PMC-1002

OPERATOR & MAINTENANCE

MANUAL
 Table of Contents

Pages

General Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2

Safety Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3

Machine Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4

Basic Cup Formation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5

Operator Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 7

Production Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 8

Lubrication and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9

Operator Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 10

Main Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 11

Center Dwell and Station Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Cam Follower Replacement. Mandrel, Rimming Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Checking and Setting Reduction Drive Pinion Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13

Mechanical Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 12

Mechanical Adjustment, General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Roll Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Blank Hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Rotary Feeder Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Bottom Stock Unwind Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
Bottom Stock Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
Bottom Maker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
Bottom Punch and Die Sharpening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
Sidewall Feeding (Servo). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19

 PMC-1002
Table of Contents

Pages

Sidewall Die. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

Blank Feeding (Rotary). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31
Sidewall Sealer (Heaters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
Transfer Turret. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-42
Bottom Disc Preheater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46
Heat Gun Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-51
Station Slide Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-52
How to Square Up the Station Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-55
Folding Wing Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-56
Mandrel Turret and Mandrel Tooling, Seam Clamps Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-66
Bottom Heat Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-72
Roller Incurl Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-77
Bottom Finish Station—Slide and Station Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-81
Rimming Turret, Pocket Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-87
Tamper Lubricator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-90
Rimming Stations 1, 2, and 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-92
Station Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-95
Turret to Turret Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-96
Oil Filter Replacement of Filter/Cleaning Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-94

Mechanical Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 13

Mechanical Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 14

Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

PMC-1002 ii
 PMC-1002
General Statement
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GENERAL STATEMENT

Understanding the formation of cups and containers as a result of the operational sequence of
the machine is vital for trouble free operation. The PMC-1002 should be considered a
combination of separate machines, each performing a special function in the successive steps of
cup or container production. Study the machine and learn the proper names and functions of all
the different components and controls. Make certain that you know and understand all the
safety components and safety procedures before turning on the machine. Only PMC trained and
qualified individuals should operate, or perform any maintenance repairs or procedures on this
machine. A lock-out/tag-out safety system must be used when working on the machine.
Anytime an adjustment is needed, or any task that requires opening the machine guard doors at
least two emergency stop buttons must be engaged. At no time should any of the safeties be by-
passed or eliminated. The machine should never be operated without all the guards properly in
place.

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 PMC-1002
Safety
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SAFETY

GENERAL INFORMATION – SAFETY

All safety information is presented as guidelines that should be followed by all personnel.
These guidelines must be understood and maintained without exception whenever operating,
cleaning, or any maintenance or repair is attempted on the PMC-1002.

ELECTRICAL DISCONNECTS

All PMC electrical disconnects have the ability to be locked out with the use of safety locks and
lockout hasps.

SAFETY LABELS

Safety labels are installed on the machine to indicate the nature of the hazards in the area, and to
indicate how such hazards can be avoided.

EMERGENCY STOP PUSHBUTTONS

Red-mushroom head emergency stop buttons are located on the operators control panel and in
several other locations around the machine. They are to be used to stop the machine in the event
of an emergency or when any unsafe condition or practice is observed. Figure 2-1 shows the
locations of the emergency stop pushbuttons around the machine.

EMERGENCY STOP BUTTON

EMERGENCY STOP BUTTON

EMERGENCY STOP BUTTON

(ROLL FEED ONLY)

EMERGENCY STOP BUTTON OPERATOR

(BLANK FEED ONLY)
EMERGENCY STOP BUTTON

Figure 2-1

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 PMC-1002
Safety
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SAFETY NOTICES

There are three levels of safety notices used in this manual:

DANGER – Indicates a hazard, practice or condition that CAN or WILL result in

serious personal injury or death and damage or destruction of the equipment if the
accompanying instruction or notice is not adhered to.

WARNING – Indicates a hazard, practice or condition that MAY result in serious

personal injury or death and damage of the equipment if the accompanying instruction
or notice is not adhered to.

CAUTION – Indicates a practice or condition that MAY result in personal injury or

damage to the equipment if the accompanying instruction or notice is not adhered to.

SAFETY RULES AND PROCEDURES

The PMC-1002 requires regular, periodic maintenance to ensure reliable service. The operator
or maintenance personnel with a minimum of training can easily do the shift and daily
maintenance that has to be performed. However, no maintenance should be performed unless
all safety precautions are thoroughly understood.

Follow all instructions in this manual for safe operation.

Follow all company and industry standard safety policies regarding this kind of machinery that
may exceed those listed in this manual.

Keep all safety features, interlocks and sensors in good working condition.

Ensure that the machine is adequately grounded.

ALWAYS turn off machine power and LOCK OUT to ensure that all mechanical motion has
stopped and can’t be started before removing any machine guards.

EMERGENCY STOP SAFETY CIRCUIT

The PMC-1002 is equipped with an emergency stop safety circuit, which uses an emergency
stop safety relay. Safety devices such as guard door limit switches and emergency stop
pushbuttons are wired in series to the emergency stop safety relay. A contact from a fault relay
is also wired into the safety circuit. Pressing an emergency stop pushbutton or opening a guard
door will de-energize the emergency stop safety relay. The machine cannot be run or jogged
when the safety relay is de-energized. The relay can be re-energized by pressing the Fault Reset
pushbutton, only after all emergency stop pushbuttons are returned to the outward “safe”
positions, the guard doors are closed, and there are no active machine faults.
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 PMC-1002
Safety
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MACHINE GUARDS

Guard door safety limit switches monitor the machine guard doors. Opening a guard door will
cause the emergency stop circuit to be de-energized, which will prevent the machine from being
run or jogged. The machine can only be run or jogged when the emergency stop relay is
energized.

WARNING: NEVER OPERATE THE MACHINE WITH A GUARD DOOR

OPEN. FAILURE TO FOLLOW THIS PROCEDURE MAY LEAD TO
SEVERE INJURY OR DEATH.

EMERGENCY STOP PUSHBUTTONS

The PMC-1002 is equipped with several emergency stop pushbuttons. These pushbuttons,
when depressed, will be maintained in the inward, or safe, position. Pressing any emergency
stop pushbutton will cause the emergency stop circuit to be de-energized, which will prevent the
machine from being run or jogged. The machine can only be run or jogged when the emergency
stop relay is energized.

SAFETY BYPASS FEATURE

The Safety Bypass allows qualified setup mechanics

to jog the machine with a guard door open for setup
purposes, such as tooling changes. The bypass switch
is key locked so only a qualified technician with a key
can bypass the operator side guard door. The bypass
key switch is located on the main electrical console,
see figure 2-2. The safety bypass feature is not
intended for use by the machine operator, and under
normal machine operation should not be used as a
convenient method to clear machine jams. Figure 2-2

SAFETY BYPASS OPERATION

• Only the operator side guard door is bypassed with Safety Bypass Mode on. This makes
it much less likely that someone on the other side of the machine, or located in a blind
area, could be accidentally injured when the machine is jogged in the bypass mode.
• The machine will not run in Run Mode with any guard door open while the machine is in
Safety Bypass Mode.
• In Jog Mode with the Safety Bypass Mode on, and with the operator side guard door
open, the machine will only run incrementally for ½ second when the start buttons are
depressed and held. Both start buttons must be released and then depressed again to
continue jogging the machine. The machine will jog normally if the start buttons are
depressed and released before the ½ second period expires.
• In Safety Bypass Mode with the guards closed, the machine will jog or run continuously
when the start buttons are depressed and held.
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 PMC-1002
Safety
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WARNING BOXES

WARNING
DO NOT OPERATE MACHINE WITHOUT GUARDS IN PLACE OR WITH
MACHINE ENCLOSURE GUARD INTERLOCK SWITCH OFF.

WARNING
HIGH-VOLTAGE LINES AND TERMINALS ARE MARKED “HIGH-
VOLTAGE”. DO NOT REMOVE THESE LABELS. CONTACT WITH
THE HIGH-VOLTAGE LINES AND TERMINALS COULD RESULT IN
DAMAGE TO THE CONTROLS SYSTEM AND SERIOUS INJURY OR
DEATH.

WARNING
TURN OFF AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT MAY RESULT IN
UNEXPECTED STARTUP, CAUSING PERSONAL INJURY OR DEATH.

DANGER
FAILURE TO ADEQUATELY GROUND THE MACHINE, ESPECIALLY
IN A WET ENVIRONMENT, CAN RESULT IN PERSONAL INJURY OR
DEATH.

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 PMC-1002
Safety
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DANGER
KEEP CLOTHING AND PERSONAL OBJECTS (FINGERS, JEWELRY,
HAIR) AWAY FROM MOVING PARTS. HIGH TORQUE VALUES ARE
REQUIRED TO OPERATE THE MACHINE. IF PERSONAL OBJECTS
ARE CAUGHT IN THE MACHINE, SEVERE PERSONAL INJURY OR
DEATH WILL RESULT.

WARNING
RELEASE ALL AIR PRESSURE IN THE PNEUMATIC AND
LUBRICATION SYSTEMS BEFORE OPENING ANY LINES OR
CONTROL COMPONENTS. AIR OR LUBRICANT UNDER PRESSURE
COULD BE FORCED OUT OF THE SYSTEM, CAUSING PERSONAL
INJURY OR DEATH.

CAUTION
DO NOT USE UNDUE FORCE TO MOVE DRIVETRAIN BY HAND.
SOME COMPONENTS USE PNEUMATIC PRESSURE FOR
POSITIONING, AND CAN BE DAMAGED OR DESTROYED IN MANUAL
DRIVETRAIN MOVEMENT.

CAUTION
SUFFICIENT FORCE CAN BE GENERATED DURING HAND
OPERATION TO DAMAGE MACHINE PARTS THAT ARE
IMPROPERLY ADJUSTED.

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 PMC-1002
Safety
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WARNING
DO NOT SPRAY THE ELECTRICAL COMPONENTS OF THE MACHINE
WITH ANY LIQUID WHILE POWER IS APPLIED. LIQUIDS IN THE
ELECTRICAL COMPONENTS CAN CAUSE SHORTS, DAMAGING THE
COMPONENTS AND CAUSING PERSONAL INJURY OR DEATH.

DANGER
DO NOT USE FLAMMABLE LIQUIDS FOR CLEANING WHEN
COMPONENTS ARE HOT TO THE TOUCH. FLAMMABLE LIQUIDS
WILL IGNITE RAPIDLY, CAUSING SERIOUS INJURY OR DEATH.

DANGER
ISOPROPYL ALCOHOL IS FLAMMABLE AND SHOULD NOT BE
EXPOSED TO OPEN FLAME OR HEAT SOURCES. IGNITED IT WILL
FLASH, CAUSING SERIOUS INJURY OR DEATH.

CAUTION
DO NOT USE A PRY BAR TO LIFT THE SEAM CLAMPS OR OPEN
THE TRANSFER TURRET GRIPPERS.

CAUTION
DO NOT ROTATE THE MACHINE UNTIL THE FAULT HAS BEEN
IDENTIFIED AND SAFELY CORRECTED TO PREVENT DAMAGE TO
THE MACHINE OR OPERATOR.

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 PMC-1002
Safety
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WARNING
DO NOT ATTEMPT TO CLEAN THE MACHINE WHILE IT IS RUNNING.
CLEANING THE MACHINE WHILE IT IS RUNNING CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH AND DAMAGE THE
MACHINE AND THE CONTAINERS.

CAUTION
ALWAYS WEAR PRIMARY EYE PROTECTION (SUCH AS SAFETY
GOGGLES) WHEN USING COMPRESSED AIR TO CLEAN THE
MACHINE. NEVER POINT A COMPRESSED AIR HOSE AT ANYONE.
HIGH-PRESSURE AIR CAN DAMAGE EYES AND BLOW PARTICLES
AT HIGH VELOCITY.

The main drive motor is equipped with a brake to hold the machine station when it has been
stopped. An electric brake, or an air operated brake will hold the machine stable until the
machine is run/jogged or until the brake release has been activated to allow the machine to be
hand wheeled.

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 PMC-1002
Safety Devices
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SAFETY DEVICES

Read all the instructions and information found in Section 2, Safety. Become familiar with all
safety labels, safety guards, and all the emergency stop push buttons located on the PMC-1002
before attempting operation or performing any maintenance.

A series of electromechanical devices are located on the machine to detect the most common
malfunctions. In addition, electrically interlocked shutdown switches and visual gauges are
provided to monitor proper oil pressure, oil flow, and filtration for the main drive lubricant.
These devices are monitored by the PLC and will show up as a fault. They include:

SIDEWALL BLANK

A photoelectric switch, mounted on the guide rods of the sidewall sealer, detects the absence of
blanks and stops the machine.

CUP ON MANDREL

If the cup shell is not blown off the mandrel, it will trip the limit switch mounted on the turret
torque arm. Once this switch has been tripped, the machine stops immediately and
automatically goes into reverse jog mode. The machine will now only jog backwards to clear
the machine. Once cleared the machine can be reset by turning the drive mode selector switch
to the run position, or by using the touch screen in the machine reverse section on the options
screen.

CUP IN POCKET

If a cup is not discharged properly or there are multiple cups in a pocket, a limit switch mounted
to the turret torque arm will be tripped causing the machine to stop so that it can be cleared.

HOT HEADS

On all three rimming station form tools, a thermocouple holds the main control circuit open
until the pre-set operating temperature is obtained. The machine cannot be operated under
power in any mode until that temperature is reached. The typical optimum operating range is
155 °F. to 190 °F.

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 PMC-1002
Safety Devices
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HAND WHEEL

A limit switch is mounted in the main drive belt guard, which will prevent the machine from
being run or jogged with the guard door open. This guard door should only be opened to use the
hand wheel wrench.

ENCLOSURE GUARD DOORS

Limit switches are mounted so that the machine cannot be run or jogged while the enclosure
doors are open.

PRESSURE SWITCHES

The machine has factory preset switches for the main air pressure and the oil pressure. When
there is insufficient air or oil pressure the machine will stop and not be able to go into run until
the pressure is restored. Note: The machine will still jog with either low oil or low main air
pressure.

CYCLE STOP

When the cycle stop button is activated, both the sidewall feed and the bottom feed shut off,
allowing no additional sidewall and bottom blanks to enter the machine. The machine will
continue to run until the last cup formed is discharged from the machine. This is approximately
16 cycles. The machine then will come to a complete stop with the mandrels in between the
stations.

EMERGENCY STOP

When any one of the emergency stop buttons are engaged, the machine stops immediately and
cannot be jogged or run until that button is disengaged and the fault reset at the operators control
panel.

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 PMC-1002
Machine Components
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MACHINE COMPONENTS

BASIC COMPONENTS

The PMC-1002 cup converting machine consists of the following main assemblies:
• Sidewall feeder or rotary blank placer
• Bottom stock feeder
• Three counter rotating turrets
o Transfer turret
o Mandrel turret
o Rimming turret
• Folding wing assembly
• Bottom forming stations
o Bottom heat station
o Roller incurl station
o Bottom finish station
• Rim forming stations
o Tamper lube station
o 1st rimming station
o 2nd rimming station
o 3rd rimming station

See Figure 4-1 for the location of all these stations.

A programmable logic controller (PLC) controls and times the actions of these assemblies to
properly form a cup.

BOTTOM FINISH STATION AUXILIARY CLAMPS OPEN SWITCH

BOTTOM STOCK SCRAP CHUTE
BOTTOM INCURL STATION CUP DISCHARGE RIMMING TURRET

MANDREL TURRET
BOTTOM STOCK LIFT
BOTTOM HEAT STATION

TRANSFER TURRET

BLANK FEED OR ROLL FEED

3rd RIMMING STATION

2nd RIMMING STATION

SIDEWALL HEATERS 1st RIMMING STATION

FHA REGULATOR PANEL

BOTTOM DISC PREHEAT STATION
OPERATOR TAMPER LUBRICATOR STATION
BOTTOM MAKER

Figure 4-1

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 PMC-1002
Machine Components
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Below is a more detailed description of each assembly.

ROLL FEED

SIDEWALL ROLL STAND

The sidewall roll stand holds the sidewall stock to be fed into the machine on a roll fed machine.
It incorporates an automatically controlled air brake and has lateral alignment capability of the
roll to the feeder.

SIDEWALL SERVO FEEDER

The sidewall servo feeder feeds sidewall stock to the sidewall blanking die. Constant metering
rolls continually pull sidewall stock from the roll stand and feeds it into a loop. Servo feed rolls
then feed the proper amount of paper from this loop to the sidewall blanking die.

SIDEWALL BLANKING DIE

This is where the sidewall blank is die cut. The blanking punch is lever actuated from the main
drive camshaft in the lower base. The cutting shear on the face of the punch and the stepped
surface in the lower die sections keep shear forces to a minimum. The blanking punch is in the
upper section of the die holder and the blanking die is in the lower. When the sidewall stock
enters the die closes making the first cut which is the bottom edge of the blank. The die then
opens allowing the web to advance. The second stroke of the die cuts the top edge of the first
blank and the bottom edge of the following blank simultaneously. The fully cut blank is
clamped by the transfer turret grippers just before the die closes making this cut.

PRINT REGISTRATION

Registration of print on a cup is done by means of a servo driven feed to length indexing system.
Print will be maintained on the cup while any print repeat irregularities will be put into the
bottom of the cup.

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 PMC-1002
Machine Components
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BLANK FEED

INFEED CONVEYOR

The infeed conveyor is actually an accumulation table to keep a ready supply of blanks available
for continual cup production.

ROTARY PLACER

This assembly pulls a printed, cut, sidewall blank from the blank hopper that’s adjustable for
various size sidewall blanks. Vacuum through vacuum cups remove the blank from the hopper
and with a rotary motion places them on the blank shuttle table.

BLANK SHUTTLE

The blank shuttle is a sliding table with adjustable pushing guides that receive the sidewall
blank from the rotary placer and carries it forward to the transfer turret where it is captured by
the gripper fingers.

TRANSFER TURRET

Held by the grippers the transfer turret indexes the sidewall blank through the sidewall sealer
station and then to the wrapping position at the folding wings. The transfer turret is indexed by
a cam on the main driveshaft in the lower drive.

GRIPPER PLUNGERS

Plungers are located under the transfer turret gripper assemblies. There is one near the sidewall
die and another near the folding wings. These plungers come up at the proper time and open the
transfer turret grippers.

SIDEWALL SEALER STATION

This station heats the side seam area and preheats the bottom seal area of the sidewall blank,
which have a coating of low density, heat sealable polyethylene. Heat is applied by hot air
directed through nozzles mounted above and below the areas to be heated. Heat temperature is
regulated by the PLC, and monitored by thermocouples mounted in the airflow of each heat gun.
Airflow comes from eductors, which are mounted in the upper enclosure section, and is
controlled with regulators mounted in the FHA control panel. A safety pressure switch protects
the heaters in the event of loss of airflow.

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Machine Components
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BOTTOM STOCK UNWIND

The bottom stock unwind holds the roll of bottom stock. As the feeder feeds the stock it is
pulled off the roll and tracks through a series of idler rollers guiding it properly to the feeder.

BOTTOM STOCK SERVO FEEDER

The servo bottom stock feeder feeds bottom stock from the roll into the bottom maker. A set of
constant feed metering rolls pulls the paper from the roll and into a loop at the feeder. Servo
driven feed rolls then feed the proper amount of paper into the bottom maker. A lubricator can
also apply mineral oil to the web to aid in forming the bottom blank or disc.

BOTTOM MAKER

The bottom maker has an adjustable set of guides that allow the bottom stock to be positioned
properly. A cutting die cuts a round disc, which is pushed through a draw die that forms a skirt
on the bottom disc. The disc is then pushed by the draw punch into the nose cone of a mandrel
nose cone. The bottom stock scrap continues through the bottom maker and into a tube mounted
to the top of the machine, which guides it to the edge of the machine to be disposed of.

MANDREL TURRET

The mandrel turret indexes seven mandrels that hold the cup shell during the bottom forming
process. The rotary manifold at the top of the turret supplies vacuum to hold the bottom disc in
place while indexing to the folding wings. The manifold also supplies air for cup shell blow-off
at the transfer position.

FOLDING WING STATION

At this station a formed, preheated bottom disc is in the mandrel nose and a heated blank held in
the transfer turret gripper fingers meet at the folding wing station. At this time the paper clamp
comes up and secures the blank to the bottom of the mandrel. The gripper fingers now open and
the folding wings start to close. The wings close wrapping the sidewall blank around the
mandrel. When the wings are closed the two edges of the blank that were heated overlap
creating the side seam. The seam clamp then comes down on the side seam clamping it to the
mandrel. The folding wings now open so that the mandrel turret can index this formed shell to
the bottom heat station.

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 PMC-1002
Machine Components
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BOTTOM HEAT STATION

At this station the primary and secondary seal areas on the inside of the shell as well as the skirt
of the bottom disc are heated. This is done as the bottom heat nozzle slides forward entering the
cup shell to the properly adjusted depth. The heat nozzle then retracts and the mandrel then
indexes to the roller incurl station. During the index the mandrel stem extends, pushing the
bottom disc into the proper heated position in the shell. Also during the index the shell passes
over the bottom lubricator, which applies lube which aids in the forming of the cup bottom.

ROLLER INCURL STATION

At this station the sidewall stock that extends beyond the bottom disc skirt is curled inward.
The bottom incurl tool consists of a roller head mounted on a spindle, which is driven by an
electric motor. The roller head has u-shaped grooved rollers. As the head is spinning, the station
advances forward curling the edge of the shell in and over the bottom disc skirt to the properly
adjusted position.

BOTTOM FINISH STATION

At this station the bottom seal is finished and the bottom edge of the shell is squared off. This is
done by a spinning roller and flange assembly mounted on a slide block inside the housing.
Forward motion of the station causes the slide block to move, off setting the knurling roller
towards the clamp ring. An electric motor spins the shaft that the slide is mounted on causing
the knurling roller to spin inside the bottom of the cup shell. The clamp ring is water cooled to
prevent heat build-up as the roller is squeezing the layers of paper against the clamp ring. The
roller knurls the bottom as it squeezes these layers of paper together as the flange squares the
bottom edge achieving optimum bottom sealing.

TRANSFER POSITION

The mandrel with a finished cup shell indexes to the transfer position which is where it is
directly across from a rimming pocket At this point the cup shell is blown into a rimming
pocket where it is held in place by vacuum.

RIMMING TURRET

The rimming turret indexes seven pockets, which hold the cup shell through the rim forming
process. The rotary manifold on the top of the turret supplies vacuum to hold the shell in place
while rimming and air so that the finished cup can be discharged from the machine.

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Machine Components
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TAMPER LUBE STATION

Once the rimming pocket indexes to this station the tamper lube head advances forward firmly
seating the cup shell into the pocket as it applies a film of lubricant to the top inside edge of the
cup shell to aid in forming the rim.

1ST RIMMING STATION

Once the rimming turret has indexed to this position the rimming station advances toward the
pocket. A heated form tool comes in contact with the top edge of the shell and starts to curl the
shell. The station then retracts and the rimming turret indexes the pocket to the next rimming
station.

2ND RIMMING STATION

At this station a heated form tool advances forward to curl the rim more. On each pocket a die
ring is mounted which aids in forming the rim. As more paper is curled it comes into contact
with the die ring. After more of the rim is formed the station retracts and the rimming turret
then indexes to the final rimming station.

3RD RIMMING STATION

At this position this station advances forward so that the heated form tool comes into contact
with the die ring mounted to the front of the pocket. This finishes and sets the rim. The station
then retracts so the rimming turret can index to the discharge position, where the finished cup is
blown from the machine.

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 PMC-1002
Basic Cup Formation
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BASIC CUP FORMATION

A paper cup goes through three basic stages before it is considered a finished cup. It starts the
process as a blank, both a sidewall and a bottom blank. It is then formed into a cup shell and
finally into a finished cup. A description of the overall cup forming process for the PMC-1002
is as follows: The bottom servo feeder feeds bottom stock to a punch and die set within the
bottom maker. A bottom blank is cut and formed then pushed into the mandrel nose where it is
secured by vacuum. This mandrel then indexes to the bottom disc preheat station. This station
moves in and preheats the bottom disc. At the same time a sidewall blank is delivered to the
transfer turret. The transfer turret indexes bringing the sidewall blank to the sidewall sealer
station. The blank, once heated is indexed to the folding wings where it is wrapped around a
mandrel. It then indexes through the bottom heat, roller incurl, and bottom finish stations to
finish the bottom of what now is referred to as a cup shell. The mandrel turret indexes this cup
shell to a position where it is then transferred to a pocket on the rimming turret. The rimming
turret then indexes the cup shell through the tamper lube, 1st, 2nd, 3rd rimming stations which
form a finished rim making the cup complete. The cup is then discharged from the machine.

SIDEWALL AND BOTTOM BLANK

Either a rotary placer and shuttle table or a servo sidewall feeder and blanking die are
responsible for delivering the sidewall blank to the transfer turret, where it is secured by a set of
gripper fingers. The bottom stock is fed by a servo feeder that feeds the bottom stock into the
bottom maker. The bottom maker has a punch and die set that cuts the bottom disc from the
bottom stock. It also has a draw punch and die that forms a skirt on the bottom disc. The
bottom disc now formed is pushed into the mandrel nose cone and held in place by vacuum.

SIDEWALL SEALER
The transfer turret indexes the sidewall blank to the sidewall sealer where the side and bottom
edges of the blank are heated in preparation for cup shell forming. The mandrel turret indexes a
mandrel with a formed bottom inside the mandrel nose to the bottom disc pre heater where the
bottom skirt is preheated.

THE SHELL
The transfer turret then indexes the heated sidewall blank to the folding wings. At the same time
the mandrel turret indexes a mandrel with a preheated bottom to the folding wings. The
sidewall blank is then wrapped on the mandrel by the folding wings making a cup shell. The
mandrel turret then indexes the shell to the bottom heat station.

BOTTOM HEAT STATION

At the bottom heat station the inside of the wrapped shell is heated at the bottom seal area, while
the inside skirt of the bottom disc is also heated. Once heated the mandrel turret indexes to the
roller incurl station. As the mandrel with the heated shell starts to index the mandrel stem starts
to push the bottom into its final position in the shell.

BOTTOM INCURL
As the mandrel with the shell is indexing to the roller incurl station, lubricant is applied to the
outside of the shell to aid in forming the bottom. At this station the bottom edge of sidewall is
curled inward over the skirt of the bottom blank.
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 PMC-1002
Basic Cup Formation
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BOTTOM FINISH STATION

The mandrel is indexed to the bottom finish station after the roller incurl station has rolled in the
bottom. Here is where the seal at the bottom is completed. The bottom is also finished,
knurled, and squared. When finished the shell is indexed to the transfer position where it is
transferred to the rimming turret, where it is secured by vacuum into a pocket.

TAMPER LUBE STATION

The rimming turret indexes the pocket retaining the cup shell to the tamper lube station. At this
station the cup shell is pushed into the pocket setting it tightly in. At the same time lubricant is
applied to the top inside edge of the shell to aid in forming the rim.

1st RIMMING STATION

The rimming turret then indexes the shell in the pocket to the 1st rimming station. At this station
a forming tool along with the die ring that’s mounted to the pocket start to form a rim on the cup
shell. This station just starts curling the rim. It then indexes to the 2nd rimming station.

2nd RIMMING STATION

At this station the rim is formed more but not completed. The rimming turret then indexes to
the 3rd rimming station.

3rd RIMMING STATION

At this station the form tool advances to touch the die ring, which finishes the rim. Once
complete the rimming turret then indexes the pocket to the discharge position where the finished
cup is blown out of the machine.

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 PMC-1002
Operator Controls
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OPERATOR CONTROLS

OPERATORS PLC TOUCHSCREEN AND CONTROLS

The interface to the programmable logic controller is the PLC touchscreen. The operator can
touch any of the “go to“ panels right on the screen to display current machine states as well as
make adjustments to operational and maintenance parameters. The touchscreen has password
access control on some timing and speed screens. Before making any adjustments or changes,
record the information that is going to be changed. In doing so you can always go back to the
original setting if the change does not work.

TOUCH SCREEN

The touch screen has many screens and stores much valuable information such as timing, heat
settings and more. Take time to learn the different screens and what they contain. The
following will explain what you will find on these screens:

MAIN SCREEN

At the top of this screen you will find a calendar – month, day, year, a clock showing hours and
minutes, the actual machine speed and the current production count. The rest of the screen is as
follows:

Heaters – takes you to the heater main screen

Speed Select – takes you to the speed select screen

Machine Timing – takes you to machine timing #1 screen

Options – takes you to the options screen

Fault Active – lights up when there is a fault

Press to view fault – takes you to a screen that will identify the fault and suggest corrective
measures

Maintenance Required – will light up when maintenance or lubrication is required – when

touched it will display a screen telling what’s required

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Operator Controls
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HEATER MAIN SCREEN

This screen will display the actual temperature and the setpoints for all the heaters at the
sidewall sealer station. The setpoint will be on the left side and the actual on the right. After
touching one of the blocks a screen will come up so that the temperature can be changed by
touching the “press to change setpoint” box which will bring up a keypad to enter the new
temperature. Make certain that the enter key is pressed when done. The enter key is located in
the lower right hand corner.

Main screen – will take you back to the main screen

Hot heads – will take you to a screen that’s the same as this but covering the heaters for the
rimming stations.

SPEED SELECT SCREEN

This screen displays four different speeds that can be changed if required. While this screen is
being displayed all that is needed to change the speed to one of the four choices is to touch that
block. This screen is accessible only with a password.

Main screen – returns you to the main screen

Custom speeds – brings up the four speed boxes. When any one of them is pressed a keypad
will appear allowing you to change that preset speed.

MACHINE TIMING

The machine timing screens are accessible only with a password. This will bring you to the first
of two timing screens. On this screen you will find the following:

Mandrel Blowoff Turn On - This allows you to adjust the Mandrel Blowoff Turn On position.
Touching this button brings up a keypad allowing you to change the timing. After the new
timing number has been entered you must hit the enter key located in the lower right hand
corner.

Mandrel Blowoff Turn Off – This allows you to adjust the Mandrel Blowoff Turn Off position.
Touching this button brings up a keypad allowing you to change the timing. After the new
timing number has been entered you must hit the enter key located in the lower right hand
corner.

Rimming Blowoff Turn On – This allows you to adjust the Rimming Blowoff Turn On position.
Touching this button brings up a keypad allowing you to change the timing. After the new
timing number has been entered you must hit the enter key located in the lower right hand
corner.

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 PMC-1002
Operator Controls
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Rimming Blowoff Turn Off – This allows you to adjust the Rimming Blowoff Turn Off
position. Touching this button brings up a keypad allowing you to change the timing. After the
new timing number has been entered you must hit the enter key located in the lower right hand
corner.

Bottom Scrap Air Turn On – This allows you to adjust the Bottom Scrap Air Turn On position.
Touching this button brings up a keypad allowing you to change the timing. After the new
timing number has been entered you must hit the enter key located in the lower right hand
corner.

Bottom Scrap Air Turn Off – This allows you to adjust the Bottom Scrap Air Turn Off position.
Touching this button brings up a keypad allowing you to change the timing. After the new
timing number has been entered you must hit the enter key located in the lower right hand
corner.

Main Screen – returns you to the main screen

Timing #2 – takes you to the second timing screen

Machine position – this is the actual position of the machine in degrees. “0” is the center of
dwell.

MACHINE TIMING #2

The machine timing screens are accessible only with a password. This will bring you to the
second timing screen. On this screen you will find the following:

Folding Wing Air Turn On – This allows you to adjust the Folding Wing Turn On position.
Touching this button brings up a keypad allowing you to change the timing. After the new
timing number has been entered you must hit the enter key located in the lower right hand
corner.

Folding Wing Air Turn Off - This allows you to adjust the Folding Wing Turn Off position.
Touching this button brings up a keypad allowing you to change the timing. After the new
timing number has been entered you must hit the enter key located in the lower right hand
corner.

Cycle Stop Position - This allows you to adjust the Cycle Stop position, which is the position
that machine stops when the cycle stop button is pushed. Touching this button brings up a
keypad allowing you to change the timing. After the new timing number has been entered you
must hit the enter key located in the lower right hand corner.

Bottom Tension - This will bring up a screen that allows you to adjust the tension on the bottom
stock at different roll diameters.

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Operator Controls
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Machine Encoder Zeroing – will bring up a screen that will allow you to re-zero the encoder.
This screen is self-explainable. Just keep in mind that the machine is at zero when the draw
punch is fully extended, or the pointer on the drive gear in the main drive is at zero.

Bottom Servo – will bring up the bottom feeder servo screen. On this screen you will find:

Not In Manual Index Position – when this block is red it means that you cannot use the
bottom stock index button on the control panel because the machine is in the wrong position.
When it turns green it means that the machine is in the proper position to use the index
button.

Bottom Feed Length – this block will bring up a keypad allowing you to change the feed-up
length of the bottom. The feed length should be set with the feed length that is on the cup
drawing. When done the enter button must be pushed.

Index Position – this block will bring up a screen that will allow you to change the feed start
timing on all four of the preset machine speeds.

Splice Options – this block will bring up a screen that will allow you to turn the splice
option on or off. It also allows you, when turned on, to either have the machine cycle stop
when a splice is detected or have the splice accelerate through the bottom maker and not be
cut.

Main Screen – brings you back to the main screen

Timing #2 – takes you back to the #2 timing screen

Machine Position – indicates the position of the machine in degrees

Sidewall Servo – this will bring up the sidewall servo feeder screen. On this screen you will
find:

Not In Manual Index Position – when this block is red it means that you cannot use the
sidewall feed index button on the control panel because the machine is in the wrong
position. When it turns green it means that the machine is in the proper position to use the
index button.

Side Feed Length – this block will bring up a keypad allowing you to change the feed-up
length of the sidewall. The feed length should be set with the feed length that is on the cup
drawing. When done the enter button must be pushed.

Registration Index Position – this block will bring up a screen that will allow you to change
the feed start timing on all four preset machine speeds when running printed, registered
stock.

Non–Registration Index Position – this block will bring up a screen that will allow you to
change the feed start timing on all four preset machine speeds when running plain stock.
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Operator Controls
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Main Screen – will take you back to the main screen.

Timing #2 – will take you back to the #2 timing screen.

Machine Position – indicates the machines position in degrees.

Main Screen – will take you back to the main screen.

Timing #1 – will take you back to the #1 timing screen.

Machine Position – indicates the machines position in degrees.

OPTIONS SCREEN

Production Data – shows the machine run time and the production counts

Machine Reverse – enables the machine to be jogged backwards

Fault History – lists past and current faults

Maintenance Required – lists maintenance and lubrication requirements

Main Screen – returns to the main screen

CONTROL PANEL SELECTOR SWITCHES

Located on the lower sides, one on each side, of the control panel, are the start/jog buttons. In
order to jog or run the PMC-1002, both buttons must be pressed at the same time.

DRIVE MODE
JOG – pressing both start buttons while the selector switch is turned to jog will operate the
machine only as long as the buttons are held in.
RUN – pressing both start buttons after the selector switch is turned to the run position will
start continuous operation. Note: there is a five second window to press the buttons
after the selector switch is turned to the run position.

MACHINE MODE
SET-UP – all heat guns are in position and the power to the heat guns is off. Sidewall fault
circuit and low temperature fault circuits are bypassed.
TEST – all heat guns are in the run position and power to the heat guns is on. Machine
vacuum must be turned on manually. This mode is used to produce burn tests.
RUN – power to heat guns is on. All machine functions operate normally.

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6-5
 PMC-1002
Operator Controls
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HEATERS
Turns all heaters on or off.

CLAMPS OPEN
Opens and closes transfer turret gripper fingers and the mandrel turret seam clamps

FAULT RESET
Resets all electro-mechanical devices after a safety device has been tripped and the fault
corrected.

SIDEWALL FEED INDEX (roll feed only)

When pressed it will feed one length of sidewall stock

SIDEWALL METERING ROLLS (roll feed only)

Operates the sidewall stock feed rolls in either a forward or a reverse direction.

BOTTOM FEED INDEX

When pressed it feeds one feed length of bottom stock.

BOTTOM METERING ROLLS

Operates the bottom stock feed rolls in either a forward or a reverse direction.

RIMMING LUBE PRIME

Operates the lube solenoid allowing oil to flow to the tamper lube head. Oil will flow for as
long as the button is pressed.

SIDEWALL FEED
THREAD (roll feed only) – opens feed rolls at the sidewall feeder allowing sidewall stock to
be threaded.
OFF – doesn’t allow the blank to be pulled or on a roll fed machine it doesn’t allow roll
stock to be fed.
ON – allows blank to be pulled or sidewall stock to be fed.

BOTTOM FEED
THREAD – opens feed rolls on the bottom feeder to allow bottom stock to be threaded
OFF – disengages the bottom stock feed rolls
ON – allows bottom stock to be fed

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 PMC-1002
Operator Controls
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CYCLE STOP
Allows the machine to run out the cup cycle clearing all cups before stopping.

