Machine Maiternance

D O C U M E N TA Z I O N E T E C N I C A

USER’S MANUAL

014AZ011A HYDRAULIC PRESSES

PH 1890 - PH 2090 - PH 2590 PH 2890

TECHNICAL DOCUMENTATION DOCUMENTATION TECHNIQUE TECHNISCHE DOKUMENTATION DOCUMENTACION

TECNICA

DOCUMENTAÇÃO

TÉCNICA

LISH

ENG

014AZ011A TABLE OF CONTENTS

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014AZ011A TABLE OF CONTENTS USER’S MANUAL

HYDRAULIC PRESSES

PH 1890 - PH 2090 - PH2590 PH 2890 - PH 3590 MANUFACTURER SACMI IMOLA Via Selice Provinciale, 17/A 40026 IMOLA (Bologna) - ITALIA

PUBLISHED ON October 31, 2003

VERSIONS PH1890A - PH2090A - PH2590B - PH2890B 0-3

014AZ011A TABLE OF CONTENTS

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014AZ011A TABLE OF CONTENTS 1

Page GENERAL INFORMATION ........................................................................................................................1 - 1 1.1 INTRODUCTION ........................................................................................................................ 1 - 1 1.2 WHERE TO KEEP THE MANUAL ............................................................................................. 1 - 1 1.3 HOW TO USE THE MANUAL .................................................................................................... 1 - 1 1.4 USERS OF THE MANUAL ......................................................................................................... 1 - 1 1.5 WARRANTY ............................................................................................................................... 1 - 2 1.6 SUPPLEMENTS ......................................................................................................................... 1 - 2 1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL .............................................................................................................................1 - 2 1.8 TARGA PER L'IDENTIFICAZIONE DELLA MACCHINA .......................................................... 1 - 5

2

MAIN FEATURES ......................................................................................................................................2 - 1 2.1 MACHINE DESCRIPTION ......................................................................................................... 2 - 1 2.1.1 MAIN MACHINE ASSEMBLIES ................................................................................................. 2 - 1 2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ................................................. 2 - 7 2.2 OVERALL DIMENSIONS ........................................................................................................... 2 - 8 2.3 TECHNICAL DATA .................................................................................................................. 2 - 10 2.3.1 SPECIFICATIONS ................................................................................................................... 2 - 10 2.3.2 AIRBORNE NOISE LEVELS .................................................................................................... 2 - 12 2.3.3 DUST SUCTION HOODS ........................................................................................................ 2 - 13 2.3.4 RATING PLATE ....................................................................................................................... 2 - 14 2.4 DIAGRAMS .............................................................................................................................. 2 - 15 2.4.1 HYDRAULIC AND PNEUMATIC DIAGRAMS ......................................................................... 2 - 15 2.5 OPERATION ............................................................................................................................ 2 - 23 2.5.1 COMPRESSED AIR SUPPLY ................................................................................................. 2 - 23 2.5.2 FAST HEATING ....................................................................................................................... 2 - 23 2.5.3 HEAT EXCHANGER SYSTEM ................................................................................................ 2 - 23 2.5.4 OIL LEAK CIRCUIT .................................................................................................................. 2 - 24 2.5.5 MAIN PUMP RUNNING - SAFETY BAR INTERLOCKS ACTIVATED (RAISED) .................. 2 - 24 2.5.6 POSITION TRANSDUCER - SETTINGS ................................................................................. 2 - 25 2.5.7 SAFETY BAR INTERLOCKS INACTIVATED (LOWERED) .................................................... 2 - 26 2.5.8 ENCODER RESETTING .......................................................................................................... 2 - 26 2.5.9 DIE-SET CONTROL CIRCUIT ................................................................................................. 2 - 26

3

SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 1 3.1 SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE ............................................. 3 - 1 3.2 NORME GENERALI ....................................................................................................................3 - 3 3.3 INSTALLATION ...........................................................................................................................3 - 4 3.4 HANDLING PROCEDURES ...................................................................................................... 3 - 4 3.5 PERSONNEL TRAINING ........................................................................................................... 3 - 5 3.6 OPERATING INSTRUCTIONS .................................................................................................. 3 - 6 3.6.1 CLEANING ..................................................................................................................................3 - 7 3.7 MAINTENANCE ......................................................................................................................... 3 - 8 3.8 MACHINE NOT IN USE ............................................................................................................. 3 - 8 3.9 DECOMMISSIONING THE MACHINE ...................................................................................... 3 - 8

4

INSTALLATION PROCEDURES ...............................................................................................................4 - 1 4.1 HOW TO LIFT AND PLACE THE PRESS IN POSITION .......................................................... 4 - 1 4.2 CONNECTIONS ......................................................................................................................... 4 - 1 4.2.1 EARTH CONNECTION ............................................................................................................. 4 - 2 4.2.2 INSTALLING AND REMOVING THE DIE-SET ..........................................................................4 - 3 4.2.3 CONNECTING THE DIE-SET HEATER .................................................................................. 4 - 12 4.2.4 CONNECTING THE MAGNETIC LOCK .................................................................................. 4 - 13 4.2.5 CONNECTING THE DUST EXTRACTION SYSTEM .............................................................. 4 - 13

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014AZ011A TABLE OF CONTENTS 5

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Page START-UP PROCEDURES ...................................................................................................................... 5 - 1 5.1 GENERAL .................................................................................................................................. 5 - 1 5.2 PRELIMINARY CHECKS ........................................................................................................... 5 - 1 5.2.1 CHECKING THE CONNECTIONS: ........................................................................................... 5 - 1 5.2.2 MOTOR M3 ................................................................................................................................ 5 - 1 5.2.3 MOTOR M11 ...............................................................................................................................5 - 1 5.2.4 MOTOR M1 ................................................................................................................................ 5 - 1 5.2.5 SETTING THE PRESSURE ...................................................................................................... 5 - 2 5.2.6 TOP DEAD-CENTER POSITION ............................................................................................... 5 - 2 5.2.7 SAFETY DEVICES ......................................................................................................................5 - 2 5.2.8 AUXILIARY EQUIPMENT PRESSURE ......................................................................................5 - 2 5.2.9 FILLER-BOX ...............................................................................................................................5 - 2 5.2.10 KNOCKOUT CONTROL (SPE ONLY) ........................................................................................5 - 3 5.3 ADJUSTMENT PROCEDURES ................................................................................................. 5 - 4 5.3.1 KNOCKOUT ADJUSTMENT ...................................................................................................... 5 - 4 5.3.2 PRELIMINARY ADJUSTMENTS TO THE HYDRAULIC SYSTEM ............................................5 - 5 5.3.3 ADJUSTING THE SPEED OF THE FILLER-BOX ......................................................................5 - 6 5.3.4 PLUNGER BRAKING ADJUSTMENT ........................................................................................5 - 8 5.3.5 PLUNGER PARALLELISM ERROR .......................................................................................... 5 - 8 5.3.6 PLUNGER MOTION SETTING .................................................................................................. 5 - 8 5.3.7 SETTING THE PRESS-CYCLE ................................................................................................. 5 - 8 5.3.8 DE-AERATION ADJUSTMENT ................................................................................................. 5 - 9 5.3.9 ADJUSTING THE DIE-SET PROTECTION DEVICE (FOR LACK OF POWDER) ................... 5 - 9 5.3.10 AUTOMATIC CYCLE ................................................................................................................. 5 - 9 5.3.11 SWITCHING ON THE FILLER-BOX SPEED CONTROLLER ................................................. 5 - 10

014AZ011A TABLE OF CONTENTS 6

7

Page OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1 6.1 CONTROLS................................................................................................................................ 6 - 1 6.1.1 CONTROLLER ........................................................................................................................... 6 - 2 6.1.2 ELECTRICAL CABINET ............................................................................................................. 6 - 8 6.2 START-UP AND SHUTDOWN PROCEDURES ........................................................................ 6 - 9 6.2.1 ROUTINE START-UP PROCEDURE ........................................................................................ 6 - 9 6.2.2 MACHINE SHUT DOWN .............................................................................................................6 - 9 6.2.3 STOPPING THE MACHINE IN EMERGENCIES ...................................................................... 6 - 9 6.2.4 SHUTDOWN DURING A POWER FAILURE ............................................................................. 6 - 9 6.2.5 SHUTDOWN DURING AUTOMATIC OPERATION ...................................................................6 - 9 6.3 PRESSURE-LOAD GRAPHS .................................................................................................. 6 - 10 6.4 AUTOMATIC CYCLE ............................................................................................................... 6 - 14 6.4.1 FILLER-BOX START-UP ......................................................................................................... 6 - 15 6.4.2 POWDER INFEED ................................................................................................................... 6 - 16 6.4.3 FILLER-BOX OPERATION ...................................................................................................... 6 - 16 6.4.4 DIE-SET DOWNSTROKES ...................................................................................................... 6 - 17 6.4.5 FAST DOWNSTROKE ............................................................................................................. 6 - 19 6.4.6 DOWNSTROKE WITH BRAKE APPLIED ............................................................................... 6 - 19 6.4.7 DELAY TIME FOR THE 1ST PRESS STROKE ...................................................................... 6 - 19 6.4.8 FIRST PRESS-STROKE .......................................................................................................... 6 - 20 6.4.9 1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER (WITH OR WITHOUT ACCUMULATORS) .................................................................................................................. 6 - 20 6.4.10 1ST SEPARATE PRESS-STROKE ......................................................................................... 6 - 20 6.4.11 DEAERATION .......................................................................................................................... 6 - 21 6.4.12 SECOND PRESS-STROKE (LAST PRESS-STROKE) ........................................................... 6 - 21 6.4.13 SECOND DIRECT PRESS-STROKE ...................................................................................... 6 - 21 6.4.14 PRESS-STROKE WITH PRESSURE BOOSTER ................................................................... 6 - 21 6.4.15 SECOND SEPARATE PRESS-STROKE ................................................................................ 6 - 22 6.4.16 DIE-SET UPSTROKE .............................................................................................................. 6 - 22 6.4.17 CYLINDER PRESSURE RECOVERY ..................................................................................... 6 - 22 6.4.18 UPSTROKE WITH BRAKE APPLIED ...................................................................................... 6 - 23 6.4.19 FAST UPSTROKE ................................................................................................................... 6 - 23 6.4.20 KNOCK-OUT ............................................................................................................................ 6 - 23 6.4.21 SFS CYCLE: UPPER FORMING DIE (OPTIONAL) ................................................................ 6 - 24 6.4.22 MOBILE DIE ............................................................................................................................. 6 - 24 6.4.23 DIE OVER-TRAVEL ................................................................................................................. 6 - 24 6.4.24 BRUSH OPERATION ............................................................................................................... 6 - 25 6.4.25 MOVEMENTS IN MANUAL MODE .......................................................................................... 6 - 26 6.4.26 MOVEMENTS IN SET-UP MODE ........................................................................................... 6 - 26 6.4.27 RESETTING THE ENCODERS ............................................................................................... 6 - 27 ADJUSTMENT PROCEDURES ................................................................................................................ 7 - 1 7.1 SETTING THE VARIABLE DELIVERY PUMP .......................................................................... 7 - 1 7.2 SETTING AND ZERO-SETTING THE POSITION ENCODER ................................................. 7 - 6 7.2.1 PLUNGER TRANSDUCERS...................................................................................................... 7 - 6 7.2.2 FILLER BOX ENCODER (DCL) ................................................................................................. 7 - 6 7.2.3 ALM ENCODER (DCL) ...............................................................................................................7 - 6 7.2.4 KNOCKOUT ENCODER (SPE) ................................................................................................. 7 - 7 7.2.5 FILLER-BOX ENCODER (DCP) .................................................................................................7 - 7

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014AZ011A TABLE OF CONTENTS 8

9

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Page MACHINE MAINTENANCE ...................................................................................................................... 8 - 1 8.1 MAINTENANCE SCHEDULE ......................................................................................................8 - 1 8.1.1 LUBRICATING THE KNOCKOUT FEELER PINS ......................................................................8 - 4 8.1.2 VACUUM .................................................................................................................................... 8 - 4 8.2 SPECIAL MAINTENANCE ......................................................................................................... 8 - 5 8.2.1 SERVICING THE PLUNGER BUSHES ......................................................................................8 - 5 8.2.2 FILLING THE RESERVOIR ........................................................................................................8 - 5 8.2.3 DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND RESERVOIR .......................... 8 - 5 8.2.4 DRAINING OIL FROM THE HOSES AND HYDRAULIC CONTROL ASSEMBLIES .................8 - 7 8.2.5 OIL RECIRCULATION AND FILTERING ................................................................................... 8 - 8 8.2.6 REPLACING PROPORTIONAL VALVES YV22a AND YV22b FOR THE KNOCKOUT (ONLY SPE) ............................................................................................................................... 8 - 9 8.3 TORQUES (NUTS & BOLTS) .................................................................................................. 8 - 10 8.4 SERVICING THE HEAT EXCHANGER ................................................................................... 8 - 11 8.4.1 REPLACING THE GASKETS .................................................................................................. 8 - 11 8.4.2 SECURING THE STAY BOLTS ............................................................................................... 8 - 12 DECOMMISSIONING ................................................................................................................................ 9 - 1

014AZ011A GENERAL INFORMATION 1

GENERAL INFORMATION

1.1

INTRODUCTION

E0004P

1

WARNING!

Carefully read the entire User’s Manual before working on the machine and/or the packaging of the various parts. This manual contains important information for safeguarding the operators, maintenance staff as well as the machine itself. SACMI reserves the right to modify the machine and manual without giving prior notice. Copyright. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI. The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied, reproduced, disclosed or transferred.

1.2

E0004P

WHERE TO KEEP THE MANUAL

WARNING!

This manual is to be considered an essential part of the machine and must be kept along with it even if the machine is sold. Always keep the manual near the machine where it can be easily consulted. The manual must always be at hand so that the operator and maintenance staff are able to rapidly consult it at all times.

1.3

HOW TO USE THE MANUAL

The lay out of this manual allows it to be easily consulted as all the information and instructions provided are grouped together and divided into chapters and paragraphs. The user has to simply refer to the table of contents. The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to the operator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and are written in italics, as shown below.

E0004P

WARNING!

Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must be carefully read in its entirety as it contains important information and warnings regarding safety.

1.4

USERS OF THE MANUAL

In this manual the machine operators are categorized as follows: - Operator: this is the person responsible for supervising and operating the machine. - Routine maintenance men. For a more detailed description, see the paragraph dealing with OPERATOR TRAINING in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.

1-1

014AZ011A 1 1.5

GENERAL INFORMATION WARRANTY

SACMI shall be held responsible only for the machine as it was configured at the time of delivery. Any operations that alter the configuration of the machine or operating cycle must be carried out by SACMI personnel or duly authorized by SACMI S Engineering Dept. SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.

E0004P

ATTENTION!

The machine operators and maintenance staff are not responsible for carrying out operations under warranty, special maintenance and repairs. These operations are to be performed only by the manufacturers specially trained technicians. For this reason, these types of operations are not dealt with in this manual.

1.6

SUPPLEMENTS

Information regarding the electric and electronic components is given in three handbooks provided separately. These handbooks are entitled: - USE OF THE MICROPROCESSOR-BASED CONTROL SYSTEM (Instructions B Manual) - ELECTRONIC CARDS - LIST OF DEVICES Information regarding unpacking and handling the machine is given in two handbooks provided under separate cover. These handbooks are entitled: - HANDLING OPERATIONS - UNPACKING OPERATIONS The above mentioned handbooks supplement this manual.

1.7

LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL

DANGER SYMBOLS

General danger E0004P

Hot surfaces - danger of being burnt E0002P

Danger - hands can be crushed E0003P

High tension - danger of electric shock E0007P

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014AZ011A GENERAL INFORMATION

1

Danger of entanglement in moving parts E0010P

Risk of explosion E0035P

WARNING SIGNS O2

It is forbidden to use oxygen to recharge the accumulators E0034D

ALERT SYMBOLS

Heavy duty gloves must be worn E0005O

The indicated point must be effectively grounded E0006O

OTHER SYMBOLS

E0009C

A list of tools required to carry out maintenance is provided.

1-3

014AZ011A GENERAL INFORMATION

1

SYMBOLS

This symbol indicates the machine version with SMU system. C1819

The descriptions and/or figures accompanied by this symbol refer only to this machine version.

This symbol indicates the machine version with proportional knockout (SPE) C1820

The descriptions and/or figures accompanied by this symbol refer only to this machine version. This symbol indicates the machine version with linear loading device (DCL) C1821

The descriptions and/or figures accompanied by this symbol refer only to this machine version.

This symbol indicates the machine version with crank/connecting rod loading device (DCP) The descriptions and/or figures accompanied by this symbol refer only to this machine version.‘

1-4

014AZ011A GENERAL INFORMATION 1.8

1

TARGA PER L'IDENTIFICAZIONE DELLA MACCHINA

C1812

TIPO TYPE MATRICOLA No. SE R I A L N U M B E R ANNO YE A R

VIA

SELICE

PROVINCIALE

17/A

IMOLA

-

I TA L I A

E0021

E0004P

ATTENZIONE!

Le macchine descritte nel presente manuale istruzioni sono progettate per il funzionamento indipendente e quindi possiedono i requisiti essenziali di sicurezza richiesti dalla direttiva 89/392/CEE esclusivamente nella configurazione standard prevista dalla SACMI e costituita da: - pressa idraulica PH - carrello parte fissa CAL - carrello parte mobile CAF - CAS - dispositivo alimentazione polveri ALM - ACP - TRAMOGGIA FISSA nell'installazione descritta al paragrafo NORME PER L'UTILIZZO del presente manuale istruzioni. L'installazione di dispositivi diversi da quelli sopra descritti o secondo modalità diverse da quanto indicato al paragrafo NORME PER L'UTILIZZO del presente manuale istruzioni (se non specificatamente approvato dalla SACMI) comportano la perdita dei requisiti essenziali di sicurezza. 1-5

014AZ011A 1

1-6

GENERAL INFORMATION

014AZ011A MAIN FEATURES 2

MAIN FEATURES

2.1

MACHINE DESCRIPTION

2

The press is a fully automatic machine especially designed to press ceramic powder to produce floor and wall tiles or other similar products. Either mechanical or isostatic compacting can be employed depending on the type of die-set installed. In addition, the machine can produce tiles with powders that have different characteristics (double layer). The distinctive feature of the machine is that it uses hydraulic power to perform the whole work-cycle: from loading the die set and performing the press-stroke, to the removal and ejection of the work-pieces. The most important machine assemblies are described below (the references are given in figure 2.1.1). 2.1.1

MAIN MACHINE ASSEMBLIES

FRAMEWORK The machine includes the framework 1, base, four columns and crosshead 3 which contains a hydraulic cylinder. The latter houses a hydraulic cylinder within which a double-acting piston 4 slides. The cylinder is attached to the plunger 2 so that it can be effectively driven. The upper part of the crosshead is designed to contain the hydraulic oil required for machine operation. The plunger 2 slides on the columns through bronze wear-resistant bushes. The main cylinder operates the plunger.

HYDRAULIC SYSTEM A pressure booster 7, located inside the upper part of the crosshead, generates the pressure directly within the cylinder so that the programmed press-strokes can be carried out. A number of control assemblies hold the valves and the logic elements required to operate the machine parts and control the operating pressures. These assemblies are located on the machine body near the actual points of use. These control assemblies are listed below: - Logic element assembly 20. Used to control the pressure required to perform the press cycle. - Accumulator control assembly 21. Used to control the upward and downward movements of the plunger. The assembly also includes a brake, which reduces the speed of the plunger while the die set is being closed. - Aux. equipment control assembly 22 which is used to operate the filler box and any other optional equipment (i.e. top forming die-sets, etc..) installed. - Knockout control assemblies 23 (only with SPE) used to control the tile ejection system. - SMU control assembly 24 (only with SMU) mounted on the aux. equipment control assembly. The hydraulic system 27 provides the amount of oil needed to operate the actuators, controls the operating temperature and filters the oil. The oil is drawn out of the reservoir by a variable-displacement, axial-piston pump and delivered to the hydraulic circuit at the required flow rate and pressure. The hydraulic circuit is kept under pressure so as to prevent the highly abrasive dust produced from getting in. The hydraulic power unit is provided with an oil/water heat exchanger which keeps the temperature of the oil within the normal operating limits. The circuit is also provided with a pump-and-motor assembly which is used to cool down and circulate the oil within the heat exchanger. The hydraulic piping 18 includes all the parts, pipes and hoses which link up the various units. The oil-leak collector 28 is used to collect any oil leaks at ambient pressure. A pump, located in the hydraulic power unit, will then send the oil collected to a pressurized tank.

2-1

014AZ011A MAIN FEATURES

2

DCP FILLER-BOX (DCP TYPE) The filler box is used to load the powder and eject the formed tiles. It includes a support frame 9 which can be removed from the press so as to rapidly replace the die-set from the back of the press. During this stage the mechanical parts move at a speed which is lower than that set by current safety standards (16 mm/sec) — this avoids hazardous situations for the operator from arising. The support frame holds up and guides the mobile part of the filler box which includes the actual body 10 and a powder feed hopper 11. The latter is mounted over the mobile part of the filler box and may be fed with powder delivered directly from the main hopper or through a mixer. The hydraulic geared motor mounted on the support frame drives the mobile part of the filler box through the use of a crank gear, transforming rotary motion into alternative straight motion. The speed and stroke of the filler box as well as the point at which the motor stops can all be set. All the parts which link the filler box to the press are provided with quick couplings for connection to electrical, hydraulic, pneumatic or mechanical parts.

DCL C1821

FILLER-BOX (DCL TYPE) The filler box is used to load the powder and eject the formed tiles. It includes a support frame which can be removed from the press so as to rapidly replace the die-set from the back of the press. During this stage the mechanical parts move at a speed which is lower than that set by current safety standards (16 mm/sec) — this avoids hazardous situations for the operator from arising. The support frame holds up and guides the mobile part of the filler box which includes the actual body and a powder feed hopper. The latter is mounted over the mobile part of the filler box and may be fed with powder delivered directly from the main hopper or through a mixer. The electric motor mounted on the support frame drives the mobile part of the filler box through the use of cogged belts. The speed and stroke of the filler box as well as the point at which the motor stops can all be set. All the parts which link the filler box to the press are provided with quick couplings for connection to electrical, hydraulic, pneumatic or mechanical parts.

C1819

SMU

SMU HYDRAULIC KNOCKOUT The SMU system 6 features a base plate and a punch holder which incorporates the tile knockout. The system is basically used to remove the finished tiles from the die set. The tile is carried to the same level as the die where it is then ejected by the filler box. The lower punches in the die set move down, creating a cavity for the material to be pressed. The depth of the cavity can be set in manual mode from the controller. This operation can also be done automatically after the desired tile thickness has been set. The two cylinders for the 1st downstroke and the four cylinders for the 2nd downstroke are controlled by two separate solenoid valves. The over-travel control is used to position the die below the lower punch level. Operated by a solenoid valve, the control is used to clean and facilitate the removal of the lower punches.

2-2

014AZ011A MAIN FEATURES

2

SPE C1820

UNIVERSAL/ELECTRONIC KNOCKOUT (SPE) This system consists of three control assemblies linked together through pins. The external ones incorporate the tile ejection system while the central one acts as a support. Basically, this system 8 is used to knock the tiles out of the dieset so that they are level with the die. The tiles are then ejected by the filler box. The mobile part of the die-set is connected to the four cylinder rods with two quick couplings. The cylinders are series connected hydraulically through an intermediate duct. Each pair is controlled by a proportional valve. Two position transducers record the position of the mobile part of the filler box. An axis control card piloted by the microprocessor regulates movement of the mobile part in real time. The encoder signals are processed and valves are piloted for this purpose. As a result, the speed of the die-set, as it moves up and down, as well as the upper limit switch are kept under control. The four cylinders are also used for the die-set overtravel when the lower punches are cleaned and to make replacement easier. The punches are then moved down recreating the cavity that receives the material to be pressed. The soft filling height is automatically determined after setting the desired tile thickness. The knockout comes with four special cylinders used to raise the die-set, thus making the assembly and disassembly operations easier to perform. This operation can be performed by placing gauged spacers between the die-set mobile block and the fixed section of the die-set to make the die-set stiff. In addition, the knockout has an independent circuit that collects any oil that has leaked out of the main cylinders. INTAKE , FILTER AND EXHAUST OPENING FOR THE AIR IN THE DIE SET The air which flows in and out of the lower part of the die set passes though the filter unit 5. GUARDS AND SUCTION HOODS The mechanical lock 15 prevents the plunger from accidentally moving down while the die set is being cleaned and maintenance operations are carried out. A number of covers 29 protect the working parts. The suction hoods 16 draw the dust out of the process zone. MICROPROCESSOR-BASED CONTROLLER The microprocessor-based controller 31 is used to program the work-cycle that the press will perform automatically. The controller consists of the following parts: - a control keyboard 35; - a computer terminal 35 to display the set-up parameters, operating data and fault messages; - electronic cards; Furthermore: - a plunger positioner 33 is connected to the controller. The equipment incorporates one or two encoders which record the position of the plunger and transmits data to the computer system. - the electrical wiring 30 is based on the same principle as the hydraulic system. It includes all of the electrical and electro-mechanical parts of the press: miniature switches, proximity sensors and related cams, connecting cables, terminals, etc.. The machine may come with a personal computer (optional) that processes and displays the data received from the microprocessor along with the historical data in real time.

2-3

014AZ011A 2

MAIN FEATURES

ELECTRICAL CABINET The electrical cabinet 32 contains the equipment needed to start and stop all of the motors on the press, the transformers for the die-set heaters, contactors, thermal relays, fuses, etc... DIE SET The forming die 34, which is used to give the pressed powder the required shape, consists of two parts. The lower part (attached to the base of the machine) incorporates the die, which rests on a number of supports, and the lower forming punches that are joined to the hydraulic knockout. The upper part, which is attached to the plunger, is provided with the mounting plate for the upper punches. The die as well as the upper and lower punches, are warmed up by electric heating elements so as to prevent the powder from sticking. Three temperature probes continuously measure the temperature in the punches and die. Three separate instruments can thus control and monitor this important variable.

