SCREW CAP APPLICATOR

S.C.A.

Operator’s Manual
 SCREW CAP APPLICATOR

WARRANTY ............................................................................................................. I

1.0 TECHNICAL FEATURES ....................................................................................... 1

LAY-OUT RG50 .................................................................................................................. 2
TECHNICAL DATA ............................................................................................................. 4
PNEUMATIC SYSTEM ....................................................................................................... 5

2.0 OPERATION ........................................................................................................... 6

2.1 STARTING ................................................................................................................. 7
2.2 ALARMS ON THE SCA DEVICE’S PROGRAMME ................................................. 12

3.0 OPERATING MANUAL ......................................................................................... 13

3.1 INTRODUCTION ...................................................................................................... 14
CARTON WITH CAP ........................................................................................................ 14
CARTON WITHOUT CAP ................................................................................................. 14
RESET CYCLE ALARM .................................................................................................... 14
AUTOMATIC CYCLE ........................................................................................................ 14
MANUAL CYCLE .............................................................................................................. 15
ALARMS ........................................................................................................................... 15
WARNINGS ...................................................................................................................... 20
3.2 MAINTENANCE OF THE SCREW CAP UNIT ......................................................... 21
ALIGNING THE CAP ON THE CARTON .......................................................................... 21
ALIGNING THE ARM FOR CAP LOADING ...................................................................... 22
ALIGNING THE SONOTRODE’S ARM ............................................................................. 23
ALIGNING THE ULTRASOUND HEAD WITH THE CAP .................................................. 25
ADJUSTING THE DAMPERS ........................................................................................... 26
ADJUSTING THE CYLINDER SENSORS......................................................................... 27
ADJUSTING THE CAP PHOTOSWITCH ON ARM ........................................................... 28
ADJUSTING THE CAPS’ DETECTION PHOTOSWITCH ON GUIDE ............................... 28
ULTRASONIC SYSTEM CONTROL (OVERLOAD ALARM) ............................................. 29
ADJUSTING THE CAPS’ DETECTION PHOTOSWITCH ON ORIENTING DEVICE......... 32

4.0 WIRING DIAGRAM ............................................................................................... 33

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 SCREW CAP APPLICATOR

SCA
Operation and Maintenance Manual

SERIAL NUMBER :

ISSUE : 04-2008

WARNING

Operators and maintenance personnel must read this manual carefully

before using the machine or carrying out maintenance work. Keep this
manual near the machine for consultation at any time and together with the
machine in the event of resale.

IMPORTANT
THE BOTTLING MACHINE MUST BE RUN BY A SINGLE OPERATOR, WHO WILL BE
RESPONSIBLE FOR ALL START-UP OPERATIONS. GALDI TECHNICIANS WILL
SUPPLY ALL TECHNICAL INFORMATION (ALSO BY MEANS OF THE USER AND
MAINTENANCE MANUAL) NECESSARY TO OPERATE THE MACHINE AND TO
CARRY OUT ROUTINE MAINTENANCE.

Approved:

Date……………..……..……………..

Operator’s name……………………

Signature….…………………………

GALDI S.r.L.
Via Enrico Fermi, 43/B - 31038 POSTIOMA (TV) - Tel. 0039(0)422/482211 - Fax 0039(0)422/482230

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 SCREW CAP APPLICATOR

WARRANTY
GALDI S.r.l. guarantees that its machines are built in compliance with the latest
manufacturing criteria, with the best material available and using best industrial practices.
The company undertakes to replace, for a period of one year from delivery, any parts
made by Galdi s.r.l. that are found to present manifest or concealed manufacturing
defects. The warranty does not cover electrical components and parts not manufactured
by Galdi S.r.l..
The warranty will be declared null and void in the event of improper use, unauthorised
work or failure to apply the instructions given. The warranty covers materials only and
does not provide for damages arising from machine downtime or other reasons. Send
parts to be replaced carriage paid to the manufacturer, who will assess the claim and
provide replacements accordingly.

