Automatic Hot Air Sealing Machine

SÖNMEZ MAKİNA INDIA PVT LIMITED

100% subsidiary of Sonmez Makina Oto. Turkey
Nirjan,Safidaon Road Jind Haryana. 126102
01681-291827, 291828, , 8199922201
E-mail: sonmezmakina@asia.com
http://www.sonmezmakina.com
 Automatic Hot Air Sealing Machine

List of Electrical Components & its FLP Enclosure CCOE Reference No.

S.no Electrical Make CCOE Ref. No. Test Report

Components

1. FLP Solenoid Valve Rotex P218046/1 KEPL/EX/R/12-007

2. Flame proof Heater Escorts ltd. P272198/1 CIMFR/TC/P/H125
Sudhir Switch R1(1)136/Sudhir/81-vi CIMFR/TC/SR/H1104
3. Photo Sensor TRI-FLP P316543/3 CIMFR/TC/P/714
Enclosure
4. Selector Switch TRI-FLP P316543/7 CIMFR/TC/P/799
5. PLC Enclosure TRI-FLP P316543/10 CIMFR/TC/P/690
6. Other FLP Enclosure TRI-FLP P316543/10 CIMFR/TC/P/690
 Automatic Hot Air Sealing Machine

List of Components manufacturing in House and Outsources for Hot Air Sealing Machine

S.no Components In House Out source Quality control

system

1. Mechanical structure Manufacture by SMIPL Fully Load Test

2. Sealing Head Manufacture by SMIPL Fully Load Test
3. Pneumatic Cylinder SMC/Camozi Test Certificate
4. Solenoid Valve Rotex/ASCO Test Certificate
5. Flame proof Heater Escorts Test Certificate
Ltd./Sudhir
6. Pneumatic Valves SMC/Camozi Test Certificate
7. Flameproof Junction Box TRI FLP Test Certificate
8. Flameproof armoured Polycab/LAP Test Certificate
Cable
9. Flameproof cable gland TRI FLP Test Certificate
10. Flameproof start stop push TRI FLP Test Certificate
button
11. PLC (Housing in FLP Box) Delta Test Certificate
12. Photo Electric Sensor Optex Test Certificate
(Housing in FLP Box
13. Hot air ON/Off pneumatic Avcon Test Certificate
valve
 Automatic Hot Air Sealing Machine

Quality control and Testing Protocol used in Hot Air Sealing.

1. Design the Machine according to smoothly operation.

2. Chemical test the all mechanical parts as per material specification.
3. Design the Mechanical sheet structure
4. CNC Profile cutting as per mechanical structure design.
5. Welded the mechanical structure as per ISO 15614 standards.
6. Test the Load and welding by NDT Method.
7. Purchase the machine parts with test report.
8. Assemble the machine parts after pass the test report by Quality Officer.
9. Test the complete machine after assembled regularly one week in full load and full recommended
pressure with Filled cylinder (BY water and Air)
10. All testing procedure checked by Quality officer.
11. Machine dismantle, After successfully testing satisfaction by Project head and Quality officer
12. Start the painting procedure, After Dismantle the machine parts
13. Painting procedure: i) sand blasting to SA 2.0 as per SIS 55900.
ii)2 coat of zinc chromate red oxide and 1 coat light gray (shade 631 of IS-5)
iii) Provide 2 coat of PU paint within two days.
14.) Finally assemble the machine after dry the paint.
15). Test the machine with full load and full recommended pressure till 100,000 successfully operation.
 Automatic Hot Air Sealing Machine

Details of standard/codes following for fabrication of the Hot Air Sealing Machine including its
component

S.no Components In House

1. Mechanical structure IS-2062 & 1161

2. Sealing Head IS-2062 & 1161
3. Pneumatic Cylinder ISO6431
4. Solenoid Valve IS 60079-17
5. Flame proof Heater IS1239

6. Pneumatic Valves ISO-5599,DIN ISO6431

7. Flameproof Junction Box IS-2148
8. Flameproof armoured Cable IS-8130
9. Flameproof cable gland IS-2148
10. Flameproof start stop push button IS-2148

11. PLC (Housing in FLP Box) IEC 61131-3

12. Photo Electric Sensor (Housing in FLP Box IEC 61131-3

13. Hot air ON/Off pneumatic valve ANSI/FCI-69-1

 Automatic Hot Air Sealing Machine

Hot Air sealing machine is designed for quick and safe shrinking of PVC Seal of filled LPG cylinders valve.

General Description

Machine Hot Air Sealing Machine

Dimensions 1400 * 1200 * 1850 MM

Capacity Maximum 1800 Cylinder/Hr.

