OPERATING AND SPARES MANUAL

500 CANMAKER
Machine Code: 015047

B ook1
Bodym ak er
Original Instructions
 PUBLISHER

CarnaudMetalbox Engineering Limited

This manual contains confidential material included solely for
the benefit of our customers. No part of this manual may be
reproduced in any form, or by any means, without prior per-
mission in writing from CarnaudMetalbox Engineering Limited

Published by
CarnaudMetalbox Engineering Limited
Dockfield Road - Shipley - West Yorkshire - BDI7 7AY - England
Registered Office; Dockfield Road, Shipley, BD17 7AY United Kingdom, Registered in England No. 472767
Tel : +44 1274 846200 Fax : +44 1274 846201
 Declaration of Conformity CE
In accordance with EN 45014:1998

We CarnaudMetalbox Engineering Limited

Of Dockfield Road
Shipley
West Yorkshire
BD17 7AY
United Kingdom

Declares on its sole responsibility that the following equipment:

Equipment 5500 Canmakers.

Comprising:-
Model / serial number 5000 Bodymaker MK II Serial numbers 673-S to 681-S inclusive.
Model / serial number 550 Trimmer Serial numbers 384-S to 392-S inclusive.

With fundamental safety standards as per Directives and further amendments as follows:

(List of Directives)
New Approach Technical Directives
Machinery 98/37/EC
Low Voltage 73/23/EEC (as amended by 93/68/EEC)
Electromagnetic Compatibility 89/336/EEC (as amended by 92/31/EEC & 93/68/EEC)
Pressure Equipment 97/23/EC

has been designed and manufactured to the following specifications:

(List of harmonised standards and their titles)

BS EN 12100–1: 2003 Safety of Machinery: Basic Terminology, Methodology.

BS EN 12100–2: 2003 Safety of Machinery: Technical Principles.
BS EN 60204: 2006 Safety of Machinery. Electrical Equipment of Machines.
BS EN 953: 1998 Safety of Machinery. Guards. General Requirements for the Design and
Construction of Fixed and Movable Guards
BS4500 ISO Limits & Fits
BS EN 418:1992 Safety of Machinery. Emergency Stop Equipment, Functional Aspects.
Principles for Design
SI 1999 No. 2001 Pressure Equipment Regulations 1999

Company Standards
Volume 1: Materials
Volume 2: Engineering

I hereby declare that the equipment named above has been designed to comply with the relevant
sections of the above referenced specifications. The unit complies with all essential requirements
of the Directives.

Signed by

Name: Daniel Egerton

Position: Technical Manager

Done at Shipley

On 30 June 2011
OPERATING AND SPARES MANUAL

500 CANMAKER
Machine Code: 015047

B ook1
Bodym ak er
Original Instructions

CONTENTS

Preface
Section 1 Introduction
Section 2 Installation
Section 3 System Function
Section 4 Machine Controls
Section 5 Operation Procedure
Section 6 Fault Finding
Section 7 Maintenance and Setting
Section 8 Lubrication
Section 9 Proprietary Equipment
Section 10 Spares
 PREFACE

Preface

This publication has been prepared to assist in installing, operating and maintaining CarnaudMetalbox
5500 Canmakers.

The publication is divided in to two books, each containing technically informative sections aiming to pro-
vide specific information for running the machine.
Book 1 covers information relating to the Bodymaker and Hydraulic Power Pack.
Book 2 covers information relating to the Trimmer Unit and interconnecting Conveyor.

The 5500 Canmaker is of CarnaudMetalbox design and manufacture and is subject to continuous develop-
ment. This manual may therefore not reflect the very latest innovations introduced during the manufacture
of a particular machine; these will be introduced into subsequent editions at the earliest opportunity.

Machinery manufactured by CarnaudMetalbox Engineering is safe and without risk provided that it is
installed and used for no other purpose than that intended and is in good working order in accordance with
our instructions and recommendations.

This publication contains confidential material included solely for the benefit of our customers. No part of
this publication may be reproduced in any form, or by any means, without prior permission in writing from
CarnaudMetalbox Engineering plc.
 INTRODUCTION

SAFETY

ALL personnel should apply safe working proce-

dures at ALL times.

Reference to Safety herein should be applied in

conjunction with your factory procedures

INDEX: PAGE:

General Information 1
Can Travel 2
The Drive System 3
Hydraulic Circuit for Clutch and Brake Operation 4
Lubrication System 6
Coolant System 8
General Safety Notes 9

12/Feb/98
 INTRODUCTION

1.1 General Information

The 5500 Canmaker is a horizontal, heavy duty double action press integrated with a 4 head rotary trimming
unit. It is designed and built to manufacture one piece, trimmed, can bodies from pre-drawn cups, maintain-
ing extremely close tolerances over long production runs.

The basic machine operating cycle consists of a forward and return stroke of the Ram as it is draws the cup
stock through the tooling to form the untrimmed can body.
A Rotary Cup Feed mechanism places a pre-drawn cup into the Cup Holder and the initial forward motion
of the reciprocating Ram forces the cup through a Redraw Die, reducing the inside diameter of the cup.
As the Ram continues it’s stroke the cup is then drawn progressively through three Ironing Dies to reduce the
wall thickness of the cup by ironing the wall between the outside diameter of the Ram Punch and the inside
diameter of the Die Rings, this to obtain the proper gauge and desired length of can body prior to trimming.
At the end of the Ram’s forward stroke the can body is forced against a Doming Die to form the can base.

Ironed can bodies are stripped from the Punch by segmented spring action fingers and Air Strip Assist as the
Ram commences its return stroke. Complete but untrimmed can bodies are then picked up by a Discharge
Turret that accelerates them away to the Interconnecting Conveyor for processing at the Trimming Unit.

At the Trimming Unit cans are fed into a Vacuum Infeed Turret from where they are transferred to the Main
Turret and loaded via a Pusher arrangement onto one of four self centring Tooling Heads. Within the Tool-
ing, Ejector Segments conform to the profile of the untrimmed can rim and the can is held stationary whilst
a Penetrating Disc moves eccentrically against an Outer Knife, trimming the can rim in one progressive
movement. On completion of the trimming operation the can exits the 5500 Canmaker via Guide Rails.

The basic machine design is such that it functions with a minimum of operator attention and maintenance. It
contains control devices to detect and automatically stop the machine should a malfunction occur.

A typical installation comprises a 5500 Canmaker machine, Electrical Controls and Cabinet, and lubrication
Hydrolube Unit.

February 2001 Page 1-1

 INTRODUCTION

1.2 Can Travel

a. On the return stroke of the Bodymaker the Punch Sleeve and Redraw Blank Holder pull back together
until sufficiently clear of the Load Station area when the face of the Rotary Cup Feeder Cam starts to
push the incoming cup into position in the Cup Locator.
b. The Cup Feeder Cam is timed to the rest of the machine motion so that the cup is fully in position and
held by the ‘point’ of the Cam when the now forward travelling Blank Holder is approximately 1/8” clear
of the cup.

Can Body
Redraw
Die
Blank Holder

Punch
Motion
Dome Station

Punch
Sleeve
Stripper

c. The Blank Holder continues forward in advance of the Ram, entering the cup and carrying it forward
until it is just clamped against the face of the Redraw Die. At this point the nose of the Punch Sleeve
makes contact with the base of the cup in the Redraw Die. The base of the cup remains clamped between
the Blank Holder and the face of the Redraw Die throughout the redrawing operation. This is achieved
by allowing the redraw mechanism to overtravel on the constant motion Redraw Cams.
d. The Wall Ironing Punch continues its forward stroke and pushes in sequence the redrawn cup through
the first, second and third Wall Ironing Rings, which along with the Redraw Die are mounted in an as-
sembly called Cradle. Approximately sized spacers are located between the Redraw Dies and Wall Iron-
ing Rings so that the progressively elongated body cannot iron in two rings simultaneously.
e. The wall Ironing Punch continues its forward stroke pushing the wall ironed cans through the Mechan-
ical Stripper, through the Discharge Turret Pocket into the Dome Die to form the bottom profile.
f. The Wall Ironing Punch starts its return stroke and an Air Strip Assist is activated to induce air pressure
through the Ram and Wall Ironing Punch to blow the can off the Punch. A Mechanical Stripper, situated
in the Front Bulkhead, assists in removing the can from the Punch as it moves back.
g. The Discharge Turret picks the can up from the Dome Station and accelerates it away to the Discharge
Conveyor. The Turret is then positioned ready to pick up the next can.
h. The Wall Ironed Punch continues its return stroke, The Redraw Carriage is moved by cam operation
back and the Rotary Cup Feed delivers another cup and the cycle is repeated.