2-4

014AZ011A MAIN FEATURES

SMU

Figure 2.1.1/A - OVERALL VIEW OF THE SMU C1819

1 2 3 4 5 6 7 9

2

7

Framework Plunger Crosshead and hydraulic cylinder Hydraulic cylinder Air filtering in the die-set SMU hydraulic knockout Pressure booster Filler-box mount (CAL)

32

20 5 18 27 28

15 2

24 35 29 30

31

11

9

22

10 10 11 15

3 21 33 6

4

C1825

34

1

16

16 17 18 20 21 22 24 27 28 29 30 31 32 33 34 35

Mobile part of filler box (CAF) Hopper (ALM) Mechanical lock and safety guards Suction hoods Spring shock-absorber Hydraulic lines Logic element control assembly Accumulator control assembly Aux. equipment control assembly SMU control assembly Hydraulic power unit Oil leak collector Covers Electrical wiring Microprocessor-based control system Electrical cabinet Plunger position control Die-set Control keyboard

2-5

014AZ011A 2

MAIN FEATURES

SPE

Figure 2.1.1/B - OVERALL VIEW OF THE PRESS EQUIPPED WITH SPE EJECTOR C1820

32 1 2 3 4 5 7 8 9 10 11

7

Framework Plunger Crosshead and hydraulic cylinder Hydraulic cylinder Air filtering in the die-set Pressure booster SPE hydraulic electronic knockout Filler-box mount (CAL) Mobile part of filler box (CAF) Hopper (ALM)

20 5

18 27 28

15 2

35

8 29 30

11

9

31

10

15 3 21

33 16 34

4

C1826

1 2-6

22

23

16 18 20 21 22 23 27 28 29 30 31 32 33 34 35

Mechanical lock and safety guards Suction hoods Hydraulic lines Logic element control assembly Accumulator control assembly Aux. equipment control assembly Knockout control assembly Hydraulic power unit Oil leak collector Covers Electrical wiring Microprocessor-based control system Electrical cabinet Plunger position control Die-set Control keyboard

014AZ011A MAIN FEATURES 2.1.2

2

INTENDED, PROHIBITED AND MISUSE OF THE MACHINE

INTENDED USE OF THE MACHINE The equipment described in this manual is designed to manufacture ceramic tiles. The emergency stop buttons have priority over all controls, therefore if the press is started from a distance, it can always be stopped by using the dedicated controls on the machine. Furthermore the machines placed before and after the press may send pulses which will stop the press in case of malfunctioning. The press must be restarted from its control panel. The restart procedure will only take place if trigger pulses are received from the machines in line.

E0004P

WARNING!

If the machine is remote controlled, it is the customer’s responsibility to provide the operators with adequate training. The machine can operate in manual or automatic mode. To enable the desired mode of operation, use the relevant selector switch located on the control panel. UNINTENDED AND PROHIBITED OPERATIONS No other tasks except those specified by the Manufacturer are to be performed. For this reason, the Manufacturer shall not be held responsible for the consequences deriving from the failure to observe the instructions contained herein. MISUSE OR ERRONEOUS USE The manufacturer shall not be held responsible for any injury to persons or damage to the machine deriving from incorrect and erroneous use of the machine. Generally speaking, the most common causes of incorrect use are listed below: - personnel not adequately trained to perform the required operations - fatigue (above all during the night shift) or distraction - negligence caused by superficiality or wrong habits. Remember that the machine is to be controlled and run exclusively by expert well trained personnel who are able to: - correctly operate the machine under normal conditions - and face any emergencies, this is fundamental!

2-7

014AZ011A MAIN FEATURES

2 2.2

OVERALL DIMENSIONS

DCL

Figure 2.2/A - OVERALL DIMENSIONS

1700

C1821

V

Ø1500

H Z

D

C

R

A B

MAX S

U

T

G

200

C1875

F E K

Minimum service area

M

P

L

O

I

N

A B C D E F G H I K L M N O P R S T U V Z

2-8

(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

PH 1890 4890 4300 700 590 2539 1040 920 5220 1165 2000 2835 2860 1200 2170 1150 730 160 6500 6000 500 4000

PH 2090 4890 4300 700 590 2539 1040 920 5220 1165 2000 2835 2860 1200 2170 1150 730 160 6500 6000 500 4000

PH 2590 4991 4321 700 670 2660 1180 929 5250 1095 2000 2905 2860 1200 2170 1150 730 160 6500 6000 500 4000

PH 2890 4991 4321 700 670 2660 1180 929 5250 1095 2000 2905 2860 1200 2170 1150 730 160 6500 6000 500 4000

(Minimum for knockout)

014AZ011A MAIN FEATURES 1700

DCP

Figure 2.2/B - OVERALL DIMENSIONS

2

V

Ø1500

H Z

MAX S D

C

R

B

A

U

T

G

200

C1876

F

E

K

Minimum service area

M

P

P

L

O

I

N

A B C D E F G H I K L M N O P R S T U V Z

(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

PH 1890 4890 4300 700 590 2539 1040 920 5220 1165 2000 2835 2860 1200 2170 1150 730 160 6500 6000 500 4000

PH 2090 4890 4300 700 590 2539 1040 920 5220 1165 2000 2835 2860 1200 2170 1150 730 160 6500 6000 500 4000

PH 2590 4991 4321 700 670 2660 1180 929 5250 1095 2000 2905 2860 1200 2170 1150 730 160 6500 6000 500 4000

PH 2890 4991 4321 700 670 2660 1180 929 5250 1095 2000 2905 2860 1200 2170 1150 730 160 6500 6000 500 4000

(Minimum for knockout)

2-9

014AZ011A 2

MAIN FEATURES

2.3

TECHNICAL DATA

2.3.1

SPECIFICATIONS

PERFORMANCE Max. soft clay filling

with SMU (standard) with SMU (special on request) with SPE

Max. plunger stroke Column diameter Distance between the columns Distance between press table and plunger Max. knockout force Max. pressing force Max. cylinder pressure Cycles per minute Strokes per cycle ELECTRICAL SYSTEM Voltage: Aux. circuitry Die-set heating Solenoid valves Power: Main motor Heat exchanger pump motor Die-set heater (standard punches) Die Controller Oil leak collector pump

2 - 10

mm mm mm mm mm kN kN bar up to

(regulated) (50 Hz) (50 Hz) (50 Hz) (50 Hz) (50 Hz) (50 Hz)

V c.a. V c.a. V kW kW kW kW kW kW

PH 1890 32 50 74 mm 320 1750 mm 90 18000 318 22 1-2-3

PH 2090 32 50 74 160 320 1750 600 90 20000 352 22 1-2-3

PH 2590 32 50 74 160 390 1750 600 90 25000 350 21 1-2-3

PH 2890 32 50 74 160160 390 1750 600600 90 27500 388 21 1-2-3

PH 1890 110 50 24 75 7.5 10 + 10 4 1 0.18

PH 2090 110 50 24 75 7.5 10 + 10 4 1 0.18

PH 2590 110 50 24 75 7.5 10 + 10 4 1 0.18

PH 2890 110 50 24 90 7.5 10 + 10 4 1 0.18

014AZ011A MAIN FEATURES HYDRAULIC SYSTEM Hydraulic oil: system capacity viscosity at 40°C viscosity index greater than FZG test stage Max. operating pressure in hydraulic power unit Accumulators Main circuit capacity precharge pressure Aux. circuit capacity Pilot valve circuit capacity SMU die control capacity precharge pressure Main filter Filtering capacity Filter cartridge in tank Filtering capacity Filter cartridge (plate type) Filtering capacity Cooling system Heat to be dissipated kW

Pressurisation,

Water used at 20°C Water pipe connection diameter Hoses, Inside diameter Max. pressure Max. pressure (with plunger raised)

l cSt.

bar l bar l l l bar µ µ µ 52 Kcal/h l/1' mm bar bar

FILLER BOX-EJECTOR ASSEMBLY Gearbox lubrication: EP oil viscosity WEIGHTS Weight

Press body Hydraulic power unit Aux. equipment (controller, electrical cabinet, filler-box, etc.)

2

PH 1890 950 46 110 11 180 20+20+20 110 12 1 2,5 110 12 250 6 52 45000 40 1"1/2 40 4 1.5

PH 2090 PH 2590 PH 2890 950 1100 1100 46 46 46 110 110 110 11 11 11 180 180 230 20+20+20 20+20+2024.5+24.5+24.5 110 110 130 12 12 12 1 1 1 2,5 2,5 2,5 110 110 110 12 12 12 250 250 250 6 6 6 52 64 45000 45000 55000 40 40 50 1"1/2 1"1/2 1"1/2 40 40 40 4 4 4 1.5 1.5 1.5

PH 1890 ISO VG 320

PH 2090 PH 2590 PH 2890 ISO VG 320 ISO VG 320 ISO VG 320

kg kg

51000 890

51000 890

64000 890

64000 890

kg

2800

2800

2800

2800

2 - 11

014AZ011A MAIN FEATURES

2 2.3.2

AIRBORNE NOISE LEVELS

Test conditions: - Operating conditions (refer to ISO/DIS 11202 specification, paragraph 9.5): - a wooden test piece was used - a sound-proof system provided - Type of process: manufacture of ceramic products - Work cycle: die-set loading, one or more press-strokes and deaeration and final formation of product - Test conditions:

-

PH 1890

PH 2090

PH 2590

PH 2890

Cycles/minute

14.7

14.7

14.6

14

Hydraulic power unit pressure (bar)

180

180

180

220

Operating pressure (bar)

300

300

300

300

Test environment Testing department at Sacmi Imola

Test instruments used Class 1 (IEC 804) Sound pressure level (ISO/DIS 11202) Sound power level (ISO 3746) Noise levels measured PH 1890

PH 2090

PH 2590

PH 2890

LpA

P1

72.5

72.5

72

74

(dBA)

P2

76.5

76.5

75

78.5

96

96

94

96

LwA (dBA)

LpA

Continuous A-weighted sound pressure level.

LwA

Acoustic power level in dB weighted A.

P1 = Occasional control post P2 = Noisiest position of the ideal machine perimeter measured at floor level FIGURE 2.3.2 - POINTS WHERE NOISE LEVEL WAS MEASURED PH 1890 - PH 2090

PH 2590 P2

PH 2890

C0834

C0834

C0834

P2 P1

2 - 12

P1

P2

P1

014AZ011A MAIN FEATURES 2.3.3

2

DUST SUCTION HOODS

Dust is let into the atmosphere during normal machine operation. The press is equipped with suction hoods designed to capture the dust particles. These hoods are to be connected to a suitable suction system. A drawing illustrating the points where the hoods are installed along with the air delivery rates required for proper operation is given below.

Suction outlet

Front hood Rear hood Rear powder level limit Front powder level limit (optional) Powder level limit, Cleaning

ID symbol

No. of outlets

Outlet diameter (mm)

Total delivery rate qt (m3/h)

Height from floor (m)

S250 S260 P004 P002 P010

2 2 6 2 1

150 150 80 100 50

2540 2540 2160 1080 141

+3.3 +2.5 -0.1 -0.1 +0.8

P004 C306

S260 NOTE: Suction system vacuum before reaching the press must fall within “130 and 150” mm of H2O (= “0.0126 and 0.0145” bar).

NOTE: Use anti-static tubes to connect the hoods to the suction system.

S250

P010

P002

S250

S270

S270

S270

S270

2 - 13

014AZ011A 2 2.3.4

MAIN FEATURES RATING PLATE

C1812

2 - 14

014AZ011A MAIN FEATURES 2.4

DIAGRAMS

2.4.1

HYDRAULIC AND PNEUMATIC DIAGRAMS

2

The schematic is presented as a block diagram in order to highlight the different separate areas in the machine. The hydraulic and pneumatic parts are numbered and listed so that the functions can be well identified.

Block diagram A B C D E F G H I L M P Q R S T U V

PREFILLING TANK HOPPER GATE CONTROL PRESS-STROKE CONTROL UPSTROKE, DOWNSTROKE, BRAKING AND PRESSURE CONTROL AUX. EQUIPMENT CONTROL ASSEMBLY SPE TYPE KNOCKOUT CONTROL SMU TYPE KNOCKOUT CONTROL SPE KNOCKOUT HYDRAULIC POWER UNIT BLOWER CIRCUIT (OPTIONAL) SFS CONTROL (OPTIONAL) MIRROR-FINISHED DIE-SET (OPTIONAL) DIE RELEASE CONTROL (OPTIONAL) MOBILE BRUSH PNEUMATIC CONTROL (OPTIONAL) MOBILE BRUSH PNEUMATIC SYSTEM (OPTIONAL) FIXED AND MOBILE BRUSH HYDRAULIC CONTROL (OPTIONAL) OPTIONAL FILLER-BOX (OPTIONAL) THIRD DIE-SET DOWNSTROKE CONTROL (OPTIONAL)

2 - 15

ASPIRAZIONE POMPA

- AIR OIL DELLO SCAMBIATORE ARIA - OLIO EXCHANGER PUMP INTAKE

C1820

2 - 16

YV22s

184

YV25

196

YV304b

180b2

180b1

BQ5

YV22b

H

179

122

123

124

125

YV22a

YV304a

198

179

72

F

BP6 BP7

BQ5

180a1

126

71

73

180a2

184

166

YV290

271 74

069

252

SP5

P

V

YV70

140

143

142

119

M

Q

YV298

B

336

337

M

339

YV172 338

249

258

205 SP4

U

YV20s

YV32s

108

YV40

117 116

YV20a

YV32d

109

YV19

YV193

174

YV47

250

90 BQ3

P

118

YV32m

M15 132 92

YV39

YV38

YV31d YV31s

247

BP1

P

183

141

145

YV107

89

36

SP2

120

67

188

E

4

YV11r

12

SQ59a

42

7

13

112a

111

10

YV53

D

219

220

115

18a 18b 18

YV41

131

C

144

M

M1

154

224

YV99 112

SQ60

U

T

L

79

MANDATA POMPA - AIR OIL SCAMBIATORE DELLO ARIA - OLIO EXCHANGER PUMP DELIVERY

M

SL 4 SL 3

YV171i

SP1

84 85

M11

86

78

54

105

M3 M

59

60

H2O

I

C2341

YV279 H2O

82

S

48

269

R

YV192

267

266

264

270 269

195

194

265

T

YV171a

YV173

SP3

270

195

49

BT4

269

269

222

YV221

277

273

272

SQ50a

SQ61

223

275

58

B

Figure 2.4.1/A - HYDRAULIC & PNEUMATIC SYSTEM SCHEMATIC FOR SPE TYPE KNOCKOUT

2

A

75

SPE

014AZ011A MAIN FEATURES

ASPIRAZIONE POMPA OIL - AIR DELLO SCAMBIATORE ARIA - OLIO EXCHANGER PUMP INTAKE

179

184

123

180 181 189

122

125

124

A

YV290

126

71

73

189 181 180

184

271 74

179

72

069

V

YV170 YV135

169

3a CADUTA

75

YV21

242

G

YV22

61

YV107

89

36

V

YV70

23

M

P

140

P

B

336

337

M

339

YV172

249

258

205

YV20s

U

SP4

YV32s

108

YV40

117 116

YV20a

YV32d

109

YV19

YV193

174

YV47

338

118

YV32m

250

90 BQ3

251

142 143

YV129

183

141

145

119

M15 132 92

YV39

YV38

YV31d YV31s

247

BP1

P

SP2

120

67

188

E

4

YV11r

12

SQ59a

42

7

13

112a

111

10

YV53

D

219

220

115

18a 18b 18

YV41

131

C

144

M

M1

154

224

YV99 112

SQ60

U

T

L

79

MANDATA POMPA - AIR OILSCAMBIATORE DELLO ARIA - OLIO EXCHANGER PUMP DELIVERY

M

SP1

SL 4 SL 3

YV171i

S

H2O

I

YV279 H2O

82

C2342

48

269

R

YV192

267

266

264

270 269

195

84 85

M11

86

78

54

105

M3 M

59

60

T 265

194

YV171a

YV173

SP3

270

195

49

BT4

269

269

222

YV221

277

273

272

SQ50a

SQ61

223

275

58

B

Figure 2.4.1/B - HYDRAULIC & PNEUMATIC SYSTEM SCHEMATIC FOR SMU TYPE KNOCKOUT

SBLOC. ASTE

SMU

1a CADUTA

C1819

014AZ011A

MAIN FEATURES 2

2 - 17

2a CADUTA

014AZ011A 2

MAIN FEATURES

Figure 2.4.1/C - LOGIC ELEMENT ASSEMBLY 220 YV38

YV71

BP1

SP2 YV19 YV40

YV41 120

119 118 117 116 C1827

131 Figure 2.4.1/D - BRAKE CONTROL ASSEMBLY 18a

18 89

YV39 18b

YV32m

YV107

YV31d YV31s

247 132

108 115

M15 92 174

C2097

YV53

YV47 90 YV325 YV32d

2 - 18

258

109

014AZ011A MAIN FEATURES

2

Figure 2.4.1/E - AUX. EQUIPMENT - SMU CONTROL ASSEMBLY

C1819

141

SMU

YV172 YV193 YV20s SP4 SP5

YV129 337

YV20a

250

YV20s

12 339

205

249

YV22

336

YV21

188 140

252

112a 10 C1858

YV11r 143 183 338 251 142

YV135

YV170

Figure 2.4.1/F - AUX. EQUIPMENT - SPE CONTROL ASSEMBLY 141 C1820

SPE

YV172 YV193 YV20s SP4

337

SP5

YV129 250

YV20a

12 339 249

205

336 188 140 252

112a 10 C1859

YV11r 143 183

338

251

142 2 - 19

014AZ011A 2

MAIN FEATURES

Figure 2.4.1/E - KNOCKOUT CONTROL ASSEMBLIES

198 YV22a

166 196 BP6 YV304a

YV304b

C2125

YV22b

YV25

YV22s

Figure 2.4.1/H - SPE PROPORTIONAL KNOCKOUT (FRONT VIEW)

SPE C1820

180a1

180a2

180b2

C1816

180b1

2 - 20

BP7

014AZ011A MAIN FEATURES

2

LIST OF THE HYDRAULIC AND PNEUMATIC COMPONENTS (SMU - SPE) 004 007 010 012 013 018 018a 018b 023 036 042 048 049 054 058 059 060 061 067 069 071 072 073 074 075 078 079 082 084 085 086 089 090 092 105 108 109 111 112 112a 115 116 117 118 119 120 122 123 124 125 126 131 132 140 141 142 143 144 145 154 166 169 174 179 180 180a1

Check valve, Accumulator, Aux. equipment control Manual check valve, Accumulator control assembly drain Valve (pilot-operated), Low pressure control Accumulator, Aux. equipment (filler-box and lift control) Pressure gauge, Pump and cock Accumulator, Press-stroke and upstroke Accumulator, Press-stroke and upstroke Accumulator, Press-stroke and upstroke Flow control Pressure gauge, Cylinder and cock Hydraulic motor, Filler-box Heat exchanger Suction filter, Main pump Check valve, Oil leak collector pump Main pump Reducer valve, Brush rotation Restrictor, Brush rotation Restrictor, Non return valve Pressure gauge, Aux. equipment pressure and cock Check valve (hydraulic release), Die upstroke Safety valve, Pressurisation Air filter, Pressurisation circuit Pressure reducer, Air in the pressurisation circuit Check valve, Air in the pressurisation circuit Pressure gauge, Air in the pressurisation circuit Filtering unit pump Filter Check valve, Filtering unit delivery line Coupling (oil collector pump) Oil collector pump Filter, Oil collector pump suction line De-aeration proportioner Flow rate control, Slow upstroke Pressure relief valve, Brake system Oil leak collection tank Logic element, Upstroke Logic element, Downstroke Pressure relief valve Pilot-operated valve, Line pressure Safety valve, Hydraulic circuit Logic element, Accumulator shut-off during presscycle Logic element, Flow booster (1st press-stroke) Logic element, Cylinder pressure Logic element, Cylinder drain Logic element, Booster drain Logic element, Pressure booster Plunger Rod Cylinder Booster assembly Prefilling tank Logic element, Booster supply, 2nd press-stroke Flow control, Plunger braking Pressure reducing valve, Mirror finish die-set Accumulator, Mirror finished die-set Pressure gauge, Mirror finished die-set Drain cock, Mirror finished die-set Cock, Main pump suction line Restrictor, Non return valve, Mirror-finished die set Cock, Suction system Reducer valve, Intermediate duct between cylinders 180a1 and 180a2 Twin restrictor, 3rd downstroke control Logic element, Braking Cylinder, Die over-travel SMU knock-out cylinder Knock-out cylinder

180a2 180b1 180b2 181 183 184 188 189 194 195 196

Knock-out cylinder Knock-out cylinder Knock-out cylinder Cylinder, Loading adjustment, 2nd SMU downstroke Check valve, Die hydraulic release SFS cylinder Pressure reducer, Aux. equipment circuit Cylinder, Additional downstroke control Pressure relief valve, Brush drive Hydraulic motor, Brush Pressure gauge, Intermediate duct between knockout cylinders 198 Pressure gauge, SPE return stroke chamber 2 + 2 cylinders 205 Proportional safety filter 219 Check valve, Pilot system accumulator 220 Pilot system accumulator, Logic element control ass’y 222 Flow control and silencer, Gate cylinder 223 Flow control and silencer, Gate cylinder 224 Gate cylinder 242 Twin throttle valve, 2nd downstroke 247 Check valve, Cylinder downstroke 249 Restrictor, SFS delivery line 250 Restrictor, SFS accumulator 251 Check valve, Hydraulic die release 252 Proportional filter (10 um) 258 Change-over valve 264 Air filter, Brush ass’y 265 Pressure gauge, Brush ass’y 266 Pressure reducer, Brush ass’y 267 Oiler, Brush ass’y 269 Flow regulator, Brush drive cylinder 270 Cylinder, Brush drive 271 Filter, Pressurisation system 272 Air filter, Hopper assembly 273 Pressure reducer, Hopper assembly 275 Pressure gauge, Hopper assembly 277 Oiler, Hopper assembly 336 Pressure relief valve, SFS circuit 337 Accumulator, SFS circuit 338 Pressure gauge, SFS circuit 339 Drain cock, SFS circuit BP1 Transducer, Cylinder pressure BP6 Pressure transducer, SPE upstroke BP7 Pressure transducer, SPE downstroke BQ2 Filler-box encoder BQ3 Position transducer, Brake logic-element BQ4 Cylinder A encoder, Proportional knockout BQ5 Cylinder B encoder, Proportional knockout BQ6 Plunger encoder (R.H.) BQ7 Plunger encoder (L.H.) BQ10 ALM encoder BT4 Thermocouple, Hydraulic power unit reservoir M1 Motor, Main pump M3 Oil leak collector pump motor‘ M11 Motor, Recirculating pump M15 Motor, Brake system M20 Linear filler-box motor (optional) SL3 Min. oil leak level SL4 Max. oil leak level SP1 Pressure switch, Main filter service SP2 Pressure switch, Cylinder (safety) SP3 Pressure switch, Air pressurization SP4 Pressure switch, Filler-box valve filter service SP5 Pressure switch, Proportional valve filter service (knockout) SQ2 Proximity switch, Filler-box encoder reset SQ3 Sensor, Die-set up SQ50a Miniature switch, Suction line cock 2 - 21

014AZ011A 2 SQ51 SQ52 SQ59 SQ6 SQ60 SQ61 YV11r YV19 YV20a YV20s YV21 YV22 YV22a YV22b YV22s YV25 YV31d YV31s YV32d YV32m YV32s YV38 YV39 YV40 YV41 YV47 YV53 YV70 YV99 YV107 YV129 YV135 YV170 YV171a YV171i YV172 YV173 YV192 YV193 YV221 YV279 YV290 YV298 YV304a YV304b

2 - 22

MAIN FEATURES Limit switch, Right-hand safety bar Limit switch, Left-hand safety bar Limit switch, Filler-box backwards Sensor, Die-sets down Sensor, Hopper gate open Sensor, Hopper gate closed Solenoid valve, Quick oil heating Solenoid valve (pilot-operated), 2nd press-stroke direct) Solenoid valve, Filler-box Solenoid valve, Filler box interlock Solenoid valve, 2nd die-set downstroke Solenoid valve, 1st die-set downstroke Proportional solenoid valve, Cylinders 180a1 and 180a2 control Proportional solenoid valve, Cylinders 180b1 and 180b2 control Safety solenoid valve Solenoid valve, Slow SE die-set movement Solenoid valve, Slow downstroke Solenoid valve, Slow upstroke Solenoid valve, Plunger downstroke Solenoid valve, Booster upstroke Solenoid valve, Plunger upstroke Solenoid valve (pilot-operated), Pressure booster Solenoid valve, De-aeration Solenoid valve (pilot-operated), Flow booster, 1st press-stroke Solenoid valve, Flow booster, 2nd press-stroke Solenoid valve, Brake system Solenoid valve, Accumulator shut-off Solenoid valve, Main cylinder drain Solenoid valve, Pump control drainage Solenoid valve, Automatic plunger upstroke Solenoid valve, Die over-travel control Solenoid valve, Knockout rod lock Solenoid valve, 3rd die-set downstroke (optional) Solenoid valve, Brush hydraulic motor control Solenoid valve, Brush hydraulic motor control Solenoid valve, SFS die-set cylinder drain Solenoid valve, Die-set blower Solenoid valve, Brush drive Solenoid valve, SFS punch return stroke Solenoid valve, Hopper gate pneumatic system Solenoid valve, Cooling water Solenoid valve, Pressurization control Solenoid valve, Lower die-set release Solenoid valve, Pressure restoration, Intermediate duct between cylinders 180a1 and 180a2 Solenoid valve, Pressure restoration, Intermediate duct between cylinders 180b1 and 180b2

014AZ011A MAIN FEATURES 2.5

2

OPERATION

The identification numbers and symbols of the hydraulic, pneumatic and electrical components mentioned below refer to the HYDRAULIC AND PNEUMATIC DIAGRAM. 2.5.1

COMPRESSED AIR SUPPLY

The unit consists of filter 72, pressure reducer 73, check valve 74, pressure gauge 75, valve YV290 and pressurisation system air filter 271. The compressed air is used to pressurise the tank and to put the hydraulic oil contained in it under constant pressure. The pressure reducer must be set so that a pressure of 1 to 1.2 bar is provided inside tank 126. Safety valve 71 is used to prevent any over-pressure within the tank from forming. Pressure switch SP3, which keeps pressurisation under control, is mounted on the suction line of pump 58. It prevents the main pump from being started up if the pressure in the air lines is insufficient. If this happens, a fault message will be displayed. A unit (which consists of filter 272, pressure reducer 273, pressure gauge 275, lubricator 277 and solenoid valve YV221) controls cylinder 224 to operate the feed hopper gate, provided that this optional device is installed. An additional assembly – which includes filter 264, pressure reduce 266, pressure gauge 265, lubricator 267, solenoid valve YV192, pressure reducer 194 and flow regulators 269 – controls cylinders 270 that drive the mobile brush (optional).