All rights reserved. No part of this manual may be used or reproduced in any form or by any means, stored in
a database or retrieval system, without the written permission of GALDI. While all precautions were taken
while preparing this manual, GALDI declines all liability for errors or omissions, as well as for damage
resulting from the use of the information contained in this manual. For more information, contact the GALDI
engineering department.

The text translation may contain mistakes or incorrect interpretations. In the event of unclear or illogical instructions, please contact
GALDI.
GALDI S.r.L.

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SCREW CAP APPLICATOR

1.0 TECHNICAL
FEATURES

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 SCREW CAP APPLICATOR 1.0
LAY-OUT RG50

A-STYLE Hole on the 4th pannel

B-STYLE Pure Pack
S.C.A.


3100
1150
min.800 - max 3500

850

1200
1140

190

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SCREW CAP APPLICATOR 1.0

A-STYLE Hole on the 4th pannel

B-STYLE REX

S.C.A.

3100

1150

min.1600 - max 3500


1530
1200

850

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 SCREW CAP APPLICATOR 1.0
TECHNICAL DATA

 The eletrical consumption is approximately 3.5 kW.

(380V – 50/60 Hz + N + G)

 The air consumption is approximately 65 nl/min at pressure 6 bar.

(½”G connection)

 Weight: 400Kg

CAUTION

It is essential to check the quality of compressed air; it should be as clean as possible

and in particular free from
- damp;
- dust;
- gas, bacteria, viruses;
- olio coming from the compressor.

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 SCREW CAP APPLICATOR 1.0
PNEUMATIC SYSTEM

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SCREW CAP APPLICATOR

2.0 OPERATION

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 SCREW CAP APPLICATOR 2.0
2.1 STARTING

 The caps are randomly fed onto the magazine (87).

 A turbine generates an air flow inside the magazine (87), which helps the caps’ feeding
through a pipeline (71) up to the orienting unit's magazine (86), which is placed over the
filling machine. A sensor helps keeping the cap position over the orienting unit unchanged.

 The caps are delivered oriented to the same direction and are conveyed towards the
applicator by means of guides (61).

86

61
71
95

87
82

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 SCREW CAP APPLICATOR 2.0

 Whenever sensors (0) (fig.1) detect the presence of Gable Top containers under the fixing
device a pneumatic cylinder (91) moves a cap onto the fixing device head (21). Then the
fixing device (12) is lowered down to the Gable Top inside (fig.2) by the cylinder (2) and
introduced into the cap hole by moving forward a sled (18)

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 SCREW CAP APPLICATOR 2.0
 At the same time a sled (5) pushes forward an ultrasonic welder-head sonotrode (84) and
then rests it to the Gable Top side with the cap ready

 A generator (82) sends out a welding pulse and the SCREW CAP is ultrasonic welded on the
Gable Top carton.

86

61
71
95

87
82

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 SCREW CAP APPLICATOR 2.0

 The sonotrode and fixing device heads are finally retracted (fig.4) and the fixing device is lifted
up to let the carton free to advance (fig.5).

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 SCREW CAP APPLICATOR

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1) Sonotrode body
2) Application arm
3) Cap separator FIGURE 6
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 SCREW CAP APPLICATOR 2.0
2.2 ALARMS ON THE SCA DEVICE’S PROGRAMME

 No caps on the orienting unit

 No caps on the guides

 Cap not loaded onto the fixing device head

 No hole on the carton

 Missing cap in the cartons after the applicator unit

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SCREW CAP APPLICATOR

3.0 OPERATING
MANUAL

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 SCREW CAP APPLICATOR 3.0
3.1 INTRODUCTION
IMPORTANT

NEVER PUT YOUR HANDS INSIDE THE MACHINE BEFORE YOU HAVE
PRESSED THE EMERGENCY BUTTON OR SWITCHED OFF THE
COMPRESSED AIR SYSTEM.