Page 1-2 12/Feb/98

 INTRODUCTION

1.3 The Drive System

a. The Bodymaker consists of three drive sub assemblies, all driven by the same motor. The Motor drives
the Flywheel through a Pulley and Belt system. The Flywheel transmits the drive through a Hydraulic
Clutch and Brake Unit to the Crankshaft.
b. Drive to the Ram: The main drive to the Ram is taken from the Crankshaft and Crankshaft rotation is
transmitted into Swing Lever oscillation through the Primary Connecting Rod. The Swing Lever move-
ment is transmitted to the Slide Block through a Secondary Connecting Rod. The Slide Block is precisely
guided by the Slide Ways and Front Bushing to carry the Ram in a straight line
c. Drive to the Hold Down (Redraw Mechanism): The Hold Down drive is taken from the Cams secured
to, and revolving with the Crankshaft. The Cam Levers transfers the Cam Follower movement via a link-
age system to the Hold Down Push Rods to drive the Hold Down mechanism in a reciprocating motion.
The Cam Followers are held against the Cam by two Air Spring Arrangements.
d. Drive to the Power Take-Off Shaft: A 90 degree Bevel Box mounted onto the end of the Crankshaft pro-
vides change to the axis of drive for the Power Take-Off Shaft which is supported the full length of the
machine and drives the following units:
i. Electrical Timing Unit
ii. Rotary Cup Feed
iii. Discharge Turret

12/Feb/98 Page 1-3

 INTRODUCTION

1.4 Hydraulic Circuit for Clutch and Brake Operation

8
Rotary 9 7
Joint
Hydraulic
Clutch & Brake
Coooling Oil Extent of Power Pack
11 L/Min
13 L/Min 4L
Accumulator 4
13 Precharge
EM 45BAR 45BAR
5
Cooling 3
water

Collection Tank 68BAR 6

12 2
11

11 L/Min

EM
2.2KW

HYDRAULIC CLUTCH / BRAKE CIRCUIT

1
11 L/Min
10

15
10BAR

14

75 Litres
Mobil: DTE Light VG32

There are two independent hydraulic circuits - pressure circuit and cooling circuit.
1.4.1 Description of Pressure Circuit

a. Double Pump (1).

This half of the pump delivers 11litres/min. of hydraulic oil to operate the clutch/brake at a nominal
pressure at the Hydrolube Unit of 70 BAR. Refer to instruction 1.4.2.a) for reference to double pump
(10)
b. Relief Valve (2).
This valve provides over pressure protection and diverts excess flow to the tank should its setting (70
BAR at the Hydrolube Unit) be exceeded
NOTE: No adjustment to this valve should be attempted to change the above pressure.
c. Accumulator (3).
The accumulator is required to store the high pressure oil to the clutch/brake. The nitrogen pressure
should be periodically checked and adjusted to 45 BAR. This should be done with a fully de-pressurised
hydraulic circuit.
d. Pressure Gauge (4).

Page 1-4 12/Feb/98

 INTRODUCTION

This gauge gives the system pressure of 70 BAR.Pressure Switch (5).

If the Pressure drops below 65 BAR, this switch warns of low oil pressure. Should this occur do not op-
erate the clutch/brake, find the reason for low pressure and rectify immediately.
e. Drain Down Valve (6).
This valve should be permanently closed during normal clutch/brake operation.
IMPOTANT: For maintenance on the Power Pack it is necessary to de-pressurise the oil in the circuit
by opening this valve until the gauge (4) reads zero. This should be done with the pump motor switched
off. Before re-starting the pump this valve should be completely closed.
f. Orifice (7).
This is a fixed orifice mounted in the fittings (behind the pressure safety valve (Refer to machine Hy-
draulics Assembly). This orifice is required to prevent shock waves in the hydraulics reaching and dam-
aging the clutch/brake. Under no circumstances should this orifice be removed.
g. Press Safety Valve (8).
To ensure safe operation of the clutch/brake this valve is dual solenoid operated with Limit Switches on
each Spool. Should a fault occur on either solenoid the press safety valve will not function. During this
time the brake will be applied as the oil in the cylinder is exhausted to the tank. A message display on the
machine will display `Clutch Valve Fault’.
With a fault on the Press Safety Valve it will not be possible to operate the Clutch/Brake.
h. Rotary Joint (9).
The Rotary Joint at the end of the crankshaft delivers both pressure oil and cooling oil to the clutch/
brake.
It is essential that ALL gaskets are fitted when this item is removed or replaced.
1.4.2 Description of Cooling Oil Circuit

a. Double Pump (10).

This half of the double pump is used to supply cooling oil to the clutch/brake at a flow rate 11 litre/min.
b. Filter (11).
The oil for the filter is electrically monitored to warn of a blocked filter.
c. Cooler (12).
Before the oil is fed to the clutch/brake a water cooler reduces the temperature of the oil to ensure effi-
cient removal of heat from the clutch/brake.
1.4.3 Collecting Tank
All the oil returned from the clutch/brake housing is collected and pumped back to the main pressure pack
by a motorised Scavenging Pump (13). This is controlled by a float sensor and electrical timer in the collection
tank.
1.4.4 Power Pack

The power pack for the clutch/brake has a capacity of 75 litre. A sight glass, (14) allows nominal monitoring
of the oil level, whilst a float switch, (15) gives a warning of low oil level. The oil level in the power pack will
very depending on the oil level in the Accumulator and collecting tank.
1.4.5 Oil Type

It is essential that the oil used is of the correct type. Refer to the machine Lubrication chart on the side of the
Bodymaker (also shown in this manual, Section - Lubrication).
IMPORTANT The oil should be changed periodically using the same type of oil.

12/Feb/98 Page 1-5

 INTRODUCTION

1.5 Lubrication System

3/8" I/Dia. Hose

0.030" Jet
3/8" I/Dia. Hose
0.048" Jet
3/8" I/Dia. Hose
0.022" Jet
3/8" I/Dia. Hose
0.048" Jet

Pressure
Gauge
Manifold PTO
Gearbox
Quill
Main Bearing

Main
Bearing
1/4"
1/4" I/Dia I / Dia
Hose Hose

Yoke Manifold
1/2" Dia with In-line Filter
Hose
Cam Lever Yoke Sub-Assembly Cam Lever
1 off 0.026" Jet
10 off 0.022" jets

Bearing Block (2off)

∅ 8Tube

0.038" Jet

Primary Primary
Bulkhead Bulkhead

Hydraulic Clutch / Brake

fitted to Crankshaft

Manifold
Rotary
Union

Pressure
Hydrostatic Manifold Switch
Hydrolube 3/4BSP Feed Line
Unit P4
1 1/4BSP Return Line
P8
P1 1 1/2BSP Suction Line
P9 P10 P14
Press
1/2" 1/2" 1/2" Safety
BSP BSP BSP Valve
Machine Sump
Clutch / Brake Return Line
Clutch Brake Cooling Line

Clutch / Brake Feed Line

Page 1-6 30/Aug/06

 INTRODUCTION

Lubrication System: Lubrication for the Bodymaker is provided by means of a High Pressure Lubrication
System. A separate Hydraulic Power Pack, mounted on a chassis frame and positioned adjacent to the Bod-
ymaker, provides a means for oil conditioning and recycling back to the Bodymaker.