EMERGENCY STOP
Stops all machine motion and functions immediately

The PMC-1002 has additional operator controls, which are located at various other locations on
the machine. See Figure 6-1. The other controls are as follows:
• FHA REGULATOR PANEL
• BOTTOM STOCK ROLL LIFT
• AUXILIARY SEAM CLAMP LIFT
• BOTTOM STOCK BRAKE ON/OFF

BOTTOM FINISH STATION AUXILIARY CLAMPS OPEN

BOTTOM STOCK SCRAP CHUTE
BOTTOM INCURL STATION CUP DISCHARGE RIMMING TURRET

MANDREL TURRET BOTTOM STOCK LIFT

BOTTOM HEAT STATION

TRANSFER TURRET

BLANK FEED OR ROLL FEED

3rd RIMMING STATION

2nd RIMMING STATION

SIDEWALL HEATERS BOTTOM STOCK BRAKE ON/OFF

FHA REGULATOR PANEL 1st RIMMING STATION

BOTTOM PREHEAT STATION

OPERATOR TAMPER LUBRICATOR STATION
BOTTOM MAKER

Figure 6-1

FHA REGULATOR PANEL

These regulators are used to control the amount of air
that flows through the heaters. Above each regulator
is a gauge to indicate what the airflow is. Preheat #1
and #2 refer to the index position of the sidewall
blank indexing through the sidewall sealer station.
See Figure 6-2. The regulators are as follows:
• BOTTOM DISC PREHEAT
• BOTTOM HEAT STATION
• UPPER SIDE SEAM
• LOWER SIDE SEAM
• SIDEWALL BOTTOM PREHEAT #1 Figure 6-2
• SIDEWALL BOTTOM PREHEAT #2

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Operator Controls
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BOTTOM STOCK ROLL LIFT

Located on the opposite side of the main
pneumatic cabinet. See Figure 6-3. Turn and
hold the selector switch to the left (raise) to raise
the bottom stock roll hub. Turning the selector
switch to the right (lower) will lower the bottom
stock roll hub. Once the switch is released it will
return to the off position. This feature is used to
aid in mounting a roll of bottom stock.

Figure 6-3

AUXILIARY SEAM CLAMP LIFT CONTROL

This is located on the opposite side of the machine
from the operator control panel. See Figure 6-4.
This switch is used to open the transfer turret
gripper fingers and the mandrel turret seam
clamps to aid in removing cups and sidewall
blanks.

Figure 6-4

BOTTOM STOCK BRAKE ON/OFF

This is located on the operator side of the main
pneumatic cabinet. This switch will turn the
bottom stock brake either on or off.
See Figure 6-5.

Figure 6-5

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 PMC-1002
Operator Controls
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BOTTOM STOCK SCRAP

Controls the amount of air used to assist the
bottom stock scrap down the scrap chute. See
Figure 6-6 for its location.

Figure 6-6

BOTTOM STOCK LUBE

Controls the amount of lubricant (mineral oil
only) being supplied to the felt lubricator mounted
at the front of the bottom maker. See Figure 6-7
for the valve location on the lower right side of
the operator control panel.

RIMMING LUBE
Controls the amount of lubricant to the tamper
lube head. There are three separate valves for the
three lines. See figure 6-7 for the valve location
on the lower right side of the operator control
panel. Figure 6-7

FOLDING WING AIR ASSIST

Controls the amount of air used to guide the
sidewall blanks at the folding wings. The
adjusting valve is located at the lower left side of
the operators control panel. See Figure 6-8.

Figure 6-8

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Operator Controls
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LUBE TANK PRESSURE

Located at the lube tank is a regulator to control
the amount of air pressure in the lubricant tank,
which pushes the lube through the lines to the
point of use. Set at 4-5 psi. See Figure 6-9.

VACUUM VALVES
Controls the amount of vacuum in the recovery
tank for excess lubricant from the roller incurl and
tamper lube stations. The valves are located at the
recovery tank. See Figure 6-9.
Figure 6-9

SIDEWALL SEALER CYLINDER CONTROLS

Used to regulate the air at the cylinders to control
the rate of heater travel. Located on the inside of
the enclosure upright to the left of the operators
control panel.

For Blank Feed Machines see Figure 6-10.

A. Upper Sidewall Heater Cylinder Control

Engage
B. Upper Sidewall Heater Cylinder Control
Disengage
C. Lower Sidewall Heater Cylinder Control
Engage
D. Lower Sidewall Heater Cylinder Control
Disengage
E. Sidewall Blank Detect Purge Air Adjust

Figure 6-10

For Roll Feed Machines see Figure 6-11.

A. Upper Sidewall Heater Cylinder Control

Engage
B. Upper Sidewall Heater Cylinder Control
Disengage
C. Lower Sidewall Heater Cylinder Control
Engage
D. Lower Sidewall Heater Cylinder Control
Disengage
E. Sidewall Blank Detect Purge Air Adjust
F. Sidewall Registration Eye (Feeder) Purge Air
Adjust
Figure 6-11
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 PMC-1002
Operator Controls
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CALIBRATE REGISTRATION
Used to ensure that the sensor is detecting the
registration mark on printed sidewall stock. This
is located at the sidewall feeder. See Figure 6-12.

Figure 6-12

BLANK SEPARATOR AIR

This controls the amount of air directed to the top
edge of the blanks in the hopper prior to being
picked by the rotary placer. It’s purpose is to help
keep the blanks separated. The adjusting valve is
located on the inside of the enclosure upright to
the left of the operators control panel. See Figure
6-13.

Figure 6-13

BLANK HOLD DOWN

The valve controls the amount of air used to keep the leading edge of the sidewall blank
down as it goes under the transfer turret gripper fingers. The valve is located on the inside
of the enclosure upright to the left of the operators control panel. See Figure 6-13.

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 PMC-1002
Cleaning
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CLEANING

Housekeeping is a term that is used to describe the process of maintaining your work area to be
clean and free of clutter. Good housekeeping should be maintained not only for your safety, but
also for your equipments performance and product quality. The PMC-1002 does require regular
cleaning to ensure reliable operation and performance. During normal operation of the PMC-
1002 there will be a buildup of ink, paper dust, and poly on various parts of the machine that
must be routinely cleaned by the operator. There will also be some cleaning that may require
the assistance of the maintenance department. There will actually be three different times when
cleaning needs to be done. They would be:
1) Routine shift to shift cleaning
2) Scheduled cleaning from the PMC-1002 maintenance and lubrication schedule
3) Prior to machine startup when the machine has been down for any length of time.

SAFETY

No cleaning should be preformed unless the safety precautions are thoroughly understood and
are adhered to without exception.

CAUTION: BEFORE ANY CLEANING, ENGAGE AT LEAST TWO

EMERGENCY STOP BUTTONS.

Note: Never defeat any safety device or interlocks on the machine.

The machine and the areas directly adjacent to it should be kept clean and free of debris such as,
discarded blanks and containers, etc. as this can create safety hazards for the operator and for
the machine itself.

Fires are another safety concern directly related to housekeeping and cleaning. High
temperatures are used to produce the seals on the cups. These temperatures are high enough that
paper and debris not cleaned off the machine could ignite creating a fire. Keeping the machine
clean will greatly minimize this risk of fire.

When cleaning some things to remember are:

DO NOT allow tools, bolts, fittings, or any other metallic objects to lie on any machine surfaces
during production.

DO NOT use steel wool on machine surfaces. It may cause rusting, contamination of lubricated
surfaces, or damage to specially coated surfaces.

DO NOT use chlorine, ammonia, alkalis, acids, or any cleaning solutions that will damage
metallic machine surfaces, cause corrosion, or contaminate the cups.

DO NOT spray water on the machine at any time.

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7-1
 PMC-1002
Cleaning
___________________________________________________________________________________________________________________

DO NOT use sharp knives or box cutters when clearing mandrels. Damage to mandrels will
result, causing poor machine performance.

CLEANING AIDS

Basic equipment and supplies needed to clean and disinfect the machine may include:

Safety glasses or goggles

Clean soft cloths
Hand pump spray bottle
Scotch brite #86 scouring pads or equivalent
Small brass brushes
Medium brass brushes
Blunt blade scraper
Small putty knife
Isopropyl alcohol
Commercial sanitizing solution
A good quality, portable high capacity vacuum cleaner capable of getting into hard to reach
areas should also be available for cleaning.

Note: Compressed air may be used to clean inaccessible areas. Observe all appropriate safety
regulations for the use of compressed air.

CLEANING PRIOR TO PRODUCTION

Prior to starting the machine for production that has sat idle for a length of time, perform the
following procedures:
1) Ensure that the machine power is off.
2) Ensure that the heaters are turned off.
3) Engage an emergency stop button.
4) Inspect the machine and remove all loose paper, dust, and debris.
5) Using a soft cloth, wipe off any excess lubrication from the machine.
6) Moisten a clean, soft, lint free cloth with isopropyl alcohol or warm clean water and
wipe off all container contact areas i.e.: mandrels, folding wings, pockets, ect.
7) Remove any poly build up that’s found, especially the sidewall blank guide area at the
sidewall sealer.
8) Wipe down all container contact surfaces with sanitizing solution and allow to dry.
9) Turn on the power, air, and vacuum and start the machine. Refer to the start-up section
of this manual for proper startup procedure.

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7-2
 PMC-1002
Cleaning
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SHIFT TO SHIFT CLEANING

The PMC-1002 should be cleaned each 8-hour shift. You can incorporate this cleaning
procedure with the PMC-1002 lubrication schedule, roll change, at shift change, or however it
may best suit your operational needs. The following is a procedure for this task:
1) Cycle stop the machine which will automatically clear the machine and stop with the
mandrels between stations.
2) Engage an emergency stop button.
3) Open all of the overhead enclosure doors.
4) Gently blow all loose debris off the machine using compressed air.

Caution: Always wear primary eye protection such as safety goggles when
using compressed air to clean the machine. Never point a compressed air
line at anyone. This may cause serious personal injury.

5) With the use of a brass brush or a scraper, clean the built-up poly residue from the
sidewall sealer blank guides and the transfer turret gripper fingers.

Caution: Care should be taken when working near any of the heaters.
They are extremely hot and touching them in any way may cause serious
burns or injury.

6) With a clean cloth wipe any excess lubricant and debris from the folding wing assembly.
7) Ensure all mandrels are clean. Remove any burnt on residue with a scotch brite pad.
8) With a clean cloth wipe out the pockets removing any oil residue.

Caution: Use care when cleaning the pockets, as the die rings mounted to
them are sharp and could cause serious injury.

9) Using the “clamps open” option, open the clamps. Make sure the seam clamps are
clean. Check and clean the gripper fingers and the transfer turret wear ring. Use a brass
brush or a scotch brite pad for cleaning.
10) Close the clamps.
11) With a soft cloth wipe the machine top removing any left over debris and oil residue.
12) Close all the enclosure doors.
13) Disengage the emergency stop buttons and reset the fault at the operators control panel.
14) Start the machine. Once the machine has been started, clean the surrounding floor area
to make it safe.

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7-3
 PMC-1002
Cleaning
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SCHEDULED CLEANING

There will be other cleaning of the PMC-1002. Some of it is scheduled through the
maintenance and lubrication section of this manual as well as on the operators control panel
touch screen. The schedule for the remaining areas that will require cleaning will be very much
dependant on the quality of your materials and your environment. These factors will determine
the frequency of cleaning, even though they may be in the schedule. Some of these areas, if left
dirty, will actually cause machine problems and cup defects. The following are some of these
areas:

Note: You may decide that the maintenance department should be involved, as some of these
assemblies will require disassembly to properly clean them.

WARNING: BEFORE ATTEMPTING ANY OF THESE SCHEDULED

CLEANING OPERATIONS, TURN OFF MAIN POWER AT THE
ELECTRICAL CONSOLE DISCONNECT AND LOCK OUT.

1) DIE RINGS
With the machine stopped, the pockets between the rimming stations, and an emergency
stop button engaged, the die rings can be cleaned. Use a clean cloth to remove any loose
material and a soft brass brush to remove the rest.

Caution: These die rings have sharp edges; use care when cleaning to
avoid injury.

2) RIMMING TOOLS
With the machine stopped, the pockets between the rimming stations, and an emergency
stop button engaged, the rimming tools can be cleaned. Use a soft brass brush to clean.

3) HEATER NOZZLES
Heater nozzles may at times become loaded with built-up poly residue and need to be
cleaned. This needs to be done by a trained, qualified person. The nozzles will have to
be removed from the machine to be cleaned properly and once cleaned they will have to
be properly installed. The heaters must be turned off and allowed to cool before this task
is started. Nozzles can be wire wheeled to clean them.

4) DRAW PUNCH AND DIE

The schedule for this cleaning is in the maintenance and lubrication section of this
manual and also in the operators control panel touch screen. In order to properly clean
these, the draw punch will need to be removed. Use the following procedure:
a) Stop the machine with the mandrels between stations.
b) Engage an emergency stop button
c) Remove the socket head bolt from the center of the draw punch. See Figure 7-1.
d) Carefully pull the draw punch from the ram being sure not to lose the ground
spacer that sits between the ram and the draw punch. See Figure 7-1.

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7-4
 PMC-1002
Cleaning
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DRAW PUNCH
MOUNTING SCREW

SPACER

Figure 7-1

e) Wipe the draw punch and spacer clean.

f) Reach in and wipe as much debris as you can from inside the draw die.
g) With compressed air gently blow the remaining material out of the complete die
block assembly. See Figure 7-2.

Figure 7-2

h) Put a small amount of grease on the face of the spacer and slide the spacer onto
the draw punch. The grease will help keep the spacer from falling off when the
draw punch is put back in.
i) Install the draw punch back into the ram and install the socket head bolt making
certain that it is securely tightened. If this bolt is left loose and works its way out
it will cause severe damage.

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7-5
 PMC-1002
Cleaning
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5) BOTTOM FINISH TOOLING

The proper schedule for cleaning this tooling is located in the maintenance and
lubrication section of this manual as well as on the operators control panel touch screen.
In order to properly clean the tooling, the clamp ring must be removed. Before
removing the clamp ring, make a mark on the clamp and on the housing that line up to
each other so that when the clamp ring is put back on, the relief orientation is the same
as it was. See Figure 7-3. The clamp ring is a two-piece water jacket and should not
have to come apart. Use the following procedure to remove and clean this tooling:
a) Stop the machine with the mandrels between stations.
b) Engage an emergency stop button.
c) Shut off the cooling water supply at the supply valves.
d) Disconnect the two poly flo lines to the clamp ring.
e) Remove the four hex head mounting bolts on the front of the clamp ring and remove
the clamp ring.
f) Slide the roller and flange assembly off the slide block.
g) With a clean cloth wipe all the components clean.
h) Check to make certain that the bearing is free and in good shape.
i) Reassemble.

Figure 7-3

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 PMC-1002
Production Startup
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PRODUCTION STARTUP
When getting ready to start a machine that has been sitting idle for any length of time, or a new
machine, the following procedure should be followed:

CAUTION: BEFORE PERFORMING ANY TASK THAT REQUIRES A

GUARD DOOR TO BE OPENED, ENGAGE AT LEAST TWO EMERGENCY
STOP BUTTONS.

1) Inspect the machine for any foreign objects or debris such as cups, sidewall blanks,
bottom discs, and remove them.

2) Make sure all guards are in place and in proper working order.

3) Wipe excessive dust and lubricant from the top of the machine.

4) Lubricate the machine in accordance with the operator’s lubrication schedule found on
the operators control panel touch screen or in the lubrication and maintenance section of
this manual.

5) Check the mineral oil level in the reservoir and fill as necessary.

6) Drain the lubricant recovery tank.

7) Turn on the main air to the machine and check airflow to the gauges.

8) Turn on the vacuum supply to the machine.

9) Turn on the main power to the machine.

10) Check the PLC touch screen display to see that all operating parameters are displayed.

11) Turn the heater selector switch on. The illuminated switch will blink until the heaters
are all up to the preset temperature. It is a good idea to go to the heater screen on the
touch screen to observe heating cycle.

Note: The machine will not jog or run until the rimming hot heads are within 15 °F of
the preset temperatures.

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8-1
 PMC-1002
Production Startup
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12) Check for proper bottom disc. With the drive selector switch in “jog”, and the sidewall
and bottom feed selector switches in the “off” positions, jog the machine to center of
index or until the mandrels are between stations. Turn the bottom stock metering roll
switch to “forward”, watching to ensure that there is a proper loop at the bottom stock
feeder. (The end of loop should be between the two sensors. Now press the bottom feed
index button which will feed one feed length of bottom stock thru the bottom maker.
Next jog the machine one cycle again stopping the mandrels between stations. The
mandrel between the bottom maker and the bottom disc preheat station will have a
bottom placed in the nose cone. At this time engage an emergency stop button, open the
guard door, pull the bottom from the mandrel and inspect.

13) Check for proper sidewall blank. (Roll fed machine only)
With the drive selector switch in the “jog”
position and the sidewall and bottom feed
switches in the “off” positions, jog the
machine so that the transfer turret gripper
fingers are open at the sidewall die position.
Next turn the sidewall feed selector switch to
the “thread” position, which opens the
sidewall feed rollers. Remove the sidewall
stock from the feeder and make a radius cut at
the printed credit line. See Figure 8-2.
Reinstall the sidewall through the feeder and
die and into the open grippers making sure to Figure 8-2
stop the registration mark ¼” short of the
registration sensor at the feeder. Now turn the sidewall feed selector switch to the “on”
position. Jog the machine one index, stopping when the grippers at the die are open.
Remove this first blank. Press the sidewall feed index button. This will feed the
sidewall one feed length. Finally jog the machine until the die cuts the sidewall stock
and this will be a proper blank and the feeder is ready to run.

Note: On a blank fed machine turn the sidewall feed switch on and make sure it is
pulling blanks properly. If the blanks have been left in the hopper for a length of time,
some of the blanks may have taken a set and will need to be removed.

14) At the operators control panel, press the fault reset button to clear all faults that may
have occurred up to this point.

15) Turn the machine mode selector switch to the “run” position.

16) Turn the sidewall feed selector switch to the “off” position.

17) Turn the bottom feed selector switch to the “on” position.

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8-2
 PMC-1002
Production Startup
___________________________________________________________________________________________________________________

18) Turn and release the drive mode selector switch to the run position. You now have 3
seconds to depress both green start buttons at the same time to start the machine. If the
machine does not start, check the touch screen for faults and reset, and repeat this step
again.

19) Once the machine has reached speed and cycles without any problems, turn the sidewall
feed selector switch to the “on” position. This will start both the bottom and the sidewall
feeding.

Note: In order to feed sidewall stock and bottom stock in the run position, both selector
switches must be in the “on” position. If either switch is turned off the other will stop
feeding as well.

To stop the machine push any emergency stop button located around the machine and
the machine will stop immediately. Or push any of the cycle stop buttons and both the
sidewall and the bottom feeds will shut off and the machine will cycle until it is empty of
all cups. Make sure that when stopped the mandrels are between stations.

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8-3
 PMC-1002
Lubrication and Maintenance
___________________________________________________________________________________________________________________

LUBRICATION and MAINTENANCE

LUBRICATION GENERAL

The importance of proper and sufficient lubrication cannot be overemphasized! Improper or

insufficient lubrication can result in premature wear or damage to parts and assemblies. This
section provides instructions for initial lubrication of a new machine as well as a schedule of
regular intervals thereafter.

CAUTION: ANY TIME LUBRICATION IS TO BE DONE WITH THE GUARD

DOORS OPEN, ENGAGE AT LEAST TWO EMERGENCY STOP BUTTONS.

INITIAL LUBRICATION

After installation of a new machine or any time a machine has been out of service for an
extended period of time the following initial lubrication procedures must be followed before the
machine is put into operation. Review the operator’s lubrication schedule and procedures in this
section for the correct type and quantity of lubricant to be used.

1) Oil mandrel turret guide rods

2) Oil transfer turret bushings
3) Check main drive oil level

LUBE PANEL

The lube panel is located on the rear lower base leg, opposite the operator control station, for
ease of service.
A blank fed machine will have one fitting for the folding wing pivot pin.
A roll fed machine will have four fittings, one for each of the following:
1) Folding wing pivot pin
2) Sidewall die actuator connecting link
3) Sidewall die actuator lever
4) Sidewall die actuator pin

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 PMC-1002
Lubrication and Maintenance
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LUBRICATION REFERENCE

Light Oil............................................. SAE 20

Grease ................................................ Lubriplate # 1200-2 or equivalent
Mineral Oil......................................... Penreco, Drakeol 9, Arco Prime grade 90, or equivalent
Silicone .............................................. General Electric SF-18-390CS, or equivalent
Main Drive Oil ................................... Mobilgear SHC-320, or equivalent
Roll Stand Hydraulic Oil ................... Mobil DTE-26, or equivalent
EP Grease........................................... Chevron Rykon EP 2, Exxon Polyrex EP2, or equivalent

LUBRICATION AND MAINTENANCE SCHEDULE

8 HOUR
Description Application Lubricant
Mandrel Turret Guide Rods Hand Oil Light Oil
Sidewall Die Grease Fitting (3) Grease
Roll Stand Arbor Bearings Hand Oil Light Oil

Additional Tasks
Drain lubricant recovery tank
Refill lubricant supply tank

24 HOUR
Description Application Lubricant
Mandrel Turret Seam Clamp Grease Fittings (7) Grease
Roller Cam

48 HOUR
Description Application Lubricant
Folding Wings Grease Fitting Grease

120 HOUR
Description Application Lubricant
Transfer Turret Modules Grease Fitting (25) Grease (Must use Mobilith SHC 460 or
equivalent)
Rotary Placer Main Shaft Grease Fitting (3) Grease
Bottom Finish Knurl Roller Hand Grease EP Grease
Folding Wing Rod End Grease Fitting (2) EP Grease

Additional Tasks
Wash or replace the main drive lube oil filter
Clean the heater air intake filters
Clean and inspect the main air filter and sediment bowl
Check oil cooler fan filter and clean as needed
Remove bottom finish roller and flange assembly, clean and inspect
Remove bottom maker draw punch, clean and inspect punch and die
Check jam nuts on folding wing push rods for tightness
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 PMC-1002
Lubrication and Maintenance
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1500 HOUR
Description Application Lubricant
Bottom Stock Unwind Grease Fitting Grease

Additional Tasks
Take a sample of main drive oil and check for contamination
Make a visual inspection of all tooling and check mounting hardware for proper tightness
Check all main drive chains for proper tension
Make a visual check of all main drive cam followers
Clean oil pan sump magnets and check for any unusual debris in sump
Check condition and tension of the main drive belt
Check condition and tension of the oil pump drive belt
Check condition and tension of the bottom finish drive belt
Check condition and tension of the roller incurl drive belt
Check condition and tension of the bottom stock servo and constant feed roll belts

Roll Feed Machine

Check encoder drive belt
Check sidewall servo drive belt

Blank Feed Machine

Check rotary placer drive belt
Check the two rotary placer timing belts

3000 HOUR
Description Application Lubricant
Main drive oil level Dip Stick Mobilgear SHC-320
Mandrel turret rotary manifold Hand Apply through Fittings Mineral Oil
Rimming turret rotary manifold Hand Apply through Fittings Mineral Oil
Rotary placer vacuum manifold Hand Apply Mineral Oil

Additional Tasks
In the main drive make a visual check of all the gear sets for abnormal wear
Check main reduction drive pinion for excessive backlash

6000 HOUR
Drain and clean main drive oil pan and replace oil with new Mobilgear SHC-320 or equivalent
Drain and refill the roll stand hydraulic lift reservoir with Mobil DTE 26
Replace the roll stand hydraulic lift filter

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9-3
 PMC-1002
Operator Adjustments
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OPERATOR ADJUSTMENTS

ROLL FEED

LOADING WEB STOCK

On preprinted web stock, load the roll so that the printed side is threaded into the feeder facing
downward. On double poly coated stock, load the roll so that the shiny poly surface side is
down. On single poly coated stock, it is threaded into the feeder with the poly coated side
facing up. When preparing to load a new roll take note as to how the old roll was wound and
load the new roll accordingly.

To actually load a roll, follow this procedure:

1) Insert the core chuck into the roll

2) Position the roll so that the arbor shaft is aligned with the bearing block on each side.
3) Using the height adjust switch, raise the roll stand to seat the arbor shaft into the bearing
blocks and continue to raise it until the roll stand top surface is level. See Figure 10-1.

Figure 10-1

4) Connect the brake shaft to the arbor shaft then secure it with the retaining screw.
5) Secure the arbor latches.
6) Inflate the core chuck sufficiently to hold the roll in place, making sure the roll is
straight and runs true. The core chuck may need to be deflated and inflated several times
to accomplish this.
7) Proceed in threading the sidewall web stock. See Figure 10-2 for threading diagram.

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10-1
 PMC-1002
Operator Adjustments
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VIEW OF WEB DECURLER

WHEN ROLL IS UNWOUND
FROM THE TOP

SIDEWALL ROLL STAND

SIDEWALL FEEDER

VIEW OF WEB DECURLER

WHEN ROLL IS UNWOUND
FROM THE BOTTOM

Figure 10-2

ROLL STAND LATERAL ADJUSTMENT

The roll stand is equipped with a hand wheel, which allows you to adjust the roll from side to
side so that the paper can be fed straight into the sidewall feeder.

UNLOADING AN EMPTY WEB ROLL

1) Turn the brake switch to the off position.

2) Release air pressure from the chuck.
3) Push in the spring loaded pins and open
the arbor latch on each side. See Figure
10-3.
4) Unscrew the retaining screw and remove
the brake shaft from the arbor shaft.
5) Remove the arbor shaft from the roll
stand.
6) Remove the arbor shaft/core chuck from
the empty roll.
Figure 10-3

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10-2
 PMC-1002
Operator Adjustments
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SIDEWALL SERVO FEEDER

This is for roll fed machines only

THREADING SIDEWALL STOCK

1) Jog the machine until the transfer turret
gripper fingers at the sidewall die position
are open.
2) At the operators control panel turn the
sidewall feed selector switch to the “thread”
position, which will open the feed rolls.
3) Make a radial cut along the bottom radius of
the first printed blank just in front of the
credit line. See Figure 10-4.
4) Thread sidewall web stock into the sidewall
feeder as shown in Figure 10-2. Keep
pushing the web into the feeder until it Figure 10-4
returns. Then feed the web into the feeder
web guides. Continue to feed the web
through the servo feed rolls, thru the sidewall
die, and into the grippers. Stop the
registration mark ¼" short of the registration
sensor on the feeder. See Figure 10-5.
5) At the operators control panel turn the feed
selector switch to “off”.
6) At the operators control panel use the
sidewall metering rolls selector switch,
turning it to the forward position to create a
feed loop. The loop should extend to a point
somewhere between the two loop sensors. Figure 10-5
See Figure 10-6.
7) Now jog the machine one index until the
next set of transfer turret gripper fingers
opens at the sidewall die position. Remove
the first fed and cut blank.
8) At the operators control panel press the
“sidewall index” feed button to advance one
feed length and the sidewall is now ready to
run.

Figure 10-6

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10-3
 PMC-1002
Operator Adjustments
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WEB GUIDE ADJUSTMENTS

There are four web guide adjusting knobs on the operator side of the sidewall servo feeder, two
at each end of the guides. There is one inside and one outside, at each location. See Figure 10-
7. The inside knob has control in moving the entire web. Counterclockwise rotation moves the
web towards the operators side of the machine. Clockwise rotation moves the web away from
the operators side. The outside knob opens and closes the guides to compensate for a change in
the width of the web. Counter clockwise opens the guides and clockwise closes the guides.
Moving any of the knobs a lettered mark = 0.010". One full revolution of the knob makes a
move of 0.050".

Figure 10-7

REGISTRATION SENSOR

To properly calibrate the registration sensor, first position the sidewall stock registration mark
directly over the sensor and press the “registration calibrate” button located at the operators side
of the feeder. Then move the sidewall stock so that the mark is off the sensor and again press
the “registration calibrate” button. The sensor is now calibrated to detect the registration mark
on the sidewall.

BLANK FEED

A blank fed machine will have an infeed conveyor, with or without an incline, and a
blank hopper.

LOADING BLANKS

Blanks will need to be loaded, poly side in, printed side out. Care should be taken to ensure
blanks are put in neatly, straight, and square. Make sure that the blanks are touching the stop
fingers at the front of the hopper. Be careful not to pack blanks in too tightly. NOTE: All
blanks should be fanned prior to loading to help eliminate them from sticking together.

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10-4
 PMC-1002
Operator Adjustments
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BLANK SEPARATOR

An air nozzle is located at the top, front position of the blank hopper. See Figure 10-8. It can
be adjusted to gently blow air at the top edge of the blanks to help keep them separated, not
stuck together, for proper feeding. A valve is mounted on the inside of the enclosure upright.
See Figure 10-9. Just enough air should be used to keep the blanks separated so they feed one at
a time.

Figure 10-8 Figure 10-9

ROTARY PLACER

Driven by the rotary placer drive assembly, this unit picks the blanks from the hopper, by means
of vacuum through vacuum cups, and delivers them to the blank shuttle.

BLANK SHUTTLE

The blank shuttle receives the blank from the rotary placer and transfers it to the transfer turret.
Adjustable pushers on the shuttle are positioned to capture and push the blanks. These
adjustments are critical and will effect proper feeding.

BLANK HOLD DOWN

BLANK FEED MACHINES

Two air nozzles are mounted above the blank as it enters the transfer turret gripper fingers.
They should be positioned just to the side of the gripper. An air valve is mounted on the
inside of the enclosure upright. See Figure 10-10. Adjust the air so that it gently blows
down the leading edge of the blank as it is entering the gripper fingers. See Figure 10-11.
Using too much air can create problems with the blank diving into the wear ring.

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10-5
 PMC-1002
Operator Adjustments
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Figure 10-10 Figure 10-11

ROLL
FEED MACHINES

On roll fed machines a formed stainless steel guide is mounted to the die assembly and
positioned so that it guides the leading edge of the web as it is fed into the grippers.

TRANSFER TURRET CLEARING

CAUTION: Do not index the machine until any fault has been identified and
safely corrected and the fault cleared and reset to prevent any damage to the
machine or injury to the operator.

The PMC-1002 has two selector switches, one on the operators control panel and one on the
opposite side of the machine, that allow the operator to raise all the seam clamps and to open all
the gripper fingers so that sidewall blanks, bottom discs, or partially formed cups can easily be
removed. This will be necessary whenever the machine has been emergency stopped. This will
happen as a fault occurs or an emergency stop button is pressed. Only after the fault has been
identified and corrected should the machine be jogged or turned over by hand.

CAUTION: Do not use a pry bar or screw driver to lift the seam clamps or to
open the gripper fingers.

CAUTION: Avoid touching any of the heaters while clearing the machine. They
are extremely hot and will cause severe injury.

CAUTION: Any time you will be reaching into the machine for clearing, an
emergency stop button must be engaged.

CAUTION: Do not use sharp knives or box cutters for removing cups from
mandrels as damage to mandrels will occur causing machine down time.

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10-6
 PMC-1002
Operator Adjustments
___________________________________________________________________________________________________________________

BOTTOM STOCK UNWIND

LOADING BOTTOM STOCK

1) Unscrew locking knob. Remove washer and roll retainer, and remove empty roll core,
if any.
2) At the bottom stock roll lift control station,
turn the selector switch to raise or lower the
unit so that the roll hub is aligned with the
new rolls core for ease of loading. See
Figure 10-12.
3) Slide new roll onto the hub and raise the unit
using the selector switch.
4) Reinstall the roll retainer, washer, and the
locking knob, making sure the knob is
tightened.
Figure 10-12
THREADING THE BOTTOM STOCK

1) Jog the machine to the center of index position making sure the mandrels are
between stations.
2) At the operators control panel turn the bottom feed selector switch to the “thread”
position, which opens the feed rolls of the bottom feeder.
3) Turn bottom stock roll brake off.
4) Lead the bottom stock web from the roll, through the guide rollers, around the corner by
following the threading diagram in Figure 10-13 (for the standard bottom stock feeder)
and Figure 10-14 (for the offset bottom stock feeder).
5) Continue leading the bottom stock web through the bottom stock feeder as per Figure
10-15. Once through the feeder, continue down into the guides and through the die
block assembly, (Figure 10-16) ending up with the bottom stock into the scrap chute.

Figure 10-13 Figure 10-14

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10-7
 PMC-1002
Operator Adjustments
___________________________________________________________________________________________________________________

Figure 10-15

DIE BLOCK ASSEMBLY Figure 10-16

6) At this point turn the bottom feed selector switch to the “off” position closing the
feed rolls.
7) At the operators control panel turn the bottom metering rolls selector switch to
“forward” or “reverse” to position the feed loop between the two loop sensors. See
Figure 10-17. The feed loop sensors maintain a large enough loop to have enough paper
available to feed.

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10-8
 PMC-1002
Operator Adjustments
___________________________________________________________________________________________________________________

8) At the bottom stock roll wind the roll to take

up all the remaining slack and then turn on the
bottom stock roll brake. Slack left in place
will cause the bottom stock to break.

SCRAP CHUTE AIR ASSIST

The scrap chute is equipped with an air nozzle to aid

moving the bottom stock scrap through the chute.
Adjust the valve, located at the enclosure upright by
the lube recovery tank. See Figure 10-18. Use only Figure 10-17
the amount of air needed to keep the scrap moving
smoothly.

BOTTOM STOCK FELT LUBRICATOR

The PMC-1002 is equipped with a felt lubricator for

the bottom stock if needed. The assembly is fully
adjustable to apply lube to the bottom stock just
before the die block. See Figure 10-19. The amount
of lube can be seen at the sight glass and adjusted at a
valve located at the bottom right side of the operators
control panel. Use only if needed and use as little
lube as possible. Too much lube will accumulate in Figure 10-18
the scrap chute causing the scrap to jam. It will also
make the bottoms very oily.

SERVO BOTTOM FEEDER METERING ROLLS

The constant feed metering rolls pull the bottom stock

from the bottom stock roll stand into a loop between
the constant feed rolls and the servo feed rolls. These
rolls are driven by an AC variable speed drive so that
the loop is maintained at all machine speeds. The
loop is monitored by a long loop sensor and a short
loop sensor. If the loop reaches the high loop sensor
the roll speed will automatically slow down for a
short period of time allowing the loop to be used Figure 10-19
making it shorter. If the loop reaches the short loop
sensor the roll speed will increase bringing paper faster, which will build the loop again.

SERVO FEED ROLLS

The servo driven feed rolls index the bottom stock into the die block assembly. The amount of
feed is adjusted at the operators control panel touch screen. The feed length is given on the cup
drawing. The timing is also controlled by the PLC and set at the touch screen. Once set this

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should not have to be changed. The timing is set so that the web indexes just after the punch
clears the paper path.

BOTTOM MAKER

The bottom maker has two internal rams. One ram operates the cutting punch and the other ram
operates the draw punch. A die block assembly mounted to the front of the bottom maker
houses the cutting die and the draw die. See Figure 10-20. The guides for the bottom stock
actually fit into the top of the die block assembly to maintain control of the bottom stock. These
guides are adjustable both for width of the web and for centering of the web to the cutting
punch. These adjustments are made by means of an adjusting knob and an adjusting bolt
located on the operators side of the bottom maker. See Figure 10-21. The adjusting bolt is used
for centering the web on the cutting punch so that a full bottom disc is maintained. Doing this
also keeps the bottom stock scrap together making it travel down the scrap chute easily.
Turning the bolt counter clockwise will move the web away from the operator and by turning
the bolt clockwise the web will come towards the operator. The adjusting knob is used for
adjusting the width of the guides. This allows for changes in the bottom stock width. Turning
the knob counter clockwise will open the guides and turning the knob clockwise will close the
guides. It is important to have only enough clearance between the bottom stock and the guides
that the bottom stock passes through freely without wandering. Approximately 1⁄32" clearance is
proper.

Figure 10-20 Figure 10-21

SIDEWALL SEALER

Sidewall blanks indexed by the transfer turret are heated at the sidewall sealer station. At this
station the side seam areas, both upper and lower are heated and the bottom seal area of the
blank is preheated. This station consists of several assemblies.

BLANK GUIDES

A series of guide rods are mounted at the sidewall sealer. These rods are positioned under and
over the sidewall blank. Their purpose is to keep the blank as flat as possible while being
heated and indexed to the folding wing station.

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SIDEWALL BLANK DETECTOR

A sensor is mounted to detect if a blank has been fed and is indexing through the sidewall sealer
station. The sensor is mounted above the incoming blank. See Figure 10-22. The sensor
mounting block also has an adjustable air jet that blows air gently over the sensors face, keeping
it clean of paper dust. The adjusting valve is located inside the enclosure upright to the left of
the sidewall sealer. The sensor is factory set to e-stop the machine if two blanks in a row are
missing. Adjust the air so that it just blows across the sensor.

Figure 10-22

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HEATERS

The heaters consist of a heat gun and a nozzle. The heat gun is a tube with a heat element
inside. Air is blown through this tube and heated. A nozzle is mounted on the end of the heat
gun. This nozzle receives the heated air and distributes it to the blank. The shape and the size
of these nozzles are determined by cup size. The amount of heat produced by the heat element
is controlled by the PLC and can be adjusted at the operator control touch screen. Regulators
located at the FHA control panel control the amount of air used. This panel is mounted on the
rear enclosure upright. See Figure 10-23. Both the air and the temperature settings have been
pre-set at PMC. Due to environmental and material changes, these adjustments will need to be
changed occasionally. Heat adjustments should be made in increments of 25 ºF. until the
desired seal is obtained. When air pressure changes are made they will change the penetration
of the heat into the board stock. Too much or too little can create other problems such as: Too
much will burn or blow the poly coating from the board, and too little may result in a poor seal
because of little penetration.