CARTON WITH CAP

 To enable the Screw Cap Applicator you have to complete a RESET CYCLE and then make an
AUTOMATIC CYCLE

CARTON WITHOUT CAP

 It is possible to disable the Screw Cap Applicator from the “Recipe” page

 Turn the AUTO-MAN switch to the AUTO position

RESET CYCLE ALARM

 Turn the AUTO-MAN switch to the AUTO position

 Keep the RESET button pressed for about 1 second

AUTOMATIC CYCLE
 Select “SCA” in the “Recipe” page

 Complete a RESET CYCLE

 Press the START button (when the SCREW CAP ON light is on, the applicator is ready to start)

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 SCREW CAP APPLICATOR 3.0
MANUAL CYCLE
 Turn the AUTO-MAN switch to the MAN position

 Press the STOP button for about 3 seconds

 Select the line you want to operate by the LINE 1-LINE 2 switch (only for double applicator)

 Press the START button to operate the forward cycle.

 Press the STOP button to operate the backward cycle.

IMPORTANT:

While in "manual cycle", switch off the generator when you are checking the sonotrode arm alignment
and you want to disable welding.

ALARMS

1. NO CAPS IN GUIDE

- There are no caps on the guide:

o Make sure the caps are not blocked in the top part of the guide or in the cap diverter;
remove any damaged caps.
o
- The guide is full of caps but the photocell (10) does not read the caps present:
o Clean the photocell
o Check that the signal (yellow LED) is on in the presence of caps and is off otherwise;
to do this, try placing a cap in front of the photocell (10) and check the response. If
necessary, adjust the intensity of the photocell or its orientation to obtain the
correct signal.

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 SCREW CAP APPLICATOR 3.0
(14) (15) (10) (5) (11) (9) (10) (4) (16) (8)

(7) (12) (6) (13)

2. CAP NOT LOADED ON ARM ALARM

- The cap was not correctly loaded on the arm.

o make sure the caps are not blocked on the guide.
o carry out a check with the MANUAL CYCLE to verify the situation;
o make sure the cap selector (3) is not blocked, lubricating it if necessary.
o make sure the cap loading piston (10) moves freely

- The cap was loaded but the photocell did not read it.
o Clean the photocell (4)
o carry out a check with the MANUAL CYCLE to verify the situation; when the cap is
loaded the photocell must give the signal (yellow LED); when the cap is not loaded the
photocell must not give the signal. Otherwise, adjust the intensity of the photocell
or its orientation to obtain the correct signal (try placing a cap on the arm and
removing it and verify the response and signal)

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 SCREW CAP APPLICATOR 3.0
3. CAP REMAINING ON ARM

- A cap remained loaded on the arm after carrying out a sealing.

o Make sure the ultrasound generator is on
o Check that the OVERLOAD signal is not activated on the ultrasound generator during
sealing, otherwise refer to the section OVERLOAD ALARM.
o Make sure the cap applicator carries out sealing only in the presence of a carton. If
the applicator carries out sealing without a carton, check the limit switch or the
presence photocells located on the line, because they could give a signal even when
the package is not present.

- There is no cap in the arm.

o The photocell (4) gave the presence signal even though the cap is not present on the
arm.
o Make sure there are no blocked caps in front of the photocell (4)
o Clean the photocell
o carry out a check with the MANUAL CYCLE to verify the situation; when the cap is
loaded the photocell must give the signal (yellow LED); when the cap is not loaded the
photocell must not give the signal. Otherwise, adjust the intensity of the photocell
or its orientation to obtain the correct signal (try placing a cap on the arm and
removing it and verify the response and signal)

4. CAP BLOCKED IN LOADING

- The cap was loaded but the photocell did not read it, therefore the system tried to load
another one.
o Clean the photocell(4)
o carry out a check with the MANUAL CYCLE to verify the situation; when the cap is
loaded the photocell must give the signal (yellow LED); when the cap is not loaded the
photocell must not give the signal. Otherwise, adjust the intensity of the photocell or its
orientation to obtain the correct signal (try placing a cap on the arm and removing it
and verify the response and signal).

