OPERATION MANUAL

AUTOMATIC CAPPING MACHINE

MODEL: CS 5200
CLIENT: ????
SERIAL # ????
ALL EQUIPMENT OPERATOR MUST READ AND UNDERSTAND
THIS MANUAL BEFORE OPERATING THIS MACHINE

ALL GUARDS MUST BE IN PLACE WHILE OPERATING THIS

MACHINE

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 1 of 15
MACHINE MODEL: CA 5200
 ALL PROPOSAL, QUOTATIONS AND ORDERS ARE SUBJECT TO
THE FOLLOWING TERMS AND CONDITIONS

1. Quoted Prices are FOB point of shipment (Miami, FL), freight collect or prepaid. The contents of all quotations are
subject to change without notice.

2. Brochures and literature are subject to constant design improvements and are not binding in detail.

3. ACASI MACHINERY INC. warrants that the subject goods and equipment are manufactured in conformity with the
specifications pertaining thereto. THIS WARRATY IS EXPRESSELY IN LIEU OF ANY AND ALL WARRANTIES
EXPRESS OR IMPLIED. THERE IS NO WARRANTY THAT THE GOODS AND EQUIPMENT ARE
MERCHANTABLE OR FIT FOR A PARTICULAR PURPOSE.

4. Stock subject to prior sale, order will be entered and delivery will be after credit approval.

5. All orders are subject to final acceptance from ACASI MACHINERY INC, quoted Prices are subject to final
confirmation at the time that the order is placed.

6. By acceptance of this quotation, through the purchase of the goods or equipment described herein. Buyer agrees to
hold harmless and indemnify ACASI MACHINERY INC. against any claim cost, lost of profit or expense, including,
by way of illustration, not limitation, consequential damages, attorneys fees, court costs and all other losses incurred
by any person or entity by reason of use, operation, maintenance, ownership or possession of the subject goods or
equipment.

7. Shipments dates are not guaranteed and are subject to delays due to causes beyond the seller control. The seller shall
not be liable for late or non-delivery due to accident, strike, fire any Act of God or other causes beyond shipper’s
control.

8. Orders are not subject to cancellation except with seller’s consent and upon terms indemnifying seller against loss.

9. Sales use, excise, property or similar taxes relating to this order are not included. The Seller shall have right at any
time to bill Buyer for any such tax, which Seller may be called upon to pay.

10. No modification shall be affected by the acknowledgement or acceptance of purchase order containing different
conditions.

11. None of the terms and conditions contained herein may be added to, modified superseded or otherwise altered
except by written consent from ACASI MACHINERY INC.

12. This document and any obligations arising hereunder shall de construed and understood under FLORIDA law only.

13. Until full payment is made by the purchaser-customer, title to any goods or equipment sold hereunder shall remain,
for repossession purposes with the seller. Purchaser-customer agrees to insure the goods or equipment against any
loss or liability.

Company : _________________________________________________________________________________________________

Company Representative: ___________________________________________________________________________________

Title: ______________________________________ Date: ______________________________________

Signature ______________________________

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 2 of 15
MACHINE MODEL: CA 5200
 INDEX

I. Introduction ....................................................................................................... 4
II. Reception of the equipment ............................................................................. 4
III. Initial machine set-up ........................................................................................ 6
IV. Requirements for the Start up of the machine …............................................... 7
V. Maintenance ...................................................................................................... 7
VI. Electrical system .............................................…………………………….…. 9

VII. Start up of the machine ..........………………………………………………... 11

VII.1. Total height of the machine adjustment ……........................................ 11

VII.2. Gripper belts adjustment ....................................................................... 11

VII.3. Capping discs adjustment ..................................................................... 12

VII.4. Cap seating system ………………........................................................ 14

VII.5. Top guide ..........………………………………………...……………. 14

VIII. Cap Handling ……………....……………………………………………...…. 15

VIII.1. Cap delivery system …………………………......…………………… 15

VIII.2. C Curve ................................................................................................. 17

VIII.3. Centrifugal cap unscrambler ................................................................. 17

VIII.4. Cap hopper ............................................................................................ 18

IX. Start up of the centrifugal cap unscrambler ........................................……….. 18

X. Troubleshooting ...........................………………………………………….… 19

Tightener drawings ..….……………………………….................................... A

Cao unscrambler drawings .…….…………….................................................. A

C Curve drawings .........………...………………………………...................... A

Cap shoe drawings .............................………………....................................... A

Hopper drawings …………...………................................................................ A

Purchased components manuals ........................................................................ A

Electrical drawings …………………………………………………………… A

A = Appendix

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 3 of 15
MACHINE MODEL: CA 5200
 I. INTRODUCTION

The operating manual is an important guide on how to work with the equipment you have
purchased. Following the instructions on this manual will prevent problems on the start
up of the machine, it will give you better production speeds and it will increase the life of
your machine.