CAUTION: Too little airflow will result in heater element damage or failure. Do
not adjust below 25 psi on the bottom heater regulator or below 15 psi on the
others.

Note: All heat guns have one heat element in them except for the bottom heater, which
has three.

Figure 10-23
NOZZLES

Sidewall nozzles are chambered housings that are baffled to control heated airflow to the
sidewall blank. Each nozzle is designed for a particular cup.

SIDEWALL HEAT PATTERN

A heat pattern test is the only real way to find out where the heaters are positioned. All the
sidewall heaters are adjustable to allow for proper sealing. The PMC-1002 allows you the
ability to actually test burn a blank and adjust as needed. The following is the procedure to test
burn a blank:

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CAUTION: BEFORE REACHING INTO THE MACHINE, ENGAGE AT

LEAST TWO EMERGENCY STOP BUTTONS.

1) Clear the machine of all cups and blanks.

2) At the operators control panel turn the drive mode selector switch to “jog”.
3) Turn the bottom feed selector switch to “off”.
4) Turn the sidewall selector switch to the “on” position.
5) Jog the machine until the first blank gets to the second sealing position. This will have a
blank at both sealing positions.
6) Turn the machine mode selector switch to the “test” position.

CAUTION: Be careful not to leave the switch in the test position too long,
as the blanks will burn so badly that the heat pattern will not be visible or
the blanks may start on fire.

7) View the pattern and adjust as necessary. When viewing you will be looking for the
placement of the individual holes from the nozzles. If these holes are not present, the
heater may not have been in test long enough. If there is a brown strip instead of holes
the heaters were left in the test position too long.

CAUTION: Use extreme caution when working in the sealing area as the heaters
are extremely hot and will cause serious injury or burns.

CAUTION: Always make sure that the machine has at least two emergency stop
buttons engaged when working on the machine.

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PROPER POSITIONING OF THE HEAT PATTERN

It is very important to have all the heaters positioned properly to achieve a good seal.
Improperly positioned heaters will result in a poor seal and may result in other cup defect
problems. The following information will give you a solid starting point. Determine the width
of the side seam. Position both the upper and lower side seam heaters so that the row of holes is
centered in the seam area. Also make sure that there is a hole positioned at the very upper edge
of the blank. See Figure 10-24. Note: The row of holes should be parallel to the edge of the
blank. Now determine the bottom depth of the cup. The bottom preheats row of holes should be
positioned parallel to the bottom radius of the blank 1½ times the bottom depth up from the
bottom edge of the blank. Note: These are good starting positions. They may need to be
adjusted slightly from these starting points.

CAUTION: BEFORE REACHING INTO THE MACHINE, ENGAGE AT

LEAST TWO EMERGENCY STOP BUTTONS.

UPPER SIDE SEAM NOZZLE POSITION 1/2 THE SIDE SEAM WIDTH

LOWER SIDE SEAM NOZZLE POSITION 1/2 THE SIDE SEAM WIDTH

POSITION SIDE SEAM NOZZLES SO THAT HOLES

ARE AT THE TOP EDGE OF THE BLANK

BOTTOM PREHEAT NOZZLE POSITION IS 1 1/2 TIMES THE BOTTOM DEPTH OF THE CUP

Figure 10-24

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BOTTOM DISC PREHEAT

When a mandrel indexes from the bottom maker it then stops at the bottom disc preheat station.
Here a heat nozzle mounted to a gun advances forward putting the nozzle into the mandrel nose
so that it preheats the bottom disc skirt. The nozzle has a single row of holes and should be
positioned so that the row of holes is ½ way up the skirt. A burn test will help determine if the
nozzle is in the proper position. To perform a burn test use the following procedure:

CAUTION: BEFORE REACHING INTO THE MACHINE, ENGAGE AT

LEAST TWO EMERGENCY STOP BUTTONS.

1) Clear the machine of all cups and blanks. Clearing can be done by cycle stopping the
machine or done manually- refer to clearing in the transfer turret section.
2) At the operators control panel turn the drive mode selector switch to the “jog” position
3) Turn the sidewall feed selector switch to the “off” position.
4) Turn the bottom feed selector switch to the “on” position.
5) Jog the machine until the bottom maker cuts, forms, and places a formed bottom into the
mandrel nose cone.
6) Jog the machine one more index stopping when the bottom disc preheat station is all the
way forward.
7) Turn the machine mode selector switch to the “test” position.

CAUTION: Be careful not to leave the switch in the test position too long,
as the blanks will burn so badly that the heat pattern will not be visible or
the blanks may start on fire.

8) Jog the machine so that mandrel with tested bottom is in between stations. Remove the
bottom disc and inspect. Small brown holes should be visible around the inside of the
skirt. If the small hole pattern is not visible, the heater may not have been in test long
enough or to long burning the bottom disc.
9) Once the pattern has been identified adjust as needed.

CAUTION: Use extreme care when working around heaters as they are
extremely hot and can cause serious injury or burns.

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FOLDING WING STATION

At this station the actual folding or wrapping of the sidewall blank takes place. The folding
wings wrap the blank around a mandrel, both of which are tooling items that are designed
specifically for a cup. As the sidewall blank has indexed through the sidewall sealer station, it
arrives at the folding wing station. At this point the paper clamp rises from the center of the
folding wings and secures the sidewall blank to the bottom of the mandrel with enough pressure
to firmly hold the blank in place for proper wrapping. This clamping pressure is preset by PMC
by means of precision ground spacers; there is no adjustment. The clamp stops approximately
½ the thickness of the sidewall away from the mandrel. This ensures that there is enough
pressure to secure the blank and the clamp never touches the mandrel causing wear when the
machine is run with no paper. Once the clamp has secured the blank, the transfer turret gripper
fingers open. The folding wings now start to close, one ahead of the other to allow for overlap
of the side seam. The folding wings are adjusted so that when fully closed there is no gap
between the wings and the blank, or between the blank and the mandrel. With the wings
properly set they will not touch the mandrel when closed without a blank in place. If the wings
do touch the mandrel without paper they need to be readjusted. As the trailing wing closes,
allowing for the side seam overlap, the mandrel turret seam clamp comes down applying
pressure to the side seam area to create a seal and to secure the shell to the mandrel. At this
time the lower paper clamp retracts and the folding wings open so that the mandrel turret can
index. If problems develop as the blank is being indexed into the folding wing station an air
nozzle is positioned at the folding wings so that air can be applied to help lift the sidewall blank.
This will at times be needed to help the blank clear the wings and the paper clamp. It is also
used to lift the blank when wrapping keeping the blank out of the wings. This air is controlled
by a valve located at the lower left corner of the operators control panel. See Figure 10-25. Use
only the amount of air that is needed; using too much air can also create problems.

Figure 10-25

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MANDREL TURRET

The mandrel turret is an indexing turret which has seven mandrels mounted to it for cup
forming. Each particular cup size requires mandrels specifically designed for that cup. A rotary
manifold is mounted on top of the turret allowing air and vacuum to be channeled thru the
turret. The ½" line and valve control the vacuum, used to hold the bottom disc in the mandrel
nose. The ⅜" line and valve control the air used to blow the cup shell off the mandrel into the
rimming turret pockets. The ¼" line supplies air for the seam clamp lift mechanism. Each of
the seven mandrels is an assembly itself. See Figure 10-26. The nose cone mounted to the front
of the mandrel holds the formed bottom disc. The stem running through the center of the
mandrel has the passageway for the air and vacuum. On the inside of the turret is a stem extend
assembly, which with the use of a cam and bearing rollers push the stems out. The stems are
extended to place the bottom disc into its final position after the bottom heat station. These
mandrel assemblies will have to be taken apart and cleaned periodically to maintain proper
operation. See the lubrication and maintenance section of this manual for the schedule. Above
each mandrel is a seam clamp assembly. See Figure 10-27. These assemblies have spring
loaded guide rods that are mounted through the turret. The bushings that guide these rods will
need to be lubricated. See the lubrication and maintenance section of this manual for the
schedule. At the bottom of these guide rods is a yoke that carries a bearing. These bearings ride
a cam track that is mounted to the top of the machine. This cam track controls opening the seam
clamps and is non-adjustable. See the lubrication and maintenance section for the proper lube
schedule. The seam clamp arm is mounted to the top of the two guide rods. Mounted to it are
the seam clamp holder and the seam clamp. See Figure 10-28. Under the seam clamp arm,
centered between the two guide rods is an adjusting screw. See Figure 10-29. This screw
positions where the seam clamp stops on its way down to the mandrel. The proper setting is ½
the sidewall thickness away from the mandrel. This allows enough pressure to make the side
seam and prevents the seam clamps from hitting the mandrels when there is no blank in place.
The seam clamps should be checked periodically to ensure that they pivot freely.

CAUTION: Do not use a pry bar or a screwdriver to force open the clamps; use the
clamps open feature.

CAUTION: Never use a sharp instrument such as a knife or razor blade to remove
cups from the mandrels as this may damage the mandrels.

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Figure 10-26

Figure 10-27

Figure 10-28 Figure 10-29

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10-18
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BOTTOM HEAT STATION

This station is the heat source for primary and secondary bottom seals. When a mandrel is
indexed from the folding wings to this station, the nozzle mounted to the heat gun advances
forward, putting the nozzle into the cup shell. This heat gun, unlike the others, has three heater
elements inside of it which allow for more heat. The airflow going through this assembly is
regulated at the FHA control panel. The temperature and airflow have been set by PMC but
may require adjustment due to environmental or material changes. When making temperature
adjustments make them in 25 ºF increments.

Note: If the airflow is adjusted, do not adjust below 25 psi at the FHA panel, or heater element
damage or failure may result. If proper positioning of this heater is in question, a burn test
should be done using the following procedure:

CAUTION: BEFORE REACHING INTO THE MACHINE, ENGAGE AT

LEAST TWO EMERGENCY STOP BUTTONS.

1) Clear the machine of all cups and blanks

2) Turn the machine mode selector switch to the “jog” position
3) Turn the sidewall feed and the bottom feed selector switches to the “on” position
4) Jog the machine until the first sidewall and bottom disc have been wrapped at the folding
wings.
5) Engage an e-stop button
6) Remove all the sidewall blanks and the bottom discs except the one just wrapped.
7) Turn the sidewall feed and the bottom feed selector switches to the “off” position.
8) Jog the machine until the wrapped shell is at the bottom heat station and the station is
fully forward.
9) Turn the machine mode selector switch to the “test” position.

CAUTION: Be careful not to leave the switch in the test position too long, as the
blanks will burn so badly that the heat pattern will not be visible or the blanks
may start on fire.

10) Jog the machine to the next center of index, which will position the mandrel with the test
burn between the bottom heat station and the roller incurl station.
11) Use the clamps open feature and remove the cup shell from the mandrel.
12) Close the clamps.
13) Inspect the burn pattern and adjust if needed.

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The bottom heat nozzle is designed with two rows of holes for the air to flow from. The proper
position is when the nozzle is all the way forward; one row of holes should be inside the
mandrel nose and the other row outside. See Figure 10-30. Use this as your starting point. Do
not allow the nozzle to touch the mandrel in the full forward position.

CAUTION: Use extreme care when working around the heaters as they are
extremely hot and can cause serious injury or burns.

Figure 10-30

MANDREL STEM EXTEND

As the mandrel leaves the bottom heat station the mandrel stem is advanced forward pushing the
formed bottom disc into its heated final position. This should be timed so that the stem starts to
extend as soon as the mandrel starts to index. See Figure 10-31.

Figure 10-31

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10-20
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ROLLER INCURL LUBRICATION

A reservoir that has an electronically controlled level of lubricant is mounted between the
bottom heat station and the roller incurl station. See Figure 10-32. The lubricant comes from
the lubricant supply tank mounted on the main drive motor enclosure. A float inside the
reservoir sends a signal to the PLC, which opens and closes a valve to maintain the proper level.
Lubricant is applied to the outside bottom of the shell as it indexes past the reservoir by a piece
of felt sticking up out of the reservoir; this aids in forming the shell bottom. It is adjusted so
that the felt just touches the shell. This is a wearable item and will require adjustment and
replacement at some time. Any excess lube is collected in a tray that has a vacuum line attached
to it, which draws the excess to the lube recovery tank, mounted on the main drive
motor enclosure.

CAUTION: BEFORE REACHING INTO THE MACHINE, ENGAGE AT

LEAST TWO EMERGENCY STOP BUTTONS.

Figure 10-32

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ROLLER INCURL STATION

After the lubricant is applied to the shell it can now be formed. At the roller incurl station, the
sidewall stock that extends beyond the mandrel nose is curled inward by a spinning roller head.
This head has free spinning u-grooved rollers. An electric motor and drive belt turn the head.
The rollers are positioned so as the station advances forward, the rollers come into contact with
the edge of the blank and roll it inward as it continues forward. Properly positioned rollers will
curl the sidewall stock over the bottom disc skirt to resemble a backwards J. See Figure 10-33.
There is also a center plug that aids in the forming. The plug is mounted on a shaft that runs
through the center of the roller head. This plug is specifically designed for the cup being run.
The plug is properly adjusted by advancing the station forward to its maximum position and
setting the face of the plug to be 0.030" away from the face of the extended mandrel stem. The
roller head is also adjustable in and out. It should be set so when measured, after it’s curled in,
it measures 0.010" more than the finished cup bottom dimension. This dimension is located on
the cup drawing. This measurement is a good starting point. It may have to be set differently
based on the variations of the blanks. It is measured from the outer edge of the bottom (after its
rolled) to the bottom of the cup. See Figure 10-34. It is important that the rollers be kept clean
and the drive belt stays tensioned properly.

CAUTION: BEFORE CLEANING THE ROLLERS, MAKE SURE YOU

ENGAGE AT LEAST TWO EMERGENCY STOP BUTTONS.

Figure 10-33 Figure 10-34

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BOTTOM FINISH STATION

At this station the bottom of the shell is finished off and the bottom seal is completed. The
station has a water cooled clamp ring that supports the outside of the shell as the bottom is
formed. It is important that the water is chilled (50◦F–60◦F) so the tooling does not overheat.
The station also has a belt driven tool spindle, which spins the tool. The tool, which is the
knurling roller, mounts on a slide block. As the station advances forward, a mechanical linkage
offsets the slide block, bringing the knurling roller out towards the clamp ring and applies
pressure to seal the bottom. Part of the knurling roller assembly is the roller flange, which
squares off the bottom edge of the cup. See Figure 10-35. The amount of pressure being
applied with the knurling roller can be adjusted. Centering of the roller is very important. It
must be centered to fit into the incurled shell without damaging the shell. The station is also
positioned to stop at the correct spot on its forward travel.

WARNING: BEFORE MAKING ANY ADJUSTMENT AT THIS STATION

TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,
DISCONNECT, AND LOCK OUT.

NOTE: All adjustments and set-up of this station should be done only by a qualified technician
that has been thoroughly trained by PMC, as tooling and station damage or failure may result
from improper set-up or adjustment!

Figure 10-35

The clamp ring and roller assembly will need to be removed and cleaned at regular intervals.
Check the lubrication and maintenance section for the proper schedule. It is also important to
make certain that the drive belt is tensioned properly and that the knurling roller turns freely.

CUP SHELL TRANSFER

As the mandrel leaves the bottom finish station, the mandrel stem extends, breaking the shell
loose from the mandrel. The mandrel indexes to a position directly inline with a rimming
pocket, and then a PLC controlled air blast blows the shell from the mandrel into the pocket.

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RIMMING TURRET

The rimming turret is an indexing turret which has seven pockets mounted to it. The pockets
hold the cup shell so it can be rimmed. Each particular cup size requires pockets that are
designed for that cup. A rotary manifold is mounted to the top of the turret for air and vacuum.
There are two vacuum lines and one air line, which all have valves to regulate the amount used.
See Figure 10-36 for location of these valves:
1) Transfer vacuum – holds the cup shell in the pocket once it’s transferred from the
mandrel turret.
2) Cup hold vacuum – holds the cup shell tightly in the pocket while the rim is being
formed.
3) Blow off air – blows the finished cup out of the pocket and discharges it from the
machine.
Note: Care needs to be taken when setting these valves. For example, too much cup hold
vacuum may weaken or destroy the bottom seal of the cup causing leakers. Use only the
amount of vacuum needed.

Figure 10-36

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POCKETS

Each pocket assembly consists of several components. A die ring is mounted to the outer face
of the pocket. This is a tooling item that helps form the rim. At the bottom of the pocket is an
adjustable cup stop. The cup stop is adjusted up or down for cup height changes and it supports
the bottom of the shell while the rim is formed. To make an adjustment to the cup stop or
knockout, for a height change, you will need to use the two special tools supplied with the
machine. See Figure 10-37. The following procedure should be used when adjusting the
pockets:

WARNING: BEFORE MAKING ANY ADJUSTMENT, TURN OFF MAIN

POWER AT THE ELECTRICAL CONSOLE, DISCONNECT, AND LOCK
OUT.

1) Use a depth micrometer and measure from the die ring to the bottom of the knockout and
record this dimension.
2) Insert the two pin “T” handle wrench so that the pins fit into the two holes in the
knockout. See Figure 10-37.
3) Place the long “T” handled allen wrench through the pin wrench.
4) Turn the pin wrench counterclockwise to loosen the locking screw.
5) Turn the allen wrench clockwise to lower the cup stop, causing the cup to get taller, and
counterclockwise to raise the cup stop, making the cup get shorter.
6) Turn the pin wrench clockwise to retighten the locking screw.
7) Measure the pocket depth again to see what change has been made.
8) Repeat the process for the remaining pockets.

Note: It does not take a lot of adjustment to change the depth. Make small adjustments. Make
all the pockets the same. Also keep in mind that too much adjustment will cause cup damage.
The cup stop also has a hole thru the middle for vacuum and air. This cup stop assembly is run
on an internal cam that at the discharge position pushes out, helping to break the cup free for
discharge. This knock out cam is adjustable. See Figure 10-38.

Figure 10-37 Figure 10-38

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TAMPER LUBE STATION

Once a pocket has received a cup shell it then indexes to the tamper lube station. At this station
the cup shell is firmly seated into the pocket at the same time the top edge of the shell is
lubricated to aid in rim forming. The tamper lube head is a tooling item designed specifically
for a particular cup. This head is mounted to the station slide and is adjustable for centering as
well as for its stopping position in forward travel. The lubrication is applied by means of a felt
cord sandwiched between the two pieces of the head. This felt is a wearable item. As it wears
down its ability to apply lube diminishes and it will need replacing. When replacing the felt it
will have to be fit. You will need to produce some cup shells without rims ahead of time. The
felt should be cut diagonally to make a good seam. The seam should be located at the 11:00 or
1:00 position when installed. See Figures 10-39 and 10-40. Once the felt is in the head and
secured, test fit a cup shell by pushing the cup on to the tamper head. A slight drag should be
felt. If it is too tight it will damage the cup as it goes in or pull the cup out of the pocket as the
unit retracts. If it is too loose it will not wipe the lubricant on the shell properly. To make the
felt smaller, cut off a small piece of material on one end and stretch it as you put it together. To
make it larger, start with a longer piece of felt. To center the head use the following procedure.

Figure 10-39 Figure 10-40

WARNING: BEFORE MAKING ANY ADJUSTMENT, TURN OFF MAIN

POWER AT THE ELECTRICAL CONSOLE, DISCONNECT, AND LOCK
OUT.

1) Place a cup shell, without a rim, into the pocket that will be indexed to the tamper station
next.
2) Loosen the three mounting bolts that secure the tamper head.
3) By hand turn the machine so that the head is moving forward into the shell until it is all
the way forward. Be careful not to damage the shell as this is happening. You may have
to move the head to guide it in.
4) Turn the machine backwards until the head is out of the shell and you can get at the
mounting bolts.
5) Tighten the mounting bolts.
6) Turn the machine forward again to check the alignment of the head. Readjust if needed.

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With the head now centered, the forward position of the unit can be set. The head will move
forward and back straight because it has a key under the mounting bracket. The proper position
is that when the station is all the way forward, it should firmly push the cup shell into the pocket
without crushing the shell. If an adjustment is needed loosen the two mounting bolts, see Figure
10-41, and slide the unit forward or back. When done recheck to make sure the shell is seated
properly and not damaged. The amount of lubricant going to the head is controlled by three
valves located at the lower right hand side of the operators control panel. See Figure 10-42.
The head has three lube lines attached to it. Valve number 1 controls the right side of the head.
Valve number 2 controls the top of the head, and valve number 3 controls the left side. See
Figure 10-43. Valve number 2, which is the top, should be adjusted to have the most lube and
valves numbers 1 and 3 should be adjusted to have very little. This is set this way because oil
from the top will wick down on both sides. The important thing to remember is to use only the
amount of oil that’s needed. There is a tray mounted under the head to collect any excess oil. A
vacuum line carries this oil to the recovery tank.

Figure 10-41 Figure 10-42

Figure 10-43

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RIMMING STATIONS

All three rimming stations have heated form tools mounted to them. These tools are specifically
designed to fit a particular cup size. A thermocouple in each tool monitors the heat that the PLC
controls. The PMC-1002 cannot be jogged or run until the temperature of all three tools is
within 15 ºF of the actual set points which is controlled by the PLC and set at the operators
control panel touch screen. Typical optimum operating temperatures are 155 ºF. and 190 ºF.
These temperatures will vary based on environmental and material conditions. These heated
form tools are mounted to adjustable rams. They are all adjusted the same way, but will have
different stopping positions. These stations also have spring overload protection that has been
factory set. The overload springs help prevent damage to the tooling and station in the event of
crushed or multiple cups. It is important that the form tools are periodically cleaned to maintain
good rim forming. For proper cleaning procedures refer to the cleaning section of this manual.
For adjustments go to the mechanical adjustment section of this manual.

1ST RIMMING STATION

This station is adjusted so that as the station advances to its forward position the edge of the
shell is rolled outward as the center section or nose of the tool stretches the paper and supports it
from the inside of the shell. When the station has cycled in and out the shell has a slight curled
edge, which is the start of a rim. See Figure 10-44.

Figure 10-44

2ND RIMMING STATION

This station basically performs the same as the 1st station except its adjustment allows the
station to advance forward more curling the edge creating more of a rolled rim.

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10-28
 PMC-1002
Operator Adjustments
___________________________________________________________________________________________________________________

3RD RIMMING STATION

This station is adjusted to advance forward until the die ring is touched. This completes and sets
the rim. See Figure 10-45.

Figure 10-45

CUP DISCHARGE STATION

After the rim has been finished at the last rimming station, it indexes with a finished cup to the
discharge position. While indexing the cup stop located in the bottom of the pocket is pushed
forward breaking the breaking the cup free from the pocket. As the pocket stops at this position
the PLC controls an air blast, blowing the finished cup from the machine.

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10-29
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

MAIN DRIVE

All the cams in this drive are keyed to the drive shafts so that there is not any timing involved
with anything that is cam driven. Other than the timing of the stations, that may require setting
when replacing the drive chains, there are no adjustments required in the PMC-1002 main drive.
For the sake of convenience, anything that may require adjusting has been designed to be
located on the top of the machine and has been discussed in the machine adjustment section of
this manual. Discussed in this section will be the timing of the stations through the drive chains,
the inspection of cam followers and cams, the inspection of drive chains, the inspection of gear
sets, the main reduction drive set-up, and the replacement of cam followers.

CAUTION: BEFORE MAKING ANY ADJUSTMENTS OR REPAIRS,

ENGAGE AT LEAST TWO EMERGENCY STOP BUTTONS. LOCK-OUT
SYSTEM SHOULD ALSO BE USED ANY TIME A TASK IS PERFORMED IN
THE LOWER DRIVE.

STATION TIMING

All the stations on the PMC-1002 are chain driven

and timed by these drive chains from the main
camshaft. As with all PMC equipment, the timing is
done in reference to the center of dwell. The turret
drive cams, transfer, mandrel, and rimming have two
sections, index and dwell. When indexing the turrets
are moving and all the stations must be back and out
of the way. When the cam reaches the dwell portion,
all the stations need to advance inward and do their
work and retract while the turrets are stationary. To
aid in the timing of the stations, while under the
machine the large drive gear mounted to the end of Figure 11-1
the main shaft is stamped with degree marks with “0”
being the center of dwell. See Figure 11-1. There are
three gearboxes that are driven from the main shaft.
Each one of these gearboxes drive several stations.
The gearbox mounted to the roller incurl station
drives the roller incurl, bottom heat, and on a blank
fed machine, the shuttle drive and the rotary placer
drive. On a roll fed machine this gearbox will drive
the roller incurl, bottom heat, and the encoder drive.
The gearbox that’s located closest to the rimming
turret drives the 2nd and 3rd rimming stations and the
bottom finish station. The third gearbox located on
the other side of the drive drives the bottom maker,
1st rimming station, tamper lube, and the bottom disc
preheat station. Starting with the cluster that includes Figure 11-2
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11-1
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

the bottom finish station, the timing is as follows:

Identify the timing mark that’s on the end of the
shafts. (The timing mark is a small grove milled in
the end of the shaft.) This timing mark is in line with
the keyway in the shaft. At the bottom finish station
the mark should be pointed to the center of the
mandrel turret. See Figure 11-2. The 2nd and 3rd
rimming stations should have their timing marks
pointing to the center of the rimming turret. See
Figure 11-3. The chains can now be connected.
After properly tensioning the chains check to make
sure that the timing marks are still pointing at the Figure 11-3
center of the correct turrets. If not, disconnect the
chain and re-time. Now position the main shaft so the
“0” mark is aligned with the pointer that is mounted
to the bearing bracket at the main drive gear. See
Figure 11-4. The drive chain that runs from the
gearbox to the main shaft can now be installed.
Again once the chain is properly tensioned check to
make sure that all the timing marks are in the correct
positions. Note: When installing the chains make the
connection on the idler side. Install the chain on the
tight side first. If the chain does not fit exact on the
tight side, turn the station the shortest direction to get
the chain to fit.
Figure 11-4

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11-2
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

CAUTION: The bottom finish station has loaded springs that MUST BE
UNLOADED on the upper part of the station. Failure to do so may result in
serious injury.

The following procedure is used to remove the spring load from the bottom finish station:

WARNING: BEFORE PERFORMING THIS TASK TURN OFF MAIN POWER

AT THE ELECTRICAL CONSOLE, DISCONNECT, AND LOCK OUT.

1) Shut the power to the machine off.

2) Remove the drive belt from motor to the station. Note: Support the motor and stand,
so it does not fall.
3) Remove the four bolts that secure the motor stand to the station and swing the stand out
of the way. See Figure 11-5. Secure motor stand so that it is out of the way and so it
will not fall or hang from electrical connection.

REMOVE THESE TWO BOLTS

ON EACH SIDE (4 TOTAL)

Figure 11-5

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11-3
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

4) Remove one of the upper, outside socket head bolts and one of the lower, outside socket
head bolts. See Figure 11-6.

REMOVE ONE UPPER AND

ONE OPPOSING LOWER BOLT

Figure 11-6

5) Install a 6 inch piece of 3⁄8 inch-16 threaded rod into the two places that the socket heads
were removed. Make sure to thread in about 1 inch of the rod.
6) Install a flat washer and a hex nut onto each threaded rod, running the nuts up snug to
the cover plate.
7) Remove the remaining three socket head bolts.
8) Slowly and evenly back the two nuts off, making sure that the rods do not unscrew until
the spring pressure has been eliminated.

Reverse this process when finished to reload and reassemble the station.

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11-4
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

CAUTION: Bottom Pre-Heat, Bottom Heat, Bottom Finish, and Blank Shuttle Stations
are spring loaded and the load MUST BE REMOVED before any work is done to
the drive.

On a roll fed machine the gearbox drives the bottom incurl station, bottom heat station, and
encoder drive. On a blank fed machine the gearbox drives the roller incurl station, bottom heat
station, shuttle drive station, and rotary placer gearbox. The gearbox mounts to the roller
incurl station. The driveshaft of the station is connected to the top gear of the right angle gear
set. To time this section, start by positioning the roller incurl station in its proper position.
Looking into the gearbox you will find a cover plate
with two bolts in it. See Figure 11-7. Turn the
station so that the two bolts are perpendicular to the
center of the mandrel turret. See Figure 11-8. This
will either be the right position or 180 degrees out.
To verify, check the top of the machine to make
sure the roller incurl station is all the way forward.
If the station is in the back position turn the station
180 degrees. At the bottom heat station there is a
timing mark on the shaft. See Figure 11-9. This
mark should be made to point at the center of the
mandrel turret. Figure 11-7

Figure 11-9

Figure 11-8

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11-5
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

CAUTION: Bottom Pre-Heat, Bottom Heat, Bottom Finish, and Blank Shuttle
Stations are spring loaded and the load MUST BE REMOVED before any work
is done to the drive.

The following procedure MUST BE FOLLOWED to remove the pressure:

WARNING: BEFORE PERFORMING THIS TASK TURN OFF MAIN POWER

AT THE ELECTRICAL CONSOLE, DISCONNECT, AND LOCK OUT.

1) Remove the warning plate bracket.

2) Remove one of the outside mounting bolts and
install a 6 inch piece of threaded rod with a
flat washer and a nut run snug against the
plate. See Figure 11-10. Make sure that there
is at least ¾ inch of the rod threaded in.
3) Repeat step 2 on the other outside mounting
bolt.
4) Remove the center mounting bolt.
5) Slowly and evenly back off the two nuts
relieving the pressure.
Figure 11-10
Reverse this process when finished to reload and
reassemble the station.

If the machine is roll fed, the remaining sprocket or

station in this drive group will be the encoder drive
station. It requires no timing. Remember that the
chains should always be connected on the idler side
and that tight side used for timing. Once the chains
have been tensioned check the timing again and make
any changes that may be needed. If the tight side of
the chain does not fall into the teeth of the sprocket
turn the sprocket in the shortest direction to align it.
With all these stations timed the main shaft should be
put at “0” and the chain connected from the gearbox
to the main shaft. Figure 11-11

On a machine that is blank fed, there will be a rotary placer gearbox instead of the encoder
station. It has no timing. There will be an additional station next to the rotary placer gearbox
that will require timing. See Figure 11-11. This station has a timing mark on the end of the
shaft that should be pointed to the center of the transfer turret. The chain is then connected.

CAUTION: Bottom Pre-Heat, Bottom Heat, Bottom Finish, and Blank Shuttle
Stations are spring loaded and the load MUST BE REMOVED before any work
is done to the drive.

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11-6
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

The following procedure MUST BE FOLLOWED to remove the pressure:

WARNING: BEFORE PERFORMING THIS TASK TURN OFF MAIN POWER

AT THE ELECTRICAL CONSOLE DISCONNECT AND LOCK OUT.

1) Remove the warning plate bracket.

2) Remove one of the outside mounting bolts and
install a 6 inch piece of threaded rod with a flat
washer and a nut run snug against the plate. See
Figure 11-12. Make sure that there is at least ¾
inch of the rod threaded in.
3) Repeat step 2 on the other outside mounting
bolt.
4) Remove the center mounting bolt.
5) Slowly and evenly back off the two nuts
relieving the pressure.

Reverse this process when finished to reload and Figure 11-12

reassemble the station.

The last group of stations that requires timing is the gearbox that drives the bottom maker,
tamper lube, 1st rimming, and the bottom disc preheat stations. The bottom maker and the
tamper lube stations do not have timing marks. They are positioned so that the draw punch of
the bottom maker is fully extended, and the tamper lube station is turned so that it also is all the
way forward. These two stations can now be chained.
The 1st rimming station has a timing mark that should
be pointed to the center of the rimming turret and the
chain connected. The bottom disc preheat station has
a timing mark that should be pointed perpendicular to
the side of the machine. See Figure 11-13. Once the
stations are all connected the main shaft should be at
“0” and connected to the gearbox. Remember that the
connectors should be on the idler side and that the
timing is done with the chain tight on the tight side.
If a chain does not line up when timing, move the
sprocket with the least amount of movement. Figure 11-13

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11-7
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

TURRET DRIVE CAMS AND CAM FOLLOWERS

The PMC-1002 uses roller gear design on the cams that drive the three turrets. Through the use
of a cam follower plate and cam followers these turrets are positively indexed. The alignment
and relationship between the cams and the cam follower plates and cam followers is extremely
critical to the performance and longevity of both the cams and the cam followers. It is
important that a periodic visual inspection of the cams and the cam followers is done. This
should at least be done at the frequency that is outlined in the lubrication and maintenance
section of this manual.

VISUAL INSPECTION

When making a visual inspection, the first thing to look at after the oil pan has been lowered is
the cam followers. If they appear to be black and have no marks on them, they are fine and will
not need further examination at this time. If any of the cam followers are completely silver in
color it is time to measure them. To measure them correctly, they must be at room temperature.
Measuring them when they are hot will give false measurements. If the cam follower measures
0.001 inch smaller than its nominal size, it must be replaced. Failure to do so will result in
cam damage or failure. If a cam follower has silver stripes or bands on it, a closer examination
of the cam follower is needed. If it appears to a rough finish, it will need to be replaced. If the
cam follower has a smooth finish, it can be run as long as it is monitored and does not get
worse. If any amount of silver is visible on the cam follower, the cam should be inspected. If
any roughness is found anywhere on the cam track it must be evaluated by a qualified person
trained by PMC or by a PMC service tech. The cam will need to be polished to eliminate any
roughness which will damage good or new cam followers; in turn will damage the cam again. It
is strongly advisable to have a PMC service tech work along with you the first time to ensure
that this is done properly. This is also a great time for training. If ever in doubt about any cam
or cam follower issues, call PMC.

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11-8
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

CAM FOLLOWER REPLACEMENT

Cam followers are an item that will wear and at some point need replacing. Although the cam
followers could be changed while in the machine, it is much easier and more accurate to remove
the cam follower plate from the machine and do the work on a workbench. The following is the
procedure used for removing the mandrel cam follower plate, which is the largest and heaviest.
The other two cam follower plates will be removed the same way. The difference is that they are
smaller and lighter, and may have different size mounting bolts and locating pins. Most of the
removal and installing will require two people.

WARNING: BEFORE STARTING TURN OFF MAIN POWER AT THE

ELECTRICAL CONSOLE, DISCONNEC, AND LOCK OUT.

1) Make certain that the main power is off and the machine is locked out.
2) Hand turn the machine so that the main shaft is at “0” or in the center of dwell.
3) Wipe oil from the cam followers and the cam follower plate to make handling safer.
4) Break loose the five mounting bolts. See Figure 11-14.
5) Remove one of the bolts and install a 12 inch
piece of ½ inch-20 threaded rod with a flat
washer and a nut on the bottom end. Make
sure to thread the rod at least 1 inch into the
threads. This will act as a safety and keep the
cam follower plate from falling on you or to
the floor.
6) With one person applying pressure upward
holding the cam follower plate up, remove the
remaining four bolts. This will allow the
cover plate to come down far enough to
reinstall two of the mounting bolts without the
cover plate. These bolts should be put into the Figure 11-14
hole next to each pull dowel. See Figure
11-15. These two bolts should now be
tightened down.
7) With a pin puller or a slide hammer remove
the two pull dowels.
8) With the two mounting bolts in and the pins
removed, take the nut and washer off the
threaded rod, and remove the rod along with
the cover plate.
9) With someone holding the cam follower plate
up in place, remove the two mounting bolts
and pull the cam follower plate down and out
of the machine. Figure 11-15
CAUTION: THE CAM FOLLOWER PLATE IS VERY HEAVY. USE
CARE THAT WHEN REMOVING, IT DOES NOT FALL. IF THE CAM
FOLLOWER PLATE FALLS ON YOU IT MAY CAUSE SERIOUS
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11-9
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

INJURY.

With the cam follower plate now removed take it to a workbench. The first step will be to clean
the unit prior to disassembly. If a parts washer is available submerge the unit and with a brush
clean all the oil and residue off. When clean, wipe or blow the cam follower plate dry.

CAUTION: Follow all safety procedures when using compressed air.