- The cap was loaded but the sensor (5) did not read the movement of the piston that loads
the cap on the arm.
o Make sure the cap is correctly loaded.
o Check cap loading - arm alignment; if necessary carry out adjustment with the screws
(11) for side movement and with the screw (12) for vertical movement.
o Make sure the sensor (5) works correctly by trying a MANUAL CYCLE. Replace it in
case of malfunctioning.

- The cap was not correctly loaded.

o The pneumatic piston (10) may be blocked; lubricate it if necessary.
o The solenoid valve that controls the piston (10) does not work properly: replace it

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 SCREW CAP APPLICATOR 3.0
5. ARM GOING FORWARD ALARM

- The sensor (6) did not give the arm forward signal approx. ½ second after actuation of the
valve. Arm speed may be too slow.
o Arm speed may be too slow. The pneumatic piston (10) may be blocked; lubricate it if
necessary.
o The sensor (6) is not properly positioned; check the correct position, loosening the
sensor and moving it forward and back on the line where the LED stays on. Find the
middle position and fix it.
o The cap was loaded off position, therefore the arm was unable to move completely
forward with the sonotrode. Check cap loading - arm alignment; if necessary carry out
adjustment with the screws (11) for side movement and with the screw (12) for vertical
movement.
o Check the position of the sensor (6) with the MANUAL CYCLE.

6. ARM GOING BACKWARD ALARM

- The sensor (8) did not give the low arm signal approx. ½ second after actuation of the valve.
o Arm lowering may be too slow. The pneumatic piston (16) may be blocked; lubricate it
if necessary.
o The solenoid valve that controls the piston (16) does not work properly; replace it if
necessary.
o The sensor (8) is not properly positioned; check the correct position, loosening the
sensor and moving it forward and back on the line where the LED stays on. Find the
middle position and fix it.
o Check the position of the sensor (8) with the MANUAL CYCLE.

7. S.C.A. BLOCKED

- Check the status of the sensors and the photocells in the initial position of the cap applicator.
Only 3 sensors must be active (for each line): arm up, arm back and sonotrode back. The
sensors (5)(6)(7)(8) and the photocell (4) must be off.

8. CAP ORIENTATOR THERMAL SWITCH ALARM

- Check the QFM18 thermal switch inside the electric panel of the applicator
- If the thermal switch trips repeatedly, make sure the rotation of the cap orientator disk is not
blocked by an incorrectly positioned cap
- Check motor absorption

9. CAP BLOWER THERMAL SWITCH ALARM

- Check the QFM19 thermal switch inside the electric panel of the applicator
- If the thermal switch trips repeatedly, check the motor absorption

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 SCREW CAP APPLICATOR 3.0
10. CAPS IN SLIDE ALARM

- No caps on the guide:

o Make sure the caps are not blocked in the top part of the guide or in the cap diverter;
remove any damaged caps.

- The guide is full of caps but the photocell (10) does not read the caps present::
o Clean the photocell
o Check that the signal (yellow LED) is on in the presence of caps and is off otherwise;
to do this, try placing a cap in front of the photocell (10) and check the response. If
necessary, adjust the intensity of the photocell or its orientation to obtain the correct
signal.

11. NO CAPS IN BALL FEEDER ALARM

- There are no caps in the orientator.

o There are no caps in the store.
o The caps are blocked in the store.
o The cap vibrator inside the store does not work properly.
o The photocell inside the orientator gives the signal (yellow LED) even if there are no
caps. Clean the photocell, adjust the intensity or change the orientation of the
photocell.

- The orientator is full of caps

o The photocell inside the orientator does not give the signal (yellow LED) even if there
are caps. Clean the photocell, adjust the intensity or change the orientation of the
photocell.

12. LOW COMPRESSED AIR PRESSURE

- Check the compressed air gauges and make sure they are correctly adjusted.