Please do not hesitate to contact us if any problem presents or if you need technical
assistance.

MAKE SURE THE AIR AND POWER HAS BEEN CUT OFF BEFORE YOU
PERFORM ANY MAINTENANCE OR SET-UP ON THE MACHINE.

Disregard of maintenance for the machine will cancel the machine’s GUARANTEE.

II. RECEPTION OF THE EQUIPMENT

When transporting the machine, the machine will be delivered in a crate or pallet. Make
sure you use an experienced certfied equipment handling company to uncrate the
machine.

Make sure you have received all the necessary components according to the equipment
bought.

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 4 of 15
MACHINE MODEL: CA 5200
 CAPPING MACHINE WITH CAP
BASIC SYSTEM
FEEDER AND HOPPER

Height adjustment knob 1 1

Height screw base 4 4

Cap hopper 0 1

Cap hopper screws 0 4

III. INITIAL MACHINE SET-UP:

The purpose of this procedure it’s to get the user familiarized and ready for the start up of
the machine.
PROCEDURE:

a) Read the manual completely before beginning the set up. Get familiarized with the
control panel, turn on and off switches, vibration control and emergency stop (See
panel control).
b) Level the conveyor, this is an important step because it will avoid container instability
during the camping process.
c) Elevate the capping machine so that the gripper belts are above the conveyor, for this
turn, with the provided knob (Part 64, Drawing: CS5200-01), the mechanical jack
ring located in the bottom part of the chassis (Part 58E, Drawing: CS5200-01).
d) Move the machine to the desired position over the conveyor.
e) The Capper should be located so that the belts, capping discs, cap feeder, etc. are
centered over the conveyor.
f) Make sure all the switches are off.
g) Plug the electricity to the bottom of the electric panel, 110 Volts, 60/50 Hz.

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 5 of 15
MACHINE MODEL: CA 5200
h) The machine should be leveled on the frontal to back side and on the lateral sides, to
do this put a level on top of the machine, in case the equipment is not leveled adjust
the height with the 4 chassis height screws (Part 50, Drawing: CS5200-01) supported
over the bases of the height screws. Try to level the machine as close to the floor as
possible. If the machine lost the center position respect to the conveyor move lightly
the machine over its supports by hitting the bases with a rubber hammer.

IV. REQUIREMENTS FOR THE START UP OF THE MACHINE

Electrical requirements: 110 Volts, 60/50 Hz, 15 Amp.

V. MAINTENANCE
Capping discs: (Part 10, Drawing: CS5200-09-COMP)
These parts wear constantly, their lifetime depends of the caps, container compatibility,
adjustment, etc.
It is recommended to change the parts by pairs.
To increase performance, the discs could be turned around or moved closer to each other
once they have suffered an equal amount of wear.

Gripper belts: (Part 40, Drawing: CS5200-05- COMP)

The belts suffer certain wear due to sliding and falling of containers which stride along its
normal functioning. Once the belts star to fail in the capping process they should be
replaced immediately. It is recommended to replace both belts and verify their width.

Cross gear box (Tol-o-matic):

For the six (Part 24, Drawing: CS5200-09- COMP) lubricate with 5 grams of high
temperature (Up to 400 F) grease every 1.5 months.
7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 6 of 15
MACHINE MODEL: CA 5200
For the two (Part 26-28, Drawing: CS5200-05-COMP), lubricate with 10 grams of high
temperature (Up to 400 F) grease every 1.5 months.
Every 6 months, take apart, clean and lubricate with approx. 30 grams of high
temperature (Up to 400 F) grease.