With a large c-clamp secure the cam follower plate to

a solid worktop. See Figure 11-16. The cam follower
plate is a two piece assembly and the first step is to
loosen the fourteen socket head screws that hold the
two halves together. Do not remove them. Just make
certain that they are all loose. The next step is to
break all the cam cam followers loose. Use a ¾ inch
allen socket on a large breaker bar. Insert the allen
socket into the cam follower and break them loose
turning them a half turn after loose. Now remove the
fourteen socket head screws. With a soft hammer
give the top section of the cam follower plate a sharp
rap to break it loose. Remove the top half of the plate
and take out the seven cam followers. Remove the
square nuts from the cam followers and discard the
cam followers. The nuts and the two halves of the Figure 11-16
cam follower plate will now need to be cleaned
thoroughly. Starting with the nuts, wash them with
parts cleaner and then using an oilstone, stone both
faces to remove any burrs. On the bottom half of the
cam follower plate use a ½ inch-20 tap and chase the
threads clean in the fourteen mounting holes. The
two halves of the cam follower plate now need to be
deburred. Using a fine grade of emery cloth go over
all the edges, especially the edges of cam follower
bores making sure there are absolutely no burrs or
rough spots. When this has been done, both halves
will need to be thoroughly washed again. When
done, a flat stone needs to be run over both mounting
surfaces and the front face that the cam follower
shoulders too. Set these two pieces aside and cover
with a clean rag. The new cam followers will now
need to be prepped. Start by removing the new cam
followers from the boxes and wiping off the grease.
When clean use a micrometer to measure the diameter
of the cam follower shell. They must all be within
0.0002 inch of each other. If not, check more cam
Figure 11-17
followers until you have a set of seven. Now that you

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11-10
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

have a set of seven cam followers the same size, they

will need to be deburred. Use a stone to remove all
the burrs from the cam follower stud between the
roller and the threads. See Figure 11-17. Also stone
the mounting ring face on the back of the roller. See
Figure 11-18. The nuts can now be put back on the
cam followers. They should be positioned so that the
face of the nut is as close to the cam follower plate as
possible still allowing them to be put in. See Figure
11-19. This is done to minimize the amount of
turning of the cam follower when tightening. Apply a
thin coat of machine oil to the bores on the bottom
half of the cam follower plate. Place the new cam Figure 11-18
followers into the lower half making sure that the lock
nuts are as close as possible to the cam follower plate.
See Figure 11-19. With the cam followers in place
apply some machine oil to the cam follower studs.
Install the top half of the cam follower plate making
sure that the match marks line up. NOTE: The two
halves of the cam follower plate must be put together
one way, with the match marks aligned. Clean the
thread of all the mounting bolts and insert the
fourteen mounting bolts into the cam follower plate
and just snug them by hand. Start with one bolt and
work your way around the cam follower plate,
snugging each bolt in succession until they are snug
enough that, the cam follower plate will turn with the
cam follower plate sitting flat on a clean rag. If the Figure 11-19
bolts are any tighter, the cam followers will not turn
as they are tightened. Now the cam followers can be
locked in. A torque wrench that is capable of 150–
250 ft/lbs will be required. Torque all the cam
followers to 150–250 ft/lbs. With the cam followers
locked in, the fourteen mounting bolts will need to be
torqued to 90 ft lbs. At this point with everything
tightened, the cam follower plate needs to be checked.
For proper checking you will need a surface table or a
flat, machined surface. Stone the bottom surface of
the cam follower plate and place it on the table. Set
up a height gauge and zero it on one of the cam
followers. See Figure 11-20. Leaving the height
gauge in place, turn the cam follower plate so all of
the cam followers pass under the indicator. There
should be no more than .001 inch difference between Figure 11-20
all the cam followers. If there is more, the cam
follower plate will need to come apart and be
deburred, cleaned, and reassembled until it’s correct.
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11-11
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

When the cam follower plate is correct, remove the

fourteen mounting bolts one at a time, apply locktite
and torque the bolt at 90 ft/lbs.

With the cam follower plate now complete, the drive can be prepared for installation of the cam
follower plate. Start by running a ½ inch-20 tap into the five threaded mounting holes. Clean
the threads on the five mounting bolts. Use a flat stone on the bottom of the turret shaft to
remove any burrs. Check the diameter of the turret shaft and remove any burrs found. Check
the pull dowels making sure that they are all galled. Now is an ideal time to inspect the cam
track for any wear or scuff marks. If any are found, they will need to be evaluated by qualified
PMC trained person to determine the severity of damage and whether or not they should be
polished. Polishing should also be done by a qualified, PMC trained person or by a PMC
service tech. If there are any questions concerning the cams contact PMC.

It is a good idea to place all parts and tools under the machine before starting to reinstall. Do
not use the old shakeproof lock washers, use new ones instead. An additional piece of threaded
rod will be needed to aid in reinstalling the cam follower plate. The cam follower plate will
only bolt up one way. The pull dowels are offset. Take a few moments to examine the
relationship between the bolts and the two pins so that the cam follower plate is installed in the
correct orientation the first time. Without the nuts and flat washers install the two pieces of
threaded rod opposite of each other in the turret shaft. One person can now lift the cam follower
plate up using the guide rods through the mounting holes and the second person can place the
flat washers and nuts on the threaded rods and turn them up as far as they will go by hand. At
this point the cam follower plate should be secure and not able to fall. Slowly and evenly
tighten the nuts drawing the cam follower plate up. Use care as the cam follower plate is just
starting on the turret shaft to ensure that it is straight. If it is not straight it will bind and gall the
shaft making it nearly impossible to get on. When the cam follower plate is all the way on,
secure it with one of the mounting bolts and remove the two pieces of threaded rods. Thread a
hex head bolt into the threaded end of the dowel pins. Use a short enough bolt that it will thread
completely into the pin. Apply a generous amount of never sieze on to the pins and drive them
in, using a hammer hitting the top of the hex head bolt until the pins are all the way in, flush
with the cam follower plate, then removing the hex head bolts. With one person holding the
cam follower plate up the second person can remove the one mounting bolt. Replace the cover
plate and install the five mounting bolts with new shakeproof washers and locktite applied to the
threads. Torque the mounting bolts to 90 ft/lbs, tightening every other bolt around the bolt
circle until they are all torqued. When the cam follower plate is installed and tightened down,
its relationship to the cam needs to be checked. Refer to the cam positioning section for the
proper alignment specs. This same procedure should be followed on the other two cam follower
plates. For tightening the cam followers in the other two cam follower plates the torque values
are: Rimming cam followers = 100 ft/lbs. Transfer followers = 50 ft/lbs.

CAM POSITIONING

Proper cam position is extremely critical for machine performance and cam and cam follower
longevity. This is an adjustment that must not be made by anyone not thoroughly trained by
PMC. If the cam appears that it may require an adjustment, a PMC service tech should be
called in. If one of the roller gear cams is set incorrectly it will destroy a new set of cam
__________________________________________________________________________________________________________________

11-12
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

followers in minutes and more than likely damage the cam. If you have any questions on any of
these cams call PMC. Proper positioning is established by reading and interpreting the results
of bluing. This is something that can only be learned by working with a qualified PMC service
tech. There are too many variables, and each machine can be slightly different for a description
of this procedure to be put into text.
MAIN REDUCTION DRIVE

The main reduction drive is a ring and pinion set.

The main drive motor drives the pinion that drives the
ring gear that is mounted to the main shaft. The
pinion is driven with a drive belt, which will require
inspection as scheduled in the maintenance and
lubrication section of this manual. The backlash
setting of the ring and pinion must also be checked as
scheduled in the maintenance and lubrication section
of this manual. As the ring gear wears, the backlash
will require readjusting. The backlash is measured at
the pulley mounted to the top of the pinion shaft. The
proper setting will measure 0.004 inch and is Figure 11-21
measured by placing a magnetic base and indicator so
that the indicator needle is placed at one of the mounting bolts of the pulley. See Figure 11-21.
When measuring the backlash the drive belt must be loosened so that the pinion shaft is able to
turn. The backlash will need to be checked in at least eight positions. To accomplish this,
measure and record the first measurement then retighten the drive belt enough to turn the
machine and turn the machine by hand so that the pulley makes one revolution. Loosen the drive
belt and make and record another measurement. Repeat this procedure until you have at least
eight measurements. Readjust using the smallest measurement, making it 0.004 inch when the
machine is hot. As the machine runs and the gearset wears, adjustment should be made when
the smallest measurement exceeds 0.015". To make the actual adjustment use the following
procedure:

WARNING: BEFORE STARTING TURN OFF MAIN POWER AT THE

ELECTRICAL CONSOLE DISCONNECT AND LOCK OUT.

Remove the main drive belt guard

1) Loosen the main drive belt by loosening the nut on the backside of the motor mounting
plate and swing the motor and plate in.
2) Loosen the three mounting bolts that secure the pinion seal plate. See Figure 11-22.

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11-13
 PMC-1002
Main Drive
___________________________________________________________________________________________________________________

Figure 11-22

3) Lower the scissors lift assemblies on the oil pan and remove the twelve mounting bolts
that secure the pan. Lower the oil pan.
4) If the pinion housing is pinned remove the pull pins. Do not use again.
5) Loosen the four mounting bolts at the pinion housing.
6) Pry the pinion housing forward and tighten the mounting bolts. Make sure that the
housing slides straight forward keeping the
pinion positioned properly on the ring gear
using fixtures MT-1591 and MT-1594. See
Figure 11-23.
7) With the indicator, measure the backlash
again. Repeat the process until the proper
backlash is achieved.
8) Install new shake-proof lock washers and use
Locktite on the bolts when tightening. Torque
the bolts to 150 ft lbs.
9) Tighten the three mounting bolts on the
Figure 11-23
seal plate.
10) Properly tension the main drive belt and
replace the belt guard.

While in the lower drive working on the pinion visually inspect the gear set by looking at the
wear pattern and the condition of the gear teeth. If something looks unusually worn or broken
have a qualified person, or a PMC service tech take a look.

GEARSETS IN GENERAL

All the gear sets in the lower drive will require a visual inspection as scheduled in the
maintenance and lubrication section of this manual as well as displayed on the operators control
panel touch screen. All three gearboxes have a gear set, the reduction drive is a gear set, and the
gear on the end of the main shaft that drives the gear on the end of the auxiliary shaft are a gear
set. When inspecting look for an unusual wear pattern or damage to any of the teeth. If anything
is found have a qualified person or a PMC service tech evaluate.

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11-14
 PMC-1002
Mechanical Adjustments
___________________________________________________________________________________________________________________

MECHANICAL ADJUSTMENTS

GENERAL
Your machine has been checked, tested, and properly adjusted to produce an accepted cup at
PMC before it was shipped. Machine adjustments must not be attempted until the effects of
the adjustments on the product and the machine are fully understood. The warranty does not
extend to components that are damaged or broken as the result of improper adjustment or
operation.

CAUTION: BEFORE MAKING ANY ADJUSTMENTS, ENGAGE AT LEAST

TWO EMERGENCY STOP BUTTONS.

CAUTION: Improper or careless adjustments may cause severe damage and

almost always result in loss of production. Check the mechanical
troubleshooting guide in Section 13 of this manual to analyze the probable cause
of the malfunction before attempting any adjustment procedures. Most
malfunctions can be traced to problems, which cannot be solved by adjusting the
machine. These include air or vacuum failures, poor materials, dirty machine,
and lack of lubrication.

IMPORTANT

Machine adjustment should be the exception rather than the rule. If an adjustment is deemed
necessary, the machine must be manually cycled to ensure that the machine is free and not
binding. Also, so there are no interferences caused by the adjustment.

CAUTION: Sufficient force can be generated during hand cycling to damage

machine components that are improperly adjusted.

CAUTION: Should machine become hard to turn by hand or added resistance

is felt, STOP until the problem has been identified and corrected.

IMPORTANT

If the adjustment, that has been made, does not correct or improve the problem, return to the
original setting.

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SIDEWALL STOCK ROLL STAND

The following machine adjustment procedures apply to machines that are roll fed.

CAUTION: BEFORE MAKING ANY ADJUSTMENTS, ENGAGE AT LEAST

TWO EMERGENCY STOP BUTTONS.

ROLL STAND

The PMC sidewall roll stand is compatible for use

with either an air chuck or an air shaft assembly,
which are both inflatable by using the supplied
regulated inflator. Refer to Figure 12-1. The
following is a description of the available
adjustments.

Figure 12-1

LATERAL ADJUSTMENTS

Turning the hand wheel allows you to move the roll

of sidewall stock from side to side, allowing for
proper alignment of the web. Clockwise rotation of
the hand wheel will bring the roll towards the hand
wheel and counter clockwise rotation will move the
roll away. See Figure 12-2.

Figure 12-2

HEIGHT ADJUSTMENT

A selector switch mounted on the side of the roll

stand controls the raising and lowering of the unit so
that a roll of sidewall stock can be easily mounted.
Refer to Figure 12-3.

Figure 12-3
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WEB TENSION CONTROL

An automatic sidewall web tension control unit maintains the required amount of tension after
the initial adjustment. A sensor aimed at the roll of web stock detects the change in roll
diameter. As the roll is consumed and the roll diameter becomes smaller, a transducer
readjusts the brake pressure, maintaining smooth feeding.

WEB TENSION SETUP

The transducer once set up properly will automatically readjust the brake pressure as the
sidewall roll decreases in size. This adjustment will not have to be changed for a new roll of
web stock of the same dimensions is used. The adjustments are made using the following
procedure:
1) Turn on the air supply at the regulator, and adjust the regulator fully open. See Figure
12-4.

Figure 12-4

2) Place an empty roll core on the roll arbor and place in position on the roll stand.
3) Adjust the zero adjust potentiometer, located on the bottom of the transducer. See
Figure 12-5. This needs to be adjusted until the gauge at the regulator reads 5-7 psi.

Figure 12-5
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4) Place a full roll of sidewall stock on the arbor. Roll the roll to the position it would be
if placed on the stand.
5) Adjust the span potentiometer, located on the bottom of the transducer. Refer to Figure
12-5. This needs to be adjusted until the gauge at the regulator reads 40 psi.

NOTE: This procedure will have to be repeated several times to make sure the
pressures repeat. When adjusting the zero, turning the screw clockwise will decrease
the pressure and counter clockwise will increase the pressure. When adjusting the span,
turning the screw clockwise will increase the pressure, and turning the screw counter-
clockwise will decrease the pressure.

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BLANK HOPPER AND CONVEYOR SETUP

The following machine adjustment procedures apply to machines that are blank fed.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE

DISCONNECT AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

Vacuum Bars to Hopper Timing

1) Loosen all (4) trans-torque bolts. See Figure

12-7.

2) Loosen rotary placer clamp nut. See Figure

12-6.

3) Set Rotary end plates so they are all level

with base of machine. See Figure 12-6.
Figure 12-6
4) Tighten clamp nut. See Figure 12-6.

5) Rotate vacuum bar so the stems are

perpendicular to the blanks. Figure 12-6.

6) Line up the pulley with stationary gear, and

tighten trans-torque. See Figure 12-7.

7) Recheck level of end plates and stems

perpendicular to blank. See Figure 12-6.

8) Draw circle around vacuum cups onto blank.

See Figure 12-8.
Figure 12-7
9) Loosen Clamp Nut. See Figure 12-6.

10) Rotate rotary head by hand to next vacuum

bar.

11) Set rotary end plates so they are level with

the base of machine. See Figure 12-6.

12) Tighten clamp nut. See Figure 12-6.

Figure 12-8
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13) Rotate Vacuum Bar so vacuum cups are lined

up in the circles on the blank that was done in
step 8.

14) Line up pulley to stationary gear, and tighten

trans-torque. See Figure 12-7.

15) Re-check level of end plates and vacuum cups

centered in circles on blanks. See Figure 12-6.

16) Repeat steps 9–15 for remaining 2 bars.

Figure 12-9

Hopper Set-Up

1) Adjust the side guide rods and upper retainer fingers so the blank template can be
installed in hopper. Remember this is only an initial setting.

2) Center the template in the hopper. Use lower

guide rails as a reference point for centering;
center the template over the lower rods.

3) Adjust the 4 side guide rods and 2 lower guide

rods so the blank template is parallel and flush
with the front of the 3/4" diameter posts in front of
the hopper. It is important that the blank template
is resting flat against all 6 retainer washers on the
ends of the guide rods. See Figure 12-11.
Figure 12-10
4) Adjust the side guide rods so they are equal
distance apart on the template. The guide rods
should be approximately 1/3 up the blank for the
lower guide rods and approximately 2/3 up the
blank for the upper guide rods See Figure 12-12.
When making this adjustment, be sure the guide
rods are parallel with the hopper and the blank
template remains centered over the lower guide
rods.

5) Adjust the blank fingers so they are about 1/8"

below the top of the blanks. Make sure the air
lines are just in back of the leading edge of the Figure 12-11
blank template. See Figure 12-14.

6) Remove the template from the hopper and put the blanks in the hopper. Fill the hopper
until the blanks start to collect on the conveyor.

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7) Check side-to-side play of the blanks

between side guide rods clearance between
blanks and guide rods should be
approximately 1 blank thickness gap at pick
side and 3 blank thicknesses on the
conveyor side. This will allow the blanks to
funnel down the hopper. See Figure 12-12.

8) Adjust the top guide rails to approximately 2

blank thicknesses above the blanks. See
Figure 12-15.
Figure 12-12
9) Adjust the incline side guides on conveyor
so blanks flow straight into the hopper.
Make sure the guide is parallel with the
conveyor. See Figure 12-16.

10) Fill the incline with blanks and set the

incline activator so it is at the top of the
transition point of the blanks from the
conveyor to the hopper. See Figure 12-15.
Set the height of the conveyor activator arm
so that the conveyor just stops moving.

11) Align the conveyor blank side guide even

with incline side guide and parallel with
conveyor. Set lever at transition point Figure 12-13
between conveyor blanks and incline blanks.
Set arm so conveyor turns on at the same
time as incline belt turns on. See Figure 12-16.

12) Adjust hopper to pick blank approximately on the upper 1/3 of the blank. See Figure
12-17 and 12-18. To do this, turn the 2 adjusting knobs under the feeder. See Figure
12-9.

13) Adjust bump of suction cups to blanks by loosening the locking bolts and using the
adjusting bolt to achieve approximately 1/8 compression of the vacuum cups against the
blank. See Figure 12-18.

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Figure 12-14
Figure 12-15

Figure 12-16 Figure 12-17

Figure 12-18
Figure 12-19

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Rotary Feeder Timing

1) Position shuttle in full back position.

2) Loosen clamp-nut. See Figure 12-6.

3) Rotate blank down, in front of pushers.

4) The top of the blank should be about 3/16" in front of the pushers and the bottom about
1"–1 1/2" above the shuttle. See Figure 12-13.

5) Adjust the vacuum to release when the blank in this position. This is done by adjusting
the turnbuckle attached to the vacuum plate on the side of the rotary feeder. See Figure
12-13.

6) Reapply power to the machine and test the blank feed. It may be necessary to make
minor adjustments to get proper feed and wrap on the mandrel.

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BOTTOM STOCK ASSEMBLIES

The bottom stock assemblies consist of the bottom stock unwind; bottom stock feeder, and the
bottom maker.

CAUTION: BEFORE MAKING ANY ADJUSTMENTS, ENGAGE AT LEAST

TWO EMERGENCY STOP BUTTONS.

BOTTOM STOCK UNWIND

The design of the PMC 1002 bottom stock unwind

allows rolls of bottom stock to be used regardless of
how it has been wound. It is important that as the web
travels upward to the first upper roller that it is
twisted 90 degrees so that the side of the paper you
want on the inside of the cup is facing upwards. See
figure 12-20. On single poly web stock the poly side
would be facing up. The rollers that the web travels
over and around are adjustable so that the web can be
made to track flat and centered. See figure 12-21. The
angle roller, see figure 12-22, is set so that the paper
not only tracks flat but is centered going into the Figure 12-20
feeder. The collars on these rollers are set to have
approximately 1/16 clearance on each side of the paper. This system also now has an
automatically adjusting brake that changes the brake pressure as the roll decreases in size. In
order for this system to work properly it is important that the bottom stock roll retainer is
tightly fastened. The brake pressures have been preprogrammed at the factory. If an adjustment
is needed it can be done at the operators control panel touch screen. When making an
adjustment it is important that you use only enough pressure to prevent the roll of bottom stock
from free wheeling when an emergency stop button is pressed, regardless of the diameter of the
roll.

Figure 12-21 Figure 12-22

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BOTTOM STOCK FEEDER

The bottom stock feeder is a servo feeder, which advances the feed length of bottom stock by
means of a servo motor controlled by the PLC. The feeder also has a constant feed roll that
actually pulls the bottom stock from the roll and maintains a supply of paper (loop) to be fed
through the feeder at a predetermined feed length. The feed-up length information is on the
cup drawing. Because the bottom stock feeder is servo driven, this allows the feed adjustment
to be made at the PLC touch screen, located at the operators control panel.

FEED-UP

The procedure to set or change the feed length is as follows:

1) Go to the main screen of the operators control panel touch screen.
2) Touch the “MACHINE TIMING” block.
3) On this screen touch the “TIMING #2” block.
4) On this screen touch the “BOTTOM SERVO” block.
5) On this screen touch the “BOTTOM FEED LENGTH” block.
6) This will bring up a keypad. Using the feed-up dimension from the cup drawing, enter
it on the keypad. Be careful not to forget the decimal point. When finished press the
enter key in the lower right hand corner. The feed-up has now been set.

FEED ROLL ADJUSTMENT

The feed roll adjustment is commonly referred to as “nip”. The nip is the amount of pressure
put on the paper at the feed rolls. If adequate pressure is not placed on the paper, it may slip
and not feed properly. This adjustment is made by adjusting the gap between the rollers with
no paper. Both the constant feed rolls and the servo feed rolls should be set to the same gap.
The proper setting is ½ the thickness of the paper for steel rolls OR 1/3 the thickness of paper
for rubber rolls.. To adjust the servo rolls follow this procedure:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE

DISCONNECT AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH..

1) Turn the bottom feed selector switch on the

operators control panel to the “on” position.
2) Loosen the jam nuts on the activating rod.
3) Adjust the nuts on each side of the casting so
that the gap between the rollers is 1/3 the
paper thickness. The use of a feeler gauge
will be required. See Figure 12-23.
4) Lock the rear jam nut tight to the adjusting
nut.
Figure 12-23
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12-11
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5) Adjust the front nut so there is 0.050" between it and the casting. See Figure 12-24.

Figure 12-24

The front (servo) roll nip is now set. To set the rear (constant feed) roll nip, follow this
procedure:
1) With the bottom feed selector switch on the
operators control panel, in the “on” position,
loosen the two setscrews on the adjustable
stop. See Figure 12-25.
2) Adjust the stop so that the gap checked with a
feeler gauge is ½ the paper thickness between
the two rolls.
3) Retighten the two setscrews securely.

Care should be taken when working with the servo

feed rolls as they made of a somewhat soft rubber Figure 12-25
material and could be damaged easily. The front
roller of the servo rollers is stationary and the rear roller is activated in and out. The roller
moves forward to feed and back when the feed is off. The rear roller does have two springs on
the assembly for overload protection. See Figure 12-26.

Figure 12-26

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DRIVE BELTS

CAUTION: BEFORE MAKING ANY ADJUSTMENTS, ENGAGE AT LEAST

TWO EMERGENCY STOP BUTTONS.

Both the servo and the constant feed rolls are driven with timing belts. There is no actual
timing involved. To adjust the tension of these belts, the bracket mounting bolts need to be
loosened and the bracket moved so that the belts are the proper tightness. See Figure 12-27.
The bolts can then be retightened. The proper tension on the drive belts should be not so loose
that the belt can jump teeth, and not so tight that it will cause belt, bearing, or shaft damage. In
the center between the pulleys there should be approximately 1/64" of movement for every inch
of span. See Figure 12-28.

Figure 12-27 Figure 12-28

FEED LOOP SENSORS

There are two sensors mounted at the back of the feeder. These sensors monitor the size of the
loop. The spacing of the sensors is fixed. The height of the sensors is set to be flush with the
stainless steel loop guard. See Figure 12-29.

Figure 12-29

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SPLICE DETECTOR

The PMC-1002 is supplied with a splice detecting

system for the bottom stock. It has two sets of
sensors, one mounted at the rear of the feeder, and
one mounted near the front. See Figure 12-30 and
12-31. When the rear sensor detects a splice it
sends a signal to the PLC and slows the machine
down to 240 cpm. When the front sensor detects
that splice it sends a signal to the PLC and the
servo feed roll accelerates to rapidly feed 4 times
the feed length of bottom stock through the
bottom maker so that the splice is not cut. At this
time the bottom stock air assist comes on constant Figure 12-30
for approximately 25 cycles to help the splice
clear the scrap chute, then returns to pulsing,
which is normal. At this time the machine will
automatically return to operating speed. NOTE: if
machine speed is set at 240 cpm or less, it will not
slow down. It is important to maintain the
alignment of the sensors. The sensitively of the
sensors can be adjusted as follows:

1) At the operators control panel, open the panel

and locate the sensor set buttons. See Figure
12-32.
2) Place a piece of splicing tape between the Figure 12-31
sensors and press the button.
3) Place a piece of bottom stock between the
sensors and again press the button. This
should be done for both splice sensors.
4) If the tape is ever changed to another kind of
tape this procedure will need to be repeated.

BOTTOM STOCK LUBRICATOR

CAUTION: BEFORE MAKING ANY

ADJUSTMENTS, ENGAGE AT LEAST
TWO EMERGENCY STOP BUTTONS.
Figure 12-32
The PMC-1002 bottom feeder is equipped with a felt
lubricator. If the quality of your bottom stock dictates that the lubricator be used, position it to
be centered on the web and position the felt to make light contact with the paper. It is also
important that you use only the amount of oil needed. Excessive oil will cause problems such
as paper jams at the bottom maker.
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FEEDER POSITION

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE

DISCONNECT AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH..

The bottom stock feeder is mounted on top of the bottom maker. It is positioned by means of a
key, allowing it to be moved, on center, only forward and backwards. It should be positioned
so that the bottom stock web feeds straight down into the die block mounted to the front of the
bottom maker. See Figure 12-33.

Figure 12-33

FRONT WEB GUIDES

CAUTION: BEFORE MAKING ANY ADJUSTMENTS, ENGAGE AT LEAST

TWO EMERGENCY STOP BUTTONS.

The bottom stock feeder web guides are mounted in

the front of the feeder and goes downward into the die
block assembly. The guides can be adjusted from
side to side, as a pair, to center the web at the cutting
die, and in and out to allow for changes in the web
width. The width of the guides should be set so that
the bottom stock just passes through them without
any resistance, (approximately 1/32" max.) but not
wide enough to allow the paper to move side to side.
The adjustments are made using an adjusting knob,
and an adjusting bolt located at the side of the feeder. Figure 12-34
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See Figure 12-34. The centering adjustment is made using the bolt. After loosening the jam
nut, turn the bolt until the proper position is achieved. Turning the bolt counter clockwise will
move the web away from the operator station and turning the bolt clockwise will bring the web
towards the operator station. The width of the guides is adjusted using the adjusting knob.
Turning the knob counter clockwise will open the guides and turning it clockwise will close the
guides. When adjusting the guides closer together, there is a stop. This stop is built into the
die block, and is meant to prevent the guides from being placed in front of the bottom cutting
die. If the guides would need to be positioned far enough in to hit the stops the bottom stock is
too narrow, and should be replaced with the proper stock.

BOTTOM MAKER

The bottom maker and its tooling cut, form, and place the bottom disc. The bottom maker is
chain driven and timed in the lower drive. The timing will be discussed in the timing section
of the main drive. Inside the housing there are two rams, the cutting punch ram, and the draw
ram. The draw ram is non-adjustable. The draw punch is positioned by means of a spacer that
is located between the ram and the draw punch. The spacer is factory ground so that the
face of the draw punch is the paper thickness plus 0.010" (minimum) away from the face of
the mandrel stem when the draw punch is fully extended. See Figure 12-35. The cutting
punch ram is adjustable. The cutting punch ram is positioned so that when the cutting punch
is fully forward it is 0.030" from bottoming out in the draw die. See Figure 12-36.

MANDREL

PAPER THICKNESS PLUS 0.010"

Figure 12-35

CUTTING PUNCH 0.030" FROM BOTTOMING

Figure 12-36

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To make this adjustment remove the rear cover mounted on the back of the bottom maker and
follow this procedure:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE

DISCONNECT AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Remove one mandrel so that when the

machine is cycled there is no mandrel in front
of the bottom maker.
2) Hand cycle the machine until the cutting
punch ram is at the full forward position of its
stroke.
3) Loosen the drive yoke adjusting nuts. Adjust
so the cutting punch is 0.030" from bottoming
in the draw die.
4) Retighten the locking nuts securely.

NOTE: Use shim stock or a feeler gauge to measure Figure 12-37

this gap. See Figure 12-37.

This adjustment is preset at the factory but will be needed as the punch and die set are
sharpened. After sharpening, shims may be required behind the cutting die to maintain its face
position to the draw die. This dimension is 0.094"; which is measured from the face of the
cutting die to the face of the draw die. See Figure 12-38. NOTE: The cutting die is ground
sharp on both sides so that it can be flipped to gain more time in between sharpening. The
cutting punch is ground with a shear. The proper mounting is to position the punch with the
smaller slot on top and the larger slot on the bottom. See Figure 12-39.

0.094

Figure 12-38 Figure 12-39

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BOTTOM PUNCH AND DIE SHARPENING

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.
A dull cutting edge with moderate surface wear can be repaired by surface grinding the bottom
punch and bottom blanking die. For maximum die life and best cutting results, dies and
punches should be sharpened before the cutting edge deteriorates so badly that they will not cut
at all. A dull die creates excessive paper dust that will accelerate wear of the cutting edge.
The bottom blanking die has two cutting edges and can be reversed once before sharpening is
required. Both sides of the cutting edges should be
sharpened flat. Take note of the thickness that is
reduced in sharpening. This difference will be close
to the amount of shim required when reinstalling.

NOTE: The punch is ground with a shear. Make

note of the shear direction see Figure 12-40. SHEAR

The amount of shear on a bottom, less than 3 ½" in

diameter, is 1 degree. On a bottom larger than 3 ½"
the shear is ½ degree. Recommended grinding
method for sharpening punch and die sections are:
Figure 12-40
1) Wheel specifications
Aluminum oxide grit size.............60
Grade ............................................1
Structure .......................................8
Bond .............................................Vitrified
2) Depth (per feed) ....................................0.0005" - 0.0010" (0.013 - 0.025 mm)
3) Cross feed .............................................0.031" (0.79 mm)

Punch and die surfaces should be surface ground for best results. If the die is sharpened
regularly, remove only enough material to restore the cutting edge, approximately 0.003"-
0.005" (0.08-0.13 mm). Hone the cutting edges with leather after sharpening.

NOTE: When reinstalling the cutting punch, make sure the high point of the shear is vertical,
relative to web travel.

The die block assembly needs to be cleaned. See the cleaning section of this manual for
frequency and procedure. Failure to clean may result in failure of the ram seal, which will
allow machine oil to contaminate the bottom stock and build up in the scrap chute, causing
jams.

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SIDEWALL FEEDING
The PMC-1002 is capable of being fed several different ways. One way is roll fed, which
utilizes a pre-printed roll of sidewall stock. The other is blank fed, which utilizes pre-printed,
pre-cut blanks.

ROLL FEED

Roll feeding is done by the sidewall servo feeder, which actually pulls the web from the roll as
it feeds the sidewall paper into the die to be cut.

The servo feeder is an exact registration system. The servo will move exactly from mark to
mark. The quality of the cups will be a direct reflection of the quality of the print and its
repetition throughout the roll. Some of the advantages of servo feeding include the following:

1) Ability to instantly change feed lengths.

2) True auto starting and cycle stopping.
3) Increased machine efficiency due to less frequent feeder jams.
4) Quieter operation.
5) Easier setup.

SIDEWALL SERVO THEORY OF OPERATION

The servo feeder can be selected to operate with the registration either “ON” or “OFF”. With
the registration selector switch set to the “ON” position, the servo will index the paper with
respect to the registration marks. The register mark is positioned 0.25" before the registration
sensor. In this way the registration mark will be detected in the first 0.25" of paper travel when
the servo indexes the paper into the cutting die. The index occurs as follows: As the machine
is running in the “RUN” mode, with the feed switches set to “ON”, the servo will be triggered
to begin the index; at the index position setting that has been entered into the touch screen.
The servo will begin. The index is at a low velocity until the registration mark is detected.
When the mark is detected the servo will accelerate to a high velocity for the remainder of the
move to complete the index. The remainder of the move is the feed length minus 0.25".
Remember that the 0.25" is the ideal distance to the registration mark at the beginning of the
index. The feeder will continue to feed until the sensor detects the registration mark. If the
registration mark is not detected, a “REGISTRATION MARK MISSING” fault will occur and
the machine cycle will be stopped. Once the registration mark is detected the registration
sensor output is ignored until the beginning of the next index. Therefore, if the sensor detects
the same color as the registration mark while the index is in progress, the signal is ignored.
With the registration selector switch in the “OFF” position, the servo will index the paper
without searching for the registration mark. Therefore, each index will be exactly the entered
feed length.

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TIMING

The servo start position is set on the touch screen. The correct setting can be determined
through trial and error; however, the easiest and most exact method to properly set timing is to
use a high-speed camera. The touch screen allows for both a registered index start position and
a non-registered start position. Because the servo must search for the registration mark at a
slow speed (making the registration move longer) at the beginning of the index, two different
start positions are required. Therefore, the registered index start position will be set to an
earlier machine position, compared to the quicker non-registration index. Each different
machine speed will have its own set timing. In order to change any or all of these settings you
must go to the operators control panel touch screen:

On the main screen press the “MACHINE TIMING” block.

On machine timing screen press the “TIMING #2” block.
On the timing #2 screen press the “SIDEWALL SERVO” block.
On the sidewall servo screen press either the “REGISTRATION” or the “NON-
REGISTRATION” index position blocks.
On either screen a keypad will appear. Use the keypad to change the start position based on
machine speed. When finished press the enter key located in the lower right corner.

MECHANICAL SETUP

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

HEIGHT SETUP

The proper setting for the height of the feeder is

positioned 0.010" above the die. This is measured
from the feed tabletop to the top of the bottom
section of the die. This is adjusted by first loosening
the mounting bolts and turning the jackscrews.
NOTE: MEASURE AT BOTH SIDES TO ENSURE
THAT THE FEEDER IS PARALLEL. Once this is
done, tighten the mounting bolts and recheck the
dimension. See Figure 12-41. Finally, tighten the
jam nuts on the jackscrews.

Figure 12-41

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GUIDE POSITIONING

CAUTION: BEFORE MAKING ADJUSTMENTS, ENGAGE AT LEAST TWO

EMERGENCY STOP BUTTONS.

The two side guides on the feeder table are positioned to center the sidewall web in the die.
They are also used to control the web. They should be adjusted so that at the front, near the
die, there is 0.005" to 0.010" clearance between the guides and the web. At the rear of the
feeder the setting is slightly wider, allowing 0.020" to 0.025" clearance. These adjustments are
made by using the two double knobs, one at the front of the feeder and one at the back of the
feeder. Both adjustments are on the operator’s side of the feeder. The inside knob controls the
movement of the entire web. Counter clockwise rotation moves the web towards the operator
side; clockwise rotation moves the web away. This will be used to center the web in the die.

The outside knob controls opening and closing the guides to compensate for the web width.
Counter clockwise rotation opens the guides and clockwise rotation closes the guides. A move
from mark to mark is equal to 0.010", and one complete revolution of the knob is equal to
0.050". See Figure 12-42.

Figure 12-42

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FEED ROLL ADJUSTMENT

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

The feed roll adjustment is commonly referred to as

the “NIP”. The nip is the amount of pressure put on
the web stock. If adequate pressure is not placed on
the web, the web will slip and not feed properly. This
adjustment is made by adjusting the gap between the
rollers, with no paper. Both the constant feed rolls
and the servo feed rolls should be set to the same gap.
There is an adjuster on both ends of the rollers for
each of the two sets of rollers. There is also a spring
pressure adjustment. See Figure 12-43. The springs
should be set so there is 1" from the washer to the
frame. See Figure 12-44. This is adjusted by
loosening the jam nut and turning the bolt until the Figure 12-43
proper 1” setting is reached. Then retighten the jam
nut. Once the spring pressure has been set the nip
(gap between the rolls) can now be adjusted. The
proper setting is 0.004" between the rolls. This is
measured with a set of feeler gauges. The adjustment
is made by loosening the jam nut and turning the
adjusting screw until the gap is 0.004". See Figure
12-45. It is very important that this setting is the
same on both ends of the rollers. If not, the paper will
not track properly. NOTE: the feed rolls must be
clean and free of debris. Once this has been properly
set, retighten the jam nuts. With the jam nuts
tightened, double check the setting.
Figure 12-44

Figure 12-45
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FEED-UP

The consistency of the sidewall blanks is greatly dependent on the accuracy of the print of the
sidewall paper. The PMC sidewall feeder is a registered cut to length system. Each sidewall
blank is made from two separate cuts. The sidewall bottom is cut first, and then the top edge is
cut in the next index. The top cut is made while the paper is in the grippers. All the blank
length variations, due to print quality, are reflected in the bottom cut. This variation will be
seen in the bottom skirt of a finished cup. The cup drawing will indicate the correct feed
length for the cup. Best results, print repeatability, should be held to +/- 0.015". Therefore the
registration marks must be within +/- 0.015" of their ideal location. When the print quality is
outside of this tolerance, the inaccuracy will be reflected in the blank length and will be seen as
short and long bottom skirts of the cup. To actually set the feed length, go to the operators
control panel touch screen and use the following procedure:

1) Press the MACHINE TIMING block to bring up the TIMING screen.

2) Press TIMING #2 block to bring up the second timing screen.
3) Press the SIDEWALL SERVO block to bring up the SIDEWALL SERVO feeder
screen.
4) Press the SIDE FEED LENGTH block to bring up a keypad.
5) Using the feed length dimension from the cup drawing, enter the length. When finished
press the enter key located in the lower right corner of the keypad.