2.5.2 FAST HEATING In order for the press to run efficiently, the oil temperature must be kept at around 40°C. When the machine begins to run, the oil is normally at ambient temperature, therefore it is necessary to heat it up to at least 30°C before starting an automatic work-cycle. However, the machine can be started up. NOTE: With temperatures lower than 5°C, use an external heater. To heat the oil, start up the pump with the safety bar raised. If the temperature is below 30°, valve YV11r will be energised and the oil heating circuit will begin to operate. The pump will circulate the oil at a pressure of 150 bar (set for valve 10). The electrical power dissipated is then turned into heat. The power dissipated in pressure relief valve 10 will cause the oil to be warmed up in a short time (10 to 15 minutes approx.). If the oil temperature is found to be <2°C, the controller will not allow drive motor M1 to start running.

2.5.3 HEAT EXCHANGER SYSTEM The system consists of pump-and-motor unit M11-78, plate-type heat exchanger 48 and filter 79. Pump 78 draws the oil from the tank of the hydraulic power unit and delivers it to filter 79 and heat exchanger 48. The oil is then cooled down and returned to the tank. Filter 79 is provided with pressure switch SP1 which indicates when it is clogged. Check valve 82 is used to prevent the oil from going back into the filter when the filter elements are being replaced. The flow rate of the cooling water is controlled by valve YV279. The microprocessor based system measures the oil temperature thanks to thermocouple BT4 (located on the hydraulic power unit’s reservoir). After the temperature rises and reaches 41°C, YV279 will be energised; after it reaches 39°C, YV279 will be de-energised. Drive motor M1 will stop if motor M11 shuts off. As a result, the automatic work-cycle will be interrupted. First run the heat exchanger to bring motor M1 back into operation.

2 - 23

014AZ011A 2

MAIN FEATURES

2.5.4 OIL LEAK CIRCUIT The oil that leaks from the main cylinder 124 rod, the booster and SPE is collected in tank 105. The level control in the tank 105, called “first level control” (SL3) start motor-pump unit M3-85 when the maximum allowable level has been reached. The oil taken in by the pump passes through filter 86 and is sent to the hydraulic power unit reservoir. Check valve 54 prevents the oil from flowing back to tank 105. When the minimum level is reached, this control device stops the pump. The “second level control” (SL4) inside the tank 105 sends a fault signal if the oil cannot be pumped into the hydraulic power unit reservoir (e.g. coupling between motor and pump broken, suction filter 86 clogged, overload cut-out for motor M3 tripped, etc...). The microprocessor control system processes the signal and shuts down the press.

2.5.5 MAIN PUMP RUNNING - SAFETY BAR INTERLOCKS ACTIVATED (RAISED) The microprocessor-based control system is energised along with the motor starters when the master switch is turned to its “on” position. a) the following units start running when key “0” is pressed: - Fan motor in the sound-proof housing (if installed); - Motor-and-pump assembly for the filtering unit and heat exchanger M11-78. b) if key “0” is pressed again (at least five seconds must elapse between operations A and B), the following unit will start running: - Main pump and motor M1-58.

Unit M1-58 is started up under no-load conditions in a pre-determined sequence when solenoid valve YV99 controls the drainage of the pump pressure regulator. Filter 49 and pressure switch SP3 are installed on the suction line of pump 58. The pressure switch indicates when filter 49 is clogged. In fact, if the pressure in the suction line falls below the allowable levels, pressure switch SP3 will change over and transmit a signal to the microprocessor system which, in turn, will cause the motor which drives the main pump to stop running. A fault message will appear on the screen of the microprocessor system. The delivery line of pump 78 is fitted with filter 79 and pressure switch SP1. The latter indicates when filter 79 is clogged. The pressure in the circuit is around 20 bar (see the instructions for the variable delivery pump). As soon as solenoid valve YV22s is energised, oil is delivered to solenoid valves YV22a and YV22b which keep the die-set in position.

2 - 24

014AZ011A MAIN FEATURES

2

2.5.6 POSITION TRANSDUCER - SETTINGS The encoders are digital position transducers which continuously monitor the position of the plunger, the filler-box and the knockout. The data entered into the microprocessor based control system provides the machine with information. Consequently, the machine will perform the programmed operations when the positions of the plunger, the knockout and the filler-box (detected by the transducers) coincide with the settings. Encoders 1 and 2 (plunger position) “BQ6” and “BQ7” The following settings can be entered for the plunger (see the Instructions B manual): - Plunger stoppage due to lack of powder - Plunger down position (trigger pulse to start the press-stroke) - Braking space - Plunger raised position (automatic mode) - End of braking during plunger upstroke - Plunger parallelism error: this value, expressed in mm, indicates the maximum degree to which the plunger is inclined during the press-cycle

Encoder 3 (filler box position) “BQ2” The following settings can be entered for the filler-box (see the Instructions B manual): - Position filler-box reaches when fully back - Position filler-box reaches when fully forward - Approach setting - Filler-box speed during the forward stroke - Filler-box speed during the return stroke - Approach speed - Filler box position for first die-set downstroke - Filler-box speed in manual mode Sensor SQ2 will reset the encoder when energised by the cam. The latter is integral with the mobile part of the fillerbox.

SPE C1820

Encoders 4 and 5 (knockout position) “BQ4” and “BQ5” (only with SPE) The following settings can be entered for the knockout (see the Instructions B manual): - Upper end-stops A and B - Speed during upstroke - Speed during downstroke - Tile knockout between punches - Knockout timing with filler-box during loading

2 - 25

014AZ011A MAIN FEATURES

2

DCL C1821

Encoder 6 (ALM position) “BQ10” (only with DCL) The following settings can be entered for the filler-box cycle (see the Instructions B manual): - Position ALM reaches when back - Position ALM reaches when forward - ALM speed during forward stroke - ALM speed during return stroke - Position ALM reaches when the hopper gate is opened - Position ALM reaches when the hopper gate is closed Sensor SQ10 will reset the encoder when energised by the cam. The latter is integral with the mobile part of the fillerbox.

2.5.7 SAFETY BAR INTERLOCKS INACTIVATED (LOWERED) When the safety bar is lowered the pressing valves are enabled and the press can run in automatic mode if the fillerbox is installed and tile ejector placed in front of the machine is present. Throughout the work-cycle valve 111, at the pressure set for 112a acts as an hydraulic safety device for the circuit (the operating and safety pressures are given in chapter 7 - ADJUSTMENT PROCEDURES). Once the pressures for the relief and safety valves have been set, it is good practise to block the adjusters (by using the locknuts) on the two valves. By doing this, vibrations will be prevented and the adjusters will not come loose, as a result, the pressure settings can be maintained over long periods. The pressure in valve 112, referred to as “line pressure”, can be adjusted when valve YV99 is energized.

2.5.8 ENCODER RESETTING To perform this operation, press keys 28 & 5 at the same time. This is to be done whenever the microprocessor based system is disconnected. The encoders must be reset in order to start the machine cycling in automatic mode. “ENCODER NOT RESET” will appear on the display of the microprocessor control system so as to inform the operator when this is to be done. Once the plunger encoder has been reset, the program will restore the filler-box and knockout encoders to normal operating conditions.

2.5.9

DIE-SET CONTROL CIRCUIT

C1819

SMU

WITH SMU LIFT SYSTEM Press pushbuttons 25 & 13 to energise solenoid valve YV22 and YV21. Solenoid valve YV22 delivers oil to the bottom part of cylinders 180 used to raise the lower punches. Simultaneously, the upper part of cylinders 180 is joined to the drain through YV22. Adjust flow control 61, located under solenoid valve YV22 to adjust the speed at which the upward movement takes place. To adjust the downstroke speed, work on the throttle located on the line in the point where the pipe used to connect the cylinder for the first downstroke starts. Solenoid valve YV21 delivers oil to die-set upstroke cylinders 181 through flow control 242. The latter is used to adjust the speed for the last downstroke. As a result the lower punches reach the same level as the die. The upstroke speed is determined by a fixed gigler.

2 - 26

014AZ011A MAIN FEATURES

2

SPE C1820

WITH SPE KNOCKOUT Press pushbuttons 13 & 25 to energise solenoid valve YV22s and YV25 as well as proportional valves YV22a and YV22b. Solenoid valve YV22s delivers oil to valves YV22a and YV22b which, in turn, supply oil to cylinders 180a1, 180a2, 180b1 and 180b2. The latter are used for the upward and downward movement. The cylinders on each side are joined to one another by an intermediate duct which ensures perfect timing. The pressure in the intermediate duct is restored by solenoid valves YV304a and YV304b. During each cycle the latter join the intermediate chambers to the reduced pressure line. This is accomplished through reducer 166. In order for the cylinders to be precisely positioned, the gauges 196 and 198 should read the values given on the plate. Check periodically. If this does not happen, proceed as directed in paragraph 4.2.2 - INSTALLING AND REMOVING THE DIE-SET. The speed and timing are controlled by the axis control card. The latter, in turn, is controlled by the microprocessor according to the position of the cylinders. Transducers BQ4 and BQ5 are used to monitor this position.

2 - 27

014AZ011A 2

2 - 28

MAIN FEATURES

014AZ011A SAFETY EQUIPMENT AND PRECAUTIONS 3

SAFETY EQUIPMENT AND PRECAUTIONS

3.1

SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE

3

(refer to figure 2.4.1/A)

E0004P

The operator may be injured, cut or get caught in moving machine parts while working in the area where the powder is loaded or in the area around the die set. A number of barrier guards have been provided to prevent the operator from gaining access to these hazardous areas: - Fixed guards on the powder infeed system - Fixed side guards mounted near the press columns - Fixed guards mounted on the front of the press - Fixed guards on the working parts of the filler box infeed system - Front safety bar with mobile guard None of the fixed guards can be removed without using special tools. Furthermore, they will not stay in position unless suitable fasteners are used. The mobile guard is basically a grid which moves when the safety bar when the safety bar is operated. In any case, the size of the steel mesh is such as to prevent access to the hazardous area. When the safety bar is raised, two limit switches – located on the front part of the machine – prevent any powered movements from being performed. Moreover, two mechanical locks are engaged to prevent the plunger from abruptly moving down. Two interlocking devices, which are triggered by the powder infeed system, are found at the rear of the machine. When the feeder is not operated and the area at the rear of the die-set is clear, only the plunger can move slowly down (at a speed of less than 16 mm/sec) by using self-maintained pushbuttons. The press is also provided with two red emergency stop buttons (on a yellow background). One button is located on the control panel while the other is to be found at the rear of the press. These buttons are to be pressed whenever an emergency situation arises, causing the machine to stop and the oil in the hydraulic accumulators as well as in the pump to be drained. The machine is to be reset whenever an emergency stop button has been pressed. The hydraulic system is provided with a pressure relief valve 112a set to the maximum allowable value. This ensures trouble-free operation and prevents the pressure in the hydraulic system from exceeding the permitted levels in the presence of malfunctioning. In addition, a safety valve 71 is on the hydraulic reservoir so as to prevent the pressure from exceeding 2.25 bar. The pressure setting cannot be changed as the valve is sealed.

3-1

014AZ011A 3

SAFETY EQUIPMENT AND PRECAUTIONS

Reference standards EN 292-1

Safety of machinery - Basic concepts, general principles for design. Part 1: Basic terminology, methodology. EN 292-2 Safety of machinery - Basic concepts, general principles for design. Part 2: Technical principles and specification. EN 294 Safety of machinery - Safe distances to prevent danger zones being reached by the upper limbs. EN 349 Safety of machinery - Minimum gaps to avoid crushing of parts of the human body. EN 418 Safety of machinery - Emergency stop equipment, functional aspects. Principles for design. EN 953 Safety of machinery - Guards. General requirements for the design and construction of fixed and movable guards. EN 982 Safety of machinery - Safety requirements for fluid power systems and their components. Hydraulics. EN 983 Safety of machinery - Safety requirements for fluid power systems and their components. Pneumatics. EN 1088 Safety of machinery - Interlocking devices associated with guards. Principles for design and selection. EN 12692: 1999 Machines for ceramic industry Safety of presses

3-2

014AZ011A SAFETY EQUIPMENT AND PRECAUTIONS 3.2

3

NORME GENERALI

E0004P

INSTALLATION Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations in force in your country. It is extremely important that the machine is properly connected to adequate earth electrodes. SACMI shall not be held responsible for any property damage or personal injury resulting from improper installation. SAFETY DEVICES & GUARDS The machine comes equipped with electrical and/or mechanical safety devices which safeguard the machine and the operator. The safety devices and guards provided MUST NOT be removed or inactivated under any circumstances. SACMI shall not be liable for any damage or injury if the machine operator fails to observe these precautions. CHECKS, REPAIRS & MAINTENANCE Do not perform any checks, repairs or maintenance operations on moving parts. Use clearly visible signs to warn all personnel of possible danger. Before carrying out these operations, disconnect the electricity supply by using the main switch. The main switch is to be padlocked in the “power off” position so that the machine cannot be started up accidentally. To ensure overall machine efficiency and trouble-free operation, it is essential that the directions supplied by SACMI are followed and that the required maintenance is carried out. It is advisable to periodically check all of the safety devices for proper functioning and the insulation of the electrical cables. The latter must be replaced if damaged. LIVE ELECTRICAL PARTS It is severely forbidden to work on or near live electrical parts. The electrical cabinet doors must be kept locked with key and warning signs signaling potential danger must be placed on them Before opening the electrical cabinets or switchboards, disconnect the electricity supply with the main switch. QUALIFIED PERSONNEL The assembling, disassembling and servicing of the machine must be performed by qualified personnel. When carrying out these operations, always use adequate equipment and follow the instructions provided. MACHINE NOT IN USE If the machine is not going to be used for a long period of time, it is to be made inoperative by disconnecting the power lead from the mains and applying all the required safety devices.

3-3

014AZ011A 3 3.3

SAFETY EQUIPMENT AND PRECAUTIONS INSTALLATION

E0004P

The machine must be placed on concrete foundations as specified by SACMI. In particular, the foundations should be able to resist the stress applied when the press is operated. The customer should provide the ducts and conduits for the hydraulic lines and electrical wiring. These are to be made in non-slip sheet metal and should conform to current engineering regulations. If the machine comes with a conventional knockout, the well must be provided with fixed covers which can only be removed by using specific tools. The machine must be properly earthed in compliance with current safety regulations. SACMI shall not be held responsible for injury to personnel or damage to equipment if the machine is improperly installed. Machine assembly, installation and commissioning are to be performed by the Manufacturer’s personnel, therefore the relevant procedures are not described herein.

3.4

HANDLING PROCEDURES

E0004P

SLINGING THE LOAD To properly and safely lift the machine, always follow the directions below: - Use adequate lifting equipment. - Cover all sharp edges. - Check the safety device the hook is provided with. - Do not move the load unless it is securely slung. Before lifting: - Make sure all personnel are away from the machine. - Make sure the load does not sway. - Make sure all parts which may fall are secured in position. - Lift the machine vertically in order to prevent collision with anything placed nearby HANDLING The load should always be lifted and handled with the aid of sticks, levers and grapples. Never use your hands! The person in charge of handling and lifting must always: - Know where the machine is to be carried. - Instruct the crane operator from a visible position. - Stop the operations if hazardous situations occur (e.g. personnel passing by). PLACING THE LOAD Before the load is placed in position: - make sure the floor is level and strong enough. Never place loads near: - Exits - Fire fighting equipment - Passageways - Control panels - Power lines The load is to be placed on suitable supports in order to keep it stable and help the personnel remove the sling. Never place containers in bad condition with protruding parts on top of each other. Never stack parts to a height which may affect stability.

3-4

014AZ011A SAFETY EQUIPMENT AND PRECAUTIONS 3.5

3

PERSONNEL TRAINING

E0004P

The factory supervisor should see that the machine operators: - meet the requirements listed below; - have fully understood the instructions contained in the manual; - are well trained on how to safely carry out their tasks; - have received specific instructions on how to operate the machine correctly. The machine operators should: - understand the instructions provided and have specific experience in operating this type of machine - be sufficiently educated so as to be able to read and fully understand the contents of this manual as well as the drawings provided - have a good technical background (in the electric, mechanical, hydraulic and pneumatic fields) so that they are able to safely carry out the jobs they are responsible for as specified in the manual - know all the safety rules and regulations in force in the country where the machine is installed i.e.: - general rules (regarding hygiene and on-the-job safety as well as work accident prevention) - specific rules (for the type of product being manufactured) The maintenance staff should be employed on the basis of the same criteria. In addition, they must be qualified in specific technical fields (mechanical, electric, hydraulic and pneumatic) so that they can safely carry out the operations they are responsible for (as specified in the manual). Tasks the operator and maintenance staff are and are not responsible for The operations for running and maintaining the machine the personnel is responsible for (operation, routine maintenance, special maintenance) are subdivided in the various parts of this manual. It is fundamental that the members of the staff carry out only the tasks in the areas they are specifically responsible for (mechanical, electric, hydraulic and pneumatic fields).

3-5

014AZ011A 3 3.6

SAFETY EQUIPMENT AND PRECAUTIONS OPERATING INSTRUCTIONS

E0004P

The machine comes equipped with electrical and/or mechanical safety devices which safeguard the press and the operator. The press must be used in accordance with the instructions provided by the manufacturer otherwise these devices cannot ensure maximum safety. Moreover, the safety devices and guards provided MUST NOT be removed or inactivated under any circumstances. The Manufacturer shall not be liable for any damage or injury if the machine operator fails to observe these precautions. The controls and devices the machine is provided with will only guarantee maximum safety if a powder infeed system approved by SACMI is used. Furthermore, only die sets, which employ a suitable upper punch lock, are to be used. The upper punch locking system may use permanent magnets or be of the mechanical or electro-mechanical type. In this case, a special mechanical system is used to prevent the punches from inadvertently moving down. The manufacturer of the die-set is responsible for any risks that derive from the tools. The press can operate in three modes. Simply turn the selector switch located on the control panel to automatic, manual and set-up. Automatic operation When the machine runs in automatic mode the personnel do not need to perform any operations. A number of barrier guards have been provided to prevent the personnel from gaining access to the hazardous areas (i.e. around the dieset). In particular: - Fixed guards are mounted on the powder infeed system - Fixed guards at the sides of the press near the columns. The guards include an access door which can be opened with special tools, thus allowing the operator to visually check machine functioning without gaining access to hazardous areas of the machine. - Fixed guards are on the working parts of the filler box infeed system. The strokes of the filler box should be set when the machine is stopped. - Front safety bar with mobile guard. This bar is wired up to the microprocessor-based control system. When the bar is completely down, it prevents the operator from gaining access to the work areas during the production run. All the guards have been placed at a safe distance as recommended by current safety standards (EN 294). The front guards also include a tile ejector. The latter, in turn, should be provided with fixed covers so as to prevent access to the die-set (figure 3.6). If the front safety bar is raised, two mechanical locks are engaged to prevent the plunger from abruptly moving down. This arrangement prevents the press from performing any hazardous powered movements which may harm the operating personnel. Moreover, the plunger can be raised so as to disengage the mechanical locks and allow single parts of the die-set to be moved so as to perform routine cleaning. Manual operation If all the safety devices provided for safe operation in automatic mode are operative, the filler-box, knock-out and plunger can be moved in manual mode. If the safety bar is raised, the filler-box can no longer be moved. The knock-out can be moved and the plunger can be raised to disengage the mechanical locks. “Set-up” Only the maintenance personnel can operate the machine in this mode. The plunger moves slowly up and down (< 16 mm/s) so as to replace the die-set. In this case, the filler-box slide at the rear or the front tile ejector is to be removed so as to gain access to the machine. Do not perform any operations with the machine running. To install the die-set, see chapter 4 - INSTALLATION PROCEDURES. The press is also provided with two emergency stop buttons . One button is located on the control panel while the other is to be found at the rear of the press. These buttons are to be pressed whenever an emergency situation arises, causing the machine to stop and the oil in the pump to be drained.

3-6

014AZ011A SAFETY EQUIPMENT AND PRECAUTIONS

3

HOW TO INSTALL THE MACHINE The diagram below illustrates the lay-out of the machine as foreseen by the manufacturer. The machine will run properly only if configured as shown in the figure. The device for removing and handling the pressed products, is not an integral part of the machine. However, top safety cannot be ensured unless this device is installed. This device has to be fitted with an electro-mechanical sensor that sees whether the tile discharge belt has been positioned. This sensor has to be series connected to the other safety switches installed on the press. Figure 3.6 - RULES FOR OPERATION

TILE KNOCKOUT

C1327

3.6.1

CLEANING

Stop the machine to clean it. Follow the procedure below: - Fully raise the plunger by pressing buttons 25 & 3 located on the control panel. - Raise the safety bar and, at the same time, operate the lever located at the side.

E0004P

WARNING!

When cleaning the die-set, the personnel must wear adequate clothing for protection against heat. For more thorough cleaning, perform the same procedures as recommended for maintenance.

3-7

014AZ011A 3 3.7

SAFETY EQUIPMENT AND PRECAUTIONS MAINTENANCE

To ensure machine efficiency and trouble-free operation, keep to the instructions outlined by SACMI when performing the routine maintenance described in chapter 8 - MACHINE MAINTENANCE. In particular, periodically check all the safety devices and the emergency stop buttons for proper functioning. Make sure the electrical cables are well insulated and replace them if damaged. Check that the ground electrodes are efficient. The maintenance personnel should have the qualifications indicated in the PERSONNEL TRAINING paragraph contained in this chapter. Before performing any maintenance, carry out the following operations: 1) Fully raise the plunger by pressing buttons 25 & 3 located on the control panel. 2) Raise the safety bar and, at the same time, operate the lever located at the side. 3) Turn the main pump off by pressing key 4. 4) Press the emergency stop button. 5) Disconnect the supply by using the main switch. The latter can be locked in its “OFF” position so as to prevent the machine from being accidentally started up. Use a padlock (not provided). 6) Drain the oil from aux. equipment accumulators 12 by switching over die-set solenoid valves YV22 manually until the knockout no longer moves. 7) Drain the upper accumulators by switching over either “cylinder pressure” solenoid valve YV19 and/or “downstroke and upstroke” solenoid valves YV32s and YV32d manually at the same time. 8) If accumulators 141 and 337 are installed, they have to be drained with valves 143 and 339. When working above shoulder height, use adequate means as recommended by current safety practises. Furthermore, the maintenance personnel should use all personal safety gear called for by the job.

E0004P

WARNING!

Do not use any machine parts as hand-holds. LIVE ELECTRICAL PARTS Never work on or near electrical parts. The electrical cabinet doors must be locked and provided with visible warning signs. Before gaining access to the electrical cabinet, turn the main switch to the “Off” position.

3.8

MACHINE NOT IN USE

If the machine is to remain inoperative for a certain period of time, proceed as follows: 1) Fully raise the plunger by pressing buttons 25 & 3 located on the control panel. 2) Raise the safety bar and, at the same time, operate the lever located at the side. 3) Press key 4 to shut off the main pump. 4) Press the emergency stop button. 5) If supplied, drain the oil from the hydraulic accumulators 141 & 337 by using the valves 143 and 339. 6) Disconnect the machine from the electricity supply by unplugging the power cable.

3.9

DECOMMISSIONING THE MACHINE

When decommissioning the press, refer to Chapter 9, DECOMMISSIONING.

3-8

014AZ011A INSTALLATION PROCEDURES 4

INSTALLATION PROCEDURES

4

Figure 4.1 - LIFTING AND PLACING THE PRESS

Only SACMI personnel are authorized to install and commission the machine.

4.1

HOW TO LIFT AND PLACE THE PRESS IN POSITION

Use ropes and other suitable equipment when lifting the press. Always follow the safety regulations in force in your country. To properly place the press, refer to the foundation plan provided.

E0004P

IMPORTANT

Follow the instructions given for lifting the machine in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS. The load must always remain perfectly horizontal (regardless of the type of equipment used for hoisting) while being moved.

C1831

E0009C

EQUIPMENT

- Pair of ropes - Pair of safety clamps

4.2

PH 1890

kg 51.000

PH 2590

kg 64.000

PH 2090

kg 51.000

PH 2890

kg 64.000

CONNECTIONS

The connections must be performed by qualified personnel. Carefully follow the instructions provided by the manufacturer.

E0004P

WARNING!

As there are a number of electronic converters inside the electrical cabinet, make sure the ground fault circuit interrupters on the power supply are of the B type (as recommended by CEI 64-8 specifications, par. 532.2.1.4 thereby ensuring adequate protection against leakage currents.

4-1

014AZ011A 4 4.2.1

E0004P

INSTALLATION PROCEDURES EARTH CONNECTION

WARNING!