MACHINE CLUTCH

BODYMAKER
Clutch
Actuation

SUMP SUMP Pump

Clutch
Cooling
High Filter
Pressure
P1
Cooler
P10

P4
P9
P14

SUMP SUMP

HYDRAULIC POWER PACK

From the Power Pack ‘Clean’ Sump clean and thermostatically controlled cooled oil is pumped 76litres/min.
(20gpm) through a Filter to the Bodymaker. A Manifold Block on the side of the Bodymaker Crankcase di-
vides the system into two, and at this point the pressure is monitored and Safety Switches incorporated to
protect the system.

From this Manifold one High Pressure line is taken into the machine via the Swing Lever to lubricate the Pri-
mary Conn Rod Small End Bearing and also the Slide Block Hydrostatic Pads, ensuring that there is no metal
to metal contact between the Slide Block and Slideways.

A second line is taken via a Pressure Gauge Manifold on the Motor Mount Side Plate (Power Take-Off side
of the machine) from where the system is again divided to lubricate the Front Hold Down Push Rod Bearings
and Power Take-Off Gearbox, The Cam Levers, Crankshaft Main Bearing, Quill Main Bearing, and via the
Crankshaft, the primary Connecting Rod Big End Bearing.

Dirty’ oil is pumped from the Bodymaker back to the Power Pack where it is then pumped, 92litres/minute
(24gpm), through a Filter and Oil Cooler into a Pressurised Tank (‘Clean’ Sump).

Notes:
i. For recommended lubricants and additional manual oil and grease lubrication, refer to this man-
ual - Lubrication Section.
ii. For Hydraulic Power Pack additional information and General Arrangement Drawing refer to this
manual - Proprietary Equipment.

30/Aug/06 Page 1-7

 INTRODUCTION

1.6 Coolant System

As applied to a Wall Ironing machine the term `Coolant’ means both a lubricating and temperature control-
ling liquid.

A relatively small percentage of lubrication is needed for the Drawing and Wall Ironing process whereas a rel-
atively large percentage of water is needed to dissipate the extreme heat generated in the Wall Ironing process.

Considerably more heat is generated in wall Ironing steel cans than aluminium cans. Therefore more ‘Cool-
ant’ is needed for steel - meaning more litres per minute, but not necessarily a high percentage of lubrication
material.

The coolant is supplied to the Bodymaker from a Conditioning Unit. The constant flow of coolant through
the tooling keeps it at a constant temperature. CONSTANT temperature is much more important than EX-
ACT temperature.

The Wall Ironing Punch and Wall Ironing Rings expand when heated - as do most metals.

The Coolant limits, or controls, the amount of expansion by keeping the heat of the tooling constant. Even
so, there is a slight expansion of the tooling between Wall Ironing the first can and the 5th and 6th cans. Dur-
ing that time, heat is generated above temperature of the Coolant but quickly levels off as the Bodymaker con-
tinues to run.

Recommended Coolant flow : Refer to machine installation drawing supplied with the machine (this manual
Section 2 refers.

Page 1-8 12/Feb/98

 INTRODUCTION

1.7 General Safety Notes

1.7.1 Accident Prevention and Safety are not only the responsibility of Managers and Supervisors but each individ-
ual person.

1.7.2 Safety is everyone’s business.

1.7.3 Accidents can be caused by unsafe procedures and / or unsafe conditions. The Factories Act and Health and
Safety at Work Act lays down certain regulations and legislative framework to promote, simulate and encour-
age high standards of health and safety at work.

The majority of all accidents are caused by human error.

1.7.4 Apart from the cost to the Company and the nation as a whole, the effect on the victim can be considerable,
i.e. loss of income, loss of faculty, additional expenditure, personal suffering, the detrimental effect on
dependants, and the effect on the victim’s social life such as the restriction of hobbies and sporting activities.

1.7.5 Prior to working on the machine, the following precautions must be taken:-

Shut down the machine Hydraulics. For some maintenance work it may be necessary to momentarily turn on
Electrical power and Air Pressure supplies to the machine. Ensure personnel are aware of what is intended
and that they are clear of the machine before power is turned on.

As additional precaution against accidental Start Up, WARNING TAGS should be attached to appropriate
Machine Controls and Valves. Such Tags should be clean and should not be left on the machine when their
purpose is fulfilled.

Take note of any operation associated with any potential hazard. These are highlighted with Safety Name-
plates fitted on the machine.

Before operating the machine ensure that:-

a. All Guard Doors and Covers are securely fixed in position.
With exception of the Power Take Off Guards DO NOT use any other guard to stand on.
b. All Automatic cut - out are operating correctly.
1.7.6 Additional Checks to ensure that a safe system of work prevails are:-

a. That all worn nuts and bolts are replaced.

b. That all spanners and other tools are in good condition, that the correct spanner or tool is used, and that
after use they are not left on the machine, but returned to their correct places.
c. That electrical cables and equipment are correctly insulated and earthed
d. That low pressure air only is used in the correct manner, for cleaning purposes. Eyeshields must be
worn.
e. That all obstructions are removed from the floor area.
f. That the floor area is free of grease and oil.
g. That the gangways are kept clear and used correctly.
h. That all Fire Exits are known and kept clear.
i. That all fire hazards are removed.
j. That hair styles are not a hazard to safety
k. That loose clothing and ties are tucked in.
l. That Safety Spectacles are worn
m. That suitable safety footwear and gloves are worn
n. That large rings and watches are removed.
o. That hearing protectors are worn when necessary.

12/Feb/98 Page 1-9

 INTRODUCTION

p. That other peoples safety is being considered.

1.7.7 Refrain from irresponsible behaviour and running in the factory.

1.7.8 DO NOT become complacent due to familiarity with your work.

Common sense and good housekeeping are important features in safety; avoid makeshift methods of any de-
scription.
1.7.9 All the rules. regulations and facilities provided to aid safe working conditions fail if people’s attitudes are not
receptive to the standards laid down.

1.7.10Report all accidents to the Surgery immediately.

Page 1-10 12/Feb/98

 INSTALLATION

SAFETY

ALL personnel should apply safe working proce-

dures at ALL times.

Reference to Safety herein should be applied in

conjunction with your factory procedures

INDEX: PAGE:

Installation Drawing 1
Siting the 5000 Bodymaker 3
Services 4
Receipt of the Crated 5500 Canmaker 5
Off Loading and Handling 6
Bodymaker, Conveyor and Trimmer Unit Installation 8
Installing the Bodymaker on its Foundation 8
Levelling the Bodymaker 10
Cleaning 12
Electrical Cabinet Connection 12
Operator Console Connection 12
Compressed Air Connection 12
Coolant Connections 12
Vacuum Connection 12
Installation and Connection of Hydrolube Unit. 13
Hydraulic Clutch and Brake 14
Recommended Checks - Electrical 15
Recommended Checks - Mechanical 18

12/Feb/98
 INSTALLATION

2.1 Siting the 5000 Bodymaker

CarnaudMetalbox Engineering are able to provide drawings showing a recommended foundation inertia
block for the machine, together with a method of securing the machine to this block. However, many cus-
tomers prefer to use their own design of foundation.

The preparation and thickness of the concrete around the foundation will depend on the sub-structure of the
siting. If in doubt seek expert advice.

It is suggested that the foundation is prepared at least two weeks prior to machine installation to allow the
concrete to harden sufficiently.

The site should be planned in advance to accommodate the complete 5500 Canmaker System which includes
the machine itself (Bodymaker and Trimmer), Hydrolube Unit, and Electrical Control Cabinet.

12/Feb/98 Page 2-3

 INSTALLATION

2.2 Services

The 5500 Canmaker requires electrical power, compressed air, cooling water and coolant as specified in the
following sections. (Refer to Installaion drawing for service connections)
2.2.1 Electrical Power

The 5500 Canmaker system comprises a total electrical power load of 85Hp. AC supply.