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 SCREW CAP APPLICATOR 3.0
WARNINGS

Few caps in slide

Ultrasonic generator alarm
Cap not load in the arm
Cap remain on the arm
Cap blocked in loading
Alarm arm going forward
Alarm sonotrode going forward
Alarm arm going down
Few cap in the slide (timer)
Overload motor of ball feeder
Overload blowing motor of caps
Few cap in the slide line 2 (timer)
Few cap in the ball feeder
Low pressure of compressed air
Few cap in the slide line 2
Cap not load in the arm line 2
Cap remain on the arm line 2
Cap blocked in loading line 2
Alarm arm going forward line 2
Alarm sonotrode going forward line 2
Alarm arm going down line 2
Alarm cap not sealed
Alarm cap not sealed line 2
Screw cap not on right position
Screw cap not on right position line 2
Sonotrode not backward
Piston load cap not backward
Arm not backward
Arm not up
Sonotrode not backward L2
Piston load cap not backward L2
Arm not backward L2
Arm not up L2
Ball feeder empty cycle activated

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 SCREW CAP APPLICATOR 3.0
3.2 MAINTENANCE OF THE SCREW CAP UNIT
N.B.
Before performing any adjustments on the SCREW CAP unit, turn off the ultrasound generator at the
switch (1) on the generator’s control panel or at the trip switch SST3 (2) inside the electric power
panel.

1 2
ALIGNING THE CAP ON THE CARTON
 If the unit does not align the cap correctly with respect to the hole in the carton (fig.1), slacken the
screws (3) and turn the screws (4) to raise or lower the cap position; slacken screws (5) to move
the cap to the left or right.

No Yes
FIG. 1

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 SCREW CAP APPLICATOR 3.0
ALIGNING THE ARM FOR CAP LOADING

Position the SCREW CAP unit in its start of cycle position.

 Turn the AUTO-MAN selector to MAN.

 Press the START button and load a cap on the arm.

START

AUTO/MAN
Khi chuyển sang chế độ Manual.
Bấm start để move FWD step
Bấm Stop để move BWD step

 Check that the cap (6) on the arm is correctly aligned with respect to the loading piston (7).

7
6

 Turn screw (8) to raise or lower the arm.

 Loosen screw (9) to move the arm to the right or left as required.

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 SCREW CAP APPLICATOR 3.0
 With the piston (7) extended and the cap loaded on the arm (10), check that there is a gap of
approx. 0.2-0.5 mm between the cap (6) and the cap carrier (6a).

 Adjust screw (11) as required to move the separator backwards or forwards.

11
6 6a

7
6

0.1/0.2 mm
10

11

ALIGNING THE SONOTRODE’S ARM

Position the SCREW CAP unit in its start of cycle position.

 Turn the AUTO-MAN selector to MAN

 Press the START button twice.

START

AUTO/MAN

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 SCREW CAP APPLICATOR 3.0
 Remove any cap from the arm.

 Press the START button.

 Check that the centre of the ultrasound head is correctly aligned with the arm.

 Adjust screw (8) to raise or lower the arm.

 Loosen screw (9) to move the arm to the right or left as required.

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 SCREW CAP APPLICATOR 3.0
ALIGNING THE ULTRASOUND HEAD WITH THE CAP

 Use a feeler gauge to check the gap between the ultrasound head (12) and the cap carrier (13) in
the closed position (without cap).
The gap must be 0.5 mm (0.6 mm for Hot Fill) ±0.05

13

12 0,5 mm ± 0.05
0,6 mm ± 0.05 (HOT-FILL)

 If necessary, adjust the position of the ultrasound head by means of screw (14).

14

14

 Use a feeler gauge to check parallelism all around the circumference of the cap carrier.

 If the gap is not uniform all around the circumference, loosen screw (15) and adjust grub screws
(16) to set the two surfaces parallel.

16

15
PARALLELISM

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 SCREW CAP APPLICATOR 3.0
ADJUSTING THE DAMPERS

 When dampers (17) and (18) are fully pressed in, there must still be about 1 mm of travel left. To
adjust them, loosen lock nut (19) and adjust to achieve the 1 mm gap.

17 18

~ 1 mm

 To adjust correct damping action, loosen the grub screw (19) and turn the graduated ring (20) to
align the “3|4” setting with the grub screw (19).