The machine has to be effectively earthed. Hook the machine up to the external protective circuit. The connection point is marked PE (EN60445). Depending on the type of electrical cabinet employed, the connection point is located: - on the copper bar located on the bottom of the electrical cabinet (see figure 4.2/A). - on the side of the main switch (see figure 4.2/B). In addition, hook the connection points on the machine frame up to the external protective circuit. These points are marked with the

symbol (417-IEC-5019).

Earth the machine (C) and perform the connections between the crosshead and the plunger (A-B). Join the earth wires (D & E) as shown in the DIE-SET WIRING DIAGRAM figure. The points where the earth connections are to be made should be free of paint. Any paint present should be removed before the relative screws are tightened in order to ensure perfect electrical continuity.

E0004P

WARNING!

Failure to earth the machine may cause serious personal injury as well as equipment damage.

Figure 4.2/A - EARTH CONNECTION

Figure 4.2/C - EARTH CONNECTION

A

Figure 4.2/B - EARTH CONNECTION

B

C C0202

4-2

014AZ011A INSTALLATION PROCEDURES 4.2.2

4

INSTALLING AND REMOVING THE DIE-SET

SPE C1820

4.2.2.1 Removing and installing die-set in presses with SPE REMOVING THE DIE-SET Preliminary operations: DIE-SET LIFT = 0 is set on the DIE-SETS/SPE page.

E0004P

WARNING!

If the die-set comes with magnetic punches, they have to be disengaged before the die-set is removed, otherwise it will be very difficult to take them out. To disengage the upper and lower magnetic punches, proceed as follows: Select “UPPER AND LOWER MAGNETIC PUNCHES = YES”. Press keys 31 - 15 and 31 - 11. The LEDs built into keys 15 and 11 will go out as soon as the magnetic locks have been disengaged. At this point, “YES” disappears from the display. To remove the die-set, proceed as directed below: 1) Make sure the die-set is fully down and the plunger is completely up. 2) Raise the bar and fit the adjustable spacers between the upper part of the die-set and the lower pads (“isostatic” pads are to be removed). The spacers must be properly positioned, each spacer should correspond to a knockout cylinder.

E0004P

WARNING !

The spacers must be properly positioned between the upper and lower parts. Take care not to damage the punches when performing this operation. 3) 4) 5) 6) 7)

8) 9) 10) 11) 12) 13) 14)

15) 16)

Store the pressure value given on gauge 196. Work on reducer valve 166 and bring the pressure to 0 bar. Check the value given on gauge 196. Turn the key switch to SET-UP. Press keys 28 and 16 to start the cycle for LOCKING/UNLOCKING the die-set. The machine will automatically carry out the cycle. With the spanner provided, release the die-set by working on the devices provided for this purpose found on the left-hand (cylinder 180a1) and right-hand (cylinder 180b2) sides. Make sure they are completely opened by turning them at least four and a half times. Set reducer valve 166 to the value previously memorized. Press keys 28 and 16 to complete the cycle for LOCKING/UNLOCKING the die-set. Go to the SPE/DIE-SET page and set DIE-SET REMOVAL = 1 Make sure DIE-SET LOCKED = NO Make sure the encoders are free and have been zero set. With the filler-box connected to the press, make certain the mobile part is not over the die-set. Carry out the SELF-LEARNING procedure. Press die-set key (13) and the green key (28) at the same time. The procedure is automatically executed. The procedure is considered completed only if an upstroke and downstroke have been carried out without any faults and is memorized while power is being delivered. Loosen and remove the screws that secure the die-set mounting plate to the knockout. Place four spacers between the block for the mobile part and the die. They should be high enough to assure the mobile part is secured to the fixed part of the die-set. Place the spacers in the corners of the block or in the point foreseen by the die-set manufacturer.

4-3

014AZ011A INSTALLATION PROCEDURES

4

SPE C1820

17) 18) 19) 20)

Block the die-set encoder. Go to the SPE/DIE-SET page and set DIE-SET REMOVAL = 2 Make sure DIE-SET LOCKED = NO Carry out the upstroke. Press the die-set key (13) and up arrow key (25) at the same time to carry out the upstroke.

E0004P

IMPORTANT!

The movement can be reversed during the upstroke and downstroke by pressing the down arrow key (30) or up arrow key (25) and then the die-set key (13). The cylinders will move either up or down after a brief pause as required. 21) When the die-set is fully up, place two spacers (supplied with the machine) 70 mm up between the knockout and table track. 22) Move the knockout cylinders down so that the die-set can rest on the spacers and the plugs can be removed from the die-set. Press die-set key (13) and the down arrow key (30) at the same time to execute the downstroke. 23) Bring the equipment (fork lift truck) for transfering the die-set near the die-set. 24) Lift the die-set up being careful not to damage the knockout cylinder plugs and die-set sensing cylinders. 25) Move the die-set away from the press bed. DIE-SET INSTALLATION Preliminary operations: a) Fully raise the plunger b) Raise the front bar c) Select “Set-Up” mode d) Thoroughly clean the parts of the press and the knockout which come into contact with the die set and lubricate with oil e) Thoroughly clean the two die-set feelers with gasoline making sure they are able to move in a regular manner.

E0004P

WARNING!

DO NOT clean the two die-set feelers with oil or grease f)

Remove the die-set from the packing container by using adequate lifting equipment and place it on two support blocks so that it is at least 10 cm from the floor.

E0004P

WARNING!

When moving the die-set, refer to the safety instructions concerning the handling of overhead loads. Do not use levers, shims etc... to lift the die-set. g) h) 4-4

Move the die-set near the press by using a fork lift truck. Check the fasteners for efficiency and completely open them by using a suitable spanner.

014AZ011A INSTALLATION PROCEDURES

4

SPE C1820

To install the die-set proceed as follows: 1) Make sure the knockout cylinders are fully down. Block the encoders that monitor when the mobile part of the dieset is down with the stop levers provided. 2) Load the die-set onto the fork of the lift truck. Gently raise the die-set making sure the fork is properly positioned in relation to the load’s centre of gravity . 3) Move the lift truck close to the press so that the die-set can be transferred from the fork to the four spacers (h = 58) on the knockout. Be careful not to damage the knockout cylinder plugs and die-set sensing cylinders. 4) Place the die-set in the middle of the press. Make sure it is properly centered back-forth and to the right-left. 5) Make sure the four gauged spacers are on the die-set between the die and block. The spacers should be in the corners of the block or in the points foreseen by the die-set manufacturer. If a mobile die is used, connect the hydraulic die support line and pressurize it so that the die can be moved fully up and then put in the spacers. 6) Go to the SPE/DIE-SET page and set DIE-SET REMOVAL = 2 7) Make sure DIE-SET LOCKED = NO 8) Carry out the UPSTROKE. Press the die-set key (13) and up arrow key (25) at the same time to carry out the upstroke. Make certain the plugs correctly enter the boxes for locking the die-set during the upstroke.

E0004P

IMPORTANT!

The movement can be reversed during the upstroke and downstroke by pressing the down arrow key (30) or up arrow key (25) and then the die-set key (13). The cylinders will move either up or down after a brief pause as required. 9) Remove the four spacers (h = 70) on the knockout. 10) Allow the knockout cylinders to perform the downstroke so that the die-set can rest on the table and be centered with the two pins. Press the die-set key (13) and down arrow key (30) at the same time to carry out the downstroke. 11) Remove the die-set from the four spacers found between the die and mobile block. If a mobile die is used, connect the hydraulic die support line and pressurize it so that the die can be moved fully up and then remove the spacers. 12) Fully tighten all the screws used to fix the die-set mounting plate to the knockout. 13) Release the die-set encoder. 14) Place the spacers between the upper part of the die-set and lower pads (“isostatic” pads are to be removed). The spacers must be properly positioned, each spacer should correspond to a knockout cylinder.

E0004P

WARNING !

The spacers must be properly positioned between the upper and lower parts. Take care not to damage the punches when performing this operation. 15) 16) 17) 18)

Memorise the pressure value read on gauge 196. Set the pressure of reducer valve 166 to 0 bar. Check the value given on pressure gauge 196. Go to the die-set left page and set DIE-SET LIFT = 0. Press keys 28 and 16 to start the cycle for LOCKING/UNLOCKING the die-set. The machine will automatically carry out the cycle.

4-5

014AZ011A 4

INSTALLATION PROCEDURES

SPE C1820

19) With the spanner provided, release the die-set by working on the devices provided for this purpose found on the left-hand (cylinder 180a1) and right-hand (cylinder 180b2) sides. Make sure they are completely closed by unscrewing them at least four and a half turns. 20) Set reducer valve 166 to the value previously memorized. 21) Press keys 28 and 16 to complete the cycle for LOCKING/UNLOCKING the die-set. 22) Go to the die-set lock page and set DIE-SET LOCKED = YES

E0004P

WARNING!

Set only after the die-set has been locked. 23) Remove the spacers. 24) Set the upper and lower stop limits (A and B) as well as the speed at which the upstroke and downstroke are to be performed. 25) Turn the PLC off and then back on to zero set the encoder for the new die-set. 26) Check the set data by moving the die-set with the machine set to SET-UP NOTE: With the “Set-Up” mode enabled, the press operates at a speed lower than 16 mm/s.

E0004P

WARNING!

Do not make any adjustments with the machine running. 27) Turn the key to MANUAL. 28) Make sure reducer valve 166 is properly set. a) with the oil temperature at approximately 45° C and the die-set raised, reach the value given on pressure gauge 198 being careful to read the gauge only after the accumulator has been recharged; b) move the die-set down and adjust reducer valve 166 by reading pressure gauge 196. It should read the pressure given in the chart below:

4-6

014AZ011A INSTALLATION PROCEDURES VALUE READ ON PRESSURE GAUGE 198 40 BAR 45 BAR 50 BAR 55 BAR 60 BAR 65 BAR 70 BAR 75 BAR 80 BAR 85 BAR 90 BAR 95 BAR 100 BAR 105 BAR 110 BAR 115 BAR

4

SET PRESSURE GAUGE 196 TO 40 BAR 44 BAR 47 BAR 51 BAR 55 BAR 59 BAR 62 BAR 66 BAR 70 BAR 74 BAR 77 BAR 81 BAR 85 BAR 89 BAR 92 BAR 96 BA

29) Allow the plunger to rest on the die-set. 30) Fasten the upper part of the die-set to the plunger. 31) Make the electrical and air connections required to operate the press (refer to paragraphs CONNECTING THE DIESET HEATER and CONNECTING THE MAGNETIC LOCK). 32) Warm the die-set up to the required temperature, as recommended by the manufacturer. 33) Set the punches to the correct position. 34) Secure the punches in place with the permanent magnets or the magnetic locks by turning the key switch to SETUP. With MAGNETIC LOCK = YES function active, press keys 26 and 15, 26 and 11. The LEDs built into keys 15 and 11 will come on once the magnetic locks have been applied. When the magnetic locks are applied, also engage the mechanical fasteners. 35) Loosen and retighten the screws which hold the die/s in place. 36) Move the punches several times to ensure they are not obstructed in any way. 37) Check all the magnetic locks provided for proper operation. 38) After operating a few minutes, check the pressure values to assure they have not been modified in any way otherwise repeat the procedure indicated at points 28a) and 28b).

4-7

014AZ011A 4

INSTALLATION PROCEDURES

SPE C1820

INSTALLING THE DIE-SET IN THE PRESS USING THE “EMERGENCY PROCEDURE”

E0004P

WARNING!

This procedure should be used only when the die-set encoder cannot be zero set. This situation occurs when there is a power failure and the die-set has already been removed therefore the die-set encoder cannot be zero set.

E0004P

IMPORTANT!

This procedure should NOT be used when the die-set is on the press as the encoder can always be zero set. When removing the die-set, carry out these preliminary steps: a) Fully raise the plunger b) Raise the front bar c) Select “Set-Up” mode d) Thoroughly clean the parts of the press and the knockout which come into contact with the die set and lubricate with oil e) Thoroughly clean the two die-set feelers with gasoline making sure they are able to move in a regular manner.

E0004P

WARNING!

DO NOT use oil or grease f) Remove the die-set from the packing container by using adequate lifting equipment and place it on two support blocks so that it is at least 10 cm from the floor.

E0004P

WARNING!

When moving the die-set, refer to the safety instructions concerning the handling of overhead loads. Do not use levers, shims etc... to lift the die-set. g) Move the die-set near the press by using a fork lift truck. h) Check the fasteners for efficiency and completely open them by using a suitable spanner.

4-8

014AZ011A INSTALLATION PROCEDURES

4

SPE C1820

To install the die-set proceed as follows: 1) Make sure the knockout cylinders are fully down. Block the encoders that monitor when the mobile part of the dieset is down with the stop levers provided. 2) Load the die-set onto the fork of the lift truck. Gently raise the die-set making sure the fork is properly positioned in relation to the load’s centre of gravity . 3) Move the lift truck close to the press so that the die-set can be transferred from the fork to the four spacers (h = 70) on the knockout. Be careful not to damage the knockout cylinder plugs and die-set sensing cylinders. 4) Place the die-set in the middle of the press. Make sure it is properly centered back-forth and to the right-left. 5) Make sure the four gauged spacers are on the die-set between the die and block. The spacers should be in the corners of the block or in the points foreseen by the die-set manufacturer. If a mobile die is used, connect the hydraulic die support line and pressurize it so that the die can be moved fully up and then put in the spacers. 6) Go to the SPE/DIE-SET page and set DIE-SET REMOVAL = 3 7) Make sure DIE-SET LOCKED = NO 8) Carry out the UPSTROKE (emergency operation). Press the die-set key (13) and up arrow key (25) at the same time to carry out the upstroke. Make certain the plugs correctly enter the boxes for locking the die-set during the upstroke.

E0004P

IMPORTANT!

Make certain the plugs correctly enter the die-set locking boxes while the movement is being carried out.

E0004P

IMPORTANT!

The movement can be reversed during the upstroke and downstroke by pressing the down arrow key (30) or up arrow key (25) and then the die-set key (13). The cylinders will move either up or down after a brief pause as required. 9) Remove the four spacers (h = 70) on the knockout. 10) Allow the knockout cylinders to perform the downstroke so that the die-set can rest on the table and be centered with the two pins. Press the die-set key (13) and down arrow key (30) at the same time to carry out the downstroke.

E0004P

IMPORTANT!

The movement can be reversed during the upstroke and downstroke by pressing the down arrow key (30) or up arrow key (25) and then the die-set key (13). The cylinders will move either up or down after a brief pause as required. 11) Remove the die-set from the four spacers found between the die and mobile block. If a mobile die is used, connect the hydraulic die support line and pressurize it so that the die can be moved fully up and then remove the spacers. 12) Fully tighten all the screws used to fix the die-set mounting plate to the knockout. 13) Release the die-set encoder.

4-9

014AZ011A INSTALLATION PROCEDURES

4

SPE C1820

14) Place the spacers between the upper part of the die-set and lower pads (“isostatic” pads are to be removed). The spacers must be properly positioned, each spacer should correspond to a knockout cylinder.

E0004P

WARNING !

The spacers must be properly positioned between the upper and lower parts. Take care not to damage the punches when performing this operation. 15) 16) 17) 18) 19)

20) 21) 22)

Memorize the pressure value read on gauge 196. Set the pressure of reducer valve 166 to 0 bar. Check the value given on pressure gauge 196. Go to the DIE-SET/SPE page and set DIE-SET REMOVAL = 0. Press keys 28 and 16 to start the cycle for locking/unlocking the die-set. The machine will automatically carry out the cycle. With the spanner provided, release the die-set by working on the devices provided for this purpose found on the left-hand (cylinder 180a1) and right-hand (cylinder 180b2) sides. Make sure they are completely closed by unscrewing them at least four and a half turns. Set reducer valve 166 to the value previously memorized. Press keys 28 and 16 to complete the cycle for locking the die-set. Go to the die-set lock page and set DIE-SET LOCKED = YES

E0004P

WARNING!

Set only after the die-set has been locked. 23) Remove the spacers. 24) Set the upper and lower stop limits (A and B) as well as the speed at which the upstroke and downstroke are to be performed. 25) Turn the PLC off and then back on to zero set the encoder for the new die-set. 26) Check the set data by moving the die-set with the machine set to manual or SET-UP.

NOTE: With the “SET-UP” mode enabled, the press operates at a speed lower than 16 mm/s.

E0004P

AWARNING!

Do not make any adjustments with the machine running. Adjust the die-set as directed from step 27 to 38.

4 - 10

014AZ011A INSTALLATION PROCEDURES

C1819

4

SMU

4.2.2.2 Installing the die-set in presses with SMU The die-set should be removed and installed by qualified personnel as indicated in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS. Only die sets which employ the following types of upper punch locks can be used 1) mechanical 2) with permanent magnets 3) electro-magnetic type with mechanical safety locks The die-set can be installed or removed by gaining access to the front or rear part of the machine. In any case, remove the powder infeed system or the tile collector so as to leave sufficient space around the press. Preliminary operations: a) Fully raise the plunger b) Raise the front bar c) Select “Set-Up” mode d) Thoroughly clean the parts of the press and the knockout which come into contact with the die set and lubricate with oil Two systems can be used to move the die-set into the press: - a fork lift truck; - special equipment for example trolleys with lift systems or roller decks.

E0004P

WARNING!

When moving the die-set, refer to the safety instructions concerning the handling of overhead loads. Perform the following operations regardless of the means used to move the die-set. 1) Remove the die-set from the packaging using adequate lift systems. Place the die-set on 2 shims so that it is raised approximately 10 cm from the floor. 2) Protect the forks of the truck to prevent damaging the die-set. 3) Place the forks under the die-set Slightly raise it, making sure the forks lift it symmetrically in relation to the center of gravity. 4) Make sure the press and die-set are thoroughly clean. 5) Bring the die-set under the plunger, making sure the it is perfectly centered in relation to the press’ elements: press columns and plunger for centering lengthwise and crosswise). 6) Remove the forks of the truck from the press or the roller surface from the lower part of the die-set. To do this, raise the die-set in one of the following ways: a) if the die-set is mounted on SMU, it is provided with four rests so that it can be easily raised b) if the press is fitted with quick change devices, the die-set can be hooked to the plunger and then moved up c) if the press or die-set are not provided with autonomous lift devices, hydraulic cylinders can be used as long as the conform with current safety regulations.

E0004P

WARNING!

Devices that are not suitable for lifting the die-set for example, levers, shims, etc.. must never be used.

4 - 11

014AZ011A 4

INSTALLATION PROCEDURES

C1819

SMU

7) Secure the base plate of the die-set to the press’ bed 8) Move the front bar down NOTE: the machine is in set-up therefore it can run at a maximum speed of 10 mm/s.

E0004P

WARNING!

Never carry out any type of operation while the machine is running. 9) Move the plunger until it rests on the die-set 10) Secure the upper part of the die-set to the plunger 11) Hook up the die-set and connect it to the pneumatic system so that it can operate (see the CONNECTING THE DIE-SET HEATER and the MAGNETIC LOCK CONNECTIONS paragraphs). 12) Bring the die-set to the required temperature within the limits determined by the die-set manufacturers 13) Center the punches 14) Secure the punches in place with permanent magnets or electromagnets, in the latter case a mechanical emergency locking device must be installed 15) Loosen and then retighten the fixing screws of the die and/or dies. 16) Move the punches a number of times to make sure they move freely 17) Make sure any magnetic locks installed are properly set

4.2.3

E0004P

CONNECTING THE DIE-SET HEATER

IMPORTANT!

Proceed as illustrated in figure 4.2.4 - DIE-SET WIRING DIAGRAM The connections must be properly performed. Failure to do so may result in severe damage to the columns and cylinder. - Do not reverse the wires between the upper and lower heating element. - Connect both wires of the upper heating elements to the die set. Do not connect one wire to the die set and the other to the plunger. - Do not earth the secondary winding of the die-set heater transformer. - Make sure that the earth connection is effective.

4 - 12

014AZ011A INSTALLATION PROCEDURES

4

4.2.4 CONNECTING THE MAGNETIC LOCK - Join the cables and connector XJ6 as shown in figure 4.2.4 - DIE-SET WIRING DIAGRAM

E0004P

WARNING!

Reversing one or more wires may cause severe damage to the machine. Figure 4.2.4 - DIE SET WIRING DIAGRAM HEATER 510-511 Upper punch cables 514-515 Lower die cables 516-517 Lower punch cables D E

MAGNETIC LOCK 911-912 Lower plate cables 921-922 Connector XJ6 (upper plate cables)

Lower punch holder-die earth cable Machine base-die earth cable

922 921

XJ6

510

D

511 514

E 515

516 517

912 911

C0524

4.2.5

CONNECTING THE DUST EXTRACTION SYSTEM

Connect the machine to the dust extraction system. The latter must meet SACMI specifications.

4 - 13

014AZ011A 4

4 - 14

INSTALLATION PROCEDURES

014AZ011A START-UP PROCEDURES 5

START-UP PROCEDURES

5.1

GENERAL

5

After the press, filler box and die-set have been properly installed, the plunger must be up and the safety bar raised (limit switch SQ51 must be energised and limit switch SQ52 must be de-energised).

5.2

PRELIMINARY CHECKS

The numbers or symbols which identify the hydraulic, pneumatic or electric components refer to the HYDRAULIC AND PNEUMATIC DIAGRAMS. The functions of the pushbuttons and selector switches are shown in the figures in the CONTROLS paragraph in chapter 6 - OPERATING INSTRUCTIONS chapter. 5.2.1 CHECKING THE CONNECTIONS: MAKE THE FOLLOWING CHECKS: - Make sure that the die-set heating elements are properly earthed. - Check the magnetic lock of the upper and lower punches for efficiency. The lights built into buttons 11 and 15 should come on. - Check that the press is connected to the workshop earth electrodes. Check the connecting cable between the plunger and the cross-head for condition. - Make sure that the oil level in the reservoir on the top of the press is correct. - Make sure that the pressure in the hydraulic system is within the correct operating range as indicated in the SPECIFICATIONS paragraph. - Make sure that the tile thickness gauge leads are properly connected. - Make sure that the filler-box limit switches and the interlocks on the safety bar are properly wired and set to their correct operating positions. - Make sure that the device which warns that the filter is clogged is properly wired. - Check the powder detector (located on the filler-box feed hopper) for efficiency. - Check that the controller and the tile transfer (placed immediately before the press) are properly connected (conditions when the machine is started up and stopped).

5.2.2 MOTOR M3 Press button 20 on the control keyboard to start “oil leak collector” pump motor M3 and make sure it runs in the right direction.

5.2.3 MOTOR M11 Start motor driven pump M11 that cools down and filters the oil by pressing push-button 0 found on the keyboard. Check the direction of rotation.

5.2.4 MOTOR M1 After pump M11 has run for at least three minutes, completely loosen the knob on safety valve 111. Start main motor M1 by pressing push-button 0 located on the control keyboard. Turn off the motor after approx. two seconds by pressing push-button 4. Check the direction of rotation of the motor after it has run for a short time. Wait for the motor to stop. Restart motors M11 and M1, let them run for a few seconds and then stop them. Idle the motor for a few minutes so that the air in the ducts and controls can be eliminated. Keep key 28 on the control keyboard pressed and gradually tighten the knob on the valve 111 to bring the pressure in the circuit to 100 bar. Make sure that there are no oil leaks at the hose fittings.

5-1

014AZ011A START-UP PROCEDURES

5

5.2.5 SETTING THE PRESSURE VARIABLE DISPLACEMENT PUMP PRESSURE Set the safety pressure by following the directions given in the ADJUSTING THE VARIABLE DISPLACEMENT PUMP paragraph found in chapter 7 - ADJUSTMENT PROCEDURES. 5.2.6 TOP DEAD-CENTER POSITION Raise the plunger to its top dead-center position by using keys 3 & 25 on the control keyboard. The main cylinder should reach its top dead-center position while the pressure in the hydraulic power unit (shown on pressure gauge 13) increases until the preset value entered during the test procedure (equal to operating pressure) is obtained. See chapter 7, ADJUSTMENT PROCEDURES. 5.2.7 SAFETY DEVICES Lower the safety bar. The filler-box is now able to perform its movements. Before performing any movements, check emergency stop buttons 24 for efficiency. 5.2.8 AUXILIARY EQUIPMENT PRESSURE Set the initial operating pressure to 150 bar. Enter this value onto the “FILLING SET UP” video page. 5.2.9

FILLER-BOX

DCL C1821

5.2.9.1 Filler-box (DCL) Make sure: - The filler-box is properly positioned and secured. - The slide plate is level with the die. - The filler-box guides are aligned and centered. - The mobile part of the filler-box is properly adjusted. - The brush is properly adjusted (if provided). - The powder feeder (ALM) is properly adjusted (if provided). - All electric connections have been properly made. - The safety guards are secured in place. Set the values for the end of the forward and return strokes (distance in mm in relation to the zero setting of the guides). Zero set the filler-box encoder by pressing keys 28 and 5. Carry out some filler-box strokes in manual mode to see whether the values for the end of the forward and return strokes are correct. Make sure limit switch SQ59 is properly set. Limit switch SQ59 provides the trigger for the plunger to move down. It should be triggered only once the mobile part of the filler-box is out of the danger zone.