Motors of basic system and caps feeder:

Part 02, Drawing: CS5200-05-COMP
Part 02, Drawing: CS5200-09-COMP
All bearings are sealed and pre-lubricated for life.
Brushes should be periodically checked, they have an initial length of 1.25 inches, when
they get to 0.625 inches they should be replaced.

VI. ELECTRICAL SYSTEM

In the control panel all the electric functions of the machine are adjusted. Bellow you will
find the explanation of its functioning (See Figure).

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 7 of 15
MACHINE MODEL: CA 5200
Start button: This activates all the electric functions of the machine, if all the switches
are on this will start the complete functioning of the equipment. When the machine is on
the button should be illuminated.

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 8 of 15
MACHINE MODEL: CA 5200
Emergency stop button: This is a security switch; it will cut the electricity to the
machine and stop all the functions in it. Once activated you will have to give it a 90
degree twist to get it out of the off position.

Capping discs: In the top section it controls the on and off of the motor. In the bottom
section it controls the speed thorough a potentiometer.

Gripper belts: In the top section it controls the on and off of the reducer-motor. In the
bottom section it controls the speed thorough a potentiometer.

Cap feeder: Not used

Cap hopper: Not used

VII. START UP OF THE MACHINE

EVERY TIME THE SET UP REQUIRES AIR FEED, AIR CUT-OFF, OR

ELECTRICITY CONNECTIONS, MAKE SURE THE GUARDS ARE IN PLACE.

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 9 of 15
MACHINE MODEL: CA 5200
We now present all the steps that should be done for the correct start up of the machine,
before following this procedure make sure the machine is placed as explained on Part III.

VII.1 Total height of the machine adjustment (according to the container)

a) Open the gripper belts so the container runs freely. Use the handwheel (Part 30,
Drawing: CS5200-05-COMP) after loosening the lock nut of width of belts (Part 36,
Drawing: CA5200-01).
b) Manually cap a container and put it in the third capping disc set (right side).
c) Adjust the machine height so the capping discs are approximately at the middle of the
cap.

VII.2 Gripper belts adjustment

Their function is to hold the containers while they pass thorough the machine. The
container should be held at the highest possible point in order to achieve the maximum
stability during the capping process.

Gripper belts width adjustment

a) Put the container in the conveyor.
b) Open the capping discs so that the container may pass freely thorought the
machine, to do this turn the discs lock nut (Part 24, Drawing: CS5200-09) in
counter clock wise direction and the discs handwheel (Part 26, Drawing: CS5200-
01) clock wise.
c) Open the gripper belts so that the container enters freely, use the handwheel (Part
30, Drawing: CS5200-05-COMP).
d) Put a container in the middle of the belt.
e) Close the belts until the container gets firmly held without crushing it.
f) Make the belts turn around and try with a container until you confirm a good hold
of the container
7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 10 of 15
MACHINE MODEL: CA 5200
 g) Fix the belts position by turning the lock nut in front of the knob in clockwise
direction.

Gripper belts height adjustment

a) To adjust the belts height, loosen the set screws of both (Part 58, Drawing:
CA5200-05) and then move all the system to the desired height. There are 2 set
screws for each belt.
b) Do the same for the other belt system.

The belts height adjustment should be done ONLY if it is suggested by ACASI on the
basis of the samples received.

IMPORTANT: Be sure to hold the system in place when adjusting height, do one belt
at a time to prevent the complete system to fall.

VII.3 Capping discs adjustment

Their function is to give the necessary torque to the caps on the containers. Each disc set
(3 set in this model) has individual adjustment, it will move the discs in the desired
direction without losing the center respect to the caps feeder and the gripper belts. To
increase the torque you can press the disc to the caps or you can increase the speed of the
capping discs.