Electrical wiring and connections must be in accordance with specifications contained in the National Stand-
ards of the country concerned.
2.2.2 Compressed Air

Compressed air is required to operate the 5500 Canmaker system. The pneumatic system incorporates filters,
regulators, and lubricators to perform the required processing.
Air Supply is required for:-
a. Bodymaker: Supply from a regular ‘shop air’ system is satisfactory provided that a constant flow of 65
SCFM at 90psi (1.85m3/min. at 6.2 bar) is assured. Special filtering of the air supply is not required.
The components served are:
i. Hold down front and rear air bags.
ii. Air strip assist.
iii. Seal pack bleed-off.
iv. Guard interlock catches.
v. Cup stop piston.
vi. Toolpack clamp ring (if fitted).
vii. Dome station pistons (depending on Domer design).
b. Trimmer: Supply from a regular shop air system is satisfactory provided that a constant flow of 50 CFM
at 80psi (1.42m3 /min. at 5.5 bar) is assured. special filtering of the air supply is not required.
The components served are:
i. Trimmer Tooling Trim Ring ejection.
2.2.3 Vacuum

Factory Vacuum required for satisfactory operation is 43 CFM at 22” HG. Vacuum is required for:
a. Bodymaker/trimmer: Interconnecting Conveyor
b. Trimmer: Can Stop, Infeed Turret and Pusher.
2.2.4 Cooling Water

The Hydrolube Unit which supplies the hydraulics system on the Canmaker, requires cooling water to main-
tain the correct oil temperature.

The cooling water requirements are 56 litres/min. at 30˚C (14.8 US gallons/min. at 86˚F).

The cooling water is used as follows:

a. 50 litres/minute for cooling machine oil
b. 6 litres/minute for cooling clutch and brake oil
2.2.5 Coolant

The 5500 Canmaker requires a constant flow of coolant 80 - 120 litres/min. at 40˚C (21 - 32 US gallons/min.
at 104˚F). Special treatment of the coolant, other than standard industry practice, is not required.

Page 2-4 12/Feb/98

 INSTALLATION

2.3 Receipt of the Crated 5500 Canmaker

The 5000 Bodymaker is prepared at Carnaud Metalbox Engineering Factory for shipment by commercial
freight carrier.

The equipment will generally be supplied in three cases:

a. Bodymaker
b. Trimmer complete with Interconnecting Conveyor and Bodymaker/Trimmer Link Guarding
c. Hydrolube Unit
d. Electrical Control Cabinet
2.3.1 Bills of Lading

These should be checked thoroughly when the shipment arrives at the customers plant and any discrepancy
notified to CarnaudMetalbox Engineering immediately.

12/Feb/98 Page 2-5

 INSTALLATION

2.4 Off Loading and Handling

All procedures relative to the Off Loading and siting and subsequent handling of the Bodymaker system com-
ponents are the responsibility of the customer or his duly authorised receiving agent
2.4.1 5500 Canmaker Installation Notes

IMPORTANT: New 5000 Bodymakers are supplied with covers (1) and (2) fitted at the Bodymaker cup infeed
and interconnecting conveyor mounting point. These covers, painted red, must not be removed until ready
to connect the Factory Cup Infeed and Interconnecting Conveyor.

Infill Panel (3) fitted at the Trimmer discharge must not be removed until ready to link to the factory track-
work, when it will need to be removed and modified/replaced to suit this trackwork.

The interface between the machine and trackwork must be correctly guarded to comply with the National
Safety Standards of the country concerned. This is the responsibility of the customer.

NOTE: The Trimmer Unit has been supplied as part of the 5500 Canmaker and until it has been correctly in-
stalled (instruction 2.14 refers) it will not be completely guarded. attempts therefore MUST NOT be made to
run this unit as a separate machine.

‘A’
2

Bodymaker

Side View with Trimmer not shown

3
1

Bodymaker

Plan View on ‘A’

Trimmer

Page 2-6 October 2007

 INSTALLATION

2.4.2 Lifting Instructions - Bodymaker (Lifting Equipment illustration refers)

The Bodymaker will normally be supplied with Lifting Beam, Chain and Shackles and Lifting Backplate.

There are four lifting points on the machine, two on the Lifting Backplate which should be attached to the
Crankcase between the Motor and rear of the Guards and other two via Shackles screwed into holes in the
top of the bed inside the Front guarding.

Circular Covers in the top of the Front Guarding need to be removed to gain access to the Shackle on the Can
Discharge side of the machine, and on the operator side the sliding door is required open (Secure in open
position) to enable connection of a Lifting Pillar.

Note: Before lifting the machine secure the front hinged guard in its closed position.

The Lifting Beam is adjustable so that the machine can be balanced with the lifting point over the centre of
gravity. The Flywheel offsets the centre of gravity of the machine quite significantly and the centre is towards
the Rear/Flywheel side. The Beam should be positioned with its Lifting Eye over this region. When setting the
machine down either onto the foundation or alongside it ensure that the levelling plates are placed under each
foot of the machine.

Lifting Beam
Safe working load (S.W.L.)2000 Kg 2 Off
4 Off
‘D’ Shackles ‘D’ Shackles
5000kg S.W.L 1000kg S.W.L

4 Off
Shortening Clutches
4 Off
Safety Hooks

4 Off
‘D’ Shackles
5000kg S.W.L

‘B’
View on ‘A’

Front Hinged Guard must be Secure Sliding door in

secured in closed position open position, for access, Leveling
when lifting the machine when lifting the machine Plates

Approximate Nett Weight:-

19” Stroke 5000 Bodymaker = 10650 Kg
21” Stroke 5000 Bodymaker = 11635 Kg
Lifting To access Lifting point 575mm Stroke 5000 bodymaker = 11635 Kg
Plate remove circular cover 26” Stroke 5000 Bodymaker = 11650 Kg
plates over guards
Lifting
Pillar

Crankcase

View ‘B’
‘A’
2 off
M30 x 80
Hex Hd Screws

October 2007 Page 2-7

 INSTALLATION

2.4.3 Lifting Instructions - Interconnecting Conveyor and Trimmer

The Interconnecting Conveyor can be lifted by hand. two people are required to lift it into installation posi-
tion.

The Trimmer (approximate nett weight: 1600Kg) should be lifted and manoeuvred into its installation posi-
tion using a Fork-Lift Truck

Refer to installation instructions 2.5

2.5 Bodymaker, Conveyor and Trimmer Unit Installation

The 5500 canmaker is supplied as two units, a Bodymaker and a Trimmer complete with Interconnecting
Conveyor for taking cans from the discharge of the Bodymaker to the Trimmer Infeed.

Once the Bodymaker has been correctly installed (instruction 2.6 refers), the Trimmer and Interconnecting
Conveyor can then be fitted to the Bodymaker.
a. Position the Trimmer with Interconnecting Conveyor and link Guarding in its correct location in rela-
tion to the Bodymaker (refer to machine installation drawing for machine weights). Use a Fork-Lift
Truck to move the Trimmer and once positioned adjust the Trimmer levelling screws to give height re-
quirement.
b. Secure the Trimmer/Bodymaker Link Guarding to the Bodymaker.
c. Check the setting of the Trimmer Infeed Guides (canmaker Book 2, Section 4 refers)
d. Adjust the Conveyor Chain tension to remove slack. Do Not over tighten.
e. The flexible vacuum hose to the trimmer Infeed Turret will have been removed prior to despatch and
will require refitting. Connect the hose from the Vacuum Pump to the Air Duct on the Trimmer. secure
in place with jubilee clips.

2.6 Installing the Bodymaker on its Foundation

The site should have been pre-prepared with 10 foundation bolts set into the floor for fastening the machine
to the foundation (one bolt for each foot of the machine).

Before lifting the machine onto the foundation ensure that a levelling pad is placed over each foundation bolt
with the dished recess uppermost to locate the feet of the machine.

Place the machine carefully onto the foundation so that the foundation bolts pass up through the centre of
each foot. Fit the special washer and two retaining nuts (supplied with the machine) to the top of the bolts
protruding from each foot but do not tighten the nuts until the machine has been levelled (instruction 2.7
refers.