The feed up has now been set. NOTE: Be sure to use the decimal point when entering the feed
up length.

SIDEWALL REGISTRATION SENSOR SETUP

The sidewall sensor must be set properly to MODE

4

insure proper detection of the registration

3

3
ON
2

marks. Starting with proper color setup the

1

SET
sensor amplifier must be adjusted. If your OUT TIM SET

registration mark is any color other than black

or gray, dip switch 1 and 2 should be set to the DLY OFF N.C. N.O.

“OFF” position and 3 and 4 should be set to Figure 12-46

the “ON” position. The N.C. or the N.O.
dipswitch should be set to the “N.O.” MODE
4

position. See Figure 12-46. If the registration

3

3
ON
2

mark is black or gray, dipswitch 1 thru 4

1

SET
should be set to the “ON” position. The N.C. OUT TIM SET

or the N.O. switch should be set to the “N.C.”

position. See Figure 12-47. DLY OFF N.C. N.O.

Figure 12-47

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PROPER SENSOR HEIGHT POSITIONING

CAUTION: BEFORE MAKING ADJUSTMENTS, ENGAGE AT LEAST TWO

EMERGENCY STOP BUTTONS.

The sensor head should be positioned 5/8" below the sidewall paper. The fiber optic head will
generate a small blue dot on the sidewall paper when the sensor is positioned properly. The
sensor is sensitive to any change from this position.

SENSOR CALIBRATION

Position the sidewall paper so that the sensor is detecting the registration mark (i.e. the blue dot
is directly on the registration mark). Press the “REGISTRATION CALIBRATE” push button,
located on the operators’ side of the feeder. Move the paper so that the sensor is on the
background paper (off the mark). Press the “REGISTRATION CALIBRATE” push button
again. The sensor is now calibrated to detect the registration mark. You can verify that the
sensor is detecting the mark by moving the paper by hand over the sensor. The display, located
on the sensor amplifier, will change colors when the mark is detected.

The fiber optic has an air jet to keep dust from accumulating on the eye. Adjust air flow
accordingly.

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POSITIONING SENSOR FOR PROPER REGISTRATION

CAUTION: BEFORE MAKING ADJUSTMENTS, ENGAGE AT LEAST TWO

EMERGENCY STOP BUTTONS.

To achieve registration, to find the proper placement of

the sensor, you will need to jog the machine until the
gripper fingers at the die are open. Cut the printed web
stock just below the credit line, simulating the die cut.
See Figure 12-48. Feed the web stock through the
guides on the feeder, continuing through the die and
into the grippers. Note the position of the registration
mark on the sidewall web. On the sensor mounting bar,
determine the set of mounting holes, which will most
closely position the sensor ¼" ahead of the registration
mark, and secure the sensor to the bar. See Figure 12-
49. This is a good starting position. After running
some cups check the registration and make any small Figure 12-48
adjustments using the small thumbscrew. See Figure 12-50. Once adjustments are made using
the thumbscrew, tighten the jam nut to lock it in place.

Figure 12-49 Figure 12-50

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SIDEWALL BLANKING DIE

The PMC-1002 comes equipped with a hoist

assembly mounted to the machine enclosure to aid in
removing or splitting the die for sharpening or
maintenance. On the upper section, there is a locking
slide bar assembly that locks into a shaft from the
lower section to keep the die sections apart so work
can be done. There is one on each side of the die.
See Figure 12-51. The lower die section is fixed, and
the upper is stroked by means of an eccentric, located
on the main drive shaft.
Figure 12-51

PUNCH ENTRY ADJUSTMENT

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

The amount of punch entry is adjusted at the die actuator shaft. This is done by repositioning
the nuts; down for more entry, up for less. Adjust using the nuts until a clean cut is made and
then lower one more flat of the nuts. A proper setting is approximately 0.030" entry past cut.
See Figure 12-52.

NOTE: Some scrap will remain in the die after cut. Do not adjust to try to push scrap out.

Figure 12-52

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CAUTION: Do not over adjust or premature die wear will result.

CAUTION: After any adjustment, make sure the adjusting nuts are tightened
securely.

DIE SET POSITIONING

Positioning of the die positions the sidewall blank on the mandrel. A good starting position is
centered on the adjusting studs, approximately 0.050" away from the transfer turret wear ring.
See Figure 12-53. Moving the die side to side will change the relationship of the seam edge to
the seam clamp. Generally this will be set so that the seam edge is flush with the seam clamp.
Moving the die in and out moves the blank up and down the mandrel. Refer to the tooling bill
for the proper distance of the edge of the paper to the end of the mandrel. To move the blank
up the mandrel, the die is moved back away from the transfer turret. To move the blank down
the mandrel, the die is moved towards the transfer turret.

TRANSFER TURRET

CENTER ON ALL 4
ADJUSTING STUDS

0.050

Figure 12-53

CAUTION: Moving the die too far forward may interfere or rub on the transfer
turret causing damage.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

To move the die:

1) Loosen the six top clamping bolts. See Figure 12-54.

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Figure 12-54

2) Loosen the four mounting nuts that secure the die. See Figure 12-55.

Figure 12-55

3) There are two setscrews at each of the four posts. See Figure 12-56. Determine the
direction that the die is to be moved. On the opposite side, loosen the two setscrews.
NOTE: The die will move approximately 0.008" for each flat of the allen wrench.
Tighten the setscrews, on the move direction side, until the opposite setscrews touch
the posts.

Figure 12-56

4) Retighten the die mounting nuts securely.

5) Retighten the top clamp bolts securely.

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6) Make certain the new die position does not interfere with any assembly or component
nearby.

DIE REFITTING

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

Badly worn sidewall dies, with a 0.0005" (0.013 mm) or more clearance, between cutting
edges can be repaired by refitting the die sections.

Each punch and die section must be removed and relocated.

Dowel holes in the mounting plates must be plugged and new holes drilled for doweling the
relocated sections.

The punch and die must be contour ground and re-sharpened. This work must be done by a
professional tool and die maker or at the customer’s option. The punch and die assembly may
be returned to PMC for refitting.

DIE RENEWAL

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

The punch and die sections of the sidewall blanking unit are made of tool steel, thermally
hardened and tempered to 59-61 Rc, and then cryogenically treated for maximum cutting wear.

A dull cutting edge with moderate surface wear can be repaired by surface grinding the punch
and die sections. For maximum die life and best cutting results, dies should be re-sharpened
before the cutting edge deteriorates so badly that it will not cut at all. A dull die creates
excessive paper dust that accelerates wear of the cutting edge.

NOTE: The punch is ground with a shear. Observe the direction and amount of the shear
before re-sharpening.

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Recommended grinding method for re-sharpening punch and die sections:

1) Wheel specifications:
Aluminum oxide grit size.............60
Grade ............................................1
Structure .......................................8
Bond .............................................Vitrified
2) Depth (per feed) ....................................0.0005" - 0.0010” (0.013 - 0.025 mm)
3) Cross feed .............................................0.031" (0.79 mm)

Punch and die surfaces should be surface ground for best results. If the die is sharpened
regularly, remove only enough material to restore the cutting edge, about 0.003"-0.005" (0.08-
0.13 mm). Hone cutting edges with leather after sharpening. The punch must have a shear
with the high point on the linear centerline of the blank in the direction of paper feed. See
Figure 12-57. The die sections (lower sections of the blanking unit) must be shimmed to
compensate for material removed during sharpening. See Figure 12-58. The front section
(next to the transfer turret) should be 0.005"-0.010" (0.13-0.25 mm) above the transfer turret
wear ring. The rear die section should be 0.035"-0.045" (0.89-1.1 mm) above the front die
section. NOTE: Shims must be full size to uniformly support the full area of the die section.
Only one shim of the proper thickness should be used. Shims should not be stacked. Use only
metal or plastic shim stock and carefully de-burr all the edges of the cut shims to ensure
flatness.

Figure 12-57
Figure 12-58

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BLANK FEED

The efficiency and control of blank feeding along with the quality of the product being
produced is greatly dependant on the quality of the blanks being used at the time. Blanks of
poor quality may not only cause loss of production and cup defect problems, but may also
cause machine damage. Blanks should be reasonably flat, dry (ink), and cleanly cut. Just as
important, they should be stored properly to control things, such as moisture. A humidity-
controlled environment is ideal for storing blanks. Make sure they are stored away from
excessive heat and cold. It is also recommended that the blanks should be fanned prior to
being loaded into the hopper or on the conveyor. This will help remove any excess paper dust
at the same time helping to ensure that the blanks are not sticking together.

Blank feeding is accomplished by a pick and place system. This system consists of several
assemblies working together. These assemblies are:

ROTARY PLACER DRIVE

This is the drive assembly that not only drives, but also times the rotary placer head to the
blank shuttle.

BLANK SHUTTLE

The blank shuttle assembly receives the blank from the rotary head and transfers it to the
transfer turret.

ROTARY HEAD

The rotary head assembly picks the blank from the hopper assembly and delivers it to the blank
shuttle table.

BLANK HOPPER AND CONVEYOR

The hopper and conveyor assembly takes the blanks that have been loaded by the operator and
delivers them to the rotary head.

SETUP

To properly set up the blank feeder you must first determine where the blank needs to be
positioned on the mandrel. The following steps will guide you through this procedure.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

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1) Take a blank and fold it in half to give you the centerline. Next scribe a line along the
bottom radius to match dimension “A” located on the tooling bill. This dimension is
approximately 2 times the bottom depth of the cup. Refer to Figure 12-59.

Figure 12-59

2) Hand wheel the machine until the mandrel turret has just stopped indexing. Insert a
blank between the lower clamp and the mandrel. Align the line scribed as dimension
“A” with the end of the mandrel nose cone. The centerline of the blank should also be
over the center of the lower clamp.
3) Hand wheel the machine forward so that the lower clamp comes up and the folding
wings wrap the blank. Check to make sure the scribe lines are in the proper position.
Readjust blank accordingly if needed.
4) Hand wheel the machine backwards until the folding wings and grippers are all the
way open.
5) At this point the blank should be in the proper position. Lay the blank down flat and set
the blank stop to touch the bottom radius of the blank. See Figure 12-60. NOTE: This
blank stop will be used to set up the transfer turret blank stop fixture.

Figure 12-60

6) Hand wheel the machine backwards, making sure the blank is under the grippers and up
tight against the blank stop, until the blank reaches the shuttle table. Stop when the
shuttle table is all the way forward but before the grippers open.

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7) Loosen the locking knobs on each side of the shuttle table. See Figure 12-61.

Figure 12-61

8) Loosen the locking screws that lock the blank pushers. Refer to Figure 12-62.

Figure 12-62

9) Slide the pushers forward and in to touch the corners of the blank. The pushers should
be forward enough so that the blank has approximately 1/32" of bow, (see Figure 12-63)
and retighten the locking knobs. Slide the pushers inward to the blank leaving
approximately 0.010" side-to-side movement and retighten them. NOTE: If pushers are
too tight or too loose you will get a very inconsistent wrap or feed problem.

Figure 12-63
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10) Now that the blank pushers are set, the transfer turret blank stop fixture should be
mounted to the shuttle plate. Adjust the screws on the fixture to touch the blank stop
previously set on the transfer turret. Tighten the jam nuts on both screws. This will
secure their position. Hand wheel the machine and set the remaining transfer turret
blank stops. Once all the stops have been set, remove the fixture and keep for future
use.

ROTARY PLACER TIMING

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.
.
1) Hand wheel the machine forward until the shuttle table has gone all the way back and
just starting to move forward.
2) Loosen the locking hub.
3) With the vacuum turned on and the drive belt loose, turn the rotary head forward, by
hand, pulling a blank from the blank hopper.
4) Adjust the rotary placer height. This is adjusted using two jackscrews, located on the
placer stand. See Figure 12-64. The proper setting is having a slight compression of the
vacuum cups on the shuttle table. NOTE: Be certain that both sides are compressed
equally. If there is too much compression, the vacuum cups will quickly wear.

Figure 12-64
5) Rotate until the blank comes down, towards the shuttle table. Stop the rotation
when the blank is approximately 1/8" ahead of the blank pushers and
approximately ¾" from lying flat on the table. See Figure 12-65. NOTE: To
adjust this 1/8" gap, the gibs on the rotary placer stand need to be loosened and the
unit slid forward or backward. See Figure 12-66. It is very important when
moving the feeder unit that it must be done squarely.

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Figure 12-65 Figure 12-66

6) Retighten the gibs and check the alignment of the infeed conveyor.
7) Adjust the vacuum manifold to start releasing the blank. This adjustment is made by
lengthening or shortening the turnbuckle. See Figure 12-67.

Figure 12-67
8) Retighten the locking hub.

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SIDEWALL SEALER
The sidewall sealer station consists of several assemblies, that together guide and applies heat
to the blank. This station has a sensor that detects missing blanks. The two main assemblies
are the heater activator and the sidewall heat guns. In addition to the adjustments outlined
here, a thoroughly understanding of cup forming is required. Refer to the cup forming section
of this manual. Heat settings and airflow requirements are outlined in the operators’ section of
this manual.

CAUTION: BEFORE MAKING ANY ADJUSTMENTS, ENGAGE AT LEAST

TWO EMERGENCY STOP BUTTONS.

HEAT GUNS

The PMC-1002 sidewall sealer station has four heat guns. Three of these guns are mounted to
the heater activator, and one gun is mounted to an activator, positioned on the base of the
machine. All four guns are the same, with the exception of a different nozzle mounted to it. A
6000 watt electric element is used in all the guns. See Figure 12-68. A thermocouple is
mounted in the gun at the end of the element. It is important that when a thermocouple is
replaced, it is repositioned exactly in the center of the heat element; so an accurate signal is
sent to the PLC, which controls the heat. Failure to do so may result in damage or failure of
the heat element.
6000 WATT HEATER ELEMENT

Figure 12-68

HEAT ELEMENT REPLACEMENT

When it is determined that a heat element is burnt out and needs replacing, the following
procedure should be maintained:

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WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Turn off the heaters at the operators control

panel.
2) Turn off the main power.
3) Turn off the main air.
4) Remove the four ¼" mounting bolts from
the back cover plate of the heat gun.
5) Carefully remove the insulated connector.
See Figure 12-69.
6) Measure and record from the housing to the
element because this dimension can be
duplicated when putting in the new element. Figure 12-69
7) Using a pair of lineman pliers, carefully grasp
the two pins on the element, gently twist and
pull at the same time. See Figure 12-70.
8) It is important, once the old element is
removed, that the inside of the gun is clean
and free of debris. Check the condition of the
seal at the top of the gun. Replace if needed.
See Figure 12-71.
9) Carefully insert the new element into the gun.
It may require a slight twist to ensure it is in,
all the way. Failure to fully seat the new
element will cause it to fail prematurely.
10) Reinstall the insulated connector and the rear
cover plate, making sure the bolts are tight. Figure 12-70
11) Turn on the main air and power.

Heat nozzles are a tooling item and are specifically

designed for each blank. These consist of: upper
side seam preheat, upper side seam/bottom preheat,
and lower side seam. The upper side seam/bottom
preheat is one nozzle with an internal isolator. Each
of the two sections has a heat gun mounted to it so
they can be individually controlled. Whenever any
of the nozzles are removed, for any reason, and
reinstalled, anti-seize should be used on the screws.
All the vertical heat guns need to be positioned, so the Figure 12-71
nozzles are the same height, for even distribution of
heat to the blanks.

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CAUTION: Heaters are extremely hot and can cause serious burns and injury.
It is best to do all work with the heaters turned off and cooled down.

CAUTION: BEFORE MAKING ANY ADJUSTMENTS, ENGAGE AT LEAST

TWO EMERGENCY STOP BUTTONS.

All the vertical heat gun/nozzle assemblies have

multiple adjustments. The side-to-side adjustment is
made by loosening the mounting bolts and moving
the slide in the gib bracket. See Figure 12-72. To
move the guns in or out, the mounting bolts of this
bracket and slide assembly are loosened. See Figure
12-73. The initial height adjustment to set all the
vertical guns, at the same height, is made by
loosening the clamping bracket and sliding the guns
up or down. This same clamping bracket will allow
the heat guns to be turned. See Figure 12-74.
Figure 12-72

Figure 12-73 Figure 12-74

Once the guns have been adjusted and are set to heat the sidewall blank in the proper position,
the height of the whole assembly (all vertical guns) needs to be set. An air cylinder operates
the up and down travel of the assembly. The assembly travels on guide rods and bearings. See
Figure 12-75. There is a stop bolt and jam nut located between the two guide rods, under the
heat gun assembly. See Figure 12-76. The height of this bolt controls the stopping position of
the heaters when they are down. A good starting position is 0.100" above the sidewall
blank. Because of the variation of blanks, this position will vary. Experiment until you
find out what works best for you. Above the gun assembly, on the two guide rods, are lock
collars. These are set to allow room and to keep the heaters away from the transfer turret when
not running, helping to reduce heat build-up. The air cylinder has flow controls, mounted on
the inside of the enclosure upright, that are set to stop the heat gun assembly from slamming up
and down. This can result in heat element damage or failure.

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Figure 12-75 Figure 12-76

The lower side seam heater is mounted to the base. It is positioned by loosening the two
mounting bolts and placing the assembly where it needs to be. The nozzle itself also pivots,
allowing for more adjustability. This assembly also moves up and down on guide rods. There
is a locking collar on each shaft to set the up limit, which should be set at 0.100" below the
sidewall blank, for a starting position. See Figure 12-77. The down limit is controlled by an
adjusting screw on the cylinder shaft. A jam nut locks this screw in position. See Figure 12-
78. This cylinder also has flow controls, located inside the enclosure upright. Set them so that
the cylinder does not slam up or down.

Figure 12-77 Figure 12-78

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SIDEWALL DETECTOR

Mounted to one of the guide brackets is a block that

holds the no blank detector and an air line. The air
line has a valve inline to regulate the amount of air
being used, to keep the face of the sensor clean. The
sensor should be positioned in the block so its bottom
face is in the air stream. The block should be
positioned so it will see the blank as it’s indexed, as
well as the gap in-between them. See Figure 12-79.
The setup procedure for the control unit is mounted to
the side of the heater activator. See Figure 12-80.
The sidewall blank detect sensor must detect each Figure 12-79
individual sidewall as they pass under it. The output
of the sensor must go “on” and “off” as each blank
passes under the sensor. The sensor is setup in the
“one shot” timing mode. The one-shot mode acts to
extend the output signal “on” duration so that the PLC
can detect the signal. Set the four dip switches on the
control, in the up as shown in Figure 12-81. See
Figure 12-82 to locate the two 15 turn clutch pots.
Set the “delay on” pot fully counter clockwise, 15
turns, or until a slight click is heard, indicating that
the delay is set completely off. The “delay off” pot
sets the duration of the one shot output from the Figure 12-80
sensor. The delay has a range of 0 to 1.5 seconds.
Set the pot fully counter clockwise. With the machine running in the jog mode and feeding
sidewall blanks, adjust the “delay off” pot clockwise. Observe the green output light on the
sensor until the green output light has about the same “off” time as “on” time with each passing
sidewall blank. The sensitivity pot should be turned clockwise as high as possible (most gain)
with the sensor operating correctly.

SENSITIVITY SENSITIVITY

MARG/SCP MARG/SCP
DELAY RANGE DELAY RANGE

ONE L ON OFF ONE L ON OFF

SHT T S S OUTPUT SHT T S S OUTPUT
POWER POWER

R G Y R G Y
15 TURN
CLUTCH POTS
DIP SWITCHES UP
DELAY DELAY DELAY DELAY
ON OFF ON OFF

Figure 12-81 Figure 12-82

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SIDEWALL BLANK GUIDES

The PMC-1002 has an arrangement of upper and lower sidewall blank guides, which are
shaped at the factory to best fit your blanks. They are mounted on several adjustable brackets,
allowing for any adjustment needed in variation of the blanks, or to allow for a tooling change
to a different size. The purpose of the guides is to support the blank as it indexes through the
sidewall sealer and to the folding wings. The guides ensure the blank stays somewhat flat, as
the heaters blow hot air onto them, and so the blanks do not run into the heat nozzles. The
upper guides are mounted to the upper heat gun assembly, so when the heaters are in the up
position the guides raise with them. This allows for easier blank removal and will aide in the
ability to clean them. The guides will need to be cleaned occasionally, as some poly will build
up during the heating process. See the cleaning section of the manual for cleaning procedures.

CAUTION: The guides become extremely hot when the machine has the
heaters on.

NOTE: After making any adjustment, check to see

that there are no interferences and that the mounting
hardware is tight. See Figure 12-83 as an example.
Always make sure that there is a guide near the
bottom, middle, and top edge of the blank. Be careful
not to have them positioned in critical seal areas, such
as the channel area (the intersection of the side and
bottom seal).

Figure 12-83

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TRANSFER TURRET
The transfer turret assembly carries the sidewall blank through the sidewall sealer and delivers
it to the folding wing station. It works in conjunction with two plunger assemblies, one at the
shuttle plate (blank feed), or blanking die (roll feed), and one at the folding wing station.
These plungers open the gripper fingers. Blank stops are mounted on the transfer turret if the
machine is blank fed. The following is an outline of the procedures for adjustments.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

TRANSFER TURRET HEIGHT

The height of the transfer turret is adjustable to

ensure a smooth transition of the blank into the
grippers. The proper height is 0.010" below the
shuttle table (blank fed) or the top of the bottom
section of the die (roll fed). Measure this using a
depth micrometer. See Figure 12-84.

The adjustment is made as follows:

Figure 12-84
WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,
DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Remove the dust cover, exposing the locking hub.

2) Loosen the six socket head screws on the locking hub. See Figure 12-85.

Figure 12-85
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3) Raise or lower the transfer turret by turning the center adjusting screw to the
proper height.
4) Retighten the locking hub. Replace the dust cover.

PLUNGER HEIGHT ADJUSTMENTS

The plungers are both adjusted the same. This adjustment allows for adequate clearance during
index and for maximum lift to open the gripper fingers. The timing of the two plungers is
fixed and cannot be changed. They are driven off keyed cams in the lower drive. Turn the
machine in forward position until transfer turret just stops moving. At this time, the proper
setting is 0.020" between the plunger head and the activating roller on the transfer turret. See
Figure 12-86. It is important to check all the activating rollers, and use the lowest roller for
this adjustment. To make this adjustment:

Figure 12-86

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Loosen the jam nut.

2) Turn plunger up or down to achieve the 0.020" dimension.
3) Retighten the locking jam nut securely.
4) Recheck your dimension.
5) Cycle the machine by hand to ensure that there is no interferences.

CLAMPS OPEN ADJUSTMENT

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.
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On the bottom of gripper assembly there is a ¼" bolt with a jam nut mounted in the center.
These bolts are what lift the grippers open, when the “clamps open” selector switch is used to
open them. All the bolts should be adjusted to ½" from the top of the bolt head, to the bracket.
See Figure 12-87.

Figure 12-87

GRIPPER FINGERS

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

The gripper fingers are mounted to the pivoting

assembly. They should be adjusted so the outer edge is
flush with the outer edge of the wear ring insert. To
make this adjustment, loosen the two mounting bolts
and slide the finger forward or backward to the proper
position. See Figure 12-88.

Figure 12-88

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TRANSFER TURRET POSITIONING

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

The proper position of the transfer turret is when the indexing stops and the turret is at its dwell
position; the gripper assembly, at the folding wing station, should be centered on the lower
clamp. See Figure 12-89.

Figure 12-89
The following procedure should be followed for adjustments:
1) Hand cycle the machine so the Transfer turret has just stopped indexing. Make sure
both plungers are in the down position, not touching the transfer turret.
2) Remove the dust cover.
3) Loosen the six socket head screws in the locking hub. See Figure 12-90. Position the
turret to be centered on the lower clamp. See Figure 12-91.

Figure 12-90 Figure 12-91

4) Retighten the locking hub securely. Replace the dust cover.

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BOTTOM DISC PREHEATER

CAUTION: BEFORE MAKING ANY ADJUSTMENTS ENGAGE AT LEAST

TWO EMERGENCY STOP BUTTONS.

The bottom disc preheat station preheats the bottom disc at the first dwell position, after the
bottom maker. The station has a heat gun mounted on it. It also has a nozzle mounted so it
cycles into the mandrel nose cone, preheating the formed bottom disc. Heat settings and
airflow requirements are outlined in the operator’s section of this manual. This station is chain
driven and timed in the lower drive. The timing will be discussed in the lower drive section of
the manual.

The heat gun has a 6000 watt electric heat element. A thermocouple is mounted in the gun, at
the end of the element. It is important when the thermocouple is replaced, its end is positioned
exactly in the center of the element so that an accurate signal is sent to the PLC, which is what
controls the heat. See Figure 12-92. Failure to do so will result in element damage or failure.

THERMOCOUPLE 6000 WATT HEATER ELEMENT

Figure 12-92

CAUTION: CARE MUST BE TAKEN WHEN PERFORMING ANY

PROCEDURE ON OR AROUND ANY OF THE HEATERS AS SERIOUS
INJURY CAN HAPPEN. EVEN TURNED OFF HEATERS CAN RETAIN
ENOUGH HEAT TO CAUSE INJURY, UNTIL FULLY COOLED DOWN.

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HEAT ELEMENT REPLACEMENT

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

When a determined heat element is burnt out and needs

replacing the following procedure should be followed:
1) Turn off the heaters at the operators control
panel.
2) Turn off the main power.
3) Turn off the main air.
4) Remove the four ¼" mounting bolts from the
back cover plate of the heat gun.
5) Carefully remove the insulated connector. See
Figure 12-93.
6) Measure, from the housing to the element, and
Figure 12-93
record so this dimension can be duplicated when
putting in the new element.

Figure 12-95
Figure 12-94
7) Using a pair of lineman pliers, carefully grasp the two pins on the element, gently twist
and pull at the same time. See Figure 12-94.
8) Once the old element is removed, it is important that the inside of the gun is clean and
free of debris. At this time check the condition of the seal, at the top of the gun.
Replace if needed. See Figure 12-95.
9) Carefully insert the new element into the gun. The element may require a slight twist to
ensure it is in all the way in. FAILURE TO FULLY SEAT THE NEW ELEMENT
WILL CAUSE THE ELEMENT TO FAIL PREMATURELY.
10) Reinstall the insulated connector and the rear cover plate, making sure the bolts are
tight.
11) Turn on the main air and the power.

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NOZZLE SETUP

The heat nozzle is specifically designed for each cup. Both the nozzle and the gun need to be
positioned properly. The following procedure is for setting up the nozzle, which needs to be
done before the gun can be positioned. NOTE: A mandrel turret test mandrel will be required
for proper set-up.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Turn off the heaters at operators control panel.

2) Turn off main air.
3) Remove the mandrel between the bottom maker and the bottom disc preheat station.
4) Stone aluminum mounting face, to ensure that it is clean and flat.
5) Install the test mandrel.
6) Hand cycle the machine so the test mandrel has stopped indexing and is in front of the
preheat nozzle. Make certain the test mandrel is not touching the nozzle.
7) Install dial indicator stud on the test mandrel (if not already in place) and attach a dial
indicator. Position the indicator so that it touches the outer diameter of the nozzle and
zero it.
8) Rotate the test mandrel to indicate the position of the nozzle. Set nozzle on the center.
9) To adjust the left to right position remove the four mounting bolts and change the
ground shims as required. See Figure 12-96.

Figure 12-96

10) To adjust the up and down position, loosen the four nozzles mounting bolts. Then,
loosen the jam nuts on the adjusting screws, adjust as needed. See Figure 12-97. Note:
The nozzle will stay straight when moved up and down as it sits on a key.

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Figure 12-97

Once the preheat nozzle is positioned correctly, tighten all the mounting hardware
securely. Now that the nozzle is correctly positioned, the test mandrel can be removed
and the mandrel replaced. The penetration of the nozzle into the mandrel nose now
needs to be set. The front face of the nozzle should be 1 1⁄2 times the bottom stock
thickness, away from the mandrel stem face when the nozzle is stroked fully forward.
This is a good starting position and should position the holes of the nozzle to be in the
center of the bottom skirt. See Figure 12-98. Do a burn test and adjust accordingly, if
needed.

Figure 12-98

To make this adjustment, follow this procedure:

1) Loosen the three bracket mounting bolts (see
Figure 12-99) and slide the bracket until the
nozzle is in the proper position. Note: The
bracket slides on a key to keep it square and
straight. A piece of plastic shim stock can be
used between the nozzle face and the mandrel
stem face, or the nozzle can be slid forward to
touch the mandrel stem. An indicator placed
on the back of the nozzle to measure how far Figure 12-99
back it moved.
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2) Retighten the mounting bolts securely.

NOTE: When working with any mounting or adjusting hardware on or near hot
components it is a good idea to use anti-seize on the threads.

CAUTION: BEFORE REACHING INTO THE MACHINE, ENGAGE AT

LEAST TWO EMERGENCY STOP BUTTONS.

To do a burn test, follow this procedure:

1) At the operators control panel, turn the sidewall feed switch to the “off” position.
2) At the operators control panel, turn the bottom feed switch to the “on” position.
3) At the operators control panel, turn the drive mode switch to the “jog” position.
4) Using the two jog buttons, jog machine slowly to cut and insert a bottom into the
mandrel nose. Continue, slowly, until the mandrel has stopped in front of the bottom
disc preheat station and the station is all the way forward.
5) At the operators control panel, turn the machine mode switch to the “test” position for a
moment. NOTE: Leaving the machine in the “test” position too long will burn the
bottom disc, making it difficult to see the burn pattern.
6) Examine the position of the heat pattern. Adjust if needed.

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HEAT GUN SET UP

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

Once the nozzle has been properly positioned to the mandrel, the heat gun must be positioned
to the nozzle. The front of the heat gun goes into the diffuser bushing of the nozzle, and must
be centered. When making any adjustment, the gun needs to be level. Leveling is done using
the adjusting screw under the front of the gun. See Figure 12-100. Positioning of the gun,
from left to right, is done by a grind spacer; this is between the heat gun and the mounting
bracket. See Figure 12-101. Up and down adjustment is done with the slotted mounting holes.
See Figure 12-102.

Figure 12-100 Figure 12-101

The depth of the heat gun into the nozzle must also be set. The proper distance is 0.625",
measured from the diffuser bushing retainer to the face of the heat gun, when fully retracted.
See Figure 12-103. This is done by loosening the mounting bolts and sliding the bracket
forward or backward to the proper dimension.

Figure 12-102 Figure 12-103

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Note: The grind spacers on this station are factory set for the center of the mandrel turret.
When properly set up, the spacers should not have to be changed.

SHROUD

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

There is a heat shroud at the nozzle. When positioned properly it helps vent the heat away
from the other machine parts. The proper position is when the heat nozzle is in the retracted
position; the shroud is positioned to be centered over the nozzle holes. See Figure 12-104.
After positioning the machine, make sure that there is no contact with the mandrel.

Figure 12-104
STATION SLIDE SETUP

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

Inside this station housing, a cam is mounted to the driveshaft. As the shaft is driven, the cam
moves the slide forward and backward. A cam follower, mounted to the slide, is spring loaded
to the cam. The slide travels on a set of linear needle bearings, one bearing unit on each side of
the slide. The bearing unit consists of a male rail, a female rail, and a roller cage. The ends of
the male rails all have roller cage stops mounted to them to prevent the cages from sliding out.

CAUTION: The slide is under a heavy spring load. This load must be taken off
anytime the slide is to be worked on. This load must also be removed before any
work takes place on the lower drive of this station.

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The following is the proper procedure to remove the

load:
1) Remove the four socket head screws that hold
the warning placard bracket. See Figure 12-
105. Remove the bracket.
2) Remove the two outer most bolts. (One on
each side)
3) Insert a piece of 3/8"-16 threaded rod, 6" long,
into each of the two holes so at least ¾" is
threaded into block.
4) Place a flat washer and a nut on each rod.
Thread the nuts up and snug to the plate. See Figure 12-105
Figure 12-106.
5) Remove the center bolt.
6) Evenly unscrew the two nuts until the spring
pressure is eliminated.
7) Remove the rear plate (with spring rods
connected). Remove springs.
8) To reassemble, reverse this procedure.

The following is the procedure to properly setup and

adjust the slide:
1) Secure the two male rail mounting bolts on the
non-adjustable side of the housing, making
sure the rail is tight to the side. Use a 0.001" Figure 12-106
feeler gauge to check. Removable Locktite
should be used on the mounting bolts. Note: the bearing mounting bolts are metric.
2) The slide has a female rail mounted on the bottom of each side of the slide. Check to
ensure the mounting bolts are tight and that a 0.001" feeler gauge will not fit between
the rail and the slide. If the rails are not tight to the slide, readjust and make certain that
the mounting bolts are tight. See Figure 12-107.

Figure 12-107

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3) With all components in place and the mounting bolts snug (if the bolts are too tight the
rail will not move) on the male rail, (adjusting side of housing) start turning the
adjusting setscrews inward, evenly, until contact is made between all the components.
The bearing preload is being set now. Adjust the setscrews until there is no up and
down movement of the slide. See Figure 12-108. Use an indicator to measure for
movement.

Figure 12-108
4) The proper load on the bearings will allow the roller cages to move, if pushed while the
slide is stationary. If they do not move when pushed they are too tight and
readjustment is required.
5) Now that the roller cages move, when pushed, and there is no up and down movement
of the slide, check to ensure that the adjustable rail is parallel to the housing. See
Figure 12-109. If not repeat this procedure.

Figure 12-109
6) Make sure all mounting hardware is tightened securely. Tighten the jam nuts on the
two adjusting screws, locking them in place.
NOTE: Once the slides are adjusted properly at the PMC, silicone is put in the
adjusting screws and a cap is placed over the screw to prevent any tampering.

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HOUSING POSITION

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

Once the slide has been setup properly, the housing can be checked and positioned to the
mandrel turret. Using a surface gauge and an indicator, check the front edge of the slide to the
mandrel face. The front of the slide must be parallel to the face of the turret. See Figure 12-
110. To make an adjustment, loosen the four mounting bolts that secure the housing to the
machine top. See Figure 12-111. The housing is piloted into a bore, which allow only turning
of the housing. Tap on the rear of the housing until front of the slide is parallel with the turret
face. Retighten the mounting bolts.

Figure 12-110 Figure 12-111

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FOLDING WING ASSEMBLY

The folding wing assembly consists of the folding wings and the lower clamp, or “paper
clamp”. Both, the folding wings and the paper clamp, are designed so when positioned
properly, they do not touch the mandrel when cycled without a blank. The folding wings are
connected to the folding wing activators, which are cam driven in the main drive. The paper
clamp is driven by an activator and cam driven in the main drive, independently of the folding
wings. In making many of the adjustments pertaining to the folding wing assembly, the term
lock-up will be used. It is very important that lock-up is understood before making these
adjustments.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

LOCK-UP

This is the position that the folding wing taper and the taper of the mandrel, with a sidewall
blank between them, all meet. At this position, there is no gap between the wings and blank, or
between the mandrel and the blank. If the folding wings were either up or down, the mandrel,
from this point, there would be a space somewhere between the three components. Finding the
lock-up position is a procedure that is done off the machine and on the bench. NOTE: Extreme
care should be used when performing this procedure. Dropping these components may
damage them so that they can’t be used and will need replacing. This procedure will require
the help of another individual from time to time. Finding lock-up is a procedure that will
require a learning curve. Until it has been done several times, you may not be comfortable
with it. It is always best to have a PMC service technician help with this procedure the first
time. The following is the proper procedure:
1) With wings, spacers, and pivot pin in place, clamp the pivot block in a vise.
2) Remove the lower clamp, being careful not to misplace the two shims.
3) Take a sidewall blank and cut approximately ½" from each side so, when wrapped, the
edges do not interfere with each other.
4) Take a mandrel and wrap a blank around it. Hold it
by hand.
5) Insert the mandrel with blank into the wings,
holding the wings closed around the mandrel.
6) Hold the wings tight against the mandrel as you
slowly push the mandrel into the wings.
7) With steady firm pressure applied on the wings,
push the mandrel until you feel it stop. Note: Too
far up will cause a gap here. Too far down will also
cause a game here.
8) With a depth micrometer, measure from the edge of
Figure 12-112
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each wing to the mandrel stem face and record these measurements. See Figure 12-
112.

9) Repeat this procedure until the measurements are duplicated and you become
comfortable with the procedure. Check for gaps with the feeler gauges. Use a clamp.
Check your numbers with the numbers on the tooling bill.

FOLDING WING AND PAPER CLAMP HEIGHT

The height of the folding wings and the paper clamp is accomplished by a grind spacer, located
under the pivot block. To determine the thickness of this spacer, use the following procedure:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Position a mandrel at the folding wing station, making sure the tooling mounting block
is in the down position. See Figure 12-113.

Figure 12-113

2) Disconnect the folding wings from the actuator rods.

3) Remove the pivot block mounting bolt and nut.
4) With a blank wrapped around the mandrel, hold the folding wings tight to the mandrel
at the lock-up position.
5) With the wings at the correct lock-up position, use a clamp (wood or soft face) to
securely hold wings in place.
6) By hand, turn the machine over until the tooling mounting block is all the way up.
7) Measure the gap between the pivot block and the tooling mounting block with feeler
gauges or shim stock.
8) Add ½ of the paper caliper to this dimension to get your lower clamp pressure.