5-2

014AZ011A START-UP PROCEDURES

5

DCP 5.2.9.2

Filler-box (DCP)

FILLER-BOX ACTUATED BY A NON-PROPORTIONAL VALVE Set filler box control = NO. Set the 10 speeds of the filler box (from the 1st forward step to the fifth return step) to 100%. Start up the filler box by pressing keys 8 and 29 at the same time. Block the flow regulator in this position. Operate the filler-box so that any air bubbles present can be eliminated from the hydraulic circuit. Carry out a few cycles in semi-automatic mode (press key F8 to select a semi-automatic loading cycle, then press buttons 28 and 2 with the mode selector key turned to AUT) making sure that the filler box always reaches the end of its stroke safely, i.e. the limit switch should be effectively triggered. Make sure that the filler box encoder setting shown on the display is lower than the value set for the end of the return stroke (usually a few mm). FILLER-BOX ACTUATED BY A PROPORTIONAL VALVE Set filler box control = NO. et the GAIN item (RP2) to its max. value and set the 10 speeds of the filler box (from the 1st forward step to the fifth return step) to 100%. Start up the filler box by pressing keys 8 and 29 at the same time. In any case, it must be greater than the presumed working speed. Block the flow regulator in this position. Set the GAIN item (RP2) to 50% and then operate the filler box so that any air bubbles can be removed from the hydraulic circuit. Carry out a few cycles in semi-automatic mode (press key F8 to select a semi-automatic loading cycle, then press buttons 28 and 2 with the mode selector key turned to AUT) making sure that the filler box always reaches the end of its stroke safely, i.e. the limit switch should be effectively triggered. Make sure that the filler box encoder setting shown on the display is lower than the value set for the end of the backward stroke (usually a few mm). Under the conditions described above (speed 100% and RP2= 50%), the speed of the filler box must be at least equal to the max. operating speed required to produce tiles of the correct size. if it is not, increase RP2 until the desired speed is reached.

SPE C1820

5.2.10 KNOCKOUT CONTROL (SPE ONLY) Move the encoders that monitor the position of the mobile part of the die-set down and secure in place. With the plunger raised and safety bar up, select SET-UP mode and go to the DIE-SET/SPE page. Set DIE-SET REMOVAL = 3 and make sure DIE-SET LOCKED = NO. Loosen the screws to bleed the air located over the knockout cylinders and control assemblies. Press the keys that move the die-set up and down a number of times until the air has been bled. Install the die-set as directed in the INSTALLING AND REMOVING THE DIE-SET paragraph. Release the encoders. Set values A and B for the end of the upstroke as well as the upstroke and downstroke speeds. Zero set the knockout encoders.

5-3

014AZ011A 5

START-UP PROCEDURES

5.3

ADJUSTMENT PROCEDURES

5.3.1

KNOCKOUT ADJUSTMENT

C1819

SMU

5.3.1.1 Adjusting the SMU knockout Set the pressure for the cylinder (which holds the die) to approx. 80 bar when a die-set with through-punches is used (50 bar with a mirror-finished die set). To set the pressure, work on relief valve 140 and observe the reading given on pressure gauge 142. Adjust the knockout speed by using restrictor 61. To adjust the speed for the first die-set downstroke work on restrictor 23 until a suitable speed is obtained. To adjust the speed for the second die-set downstroke, work on restrictor 242 until the die set rests on the base plate without banging on it. Check the first die-set downstroke by pressing buttons 13 and 30 once or twice so that the lower punch is ready to perform the second downstroke. Measure the distance between the lower punch and the upper surface of the die. If the distance is not correct, allow the die-set to rest on the base plate again by pressing push buttons 13 and 30. Push buttons 26 or 31, while keeping button 12 pressed, to increase or decrease the soft filling setting until the desired value is reached.

SPE C1820

5.3.1.2 Adjusting the SPE knockout Enter the settings for the die-set and knockout (upper stop limits A and B) and then set the upstroke and downstroke speeds (0 to 100%). If desired, enable the KNOCKOUT BTW PUNCHES function. IF KNOCKOUT BTW PUNCHES <>0, “delayed die-set upstroke” will be ignored. Set the intermediate and last downstroke in the same way. Make sure the die-set gently rests on the base plate. Lastly, check the settings for moving near the die-set as follows: 1) Move the die-set up. 2) Make sure the punches are close to the die-set. If this is not so, move the cursor to the upper stop limit and press the “+” and “-” keys on the keyboard to adjust the height of the cylinders on the left-hand side (cylinders 180a1 and 180a2) 3) Check the right-hand side (cylinders 180b1 and 180b2). If the die-set has been properly constructed it should be close to the die. If this is not the case, set the max. offset (B-A) until proper conditions are achieved. When the oil has reached its normal operating temperature (approx. 45°C), repeat the procedure from step 1.

5-4

014AZ011A START-UP PROCEDURES

5

5.3.2 PRELIMINARY ADJUSTMENTS TO THE HYDRAULIC SYSTEM The press was properly set before leaving the factory. The information given below should be used to make sure that the settings have not been altered. LOGIC ELEMENT ASSEMBLY Component

Operated by

Preliminary adjustment PH 1890/PH 2090

Preliminary adjustment PH 2590/PH 2890

120 119 118 117 116 131

YV38 YV70 YV70 YV19 YV40 YV41

Open by 9 turns Open by 1.25 turns Open by 12.5 turns Open by 3 turns Open by 3 turns Open by 7 turns

Open by 9 turns Open by 1 turn Open by 8 turns Open by 4 turns Open by 3 turns Open by 9 turns

ACCUMULATOR CONTROL ASSEMBLY Component

Operated by

Preliminary adjustment PH 1890/PH 2090

Preliminary adjustment PH 2590/PH 2890

115 108 109 174

YV53 YV32s YV32d YV47

Open by 12 turns Open by 8 turns Open by 6 turns Open by 5.5 turns

Open by 12 turns Open by 8.5 turns Open by 8 turns Open by 6 turns

5-5

014AZ011A START-UP PROCEDURES

5 5.3.3

ADJUSTING THE SPEED OF THE FILLER-BOX

DCL C1821

5.3.3.1 Filler-box speed setting (DCL) SETTING (DCL) Once the filler-box has been inspected for proper operation, set the speeds for each of the 5+5 steps which form the total stroke of the filler box (expressed in % from 0 to 100). This indicates the actual aperture of the control valve. An optimal speed range is thus determined in order to suit the product to be obtained. To properly load the powder, determine the position in which the filler-box must be when the die-set performs its first downstroke. Simulate a number of filler-box cycles in semi-automatic mode. Press pushbuttons 8 & 27 to check the filler-box for proper operation before loading the working material. If the value entered for the FILL.-BOX APPROACH POS. data item during the filler-box return stroke is greater than zero, plunger downstroke will be triggered once the FILL.-BOX APPROACH POS. setting has been passed. As soon as the filler-box reaches the end of its return stroke, the ALM cycle will start. The filler-box will reach the value set for the FILL.BOX APPROACH POS. data item after the grid has been loaded. The filler-box will run at the set APPROACH SPEED. When set to manual mode, the filler-box runs at a constant speed equal to that set for SPEED IN MANUAL MODE. When set to automatic and semi-automatic modes, the filler-box runs at the set speeds. A cycle can carried out with the ALM stationary. Loading takes place while the ALM is stationary. In this case, the grid is loaded through filler-box operation. In this case, the FILLING STROKE will equal the APPROACH STROKE. POWDER INFEED (DCL) Properly set the ALM feeder (see relevant manual). Select the desired type of loading: grid loaded while the ALM is stationary or grid loaded with ALM running. Set the time for the “DELAYED LOADING” data item. This is the length of time the hopper gate stays open. Set the “GATE CLOSING DELAY” time. This is the amount of time which elapses from when the hopper reaches the position in which the gate closes and the gate actually closes. A special cycle can be selected if double rows of tiles have to be pressed. This is done by setting 2-ROW FILLING = YES. In this case, three values have to be entered in the PLC. The first refers to the point at which the gate closes during the stroke for loading the ALM after the first row has been loaded. The second refers to the point at which the gate opens during the loading stroke to load the second row while the last one refers to the point at which the gate closes after the second row has been loaded. Move the filler-box completely backward and let powder into the feed hopper. Set the number of strokes to be performed (from right to left) during each cycle (set 1 or 2 strokes. If 50 is entered the ACP will move non-stop). Fill the die-set a few times in semi-automatic mode and make the required modifications (if the loading cycle is found to be inaccurate). After this preliminary phase has been completed, leave the die cavities full of powder. The ALM can carry out an overtravel during its return stroke to zero set the filler-box encoder. This may also be useful when installing and removing the grid. Timed filler-box and knockout operations can also be carried out during loading. In particular, the knockout can perform up to 5 movements during the filler-box return stroke, starting from the 1st downstroke position. The following are set for each movement: filler-box setting at the start of the movement, degree to which the die-set moves, filler-box return stroke setting up to setting for 1st downstroke and die-set speed during the movement.

5-6

014AZ011A START-UP PROCEDURES

5

DCP 5.3.3.2 Filler-box speed setting SETTING (DCP) Two different systems can be used: FILLER-BOX ACTUATED BY A NON-PROPORTIONAL VALVE Once the filler box has been inspected for proper operation, set the speed levels for the 5 + 5 steps which form the total stroke of the filler box. These are expressed in %: - the filler-box will run at the min. speed if a value between 0 and 75% is set - the filler-box will run at the max. speed if a value between 75% and 100% is set An optimal speed range is thus determined in order to suit the product to be obtained. To properly load the powder, determine the position in which the filler box should be when the die-set performs its first downstroke. Simulate various filler box cycles in semi-automatic mode check the filler box for proper functioning before loading the powder. FILLER-BOX ACTUATED BY A PROPORTIONAL VALVE (OPTIONAL) Once the filler box has been inspected for proper operation, set the speed levels for the 5 + 5 steps which form the total stroke of the filler box. These are expressed in % from 0 to 100 which represent the degree to which the control valve is open in relation to its maximum opening. An optimal speed range is thus determined in order to suit the product to be obtained. To properly load the powder, determine the position in which the filler box should be when the die-set performs its first downstroke. Simulate various filler box cycles in semi-automatic mode to check the filler box for proper functioning before loading the powder. POWDER INFEED (DCP) Two different systems can be used: FILLER-BOX WITH HOPPER AND ACP After the ACP device has been properly set up (see relevant manual), put powder into the filler box infeed hopper. Set the number of strokes to be carried out (from right to left) per cycle (1 or 2 strokes). If 3 is entered, the ACP will operate non-stop. FILLER-BOX WITH ALM MOBILE HOPPER Properly set the ALM device (see relevant manual). Set the “delayed loading”. This is the amount of time the hopper stays open before moving backwards. Set the “gate closing delay”. This is the amount of time which elapses from when the hopper reaches the position in which the gate closes (on the sensor) and the actual closure of the gate. Move the filler-box completely backward and place powder in the feed hopper. Set the number of strokes to be carried out (from right to left) per cycle (1 or 2 strokes). If 3 is entered, the ACP will operate non-stop. Fill the die-set a few times in semi-automatic mode and make the required modifications (if the loading cycle is found to be inaccurate). After this preliminary phase has been completed, leave the die cavities full of powder.

5-7

014AZ011A 5

START-UP PROCEDURES

5.3.4 PLUNGER BRAKING ADJUSTMENT To check the value entered for plunger braking, observe the logic element setting, which should be approx. 80. If it is not, allow the plunger to rest on the powder, press buttons 7 and 26 at the same time to increase the braking force or buttons 7 and 31 to decrease it until 80 is read. At the beginning, inactivate the brake control (SPEED CONTROL ON = NO) and set an adequate braking action (e.g., BRAKING SPACE = 90.00) in order to have safe braking during the first stage. After filling the die-set with powder, perform some downstrokes, adjust the braking action and change the logic element setting until the desired braking force is obtained. Once the machine has been started up, the automatic brake control can be activated. To do this, check that the braking space is ≥ 35.00 (if it is less than 35.00, the automatic brake control cannot be switched on).After the die-set has been filled with powder, determine the correct speed at which the punches should come into contact with the powder and then type YES for the SPEED CONTROL data item and enter the value previously read for the IMPACT SPEED. From this time on, the controller will correct the brake settings until the desired one is obtained so that the impact speed will be kept constant throughout the work-cycle.

5.3.5 PLUNGER PARALLELISM ERROR The press is equipped with two encoders that record the position of the plunger. The parallelism error during the presscycle can be established by simply comparing these measurements. This will prevent deformed products resulting from excessive inclination from being produced. The maximum allowable error can be set from the microprocessor controller (PRESSING SET-UP page). If a message indicating incorrect plunger inclination appears, check the loading state.

5.3.6 PLUNGER MOTION SETTING Read the setting entered to begin the press-stroke (punches on the powder). Slowly lower the plunger until the punches come into contact with the powder, read the plunger encoder setting (expressed in “mm” and which refers to the end of its upward stroke) and enter the setting for the IMPACT POS. Turn the key switch to “WRITE” to enter a sufficiently long temporary value to indicate that there is no powder (STOP, NO POWDER = 180.00). In this case, the control will no longer be active. Enter a setting for the end of the upward stroke (plunger up). Remember that the last setting should allow the filler-box to move freely. Enter YES for UPSTROKE BRAKING ON as well as the value for end of braking while the plunger moves up again. Allow the plunger to move up and down in manual mode with the die cavity full of powder.

5.3.7 SETTING THE PRESS-CYCLE Enter the data related to the press-cycle. Enter the number of press-strokes per cycle, the pressure settings (expressed in bar) for the first, second and (if necessary) third press-strokes. Also enter the delay time (expressed in milliseconds) for the first press-stroke as well as the first and (if necessary) second de-aeration stage. These settings should correspond to the size of the tiles to be obtained. Fill the die-set with powder in semi-automatic mode (with selector 23 set to automatic, select semi-automatic loading by pressing key F8; then press pushbuttons 28 and 2 respectively). After making sure that the powder is evenly distributed in the die cavities, perform a press-cycle in semi-automatic mode with selector 23 turned to automatic (to select the semi-automatic mode, press key F8 and pushbuttons 28 and 2 respectively). Fill the die-set approx. ten times and perform the same number of press-cycles in semi-automatic mode in order to eliminate the air in the hydraulic system and allow the automatic pressure regulators to make the required corrections. Once the tile has been properly formed, measure its thickness and adjust the level of the soft filling by pressing the pushbuttons (26 “+”) or (31 “-”) with the die-set down. Press push-button 12 to obtain tiles of the desired thickness. After the tiles have been produced, (THICKNESS CTRL IMPULSE = 0) the displayed thickness should equal the measured one), perform other press-cycles in semi-automatic mode and make sure the measured thickness corresponds to the reading given. If it does, the automatic thickness correction device can be switched on (THICKNESS CTRL IMPULSE > 0 and TILE THICKNESS = desired thickness).

5-8

014AZ011A START-UP PROCEDURES

5

5.3.8 DE-AERATION ADJUSTMENT Adjust de-aeration proportioner 89 by working on the limit screw. The system can be adjusted so that the plunger carries out a de-aeration stroke that ranges from 0 to 3.4 mm.

5.3.9 ADJUSTING THE DIE-SET PROTECTION DEVICE (FOR LACK OF POWDER) Inspect the automatic thickness gauge for proper functioning. The tile must not be too thin, as this may severely damage the die-set. Enter the setting for PLUNGER SHUTDOWN when there is not enough powder. It should be equal to the max. allowable stroke for the plunger during the press-cycle. Make sure the plunger can move down a further 0.5 mm approx. in relation to a tile of the desired thickness. Once this setting has been entered, make sure the relevant fault message is actually displayed when the plunger moves below the preset level.

5.3.10 AUTOMATIC CYCLE Check the oil level with the plunger lowered and make sure that the die-sets have reached the desired temperature. Read the die-set temperatures. With the temperature properly set, make sure the die-set moves freely. Thoroughly clean the die and start the automatic work-cycle by pressing pushbuttons 28 & 2 at the same time. During the first workstages keep the process zone under control so that emergency stop button 24 can be pressed immediately in case of malfunctioning. If there are no problems, allow the machine to run for a few minutes. Stop the work-cycle by pressing push-button 6 then check the finished product and correct as required. If tiles are to be ejected during the last cycle, enter YES for “EJECTION WHEN STOPPING”. If not, enter NO. NOTE: The corrections which require work on the press body or filler box should be made with the machine stopped. The set data set or hydraulic parts can be corrected while the machine is running. When good-quality products are obtained, duplicate the program (see the Instructions B manual) and make any adjustments required to increase productivity.

5-9

014AZ011A START-UP PROCEDURES

5 5.3.11

SWITCHING ON THE FILLER-BOX SPEED CONTROLLER

DCL C1821

5.3.11.1 Switching on the filler-box speed controller Once the press has been started up and the tiles have been properly formed (i.e. the die-set has been loaded correctly), the speed controller is switched on (FILLER-BOX CONTROL ON = YES). At this point, the time the filler box takes to perform the forward and return strokes is set (this should correspond to the time previously measured to perform the forward and back strokes). The control system sees whether the time error is 5% greater than the set time. In this case, a fault message will appear. If the error is more than 10% greater than the set time, the press will shut down.

DCP 5.3.11.2 Switching on the controller for maintaining the speeds set for filler-boxes actuated by a proportional valve (optional) (DCP) The press comes with an electronic device which energizes solenoid valves YV20a to correct any interferences which may affect the speeds set for the powder feeder. When starting up the machine, switch off this control device (filler box control on = NO). When the press has been started up and the tiles are found to be properly formed (the die-set has been properly filled), the control is switched on (filler-box control = YES). Set the times for the filler box forward and return strokes (the times set should be the same as those previously read for the forward and return strokes). Check that the gain for the forward and return strokes are between 145-155. If they are not, work on RP2 (in the controller) until the desired values are displayed (max. allowable value, RP2=70%).

5 - 10

014AZ011A OPERATING INSTRUCTIONS 6

OPERATING INSTRUCTIONS

6.1

CONTROLS

6

The following are used to control and monitor press operation: - CONTROLLER Comes provided with all the controls necessary to operate the press as well as all the diagnostic routines required to identify any fault conditions which may arise during process. - KEYBOARD Provided with all the keys required to program and control machine operation. - ELECTRICAL CABINET Contains all the control equipment for the motors, heaters and magnetic locks. Figure 6.1 - CONTROLS

CONTROLLER ELECTRICAL CABINET

KEYBOARD

C1836

All the information concerning the programming procedures and machine operation is found in the manual “USE OF THE MICROPROCESSOR BASED CONTROL SYSTEM”. IMPORTANT - “PROGRAMMING” refers to all the information required to perform a work-cycle in automatic mode. - To enable the programming mode, insert the key into the switch found on the controller keyboard. - Only authorised personnel can perform programming procedures as altering the stored data may result in severe damage to the machine. - It is advisable to keep a file of the programs loaded by using the sheets provided.

6-1

014AZ011A 6

OPERATING INSTRUCTIONS

6.1.1 CONTROLLER The programmable logic controller comes with a microprocessor system. Use the computer terminal provided to: - set up the work cycle and make modifications to the programmed work stages even when the machine is cycling. - display messages and typical process variables; - store and retrieve the data related to each pre-set press cycle; - automatically localise and “diagnose” faults; - monitor the operating pressures; - automatically gauge tile thickness; - automatically control the machine in the event of system failure.

Figure 6.1.1/A - CONTROLLER

SYSTEM CARDS

• • •

C1836

MACHINE CONTROL KEYBOARD COMPUTER TERMINAL NOTE: A detailed description of each section is given on the following pages.

6-2

014AZ011A OPERATING INSTRUCTIONS Figure 6.1.1/B - (CONTROLLER) SYSTEM CARDS

6

C1471

SYSTEM CONFIGURATION Location of cards 1-4 5 6 7 8 9 10 11-12-13 14-15-16 17-18 19 20-21

AL CPU VA IA IE IE AX ID OD ODA

POWER SUPPLY (rectified supply voltage) Central processing unit MISCELLANEOUS ANALOG INPUT ENCODER INPUT ENCODER INPUT AXES DIGITAL INPUTS (24 Vdc signals) DIGITAL OUTPUTS (energise the 24Vdc outputs) ANALOG & DIGITAL OUTPUTS (not used) RELAY OUTPUTS

OR

C2099

1

RACK - PLC

2

3

4

AL

5

6

7

8

9

10 11 12 13 14 15 16 17 18 19 20 21

CPU VA IA IE IE AX ID

ALIMENTSUPPLY AZIONE POWER

DATA ELABORAZIONE PROCESSING

INGRESSI INPUTS

ID ID OD OD OD

ODA ODA

OR OR

USCITE OUTPUTS

The configuration given above is for reference purposes only. For more detailed information, refer to the INSTRUCTIONS B manual, Chapter 2 “LIST OF DEVICES”.

6-3

6-4

B

A

24

F1

4

5

I

6

2

I

F4

7

3

F5

12

8

F6

13

9

F7

14

10

F8

15

11

20

16

21

17

-

0

22

18

2

5

1

4

8

.

R

+5

A2

A1

P

SC

SL

WD

3

6

9

19-23

MAN SET UP

E N T E R

+

AUT

G

F

E

B

27

DEL LINE

DEL CHAR

SCREEN

A2

A1

END

HOME

OFF

30

I 28

25

H

QUIT

D

WRITE

31

–

+

26

PAG

PAG

ON

29

Figure 6.1.1/C1 - (CONTROLLER) COMPUTER TERMINAL

1

R

I

0

F3

F2

C

7

-

SC

SL

WD

R

6

SMC 085-11-409 SMC 085-11-442

+5

014AZ011A OPERATING INSTRUCTIONS Figure 6.1.1/D1 - (CONTROLLER) MACHINE CONTROL KEYBOARD

014AZ011A OPERATING INSTRUCTIONS

6

Figure 6.1.1/C2 - (CONTROLLER) COMPUTER TERMINAL A B C D E F G H

25 line x 80 column, electro-luminescent display unit Function keys Numeric keypad Write enable key switch Not used Deletes last character typed in Deletes last line typed in Cursor control keys C0628

ELECTRO-LUMINESCENT DISPLAY UNIT The press comes with an electro-luminescent display unit on which the following are displayed: - fault messages - machine data - production data - actual settings - list of the programs stored - set points and any modifications made to them NOTE: To read out data, consult the INSTRUCTIONS B MANUAL.

Figure 6.1.1/D2 - (CONTROLLER) MACHINE CONTROL KEYBOARD FUNCTION Pump start Alarm reset Automatic cycle start Start of semi-automatic loading Semi-automatic press cycle start Plunger upstroke Plunger downstroke Plunger upstroke at low speed Plunger downstroke at low speed Pump stop Oil filtering unit pump stop Repositioning - Encoder reset Automatic cycle stop Braking force increase Braking force decrease Filler box forward Filler box return Punches in Punches out Upper die-set release Upper die-set lock Tile thickness increase Tile thickness decrease Die-set upstroke Die-set downstroke Lower die-set release Lower die-set lock Proportional knockout engagement Proportional knockout disengagement ALM in semi-automatic mode CP in semi-automatic mode Oil-leak collector pump start/stop ALM forward ALM back CP in manual mode Emergency stop

1st KEY

28* 28* 28* 25 30 25 30

28 26 31 29 27 25 30 31 26 26 31 25 30 31 26 28 28 28 28 29 27 27 or 29

2nd KEY Ø 1 2 2 2 3 3 3 3 4 4 5 6 7 7 8 8 9 9 11 11 12 12 13 13 15 15 16 16 17 18 20 21 21 22 24

KEY SWITCH

PUMP

AUT AUT AUT MAN/AUT MAN SET-UP SET-UP

ON ON ON ON ON ON ON

AUT

ON

MAN/AUT MAN/AUT MAN MAN MAN/SET-UP MAN/SET-UP SET-UP SET-UP MAN/AUT MAN/AUT MAN/SET-UP MAN/SET-UP SET-UP SET-UP SET-UP SET-UP AUT AUT

ON ON ON ON

ON ON

ON ON ON ON

MAN MAN MAN

Note: For more detailed information, consult the Instructions B manual.

C0628

Note: * press the F8 key to set up the work cycle. + Nearly all the procedures require the use of two keys. However, some procedures can be carried out with the use of just one key. In this case, the key to be pressed is indicated in the “2nd KEY” column. 6-5

6-6

A

24

F1

F2

0

5

I

1

R

F4

6

2

I

F5

F6

7

3

F7

12

8

F8

13

9

F9

14

10

F10

15

11

F11

X

Z

BKSP

CTRL

20

16

ALT

SHIFT

21

17

ESC

CAPS LOCK

22

18

C

DEL

TAB

C

D

E

INS

A2

A1

P

SC

SL

WD

R

+5

0

1

4

7

N

H

Y

)

1

5

&

19-23

MAN SET UP

PAGE DOWN

PAGE UP

+

B

V =

G

F

"

T

R

AUT

"

2

5

27

>

@

%

*

"

3

6

9

(

:

30

I 28

25

E N T E R

#

<

_

^

+

;

P

M 8

L

K

J

O

I

U

31

–

+

26

SMC 085-11-449

29

C1421

Figure 6.1.1/E1 - (PERSONAL COMPUTER) (OPTIONAL)

4

I

F3

S

A

SPACE

W

Q

6

SMC 085-11-442

B

014AZ011A OPERATING INSTRUCTIONS Figure 6.1.1/F1 - (PERSONAL COMPUTER) MACHINE CONTROL KEYBOARD

014AZ011A OPERATING INSTRUCTIONS

6

Figure 6.1.1/E2 - (PERSONAL COMPUTER) (OPTIONAL) A B C

Color display Function keys Mouse

COLOR DISPLAY The press comes with an electro-luminescent display unit on which the following are displayed: - fault messages - machine data - production data - actual settings - list of the programs stored - set points and any modifications made to them NOTE: To read out data, consult the INSTRUCTIONS B MANUAL.