Page 2-8 October 2007

 INSTALLATION

2.7 Levelling the Bodymaker

The Bodymaker must be levelled lengthways and from side to side to within 0.0005” per foot.

The machine should be levelled when cold using the Slideways as reference points. To take readings length-
ways use a precision spirit level on the ground surfaces of the Slideway side blocks (illustration refers).
Do not use the upper rails attached to the top of the Slideways as these are not ground flat. To take readings
from left to right, place a precision parallel on each slideway side block to allow the spirit level to span the
Slideways.

Caution : if the Slide Yoke needs to be moved at anytime, a liberal film of clean machine oil should be applied
to the contact areas before moving the Yoke. Movement of the Yoke should be kept to a minimum under
these conditions to avoid damaging the Slideways or Hydrostatic Pads.

Before making adjustments to the machine level ensure that the Bodymaker is sitting only on the 4 corner
adjusting screws and that these are seated properly in the levelling pads. The 6 centre adjusting screws should
be backed off so they are not carrying any of the weight. At this stage check that the machine is sitting at the
correct height above the floor level. This is important to ensure that any mating machinery and trackwork
align correctly. The height of the machine can be changed by adjusting the four corner screws by the same
amount. If this is done, ensure that the 6 centre screws remain free of any load.

Use the spirit level to take preliminary readings.

Determine which Bodymaker corner is the lowest and turn that adjusting screw clockwise to bring the corner
up. Continue to take readings in both directions and adjust the low-point screws until the machine is levelled
to the required accuracy.

Turn six centre adjusting screws down until they seat in the levelling pads. Tighten the screws firmly until
they take their share of the Bodymaker weight. Caution : To avoid loading the centre screws excessively and
disturbing the machine level attitude, use extreme care when tightening the centre screws.

Take final level readings along both slideways and across the slideways at both ends. If necessary, reposition
all six adjusting screws to level the Bodymaker laterally and longitudinally within 0.0005 inch per foot. When
taking final readings, turn the level end-for-end at each location to verify indication accuracy.

When satisfied that the correct machine level has been achieved, tighten the retaining Hex Nuts securely onto
the top of each foot. Tighten the second Lock Nut down onto the first Nut. Take machine level readings to
verify that machine level attitude has not changed. If readings do not repeat, loosen Hex Nuts and reposition
Adjusting Screws as required to bring the Bodymaker back to level. Tighten the Hex Nuts.

NOTE: After the machine has been in operation for six months or less, the level of the machine should be ver-
ified and the security of the floor studs and nuts be assured. This inspection should be performed at least every
six month. Unless there is evidence to suspect that the level is regularly being lost the level need only be
checked once a year. It is more important that the Anchor Bolts and Restraint Brackets are secure to prevent
machine vibration. If the level is checked it should be done with the machine oil at room temperature, this
may require the oil pumps to be turned off for a few hours.

Page 2-10 12/Feb/98

 INSTALLATION

Levelling the Bodymaker

Note: Level the machine cold Spirit level readings to
be taken in 8 places as shown
Each reading is to be within
Parallel 0.0005” per foot

Parallel Parallel

CL
Slideways
(Front Elevation)

1 4

7 Parallel

Parallel

2 5
Parallel

3 6

CL Slideways
(Plan View)

12/Feb/98 Page 2-11

 INSTALLATION

2.8 Cleaning

All brush coated (anti-corrosive) surfaces require cleaning; check all surfaces and clean as necessary with an
approved solvent, (e.g. Mobil Sevasol No. 5 or equivalent).

Care is needed with cleaning agents on the guarding. No chemicals should be allowed to contact the windows,
which are of polycarbonate material, as staining will occur.

It is advised that the interior of the Bed and Crankcase are washed using an air pressure wash gun and suitable
solvent to remove any debris which may have accumulated during shipment. Make sure all traces of solvent
are removed after spraying.

CAUTION

Most effective cleaning solvents are toxic when inhaled or ingested and prolonged skin contact can be harm-
ful. It is recommended that personnel working with strong solvents wear protective clothing, breathing
masks, eye protection and rubber gloves. These solvents are combustible when exposed to an open flame,
sparks or excessive heat and should be used only in an open well ventilated area. Situations that could initiate
combustion must be avoided

2.9 Electrical Cabinet Connection

The Control Cabinet should be permanently wired to the machine Main Junction box, using a suitable meth-
od which meets local and National Safety Standards and any other applicable standards. At all times refer to
the most current Electrical Schematics.

2.10 Operator Console Connection

The Operator console should be permanently wired to both the Machine Main Junction Box and Control
Cabinet using methods as above. The Console does not require to be connected to the factory power supply.

2.11 Compressed Air Connection (Installation Drg. at the start of this section refers)

Fittings are provided on both the bodymaker and trimmer for air connection. A standard 1” BSP (Female)
fitting is provided beneath the side guard on the can discharge side of the bodymaker and standard 1/2” BSP
(Female) fitting provided to the rear of the Trimmer Guarding. Connect the facility plumbing to the inlets
and check for air leaks.

2.12 Coolant Connections (Installation Drg. at the start of this section refers)

The 5000 bodymaker requires a constant flow of coolant through the Toolpack while making cans (120 litres/
min. at 40˚C or 32 US gallons/min. at 104˚F). The coolant feed connection is situated on the can discharge
side of the machine just behind the discharge point. The connection is 1” BSP (Female).

Coolant is drained from a collecting sump situated at the front of the machine under the Dome Station. The
drainage outlet is a 102mm (4”) o/d pipe to which a suitable connection should be made to take coolant away
for recycling.

2.13 Vacuum Connection (Installation drg. at the start of this section refers)

A 1” BSP (Female) fitting is provided on top of the trimmer guarding. Connect the factory vacuum and check
for flow rating of 80 CFM at 22” HG.

Page 2-12 03/Oct/00

 INSTALLATION

2.14 Installation and Connection of Hydrolube Unit.

The Bodymaker has an independent hydraulic power pack which supplies all hydraulics on the machine. This
is referred to as the Hydrolube Unit. The Hydraulic systems supplied by the unit are the machine’s low pres-
sure lubrication system, the Hydrostatic Bearings, Ram Bushes & Slideways and the Hydraulic Clutch/Brake
Unit.

The Unit will be supplied with all hoses required for connection to the Bodymaker. There are 7 hoses in total
and these should be connected as shown on the Installation Drawing. A general arrangement drawing of the
Hydrolube unit is also given in Section 9 of this manual. The precise positioning of the Hydrolube Unit rel-
ative to the machine will depend on customer preference and the length of the hoses will have been tailored
to best suit the position chosen.
2.14.1Cooling Water Service to Hydrolube Unit

The Hydrolube Unit requires a supply of Cooling Water (56 litres/min. at 30˚C) to control the temperature
of the oil. Water ‘in’ should be plumbed into connection P6 and water ‘out’ into P7 (see Installation Drawing).
Both connections are 1” NPT Female). If ordered these will be supplied as 1”NPT (Female)
2.14.2.Electrical Connection to Hydrolube Unit

The Hydrolube Unit should be permanently wired to the Electrical Control Cabinet, using a method which
meets local and national safety standards and any other applicable standard. At all times refer to the most cur-
rent Electrical Schematics.
2.14.3.Filling Hydraulic System

The machine Hydraulics use two oils.

The machine Crankcase and main Hydrolube tank are filled with oil used for the general machine lubrication
and for the Hydrostatic Slideways and Ram Bushes.
The Hydraulic Clutch/Brake and Flywheel Bearings have an independent oil supplied from a smaller tank sit-
uated on the front of the Hydrolube Unit.
To fill the Crankcase and Main Hydrolube tank proceed as follows.

Fill the Crankcase to a level of 350mm from the bottom of the Crankcase. Check direction of rotation of the
circulating pump on the Hydrolube unit and switch on to draw oil from the machine sump into the Hydrol-
ube Tank. Add oil to the Crankcase as tank is filling to compensate for the drop in oil level. Ensure at all times
that the oil level does not drop below the level of the suction pipe to prevent air being drawn through the
pump. The system is self bleeding but if necessary air can be bled from the tank via the plug fitted on top.
Approximately 455 Litres of oil will be required in total.