19

1
2
3
4
5

20

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 SCREW CAP APPLICATOR 3.0
ADJUSTING THE CYLINDER SENSORS

 The four actuators of the SCREW CAP unit have 2 sensors (21) each (apart from the cap
loading cylinder which has only one). These sensors detect forward and back positions.

21

 Adjust the position of the back sensor with the piston fully retracted. Loosen the nut (1) and
move the sensor backwards or forwards as required, keeping it in the middle of its reading area.

 Adjust the forward sensor in the same way but with the piston fully extended.

21

22

 The cap loading cylinder (23) has just one sensor. Adjust this with the piston extended, i.e. in the
position for loading the cap on the arm.

23

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 SCREW CAP APPLICATOR 3.0
ADJUSTING THE CAP PHOTOSWITCH ON ARM
 This photoswitch [figure 1] must have its yellow LED (only) lit when a cap is loaded on the arm.
This LED must go out when the cap is removed or the arm is in its lowered position.

ADJUSTING THE CAPS’ DETECTION PHOTOSWITCH ON GUIDE

 This photoswitch [figure 2] must have its yellow LED lit when the guide is full of caps. Both LED’s
must be off when no caps are on the guide. If necessary turn the potentiometer on the
photoswitch to adjust sensitivity [figure 4].

FIG. 2
FIG. 1

YELLOW POTENTIOMETER FOR

ADJUSTING SENSITIVITY

FIG. 4

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 SCREW CAP APPLICATOR 3.0
ULTRASONIC SYSTEM CONTROL (OVERLOAD ALARM)
 For control the ultrasonic unit (generator-sonotrode) is just necessary to press the button TEST
placed on the panel of the generator and this make automatically the electric control of the
complete system. This operation is possible to make from the control panel of the machine into
the SCA test page.

TASTO
BUTTON

 When you press the TEST button you must have the led “output” green and the horn is made
vibration for all the time that you press the button. In this case the system is OK

TRASDUCER BOOSTER HORN

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 SCREW CAP APPLICATOR 3.0
 If, when you press the TEST button, the led “output” is red this means that there is a problem. To
find the problem is necessary to work on this way.

1- Control if horn is locked to the booster (use special key give with machine).Press again button
test and if no alarm and only the first led is on then the problem is solved; otherwise continue
to point 2.

2- Disassembly the HORN and remove the screw that there is between the HORN and
BOOSTER and check if is in good condition.

SCREW

 If damage replace with a new one. Assembly the parts (put some grease between the horn and
booster for a better transmission of the vibration) and test again. If still have problem continue to
step 3.

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 SCREW CAP APPLICATOR 3.0

3- There can be some water on the connector that can make an short-circuit and create the
overload. Disconnect and try to press TEST. If Overload alarm is appear that the problem is
on the cable or the connector from the generator to transducer, so check the connector if
there is some water inside, if the soldering cable on the connector are good and with a tester
control if the cable are in short-circuit. If no alarm control the connector of the transducer.

CONNECTOR CABLE GENERATOR-TRASDUCER

4- If you still continue to have Overload alarm after this checking is necessari that you try to
disasseble one part each time and try to make the test without this part to find the damage
one.
a. Remove the horn and press test. If no alarm the problem is on the horn check again
point 1 or replace the horn.
b. Open the aluminium support were is placed the booster and disconnect the booster
from trasducer. Press TEST with only the trasducer connected and if no alarm then
control the connection screw and try to lock better the booster to the trasducer (put
some grease in the between) or replace the booster.
ATTENTION: After opening the aluminium support will be necessary (before starting
production) to check the alignement and the gap between the horn and the arm.

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 SCREW CAP APPLICATOR 3.0
ALLUMINIUM SUPPORT

c. Remove again the connector of the trasducer and press test if no alarm
try to replace the trasducer.

ADJUSTING THE CAPS’ DETECTION PHOTOSWITCH ON ORIENTING

DEVICE

 This photoswitch (24) must have its yellow LED lit when the positioner is full of caps. Both LED’s
must be off when there are no caps in the positioner.

24

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4.0 WIRING DIAGRAM