Figure 6.1.1/F2 - (PERSONAL COMPUTER) MACHINE CONTROL KEYBOARD

FUNCTION Pump start Alarm reset Automatic cycle start Start of semi-automatic loading Semi-automatic press cycle start Plunger upstroke Plunger downstroke Plunger upstroke at low speed Plunger downstroke at low speed Pump stop Oil filtering unit pump stop Repositioning - Encoder reset Automatic cycle stop Braking force increase Braking force decrease Filler box forward Filler box return Punches in Punches out Upper die-set release Upper die-set lock Tile thickness increase Tile thickness decrease Die-set upstroke Die-set downstroke Lower die-set release Lower die-set lock Proportional knockout engagement Proportional knockout disengagement ALM in semi-automatic mode CP in semi-automatic mode Oil-leak collector pump start/stop ALM forward ALM bac CP in manual mode Emergency stop

1st KEY

28* 28* 28* 25 30 25 30

28 26 31 29 27 25 30 31 26 26 31 25 30 31 26 28 28 28 28 29 27 27 or 29

2nd KEY Ø 1 2 2 2 3 3 3 3 4 4 5 6 7 7 8 8 9 9 11 11 12 12 13 13 15 15 16 16 17 18 20 21 21 22 24

KEY SWITCH

PUMP

AUT AUT AUT MAN/AUT MAN SET-UP SET-UP

ON ON ON ON ON ON ON

AUT

ON

MAN/AUT MAN/AUT MAN MAN MAN/SET-UP MAN/SET-UP SET-UP SET-UP MAN/AUT MAN/AUT MAN/SET-UP MAN/SET-UP SET-UP SET-UP SET-UP SET-UP AUT AUT

ON ON ON ON

ON ON

ON ON ON ON

MAN MAN MAN

Note: * press the F11 key to set up the work cycle. + Nearly all the procedures require the use of two keys. However, some procedures can be carried out with the use of just one key. In this case, the key to be pressed is indicated in the “2nd KEY” column.

Note: For more detailed information, consult the Instructions B manual. 6-7

014AZ011A 6 6.1.2

OPERATING INSTRUCTIONS ELECTRICAL CABINET

The electrical cabinet delivers electrical power to the motors of the hydraulic power unit and the press as well as to the die-set heater and the magnetic locks. Figure 6.1.2 - ELECTRICAL CABINET V A

Voltmeter Ammeter

V

A

QS1

C1211

6-8

014AZ011A OPERATING INSTRUCTIONS 6.2

START-UP AND SHUTDOWN PROCEDURES

6.2.1

ROUTINE START-UP PROCEDURE

6

The machine is started up from the control panel by pressing button “0”. The circulating pump will start running the first time this button is pressed while the main motor comes into operation when the button is pressed again.

E0004P

WARNING:

Never press Enable button 28 on the controller during the start up procedure. To start the automatic cycle, refer to the Instructions B Manual.

6.2.2

MACHINE SHUT DOWN

The machine can be stopped in two ways: - from the controller, by pressing key 6; - from the outer shutdown circuit (KA300).

6.2.3

STOPPING THE MACHINE IN EMERGENCIES

The machine is provided with two emergency stop buttons – one is located on the control panel while the other is to be found on the rear of the machine. When these red, mushroom-shaped buttons are pressed in, the machine and related equipment placed before it stop cycling. When the stop button is pressed: - the hardware of the solenoid valves that control the plunger is disabled; - the hardware of the motors that drive the powder loading system is disabled; - the hardware of the hydraulic power unit motors is disabled. As a result, the machine stops running and the oil in the hydraulic accumulators is drained automatically. Note that hydraulic accumulators 337 and 141 (if provided) are to be drained manually by using the valves 339 and 143. To restart the machine, proceed as follows: - Pull out the emergency stop button; - Reset the machine; - Carry out the procedure described in paragraph 6.2.1.

6.2.4

SHUTDOWN DURING A POWER FAILURE

In the event of a power failure the press automatically switches over to safe conditions. In fact, if there is a power shortage, valve YV107, directly connected to the power supply, is de-energized. As a result, the oil in the accumulators flows to the upstroke chamber and the plunger reaches the top end-stop at low speed (< 16 mm/s).

6.2.5

SHUTDOWN DURING AUTOMATIC OPERATION

If the press shuts down while running in automatic mode, the plunger automatically reaches the end-stop so that it can be locked in place. In fact, YV31s is energized in these cases joining the accumulators to the upstroke chamber. As a result, the plunger is pushed up to the end-stop.

6-9

014AZ011A OPERATING INSTRUCTIONS

6 6.3

PRESSURE-LOAD GRAPHS

PH 1890 PRESSURE-LOAD GRAPH The total force applied by the press results from the pressure exerted by the central cylinder (F). The pressure exerted by the central cylinder is indicated in column “P”. The corresponding thrusting force (F) can be read on the left-hand side by drawing a horizontal line. Once the total thrusting force has been found (F), the value must be marked at the ordinates in the graph. When the dimensions of the unfired tiles and the number of die cavities are known, the total surface area to be pressed (S) can be found. The value expressed in sq. cm is recorded at the abscissa. The straight line which intersects a certain point (whose co-ordinates represent the two values previously found) indicates the specific pressure applied to the tiles. Figure 6.3/A - PH 1890 PRESSURE-LOAD GRAPH

4-275 x 275

4-275 x 275

9-110 x 220

7-150 x 300

5-220 x 330

3-330 x 330

4-275 x 275

5-210 x 315 7-150 x 150

2-440 x 440 4-220 x 440 3-360 x 360

5-220 x 220

1-650 x 650

F (kN)

P (bar)

18000

318

16000

283 00

50

14000

45

00

00

00

40

35 q cm N/

247 00 30

211

12000 2500

178

10000 2000

140

8000 1500

6000

104

4000

71

5000

4500

4000

3500

3000

2500

2000

1500

1000

S (cm2)

C1207

Cylinder cross-section = 5674 sq. cm

6 - 10

014AZ011A OPERATING INSTRUCTIONS

6

PH 2090 PRESSURE-LOAD GRAPH The total force applied by the press results from the pressure exerted by the central cylinder (F). The pressure exerted by the central cylinder is indicated in column “P”. The corresponding thrusting force (F) can be read on the left-hand side by drawing a horizontal line. Once the total thrusting force has been found (F), the value must be marked at the ordinates in the graph. When the dimensions of the unfired tiles and the number of die cavities are known, the total surface area to be pressed (S) can be found. The value expressed in sq. cm is recorded at the abscissa. The straight line which intersects a certain point (whose co-ordinates represent the two values previously found) indicates the specific pressure applied to the tiles.

Figure 6.3/B - PH 2090 PRESSURE-LOAD GRAPH

4-275 x 275

4-275 x 275

9-110 x 220

7-150 x 300

5-220 x 330

3-330 x 330

4-275 x 275

5-210 x 315 7-150 x 150

2-440 x 440 4-220 x 440 3-360 x 360

5-220 x 220

F (kN)

P (bar)

1-650 x 650

20000

352

18000

318

16000

283 00

00

50

14000

45

00

00

40

35 q cm N/

247 30

00

211

12000 2500

178

10000 2000

140

8000 1500

6000

104

4000

71 5000

4500

4000

3500

3000

2500

2000

1500

1000

S (cm2)

C0293

Cylinder cross-section = 5674 sq. cm

6 - 11

014AZ011A OPERATING INSTRUCTIONS

6

PH 2590 PRESSURE-LOAD GRAPH The total force applied by the press results from the pressure exerted by the central cylinder (F). The pressure exerted by the central cylinder is indicated in column “P”. The corresponding thrusting force (F) can be read on the left-hand side by drawing a horizontal line. Once the total thrusting force has been found (F), the value must be marked at the ordinates in the graph. When the dimensions of the unfired tiles and the number of die cavities are known, the total surface area to be pressed (S) can be found. The value expressed in sq. cm is recorded at the abscissa. The straight line which intersects a certain point (whose co-ordinates represent the two values previously found) indicates the specific pressure applied to the tiles.

Figure 6.3/C - PH 2590 PRESSURE-LOAD GRAPH

4-275 x 275

4-275 x 275

9-110 x 220

7-150 x 300

5-220 x 330

3-330 x 330

4-275 x 275

5-210 x 315 7-150 x 150

5-220 x 220

2-440 x 440 4-220 x 440 3-360 x 360

F (kN)

1-650 x 650

2-540 x 540

1-650 x 1300 2-650 x 650

1-810 x 810

P (bar)

25000

352

24000

338

22000

310

20000

282

18000

254

16000

226 00

00

50

14000

45

00

00 35

40

q cm N/

197

00

30

169

12000 250

0

141

10000 0 200

113

8000 0 150

85

6000

56

4000

8500

8000

7500

7000

6500

6000

5500

5000

4500

4000

3500

3000

2500

2000

1500

1000

S (cm2)

Cylinder cross-section = 7088 sq. cm C0624

6 - 12

014AZ011A OPERATING INSTRUCTIONS

6

PH 2890 PRESSURE-LOAD GRAPH The total force applied by the press results from the pressure exerted by the central cylinder (F). The pressure exerted by the central cylinder is indicated in column “P”. The corresponding thrusting force (F) can be read on the left-hand side by drawing a horizontal line. Once the total thrusting force has been found (F), the value must be marked at the ordinates in the graph. When the dimensions of the unfired tiles and the number of die cavities are known, the total surface area to be pressed (S) can be found. The value expressed in sq. cm is recorded at the abscissa. The straight line which intersects a certain point (whose co-ordinates represent the two values previously found) indicates the specific pressure applied to the tiles.

Figure 6.3/D - PH 2890 PRESSURE-LOAD GRAPH

4-275 x 275

4-275 x 275

9-110 x 220

7-150 x 300

5-220 x 330

3-330 x 330

4-275 x 275

5-210 x 315

F (kN)

7-150 x 150

5-220 x 220

2-440 x 440 4-220 x 440 3-360 x 360 1-650 x 650

2-540 x 540

1-650 x 1300 2-650 x 650

1-810 x 810

P (bar)

27500

388

26000 25000

352

24000

338

22000

310

20000

282

18000

254

16000

226 50

14000

00

00 45

00 40

00 35 cm N/ q

30

197

00

169

12000 250

0

141

10000 0 200

113

8000 150

0

85

6000

56

4000

8500

8000

7500

7000

6500

6000

5500

5000

4500

4000

3500

3000

2500

2000

1500

1000

S (cm2)

C0740

Cylinder cross-section = 7088 sq. cm

6 - 13

6 - 14

Figure 6.4.1/A - BAR CHART

T1

C1819

elettrovalvola eccitata Solenoid valve energized elettrovalvola eccitata se sono selezionate le relative opzioni Solenoid valve energized if relative options have been selected END OF UPSTROKE HOPPER GATE CLOSED

END OF UPSTROKE WITH BRAKE APPLIED

END OF DIE-SET UPSTROKE

START OF UPSTROKE

END OF DELAYED DIE-SET UPSTROKE

END OF SECOND PRESS-STROKE

START OF PRESS-STROKE (0PRESSURE BOOSTER ASSISTED)

PRESSURE IN KNOCKOUT INTERMED.DUCT RESTORED

START OF RESTORING PRESSURE IN KNOCKOUT INTERMED. DUCT

START OF DELAY TIME FOR DIE-SET UPSTROKE

START OF DIRECT PRESS-STROKE

END OF DE-AERATION + T2

DE-AERATION

DECOMPRESSION

END OF FIRST PRESS-STROKE

START OF FIRST PRESS-STROKE

PUNCHES ON POWDER

START OF BRAKING

END OF AUX. EQUIPMENT RECHARGE

END OF SECOND DIE-SET DOWNSTROKE

END OF FILLER-BOX TRAVEL START OF DOWNSTROKE HOPPER GATE OPEN

6.4

END OF FIRST DOWNSTROKE

6

START OF FIRST DIE-SET DOWNSTROKE

FILLER-BOX START

014AZ011A OPERATING INSTRUCTIONS

AUTOMATIC CYCLE

In the description that follows the ID numbers and the symbols of the hydraulic, pneumatic and electrical components are also indicated in the HYDRAULIC SCHEMATIC.

YV19 YV32d T2

YV32m

YV32s

YV38

YV39

YV40

YV41

YV47

YV53

YV70

YV99 YV107

YV221

SQ59

SQ60 SQ61

C1820

SPE

YV22a YV22b YV22s YV25 YV304a YV304b

DCP

YV20a

YV20s

SMU

YV21

YV22

SQ3

SQ6

C2340

014AZ011A OPERATING INSTRUCTIONS 6.4.1

6

FILLER-BOX START-UP

DCP 6.4.1.1 Filler-box start-up (DCP) Solenoid valves YV20a and YV20s are energized when cycle start keys 28 & 2 are pressed. The oil provided by pump 58 and aux. equipment accumulator 12 passes through proportional flow control valves YV20a and YV20s start hydraulic motor 42. The motor combined with the gear unit drives the filler-box. With the microprocessor control system, it is possible to select eight different speeds for the forward and return strokes. Limit switch SQ59, mounted on the fillerbox, must be de-energized after the latter has traveled a few millimeters forward. This will prevent the plunger from moving down until the switch is triggered by the filler-box during its return stroke. This will happen a few millimeters before the filler-box stops in its initial start position, i.e. when the encoder reaches the set value. It is important that the position at which solenoid valves YV20a and YV20s are de-energized and the point where the crank stops are within the operating range of limit switch SQ59 (see figure).

Figure 6.4.1/B - FILLER-BOX START-UP ASYNCHRONOUS OPERATION C Crank’s range of action T Tolerance to be observed when repositioning the filler-box backwards 0 Theoretical position of the backward position of the filler-box FC Allowable position when the filler-box is back

T

SQ59 SQ59 TRIGGERED PREMUTO

0% FC C

SQ59 NON TRIGGERED PREMUTO NOT

100%

C0351

DCL C1821

6.4.1.2 Filler-box start-up (DCL) Press cycle start keys 28 and 2 at the same time. Electric motor M20 that drives the filler-box will start running. This motor drives the mobile part of the filler-box through a series of belts. Five different speeds can be set for the forward stroke and five for the return stroke from the microprocessor control system. Miniature switch SQ59, located on the filler box mount, must be triggered after the filler box has moved a few millimeters forwards. In this way, the plunger cannot move down until the miniature switch is triggered again when the filler box performs its return stroke (i.e. a few mm before it stops in its initial position and the encoder reaches the value set for the end of the return stroke).

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6 6.4.2

POWDER INFEED

DCP 6.4.2.1 Powder infeed (DCP) The powder can be fed in the following ways: - a feed hopper with a fixed opening; the powder is fed by gravity and no parts operate during the cycle. - a feed hopper with fully controlled opening; the hopper gate is controlled by solenoid valve YV221. The operator can thereby adjust the amount of powder loaded onto the mobile grid of the filler-box while it is traveling by entering different values for the “loading delay time” and “gate closing delay time” data items.

DCL C1821

6.4.2.2 Powder infeed (DCL) The powder can be fed by a hopper. Opening of the hopper is controlled and can be adjusted. The hopper gate is controlled by solenoid valve YV221. The operator can therefore adjust the amount of powder let into the filler-box’s grid while carrying out its stroke by setting the times for the “LOADING DELAY TIME” and “GATE CLOSING DELAY TIME” data items. 6.4.3

FILLER-BOX OPERATION

DCP 6.4.3.1 FILLER-BOX OPERATION (DCP) The encoder detects the position of the filler-box while it is moving. It is possible to decide the speed range for the fillerbox by entering the set points for the 8+8 steps of the forward and backward strokes (1) into the computer system. To vary the speeds proportionally, modify the value entered for GAIN (RP2) (2). Proportional valve YV20a will control the oil flow from accumulator 12 to motor 42 according to the set points entered. NOTE: (1) The set points are values which range from 0 to 100% and provide a speed range for each individual step. (2) This set point affects the voltage output of the microprocessor control system, increasing or decreasing the valve value.

DCL C1821

6.4.3.2 Filler-box operation (DCL) The encoder monitors the position of the filler-box while it is moving. The speed range for the filler-box can be determined by entering the set points for the 5+5 steps of the forward and backward strokes (1) into the computer system. NOTE: (1) The set points are values which range from 0 to 100% and provide a speed range for each individual step.

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014AZ011A OPERATING INSTRUCTIONS 6.4.4

6

DIE-SET DOWNSTROKES

SPE C1820

6.4.4.1 Die-set downstrokes (with SPE) The die-set downstrokes are carried out in an identical manner by operating cylinders 180a1, 180a2, 180b1 and 180b2. YV22s, YV22a, YV22b and YV25 are energized to move the die-set down. As a result, oil flows from pump 58 and accumulator 12 to the upper part of cylinders 180b1 and 180a2. Simultaneously, the oil in the lower part of cylinders 180a1 and 180b2 is drained. An intermediate duct joins the cylinders together from a hydraulic standpoint, thereby guaranteeing perfect timing. Whenever the die-set rests on the end plate, valves YV304a and YV304b are energized to restore the pressure in the intermediate duct. In fact, these valves see that the oil flows at the pressure set by reducer 166. Use the DOWNSTROKE SPEED data item to adjust the speed at which the die-set moves down. The lower punches stop moving when the microprocessor detects (through encoders) the set values have been reached. In this way, the die-sets perform the downstrokes. The cavity that has been created is then filled with the powder coming from the grid of the filler box. It is important for the 1ST D.STROKE POSITION to be correct as it determines when the powder is to be dropped and when the lower cavities are to be filled. In addition, this operation is related to a number of factors, such as the speed of the filler-box. During this stage, the mobile part of the die-set is controlled by the position transducers. The microprocessor-based controller sees whether the actual position matches with the set one. If this is not the case, the machine will stop and the relevant fault message will appear on the display. During this stage, the mobile part of the die-set should move to its lowest position. If it does not, the press automatically stops working and a fault message will appear on the display. The setting entered (for the end of the return stroke) will cause the filler box to stop in its “rest” position. Before the filler box stops moving, safety switch SQ59 must be triggered. The respective indicator light, located on the front panel of the microprocessor control system, should come on (KA59).

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OPERATING INSTRUCTIONS

C1819

SMU

6.4.4.2 First die-set downstroke (SMU) While the filler-box moves forward, the encoder records the loading position (the relevant setting can be entered into the microprocessor control system) according to the setting for the first downstroke. At this point, solenoid valve YV22 is de-energized, causing the oil to flow from pump 58 and accumulator 12 to the upper part of cylinders 180. Meanwhile, the oil coming from the lower part of cylinders 180 is drained through solenoid valve YV22. The speed for the downstroke can be adjusted with flow regulator 23 (directly mounted on the line). The lower punches stop moving when they reach a limit stop formed by cylinders 181. Solenoid valve YV21 stays on throughout the whole stage. In this way, the die-set performs its 1st downstroke, i.e. the cavity which will be filled with powder (on the grid of the filler box) is created by gravity. It is important that the 1st downstroke setting is correct as it determines when the powder is to be dropped and consequently the lower cavity filled. In addition, this operation depends on a number of other factors, e.g. the speed of the filler-box which is governed by proportional flow control valve YV20a. During this phase, sensor SQ3 must be de-energized (lower punches raised) and the cam brought opposite SQ6. If this does not happen, the machine stops and a fault message will appear on the display.

C1819

SMU

6.4.4.3 Second die-set downstroke (SMU) The filler-box continues to move until it reaches the end of its pre-determined stroke. At this point, solenoid valves YV21 and YV20s are de-energized whereas solenoid valve YV20a is assigned the OFF SET value. While solenoid valve YV21 is de-energized, cylinders 181 for the 2nd downstroke are drained. With solenoid valve YV22 de-energized, the oil delivered increases the pressure in the die-set return cylinder 180. As a result, the pressure generated within the cylinder 181 causes the oil to flow out though flow regulator 242 and solenoid valve YV21 so that the die-set can perform its downward movement. Work on plate-mounted flow regulator 242 to govern the movement. During this phase, it is essential that sensor SQ6 continues to be energized by the respective cam. If it is not, the press automatically stops working and a fault message will appear on the display (refer to the Instructions B Manual). The setting entered for the end of the return stroke will cause the filler box to stop in its rest position. Before the filler box stops moving, safety switch SQ59 must be triggered. The respective Led, located on the front panel of the microprocessor control system (KA59), should go out.

C1819

SMU

6.4.4.4 Additional die-set downstroke (optional with SMU) An intermediate rest for the lower punches allows the powder to be loaded so that two layers can be formed. The punches first rest on cylinders 189, allowing the die-set to perform its downward stroke. At this point, solenoid valve YV170 is de-energized while solenoid valve YV21 stays on. The powder is then loaded so that a second layer can be formed. The punches rest on the press table after solenoid valve YV21 has been de-energized. The speed at which the additional downstroke is performed is governed by plate-mounted flow regulator 169. The cavity can be filled twice when a second filler box triggers a press-cycle at the end of its stroke.

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014AZ011A OPERATING INSTRUCTIONS

6

6.4.5 FAST DOWNSTROKE The following conditions must be satisfied in order for the plunger to start its downward movement: - the lower punches should be fully down (recorded by position sensors) - limit switch SQ59 triggered by the box feeder when fully backwards Under these conditions, the microprocessor control system should receive an electric pulse from solenoid valve YV32d. This will relieve the pressure in the rear part of logic element 109. Simultaneously, YV32m is energized to drain the upstroke chamber of the booster. At this point, the weight of the plunger-and-cylinder assembly combined with the pressure in pre-filling tank 126, pressurises in the annular chamber of the cylinder. This pressure will overcome the push of the spring, thus opening logic elements 174 and 109. The oil is then drained from the annular chamber. The oil will encounter little resistance along the path it follows. As a result, the main cylinder will begin its downstroke as the air pushes the oil through the ports in the main cylinder pressure booster and into the pre-filling tank . The speed during this stage of the downstroke can be adjusted by working on the regulator and opening logic element 109. As this adjustment serves to bring the upper punches as close to the powder as possible, it is advisable to select the highest speed capable of meeting your specific working requirements. 6.4.6 DOWNSTROKE WITH BRAKE APPLIED As soon as the plunger exceeds the set point at which braking starts, solenoid valve YV70 is energised. Logic elements 118 and 119 are closed, shutting the respective drain circuits of the main cylinder and booster. Simultaneously, YV47, which gradually closes logic element 174. The oil is thereby forced through motor-operated flow control 132. As the latter is quite small (DN = 14), the plunger will slow down as it is lowered, causing a back pressure. As a result braking takes place. The pressure relief valve 92 is a protective device which reduces the peak pressures, therefore it must not be used to set the braking system. To adjust the speed at which the upper punches come into contact with the powder, select “SPEED CONTROL ON” = YES and set the “SPEED” to the desired value expressed mm/s. The automatic speed control can only be used if there is a braking space ≥ 35 mm. The program comes with a corrective function which, when activated, reads the impact speed and compares it to the set one. If necessary, motor M15 comes into operation to adjust flow control 132. The speed control can be turned off during braking by selecting “SPEED CONTROL ON = NO”. The length of braking can be changed by selecting: - BRAKING DURING P.CYCLE = YES: Braking is disabled by de-energising solenoid valve YV47 at the start of the 2ND BOOSTED PRESS-STROKE. - BRAKING DURING P.CYCLE = NO: Braking is disabled by de-energising solenoid valve YV47 at the start of the 1ST PRESS-STROKE. 6.4.7 DELAY TIME FOR THE 1ST PRESS STROKE The plunger will continue to move down at the pre-set speed (with braking) until the upper punches come into contact with the powder contained in the die cavities. While the upper punches are being brought close to the powder, the encoder reaches the pre-set point so as to start the press-stroke just before the upper punches come into contact with the powder. At this point, the delay time for the 1st press-stroke starts elapsing. The length of the delay time is set from the microprocessor control system. Throughout this stage, the weight of the cylinder and plunger as well as the pressure exerted by the compressed air are applied to the powder contained in the die cavities. In this way, the powder is compacted for the first time and a certain amount of air is let out. This operation is very important to obtain good deaeration during the next process stages.

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OPERATING INSTRUCTIONS

6.4.8 FIRST PRESS-STROKE Once the delay time has elapsed, the 1st press stroke will begin. The required pressure is set and measured by transducer BP1. The program which runs the microprocessor-based control system monitors the operating pressure, compares it with the set one and, if there are any deviations, corrects them. The hydraulic circuit will now be examined. The microprocessor-based control system transmits a signal to solenoid valve YV40 (1st press-stroke) which is then energised, allowing logic element 116 to open. The logic element permits the oil which comes from pump 58 and accumulators 18, 18a and 18b to flow to pressure booster ass’y 125. The flow rate of the oil can be regulated along with the working speed of the press by turning the adjuster on logic element 116. The accumulators 18 and 18b are brought into action by logic element 115. The latter is operated by solenoid valve YV53, which is energised. The cylinder chamber which has been filled with oil is put under pressure by the piston of the flow booster while the plunger moves down. The oil transmits the pressure through the main cylinder to the plunger. The pressure is shown on the display of the microprocessor-based control system. Remember that the pressure value shown on the display does not take any delay time into consideration and is therefore more accurate than any readings taken by mechanical pressure gauges. The pressure gauge 36 must always be turned off during normal operation and should only be used to read out or set the value. 6.4.9 1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER (WITH OR WITHOUT ACCUMULATORS) To allow the machine to perform the 1st press-stroke without using the pressure booster, select “1ST PRESSSTROKE WITHOUT PRESSURE BOOSTER = YES. The first press-stroke is different from the previous one from a hydraulic standpoint. The program allows for a fixed time during which solenoid valve YV40 is energised, as described in the paragraph above. Once this time has elapsed, solenoid valve YV40 is de-energised and solenoid valve YV19 is energised, thus allowing logic element 117 to open. As the line pressure is higher than that in the section between logic element 117 and the cylinder, the oil will flow into the latter. This will allow the press stroke to be completed without having to use the booster. Obviously, this type of 1st press-stroke should be performed only when a large amount of oil is needed (i.e. with SFS die-sets or any other optional equipment, for very thick tiles made from a dry ground mix, etc..). Selecting “1ST PRESS STROKE WITHOUT PRESSURE BOOSTER = YES” and “1ST SEPARATE PRESS-STROKE = YES” will allow the press-stroke to be performed without the accumulators and pressure booster (see 1st SEPARATE PRESS-STROKE). 6.4.10 1ST SEPARATE PRESS-STROKE The function of the 1st press-stroke is to remove the air from the powder to be compacted. If the first press-stroke is too fast or too abrupt, the air may not be completely released, resulting in defective tiles (i.e. grooves). It may be necessary to perform the 1st press stroke at a slower speed and a steadier pressure. This phase is known as “1st separate press-stroke”. To perform this stage, select “1ST SEPARATE PRESS-STROKE = YES”. The type of 1st press-stroke to be performed depends on the powder to be pressed. Once the delay time for the 1st press-stroke has elapsed, solenoid valve YV40, which opens logic element 116, is energised. At the same time, solenoid valve YV53, which closes logic element 115, is also energised. As a result, accumulators 18, 18a and 18b are shut off. The press-stroke ends when the cylinder reaches the set pressure, without using the accumulators. The action of the main cylinder will be slower and steadier, thus allowing the air to be let out from the powder being pressed. This type of press-stroke requires less power as the pressure in the pump is proportional to that of the cylinder (from “0” up to the max. value). The use of the accumulators would have caused the pump to work at the maximum pressure.