To fill the Hydraulic Clutch/Brake system, fill the small tank (capacity 75 litres) on the front of the Hydrolube
Unit to the maximum oil level mark. Check direction of rotation of the Clutch supply pump on Hydrolube
Unit and switch on to fill the system. The system is self bleeding but the tank will need to be topped after the
pump has run.

NOTE:
For additional information on installation of the Hydrolube Unit refer to this manual Section 9 - Proprietary
Equipment in this manual

For the Oil specifications refer to this manual Section 8- Lubrication

03/Oct/00 Page 2-13

 INSTALLATION

2.15 Hydraulic Clutch and Brake

The recommended operating pressure for the Clutch and Brake unit is 70 bar (1015psi).
Reduced pressure (below 65bar) will result in reduced clutch performance and increased clutch plate wear.
Pressure can be adjusted by the on line pressure relief valve on the Clutch and Brake Power Pack Tank.

Page 2-14 03/Oct/00

 INSTALLATION

2.16 Recommended Checks - Electrical Comments:

Warning:

Contact with sources of Electrical Energy can cause death or serious

injury. Only trained personnel who understand these dangers and the
precautions which must be taken to avoid them should carry out work
on the electrical systems of this or any other machine. the main dis-
connect feeding the control panel should be locked off during any
maintenance operation. Use safe working practices at all times.
2.16.1Static Checks

Carry out these checks with the Main Disconnect locked off

NOTE: It is assumed that the Control Panel has been fully tested after
manufacture and therefore this section does not include a full set of
checks on the Control Panel.
1. Machine and Control Panel:
Check that the machine and Control Panel have not been dam-
aged during transit or installation.
2. Protection:
Check that the incoming terminals of the Main Disconnect are
shrouded to prevent accidental contact.
3. Installation Wiring:

Check that all the wiring has been correctly installed according
to all the drawings, standards and specifications as applicable.
Pay particular attention to the sizing of power conductors and
ground wires.

Ensure that all connections are correctly numbered and tight.

Ensure as far as possible that there is no damage to insulation of

wiring.

Depending on local practice it may be advisable to test the Phase

to Phase’ and ‘Phase to Ground’ resistance of all power cables, or
obtain satisfactory proof from others e.g. The Installation Con-
tractor) that this has been done.
4. Door Interlocks

Check that the Control Panel Door Interlocks operate correctly,

but can be defected by the use of a tool.
5. Motor Circuit Breakers/Overloads

Record the full load current on each Motor Nameplate, and en-
sure that all thermal protective devices on the Control Panel are
correctly set. Comments
2.16.2Checks with Power applied

1. Keep the Main Disconnect locked off at this stage.

Open all circuit breakers in the control panel and remove 480v
fuses (if any).

12/Feb/98 Page 2-15

INSTALLATION

Check the incoming supply voltage, and if appropriate, phase ro-

tation. If this is correct, the Main Disconnect may now be closed.

proceed through the panel in a logical order closing those circuit

breakers associated with AC & DC control voltage supplies.
Check and record the value of all AC & DC control voltage, ad-
justing transformer tappings and DC power supplies if neces-
sary.
2. Safety Circuits

Check that the circuits involved with personnel safety operate

correctly, i.e.:-
a. Emergency Stops
b. Guard Switches
3. PLC Input/Output Checks

NOTE Lock off all Motor Circuit Breakers before proceeding.

Without putting the PLC into RUN operate all the devices on the
machine (push-button, limit switches, proximity sensors etc.) in
order to check that they operate correctly and the signals reach
the PLC input cards.

Check, if practicable at this stage, that all PLC controlled output

devices on the machine operate correctly.
4. Motor Checks

Close motor circuit breakers and briefly operate each contactor

to check direction of rotation.
5. Variable Speed Drives

NOTE: Remove Drive Belts to guard against Machine rotation.

Set up variable speed drive as for as possible at this stage. It may

not be possible to complete this until the machine is running and
able to process cans.
6. PLC Program Checks

Having carried out the above checks to ascertain as far as possi-

ble that all the hard wired systems operate correctly, load the
PLC program and switch the PLC to ‘RUN’.

The PLC program may already have been ‘bench tested’ or prov-
en elsewhere. The engineer responsible should use his discretion
in deciding which tests should be repeated.

NOTE: Before fitting the Main Motor Belts and running the ma-
chine, the lubrication system must be checked to ensure it is op-
erating correctly. Visual checks for oil should be made, to ensure
that the electrical monitoring system is working correctly.

A full test would include:

Fault Simulation:

Page 2-16 12/Feb/98

 INSTALLATION

Simulate every fault that is detected by the PLC program, check

that the appropriate message is displayed in each case, and that
the machine responds appropriately to the fault.
a. Recirculating Pump Overload tripped Main Pump Over-
load tripped Clutch Pump Overload tripped Scavenger
Pump Overload tripped Main Motor over-temp.
b. Sump low level Lubrication Oil under temp Lubrication
Oil over temp.
c. Low Pressure Hydrolube Filter Switch fault Low Pressure
Hydrolube Filter blocked High Pressure Hydrolube filter
Switch 1 fault High Pressure Hydrolube Filter Switch 2
fault High Pressure Hydrolube Filter blocked Clutch Oil
Filter Switch fault Clutch Oil Filter blocked Lubrication
High Pressure Warning Switch fault Lubrication High
Pressure Off Switch fault Hydrolube Pressure below 985psi
Hydrolube Pressure below 1085 psi
d. Clutch Oil Level Low Clutch Oil Pressure Low
e. Low Pressure Lubrication Switch fault Low Pressure Lubri-
cation below Pressure Emergency Stop Button Operated
Flywheel Motion Sensor fault Clutch solenoid fault Motion
or Timing Unit fault Cam Follower Air Pressure Switch
fault Bar Air Pressure Switch fault Main Air Pressure low
Cam Follower Air Pressure low Bar Air Pressure low
f. Toolpack Lid open Toolpack Lid not clamped Sliding
Guard open Front Left guard open Front Right Guard open
Slideway Guard open Flywheel Guard open Swing Lever
Guard open Discharge Guard open Dome Door open
g. Coolant Flow Switch fault Coolant Flow fault
h. Short Can Sensor not calibrated (If applicable),
Short Can,
Can Jam/Short Can Sensor fault.
i. Infeed Low level
Infeed Reverse Cup
Discharge Gate jam
Trimmer stopped
Line Control stop.
7. Normal Operation

Check the machine in normal operation in each of its operation

modes:-

BAR INCH SINGLE STROKE CONTINUOUS

Ensure that it responds correctly to System Start and Stop Com-

mands and the Line Control Interlocks.

Check that the Flywheel Guards cannot be opened unless the

Flywheel is at rest, and that none of the other guards can be
opened if the Clutch is engaged.

Check particularly those systems which detect Jams or Lubrica-

tion failures.

12/Feb/98 Page 2-17

INSTALLATION

2.17 Recommended Checks - Mechanical Comments:

2.17.1Visual Inspection of Installation

Check that the following have been completed:

1. All electrical connections to the Machine, Cabinet, Console and
Hydrolube Unit.
2. Hydraulic connections between Machine and Hydrolube Unit.
3. Cooling water connections to Hydrolube Unit.
4. Air and coolant connections to the machine.
2.17.2Cleaning the machine

1. Use an approved solvent (Mobil Sevasol No. 5 or equivalent) to

remove any anti-rust compound from bare metal surfaces.
2. Remove any debris from interior of the machine and wipe inter-
nal surfaces.
3. Clean exterior of the machine.