Operating procedure Automatic

Controlled by Programmable Logic Controller (PLC) having inbuilt HMI for displaying the
data of the system like air pressure, heating of chamber, total no of cylinder seal

Sensor for detection of Photo electric sensor infra red – Sick or Banner is used instead of
Cylinder Pneumatic actuator.
Powered by Electro-Pneumatically

Installed at On Line

Accuracy 100%

Air Pressure 5 – 6 Bar

Electrical consumption @ 440 VAC - 3Phase = 6.6 KW./4.4 KW

Approval of FLP Enclosure CCOE Nagpur & CMRI Danbad

Approval of Heater CCOE Nagpur & CMRI Danbad

Pressure Switch Flameproof with CCOE Approval

Sealing Heads 2/4 Points

 Automatic Hot Air Sealing Machine

Advantage of SMIPL Make Hot Air Sealing Machine

1. Compact design for on line automatic operation.

2. Available in 2,4,6 Points

3. Capacity:- up to 1800 Cyl. /hr.

4. High quality material used:- SMC, Festo, Commozzi, Gates.

4. Proper dressing & ferruling for easy maintenance.

5. No leakage of Hot air found during operation

6. Air consumption Less then 2.1NI / min.

7. Extendable warranty up to 5 years.

8. Photo sensors used instead of pneumatic actuator. Nil contact with cylinder means no

maintenance.

9. PLC controlled operation.

10. HMI ( Human Machine Interface) provided which will show the following message/Errors.

a. HMI will display the set Temperature as well as current Temperature.

b. HMI will also display daily production report with month and years.

c. HMI will display air pressure on which system is running, if it will go down as per minimum

limit then HMI will display message for low air pressure with checking parameters for

troubleshooting.

d. If any error occurred then HMI will display it with possible errors withy troubleshooting.

e. Machine will display the daily production report & PLC will be well capable for interfacing with

plant PC if required. Due to PC interfacing, plant officer will be capable to change the internal

setting of PLC & temperature controller.

 Automatic Hot Air Sealing Machine

Electrical Data
Control System : Closed Loop

Operating Voltage : 440 V, 50 Hz, Single, Three Phase Regulated To +- 5%

Control Voltage : 230 V, 50 Hz, Single

Maximum System Current : 12 Amp./3 Phase

Max. Power Consumption : 6.6 KW, 3 Phase

Heater Specifications : 2.2 KW, 230 V, 50 Hz ,Finned Heater – 3 Nos.

Electrical Panel Enclosure : 550 * 550 *200 MM for PLC and Indicators

: 250 * 250 * 100 MM for HMI

Panel Enclosure Group : 11A as per IS 13346/04

(IEC: 60079-0/00)

Panel Temperature Class : T3 as Per IS 2148/04 (IEC-1/01)

Protection Class : IP 65 as Per IS 12063 / 87

( IEC:60529 / 89)

Max. Temperature : 245 `C inside Hot air chamber ( Adjustable)

Control Cable Size : 2.5 Sq. mm, CU, PVC Sheathed

Power Cable Size : 4 Core 6 sq. mm PVC,

Copper Conductor Cable

Earthing Connection : 6 Sq. mm Copper Wire

 Automatic Hot Air Sealing Machine

Mechanical Data
Dimension : 750*1850*750 MM for 2 Points

Dimension : 1200*1850*750 MM for 4 Points

Dimension : 2200*1850*750 MM for 6 Points

Material Used : 8 MM MS Pipe Rectangular type

Guide Rail : Rexorth / HIWIN

Stoppers : Siraga Type

Heater : 2.2 KW/4.4 HW/6.6 KW Heating Element

Control System : PLC Controlled

Control Signal : Photo Electric Sensors

Operating Pressure : 5 Bar for sequence and Hot Air Chamber

Sealing Time : 2 Sec.

Capacity : 1800 Cyl./Hr

Chain Speed : 20 Mtrs./Minute

Air Flow Rate : 800 Lts/Minute

Control Pneumatic Tube : 4 MM

Power Pneumatic Tube : 6 MM & 8 MM

Interlocks : PLC & Photo Sensors

 Automatic Hot Air Sealing Machine

Operation Of Machines
On the selector switch.
Machine shows green indicator at panel.
Press start button.

When you power ON the machine , inlet stopper ( ST-1) will be closed & stopper (ST-4) will be open.

If any photo sensor on conveyor found the presence of LPG cylinder on the chain conveyor during starting,
and you press the start button then stopper will be remain closed. Press the start button after clearing the
machine space from entry sensor to jamming sensor.

When you press the start the button , Entry stopper (ST-1) will open & filled cylinders will come inside the
machine for sealing.

When photo sensor 12 ( exit side) & ( Entry side) 14 sense the cylinders then stopper (ST-1) will close. after
closing of all stoppers & sensing of cylinders by both sensors , sealing head will come down. After Complete
down of sealing head axial valve (Hot air stop valve) will open & generate the hot air for sealing for 2 sec.
After 2 sec sealing head will go in upward position.