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014AZ011A OPERATING INSTRUCTIONS

6

6.4.11 DEAERATION During deaeration, the upper punches move away from the powder just pressed so that the air compressed in the cavity can be released. Once the 1st press stroke has been completed, the timer which controls deaeration (set from the microprocessor system) starts running. Meanwhile, solenoid valve YV40, which closes logic element 116, is deenergised. Solenoid valve YV70 (cylinder drain) is also de-energised, allowing logic element 118 to open. This logic element eliminates the pressure created during the first press-stroke from the main cylinder, thus opening a passage to reservoir 126. At this point, YV39, which controls de-aeration proportioner 89, is energized. As a result, a 0 to 3.4 mm stroke for deaeration can be performed. Proportioner 89 pushes the plunger up, thus moving the upper punches away from the powder. In this way, the air can let out through the openings in the die-set. Once the time for de-aeration has elapsed, YV39 is de-energized and the proportioner is repositioned. Note that a timer and a suitable space left free allow de-aeration to be performed (upward movement of the plunger, expressed in mm). Obviously, the correct adjustment must be performed in the least amount of time, remembering that the finished tiles must not have any defects in finish. 6.4.12 SECOND PRESS-STROKE (LAST PRESS-STROKE) The last press-stroke is performed in two separate stages, which are: - SECOND DIRECT PRESS-STROKE - PRESS-STROKE WITH PRESSURE BOOSTER 6.4.13 SECOND DIRECT PRESS-STROKE Once the de-aeration time has elapsed, solenoid of valve YV70 is energised to close logic elements 118 and 119. Solenoid valve YV19 is then energised allowing logic element 117 to be opened thanks to the line pressure. As a result, the accumulators will be directly connected to the main cylinder. If the pressure that has been set from the controller is < 180 bar, the second press-stroke will be completed when the set point has been reached. If the set pressure is > 180 bar, YV19 will be de-energised when BP1 has reached an optimum value, thus shutting off the accumulators. At this point, the press-stroke with pressure booster will start. 6.4.14 PRESS-STROKE WITH PRESSURE BOOSTER The first stage of the press-stroke must be performed as described in the paragraph “SECOND DIRECT PRESSSTROKE”. When the pressure in the main cylinder reaches the set value (determined by the control system), solenoid valves YV19 is de-energised to close logic element 117. Solenoid valves YV38 and YV41 are energised, thus allowing logic elements 120 and 131 to open. The oil put under pressure in the pump and the accumulators 18, 18a and 18b flows to pressure and flow booster 125.

PH1890 PH2090 PH2590 PH2890

MAX. ALLOWABLE PRESSURE FOR MAIN CYLINDER (bar) 318 352 350 388

If, for any reason, the max. allowable pressure in the main cylinder is exceeded, pressure switch SP2 (set and sealed during machine inspection at the factory) will come into action to stop the work-cycle. A fault message will appear on the display of the microprocessor control system.

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014AZ011A 6

OPERATING INSTRUCTIONS

6.4.15 SECOND SEPARATE PRESS-STROKE If the second press-stroke has to be carried out at a slower and steadier speed, accumulators 18, 18a and 18b can be shut off by selecting “2ND SEPARATE PRESS-STROKE = YES” in the microprocessor based control system. As soon as solenoid valve YV19 is energised, the electromagnet of valve YV53 (accumulator shut off), which closes logic element 115, is inactivated. The logic element prevents the oil (contained in accumulators 18, 18a and 18b) from flowing into the pressure lines. As a result, only the oil which comes from main pump 58 will fill the main cylinder. Solenoid valve YV53 will be energised as soon as the operating time of solenoid valve YV19 has elapsed. If the pressure setting to be reached in the main cylinder exceeds the line pressure, the pressure booster and the accumulators must be used. This kind of press-stroke allows the user to save on energy as the pressure in the pump is proportional with the pressure in the cylinder. The pressure will not remain at its highest level as when the accumulators are used. 6.4.16

DIE-SET UPSTROKE

SPE C1820

6.4.16.1 Die-set upstroke (SPE) At the beginning of the second press-stroke, the delay time for the die-set upstroke will begin to elapse (the time is set from the microprocessor system). As soon as the delay time has elapsed, solenoid valves YV22s, YV25, YV22a and YV22b will be energised at the same time. The oil will flow from pump 58 and accumulator 12 into the lower part of cylinders 180a1 and 180b2. Simultaneously, the oil will be drained from the upper part of cylinders 180b1 and 180a2. The intermediate duct ensures perfect timing between each pair of cylinders. As a result, the lower punches will move up once the plunger has moved away. The longer the delay time, the more time required for the die-set to move up in relation to the plunger upstroke. If “KNOCKOUT BTW PUNCHES = 0” is set, the die-set upstroke delay time is ignored and the punches will move up along the plunger.

C1819

SMU

6.4.16.2 Die-set upstroke (SMU) At the beginning of the 2nd press-stroke, the delay time for the die-set upstroke will begin to elapse (the time is set from the micro-processor control system). As soon as the delay time has elapsed, the solenoids of valves YV21 and YV22 will be energized at the same time. The pressurized oil in accumulator 12 will flow into the lower part of cylinders 181 and 180, thus allowing the lower punches to move up after the plunger has begun its upstroke. If the delay time is properly regulated, the punches and plunger will move up at the same time (the tile is taken out between the punches). The longer the delay time, the greater the time required to energize solenoid valves YV22 and YV21. As a result, the lower punches will move up with a certain delay in relation to the plunger upstroke. 6.4.17 CYLINDER PRESSURE RECOVERY Entering a certain setting into the computer system will enable this option. The latter can be activated only if the pressure in the cylinder is higher than the line pressure. At the end of the last press-stroke, the oil under pressure in the cylinder is allowed to flow to accumulators 18, 18a and 18b (where the pressure is notably lower), thus energising solenoid valve YV19 and opening logic element 117. The oil will continue to flow until the cylinder pressure falls to a value equal to the line pressure + 30 bar. At this point, solenoid valve YV19 is de-energised, thereby closing logic element 117. Solenoid valve YV70 is de-energised, thus allowing the chamber in the cylinder to be completely decompressed when logic elements 118 and 119 open.

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014AZ011A OPERATING INSTRUCTIONS

6

6.4.18 UPSTROKE WITH BRAKE APPLIED To move the plunger up, eliminate the pressure in the main cylinder which was used for the last press-stroke. This is done by de-energising solenoid valve YV70 which, in turn, will open logic elements 118 and 119. Logic element 118 will open an oil passage from the main cylinder to tank 126 while 119 joins the flow booster to the tank. Meanwhile, solenoid valve YV32s, which opens logic element 108, will be energised, thus allowing the oil which comes from pump 58 and accumulators 18, 18a and 18b to flow into the upstroke chamber of the main cylinder. In addition, YV32m is de-energized so that the oil can flow from the accumulators into the upstroke booster, thus allowing the shutter to open. This takes place because solenoid valve YV38 remains energised. Logic element 120 is still operated when it opens and, as a result, the pressure built up in the pressure booster can be relieved by opening a passage to tank 126. At this point, the pilot system pressure (applied to the shutter) will cause the piston in the pressure booster to move up. The oil contained in the pressure booster can flow through the shutter up to the tank. The oil contained in the flow booster reaches the tank through logic element 119, which is operated by drain valve YV70, when de-energised. While the piston of the booster is moving up, the oil passages between the main cylinder and the tank are opened. In this way, the pressure exerted in the upstroke chamber of logic element 108 (opened by solenoid valve YV32s) can operate the main cylinder and the oil is thus allowed to enter the tank. Solenoid valves YV32s and YV47 are energised at the same time. The latter stays on until the plunger encoder reaches the setting entered for end of braking during upstroke (only if UPSTROKE BRAKING ON = YES is selected). Solenoid valve YV47 closes logic element 174 and the oil from main pump 58 and accumulators 18, 18a and 18b is forced to pass first through logic element 108 and then through restrictor 90 before reaching the chamber for the main cylinder upstroke. The oil flowing through the restrictor will allow the braking action to be properly adjusted. 6.4.19 FAST UPSTROKE When the plunger - whose position is detected by the encoder - is no longer within the predetermined braking range during upstroke, the oil which comes from logic element 108 can enter the plunger upstroke chamber as solenoid valve YV47 is de-energised. The plunger will continue to move up at a high speed until the encoder records the settings with the plunger in a high position. Solenoid valve YV32s is de-energised and closes logic element 108. Meanwhile, solenoid valve YV38 is de-energised and closes logic element 120. The plunger will now stop moving. 6.4.20

KNOCK-OUT

SPE C1820

6.4.20.1 Knock-out (SPE) To remove the finished tiles from the cavity, energise solenoid valves YV22s, YV25, YV22a and YV22b. This will cause the lower punches to move up as described in the DIE-SET UPSTROKE paragraph. Set a delay time for the die-set upstroke so as to determine when the solenoid valve is to be energised. The operator can also decide whether to take out the tiles from between the punches or remove them in a normal manner. When the die-set is fully raised, i.e. the tiles have been removed, the filler box comes on to eject the tiles. A new cycle can now begin.

C1819

SMU

6.4.20.2 Knock-out (SPE) To remove the finished tiles from the cavity, it is necessary to energize solenoid valves YV21 and YV22. This will cause the lower punches to move up as described in the DIE-SET UPSTROKE paragraph. It is possible to decide when the solenoid valve is to be energized by setting a delay time for the die-set upstroke. The operator can also select whether to take out “tiles from between the punches” or to freely remove the tiles. As soon as sensor SQ3 is energized (i.e. the pressed tiles have been removed), the box feeder will start moving to eject the tiles and a new cycle can now begin.

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OPERATING INSTRUCTIONS

6.4.21 SFS CYCLE: UPPER FORMING DIE (OPTIONAL) The control cylinders of the SFS system (184) are found in the upper part of the die-set. The system features threeposition solenoid valve YV193, YV172, accumulator 337 and pressure relief valve 336. The tiles are removed when solenoid valve YV193 has been energised (after the delay time for punch removal, which is determined before plunger upstroke, has elapsed). This allows the oil to flow from the accumulator 337 to the upper part of the cylinder 184. The speed is controlled by flow control 250. The return movement of the punches can be determined by energising solenoid valve YV172. This solenoid valve can be energised when the filler box is forward, at the end of its backward stroke or as soon as it starts moving. Energising solenoid valve YV172 will allow the oil to flow from the accumulator to the lower part of cylinders 184. To adjust the speed, work on flow control 249. 6.4.22 MOBILE DIE If a mirror finished die-set is installed, move the lower die in order to bring the upper punches into contact with the powder. A special system is used to move the die. This system includes accumulator 141 and relief valve 140, which controls the max. pressure in the lines immediately after it. During the press-cycle, the upper punch, which is rigidly mounted on the plunger, moves down the lower die. The oil which comes from the lower part of cylinders 179 flows back to partially charge accumulator 141; part of the oil is drained through relief valve 140. Once the press-cycle has been completed, accumulator 141 will provide the thrusting force and the oil required to move the die as far up as possible. The upstroke speed is controlled by flow control 145. Check valve 183 is used to prevent the die from moving down in the event of leakage when the machine remains inoperative for a long period of time. 6.4.23

DIE OVER-TRAVEL

SPE C1820

6.4.23.1 Die over-travel (SPE) This function used when the lower punches are to be cleaned. To enable, turn the selector switch located on the microprocessor system and press Die-Set Up keys 25 & 13 located on the control panel. Moreover, the key switch should be turned to “manual” or “set-up”. In this way, solenoid valves YV22a and YV22b are energised to operate cylinders 180a1, 180a2, 180b1 and 180b2, thus allowing the die-set to slowly reach its highest position + a set value. Under these conditions, the user can get at the side of the punches so that they can be cleaned or removed. Once the operation has been completed, press keys 30 and 13 (die-sets down) and turn the selector switch back to its original position.

C1819

SMU

6.4.23.2 Die over-travel (SMU) This function is used when the lower punches are to be cleaned. Use the selector switch located on the microprocessor system. Turning the selector switch to the “on” position will energize solenoid valve YV129 which, in turn, will deliver oil to the upper part of cylinders 179 and open check valve 251 thus allowing the die to move down. Under these conditions, the user can reach the side of the punches so that they can be cleaned or disassembled. To do this, raise the lower punches.

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014AZ011A OPERATING INSTRUCTIONS 6.4.24

6

BRUSH OPERATION

DCP 6.4.24.1 Brush operation (optional) (DCP) The brush is used to keep the punches and die thoroughly clean. An electric motor combined with a belt drive rotates the brush and advances the filler-box. The brush can be turned only if the press is set for automatic operation, semiautomatic loading or if the operator has enabled brush operation. If 3 is entered for “rotation enable”, rotation will always be enabled. If 1 is entered, rotation will be enabled only when the filler box is performing its forward stroke. If 2 is entered, rotation will be enabled only for filler box return. The direction of rotation of the brush can be set. When NO is entered for “REVERSE ROTATION” the direction of rotation can be selected: clockwise = YES, counter-clockwise = NO. In addition, it is also possible for the brush to reverse its direction of rotation from time to time. To do this, enter YES for “REVERSE ROTATION” and then the number of cycles between one reverse rotation and another. If a mobile brush is used, it can also move up and down. As soon as the filler-box has started up, solenoid valve YV192 will be energized, causing the brush to lower until it touches the lower die after the air cylinders 270 have been brought into action. As soon as the filler-box encoder exceeds the setting entered for the brush in high position, solenoid valve YV192 will be de-energized, thus allowing the brush to move up. The brush will remain up for the rest of the cycle.

DCL C1821

6.4.24.2 Brush operation (optional) (DCP) The brush is used to keep the punches and die thoroughly clean. An electric motor drives the brush through a belt transmission system and advances the filler-box. The brush can only be operated if the press is set for automatic or semi-automatic loading. If “ROTATION ON = 3” is selected, the brush can be operated at all times; if “ROTATION ON = 1” is selected, the brush will only operate when the filler box moves forward; if “ROTATION ON = 2” is activated, the brush will only operate when the filler box moves back. The brush can operate in the same direction or reverse after a certain number of turns. If “REVERSE ROTATION = NO”, the brush will always run in the same direction according to whether “C.WISE ROTATION = YES” or “C.WISE ROTATION = NO” has been entered. IF “REVERSE ROTATION = YES” has been entered, type in the number of cycles to be performed before the brush reverses its direction of rotation. If a mobile brush is used, it can also move up and down. As soon as the filler-box has started up, solenoid valve YV192 will be energised, causing the brush to move down until it touches the lower die after air cylinders 270 has been brought into action. As soon as the filler-box encoder exceeds the setting entered for the brush when fully up, solenoid valve YV192 will be de-energised, thus allowing the brush to move up.

6 - 25

014AZ011A 6

OPERATING INSTRUCTIONS

6.4.25

MOVEMENTS IN MANUAL MODE

A number of operations can be performed in manual mode by using the relevant keys on the control keyboard. In any case, the allowable movements will in no way endanger the operator. These movements can be performed provided that the mode key switch on the control keyboard is turned to MAN. Different situations may be encountered: - safety bar raised, light built into key 15 on and the lower punches locked in place: only the die-set can be moved up and down (push-buttons 25, 30 and 13). - safety bar raised, light built into key 15 off and the lower punches released: the machine is stopped and the die-set cannot be moved up and down. - with the safety bar up, the light built into key 15 off and the lower punches released, the following can be selected: A) “MAGNETIC LOCK = YES” to enable the magnetic lock. In this case the machine will stop and the die-set cannot move up or down. B) “MAGNETIC LOCK = NO” to disable the magnetic lock. In this case, only the die-set can move up or down. - Safety bar down and filler box installed: the plunger can move up and down (push-buttons 25, 30 and 3), the filler box can move backwards and forwards (push-buttons 27, 29 and 8), the die-set can move up and down (pushbuttons 25, 30 and 13), the ALM can move backwards and forwards (push-buttons 21, 27 and 29) and the ACP can move to the left or right (push-buttons 22, 27 and 29). In addition, the upper punches can move up and down (pushbuttons 9, 25 and 30) if the SFS is provided.

6.4.26 MOVEMENTS IN SET-UP MODE When the mode selector with key found on the control keyboard is turned to set-up only the plunger is enabled to operate at a speed lower than 16 mm/sec through solenoid valves YV31s and YV31d and the die-set can move upward and downward (push-buttons 25, 30 and 13). These movements can also be performed under the following conditions: - Safety bar down and filler-box mounted not connected to the press - Safety bar down and tile ejector not present

6 - 26

014AZ011A OPERATING INSTRUCTIONS

6

6.4.27 RESETTING THE ENCODERS Press keys 5 and 28 to execute the automatic encoder reset procedure: 6.4.27.1 Plunger encoder reset procedure - Move the plunger fully up. - Raise the safety bar and set the machine to set-up. - Enter encoder number 1 = PLUNGER on the ENCODER RESET page. Refer to the Instructions B Manual - USE OF THE MICROPROCESSOR-BASED CONTROL SYSTEM.

DCL C1821

6.4.27.2 CAL and ALM encoder reset procedure (DCL) - The ALM will move fully back to energise sensor SQ10 (ALM encoder BQ10 reset). - If encoder reset sensor SQ2 is activated, the filler-box will move forward at low speed until sensor SQ2 is no longer energized. - The filler-box moves back at low speed until reset sensor SQ2 (fully back position) has been activated (filler-box encoder BQ2 reset). - The filler-box moves forward at low speed until the end stop has been reached (set value). - The ALM reaches the end stop for the forward stroke (set value).

DCP 6.4.27.3 Filler-box encoder reset procedure (DCP) - The filler-box reaches the “0” position energizing YV20a and YV20s. - The ALM reaches the end stop for the forward stroke activating SQ23.

SPE C1820

6.4.27.4 Knockout encoder reset procedure (SPE) - Perform the last die-set downstroke. - The die-set will slowly move up until the “zero point” is exceeded by a few millimeters. - The die-set will then move completely down at low speed.

6 - 27

014AZ011A 6

6 - 28

OPERATING INSTRUCTIONS

014AZ011A ADJUSTMENT PROCEDURES 7

ADJUSTMENT PROCEDURES

7.1

SETTING THE VARIABLE DELIVERY PUMP

7

See figure 7.1/A. PUMP START-UP - Charge the hydraulic system. - Fill the pump casing by using fitting 4. Be sure that the pump casing is completely full. - Start the motor by applying small currents for a few seconds until all the air has been let out. SETTING THE MAX. POWER OUTPUTS FOR THE SYSTEM The variable delivery pump comes with a power control which limits the power absorbed to a level less than or equal to the motor rating (see chart) regardless of the pressure reached. POWER OUTPUT OF MAIN HYDRAULIC UNIT MOTOR (kW at 50Hz) PH1890/2090/2590 75 PH2890 90 This can be done by adjusting power control 5. Proceed as directed below: - Start up the main pump with the safety bar raised. - Make sure the “oil heating cycle” has been activated (YV11r energised). In addition, make sure the pressure is at 150 bar. If it is not, make sure the valves (10, 112a and 112) have been properly set (see SETTING THE SYSTEM PRESSURE and SETTING THE OPERATING PRESSURE chapters). If the oil temperature is greater than 30°C (with the oil heating cycle inactivated), the pressure should be brought to 150 bar by working on relief valve 112a. If 150 bar cannot be reached, make sure valve 112 has been properly set. (see the SETTING THE OPERATING PRESSURE paragraph). - Keep push-button 28, found on the microprocessor control system, pressed (solenoid valve YV99 is energised thus allowing the oil delivery pump to be drained through relief valve 111; the pressure will reach 150 bar). - Attach a clamp tester to the supply wires of the motor. - Turn screw 6 on the power control until the value read (in AMPERES) is the same as that given on the motor’s rating plate divided by 1.732 if a 50 Hz motor is used. On the other hand, if a 60 Hz motor is used, divide by 1.732 and then again by 1.15. The reading should be taken on each supply wire and the reference current corresponds to the average of the readings taken on the three wires. If a clamp tester is not available, use the ammeter in the switchboard remembering that the current reading corresponds to the total value for the three supply wires. As a rule, the max. output currents should be the same as that given on the motor’s rating plate if a 50 Hz motor is used. On the other hand, if a 60 Hz motor is used, it should equal the rated value divided by 1.15. Under these conditions, as the ammeter is on the cabinet’s line and not the control unit’s motor, make sure the other parts are shut off. NOTE As a rule, the maximum current should be: For 50 Hz - equal to the rated current when the reading is taken on the ammeter in the cabinet; IReading = IRated value - equal to the rated current divided by 1.732 if the reading is taken on each supply wire; IReading = IRated value : 1.732 For 60 Hz - equal to the rated current divided by 1.15 when the reading is taken on the ammeter in the cabinet; IReading = IRated value : 1.15 - equal to the rated current divided by 1.732 and then by 1.15 if the reading is taken on each supply wire; IReading = IRated value : (1.732 x 1.15)

7-1

014AZ011A 7

ADJUSTMENT PROCEDURES

- Lock screw 6 in position. After this procedure has been performed, reset valves 112a, 112 and 10 (see the SETTING THE SYSTEM AND OPERATING PRESSURE paragraph). SETTING THE MAX. SYSTEM PRESSURE (Oil heating and relief valve) In order to prevent the system from malfunctioning, a pressure relief valve is provided. This valve (112a + 111) is found on the control assembly of the lift system and filler-box. To set the pressure limits, perform the following operations: - Detach connector YV11r (oil heater valve). - Start up the main pump with the safety bar raised. - Loosen valve 112a and move it fully back. - Completely tighten valve 112 mounted on the frame of the hydraulic power unit. - Press pressure control push-button 28, found on the microprocessor control system; the pressure will reach 10 - 20 bar. Solenoid valve YV99 will be energised and the pump will reach its max. displacement (indicator 9 in position 11) and the whole delivery line will be drained. - Slowly tighten relief valve 112a until the pressure gauge for the pump 13 reads the desired pressure. - After the valve has been set, lock it in the correct position. - Attach connector YV11r (oil heater valve). As the oil should not be at its correct temperature yet, YV11r will be activated so as to start oil heating. Completely loosen relief valve 10, relieve the pressure in the upper accumulators, tighten valve 10 until the desired pressure for oil heating (150 bar) has been obtained and then tighten the adjustment screw.

PH1890/2090/2590 PH2890

MAX. PRESSURE (bar) 230 250

SETTING THE OPERATING PRESSURE (See figure 7.1/A) The valve which controls the operating pressure in the circuit 112 is mounted on the frame of the hydraulic power unit. To perform this operation, set the pressure as described above. Proceed as directed below: - Start up the main pump with the safety bar up. - Loosen pressure relief valve 112 and eliminate the pressure in the accumulators. - Gradually tighten pressure relief valve 112, with push-button 28 pressed until the desired pressure is read on the gauge and then tighten the adjustment screw. Once the adjustment procedure has been performed, pump displacement should be approx. zero (meter 9 should read 10, which corresponds to 0°). Under these conditions, oil will no longer be drained from pressure relief valve 112a.

PH1890/2090/2590 PH2890

7-2

OPERATING PRESSURE (bar) 180 230

014AZ011A ADJUSTMENT PROCEDURES

7

CHECKING THE OPERATING CONDITIONS (See figure 7.1/A) - With the motor off and the pump stopped displacement meter 9 reads 11. - With the motor on, the pump running and the safety bar raised displacement meter 9 reads 10. When pump delivery tends to drop, the line pressure will be 20 bar. - With press in stand-by mode; motor on; pump running and safety bar lowered, displacement meter 9 reads 10. When pump displacement drops, the line pressure will be the same as the operating pressure previously set. If, in these two cases, pump displacement is not zero, this means that there is an oil leak in the system (make sure that pressure relief valve 112a has been properly set). - Press cycling automatically with the use of accumulators: the amount of power and current absorbed must be as indicated (see figure 7.1/B). The power absorbed is limited to 75 kW and reduced to 13 kW, which corresponds to zero displacement when the line pressure is the same as the set one.

NOTE: Readings were taken to draw up the graphs. They should be used for reference purposes only as a large number of factors may have influenced the results, i.e.: - Number of cycles - Soft filling level - Max. operating pressure - Type of machine

7-3

014AZ011A 7

ADJUSTMENT PROCEDURES

Figure 7.1/A1- REXROTH VARIABLE DELIVERY PUMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18

Displacement control ass’y Adjustment screw, Max. displacement limit Adjustment screw, Min. displacement limit Pump inlet and drain ports Power control Adjustment screw, Power control Pressure regulator Adjustment screw, Min. pressure Displacement meter No displacement Max. displacement Pump casing Suction line Delivery line Line pressure control valve Power control mechanism Connection with external pilot system XD 18

7

8 6

4 5 3

2

1

9

12 11 10

15°

0

15° Pos. 11

Pos. 10 C0190 C0197

7-4

(View of pump from above)

014AZ011A ADJUSTMENT PROCEDURES

7

Figure 7.1/A2 - REXROTH VARIABLE DELIVERY PUMP

HYDRAULIC POWER UNIT

YV99

A

P

10

B

T

15

7 112

YV11R

6

18

5

112A

111

8

17 3 12

13

58

2

5

4 14

254 49

1

13 M

SP3

M1

Figure 7.1/B - PRESS CYCLING AUTOMATICALLY WITH HYDRAULIC ACCUMULATORS pot=10.00 KW (/div) tswp=5.041 Sec points=3531 Replay Menu Active Frame # 1-1 FIG. 1 PRESS CYCLING WITH HYDRAULIC ACCUMULATORS X Range [0.06 - 0.40]

1LdData 2SvData 3Commts 4Ca1c 10Exit

5Retrac 6List

7Title

8Cursor 9Param C0303

7-5

014AZ011A ADJUSTMENT PROCEDURES

7 7.2

SETTING AND ZERO-SETTING THE POSITION ENCODER

The reset procedure must be carried out whenever the encoder, any other related parts or the CPU card are replaced.