NOTE: Grit and debris in the machine may cause damage to internal
components and should be avoided.
2.17.3Flushing of Lubrication system

NOTE: Movement of the Yoke Slide Block in the Slideways and the
Ram in the Hydrostatic Bushes should be avoided if the hydrostatic
oil is not flowing. If movement of these components is necessary, a
liberal film of oil should be applied to the contact surfaces.
1. Remove filter from the manifold block on the Yoke Slide. (1 re-
quired. Refer to Swing Lever Assembly) and before starting any
pumps disconnect the oil pipes from the main bearings, the oil
supply pipe to the yoke slide (tie down pointing down into the
machine) and the supply pipes to the front bushings.
2. Check the condition of all filters on the Hydrolube Unit, replace
if necessary.
3. Check direction of rotation of the Hydrolube Circulating Pump.
4. Start the Circulating Pump and check the system for leaks.
5. Check that the level of oil is 350mm above the bottom of the
Crankcase.
6. Check direction of rotation of Hydrolube Main Pumps.
7. Start Main Pump and check system for oil leaks.
8. Leave both pumps running for 30 minutes to flush out oil ways.
9. Shut down both pumps and reconnect all pipes.
10. Start Circulating and Main Pumps and check for leaks at Lee Jet
points. Leave pumps running to warm oil.
11. The temperature Control Unit should be set as follows:
a. Temperature control level 45˚C (113˚F)
b. High level alarm 55˚C (131˚F)
c. Low level alarm 35˚C (95˚F)
12. Check that the cooling water solenoid opens at 45˚C and main-

Page 2-18 12/Feb/98

 INSTALLATION

tains this temperature.

13. When oil is up to temperature, ensure that the circulating pres-
sure is at 50psi and main pressure at 1500psi.
14. Leave Circulating Pump running continuously to maintain oil
temperature
15. Arrange for Low Pressure Lubrication Pump on the machine to
be started independently of Main Drive Motor.
16. Start Low Pressure Pump and check the low pressure system for
oil leaks.
17. Check that oil is flowing at the following points:
a. Crankshaft Main Journals
b. Primary Con Rod Big End.
c. Cam Follower Pins
2.17.4Machine Setting and Alignment Checks

NOTE: See Section 7 (Maintenance and Setting) of this manual for de-
tailed checking and realignment procedures.
1. Install Punch on Ram Spigot.
2. With Main Hydrolube Pump running, check Tool Cradle cen-
trality and squareness. Realign if necessary.
3. Check Cradle height.
4. Check alignment of Redraw Sleeve and squareness of front face.
5. Check setting of Cup Locator.
6. Check Cup Feed Cam timing and clearance relative to the cup.
7. Check Stripper alignment (if relevant).
8. Check Domer alignment
2.17.5Primary Operational Checks

Ensure that the following are operational.

1. Tool Pack Clamp Ring (if fitted).
2. Toolpack Coolant Flow.
3. Bar Mode functions.
4. Cup Feed Torque Limiter.
2.17.6Starting Main Drive Motor

1. Check tension of Main Drive Belts.

2. With Circulating and Main Hydrolube Pumps running, ensure
that the `Start Main Drive” message is displayed.
3. Switch Speed Selector to low speed and start Main Drive.
4. Check operation of high speed drive.
5. Check electric breaking of Drive Motor and ensure that Flywheel
Guard Door cannot be opened until Flywheel has stopped turn-
ing.

12/Feb/98 Page 2-19

INSTALLATION

2.17.7Basic Machine Operations

Check that the following functions are operational:

1. Inch Mode
2. Single Stroke - Slow speed.
3. Single Stroke - High speed.
4. Continuous Operation Mode - Low speed
5. Continuous Operation Mode - High speed
6. Backstop position
2.17.8Safety Checks

Check the following safety and fault detection features. Where rele-
vant ensure that appropriate fault message is displayed.
1. Safety Interlock Catches.
2. Guard Safety Switches.
3. Die Cover open (if relevant).
4. Short can.
5. Dome Door open.
6. Low pressure fault on High and Low Pressure Lubrication Sys-
tems.
7. Hydrolube Filter blocked.
8. Oil Sump level low.
9. Main air pressure low.
10. Rear Hold Down pressure low.
11. Flywheel Motion Detector.
12. Emergency Stop.
13. Electrical failure.
2.17.9Control Settings

These will depend on various factors including machine speed but the
following settings are good starting points.
1. Doming Hold Down 60psi.
2. Air Strip Assist 40psi.
3. Cup Hold Down 40psi
4. Main Air Pressure 85psi
2.17.10Die Progression Checks

1. Install Toolpack and allow coolant to flow for a few minutes to

heat the Tooling
2. Take a set of Die progressions.
3. Measure wall thickness and can length at each progression.
4. Ensure that ironing is not taking place in more than one Die at a
time.

Page 2-20 12/Feb/98

 INSTALLATION

2.17.11Can Quality - Continuous Operation

Check the following at low and high speeds.

1. Thickwall and Thinwall variation
2. Can length
3. Flatness of untrimmed can edge.
4. Roundness of cans.
5. Scratching - internal and external.
6. Wrinkles or saw tooth edges at open end of can.
7. Dome depth and quality.

12/Feb/98 Page 2-21

 SYSTEM FUNCTION

SAFETY

ALL personnel should apply safe working proce-

dures at ALL times.

Reference to Safety herein should be applied in

conjunction with your factory procedures

INDEX: PAGE:

Forward Stroke 1
Return Stroke 1
Operation Modes 2
Stopping the machine 3

February 2009
 SYSTEM FUNCTION

System Function

Barring
Tool

Guards Unlock
Bar Motor Start System Start / Inch System Reset Bar Run Bar

BAR SYSTEM GUARDS UNLOCK BAR

MOTOR START SYSTEM RESET
START/INCH BAR RUN

RGEN
ME
MOTOR STOP SYSTEM STOP CUP FEED SINGLE STROKE
INCH CONT

CY
E
S TOP
Emergency Stop

Motor Stop System Stop Cup Feed Single Stroke

Inch Continuous

System Function: The Bodymaker machine forms one-piece aluminium or steel can bodies from pre-drawn
cups.

The operating cycle consists of forward and return stroke of the Ram as it is draws the cup stock through the
tooling to form the can body.

3.1 Forward Stroke

The initial forward motion of the reciprocating Ram, forces a pre-drawn cup through a Redraw Die to reduce
the inside diameter of the cup.

As the Ram continues its stroke, the cup is drawn through three progressive Ironing Dies to reduce the wall
thickness, by ironing the wall between the outside diameter of the Ram Punch and the inside diameter of the
Die Ring, to obtain the proper gauge and desired length of can body.

3.2 Return Stroke

Ironed can bodies are stripped from the Punch by segmented spring action stripper fingers and an Air Strip
as the Ram commences its return stroke.

The completed, but untrimmed, can bodies are then picked up by a Discharge Turret that accelerates them
away to the Discharge Conveyor for processing at the Trimmer.

February 2009 Page 3-1

 SYSTEM FUNCTION

3.3 Operation Modes

The Bodymaker can be operated in any of the following modes:

a. Bar
b. Inch
c. Single Stroke
d. Continuous

3.3.1 Bar Mode

The Bar operation mode is used to turn (bar) the Bodymaker manually during maintenance and setup oper-
ation, or in the event of a main drive system malfunction.

The use of a Barring Tool, supplied with the machine, to bar the Bodymaker is possible with the Flywheel
Guard sliding door open and with the BAR push-button(s) held depressed. In this situation the clutch is en-
ergised and the Brake released

Depending on customer specification, a second BAR push-button is located on the Operator Control Panel
and both must be held depressed together, necessitating a second person to assist in barring the Bodymaker

WARNING: When Barring the Bodymaker with the Guard Doors open it is important that the operator is
vigilant and follows the correct procedure, ensuring that personnel are aware of what is intended and are clear
of the machine.