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ADJUSTING WINGS FOR PROPER WRAP

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) With a blank wrapped around the mandrel, hand wheel the machine until the folding
wings are both all the way closed. At this point the seam clamp will be on its way
down. Turn the machine until the seam clamp is about 1/8 inch from the mandrel. This
will ensure the wings are in the closed position.
2) Loosen the locking nut on both actuating rods. See Figure 12-114.

Figure 12-114
3) Turn the actuating rods until the wing is tight against the blank and mandrel. Check
with a feeler gauge to make sure there is no gap between the wings and blank, or
between the blank and mandrel.
4) Tighten the lock nuts and recheck.
5) Turn the machine by hand so the wings are open. Remove the blank.
6) Turn the machine again, closing the wings, with no blank. Check to make sure the
wings do not touch the mandrel, approximately 0.003 all around without paper.

CAUTION: Before closing wings on the mandrel, make sure the actuator rods
are turned all the way into the rod-end. This will ensure the wings do not
overload or get damaged.

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POSITIONING PIVOT BLOCK

Properly positioning the pivot block places the folding wings in their proper position on the
mandrel. If not in the right position, the wrap will not be good and tight, causing many
forming problems. Use the following procedure to set the block correctly.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Position the block so the folding wings are at the lock-up dimension, up the mandrel.
2) Position the block so the paper clamp is centered on the mandrel.
3) Tighten the mounting bolt and the locking nut. See Figure 12-115.

Figure 12-115
4) Once tightened, recheck for the proper lock-up dimension and that the paper clamp is
still centered. This should be done at the same time as the clamp height is set.

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Stops are mounted to the tooling mounting block, one on the side and one on the back. These
stops, when properly set, allow the pivot block to be removed and then remounted in the exact
correct position. These stops are factory ground, to be correct. The following is the procedure
for setting them:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Make certain the pivot block is in the

proper position; paper clamp centered and
correct lock-up dimension set.
2) Mount the front and rear stop, with the flat
face of the stop touching the tooling
mounting block. See Figure 12-116.
3) Measure the gap between the stop and the
tooling mounting block. See Figure 12-
117.
4) Grind the stepped side of the stop so raised
Figure 12-116
edge is the dimension measured in step 3.
See Figure 12-118.
5) Mount the two stops. Check with a feeler gauge to make certain they are correct.

Figure 12-117 Figure 12-118

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PAPER CLAMP

The paper clamp height is adjusted by means of grind spacers positioned under the clamp.
These have been factory set and should stay with the tooling set that they are ground for. To
determine the proper height of the clamp this procedure is followed:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE

DISCONNECT AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Disconnect the activating rods from the wings.

2) Remove the pivot block with wings. Take to the bench. Lock-up is determined first on
the bench.
3) Install a pair of setup shims. This will be shims that when the wings are close to a point
where there is a gap between the clamp and the bottom edge of both wings. (This gap
should be the same as the gap between the clamp and the wings at lock-up.) Make sure
the clamp is at or below the inside edge of the wings.
4) Re-adjust the shims so the clamp touches the blank when it is wrapped around a
mandrel, and the mandrel is at the lock-up position.

The paper clamp has overload protection in the event that multiple cups or sidewall blanks are
present. This allows a preset spring to collapse instead of breaking parts. If more or less
pressure is required, turning the adjuster clockwise will reduce the pressure and counter
clockwise will increase the pressure. See Figure 12-119. The paper clamp travels up and
down thru a set of linear slide bearings.

Figure 12-119

If replacement or re-adjustment is necessary, the following procedure should be followed:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.
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1) Turn off main power, air, and vacuum to machine.

2) Lower the jacks. Remove the six mounting bolts on each side of the oil pan. Lower the
pan.
3) Remove the two bolts that hold the seam clamp arm to the guide rods at the mandrel,
positioned between the bottom maker and the bottom disc preheat station. Remove the
seam clamp arm. See Figure 12-120.

Figure 12-120
4) Remove the mandrel from same position.
5) Hand wheel the machine so this position, with the clamp arm and mandrel, is at the
folding wing. Note: Make certain that the machine is not indexed past the folding wing
station, as the seam clamp roller will come off the plunger making reassembly more
difficult.
6) Make certain the side and back pivot block stops are in place and a 0.001" feeler gauge
will not fit between the stops and the pivot block. See Figure 12-121. If a gap is found,
the stops will need to be ground so they touch the block. Note: These stops are very
important. They reposition the folding wing pivot block assembly during reassembly.

Figure 12-121

7) Remove the two bolts that attach the folding wings to the rod end of the activating rods
(one on each side). Make sure the spacers between the wing and the rod end do not get
misplaced.
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8) Remove the bolt and the nut that secure the pivot block, and then remove the
pivot block.
9) Slide the oil pan out from under the machine. Perform the next four steps under the
machine, in the drive.
10) Remove the bolts that secure the folding wing oil deflector. Remove the deflector,
being careful to not loose the mounting spacers. See Figure 12-122.

Figure 12-122

11) Remove the two bolts that secure the actuator plate and remove the plate.
12) Disconnect the oil line that feeds the slide. Remove the fitting.
13) Remove the bolt on each side that secures the actuator shaft to the actuating arm. See
Figure 12-123.

Figure 12-123
14) Back on the machine top, remove the two taper pins that position the folding housing.
See Figure 12-124.

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Figure 12-124

15) Remove the four folding wing housing mounting bolts. Remove the assembly from the
machine, being careful of the o-ring cord that seals the unit to the machine top.
16) Clean the assembly with parts cleaner. Wipe dry.

With the unit clean and on the bench, the bearings can now be replaced or adjusted. To replace
the bearings, the adjustable bearing rail is loosened. The old bearings slides out, and the new
ones slides in. Note: All hardware in the lower drive should be torqued with removable
Locktite. To adjust, follow this procedure:
1) Remove the two hollow set screws on the adjusting side of housing. See Figure 12-
125.

HOLLOW SET SCREWS

LOCKING IN REGULAR SET SCREWS

Figure 12-125

2) Back off the two setscrews that adjust the rail.

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3) Remove the two metric rail mounting screws and clean the threads.
4) With a 0.001" feeler gauge, check the stationary side to ensure the rail is tight to the
housing. If not, reposition.
5) With Locktite on the threads, install the two metric mounting bolts into the adjustable
slide rail and snug them down. Do not make them so tight that the rail will not move.
6) Turn the two adjusting setscrews to bring the rail against the bearing and slide. This
should be adjusted evenly and tight enough so that there is no up and down movement
in the slide. With some pressure, the bearing cages will move when pushed.
7) When this condition is met, check to make sure the gap between the rail and the
housing is the same, top and bottom, making it parallel.
8) Tighten the two metric mounting screws.
9) Remove the adjusting setscrews one at a time. Apply Locktite and tighten against
the rail.
10) Apply Locktite to the hollow setscrews and reinstall.

To reinstall this assembly, the above procedure is reversed. It is also recommended that a
PMC service technician be called to assist with this procedure the first time that it is done.

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MANDREL TURRET
The mandrel turret is a housing that goes through the upper base of the machine. On the
bottom of the turret, in the main drive, is a follower plate that has cam followers that are
indexed by the mandrel cam on the main shaft. This lower section will be discussed in the
lower drive section. The upper mandrel turret has many components, each having different
functions. They are: mandrels, seam clamps, rotary manifold, stem extend assembly, and the
clamps open assembly.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

MANDRELS

There are seven mandrels mounted to the turret housing. The mandrel is what the sidewall
blank is wrapped around to form the cup. The mandrels are a tooling item and are designed for
a particular cup. The body of the mandrel is coated to provide durability. It is important that
no damage comes to the surface of the mandrel; this will cause wrapping or blow off problems.
At the end of the mandrel is the mandrel nose cone. Going through the mandrel is the mandrel
stem. See Figure 12-126 for an exploded view of the mandrel. Air and vacuum are channeled
through the mandrels. The air is for blow off,
and the vacuum is for holding the bottom disc
in place. There is a hollow setscrew mounted
in the center of the mandrel stem for air
acceleration. Hollow nose mandrels require
periodic cleaning, which consists of total
disassembly, cleaning, and reassembly to
ensure proper operation. While mandrels are
apart, check the condition of the seals and
replace if necessary. Also check the seal Figure 12-126
located behind the bushing retainer in the
aluminum housing. Remove the three flat head screws that hold the retainer to get at the seal.
Make sure the seal is replaced in the right direction. See Figure 12-127. For disassembly
and assembly, use #66497-A block and #204-696 socket. Place #66497-A block into a vise
and secure. Place mandrel nose down, on the block so the two pins on the block stick into the
two holes in the mandrel stem. See Figure 12-128. Now using socket #204-696, insert the two
pins into the spring housing, tighten or loosen. CAUTION: Use care to hold the mandrel
securely during this operation so the mandrel does not fall, possibly hitting the floor causing
damage to the mandrel. NOTE: The spring housing is tightened tight to the shoulder of the
stem. See Figure 12-129. Whenever the mandrels are taken off the mounting face of the
aluminum, housing should be stoned smooth and wiped clean before reinstalling the mandrel.

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If the mandrel becomes worn or damaged at the top (under the seam clamp) they can be rotated
and mounted using different mounting holes.

Figure 12-127 Figure 12-128

Figure 12-129

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The procedure for removing mandrels is as follows:

1) Position the machine so the mandrel to be removed is between the roller incurl and the
bottom finish stations.
2) Open the seam clamps with the selector switch.
3) Remove the two bolts that secure the seam clamp holder to the seam clamp arm and
slide the seam clamp and holder out. See Figure 12-130.

Figure 12-130

4) Remove the four socket head screws that secure the mandrel.
5) Insert two of those socket screws into the threaded holes on the mandrel mounting
flange. As they are tightened against the housing, the mandrel will come out of the
pilot bore, allowing it to be removed.
6) Reverse this procedure to reinstall. NOTE: If jack screws are used to remove the
mandrel (threaded holes on mandrel flange), make certain they are jacked evenly to
prevent any damage to the pilot bore in the aluminum housing and remove any burrs
left from the screws. See Figure 12-131.

Figure 12-131

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SEAM CLAMPS

There are seven seam clamps, which are also tooling

items, designed for a specific cup. Their purpose is to
provide even pressure on the length of the side seam
to create an acceptable side seal. They are mounted
in the seam clamp holders by means of a pin. This
pin allows the seam clamp to pivot so it becomes self
leveling to side seam, as it moves down to apply
pressure. If the seam clamp does not pivot freely,
inspect and repair the problem. The pin is secured
into place by a snap ring on one side. The other side
has a flat machined on the head of the pin to keep it
from rotating when it is installed into the holder. See Figure 12-132
Figure 12-132. The seam clamp is positioned so its
edge is flush with the end of the mandrel nose cone.
See Figure 12-133. This is done by finding the right
pin hole in the seam clamp holder and the proper set
of mounting holes in the seam clamp arm. It is then
fine tuned using the clearance in the mounting bolts
holes. See Figure 12-134. The seam clamp arm is
attached to two guide shafts, which ride through
bushings in the aluminum turret housing. At the
bottom of these guide shafts is a roller yoke. The
roller rides a cam track, mounted to the base of the
machine, which activates the seam clamps. The seam
clamp that is at the folding wing position is opened by Figure 12-133
a plunger, so the blank can be wrapped and then
closed. On the lower section of the guide shafts, there
are springs that ensure the clamp has pressure in the
downward position.

The seam clamp is adjustable in its downward

position. Between the two guide shafts, on the
aluminum turret housing, a stop screw is set to stop
the seam clamp arm on its way down. The proper
setting of this adjustment is to stop the seam clamp
.005" making contact from the mandrel. This setting
will allow enough pressure for a good seal, at the
same time it prevents the seam clamp from hitting the Figure 12-134
mandrel causing wear to the mandrel.

Adjustments to the seam clamp can be made between the bottom heat station and the bottom
finish station, when the seam clamp roller is not on the cam track.

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CLAMPS OPEN

In the center back of the seam clamp arm, a lift off

bolt is mounted. See Figure 12-135. When the clamp
open switch (either at the operators control panel or
on the other side of machine) is activated, an internal
cylinder raises the seam clamp lifting housing which
contacts all the lift off bolts, raising the entire seam
clamps. See Figure 12-136. This assembly is non-
adjustable. If assembly fails to operate properly
check for air leaks, and check the condition of the
seals. Replace if necessary. See Figure 12-137.

Figure 12-135

SEALS

Figure 12-136

Figure 12-137

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ROTARY MANIFOLD

The rotary manifold allows the mandrel turret to be indexed as the air and vacuum feeds stay
stationary. The stationary half of this two-piece manifold has a bonded rulon surface that
requires lubrication, cleaning, and because it is a wearable material, it will at some point need
resurfacing. Check the maintenance section of the manual for frequency and type of lube to be
used. It will also outline the frequency of disassembly of cleaning. The following is the
procedure for disassembly:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Turn off the air and vacuum.

2) Remove three poly-flow lines from fittings at the top of turret.
3) Remove the four pipe nipples that run through the torque arm.
4) Remove the four bolts that secure the mandrel turret section of the torque arm to the
rimming turret section of torque arm.
5) Remove the setscrews from the taper lock bushing in the stem extend cam adjusting
hub. Use one of the setscrews to jack the bushing loose, and then remove the bushing.
6) Remove the four bolts that secure the adjusting hub to the torque arm and remove hub.
With the hub out, carefully remove the key from the shaft.
7) Remove the torque arm section and springs.
8) Remove the four springs, the guiding shoulder bolt, and the four socket head screws
from the top of the seam clamp lifter housing.
9) Remove all seven lift off bolts from the seam clamp arms.
10) Remove the lifter housing.
11) Remove the four socket head screws that hold the cylinder assembly, and remove
the assembly.
12) Bend the locking tab from the nut. Remove the nut and washer.
13) Remove the bearing hub and stationary half of the rotary manifold.

At this time inspect, clean, and/or resurface or replace as necessary. If resurfacing is required,
remove only enough material to get a smooth, flat surface. When cleaning the manifold, make
sure the ports are also cleaned.
To reinstall, first lubricate the sealing surface with mineral oil. Then reverse the detailed
disassembly procedure. When reassembled, the stem extend timing will need to be adjusted.
NOTE: The fourth pipe nipple that was removed had a pipe plug in it. This is for an optional
mandrel that has the ability to extend the stem further out for easier cleaning. Contact PMC for
more details and pricing.

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STEM EXTEND CAM TIMING

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

The stem extend timing is adjusted by loosening the four adjusting hub mounting bolts and
turning the hub until timed. The proper timing is as the mandrel starts indexing away from the
bottom heat station, the stem should start to come out. It should be fully extended by the time
the mandrel arrives at the roller incurl station. See Figure 12-138.

Figure 12-138

BOTTOM HEAT STATION

The bottom heat station heats the primary and secondary seal areas. This station has a heat gun
mounted on it. The heat gun has a nozzle that cycle into the mandrel nose, heating the bottom
disc as well as the area of the sidewall that the bottom disc will be positioned in. Heat settings
and air flow requirements are outlined in the operators’ sections of this manual. This station is
chain driven and timed in the lower drive. Timing will be discussed in the lower main drive
section of this manual.

The heat gun, at this station, has three 6000 watt electric heat elements. A thermocouple is
mounted in the end of the gun to monitor the temperature and sends a signal to the PLC so it
can control the temperature.

CAUTION: CARE MUST BE TAKEN WHEN ANY WORK IS PREFORMED

NEAR THIS HEATER ASSEMBLY. IT IS EXTREMELY HOT AND MAY
CAUSE SERIOUS INJURY IF TOUCHED. EVEN WHEN TURNED OFF,
THE STATION WILL RETAIN HEAT FOR A PERIOD OF TIME.

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HEAT ELEMENT REPLACEMENT

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

When it is determined that a heat element is burnt out

and needs replacing, the following procedure should be
followed:
1) Turn off the heaters at the operators control
panel.
2) Turn off the main power.
3) Turn off the main air.
4) Remove the four ¼" mounting bolts from the
top cover plate of the heat gun.
5) Carefully remove the insulated connector from
the element that’s bad. See Figure 12-139. The
touch screen will display a fault when a heater Figure 12-139
element fails. When determining which heater
element has failed in the bottom heat station, use an ohm meter.
6) Measure from the housing to the element and record so this dimension can be
duplicated when putting in the new element.
7) Using a pair of Lineman pliers, carefully grasp the two pins on the element, and gently
twist and pull at the same time.
8) With the old element removed, it is important
that the inside of the gun is clean and free of
debris. At this time check the condition of the
seal at the top of the gun. Replace if needed.
See Figure 12-140.
9) Carefully insert the new element into the gun.
The element may require a slight twist to
ensure it is all the way in. Failure to fully
seat the new element will result in element
failure.
10) Reinstall the insulated connector and the rear
cover plate making sure that the bolts are tight. Figure 12-140
11) Turn on the main air and power.

The heat nozzle is specifically designed for each cup. Both the nozzle and the heat gun need to
be positioned properly. The nozzle should be set first and then the gun.

NOZZLE SETUP

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WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

Note: The set-up of the nozzle should be done cold. The nozzle must first be centered to the
mandrel. Remove a mandrel and install a test mandrel. This will be used to indicate the
nozzle. The height of the nozzle is set 0.010" below center to allow for heat expansion.
This has been done at the factory and is positioned with ground spacers placed under the
nozzle. The side-to-side adjustment is done by adjusting the jackscrews, one on each side of
the nozzle. The heat gun is positioned to be centered in the nozzle. See Figure 12-141. This
also has ground spacers that control its position, which have been ground at the factory. It is
ground to fit at assembly.

Figure 12-141

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ADJUSTING THE NOZZLE TRAVEL

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

The travel adjustment is actually setting the position the nozzle stops at as it travels forward to
the mandrel. Proper procedure for making this adjustment is as follows:
1) Hand wheel the machine so the station is all the way forward.
2) Turn the machine mode selector, switch at the operators control panel, to the
“setup” position.
3) Loosen the four mounting bolts at the nozzle mounting bracket. See Figure 12-142.

Figure 12-142
4) Position the nozzle so the first row of holes is inside the mandrel nose, and the
second row of holes is outside the mandrel nose.
5) Tighten the four mounting bolts.

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Now the heater housing can be set to the nozzle, as follows:

1) Loosen the four mounting bolts. See Figure 12-143.

Figure 12-143

2) With the station and nozzle fully forward, position the housing so there is a 2 ¼"
gap from the rear of the nozzle to the front face of the housing. See Figure 12-144.

Figure 12-144
Note: To check this setup, put the selector switch back to the “run” position; hand wheel
the machine so the station is all the way back. This gap should now be 5/8".

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ROLLER INCURL

BOTTOM INCURL LUBRICATOR

For shells with a polyethylene coating on the outside, a lubricant must be applied to the shell
bottom starting at the shell edge. Lubricant is supplied by an oil reservoir to the felt applicator.
Oil flow is controlled and automatically adjusted by the electronic float in the reservoir.
The felt applicator is positioned to make contact with the shell during mandrel turret index to
the roller incurl station. The proper oil reservoir tank pressure is 3 to 4 psi; controlled by a
regulator and gauge at the tank.

DRIVE BELT TENSION

CAUTION: BEFORE ADJUSTING THE BELT, ENGAGE AT LEAST TWO

EMERGENCY STOP BUTTONS.

The drive belt, when properly tensioned, should have 0.250" (6mm) of deflection midpoint
between the pulleys. To tighten the belt, links must be removed from the belt. Never apply
any belt dressing to the belt.

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CENTERING OF THE STATION

This station must be centered to the mandrel. To properly center the roller incurl, use the
following procedure:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Remove a mandrel and install the test mandrel.

2) Index the machine by hand, stopping the test mandrel at the roller incurl station. Make
sure the mandrel turret has stopped indexing and the roller head does not advance into
the test mandrel.
3) Remove the center plug and the roller incurl head.
4) Indicate the shaft that the roller incurl head mounts to.
5) The height should be all right, it was indicated, a spacer was ground and mounted under
the station.
6) To center the station side to side, loosen the six mounting bolts.
7) Loosen the jam nuts on the setscrews, one on each side of the station.
8) The unit is moved by loosening the setscrew on the opposite side of the direction to be
moved and tightening the setscrew on the side of the direction to be moved.
Note: Station moves sideways on a key so it stays square to the mandrel turret.
Note: When moving the station, the unit is moved by turning the set screw into the key
(under housing) which pulls the station over.
9) Once centered, retighten the six mounting bolts.
10) Snug both setscrews against the key and tighten the jam nuts.
11) Remove the test mandrel and install the mandrel.

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ADJUSTING THE HEAD AND SETTING THE ROLLERS

Set all the rollers 0.020" away from the center plug by using a feeler gauge to measure. This is
done by first loosening the locking nut on the backside of the head, one for each roller, and
turning the adjusting screw to move the roller in or out. See Figure 12-145. When finished,
tighten the locking nuts on the back of the head. The next adjustment is to position the roller
head. This adjustment must be done before positioning the center plug.

Figure 12-145

To position the roller head, use the following procedure:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,
DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.
1) Hand wheel the machine so the station is fully forward.
2) Loosen the socket head screw in the adjusting nut, located at the rear of the station. See
Figure 12-146.

Figure 12-146

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3) Using tool #106-130 (3/8" shaft) in one of the holes located around the diameter, turn
the nut. Note: Turning clockwise from the rear of the station will pull the head back,
counter clockwise will allow the head to move forward.
4) Adjust the head by first measuring the distance between the bottom of the roller form
and the end of the mandrel. See Figure 12-147.

Figure 12-147
5) This should measure, roughly, the bottom depth dimension, located on the cup drawing.
6) Reset the center plug, from the mandrel .030"
7) Once this is done, the machine should be run and e-stopped with a shell on the
mandrel between the roller incurl station and the bottom finish station.
8) Using a depth micrometer, measure the bottom depth of the shell.
9) The adjusting nut should be used to make this dimension 0.010" more than the
bottom depth dimension on the cup drawing.
10) Tighten the lock screw on the adjusting nut.
11) All adjustments in travel can be made 0.001" at a time. This can be done by using the
marks on the diameter of the adjusting nut and the scale mounted on the rear of the
housing. Note: Every mark on the scale is 0.001". Every mark on the adjusting nut is
0.010". One complete turn of the nut is 0.050".
12) Once you have obtained the proper setting, it is important to record it.
The second adjustment can now be made. This
adjustment is positioning the center plug.
1) Hand wheel the machine until the station is
all the way forward.
2) Remove the rear cover of the drive belt
guard.
3) Loosen the lock screw at the bottom. See
Figure 12-148.
4) Adjust the nut until there is 0.030" between
the plug and the end of the mandrel.
5) Tighten the lock screw.
6) Replace the rear cover of the belt guard. Figure 12-148

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STATION SLIDE SET UP

Inside this station housing, a cam is mounted to the driveshaft. As the shaft is driven the cam
moves a slide forward and backward. A conjugate cam is used here, which provides more
control. The slide has two cam followers mounted to it, one for the upper part of the cam and
one for the lower part of the cam. When setting up the slide, start with the slide rails centered.
This is possible because there are adjusting screws on both sides of the housing. The proper
load for the slide bearings is to have them tight enough that there is no up and down
movement. At the same time, you should have them just loose enough that with firm pressure
pushing on the bearing cages the bearing cage will move. Note: If changing a component in
this assembly, leave one side tight and set the bearing load to it. The following is the procedure
used to set the slide initially.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Check to make certain that the bearing rails, mounted to the slide, are tight to the slide.
Use a 0.001" feeler gauge to check the fit.
2) Install the slide, bearing cages, and outer bearing rails into the housing.
3) Tighten the two metric bolts in the outer bearing rail on one side, and snug them on the
other side.
4) Using the two adjusting setscrews, adjust the snug rail in to achieve the proper load on
the bearings. This is when there is no up and down movement on the slide and with
firm pressure you can push the bearing cage.
5) Tighten the rail down and measure the gap on both sides, between the housing and
the rail.
6) Reposition the rails and reload the bearings to the proper load so the slide is centered in
the housing.
7) Now grab the slide and push it back and forth checking for any looseness between the
cam followers and the cam. This needs to be done while making one full revolution of
the station. If any play is found, the slide will need to be moved sideways a 0.001" at a
time until the looseness is gone. It is most important to have no play when the station is
all the way forward. It is allowable to have up to 0.002" of play in the back position
but none in the forward position. If moving the slide does not take the play out, either
the cam or the cam followers will need to be changed.

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BOTTOM FINISH STATION

This station is where the bottom of the cup is finished, including the bottom seal. It is
important that this station is understood before any adjustments are made. The station is chain
driven in the lower drive, and its timing is discussed in the main drive section of this manual.
This station has a double slide arrangement that is activated by a conjugate cam. When setting
up these slides, set equal distance on both sides of the station. See Figure 12-149. The outside
set is setup and adjusted the same as the other stations.

BASE SLIDE
SET EQUAL DISTANCE ON
BOTH SIDES OF THE STATION

SET-UP OF CONJUGATE CAM SLIDE

Figure 12-149

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

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STATION CENTERING

This station also needs to be centered. The height has been done at the factory by means of a
ground spacer. To properly make this adjustment, a test mandrel and indicator are needed. To
adjust the side to side centering, use the following procedure:
1) Remove the clamp ring assembly so the inside of the housing can be indicated.
2) Loosen the six station mounting bolts.
3) Loosen the jam nuts on the setscrews, one on each side of the station.
4) The unit is moved by loosening the setscrew on the opposite side of the direction to be
moved and tightening the setscrew on the side of the direction to be moved.
Note: The station moves sideways on a key so that the station stays square to the
mandrel turret. Also note that in adjusting setscrews, the unit is moved by turning the
setscrew into the stationary key, located on the slide under the unit.
5) Once centered, be sure to re-tighten the six mounting bolts.
6) With the six mounting bolts tight, turn both adjusting setscrews in to just touch the key
and then tighten the two jam nuts.

STATION TRAVEL ADJUSTMENT

This adjustment will position the station relative to the mandrel. Changing this adjustment
will change the bottom depth of the cup. Making an adjustment here may affect the
centering or concentricity of the roller so it will need to be checked. Use the following
procedure to make this adjustment:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Hand-wheel the machine so the station is fully forward. This will be 0.875 inch
of travel.
2) Loosen the jam nut on both sides at the adjusting nut. See Figure 12-150.

Figure 12-150

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3) Adjust the nuts evenly on both sides until the proper setup dimension is reached. This
dimension can be measured two ways, with the clamp ring removed and just the
knurling roller on. Adjust until there is 0.030" gap between the roller and the end of
the mandrel. With the clamp ring and roller left on, adjust until there is 0.015" gap
between the clamp ring relief and the seam clamp. See Figure 12-151.

Figure 12-151

4) Once the head is positioned, properly tighten the two jam nuts.
5) Now that the two jam nuts are tight, the spring preload will need to be checked and
adjusted if needed. These springs, one on each side, are on the front half of the
adjusting stud. See Figure 12-152. The proper preload is 1.63" measured from washer
to washer.

Figure 12-152

6) Tighten the jam nuts when finished.

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CENTERING THE KNURLING ROLLER (CONCENTRICITY)

The knurling roller needs to be centered so it fits cleanly into the incurled bottom, without
damaging the bottom of the shell. Use the following procedure to accomplish this task

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Remove the clamp ring and knurling roller.

2) Hand wheel the machine so the station is all the way back.
3) Using a magnetic base and indicator, position the indicator on the roller bearing shaft
and zero the indicator.
4) Remove the top cover plate from the station.
5) Loosen the lock screw on the rear adjusting nut.
6) Hold the shaft from turning at the back of the station, and with wrench #216-932
(supplied with the machine) adjust the centering nut until the knurling wheel is
centered. See Figure 12-153.

Figure 12-153
7) Once centered, tighten the lock screw on the adjusting nut.
8) Replace the top cover.

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KNURLING PRESSURE

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

The station allows the amount of pressure used when knurling to be increased or
decreased. When adjusting the amount of knurling pressure, keep in mind that more
pressure is not a cure. Use the amount of pressure needed to give a good seal and a nicely
finished bottom. Use the following procedure to make an adjustment:
1) Remove the top cover plate on the station.
2) Loosen the lock screw on the pressure adjusting nut located towards the front. See
Figure 12-154.

Figure 12-154

3) Hold the rear nut, and turn the front nut using the two wrenches supplied with the
machine. Wrenches are parts #216-931 and #216-932.
4) Turning the pressure nut clockwise from the back will decrease the pressure and
counter clockwise will increase the pressure.
5) Tighten the locking screw when finished and replace the top cover plate.

DRIVE BELT TENSION

CAUTION: BEFORE CHANGING THE BELT, ENGAGE AT LEAST TWO

EMERGENCY STOP BUTTONS.

The drive belt should have ¼" or 6.35 mm of deflection at the midpoint between the pulleys.
To tighten the belt, remove links. Never apply belt dressing to the belt.

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RIMMING TURRET
The rimming turret is a housing that goes through the upper base of the machine. On the
bottom of the turret, in the main drive, is a cam follower plate that has cam followers and are
indexed by the rimming cam on the main shaft. This lower section will be discussed in the
main drive section of this manual. The upper rimming turret has several assemblies; A rotary
manifold, pockets, cup stops (knock outs), and die rings.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

ROTARY MANIFOLD

The rotary manifold allows the rimming turret to be indexed as the air and vacuum feeds
remain stationary. The stationary half of this two piece manifold has a bonded rulon surface
that requires lubrication, cleaning, and because it is a wearable material it will at some point
require resurfacing. Check the maintenance and lubrication section of this manual for
frequency and type of lube to be used. The manifold can be lubed without disassembly by
putting the lube into the vacuum lines; it will need to come apart for scheduled cleaning. The
following procedure is for disassembly:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Turn off main power to the machine.

2) Turn off the air and vacuum.
3) Remove the three poly-flow lines from the fittings at the top of the turret.
4) Remove the three pipe nipples that run through the torque arm.
5) Remove the four bolts that connect the rimming turret section of the torque arm to the
mandrel turret section.
6) Remove taper-lock and plate. See Figure 12-155.

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Figure 12-155
7) Remove the two bolts that secure the adjusting hub. Remove the hub and the key from
the shaft.
8) Remove the three bolts that secure the torque arm section. Remove the torque arm.
9) Remove the bearing lock nut and washer, and then remove the upper housing. See
Figure 12-156. Be careful not to lose the springs and washers.

UPPER HOUSING

LOCK WASHER AND LOCK NUT

Figure 12-156
10) Remove the top half of the rotary manifold; clean, inspect, and resurface as needed.
11) Reverse this procedure to reassemble. Note: Do not forget lubrication.

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POCKETS AND CUP STOPS

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

There are seven pockets mounted to the upper turret

housing, which receive the finished cup shell from the
mandrel turret and secures it as it is indexed through
the rimming stations. The pockets are specifically
designed for a particular cup. A cup stop (knock out)
assembly is mounted to the bottom of each pocket. It
supports the finished bottom of the cup shell. The
cup stops are adjustable. This adjustment changes the
cup height. A typical range would be 0.010", either
way from the cup height dimension located on the cup
drawing. Too much change can cause other problems
and cup defects. Before making any cup stop Figure 12-157
adjustment, measure from the die ring to the face of
the cup stop and record this dimension. See Figure 12-157. All the pockets should be set the
same, within 0.001" of each other. To make a pocket adjustment, you will need to use the two
wrenches supplied with the machine. The outer wrench has pins that fit the locking nut and the
inner wrench is a t-handled allen wrench that is used to raise and lower the cup stop. When
adjusting, the cup stop (knock-out) must be in the full down position. This will be between the
2nd and the 3rd rimming stations. Use the following procedure to make an adjustment:
1) Use the outer pin wrench, turning it counter clockwise to loosen the lock nut.
2) Turn the inner allen wrench clockwise to lower the cup stop and counter clockwise to
raise the cup stop.
3) Turn the outer pin wrench clockwise to tighten the lock nut.
4) Measure with a depth micrometer and compare to previously recorded dimension.

DIE RINGS

Die rings are yet another tooling item designed specifically for a particular cup and are
mounted to the pockets. The die rings form the bottom of the rim in conjunction with the 2nd
and 3rd rimming station form tools.

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TAMPER LUBRICATOR
The top curl of the cup is lubricated by a felt applicator on the tamper lube head. Oil is
pressurized in the lube tank and controlled by three regulators, located at the lower right hand
side of the operators control panel. Each regulator controls one of the three lines going to the
head. Regulator #1 controls the left side, regulator #2 controls the top, and regulator #3
controls the right side. When adjusting the regulators, it is important to use only the amount
that’s needed. The top, or #2, should be set higher than the two sides, as the excess will run
down the sides. A tray is mounted below the head to collect the overflow, which is drawn back
to the recovery tank by vacuum.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

STATION SLIDE SET UP

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

This station uses a slightly different bearing cage, a cross roller design. Its proper adjustment
and procedure is the same as the others. It is adjusted on one side of the housing and should be
set so there is no up and down movement in the slide and by exerting pressure on the cage, the
cage should move.

TAMPER ADJUSTMENT

To center the tamper head follow this procedure:

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

1) Hand wheel the machine to bring the tamper head forward to just make contact with the
cup shell in the pocket.
2) Loosen the three bolts on the backside of the tamper head.
3) By hand center, the head in the cup shell, and retighten the three bolts.
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4) Continue to turn the machine forward until the tamper head is all the way forward.
5) Loosen the two hex head screws on the rear of the slide and adjust so the tamper head
firmly seats the cup shell into the pocket. Retighten the two screws.
Note: When making this adjustment make certain that the head is square and is seating
the shell evenly.

TAMPER FELT REPLACEMENT

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

The felt cord in the tamper lube head is a wearable item and will have to be periodically
replaced. When replacing, it is very important to get the proper fit, to not only lubricate the
shell properly, but to get maximum life out of the piece of felt. Before removing the head
make certain that you have a supply of cup shells on hand so the felt can be fit properly. When
replacing the felt, the head should be removed from the machine, the new felt installed and fit
on the workbench. The following is the procedure:
1) Close the three oil regulators at the operators control panel.
2) Remove the three lines from the tamper head. Make sure you mark them so they go
back into the right places.
3) Remove the three screws that secure the head to the bracket, and remove the head.
4) Loosen the three flat head screws that hold the two piece head together enough to
remove the felt
5) Remove the felt and use it as a gauge. Make certain that you cut the new piece slightly
longer than the old piece.
6) Make a diagonal cut on both ends and install the felt into the head. Determine the
length needed, and make another diagonal cut on the opposite end. Make a smooth
joint, and tighten the head together. Put the felt seam at 11 o’clock or 1 o’clock. If the
seam is at the bottom, lube will run straight out seam. This will cause excessive usage
of the mineral oil.
7) Using a cup shell, test fit the new felt. It should fit into the shell with minimal
resistance. If it is too tight, it will pull the shell from the pocket or crush the shell. If it
is too loose, it will not lubricate properly. To properly fit the felt lubricator on a table,
push a shell over the felt and lift the shelf. If the fit is correct, the lubricator should not
fall out of the shell.
8) Reinstall the head, making sure that it is centered.
9) Readjust the oil regulators for proper oil flow.

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RIMMING STATIONS

1st RIMMING STATION

As this station advances forward to the cup shell secured in a pocket, the form tool mounted to
this station comes into contact with the upper edge of the shell. As the station continues
forward, the form tool starts to curl the paper.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

STATION CENTERING

All three of the rimming stations must be centered. In order to do this properly, a rimming
test mandrel and a dial indicator must be used. The height of the station has been preset at
the factory and a ground shim installed. To adjust the side to side centering, use the following
procedure:
1) Loosen the six station mounting bolts.
2) Loosen the jam nuts on the setscrews, one on each side of station head
3) The unit is moved by loosening the setscrew on the opposite side of the direction to be
moved and tightening the setscrew on the side of direction to be moved.
Note: The station moves sideways on a key so the station stays square to the rimming
turret. In adjusting the setscrews, the unit is moved by turning the setscrew into the
stationary key, located on the slide under the unit.
4) Once centered, be sure to retighten the six mounting bolts
5) With the six mounting bolts tight, turn both adjusting setscrews in to just touch the key,
and then tighten the two jam nuts.

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TRAVEL ADJUSTMENTS

CAUTION: BEFORE MAKING THIS ADJUSTMENT, ENGAGE AT LEAST

TWO EMERGENCY STOP BUTTONS.

Proper travel setting will allow for maximum curl,

without wrinkling or crushing. To adjust, perform the
following:
1) Loosen the socket head locking screw on the
adjusting nut. See Figure 12-158.
2) Using a 3/8" shaft placed in one of the holes
located around the diameter of the nut, turn
the nut.

Turning the nut clockwise from the rear of the station

will pull the tool back, and turning the nut counter
clockwise will allow the tool to move forward. All
adjustments in travel can be made 0.001" at a Figure 12-158
time. This is done by using the marks on the
diameter of the adjusting nut and the scale mounted on the rear of the housing. Every
mark on the scale is 0.001". Every mark or line on the nut is 0.010". One complete turn of
the nut is 0.050". Once the proper setting is obtained, it is important to record the setting
using the above mentioned marks. All three rimming stations have overload protection to help
protect the form tools. This is done by means of an adjustable spring that has been preset
at the factory. The gap between the adjustor and the housing should be 11/16".