Capping discs height adjustment

The capping disc height can only be adjusted in those shafts without the clutch
option.
a) The first set of discs (this one should not have clutch) must be centered in the cap
height when it is picked up by the container (this set of discs is normally a little
higher than the other ones).
b) The second and third set of discs must be at the height that you determined in step
VII. 1 (Machine height adjustment).
7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 11 of 15
MACHINE MODEL: CA 5200
Capping discs width adjustment
a) Put a capped container into the machine and then turn on the belts at low speed
until the container gets to the first set of discs (Part 35, Drawing: Tightener 2) and
stop the machine.
b) Loosen the discs lock nut of the first set of discs (Part 48, Drawing: Tightener 2)
and turn the handwheel (Part 47, Drawing: Tightener 2) until the capping discs
lightly touch the cap.
c) Repeat steps a) and b) for the second and third set of discs.
d) When you have finished assure the capping discs position by tightening the lock
nut of each set.
e) IMPORTANT: Adjust the gripper belts speed to make it the same as the conveyor.
f) Turn on the machine and pass the container through it. Pay attention to each set of
discs and how hard they work over the caps.
g) Make the necessary adjustments taking into account that:
The first set of discs will lower the cap to the container.
The second set of discs should thread and adjust the cap (this should be the set
which performs the greatest amount of work).
The third set should give the final torque so that all the containers exit the
machine with the same cap torque.

Clutch adjustment (optional)

This option allows the user to adjust the desired torque for the capping process, using
this option correctly will remarkably diminish the wear of the capping discs and it
will avoid marks or deformations on the caps.

a) Turn the top nut of the clutches installed in the machine in counterclockwise
direction (Part 24, Drawing: CA5200-09) until you can turn the capping discs
with your own hands.
7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 12 of 15
MACHINE MODEL: CA 5200
 b) Adjust the torque with the top nut of the clutch, increasing it by turning the nut in
clockwise direction and diminishing it in counterclockwise direction.
c) When the adjustment has been done correctly you should see how the capping
discs stop when they get the desired torque.

VII.4 Cap seating system

The main function of this system is to maintain a slight but constant pressure over the cap
while the first set of discs makes the primary threading. (See drawing: Seating of caps)

a) Place a cap over the threads of the container without threading it. (Simulating the
picking up of the cap) and then put the container underneath the system.
b) Adjust the height until the parts apply a slight pressure over the cap.

VII.5 Top guide

After the first set of discs there is a top guide, is there to keep the container guided by the
top part avoiding the unnecessary balance of the container.
a) Place a container at the beginning and another one at the end leaving 0.125 inches of
space on both ends.
b) If you need to move the whole guide back or forward, loosen the screws in (Part 44,
Drawing: CA5200-01) and slide it until you reach the desired position.

This system well implemented will guarantee the complete threaded of the caps on the
containers.

VIII. TROUBLESHOOTING

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 13 of 15
MACHINE MODEL: CA 5200
A. IF THE MACHINE DOES NOT START, CHECK:
 That the stop button is not pressed, to unlock turn it 90 degrees.
 Make sure the machine has the electricity correctly installed.
 Check the fuses.

B. NOT ENOUGH TORQUE IN THE CAPPING PROCESS

 Use the clutches to increase the torque (See VII.3).
 Increase the speed of the discs of capping (Control Panel).
 Diminish the speed of the gripper belts (Control Panel).
 Increase the pressure of the capping discs (Part 10, Drawing: CS5200-09-COMP)),
see procedure in point VII.3.
 Make sure that all the capping discs are working correctly.
 Check that there are no problems when picking up the cap.

C. THE CONTAINER IS NOT STABLE DURING THE CAPPING PROCESS

 Verify that the speed of the gripper belts (Part 40, Drawing: CS5200-05-COMP) and
the chain of the conveyor are the same.
 The container should be held by the gripper belts in the highest possible point of the
container.
 Check if the container is being pushed up or pushed down by the gripper belts. If this
is the case, level the conveyor and the machine until the gripper belts and the
transporting chain are parallel.
 Increase or diminish the width of the gripper belts (See point VII.2).
 Make sure that the capping discs are not hitting unevenly the containers, if this is the
case adjust according to VII.3.
 If the instability continues remember that there is the option of installing double
gripper belt.

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 14 of 15
MACHINE MODEL: CA 5200
D. THE CONTAINER IS BEING DEFORMED
 Open the gripper belts the maximum possible without causing the container to slide
or turn over the gripper belts.
 When working with containers of low consistency it is necessary to graduate the
width of the belts and the capping with good precision. Most of the times when it is
impossible to solve this problem, it is recommended to try a different supplier of caps
and/or containers. If you need any assistance in this issue please do not hesitate to
contact us.

7219 NW, 54th Street - Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 -
www.acasi.com
Page 15 of 15
MACHINE MODEL: CA 5200