To Bar the Bodymaker:

a. Press the SYSTEM STOP push-button, stopping the machine.
b. Press the MOTOR STOP Push-button to stop the Main Motor. The Lubrication and Clutch Pumps
MUST be kept running
c. Switch the GUARDS UNLOCK / BAR / RUN selector to BAR.
d. Open the Bodymaker sliding guard door and remove any cup stock from the Cup Locator.
e. Press the SYSTEM RESET push-button.
f. Open the Flywheel Guard Sliding Door. This will not open until the Flywheel has stopped and all the air
has been exhausted from the Rear Hold Down Cylinder.
g. Insert the Barring Tool into the Plunger arrangement on the Flywheel.
h. Press and keep the BAR push-button(s) depressed to engage the clutch. The Bodymaker can now be
barred.
3.3.2 Inch Mode

The Inch operation is used to operate the Bodymaker through partial cycles to position the Ram for mainte-
nance and setting operations.
a. Switch the INCH/ SINGLE STROKE / CONTINUOUS selector to INCH
b. Hold the SYSTEM START / INCH push-button depressed and the Ram will travel a short distance.

In this mode the various protective safety devices are fully operational (see Section 4)

3.3.3 Single Stroke Mode

The Single stroke operation mode is used to operate the Bodymaker through one full cycle to check opera-
tional set-ups and Bodymaker infeed and delivery functions.
a. Switch the INCH / SINGLE STROKE / CONTINUOUS selector to SINGLE STROKE

Page 3-2 February 2009

 SYSTEM FUNCTION

b. Depress the SYSTEM START push-button and the Bodymaker will operate through a single operating
cycle and stop at the end of the return stroke.

To produce a can in the Single stroke mode first press the CUP FEED push-button before the SYSTEM
START push-button.

NOTE: On the first Single Stroke after pressing CUP FEED push-button a cup will be loaded into the ma-
chine, but a can will not be made until the second operation in Single Stroke. To make cans on successive
strokes in Single Stroke mode it is necessary to press CUP FEED and SYSTEM START / INCH alternatively.

In this mode the various protective safety devices are fully operational (see Section 4)
3.3.4 Continuous mode

The Bodymaker is operated in this mode for normal operation. (Section 5 refers).

In this mode the various protective safety devices are fully operational (see Section 4)

Bodymaker operation will be continuous until one or more of the following events occur:
a. SYSTEM STOP push-button is depressed.
b. EMERGENCY STOP push-button is depressed.
c. One or more of the protective safety devices operates an EMERGENCY STOP or SYSTEM STOP in con-
junction with the related message display.

NOTE: In all cases conditions for Continuous mode operation must be established to resume Bodymak-
er operation.
d. The Line Controls tell the Bodymaker to stop. In this case the Bodymaker will re start automatically
when the Line Controls allow.

3.4 Stopping the machine

In normal operation the Bodymaker stops with the Ram in the rear position at the end of the return stroke
when the SYSTEM STOP push-button is depressed.

When the EMERGENCY STOP push-button is depressed an immediate stop is effected and the Ram may be
at any position in the operating cycle.

Refer to Sections 4 and 5 for more detailed information on Machine Controls and Operation procedure.

February 2009 Page 3-3

 MACHINE CONTROLS

SAFETY

ALL personnel should apply safe working proce-

dures at ALL times.

Reference to Safety herein should be applied in

conjunction with your factory procedures

INDEX: PAGE:

Operators Controls 1

February 2009
 MACHINE CONTROLS

Machine Controls

Barring
Tool

Guards Unlock
Bar Motor Start System Start / Inch System Reset Bar Run Bar

BAR SYSTEM GUARDS UNLOCK BAR

MOTOR START SYSTEM RESET
START/INCH BAR RUN

RGEN
ME
MOTOR STOP SYSTEM STOP CUP FEED SINGLE STROKE
INCH CONT

CY
E
S TOP
Emergency Stop

Motor Stop System Stop Cup Feed Single Stroke

Inch

4.1 Operators Controls

The Operator Controls Panel located on the sliding door on the operator’s side of the machine comprises the
following:.
a. Motor Start Green Push-button
This single button is used for starting most of the motors on the bod-
ymaker. Each operation of this button will start the next motor in se-
quence, as follows:

i.Main Pump - this starts the main pump motor which will draw oil
back from the machine to the Hydraulic Power Pack, but it does not
send oil at high pressure to the machine until the button is pressed
again
ii.Load Main Pump - this energises a valve which sends high pressure
oil to the machine
iii.Clutch Pump
iv.Main Motor
At every stage the operator is prompted to start the next motor by a
message such as START MAIN PUMP

February 2009 Page 4-1

MACHINE CONTROLS

b. Motor Stop Red Push-button

This single button is used for stopping most of the motors on the bod-
ymaker. Each operation of this button will stop the next motor in the
reverse sequence to the starting sequence, i.e.

i.Main Motor
ii.Clutch Pump
iii.Unload Main Pump
iv.Main Pump
c. Bar / Guards Unlock / Run Selector Switch
This selects BAR Mode or RUN Mode of operation, but also unlocks
the guards as follows.
i.In the RUN position, all guards are locked and the Main Motor may
be started
ii.In the GUARDS UNLOCKED position the Slideway Guard and the
Front Sliding and Hinged Guards may be opened
iii.In the BAR position the above two guards may be opened immedi-
ately and the Flywheel Guard may be opened only after the Fly-
wheel has come to rest.
Note: Moving this selector switch from RUN to any other position
while the machine is running will cause an Emergency Stop to the
ram and the Main Motor will also stop.

d. Bar Black Push-button

Functional when the Bar Mode is selected on the Bar/Run selector
switch. When Bar is selected and the Bar push-button s are pressed to-
gether, the clutch is energised. This allows the machine to be turned
over manually by means of a Barring Tool on the machine Flywheel.

e. Inch/Single Stroke/Continuous Selector Switch:

Permits selection of Single, Inch or Continuous modes of operation.

f. System Reset Black Push-button

When depressed removes all fault messages that signalled faults, and
permits restarting of the machine. (Providing faults have been
cleared).

g. Cup Feed Black Push-button

This button is used in Single Stroke Mode only to control the Cup
Stop. In Single Stroke mode the Cup Stop is normally closed. Pressing
the CUPFEED push-button will open the Cup Stop and allow one cup
into the machine, pressing SYSTEM START / INCH will then cause
this cup to be loaded ready to make a can. Pressing SYSTEM START
/ INCH a second time will cause a can to be made. To make a succes-
sion of cans in Single Stroke, it is necessary to press CUP FEED and
SYSTEM START / INCH alternately

h. System Start/Inch Green Push-button:

Page 4-2 February 2009

 MACHINE CONTROLS

When depressed with SINGLE STROKE or INCH previously selected

on the INCH/SINGLE STROKE/CONTINUOUS Selector Switch,
the clutch is energized to either Inch or Single Stroke the machine.

When depressed with CONTINUOUS previously selected on the

INCH/SINGLE STROKE/CONTINUOUS SELECTOR Switch, the
machine will run in continuous cycle.

i. System Stop Yellow Push-button:

Functional when the system is in the continuous mode. Will stop the
Ram at the backstop position.

j. Emergency Stop Illuminated and Retained Push-button:

When depressed, stops all motors and engages the Brake. The Ram
could be in any part of its stroke.
The Trimmer is also Emergency stopped.

k. Touch Screen Controls The touch screen is located obove the operator controls. As its name
suggests it provides a HMI (Human Machine Interface) with a screen
which is pressed by the operator to interact with the machine. The
HMI is used to display currant status, production information, faults
etc. and can be used to enter specific machine parameters such as
speeds.
l. AMCI PLS Tming Unit:
The programmable limit switch is mounted in the Control Panel
(mounted in the plc rack).
A Readout on the HMI displays the machine speed and position.

February 2009 Page 4-3

 OPERATION PROCEDURE

SAFETY

ALL personnel should apply safe working proce-

dures at ALL times.

Reference to Safety herein should be applied in

conjunction with your factory procedures

INDEX: PAGE:

Safety Checks 1
System Check 1
Start Procedure 2
Warm-up procedure 2
Automatic Cycling 2
Operational Check-Out 2
Shut Down 3
Clean Up Following Shut-Down 3

February 2009