05 Changeovers

Shared changeover method and setup checks.

1. Scope

Changeovers common to multiple i-Series machines.

2. Safety

Complete the isolations defined in 01 Safety.

3. Tooling removal

1. Stop the machine.

2. Cool hot zones where required.

3. Remove tooling using the specified lifting method.

4. Tooling installation

1. Clean locating faces.

2. Fit tooling and secure fasteners.

3. Connect services (if applicable).

5. Setup checks

• Film path aligned.

• Correct recipe selected.

• Seal tools at target temperature.

6. First-off approval

Record first-off checks and sign-off.

7. Tool change procedure (typical HMI-guided)

The exact button names vary by model.

1. Select Change tool on the HMI (this typically lowers the top tool).

2. Open the main doors.

3. Fit the base tool to the base tool pressure plate.

4. Fit the top tool and align to the heater sockets (where fitted).

5. Fit transfer arms.

6. Fit and tighten all hand fasteners.

7. Close all guards.

8. Press System Reset and acknowledge alarms.

9. Select Change tool again (this typically loads the top tool).

8. Tray guide adjustment (typical)

1. Place a tray between the guides.

2. Adjust until the tray is guided without resistance.

9. Installing new tooling (recipe setup overview)

Use this workflow when commissioning a new tool format.

1. Install the tooling.

2. Create a new recipe.

3. Set basic parameters:

   • Number of impressions.

   • Seal time and temperatures (start point: 1.0 s at 150 °C).

   • Registered film enabled (true/false).

   • Printer installed (true/false).

   • Downstream equipment fitted (true/false).

4. Set tray pitch, jaw speeds, and transfer speeds to slow values.

5. Verify tray position using controlled stops and adjust tray position/pitch.

6. Set film feed length so the cut-out aligns with the spreader plate.

7. Run test trays and adjust seal time/temperature for witness and adhesion.

8. Increase speeds after first-off approval.