&
87.50
(#0/6)*11&#+4%108';'4 5*&
105
4':014&(#0 /1&'.4'%#
120

14'37+8#.'06 OO&+#
60
105 4 x M4
THRU. 325 *11&(#0':+6%18'4 5*&
E REVISIONS
4 X 4.5
ZONE REV. NO. MODIFICATION DATE APPROVED
150
THRU.
MATL. - TREATMENT - DEBUR AND
DO NOT SCALE DRAWING
75
REVISION
75
72 BREAK SHARP
275
EDGES
M.S.SHEET (20 GAUGE)
75
150
NAME SURFACE FINISH BLOWING AND COATING DIVISION
100 ROUGHNESS GRADE ROUGHNESS VALUES
SIDEL India Pvt. Ltd. PLOT NO. B-19,MIDC,Chakan Industrial Area
DRAWN RAHUL SYMBOL Ra MICRON Mahalunge Village.Taluka Khed,District Pune-410501.INDIA
THRU. 8 TO 25
CHK'D PEJ Tel.:+91-02135-259133/259144. Fax : +91-02135-259033
1.6 TO 8
PEJ 0.025 TO 1.6
75
APPV'D TITLE:
<0.025
200 HOOD DRAWING (SR12, SR034, SR21,AE 22)
F MFG
200 1 PER M/C LINEAR TOLERANCES
QTY. ANGULAR TOLERANCES DWG NO.
OVER 10 50 - 30 120 315
DATE - 120 OVER 6 1000
29\3\07
UP TO 50 120 - UP TO 6 30 120 315 1000 2000
10
WEIGHT: 30' TOL. SCALE:1:20
TOL. 1 20' 10' 0.1 0.2 0.5 0.8
0.3 1.2
1 2 3 4 SHEET 1 OF 1
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PET STRETCH BLOW MOULDING MACHINE

Sidel India Pvt. Ltd.

DO NOT COMPROMISE ON THE UTILITIES AND

Name Email address Designation Contact No.

1.1 Purpose of This User Manual:

1.2 Method of Consult:

For maintenance: Refer Section 9

For general Safety advice and precautions, refer section 3 & 7

1.3 Manual Keeping

SECTION 2: GENERAL INFORMATION

2.1 Manufacturers identification data

Sidel India Pvt. Ltd.,

Phone : 91-(02135)-259133, 259144, 280003

2.2 Machine identification data

2.3 After sales service

Contact Person : Mr. Ramesh Akkannavar

Warranty excludes the following:

The warranty clauses are subject to warranty documents to be mutually signed

2.5 Regulations and declaration of conformity

2.6 Operators qualifications and training required

2.7 Workshop Regulations

The user is responsible for observing, performing and controlling the

2.8 Temporary Workers

Be careful with temporary workers, because they must also be trained

2.9 Responsibilities of the Operating Personnel

As soon as an operator observes malfunctions during operation, he must

SECTION 3: GENERAL SAFETY ADVICE

3.1 About this section

3.2 Glossary Used

Following terms are invariably used in the instruction manual.

3.3 Symbols and signal words used

The following symbols and signal words have been

Paragraph marked with this word denotes

3.4 Responsibilities of the operating Personnel

Only trained and instructed personnel is allowed to perform works at the

As soon as an operator observes malfunctions during operation, he must

Follow the general, national or intra-company safety instructions. You must

3.5 Safety advice and precautions to be followed

This section informs you about the machines safety installations.

We as manufacturer have taken great care, when designing this machine to

It is absolutely forbidden to inhibit the safety components installed on the

Low-safety operations must be carried out complying strictly with the

Installation and putting machine in use has to be performed by our technicians

The machine incorporates non-linear current consuming devices, which have

3.6 Safety Precautions to be followed during operation

3.7 Safety precautions to be followed during maintenance

3.8 Protective Earthing

3.9 Owners’ Responsibilities

Various levels of password protections are provided for access in to operation

The machine incorporates non-linear current consuming devices, which have

SECTION 4: INFORMATION ON THE MACHINE

4.1 General description

Correct nomenclature of the machine

PET STRETCH-BLOW MOULDING MACHINE

4.2 Prohibitive Use

4.3 Principle of Operation

To be able to vary the temperature

preform injection moulding stage, is protected from the heaters by a water-cooled

The typical PET bottle mould is a three-piece design

At the same time as the mould is closing,