7.2.1 PLUNGER TRANSDUCERS The encoders mounted on the plunger have a central area where readings are taken and two otter sections where readings are not taken (see figure) that are 66 mm and 28 mm long respectively. The operating field of the axis the encoder refers to must be centered with the area where readings are taken.

Figure 7.2.1 - RESETTING THE PLUNGER ENCODER

* = position not read ** = work zone

*

**

Dead zone 66.0 mm (2.60 in.)

* Blank area 28 mm (1.00 in.)

Perform the operations given below to reset the encoder: a) Fully raise the plunger. b) Raise the safety bar. c) Turn the selector to SET-UP. d) Go to the ENCODER RESET page on the microprocessor terminal. e) Select plunger encoder reset.

DCL C1821

7.2.2 FILLER BOX ENCODER (DCL) If satisfactory results were not obtained from the reset procedure (paragraph 6.4.27), proceed as follows: a) Move the mobile part of the CAF filler-box all the way back, energizing reset sensor SQ2 without activating switch SQ20i (approximately 10 mm from the end stop). b) Loosen the encoder mounting screws and grub screw that secures the encoder spindle to the flexible coupling. c) Plug the encoder’s connector into the encoder reset box provided. d) Turn the encoder until the red led corresponding to the encoder’s zero mark lights up. e) Fully tighten the mounting screws and grub screw on the coupling while keeping the encoder in place. f) Use keys 28 - 5 to repeat the reset procedure.

DCL C1821

7.2.3 ALM ENCODER (DCL) If satisfactory results were not obtained from the reset procedure (paragraph 6.4.27), proceed as follows: a) Move the ALM all the way back, energizing reset sensor SQ10. b) Loosen the encoder mounting screws and grub screw that secures the encoder spindle to the flexible coupling. c) Plug the encoder’s connector into the encoder reset box provided. d) Turn the encoder until the red led corresponding to the encoder’s zero mark lights up. e) Fully tighten the mounting screws and grub screw on the coupling while keeping the encoder in place. f) Use keys 28 - 5 to repeat the reset procedure. 7-6

014AZ011A ADJUSTMENT PROCEDURES

7

SPE C1820

7.2.4 KNOCKOUT ENCODER (SPE) The encoders mounted on the knockout do not need to be adjusted. If an encoder is replaced, make sure: a) The encoder has been properly installed (as directed by SACMI) and that it is able to operate freely (without being obstructed). b) The sensor is 0.5 mm below the rest surface of the die-set when the transducer is fully down.

DCP 7.2.5 FILLER-BOX ENCODER (DCP) Software reset procedure: - Fully raise the plunger. - Press keys 28 and 5 to automatically reposition the fillerbox. The filler-box will stop in any position (the filler-box stops when the encoder’s 0 pulse is read, almost surely it will not be when the filler-box is back). - Turn the key selector to MAN and press keys 29 and 8 to move the filler-box back (the filler-box moves at the speed set for the 1st forward step). - Turn the key selector to SET-UP and press keys 26, 31 and 8 simultaneously with the filler-box in this position (limit switch SQ59 should be triggered). The encoder’s offset value will be stored, i.e. the distance traveled by the filler-box from the encoder’s 0 position to the position the filler-box reaches when fully back. From this point on whenever the filler-box is moved it will return to its back position (encoder’s 0 position + offset value).

Figure 7.2.5 - FILLER-BOX ENCODER 1 2 3 4 5 6 7

Encoder 7-pin connectors Encoder reset box Half-flanges screwed on Holes with plugs to access joint Geared motor 1 22 Connecting rod

3 CK1

4

The encoder can be zero set in a conventional manner: - With the pump off and key turned to SET-UP, press keys 25, 30 and 8. - Fully raise the plunger. - Raise the safety bar. - Turn off the controller. - Disconnect the lead which runs from the connector 2 on the encoder 1. - Hook up the reset box 3.

CK2

5

6

7 C0207

Two green LEDS, located on the box 3, are used for signals CK1 and CK2. A red LED (that is more important) which lights up only when the encoder is being reset is also provided. -

Set the rod 7 perpendicular to the press, as when the filler box is fully backwards. Loosen the screws which secure the encoder to the half-flange 4. Perform the reset operations by turning the encoder body until the red led comes on. Fully tighten the screws 4. Plug the controller cable into the connector 2. Install the guard, making sure the cable is not in the way. If the operation cannot be done, perform a different procedure.

- Remove the two plugs 5 from the metal cylinder which is located just beneath the encoder. - Turn the rod 7 until the screw on the coupling is brought near the hole. - Loosen the screw in the lower part of the coupling and set the rod 7 perpendicular to the machine. Do not turn the encoder coupling. - Tighten the bottom screw. - Loosen the top screw and the screws 4 which secure the encoder to the two half-flanges. - Remove the encoder. - Turn the spindle until the red led comes on. - Re-install the encoder and tighten all the screws. 7-7

014AZ011A 7

7-8

ADJUSTMENT PROCEDURES

014AZ011A MACHINE MAINTENANCE 8

8

MACHINE MAINTENANCE

The checks and maintenance operations which must be performed on the press are described below. The first operations shown in the chart, are to be performed at the stated intervals. The other operations are to be carried out as required, i.e. at the discretion of the operator.

E0004P

WARNING!

Before attempting any maintenance, carefully read chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.

8.1

MAINTENANCE SCHEDULE

OPERATIONS

INITIAL MAINTENANCE TO BE CARRIED OUT EVERY (HOURS) :

8

40

80

200

500

2000

THEREAFTER EVERY (***) 4000

1 - GENERAL CLEANING OF DIE-SET AND PRESS

8 hours

2 - INSPECT THE FELTS FOR CONDITION

80 hours

3 - LUBRICATE THE PLUNGER BUSHES

80 hours

4 - CHECK THE KNOCKOUT

80 hours

5 - CHECK THE NUTS & BOLTS FOR TIGHTNESS

2000 hours

6

1000 hours

OIL FILTERING AND RECIRCULATION

7 - CLEAN THE INSIDE OF THE ELECTRICAL CABINET

2000 hours

8 - REPLACE THE FILTER ELEMENTS

(*)

9 - CHECK FOR LEAKS

200 hours

10 - INSPECT THE VARIABLE DELIVERY PUMP

200 hours

11 - CHECK THE EARTH CONNECTIONS FOR EFFICIENCY (**)

80 hours

12 - CLEAN THE DIE-SET AIR FILTERS

80 hours

13 - CHECK THE SAFETY DEVICES FOR EFFICIENCY

80 hours

14 - REPLACE THE AIR FILTER ELEMENT

4000 hours

OF THE PRESSURISATION SYSTEM

500 hours

15 - CHECK THE SUCTION SYSTEM FOR EFFICIENCY 16 - CHANGE THE OIL IN THE HYDRAULIC POWER UNIT 17 - CHECK THE OIL-WATER HEAT EXCHANGER

4000 hours 200 hours

FOR EFFICIENCY

18 - REPLACE THE HOSE PRESSURE BOOSTER UPSTROKE

Every 6,000,000 cycles and in any case at least every 5 years

19 - REPLACE THE HOSE FOR PLUNGER UPSTROKE

Every 6,000,000 cycles and in any case at least every 5 years

20 - LUBRICATE KNOCKOUT FEELER PINS

80 hours

(*) The operation must only be carried out when indicated. (**) Inspect each time the die-set is changed. . (***) The intervals at which these operations are to be carried out are automatically indicated on the controller display.

C2310

Approximate value

1 - GENERAL CLEANING OF THE PRESS. The filler-box, grid, slide plate and the part of the die set which rests on the table need special cleaning. 2 - INSPECT THE FELTS which protect the plunger bushes for condition. 8-1

014AZ011A 8

MACHINE MAINTENANCE

3 - LUBRICATING THE PLUNGER BUSHES (this operation must be done manually with the aid of the grease gun provided. Inject the grease through the grease fittings provided). 4 - INSPECT THE KNOCKOUT. Inspect for oil leaks and loose screws. 5 - INSPECT ALL THE NUTS AND BOLTS FOR TIGHTNESS. Refer to chart 8.3. 6 - OIL FILTERING AND RECIRCULATION. To be carried out after the first 500 hour break-in period and there after every 1000 hours. See paragraph 8.2.5 OIL RECIRCULATION AND FILTERING. 7 - CLEAN THE ELECTRICAL CABINET INSIDE. Clean the electronic and electrical equipment by removing any extraneous matter with suitable suction devices (do not blow air). Clean the contacts with ether. 8 - REPLACING THE FILTER ELEMENTS. Indicators SP1 (filter on main filtration circuit located in hydraulic power unit), SP5 (filter for ejector valve feed valve located on the knockout circuit) and SP7 (filter for proportional presscycle valves located on press-cycle control assembly) will cause fault messages to appear on the controller display screen when the filter elements are clogged. When the message “Filter clogged (SPXX)” is displayed a counter that signals “Change filter within XX” also appears. The press can continue the production cycle until the time after which the filter has to be changed is reached. Once this time is over, the press will shut down, completing the press-cycle in progress. Operation can be re-started only after the filter has been changed. As a result, the operator can change the filters from the time that spans from the message signaling the filter is clogged is displayed and the press actually shuts down thereby allowing the job to be planned in advance. Each time a filter element is replaced, thoroughly clean the filter housing. Check the condition of the filter gaskets each time the filter housing is opened. The filters monitored by indicator SP1 should be changed only when signaled by the press’ PLC or whenever the oil is changed. The filters monitored by indicators SP5 and SP7 should be changed when signaled by the press’ PLC or yearly (when scheduled maintenance is performed). Use only genuine SACMI filters to prevent malfunctions from arising.

9 - CHECK FOR LEAKS. Check the logic element and valve seats for oil leaks. Check the level in the oil-leak collector. 10 - INSPECT THE VARIABLE DELIVERY PUMP. Check the seals for wear. The following conditions must be fully satisfied for proper operation. Keep the Pressure Control button pressed and make sure that the displacement meter reads “zero”. In addition, make certain the motor which drives the pump does not use more than the set maximum power rating. If it does, call specialized service personnel.

8-2

014AZ011A MACHINE MAINTENANCE

8

11 - EARTH CONNECTIONS Inspect the earth electrodes of the machine and the earth connection between the crosshead and the plunger. If required perform the connections again Earth terminals: A - Crosshead B - Plunger C - Machine base

A

B

In addition check the earth connections for the die-set (See figure - DIE SET WIRING DIAGRAM, cables D and E, chapter 4 - INSTALLATION).

C C0202

E0004P

IMPORTANT

Before tightening the clamp screws provided, remove any paint from the press body at the points where the earth conductors are connected. This will improve electrical continuity. Failure to provide adequate earth connections may cause severe injury to the operator as well as damage to the machine. 12 - CLEAN THE DIE-SET AIR FILTERS. Remove the filters and clean with compressed air. Check the filter for condition and the gaskets for tightness (when the cover is closed). If necessary replace the filter. 13 - CHECK THE SAFETY DEVICES FOR EFFICIENCY. Make sure all the safety devices operate efficiently (e.g. stop buttons, miniature switches, fixed guards etc....). 14 - REPLACE THE AIR FILTER ELEMENT OF THE PRESSURISATION SYSTEM Replace air filter element 271 at least once a year 15 - CHECK THE SUCTION SYSTEM FOR EFFICIENCY. Make sure the suction ports are properly connected and the suction system operates in accordance with SACMI specifications. 16 - CHANGE THE OIL IN THE HYDRAULIC POWER UNIT. Change the oil, taking care to remove any deposits which may have accumulated in the reservoirs. Only oils which have the characteristics indicated in the “Specifications” paragraph must be used. 17 - CHECK THE OIL-WATER HEAT EXCHANGER FOR EFFICIENCY Make sure the oil temperature remains within the set limits and does not increase abruptly. To service the heat exchanger, refer to the instructions given in paragraph 8.4. 18 - REPLACE THE HOSE FOR PLUNGER UPSTROKE Drain the oil from the press and replace the hose. 19 - REPLACE THE HOSE PRESSURE BOOSTER UPSTROKE Drain the oil from the press, remove the cover from the pressure booster and replace the hose. 20 - LUBRICATING THE KNOCKOUT FEELER PINS Lubricate the knockout feelers as indicated in paragraph 8.1.1 - LUBRICATING THE KNOCKOUT FEELER PINS. 8-3

014AZ011A 8

MACHINE MAINTENANCE

8.1.1 LUBRICATING THE KNOCKOUT FEELER PINS Use the equipment provided with the knockout to lubricate with the die-set raised: - remove the plug from the die-set punch holder block; - connect the kit to the hole; - fill the tube 300 mm with low superficial tension lubricant (diesel fuel);

E0004P

WARNING!

Do not use oil or grease. - attach an air gun to the end of the tube and draw the lubricant inside the die-set to lubricate the feeler pins. 8.1.2 VACUUM If hydraulic components need to be replaced without draining the oil from the press, put the hydraulic circuit under vacuum with the equipment supplied with the machine. Proceed as follows: - disconnect the pressurization circuit from the air line and wait until air no longer flows out of the circuit; - connect tube A to fitting B for the vacuum device and tube C to fitting D of the vacuum device; - wait a few minutes. To avoid damaging the hydraulic circuit the time the press is kept under vacuum should be as short as possible, in any case less than 60 minutes. In addition, cover any openings in the hydraulic circuit to prevent pollutants from entering. NOTE: drain the oil from the press when replacing valves with large diameters directly connected to the reservoir i.e. YV32 and YV70d.

Figure 8.1.2 - VACUUM

C

0

12

B

A D

C2138

8-4

014AZ011A MACHINE MAINTENANCE 8.2

8

SPECIAL MAINTENANCE

8.2.1 SERVICING THE PLUNGER BUSHES (Refer to figure 8.2.1) The bushes need no adjustments. The double seals which keep out the dust and the high quality material used in manufacturing ensure a long service life. When installing the bush, make sure that the oval section which has “O” stamped on it, is turned towards the center of the press. Figure 8.2.1 - SERVICING THE PLUNGER BUSHES

O

8.2.2 FILLING THE RESERVOIR (Refer to figure 8.2.2) The reservoir is filled with the aid of a portable charge pump. - Loosen the level plug Q, located on the pre-filling tank, so that all the air can be let out. - Open the ball valve A found on the suction line. - Put one end of the suction hose B into the oil can C. - Attach the end of the delivery hose D to point N (suction hose). - Open the ball valve P. - Turn the switch F to start the charge pump. - Make sure that the oil filter G is not clogged (indicator H red).

C0306

Replace the filter element if necessary (3 µ) - Make sure the hydraulic unit is completely full of oil, by checking for oil in the hose L. Once the correct amount of oil has been put in (check with the plunger lowered): - Turn the switch F to stop the pump. - Close the ball valve P. - Remove the hose D from “N”. NOTE: If the charge pump has not been purchased, the oil coming from the cans must be properly filtered. It is essential that the filters used have a filtering capacity of 10 µ. 8.2.3 DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND RESERVOIR (Refer to figure 8.2.3) - Make sure that the ball valve A is open (suction line). - Open the check valve 7 located on the accumulator control assembly and fully tighten the relevant screw. - Place the hose D to the oil can C. - Connect the drain hose D to point N on the suction line. - Pressurise the circuit (1 BAR). - Open the ball valve P. - Drain the oil from the hydraulic power unit and reservoir.

8-5

014AZ011A 8

MACHINE MAINTENANCE

Figure 8.2.2 - FILLING THE OIL RESERVOIR

Q

A

P L

B N F H

C

C1832

G

D

Figure 8.2.3 - DRAINING THE OIL FROM THE HYDRAULIC UNIT AND RESERVOIR A

7 P

D N C1833

C

8-6

014AZ011A MACHINE MAINTENANCE

8

8.2.4 DRAINING OIL FROM THE HOSES AND HYDRAULIC CONTROL ASSEMBLIES - Connect the drain hose D to point M on the aux. equipment control assembly. - Place the drain hose D to the oil can C. - Pressurise the circuit (1 bar). - Remove the nuts on the check valve 7 and tighten the screw. As a result, the oil can flow out, reaching point M. - To drain the rest of the oil from the hoses connect the hose D to point N and open the cock P.

Figure 8.2.4 - DRAINING OIL FROM THE HOSES AND HYDRAULIC CONTROL ASSEMBLIES

R

7

D

P N

C

C1834

M

D

8-7

014AZ011A 8

MACHINE MAINTENANCE

8.2.5 OIL RECIRCULATION AND FILTERING - Periodically recirculate and filter the oil (approximately 1000 hours) by connecting the oil pump as shown in the illustration below.

IMPORTANT!

E0004P

Before connecting the pump, make sure all the hoses and fittings are thoroughly clean. -

Connect the delivery hose D (pump delivery line) at point S (prefilling tank). Connect the hose B (pump suction) at point N (suction line). Open the ball valve P. Run the oil pump (switch F) for approx. 3 workshifts and during the night. Periodically check the pump to make sure it has not stopped because the filters G have been clogged (indicator H turns red). - If necessary, replace the filter element (3 µm ). Figure 8.2.5 - OIL RECIRCULATION AND FILTERING

S

D

F

H P

B N G

8-8

C1835

014AZ011A MACHINE MAINTENANCE

8

SPE C1820

8.2.6 REPLACING PROPORTIONAL VALVES YV22a AND YV22b FOR THE KNOCKOUT (ONLY SPE) Proceed as directed below when replacing one of these valves: - Get the new valve ready by filling the various ports with fresh oil. - Press the emergency stop button and relieve the pressure. - Loosen all the grub screws shown in figure 8.4.3 to drain any oil under pressure. Once this has been done, fully tighten the grub screws.

WARNING!

E0004P

Be extremely careful not to damage the threading when tightening the grub screws. -

Replace the valve. Pressurize as required. Loosen the grub screws 1 and let the oil flow out until air is no longer present. Fully tighten grub screws 1. Start the pump. Loosen the grub screws 1. Move the die-set up and down a few times until only oil flows out of the grub screws rather than oil mixed with air. Fully tighten the grub screws 1. Shut off the PLC and then turn it back on to zero set the encoder for the new valve.

1

Figure 8.2.6 - BLEEDING THE CONTROL ASSEMBLIES 1

1

1

C2125

1

1

8-9

014AZ011A 8 8.3

MACHINE MAINTENANCE TORQUES (NUTS & BOLTS)

S.R. = Resisting cross section (sq.mm) MS = Tightening torque (kgm) V = Pre-load (corresponding to the tightening torque, kg)

NOTE: 12K class screws must be tightened with a torque wrench. The operation must be done as if they were of the 10K class. Example: A 12 mm dia. screw with a 1.75 pitch (class 12K) must be tightened to 12.28 kgm instead of 14.74 kgm.

STANDARD THREAD SCREWS

DIAMETER

mm

4

5

6

8

9

10

12

14

16

18

20

22

24

PITCH

mm

0.70

0.80

1.00

1.25

1.25

1.50

1.75

2.00

2.00

2.50

2.50

2.50

3

S.R.

sq.mm

8.11

13.31

18.68

34.57

45.77

55.28

79.92

MS = kgm

0.22

0.43

0.73

1.81

2.33

3.23

5.46

8.33

12.72

16.02

24.88

33.10

44.00

V = kg

227

373

523

978

1282

1548

2238

3084

4214

5184

6823

8436

9880

MS

0.34

0.69

1.16

2.90

3.73

5.18

8.74

13.32

20.36

25.63

35.81

43.36

60.5

V

363

596

837

1549

2050

2477

3580

4935

6742

8295

10596

13178

15800

MS

0.49

0.96

1.64

4.07

5.25

7.28

12.28

18.74

28.63

36.04

50.36

60.97

85.3

V

511

839

1177

2178

2884

3483

5035

6940

9481

11665

14900

18532

21740

MS

0.58

1.16

1.96

4.89

6.30

8.73

14.74

22.49

34.36

43.25

60.43

73.16

100.9

V

613

1006

1412

2613

3460

4179

6042

8328

11377

13998

17830

22238

26000

5S

8G

10K

12K

110.16 150.49 185.16 236.52 294.16

338

FINE THREAD SCREWS

DIAMETER

mm

-

-

-

8

-

10

12

14

16

18

20

22

24

PITCH

mm

-

-

-

1.00

-

1.00

1.50

1.50

1.50

1.50

1.50

1.50

2

S.R.

sq.mm

-

-

-

37.14

-

61.87

83.83

MS = kgm

-

-

-

1.92

-

3.52

5.68

8.83

13.37

17.48

27.16

35.81

45.7

V = kg

-

-

-

1040

-

1732

2347

3344

4516

5864

7688

9388

10800

MS

-

-

-

3.08

-

5.63

9.09

14.12

21.39

27.96

38.65

52.10

66.00

V

-

-

-

1664

-

2772

3756

5350

7226

9383

11821

11541

17200

MS

-

-

-

4.33

-

7.91

12.78

19.86

30.08

39.32

54.36

73.82

91.00

V

-

-

-

2340

-

3898

5281

7523

10161

13195

16623

21249

24300

MS

-

-

-

5.19

-

9.50

15.34

23.83

36.09

47.18

65.23

88.79

110.0

V

-

-

-

2808

-

4677

6338

9005

12194

15834

19948

21538

29200

5S

8G

10K

12K

8 - 10

119.42 161.29 209.44 263.86 324.58

374.5

014AZ011A MACHINE MAINTENANCE 8.4

8

SERVICING THE HEAT EXCHANGER

CLEANING THE HEAT EXCHANGER - Loosen the nuts on the stay bolts and move the plate away. - Check the thickness of the gaskets and replace them if necessary. - Remove the plates from the frame. - If they are dirty or covered with calcium deposits, proceed as follows:

Type of deposits

Cleaning operations

Solid deposits not stuck to the plates or grilles.

Remove them with running water at low pressure.

Sludge

Proceed as above.

Solidified sludge

Soak the plates and then proceed as above

Calcium deposits

Immerse the plates (without removing the gaskets from the grilles) in a solution containing 10% hydrochloric or nitric acid. Allow them to soak for about 5 minutes. Thoroughly rinse under running water. Repeat if necessary.

NOTE: Never remove the grilles or the gaskets from their seats except when the gaskets have to be replaced because they are worn.

E0004

IMPORTANT!

Never use solvents.

8.4.1 REPLACING THE GASKETS Check the width of the gaskets measuring it along with the plate. The gasket along with the relative plate should not be less than 4.1 mm. If worn down and less than this value, replace the heat exchanger gaskets and close it taking into consideration a precharge value for the plates for the new heat exchanger. - Remove the square mesh grille from the plate. - Remove the gasket and thoroughly clean the edges of the plate. If it is difficult to fit on the new gasket, slightly raise the curled edge of the plate with the aid of a spatula. - Reinstall the grille making sure that it fits into the internal groove which receives the gaskets.

8 - 11

014AZ011A 8

MACHINE MAINTENANCE

8.4.2 SECURING THE STAY BOLTS No special tools are required to perform this operation (e.g. torque wrenches). The value n x A, indicated in the diagram, can be exceeded (the plate cluster must be more compact) without causing the heat exchanger to malfunction (see the chart below). Tighten the stay bolts in the following order: - Secure stay bolts 1, 6, 10, 5. - Secure stay bolts 2, 7, 9, 4. - Secure stay bolts 3, 8. Repeat the operations until the required value is obtained.

Figure 8.4.2 - SECURING THE STAY BOLTS nxA

1

6

2

7

3

8

4

9

5

10 C0315

n = number of plates which form the heat exchanger.

TIGHTENING THE STAY BOLT FOR 1 PLATE

A

New gaskets

minimo

3.75

3.5

NOTE: - The first value was used when the heat exchanger was constructed and for exchangers overhauled with new gaskets. - The min. tightness is the min. allowable value. To compensate for a plate that has worn down in relation to another, do not exceed this value as when the space between plates is reduced the section for oil and water flow is also decreased causing greater loses and reducing efficiency of the exchanger.

8 - 12

014AZ011A DECOMMISSIONING 9

9

DECOMMISSIONING

When the machine is not to be used any longer and is to be dismantled proceed as follows: 1) Move the plunger to the end-stop and lock it in place so as to prevent it from moving down. 2) Turn off the machine with the main shut off switch and then unplug the power cable 3) If present, drain accumulators 141 and 337 through valves 143 and 339. 4) Drain all the hydraulic fluid from the press by following the same procedures as recommended for routine maintenance. 5) Disconnect the machine from the electricity supply. 6) Disconnect the water lines for oil cooling. 7) Disconnect the hydraulic lines. 8) Remove the filler box. 9) Disconnect the control unit electrical connections. 10) Blow off the pressurised gas in all the accumulators by using the tester-inflator available on request. 11) Remove the accumulators. 12) Remove the hydraulic control assemblies. 13) The press may be moved in the same way as during installation, therefore refer to the relevant chapter. When disassembling the machine, lift equipment must be used to remove certain parts (e.g. hydraulic control assemblies, accumulators, etc..). These operations are to be performed by qualified personnel observing current safety regulations. Use all personal safety gear called for by current safety standards when working above shoulder height.

9-1

014AZ011A 9

9-2

DECOMMISSIONING