Proximity sensor 1&2 will sense the upward position of sealing heads.
Now exist stopper will open & sealed cylinders will move for exiting. Photo sensor 3 mounted after the
distance of 2 cylinders from exit stopper will sense the cylinders and give the command to PLC for closing of
exit stopper. This photo sensor will also work as jamming sensor.

If the sealed cylinders on the conveyor are not moving then it will hold the machine & both stopper will
remain closed even after cut off.
Heavy stopper will work independently through photo sensor 1 means if cylinder is on the conveyor in front
of sensor then it will close and if not then it will open.
If cylinder falls on the conveyor then heavy stopper and entry stopper will close unless it will not reset
manually. It will ensure that none cylinder will pass without sealing.

This sequence will be controlled by PLC & plant officer can see this on PC after PLC-PC interfacing.

Ist sealing header will wait 2 sec for 2nd cylinder for sealing. If it will come then both cylinders will seal if not
come then one will seal and go out.

SÖNMEZ MAKİNA INDIA PVT LTD

100% subsidiary of Sonmez Makina Oto. Turkey
Nirjan,Safidaon Road Jind Haryana. 126102
01681-291827, 291828, , 8199922201
E-mail: sonmezmakina@asia.com
http://www.sonmezmakina.com
 Automatic Hot Air Sealing Machine

Interlocks
1. Inlet stopper of the system will not open until all sealing header will not reach in its Up position.

2. An emergency button is provided on the control panel to stop the system in any cases.
By pressing it whole system will reset & takes its initial position.

3. System will not start until it will not receive signal for proper heating from Temperature controller.

4. System will not start until it will not receive signal for minimum 5 Bar air pressure From main line
pressure switch.

5. System will not start until it will not receive signal for proper air pressure from Heating chamber.

6. Heater of the system will be controlled by PLC automatically as per our requirement.

Do’s - General
Check the Air Pressure; it should more then 5 Bar.
Check the air pressure of heating chamber.
Check the tightness of sealing gun daily. If found loose, tight it.
Check & tighten the foundation bolts.
Examine hoses for damage & change if necessary.
Check & clean face seal daily.
Clean the sealing bell mouth
Check up & down speed of sealing header.
Clean & regrease shaft seal.
Clean shaft OD.
Oil the sensing shaft daily.
Check oil level in FRL.

Don’t
Don’t over speed sealing header. It may cause mouth damage.
Don’t over speed the conveyor chain. It is interlinked with heater & PLC for operating other
parameters.
Don’t put your hand under sealing mouth during sealing of cylinder.
Don’t increase the temperature of heating chamber. It may cause melting of PVC seal.
Don’t operate the machine if air pressure is less then 5 Bar.
Don’t change the setting of pressure switch . It is interlinked with PLC for operating additional
parameters.
Don’t increase / decrease the torque.
Don’t do any job when machine is in operation.
 Automatic Hot Air Sealing Machine

Troubleshooting

S. No. PROBLEM POSSIBLE CAUSES RECTIFICATION

A1. Heater does not creates * Temperature setting at PLC may * Check the temperature setting
heating be low. on PLC Display.

* Heater is not getting electric * Check the electric connection of

power. heater.

* Incoming air pressure is low * Check the air pressure at heating

chamber & Increase it if it is
low.

A2. Sequence of the system * Main line May be Jammed. * Check the output of Jamming
does not start. sensor in PLC Display.

* Heating is not proper. * Check the temp on PLC

Display.

* Air Pressure may be low. * Check the air pressure at main

line & Heating line.

* Emergency button may be * Released it if pressed.

pressed.

* Check mobile network is

A3. PLC is not sending the * Network problem
available or not
data on mobile.
 Troubleshooting

S. No. PROBLEM POSSIBLE CAUSES RECTIFICATION

B1. Stopper is not open after * Line Jamming,. * Clear the line if jammed.
cut-off
* Sealing Header upward signal * Check output of Jamming
Sensor on PLC Display

* Check the output of PS-7&8 on

PLC Display.

B2. Alarm is permanent ON * Error * Check the error on PLC

Display & reset the certain
Parameters.

B3. PVC seal in not * May be Heating or axial valve * Check the out put port of axial
shrinking Problems. Valve whether it is chocked or
Not.

* Check the heating temperature.

B4. Machine does not start. * Sensor problem or emergency * Check the output of Photo
Problem. Sensor on PLC Display as well
As check the emergency switch
Signal whether it is present or
Not. Release if present.

.
SÖNMEZ MAKİNA INDIA PVT LTD
100% subsidiary of Sonmez Makina Oto. Turkey
Nirjan,Safidaon Road Jind Haryana. 126102
01681-291827, 291828, , 8199922201
E-mail: sonmezmakina@asia.com
http://www.sonmezmakina.com