2nd RIMMING STATION

CAUTION: BEFORE MAKING A TRAVEL ADJUSTMENT, ENGAGE AT

LEAST TWO EMERGENCY STOP BUTTONS.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

All the adjustments of this station are the same as

the 1st rimming station with the exception of the
travel. It is set so when the station is all the way
forward; the face of the form tool should be 0.020
away from the die ring face. See Figure 12-159.

Figure 12-159
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3rd RIMMING STATION

CAUTION: BEFORE MAKING A TRAVEL ADJUSTMENT, ENGAGE AT

LEAST TWO EMERGENCY STOP BUTTONS.

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,

DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

All the adjustments of this station are the same as the other two stations with the
exception of the travel adjustment. This is set so when the station is all the way forward;
the form tool just touches the die ring. See Figure 12-160. Note: Travel adjusted too far
forward will cause deflection in the station and may cause damage to the die rings and
form tool.

Figure 12-160

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STATION TO TURRET ALIGNMENT

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,
DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

All the stations on the machine must be positioned so they are square to the turret that they
work on. For the mandrel turret this would be the:
1) bottom maker
2) bottom disc preheat
3) bottom heat
4) roller incurl
5) bottom finish
6) folding wing housing

The folding wing housing is positioned by the use of an alignment fixture. All the other
stations are done by using a surface gauge and a dial indicator.

The rimming turret would have these stations aligned to it:

1) tamper lube
2) 1st rimming station
3) 2nd rimming station
4) 3rd rimming station

On all the stations the slides must be set and properly loaded before the station can be squared
to its turret. Either the key on the top of the slide or the machined edge of the slide is used.
Use the surface gauge on the slide and place the indicator on the face of the turret. Run the
indicator across the face of the turret. To make an adjustment to achieve “0” the four station
mounting bolts need to be loosened and the station housing moved until its zero with the turret.
See Figure 12-161. Once zeroed or square, the mounting bolts can be tightened.

Figure 12-161

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TURRET TO TURRET ALIGNMENT

WARNING: TURN OFF MAIN POWER AT THE ELECTRICAL CONSOLE,
DISCONNECT, AND LOCK OUT LINE VOLTAGE BEFORE PERFORMING
ANY MAINTENANCE. FAILURE TO LOCK OUT LINE VOLTAGE MAY
RESULT IN UNEXPECTED MACHINE STARTUP, CAUSING PERSONAL
INJURY OR DEATH.

During initial machine assembly, the mandrel turret and the rimming turret are aligned by
using a test mandrel on the mandrel turret and a test mandrel on the rimming turret. A dial
indicator is used to set zero from the mandrel turret to the bottom maker draw punch, and then
from the mandrel turret to the rimming turret. Between these three items, zero is obtained. In
the event of a machine crash, which may knock one or more of these components out of
alignment, a PMC service tech should be called in to evaluate the problem and assist with the
realignment and repairs.

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OIL FILTER REPLACEMENT, CLEANING, AND OIL PRESSURE

ADJUSTMENT

CAUTION: BEFORE REMOVING FILTER ENGAGE AT LEAST TWO

EMERGENCY STOP BUTTONS.

The oil filter cartridge must be cleaned and inspected

on a regular basis. The frequency is outlined in the
maintenance and lubrication section of this manual
and on the operators control touch screen. Failure to
clean the filter will cause contamination problems in
the main drive oil, which may lead to main drive
damage or failure. The filter cartridge can be cleaned
with a good quality parts washer. Once cleaned, it
should be blown dry. Note: When using compressed
air, follow all outlined safety precautions, especially
eye protection. The oil filter is located on the main
drive motor end of the machine. To get to the filter, Figure 12-162
remove the metric socket head bolts that secure the
cover plate. See Figure 12-162. With the cover plate removed, the filter can be pulled out of
its housing. Take care not to allow anything to fall into the housing while the cover is off. It is
recommended a spare filter be purchased so when the old filter is removed for cleaning a new
or clean one can be put in. This will allow time for cleaning and inspecting the dirty filter,
without any machine downtime. If an abnormal amount of debris is found in the filter, make
note, and have a qualified person inspect the drive and the stations for wear or damage.

OIL PRESSURE

The proper amount of oil pressure is 30 psi. This can be adjusted at the regulator, located in
the plumbing at the oil cooler. See Figure 12-163. Always determine the reason for making a
change in the pressure (i.e. dirty filter, bad pump, etc). Increasing the pressure to overcome a
problem or component failure will cause further damage and possibly failure of a component
or assembly.

Figure 12-163

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Mechanical Troubleshooting
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MECHANICAL TROUBLESHOOTING

This troubleshooting chart will help isolate possible malfunctions according to the nature of
defects in cups or blanks and follows the cup manufacturing sequence.

The first column lists the defect or malfunction.

The second column lists the machine station or operation to be checked.
The third column lists the condition to be checked.

IMPORTANT: Before making any adjustments, check cup specifications against actual cup
dimensions. If not correct, adjust the machine to produce the proper size cup. If cup defects
still occur refer to the following troubleshooting chart.

IMPORTANT: IF AFTER MAKING AN ADJUSTMENT, THE PROBLEM OR DEFECT IS

STILL THERE, RETURN THAT ADJUSTMENT BACK TO WHAT IS WAS AND
PROCEED TO THE NEXT STEP.

CAUTION: BEFORE MAKING MINOR ADJUSTMENTS ENGAGE AT

LEAST TWO EMERGENCY STOP BUTTONS.

WARNING: BEFORE MAKING ANY ADJUSTMENTS, TURN OFF MAIN

POWER AT THE ELECTRICAL CONSOLE DISCONNECT AND LOCK
OUT.

IMPORTANT NOTE: Before calling the factory for assistance with a technical problem
or a parts order, please try to have the following information on hand:

1) The machine model number

2) The machine serial number
3) The tooling or cup size
4) The problem you are experiencing
5) The fault information displayed on the operators control touch screen (if any)

This will enable us to help in an expeditious manner.

__________________________________________________________________________________________________________________

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Mechanical Troubleshooting
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Defect Check For

1. Short sidewall blank a. Feeder 1) Tight or improperly adjusted web

(Roll feed) guides
2) Improperly adjusted nip pressure.
3) Correct feed-up length.
4) Improper feeder timing.

b. Print repeat 1) Out of tolerance

c. Blanking die 1) Obstructions, paper scrap

2) Splice tape in die.

d. Roll stand 1) Excessive brake tension.

2. Long sidewall blank a. Feeder 1) Excessive nip pressure.

(Roll feed)
2) Foreign matter build up on feed rolls.
3) Correct feed-up length.
4) Improper feeder timing.

b. Print repeat 1) Out of tolerance

3. Sidewall web wanders a. Feeder 1) Loose web guides

sideways
b. Roll of paper 1) Alignment of roll of paper to feeder
guides
2) Loose core

4. Sidewall blank misses a. Feeder 1) Proper timing of sidewall feeder

grippers
2) Blank length-see defects 1&2 of this
section
b. Transfer Turret 1) Worn wear ring and grippers

c. Blank Deflector 1) Correct position

d. Web 1) Excessive down curl or up curl.

5. Sidewall web on infeed a. Feeder 1) Proper timing of sidewall feeder.

hits previously cut blank
during its index
b. Web 1) Excessive down curl or up curl.

__________________________________________________________________________________________________________________

13-2
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

6. Partial cut of sidewall a. Blanking die 1) Die not closing. Clean die.
blank
2) Lack of lubrication.
3) Cutting stroke.
4) Dull die.

7.Sidewall web jams in a. Blanking die 1) Scrap of splice tape in die set.
die
2) Stripper plates being held up.
3) Correct position of blank deflector.
4) Proper adjustment of sidewall feeder
timing.
b. Web 1) Excessive down curl or up curl

8. Ragged cut of sidewall a. Blanking die 1) Dull cutting edges (inform

blank maintenance)
9. No blanks fed from a. Vacuum 1) Plugged holes or torn suction cups
rotary blank placer
2) Insufficient vacuum.
3) Vacuum timing

b. Hopper and 1) Stack too tight (proximity switch out

conveyor of adjustment)
2) Adjustment of air separator.
3) Blank retainers out of adjustment.

10. Blank does not a. Shuttle 1) Blank pushers

transfer
2) Timing of rotary placer.

b. Air assist 1) Location of air jets.

2) Proper amount of air.

__________________________________________________________________________________________________________________

13-3
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

11. Blanks not held on a. Gripper 1) Foreign objects or matter on wear

transfer turret ring or under grippers.
2) Weak or broken closing springs
(under turret)
3) Blank interference during index.
4) Free operation of all parts.
5) Excessive wear of wear ring or
grippers.
b. Blank 1) Excessive warp.

12. Short feed of bottom a. Feeder 1) Foreign matter on rolls.

web
2) Tight or improperly adjusted web
guides.
3) Excess application of mineral oil.
4) Proper feed-up length and timing.
5) Improper nip adjustment.

b. Web 1) Excessive width.

2) Web caliper under spec.

13. Long feed of bottom a. Feeder 1) Proper feed-up length and timing.
web
b. Web 1) Excessive web caliper.

c. Scrap chute air 1) Excessive pressure.

14. Bottom web wanders a. Web turnover 1) Proper position.

2) Drag in roll hub and/or guides.

b. Feeder 1) Proper alignment of guides through

travel paths.

__________________________________________________________________________________________________________________

13-4
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

15. Bottom web jams a. Web 1) Correct width.

2) Splice (servo feed did not advance
web)
b. Feeder 1) Scrap accumulation in vertical
guides.
2) Scrap accumulation behind draw
punch.
3) Proper alignment of guides through
travel paths. (Check for bent guide).
c. Scrap Chute 1) Dirt or oil build up.

16. Torn skirt on bottom a. Feeder 1) Proper lubrication of web.

blank
2) Excessive caliper of stock.

b. Draw punch 1) Scrap behind punch.

2) Loose punch.

17. Deformed bottom a. Bottom blank 1) Clean cut.

blank
2) Proper lubrication of web.
3) Excessive caliper of stock.
4) Scrap behind punch.
5) Loose punch.

b. Vacuum system at 1) Holding bottom on mandrels.

mandrels
18. Bottom blank falls off a. Vacuum system 1) Holding bottom on mandrel.
2) Check gauge for correct amount of
vacuum.
3) Vacuum shut-off solenoid.

b. Mandrels 1) Clogged passages.

__________________________________________________________________________________________________________________

13-5
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

19. Poor side seam seal a. Sidewall sealer 1) Position of heat nozzles.
Temperature and air flow.
2) Plugged holes.
3) Adjustment of blank guides.

b. Mandrel turret 1) Foreign matter on seam clamp face

or on a mandrel under the clamp.
2) Broken spring on clamp actuator rod.
3) Free pivot action of seam clamp.

c. Paper 1) Creasing or other damage on blank

edge.
2) Correct poly thickness.

d. Print 1) Ink in the seal area

__________________________________________________________________________________________________________________

13-6
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

20. Poor bottom seam seal a. Sidewall sealer 1) Nozzle position. Temperature and air
flow.
b. Bottom heat station 1) Nozzle alignment, temperature and
airflow.
2) Poly buildup on nozzle.
3) Ensure all heat elements are good.

c. Bottom incurl station 1) Proper turn in.

2) Oil applicator.
3) Rollers spin freely.

d. Bottom finish station 1) Dirt in knurling wheel.

2) Free rotation of knurling wheel.
3) Proper knurling pressure.
4) Proper bottom depth on the cup.
5) Roller off center
6) Clamp ring relief position.
7) Proper cooling of clamp ring.

e. Rimming pockets 1) Cleanliness. Clean bottom of pockets

thoroughly. If cups are badly soiled
at bottom, contact maintenance.
2) Excessive vacuum.

f. Bottom stock 1) Mineral oil only.

lubricator
2) Excessive mineral oil.

__________________________________________________________________________________________________________________

13-7
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

21. Loose wrap of blank a. Bottom blank 1) Correct formation and position.
around mandrel
b. Sidewall blank 1) Blank position on transfer at each
index point from feeder through
folding station.
2) Undersized paper caliper.

c. Folding wings 1) Cleanliness.

2) Damaged side seam tuck fingers (if
used).
3) Folding wing air assist.
4) Air assist not positioned properly.

d. Lower paper clamp 1) Proper pressure.

e. Grippers 1) Proper adjustment of grippers.

f. Seam clamp 1) Seam clamp pressure (weak springs).

22. Poor bottom incurl a. Bottom incurl station 1) Proper belt tension
2) Proper position of rollers to
centerline.
3) Worn or broken roller.
4) Proper lubrication (double poly only)

5) Rollers spin freely

23. Poor bottom finish a. Bottom incurl station 1) Proper amount of turn in.

b. Bottom finish station 1) Proper drive belt tension.

2) Dirt in the knurling wheel.
3) Proper pressure adjustment of roller.
4) Roller off center.

__________________________________________________________________________________________________________________

13-8
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

24. Cup fails to blow off a. Air system 1) Proper air pressure.
mandrel
2) Proper operation of air valves and
blow off timing.
b. Mandrels 1) Clean air passages.
2) Damage to mandrels.

c. Burn pattern 1) Alignment of preheaters

2) Temperatures and air flows

d. Bottom maker 1) See defects 16, 17 and 18

25. Cups stumble on a. Air system 1) Adequate blow off pressure and
leaving mandrel or proper timing of mandrel blow off.
entering rimming pocket (See defect 24b).
b. Mandrel 1) Sticking. (See defect 24d).

26. Cup tamper crushes a. Tamper position 1) Centered, level and proper vertical
cup adjustment.
27. Tamper fails to seat a. Tamper 1) Proper height. Check spring and free
cup. movement.
b. Mandrel 1) See defect 21.
28. Cups crushed at either a. Lubrication 1) Sufficient lubrication.
top curling station
(frosting)
b. Tamper lubricator 1) Proper lubrication.
2) Proper cup seating.
c. Fit of cup in pocket 1) Looseness.
2) Dirt in pocket.
d. Curling tools 1) Concentricity with pocket.
2) Damage.
e. Hot head 1) Temperature.
f. Die ring 1) Damage or dirt.
g. Blank position 1) Proper amount of paper for rim
h. Folding station 1) Loose or offset wrap.

__________________________________________________________________________________________________________________

13-9
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

29. Cup does not blow out a. Discharge chute 1) Proper positioning.
of rimming turret pocket
b. Air system 1) Sufficient air pressure and correct
timing.
c. Pocket knock-outs 1) Free movement
30. Cup bottom edge a. Rimming turret 1) Cleanliness. Clean bottom of pockets
rounded off or dirty pockets thoroughly. If cups are badly soiled
at bottom, contact maintenance.
b. Bottom incurl 1) Excessive incurl.
2) Rollers spin freely.
c. Bottom finish station 1) Cleanliness and concentricity of
housing in relation to mandrel.
2) Proper bottom depth of cup.
d. Rimming turret 1) High setting.
knock-outs
2) Free movement.

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13-10
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

31. Flagger (rim unrolls at a. Side seam 1) Burned out heaters.

side seam)
2) Heaters not properly positioned or
leveled, or plugged holes.
3) Temperature.
4) Air flow.
b. Mandrel turret seam 1) Foreign matter on seam clamp face
clamps or on mandrel under clamp.
2) Broken spring on clamp actuator rod.
3) Excessive indentation caused by
seam clamp at top of mandrel.
4) Seam clamp pivoting freely.
c. Blank position 1) Proper amount of paper for rim.
st
d. 1 curl 1) Excessive top 1st curl adjustment.
2) Station alignment.
3) Worn or damaged tool.
e. Hot head 1) Fully closed.
2) Worn or damaged tool.
f. Tamper lubricator 1) Proper position and amount of
lubrication.
g. Folding wings 1) Fold-back of blank edge extended
beyond seam clamp.
h. Sidewall feeder (roll 1) Clean roller surfaces.
feed)
2) Worn or defective bearings in feeder
rolls.
3) Lateral movement of meter roll on its
shaft.
4) Web guides adjusted properly.
i. Paper 1) Heat seal surface treatment of poly,
amount of poly and sizing of
uncoated side.
2) Formability-moisture content, stretch
factor, direction of grain.
j. Print 1) Bleeding into side seal area.

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13-11
 PMC-1002
Mechanical Troubleshooting
___________________________________________________________________________________________________________________

Defect Check For

32. Creased sidewall seam a. Preheat 1) Proper position of side seam heaters
(double seam) and excessive temperature setting.
2) Air flow.
b. Bottom incurl station 1) Poor turnover.
c. Bottom finish station 1) Poorly formed bottom edge on shell.
d. Folding wings 1) Side seam overlap fully under seam
clamp.
2) Edge of blank interfering during
wrap (peaking)
3) Loose wrap.
e. Rimming turret 1) Proper height setting.
knock-out plungers
f. Tamper lubricator 1) Proper amount of lubrication.
g. Paper 1) Caliper matching tooling specs.
h. Seam clamp 1) Seam clamp spring pressure.
33. Pleat at sidewall seam a. Preheat 1) Proper position of heaters. Excessive
(peaking) temperature setting.
b. Folding wings 1) Side seam overlap fully under seam
clamp.
2) Edge of blank interfering during
wrap (peaking)
3) Loose wrap.
34. Out of round cups a. Sidewall sealer 1) Proper position of bottom preheat
nozzle
2) Excessive bottom preheat
temperature

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13-12
 PMC-1002
Electrical Troubleshooting
___________________________________________________________________________________________________________________

ELECTRICAL TROUBLESHOOTING

The PMC-1002 cup forming machine is built with a PLC “Touch Screen” for accurate and
detailed control of the machine. Detailed info about machine faults is contained within the
MMI program and is accessible on the “Touch Screen”. If there is a machine fault, the machine
will stop immediately or “E-Stop” and the fault screen will automatically be displayed with
information regarding the probable cause and repair to return the machine to service. In this
section you will find a copy of all the fault screens. Also note that with the electrical
documentation sent with the machine you will find an Allen Bradley manual that will have a
troubleshooting section that covers any electrical problems with the main drive. There will also
be an Indramat manual that will provide a troubleshooting guide for the servo feed drives.

TROUBLESHOOTING THE PMC 1002 SERVO SIDEWALL FEEDER

CAUTION: BEFORE REACHING INTO ANY PART OF THE FEEDER OR

DIE ASSEMBLY ENGAGE AT LEAST TWO EMERGENCY STOP
BUTTONS.

Getting “Registration Mark Missing” Faults, But The Marks Are Present On The Paper:

• Check to see that the sensor switches are set correctly for the color of the registration
mark, and recalibrate the sensor to the registration mark. See “Sidewall Registration
Sensor Setup” instructions in the mechanical adjustment section of this manual.
• Check to see that the sensor head is the correct distance from the paper. The correct
distance should be 0.625”. See “Sensor Distance To Registration Mark” setup in the
machine adjustment section of this manual.
• Make sure the paper is not free to move towards or away from the sensor head while the
machine is running. This would change the focal distance of the sensor causing the
sensor to miss marks.
• Check to see that the sensor head is clean.
• Check to see that the fiber optic cables are plugged in correctly and fully. The
transmitter side on the sensor head is the round lens, while the receiver side of the head
is square. The blue light should be coming from the round side. Check to see that the
transmitter and receiver fiber optic cables are plugged into the sensor correctly.
• Is the paper slipping? Check the nip setting found in the machine adjustment section of
this manual.

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14-1
 PMC-1002
Electrical Troubleshooting
___________________________________________________________________________________________________________________

Intermittent Short Feed Or The Sidewall Fails To Get Into The Grippers:
The machine is running well, but intermittently a short blank is made and it fails to get into
the grippers.
• To determine if the problem is mechanical or electrical, run the machine with the
registration selector switch set to the off position. If the blank lengths vary in non-
registered mode, then the problem is mechanical. Check for slipping between the feed
roll and the paper. If the blank lengths are all the same, then the problem is electrical.
See below.
• This problem can occur when the registration mark is black or gray. The sensor is setup
for a black registration mark. With this setup if no paper is detected or the distance from
the sensor to the paper changes (bad focus) the sensor will indicate that the mark is
detected. This may occur if the sidewall paper is free to move up and down above the
sensor or the hold down spring steel is pressing the paper down into the machined hole
in the feed table. When the index begins the paper is pulled tight which causes the
distance from the sensor to change, which can lead to a false detection. Since the false
detection occurred just as the index began, the resulting sidewall blank will be short
(because it was not detected at 0.25”).

To fix this problem, the paper guides must be set so that the paper cannot move up or down
above the registration sensor.

• The short feed problem can also occur as a result of electrical noise in the signal wire
between the registration sensor and the servo feeder. The registration sensor signal wire
should be separated from all high voltage and 120 VAC control wires, both in the
interconnect wiring and in the electrical console. Typically this signal should be run in
the thermocouple conduit. Also coiling excess wire or servo power cables in the main
electrical console will lead to excessive electrical noise.

Servo Will Not Index In Either “Run” Mode Or Manually:

• Check to see that the servo is enabled. The servo drive is ready and waiting for the
index command if the two-digit display on the Indramat drive (located in the main
console) reads “AF” (all fine)

If the servo drive does not display “AF” there will be a fault code displayed. Consult the
Indramat troubleshooting guide that’s provided with the electrical documentation to
determine the nature of the fault.

If the servo drive display reads “AF” (all fine), then the probable cause is that the index
command from the PLC is not reaching the servo drive. The index command from the PLC
is passed through a solid-state relay and then to the servo drive. It is likely that the solid-
state relay has failed. This solid-state relay is a terminal block style. There are spare SSR’s
located in the electrical console. Replace the solid-state relay.

__________________________________________________________________________________________________________________

14-2
 PMC-1002
Electrical Troubleshooting
___________________________________________________________________________________________________________________

Servo Was Feeding Correctly, But Now The Paper Is Jamming In The Grippers Or The Die.
• Check to see why the servo feed timing has changed. Has the machine encoder failed or
become disconnected.
• Verify that the encoder is zeroed.
• Hand wheel the machine and watch the machine position on the touch screen to verify
the encoder position is changing correctly.
• Have you changed the machine speed? The servo index timing will be different for each
machine speed.

Variations In Bottom Depth or Seeing Short And Long Bottom Skirts:

• Poorly registered paper.
• Paper is not to print specifications.
• See “Setting The Feed Length And Registration Mark And Print Accuracy” in the
machine adjustment section of this manual.

Sensor Trouble Shooting Notes:

• If the sensor is in the “color mode” and the display reads “nnn”, this means that the light
intensity is insufficient. Solution – check the operating distance and make sure that the
fiber optic cable is all the way into the sensor.
• If the sensor is in the “color mode” and the display reads “uuu” this means that the light
intensity is excessive. Solution – check the operating distance or tilt the fiber optic head
10 degrees.
• If the sensor is in the “color mode” and the display reads “----“ this means that the color
difference is too small to differentiate the color difference when in the color mode.
Solution – use the intensity mode.

PLC TOUCH SCREEN

The following pages show the screens that are on the operators PLC touch screen.

__________________________________________________________________________________________________________________

14-3
Appendix: Table of Contents

Gas Hot Air System . .......................................................................... 3

Roll Feed Sidewall Operation ......................................................... 17

Transfer Turret Gripper Segments ................................................... 21

Lid Groove Station Option .............................................................. 23

Leak Detect Set-up ......................................................................... 25

Cup Diverter Option ....................................................................... 27

Glossary of Terms............................................................................. 29

0907 appendix |1
 Gas Hot Air System
⥵⥵ For machines with serial number 94371 & above.

The patented gas fired hot air generator applies state of the art burner technology, to provide safe, clean, and controllable hot
air for heating and sealing on cup machines. The gas burner can achieve higher temperatures at lower air flow rates than can be
accomplished with electric air heaters.

How the Burner Works

Air (combustion air) and gas enter the back of the burner through separate ports, into a venturi-like mixer. The combustion air and
the gas are metered proportionally into the burner. The proper air to gas ratio, regulated by the zero governor regulator, provides
for clean combustion. A second air source called “dilution air” is mixed into the burner after the combustion section. This dilution
air is used to control the burner output temperature by the closed loop addition of cool ambient air into the hot combustion air
from the combustion chamber.

BOTTOM HEAT BURNER

FLAME ROD

IGNITOR

THERMOCOUPLE

GAS METERING VALVE

FEEDBACK TUBE

DILUTION AIR

ZERO GOVERNOR REGULATOR

GAS PRESSURE REGULATOR

0907 Gas Hot Air System |3

The Control System
The control system provides an igniter plug for ignition start and a flame sensor to monitor the flame during operation. If for any
reason the flame is extinguished, the safety system will automatically shut off the gas to the burner. A temperature controller
maintains the burner set point temperature by automatically controlling the amount of dilution air added to the exit of the
combustion chamber of the hot air generator.

Igniter & Flame Rod Fenwal Controller Configuration

An igniter spark plug and a flame rod flame sensor are Pre-purge Time = 0.0 seconds
mounted in the combustion chamber of each burner. The Trial for Ignition = 4.0 seconds
igniter provides the spark ignition for igniting the burner at
start up. The igniter stops sparking once the burner is lit. A Tries for Ignition = 1.0 second
flame sensor is used to detect and monitor the flame in the Extinction Time = 0.8 seconds
chamber. Both the igniter and flame sensor are wired to a Permitted Recycles = None
Fenwal ignition and proof of flame controller.

The gap on the igniter should be set at 0.06" (1.6 mm). When
Remote Sensing — Conditions for
replacing the igniter or flame rod, apply Copper Plate Anti-
Re-Start:
Seize compound to the threads.
1. Combustion air is on.
IGNITER GAP 2. Gas pressure is in the correct range.
0.06" [1.6 MM] GAP
Omron Temperature Controller
Each burner has an associated Omron temperature
controller. This controller monitors the burner temperature
and compares it to the set temperature on the controller.
The controller sends a 1 – 10 volt signal to a proportion
flow valve on the dilution air. The dilution air is used to
cool the products of combustion and maintain the output
Fenwal Proof of Flame Controller
temperature. As the valve opens, the burner output
Each burner has an associated Fenwal controller. The Fenwal temperature decreases. 0 on the controller means that the
controller provides the spark ignition to start the burner and proportional valve is fully closed. 100 means that the valve
monitors the flame after the burner is lit. When the burner is 100% open.
is switched on, the Fenwal controller performs a 5 second
self-test. After the self-test, the gas is turned on to the burner,
and the controller applies a spark at the igniter. The spark is
applied until the burner is lit, or for a maximum of 4 seconds.
If the burner does not light within the 4 second ignition
period, the gas is turned off, the controller will stop applying
the spark and a “flame out” fault will occur.

4| Gas Hot Air System 0907

Controls

Burner Off/On Selector Switch

Each burner has a push button “off/on” switch. Pushing the button once will initiate the burner start sequence, as follows:
The burner control circuit is energized and the Fenwal controller begins a 5 second self-test sequence. After the 5 second test, the
gas valve is opened and the Fenwal controller applies spark to the igniter spark plug. The burner green pilot light is also energized
“on” at this time. When the flame rod sensor detects a flame, the Fenwal controller stops applying spark and continues to monitor
the flame while the burner is lit.

Pushing the “off/on” button again will cause the

burner control circuit to be de-energized, which
in turn will shut off the gas to the burner. This
also sets a burner fault.
BURNER CONTROL PANEL
Manual/Auto Selector Switch
TEMPERATURE CONTROLLER
The “manual/auto” selector switch controls
the high and low temperature faults. In “auto”
mode, the heater temperature must remain BURNER TEMPERATURE
within 100 degrees F (56 degrees C) of the
set temperature. If the temperature goes out SET TEMPERATURE
of this range, a fault occurs and the gas valve
closes. When starting the burner in “auto”
mode, there is a timer that allows the heater UP/DOWN KEYS
to be out of range for three minutes without
shutting down.
DISPLAY KEY
In “manual” mode the heater may be at any
temperature without shutting down.
A/M KEY

Auto/Manual Temperature FAULT INDICATOR LIGHT

Controller Switch
The “auto/manual” ( A / M ) key on the lower ON/OFF BUTTON
left hand corner of the temperature controller
controls the output to the dilution air
proportional valve. Dilution air is the ambient MANUAL/AUTO SWITCH
air that is mixed into the hot combustion
air at the end of the combustion chamber.
DILUTION AIR FLOW METER
Controlling the amount of dilution air added
to the products of combustion is the means
by which the burner output temperature is COMBUSTION AIR FLOW METER
controlled. Increasing the dilution air acts to
cools the output temperature, while decreasing
the dilution air acts to increase the output COMBUSTION AIR METERING VALVE
temperature. The manual flow control valve
and the proportional valve are piped parallel
DILUTION AIR METERING VALVE
with each other and both valves contribute to
the total dilution air flow.

In the “manual” mode, the dilution air is

controlled by both the manual flow control
valve, mounted directly under the dilution air
flow meter and the up/down arrows on the
temperature controller which opens and closes
the proportional valve.

0907 Gas Hot Air System |5

In the “auto” mode, the dilution air flow is controlled by both Fault Reset Push-Button
the flow control valve under the dilution air flow meter and
the temperature controller which automatically opens and A fault reset push-button is located on the front of the gas
closes the proportional valve. In “auto” mode a “baseline” control cabinet. The reset button will clear a gas pressure
flow can be set with the manual flow control valve under low or high fault and also any burner fault. The fault reset
the dilution air flow meter. Then, through the use of a push-button will flash whenever a gas system fault exists.
temperature controller, the proportional valve will lock-in the
set point temperature by increasing or decreasing the amount
of dilution air trimmed into the hot combustion air at the end
of the combustion chamber.

Faults & Safe Guards

The control system is fitted with several safety systems to insure the proper and safe operation of each burner. Any fault will cause
the gas supply to be shut off to the burner. The machine is stopped if any of these faults occur while the machine is in “run” mode.
Each fault has a fault indicator light on the gas control panel. These faults are as follows:

Flame Out Fault Combustion Air Low Fault

The Fenwal gas igniter and proof of flame controller monitors A “combustion air low” fault will occur when the combustion
the presence of the flame in the burner with a flame rod air flow (derived from pressure) is too low as detected
sensor. If for any reason the flame is extinguished, a “flame by a pressure switch mounted on top of the air cabinet.
out” fault will occur. A “flame out” fault will cause the gas to Combustion air flow is monitored to insure that flow is
be shut off to the burner. present, which will prevent gas from backing up into the air
system.

Temperature Fault
Gas Pressure High & Low Fault
A “temperature fault” will occur when the burner temperature
is not within the set temperature deviation programmed Two pressure switches, mounted in the gas in-feed line,
into the temperature controller while the burner is selected monitor the incoming gas pressure. A fault is generated if the
to “auto” mode. The deviation is set at PMC to plus or minus incoming pressure is above the high pressure setting or below
100 °F (56 °C). A temperature fault will cause the gas to be the low pressure settings of the switches. A high or low gas
shut off to the burner. fault will cause the main gas valve to be closed.

6| Gas Hot Air System 0907

Air & Gas Controls To check this, set the combustion air at 110. The gas should
be at 10. If not, adjust the gas throttling valve a the burner to
achieve an 11:1 ratio. Now increase the combustion air to 165.
The gas should increase to 15. If not, use the following steps
Regulator & Zero Governor Regulator to adjust the mixture:
The gas meters on the panel are calibrated for gas at 5 psi . 1. Turn the combustion air back to 110.
Different flow meters are required for LPG and natural gas. The
gas to the burners is supplied at 5 psi . The first gas regulator 2. Remove the cover on the stem of the zero governor regu-
drops the gas from 5 psi to 1 psi. The second regulator, or zero lator.
governor, drops the gas pressure from 1 psi to 0 psi. The gas 3. If the gas flow rate increased at a greater rate than the
pressure at this point matches the pressure in the combustion combustion air, turn the adjusting screw inside the zero
chamber. When the combustion air is turned on, the air enters governor stem 1 turn clockwise. If the gas flow rate
the back of the burner into the mixer. The air flowing through increased at a lower rate than the combustion air, turn
the mixer creates a vacuum, drawing gas into the mixer. As the adjusting screw inside the zero governor stem 1 turn
the combustion air flow increases, the vacuum increases counter-clockwise.
drawing more gas into the mixer.
4. Adjust the gas throttling valve to 10.
A feedback tube is connected from the combustion chamber
to the 2 regulators. It is used to balance the pressure at the 5. Increase the combustion air to 165 and check the gas flow
zero governor with the pressure in the combustion chamber. rate.
As the pressure in the combustion chamber increases, the 6. Repeat steps 1 through 5 until the air gas ratio stays in a
pressure is fed back to the regulators, they in turn open up so range of 10:1 to 12:1.
that the pressure at output of the zero governor is equal to
the pressure in the combustion chamber. WARNING: When increasing the air flow, make
sure the burner temperature does not go above
1400 °F (760 °C).
Gas Metering Valve
For natural gas systems there is a metering valve, or throttling Gas & Combustion Air mixture
valve, between the zero governor regulator and the burner
body. This is used to set the ratio of combustion air to gas. Combustion air is mixed with gas in the mixing section of
Once this is set, the gas metering valve should not require the burner. The ratio of air to gas is extremely important in
adjustment. The gas flow rate will vary proportionally with the maintaining clean emissions from the burner. The proper air
combustion air. to gas mixture is set by using the gas metering valve and the
combustion air metering valve. The combustion metering
For propane systems, the gas metering valve is on the gas valve is mounted just below the combustion air flow meter for
panel and has to be adjusted manually as the combustion air each burner. The gas metering valve and the combustion air
is varied. metering valves must be set with respect to each other so the
correct air/gas ratio is maintained.
NATURAL GAS ZERO GOVERNOR ADJUSTMENT On natural gas systems, once the ratio is set, the mixture is
regulated by the 5 psi regulator and zero governor regulator
If the gas flow rate does not increase proportionally with the
located on the burner, just before the metering valve.
combustion air flow rate, the zero governor regulator may
As the combustion air is increased, the gas is increased
have to be adjusted.
automatically.

For propane systems, the gas metering valve is on the gas

ZERO GOVERNOR ADJUSTMENT panel and has to be adjusted manually as the combustion air
ADJUSTING
SCREW is varied.
UNDER CAP
The stoichiometric ratio is 10:1 for natural gas and 25:1 for
propane. This is the theoretical fuel to air ratio required to
THROTTLING VALVE
combust 100% of the fuel. These burners should be set up a
little lean, meaning excess air. This helps to reduce NOx and
CO emissions. The proper air to gas ratio for natural gas is 11
parts air to 1 part gas, or 11:1. The proper air to gas ratio for
propane is 27.5 parts air to 1 part gas (27.5:1).

ZERO GOVERNOR

0907 Gas Hot Air System |7

Natural Gas Set-Up Procedure
On initial startup, the gas air mixture must be set up manually. Once set, the mixture ratio will be adjusted automatically by the
zero governor regulator located at each heater. Use the following steps for initial setup of each heater:

1. Set the combustion air flow on the panel to 150 scfh . Open the gas metering valve on the corresponding burner part way.
2. Set the dilution air flow on the panel to 250 schf.
3. Have one person controlling the metering valve on the burner and another person watching the gas flow meter on the panel.
Push the “on/off” button on the gas panel for the corresponding burner. When the gas comes on, adjust the metering
valve on the burner to 13.5 schf on the gas flow meter. This may take several tries until the correct ratio is set and the burner
stays lit.
4. Tighten the set screw on the gas metering valve.
5. Repeat this process on for all burners. The air to gas ratio will stay between 10:1 and 14:1 throughout the full range of the
burner.

Propane Gas Set-up Procedure

1. Set the combustion air flow, on the panel to 150 schf. Open the gas metering valve for the corresponding burner part way.
2. Set the dilution air flow on the panel to about 250 schf.
3. Push the “on/off” button, on the gas panel, for the corresponding burner. When the gas comes on, adjust the gas meter-
ing valve to 5.5 schf, on the gas flow meter. This may take several tries until the correct ratio is achieved.
4. Repeat this process for all burners. If the combustion air is adjusted, the gas will have to be adjusted manually to maintain the
proper ratio of 27.5 : 1.

Dilution Air Proportional Valve DILUTION AIR CONTROL

The proportional air valve is used to maintain the set air
temperature. The flow control valve under the flow meter sets
a baseline flow and the proportional valve trims
the dilution air in order to maintain the set point DILUTION AIR FLOW METER
temperature. Changes can be made to the set
temperature and the proportional valve will open or close
to reach the new set point. If large changes are required, it
is best adjust the flow control valve under the flow PROPORTIONAL
meter. For the optimum operation, it is best to run VALVE CONTROL UNIT
the proportional valves at 60% open. This allows the
burner, on start up, to come to full temperature more
quickly. When initially setting up the temperatures PROPORTIONAL VALVE
use the following steps:

1. Push and hold the “A/M” key on the

temperature controller for about 2 DILUTION AIR METERING VALVE
seconds until the “Manu” light goes on.
This puts the temperature controller into manual mode.
2. Use the up and down arrows to set the output value to 60.
This will open the proportional valve to 60%.
3. Adjust the combustion and dilution air metering valves to 5. To check the proportional valve % open value, press the
the desired temperature and flow rate. Note that the gas display key (circular arrow key) on the temperature con-
flow rate will adjust automatically. troller once. Press the display key twice to return to the
4. Once the actual temperature is close to the set point, temperatures.
push and hold the “A/M” key for about 2 seconds until Once the gas panel is set up for a certain cup size, the gas
the “Manu” goes out. This will put it back into automatic system may be turned off, and then restarted without having
mode. to make any adjustments.
8| Gas Hot Air System 0907
Shut Down Procedure Temperature Adjustments
The shut down procedure is the same for natural gas The temperature must be set within a controllable
and LPG. window. First, the combustion air and fuel setting
determines the base high temperature for the process.
1. Press the “on/off” buttons on the gas panel Next, the proportional valve and the manual dilution
for each burner. This will stop the gas flow to each air control valve are used to add cool air to establish a
burner. set point temperature. If too low a temperature is set;
2. Press the main “power off” button on the gas the temperature controller will add 100% dilution air
panel. (i.e. the proportional valve will be fully open) and the
actual temperature will not be cooled down to the set
3. Turn off the manual gas valve, located on the back point temperature (i.e. the set point temperature will
of the gas panel. not be within the controllable window). If the output
4. Turn off the manual main air valve , located on the is on 100%, as indicated by the temperature controller,
back of the gas panel. the manual flow control valve under the dilution air flow
meter can be used to add additional air in order to move
5. Turn off the main electrical switch, located on the the temperature control process up into the controllable
main panel. window of operation.

Small adjustments to the temperature setting can be

Theory made to fine tune the sealing process or burner operation
once the combustion air flow and gas flow of the burner
The GHA system operates differently as compared to have been adjusted so that the burner is maintaining
the electric FHA system. The control variables of the temperature well in “auto” mode. Note that increasing
GHA system include: the temperature setting causes dilution air flow to be
decreased. Given that flow is the more dominant variable,
• Total air flow increasing the temperature may actually have a negative
• Temperature effect on transfer more heat into the board. Therefore,
decreasing the temperature setting may actually have a
• Combustion air flow setting more positive effect on getting more heat into the board
• Gas flow setting given that the dilution air flow will be increased for a
decreased temperature setting.
The goal of any heating system is to get the proper
amount of heat into the board to provide a good seal. Once the burner combustion air and gas flow rates have
There are two basic variables to transferring heat into been set, it is usually not necessary to make ongoing
the board; total air flow and temperature. Through adjustments to these settings. Fine tuning, if required,
experimentation it has been determined that total can be done by adjusting the temperature set point.
flow is a more dominant variable than temperature.
Taking action to increase total flow out of the burner
typically has a greater effect on transferring heat
into the board than does increasing the temperature
setting only.

Gas Panel Utilities

Type of Gas: Pressure Rating:
Natural: 100 ft ^3 / hr (2.83 m ^3 / hr ) Minimum: 4 psi (0.27 bar )
Propane: 40 ft ^3 / hr (1.13 m ^3 / hr ) Maximum: 5 psi (0.34 bar )

Supply Air: Electrical Supply:

10,000 ft ^3 / hr at 80 psi (283 m ^3 / hr at 5.52 bar ) 10 amps at 120 vac , 1 ph

0907 Gas Hot Air System |9

System Data

AIR PRESSURE Burner Emissions

The incoming air pressure regulator should be se to 80 psi . Gas fired devices, like the PMC burner, generate specific
The dilution air pressure should be set at 45 psi . This pressure combustion products or emissions. The products of
is limited by the maximum pressure that the proportional combustion are water vapor, carbon dioxide, carbon
dilution air valve can withstand. Setting the pressure lower monoxide (CO), nitrogen monoxide, and nitrogen dioxide.
than 45 psi will limit the maximum flow of dilution air. The Nitrogen monoxide and nitrogen dioxide are commonly
regulator is found inside the upper panel. referred to as NOX.

Incoming Air Pressure: 80 psi Although the PMC gas burner is a very low emission burner,
Dilution Air Pressure: 45 psi PMC recommends that customers vent all of their gas fired
cup machines. Since specific building codes can vary from
location to location, PMC also recommends that customers
Gas Pressure contact a local HVAC firm in their area to design and install an
adequate venting system that will meet local requirements.
5 psi gas is preferred. Consult PMC if a gas pressure other than
5 psi is to be used. It is also very important that the gas supply
flow and pressure be constant. Fluctuations in pressure or OSHA Standards
flow will have adverse effects on the GHA system.
OSHA has set a carbon monoxide limit of 50 ppm of continuous
CO exposure over any 8 hour shift during a 40 hour work
Ventilation week. The 50 ppm CO standard is not a single measurement
but is time weighted average over an 8 hour period.
The GHA system employs state-of-the-art burner technology
that provides very clean emissions. However, it is In terms of NOX emissions, OSHA has set a ceiling limit of
recommended that all GHA systems be ventilated. 5 ppm . The NOX standard is not a time weighted average limit.
It is an absolute limit that cannot be exceeded at anytime
during the workday.
Thermocouples
As for carbon dioxide levels, OSHA has set an exposure limit
The GHA system requires high temperature, non grounded of 5000 ppm. Like the carbon monoxide standard, the carbon
thermocouples. For best results use only thermocouples dioxide standard is a time weighted average limit over an 8
provided by PMC. hour period.

Since OSHA standards are environmental standards, emissions

GHA System Start-up testing must be done on site. Since all facilities are different
(i.e. different building and room sizes, ventilation flows,
Like the electric FHA heat system, the GHA system requires
production processes, etc.), indoor air quality testing can only
adequate time to heat up before the machine is run.
be handled by the customer at their facility. Emissions testing
can be conducted by either a certified industrial hygienist or
an environmental engineering firm.

10 | Gas Hot Air System 0907

Maintenance

Gas & Air Hoses

Inspect ����������������������������������� Monthly
Check for ������������������������������� Signs of wear, cracking & burn marks
Replace ����������������������������������� • Immediately for damaged hoses; otherwise,
• Every 5 Years for Gas Hoses
• Every 10 Years for Air Hoses

Gas Filter
Check for ������������������������������� If the pressure difference across the filter becomes
greater than 0.7 psi (50 mbar)
How ����������������������������������������� Connect a gas differential pressure switch across the
two screw connections on the top of the filter.
Replace ����������������������������������� • Immediately if pressure difference is greater than 0.7 psi (50 mbar); otherwise,
• Yearly (minimum)

Main Air Filter

Replace ����������������������������������� Yearly (minimum)

Gas Pressure Switches

Check ��������������������������������������� Function of high & low gas pressure switches
How ����������������������������������������� Raise & Lower the gas pressure to see if the switches are operating properly.

Gas Safety Shut-Off Valves

Inspect ����������������������������������� Yearly (minimum)
Check for ������������������������������� Leaking across either valve

Burner
Inspect ����������������������������������� Yearly
Check for ������������������������������� • Damage to the flame rod, igniter & thermocouple
• Holes or other damage to the Metal Fiber

Flame Controller
Each time the Fenwall controller powers up, it performs a self-check routine. See the Fenwall manual for
on board diagnostics & troubleshooting guide.

0907 Gas Hot Air System | 11

 Non-Conformances to the European Standard EN 746 : 1997

Requirement PMC RESPONSE

Testing
5.2.1.6

“The gas circuit shall be submitted to its PMC machines run at 5 psi (345 mbar ). If we test our equipment
test pressure and tested for tightness. The at 1.5 times the working pressure, or 7.5 psi (517 mbar ), damage
test pressure shall be not less than 1.5 would occur to the gas regulators on the burners. PMC tests our
times the maximum working pressure at machines at 5 psi (345 mbar).
any point.”

Purge Points
5.2.1.9

“Means shall be provided to facilitate During maintenance on the cup machine, the gas has no where
purging of the gas system during commis- to build up. The only area the gas is contained is in the 1/4" steel
sioning and maintenance to prevent the tubes. The amount of gas contained in these is very small. None
build up of flammable substances.” of the tubes are enclosed in an area where the flammable sub-
stances would be allowed to build up. This is not a risk.

Safety Shut-Off Valves

5.2.2.3

“The safety shut-off valve(s) shall shut off PMC gas burners are run over a wide fuel consumption range. It
the fuel to the entire plant or independent would be very difficult to implement a sensor to sense if there
zone when a hazardous situation occurs is sufficient fuel for the full range of adjustment. If a flow sensor
e.g. Insufficient Gas Flow.” was added to our machine, the sensor would have to be adjusted
every time an adjustment was made to the gas flow, defeating
the purpose of the sensor.

“The capacity control and the safety shut- This is described as separate sensing devices are required for each
off devices shall be operated through the shut-off valve. Since each burner requires two shut-off valves,
independent circuits and sensing devices.” PMC would be required to have two sets of sensors for each
burner. PMC interprets this, as each burner must be operated
through independent circuits and sensing devices.

12 | Gas Hot Air System 0907

Troubleshooting

Burner will not start

Air in gas line------------------------------ After an extended off time, air may get into the gas line. It may take several attempts
to light the burner.
Check for spark---------------------------- SHUT OFF THE GAS! Remove the spark plug (igniter) from the burner and lay it across
something metal. Select the burner ON and after 5 seconds you can observe the
spark. DO NOT HOLD THE SPARK PLUG OR TOUCH THE SPARK PLUG DURING THIS
TEST! HIGH VOLTAGE IS USED TO CREATE THE SPARK!
If no spark was observed, it is possible that one of the following occurred:
• The spark plug wire is broken between the spark plug and the Fenwal controller.
• The Fenwal controller has failed. Replace the controller.

Burner starts and temperature climbs, but shuts off with a “flame out”
fault after 10 seconds

This problem indicates that the flame sensor is not functioning.

Check the flame sensor wiring between the flame sensor and the Fenwal controller. If necessary, replace the flame sensor.

Burner flames out while running

Check if the burner is unstable------- Listen to the air exiting the heater tooling. If it is pulsing or fluttering, the burner is
unstable and should be adjusted. Try reducing the gas flow; and if necessary, the com-
bustion air. You can also tell that the burner is unstable if the ball in the gas flow meter
bounces while the machine is not running.

Burner flames out while running or not running while temperature was not varying
(burner appeared to have no problem, but flamed out)

Check to see that the flame rod The temperature is above the set point temperature.
assembly has not come loose, or re- This will occur when the temperature set point is too low. Check the temperature
place the flame rod. Also check to controller output. If the output is at 100% this means that the proportional valve can-
see that the wiring has not become not put out anymore cool air in order to bring the actual temperature down to the set
damaged------------------------------------ point temperature. This can be corrected by any one of the following ways:
• Decrease the combustion air flow.
• Increase the temperature set point.
• Add additional dilution air with the manual flow control valve under the dilu-
tion air flow meter in order to push the process into the controllable window of
operation.

The actual temperature is below the set point temperature

Check to make sure the “Auto/ The flow indicator ball in the dilution air flow meter is fluctuating, and the tempera-
Manual” button on the tempera- ture is unstable.
ture controller is set to “auto” (the The process is unstable. There are combinations of variables, i.e. air flow, gas setting,
“Manu” light should be off ).----------- and temperature setting, that cause the burner tuning to become unstable. Change
one or more of the variables until the system becomes stable.

0907 Gas Hot Air System | 13

 Burner is lit but no dilution air comes on. Heater is in auto mode.

If the burner is in “auto” mode, the burner is lit, and the temperature is above the set point and no dilution air is present, this
may indicate that one of the following problems has occurred; The 24 vdc power supply may have failed, or the dilution air
proportional valve has failed.

Gas Leaks

For safety purposes, gas utilities add an odor to natural gas in order to make gas leaks more detectable. If an employee
smells gas in the area of the gas machine, it could come from one of two sources. The first is from leaky hose or piping.
In this case, solving the problems is merely a matter of finding the leak and tightening the pipe joint. The second is from
a burner that is running too rich. When a burner is running too rich, uncombusted gas will be emitted from the burner
nozzle. For theoretically complete combustion of the natural gas, the air to gas ratio is 10 parts air to 1 part gas or 10:1. The
theoretical ratio for propane gas is 25 parts air to 1 part gas. The burners should be set up to 11:1 for natural gas and 27.5:1
at 1 for propane. See the section on gas metering valves for the proper setup procedure.

The burner button is pushed “off”— the green light goes off, but the
temperature does not drop.

The gas solenoid for the burner is stuck open — immediately replace the valve. The main gas solenoid can be shut off by
pressing control power off.

Low Gas Pressure Fault—cannot reset low gas pressure fault

The GHA systems have a two pressure switches that monitor the incoming gas pressure for both high and low conditions.
The high pressure switch is set a 7 psi and the low pressure switch is set at 3 psi . Either a high or low gas fault will cause the
main gas solenoid to be closed. To reset a low gas pressure fault press the fault reset push-button on the gas panel.

14 | Gas Hot Air System 0907

 Gas System Inspection Form

Machine S/N ________________________________

Machine Model No. ________________________________

Type of Gas ________________________________

Customer Name ________________________________

Shipping Address ________________________________

________________________________

Leak test of gas fittings and hose connections ________________________________

Gas hose integrity ________________________________

Gas line markers and temperature labels in place ________________________________

Inspected by ________________________________

Inspection Date ________________________________

Next Inspection Date ________________________________

Inspection Notes:

___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________

PA P ER M ACHINERY COR P ORAT ION

8900 West Bradley Road Milwaukee, WI 53224   (PHONE) 414-354-8050 (FAX) 414-354.8614   www.papermc.com
Roll Feed Sidewall Operation
Loading Web Stock WEB DECURLER
• On preprinted web stock, load roll so printed side is
UNWOUND FROM
threaded into feeder, facing downward TOP OF ROLL
• On double poly coated stock, load roll so shiny poly
surface side is down
• On single poly coated stock, it is threaded into the
feeder with poly coated side facing up
⥵⥵ Take note as to how the old roll was wound
& load the new roll accordingly.

To load a roll:
1. Insert core chuck into roll
2. Position roll so the arbor shaft is aligned with bearing
block on each side
3. Use height adjust switch to raise roll stand to seat arbor
shaft into bearing blocks & continue to raise until roll
stand top surface is level UNWOUND FROM
4. Connect brake shaft (inside of the brake) to arbor shaft & BOTTOM OF ROLL
then secure it with retaining screw
5. Secure arbor latches Roll Stand Lateral
6. Inflate core chuck sufficiently to hold roll in place (make
sure roll is straight & runs true); the core chuck may need Adjustment
to be deflated & inflated several times to accomplish this
The Roll Stand Lateral Adjustment is equipped with a hand
7. Proceed in threading the sidewall web stock wheel. The hand wheel allows adjustment of the roll from side-
to-side so paper can be fed straight into the sidewall feeder.
ROLL STAND
ARBOR
Unloading an
HAND
WHEEL
LATCHES RETAINING
SCREW Empty Web Roll
1. Turn brake switch to off position
2. Release air pressure from chuck
3. Push in spring loaded pins &
CORE open arbor latch on each side
ARBOR CHUCK
SHAFT 4. Unscrew retaining screw &
BRAKE remove brake shaft from arbor
shaft
5. Remove arbor shaft from roll
INFLATION BEARING stand
KIT BLOCK
6. Remove arbor shaft/core chuck
from empty roll

0907 ROLL FEED SIDEWALL OPERATION | 17

Main Operation
The sidewall servo will be “cammed” to the machine anytime the sidewall selector switch is in the on position. If the machine is
jogged or hand-wheeled with the sidewall selector switch on the paper will be fed into the machine. The feed will begin at 125°
and end at 325°. If the sidewall selector switch is turned on while the machine is between 125° to 325° the feed will begin at 125°
during the next index.

If a new product is run on the machine, an initial setup will be necessary. Once the print on the paper is in the correct position
relative to the mandrel, a scribe line can be added to the machine to assist in placing the paper in the correct location.

SIDEWALL
FEED
SELECTOR Existing Product Setup
SWITCH
The Existing Product Setup is to be used when a product has
NIP RELEASE been run before and a scribe line is located on the machine.
SELECTOR
SWITCH 1. Place the paper under the sidewall nip roll.
2. Sidewall Feed Selector Switch in the on position.
3. Jog the machine past 335°.
4. Use the nip release selector switch and position the paper
so that the mark on the paper is on the scribe line.
The machine is now ready to run.

Initial Setup
CREDIT LINE
The Initial Setup is to be used when a product has not been run before.

During the setup process the Sidewall Selector switch must be on and the machine
must not be faulted. (Clear faults before moving on to the next step.)

1. Jog the machine to approximately 110–120°.

2. Cut off the end of the web between two blanks, just in front of the credit line.
3. Using the nip release place the web under the sidewall nip roll, slide it up to the
grippers.
4. Press Enable Registration Mark Clear button (this will allow the operator
5 seconds to select Clear Registration Mark before it disables the setup
procedure).
PHOTO-EYE
5. Press Clear Registration Mark
6. Jog the machine until the photo-eye detects the mark or if there is a
clear path between the registration marks, to approximately 330–340°.
7. Press Set Registration Mark
8. The value in Register Mark Position should have changed to the position
where the mark was detected.
9. After this is completed, the machine can be run and the print position
adjusted on the mandrel by using the advance or retard buttons. This is
explained under Advance/Retard Print Position.
10. When the print position is in the correct position, stop the machine at a
position greater than 335°, place the web against the feeder extension
and scribe a line on the feeder extension equal to the position of the register mark
for future reference. See Existing Product Setup.

18 | ROLL FEED SIDEWALL OPERATION 0907

Advance / Retard Print Position
If the print is not in the correct position on the mandrel (the final cup) the operator
may advance or retard the print using the Registration Retard or Registration Advance ⥵⥵ It is possible to move the paper
buttons. If the Fine Registration Move is selected the paper will move approximately out of the registration window if
these buttons are pressed too
0.002 inches when the advance or retard is pressed. If the Coarse Registration Move is many times in a few seconds.
selected the paper will move the value in Coarse Reg. Move Length when the advance
or retard is pressed.

“No Registration Mark Detected” Fault

A No Registration Mark Detected fault will occur if too many consecutive marks are missed. The cups will be diverted and the
machine will be cycle stopped. If the marks are in fact on the paper, it may be necessary to reposition the paper or reset the
registration sensor.

Web Guide Adjustments

There are 4 web guide adjusting knobs on the operator side of the sidewall servo feeder (2 at each end of the guides). There is 1
inside & 1 outside, at each location.

1. The inside knob controls movement of

entire web
SIDEWALL FEEDER THREAD GUIDE
• Counterclockwise rotation moves
web towards operators side of
machine
• Clockwise rotation moves web away
from operators side
2. The outside knob opens/closes guides
to compensate for change in width of
web
• Counterclockwise opens guides
• Clockwise closes the guides
• Moving any knobs a letter mark =
0.010"
• 1 full revolution of the knob makes a
move of 0.050"

WEB GUIDE
Registration Sensor ADJUSTMENT KNOBS

To properly calibrate the registration sensor:

1. Position sidewall stock registration mark directly

over sensor
2. Press registration calibrate button (located at
operators side of feeder)
3. Move sidewall stock so mark is off the sensor
4. Press registration calibrate button again
5. Sensor is now calibrated to detect registration
mark on sidewall

0907 ROLL FEED SIDEWALL OPERATION | 19

TRANSFER TURRET
GRIPPER SEGMENTS

Replacing the Bushings (#109-246)

1. Using an 1 inch socket to maintain alignment,

press the old bushings out of the #315-434
FIGURE 1
turret adaptor plate. (Figure 1) FIGURE 2
2. Using an 1 inch socket to maintain alignment,
press the new bushings into the #315-434
turret adaptor plate. (Figure 2) Make sure
to seat the bushings fully (they should be
recessed below the surface of the turret
adaptor plate).
3. Using flat head screws for centering snug the
turret adaptor plate to the turret (Figure 3).
FIGURE 3
4. Lock the turret adaptor plate to the turret with SOCKET HEAD
the center socket head cap screw.
5. Replace the flat head screws one at a time
with socket head cap screws locking the turret
adaptor plate to the turret. FLAT HEAD

Parts Used:

109-246 Spring Sleeve (supersedes 108-321)

317-630 Turret Adaptor Plate (supersedes 315-434)

0907 TRANSFER TURRET GRIPPER SEGMENTS | 21

Installation of Gripper Segments

1. Install the #414-735 transfer turret segment assembly on the

turret. This should include the 2 springs (#221-051 spring posts), Parts Used:
the #108-662 and #108-663 grippers, and the #312-813 dust
shield. (Figure 4) 414-735 Gripper Module Assembly

2. With the 4 mounting screws snug, press the assembly all the 221-051 Spring Posts
way back and lock the back 2 mounting screws.
3. Check that each gripper is flush with the edge of the wear 108-662 LH Gripper (supersedes 222-444)
segment and lock the 4 gripper screws.
108-663 RH Gripper (supersedes 222-443)
⥵⥵ Note: If you are unable to set the grippers correctly,
loosen the 2 back segment mounting screws and move 312-813 Dust Shield
the segment assembly full forward before re-locking
the back 2 mounting screws. Then, set the 2 grippers.
4. Center the dust shield around the griper
blocks and tighten the 2 forward mounting
screws. FIGURE 4 FIGURE 5
5. Perform the following:
a. Using a 0.002" shim stock, check both MOUNTING
SCREWS
grippers to make sure they are laying flat
on the segment.
b. If there is a gap between the gripper and
the segment, loosen the bolt on the center
clamp (Figure 5). CENTER CLAMP
c. Tap the 2 gripper mounts side to side to
allow them to fully seat.
d. Apply downward pressure on both FIGURE 6
grippers simultaneously, and retighten the
bolt on the center clamp.
FIGURE 7
e. Check for “0” gap again and repeat this
procedure if needed (Figure 6).
⥵⥵ Note: This gap needs to be checked
any time the gripper or mounting
screws are loosened and retightened.

CHECK
FOR “0”
GAP

Grease the 5 fittings on each segment every week. (Figure 7).

Use Mobilith SHC460 or equivalent.

22 | TRANSFER TURRET GRIPPER SEGMENTS 0907

Lid Groove Station (option)

Station Function Station Adjustment

The Lid Groove Station indexes forward 1. See the Lid groove tooling assembly drawing for tooling installation
0.875" and dwells. The lid groove tooling and additional set-up procedures.
just touches the die ring at this point (not
2. With the tooling installed, adjust nuts (items #84 & #85) so tooling
overloading against the rimming die ring).
surface “A” touches surface “B” when the station is in full forward dwell
The ramp shaft (item #16) continues traveling
position. Reset springs (items #87) to the 1.63" dimension shown.
forward 0.469", off setting the lid groove roller
0.158". ⥵⥵ Adjusting items #84 & #85 will move the tooling forward in
0.125" increments. Internal station adjustment stops prevent
⥵⥵ SUB ASSEMBLY NOTE: Set gap “B” to further movement and thus prevent the ramp shaft (item #16)
0.125" prior to installing the station from coming disengaged with item #18. When adjusting the
on the machine. Adjust station tooling forward, the ramp shaft (item #16) needs to be adjusted
forward after installing tooling. forward in 0.125" increments (use item #29). Constant spring
pressure of item #94 needs to be maintained to move the shaft
forward. Resetting gap “A” to gap “B” with item #24 (nut, split)
for every 0.125" of movement will keep the spring pre-loaded
during adjustment, see step #4 for final spring adjustment.

3. Manually index the station to the full retracted (back) position. Adjust
ramp shaft (item #16) in and out with item #29 so the lid groove wheel
is on center with the station. Lock in place.
4. For the initial station set-up, set gap “A” equal to gap “B”. This will
set the spring pressure to the 2.34" dimension shown. Increase or
decrease spring pressure by adjusting item #22.

LID GROOVE STATION

0907 Lid Groove Station | 23

 LID GROOVE ASSEMBLY 504-813

2.34" = 160LB
SET-UP PRE-LOAD

SURFACE
0.875" STROKE

SURFACE

0.158"
LID GROOVE
TOOL OFFSET

24 | Lid Groove station 0907

Leak Detect Set-up

Note that this system comes equipped with a pressure regulator primarily to increase the stability of the system. Excessive
pressure will cause the bottom to blow-out, and or leaker potential. Typical regulator settings average at 3.0 psi which will make
the setting on Channel “A” to range at 3.5 – 4.0 psi . This setting has been found to be most stable thereby eliminating additional
attention.
LEAKER PS
⥵⥵ Regulators may not be as accurate as required, if so, channel A
(the trip point) may not read between 3.5 – 4.0 psi , the regulator KEYENCE AP-32
should be adjusted to make it so thereby increasing the stability. AUTO KEY A
ARROW KEYS

Pressure Switch Set-up Procedure SET KEY

⥵⥵ Note that Pressure Set-up is pre-set at PMC.

1. Press the “set” key for at least 3 seconds. ~

2. The current units are displayed. Use the arrow keys to select “inch”. BLACK 155 154 BROWN +24VDC 3
60

Press the “set” key.

150 BLUE 0 VDC 3
61

3. The operation mode is displayed. Use the arrow keys to select “F-3”.
Press the “set” key.
4. The N.O. / N.C. selection is displayed. Use the arrow keys to select
“N.O.”. Press the “set” key.
PULSE STRETCHER

1LM

5. The chattering prevention response time is displayed. Use the arrow 7 6

155 10511 19 "LEAK DETECTOR
28 PRESSURE PULSE"
PNP INPUT (PULSE =CUP OK)
MA4-2
keys to select “5”. Press the “set” key. PNP OUTPUT

8 ONE-SHOT 5
LOGIC
6. The display color selection is displayed. Use the arrow keys to select 1 MODULE
4 154

“2-C”. Press the “set” key to complete the setting procedure.

150
2 3 150

JUMPER 2 TO 3 SETS .01 TO 1.0 SECOND RANGE

Setting the Preset Values

LEAK DETECTOR TIMING DIAGRAM

Setting the Preset Values is required to adjust for the sensitivity of the PRESSURE
DETECTED
LEAKER PS OUTPUT
pressure switch. Note that only Channel “A” needs to adjust. Channel LOGIC

“B” should be set to approximately 11 psi and isn’t used. To determine 1LM OUTPUT
MODULE
OUTPUT ON

whether a cup is acceptable, the pressure must reach the setting of

channel “A”. If the pressure generated is not high enough, this cup will be
rejected.

1. In the measurement mode with the current measured value displayed, press the “set” key.
2. “A” and the current preset value flash alternately. Use the arrow keys to change the value to “.50”. Press the “set” key.
3. “B” and the current preset value flash alternately. Use the arrow keys to change the value to “11.00”. Press the “set” key.
4. Press the “set” key to complete the setting procedure and return to measurement mode.

Zero Point Adjustment

1. At normal atmospheric pressure, press the “auto” key for at least 2 seconds in measurement mode.
2. The display changes to “----”, then to zero (“0”).
0907 Leak Detect Set-up | 25
0907
Cup Diverter Set-up

The Diverter operates as follows:

From the MMI (shown to the right):

1. If the diverter is “ON”, it will divert all cups.

2. If the diverter is “OFF”, it will not divert any cups. CUP DIVERTER
NOTE THAT THE MACHINE MUST BE “RESET” BEFORE THE SERVO DIVERTER WILL MOVE
3. If the diverter is in “AUTO”, it will:
CUP CUP CUP
• Divert the first X-number of cups as directed on the DIVERTER DIVERTER DIVERTER
screen. It will then shift automatically to the production ON AUTO OFF
side.
NUMBER OF CUPS MACHINE
• Divert any cups that do not reach the required pressure. TO DIVERT AT POSITION TO BEGIN
START DIVERT
• If too many bad cups are detected in a row, the machine QC CHECK
NNN NNN
will cycle stop and display the fault shown below.
MACHINE POS
⥵⥵ The “Machine Position to Divert” setting is Main Screen RETURN
NNN
adjustable, but have rarely needed to be
changed.; however, it is normally 295 – 300 degrees
and has only rarely needed to be changed.

Too many consecutive leak detector

To “Home” the Diverter:
faults
1. Press in the E-stop button.
2. Manually move the diverter to the “Production”
Too many consecutive leak detector faults have been
position.
recorded. Check the calibration of the pressure
sensor. Check the condition of the bottom stock. 3. Press the black “Teach” button.
This fault will cause the machine to cycle stop.
4. Pull out the E-stop, reset the machine.
The machine is now ready.
Main Screen

0907 Cup Diverter Set-up | 27

0907
Glossary of Terms

Actuator: Blank shuttle:

A device that acts on another device to perform The portion of the Blank Feeder Station that moves
a machine function, such as the Transfer Turret the pre-cut Blank to the Transfer Turret.
Gripper Actuator rising against the Gripper Push
Rod to open the Gripper.
Blanking:
The process that creates Sidewall and Bottom
Alignment: Blanks by die-cutting the shapes from Web Stock.
The relationship of two machine components to
each other and to the process.
Bottom:
The portion of the Cup or Shell that is at the base of
Attached Equipment: the structure and is secured in place by forming the
Equipment not manufactured by Paper Machinery Sidewall Skirt over the Bottom Skirt.
Corporation but attached to and operating in
coordination with the main machine.
Bottom Feeder Station:
The station that supplies Web Stock to the Bottom
Blank: Blanking Station for Blanking.
A piece of Cup Stock (with specific characteristics)
that the machine turns into a Cup.
The product of the Blanking Stations in the machine Bottom Finishing Station:
before they are formed into a Shell at the Folding The Mandrel Turret station after the Bottom Forming
Station. Station and before the Rimming Transfer Station
Also called BOTTOM and SIDEWALL BLANKS. where the Shell Bottom is formed into its final shape.

Blank Feeder Station: Bottom Heat Station:

The station that includes a Magazine Stacker and The Mandrel Turret station after the Folding Station
the Blank Shuttle. and before the Bottom Forming Station where the
It stores and feeds pre-cut Blanks to the Transfer Bottom of the Shell is heated before Bottom Incurl
Turret. and Finishing.

Blank Placement: Bottom Incurl Station:

The precise position that the Blank must assume in The Mandrel Turret station after the Bottom Heat
relation to a machine components to ensure good Station and before the Bottom Finish Station where
Cup manufacture at optimum operating speed. the Bottom of the Shell is lubricated and curled into
its initial shape.

BLANK Preheat station:

The Transfer Turret station between the Sidewall Bottom Punch and Forming station:
Blanking or Blank Feeder Station and the Folding The station after the Bottom Feeder Station where
Wing Station where the Sidewall Blanks are heated the Web is punched and formed.
before being folded.

0907 GLOSSARY OF TERMS | 29

Bottom Re-Former Station: Drivetrain:
The Mandrel Turret station after the Bottom Blanking That portion of the machine, powered by the Drive
Station and before the Folding station where the System, that moves the mechanical parts of the
Bottom Blank Skirt is folded back onto itself for machine to perform machine functions.
easier Folding and Bottom Finishing.

Finishing:
Bottom Stations: The processes of the Bottom Finishing and Rim
The Mandrel Turret stations that Form and Finish Finishing Stations when the Bottom and Rim of the
the Bottom of the Shell while fastening the Bottom Cup Shell are worked into their final shapes.
to the Sidewall. They include the Bottom Finishing,
Bottom Incurl, and Bottom Heat Stations.
Folder station:
The station between the Mandrel Turret and the
Control Cabinet: Transfer Turret where:
The portion of the machine that contains the The Sidewall Blank is transferred from the Transfer
Transformers, Motor Starters, Relays, Timers, Circuit Turret to the Mandrel Turret.
Protection Devices, and Temperature Controllers. The sidewall Blank is folded around the Shell Bottom
and the Mandrel by the Folding Wings to form the
initial Cup Shell shape.
Control mode:
The stat of machine operation, as determined by
the Machine selector switch. Possible modes are Folding wings:
Set-Up, Test and Run. The parts of the Folding Station that fold the Blank
around the Mandrel.

Control System:
The portions of the machine that control and Forming:
monitor machine operation, including the Electrical The process performed by the Bottom Forming and
and Pneumatic Systems. Rim Forming stations that creates the initial shape
of the Bottom and Rim of the Cup.

Controller:
The electronic device that monitors and controls Gripper:
Heater Temperature. Also called a Temperature The portion of the Transfer Turret that:
Controller. Grips the Blank from the Blank Shuttle or the
Sidewall Blanking Station.
Holds the Blank while the turret indexes.
Cup: Releases the Blank at the Wrapping Station.
The finished, final product of the machine; the
product removed from the machine at the
Discharge Station. Gripper Actuator:
The portion of the machine:
Actuates the Transfer Turret Grippers to grip a Blank.
Discharge station: Releases the Blank at the Folding Station.
The station after the Rim Finishing Station where the
Rimming Turret carries the Cup to be ejected from
the machine. Indexing:
The movement of the Transfer, Rimming, and
Mandrel Turrets when turning on their axes.
Drive system:
Those portions of the machine that provide the
mechanical power, via the Drivetrain, to the stations
for their operation.

30 | GLOSSARY OF TERMS 0907

Knockout: Operator Control station:
The portion of the machine at the Rimming Turret The place on the machine where the operator
Pocket that rises to release tapered wall Cups for controls machine operation.
discharging.

Photo Register:
Lower Base: An optical device that senses Registration Marks
That portion of the machine below the Base Plate. on Web stock and provides signals for adjusting the
Sidewall Feeder.

Lubrication System:
The parts of the machine that provide lubricant to Pneumatic System:
the machine elements. The portion of the Control System that uses air or
vacuum to actuate devices to control machine
functions.
Machine Enclosure:
The safety structure around the main machine
that prevents direct contact with the machine Pocket:
components during operation. The portion of the Rimming Turret where the Shell is
held during rimming turret Index.

Machine Modes:
A state of machine operation set by the machine Position:
switch on the operator control panel. Modes The precise location of the Blank, Shell or machine
include, Run, Set-Up and Test. element relative to another machine element.

Main Drive Oil Bath: Preheat Station:

The lubricant in the Oil Pan that lubricates the Main The Transfer Turret Station after the Sidewall Blanking
Drive components during normal operation. Station or the Sidewall Blank Feeding Station and
before the Folding Station that heats the Blank
before Folding.
Main Drive System:
The portion of the machine that provides the
primary mechanical power and timing to the Registration:
various mechanisms and stations of the machine The condition of the Sidewall Blank Web in the
to make it operate. Sidewall Blanking Station, where the printed artwork
is in the correct position before Blanking.

Mandrel:
The portion of the machine that: Registration control:
The Blank is wrapped around at the Folding Station The portion of the Control System that detects
to form the Shell. printed Web Registration and sends signals to the
Carries the shell through the Bottom Stations. Web Feeder to make small corrections of Web
Moves the Bottom forward after heating. feeding to bring the Web into registration.
Carries the Shell to the Rimming Transfer Station.

Rim:
Mandrel Turret: The curled top of the Cup.
The portion of the machine that:
Carries Cup-Forming Mandrels.
Moves the Cup Shell from the Folding Station
through the Bottom Stations.
Moves the Cup Shell to the Rimming Transfer Station.

0907 GLOSSARY OF TERMS | 31

Rim Finishing Station: Skirt:
The Rimming Turret station after the Top Pre-Curl That portion of the Bottom and Sidewall Blanks
Station and before the Discharge Station where the that is formed by the Bottom Stations to secure the
Cup Rim is finished. Bottom in the Shell; the lower portion of the sidewall
Blank opposite the Rim; the edges of the Bottom
Blank.
Rimming Turret:
The station, containing Pockets, that carries the
Shell through the Rimming Stations and to the Stock:
Discharge Station for removal of the finished Cup The raw, roll-fed paper material that the Blanking
from the machine. stations turn into Bottoms and Sidewalls. Also called
Web.

Rotary Placer:
The station that moves the Blank from the Magazine Tamper/Lubricator Station:
to the Blank Shuttle. The Rimming Turret station before the Rim Forming
Station that:
Seats the Shell securely in the Rimming Turret
Safety Devices: Pockets.
Those parts or functions of the Control System, Applies a lubricant to the inside of the shell to
including pressure sensors and emergency stop improve Rim Finishing.
push-buttons, that disable machine operation
when actuated by the operator or by hazardous
conditions. Temperature Controller:
See Controller.

Shell:
The product made on the Mandrel at the Folding Top Pre-Curl Station:
Station. The Rimming Turret station after the Tamper/
Lubricator Station and before the Rim Finishing
Station where the Cup Rim is initially formed.
Sidewall:
The portion of a Shell that forms the sides of the
Cup; the object that is wrapped around the Transfer Turret:
Mandrel at the Folding Station; the final product of The portion of the machine that:
the Sidewall Blanking Station. Grips the Sidewall Blank off the Blank Shuttle or out
of the Sidewall Blanking Station.
Moves the Sidewall through the Preheat Station.
Sidewall Blanking Die: Moves the Sidewall to the Folding Station.
The station after the Sidewall Roll Feeder and before Releases the Sidewall at the Folding Station.
the Transfer Turret that Blanks the Sidewall Web for
processing.
Upper Base:
All parts of the machine above the Base Plate.
Sidewall Blank Feeder:
The station that holds and feeds Sidewall Blanks
into the machine. Wings:
See Folding Wings.

32 | GLOSSARY OF TERMS 0907