Operation Manual

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

PH INSTRUCTIONS B

USE OF THE SMC 085 MICROPROCESSOR-BASED CONTROL SYSTEM FOR PH PRESSES

PH 339.85.089 Rev. 00 Date 10.12.01

TECHNICAL DOCUMENTATION DOCUMENTATION TECHNIQUE TECHNISCHE DOKUMENTATION DOCUMENTACION

TECNICA

DOCUMENTAÇAO

TECNICA

ISH

L ENG

PH 339.85.089 Rev. 00 Date 10.12.01

Written by

: Leoni Luca

Written on

: December 10, 2001

Last revised

: PH 13.09.01.7TR PH 11.19.01.7TR PH 10A.16.01.7TR PH 10.22.01.7TR PH 09.20.01.7TR PH 08.27.01.7TR

Revised by

: Alberto Tassoni, ing.

Program version

:

Title

:

Number of pages

: 133

Service code

: 9512

Identification no.

: PH 339.85.089

Use of the SMC 085 microprocessor-based control system for PH Presses

SACMI SHALL NOT BE HELD RESPONSIBLE FOR MACHINE FAILURE DUE TO UNAUTHORIZED MODIFICATIONS. ANY CHANGES THAT ALTER THE CONSTRUCTION OR THE WORKING CYCLE OF THE MACHINE MUST BE CARRIED OUT OR AUTHORIZED BY SACMI’S AFTER-SALES DEPT. SACMI RESERVES THE RIGHT TO MAKE ANY CHANGES TO THE MACHINE DESCRIBED HEREIN AT ANY TIME WITHOUT NOTICE. IF THERE ARE ANY PRINTING OR OTHER ERRORS, CORRECTIONS WILL APPEAR IN THE SUBSEQUENT VERSION OF THE MANUAL. SACMI SHALL BE HELD RESPONSIBLE ONLY FOR THE TEXT IN THE ORIGINAL ITALIAN VERSION. THIS MANUAL IS PROPERTY OF SACMI. ONLY THE PURCHASER OF THE MACHINE IS AUTHORIZED TO USE IT. IT IS NOT TO BE COPIED OR REPRODUCED IN ANY FORM WITHOUT PRIOR CONSENT FROM SACMI. FAILURE TO DO SO WILL ENTITLE SACMI TO TAKE LEGAL ACTION. COPIES OF THIS MANUAL ARE AVAILABLE FROM THE AFTER-SALES SERVICE DEPT.

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PH 339.85.089 Rev. 00 Date 10.12.01

SAFETY PRECAUTIONS TO BE OBSERVED WHEN OPERATING THE MACHINE

Copies of this manual should be given to all personnel in charge of machine maintenance and operation. It is essential that the manual is read carefully in its entirety and fully understood, as it provides important instructions on how to operate the machine properly and safely. The machine must be used only for the tasks it was expressly designed for. Performing jobs other than those recommended is hazardous. SACMI shall not be held responsible for damage to the machine or injuries to personnel resulting from mishandling, improper use or unauthorized modifications. Any modifications made to the machine’s structure and/or work-cycle must be performed or authorized by SACMI’s Service Dept. The persons in charge of supervising and servicing the machine must read and fully understand the operating instructions contained in the documentation provided. Maintenance can be performed and the electrical parts and devices accessed only by competent well-trained personnel. The machine’s work-cycle can be set and controlled only by the persons in charge, or those who are duly authorized. Only well-trained personnel can operate, set-up and service the machine. The machine can be started up only after all the safety devices have been activated. Periodically inspect all the safety devices installed in the machine (stop pushbuttons, interlocks, proximity switches, limit switches, safety guards, etc..) for proper functioning. Occasionally check to see whether the machine is still efficiently grounded. If any faults are found while the machine is being run, they must be reported to the person in charge without delay. If the personnel in charge find faults which could endanger the operators, the machine must be shut off immediately and restarted only after it has been repaired. Always unplug the machines from the electricity supply before setting up or servicing them if operations which may endanger personnel are to be performed. Failure to do so may result in severe injury to personnel. Whenever carrying out maintenance of any type, always shut off the machine and block all parts before starting. This must be done even when minor jobs are performed.

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PH 339.85.089 Rev. 00 Date 10.12.01

1

INTRODUCTION

Device

Connection

State

LED indication

Pushbutton

N.O.

Pressed Released Pressed Released

Led on Led off Led off Led on

Closed in pos. x Open in pos. x

Led on Led off

N.C.

Energized De-energized Energized De-energized

Led on Led off Led off Led on

Proximity switch

N.O.

Energized De-energized

Led on Led off

Scanner Photocell

N.O.

Triggered Untriggered Triggered Untriggered

Led on Led off Led off Led on

N.O.

Energized De-energized Energized De-energized

Led on Led off Led off Led on

Above the threshold Below the threshold Above the threshold Below the threshold

Led on Led off Led off Led on

Above the set pressure Below the set pressure Above the set pressure Below the set pressure

Led off Led on Led on Led off

N.C. Selector switch Miniature switch

N.O.

Reflector/ Detector unit Contactors-relays

N.C. Level control Pressure switch Flowmeter Thermostat

N.O. N.C.

Vacuum meter

N.O. N.C.

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PH 339.85.089 Rev. 00 Date 10.12.01

2

WARNINGS

MAINTENANCE - To replace the microprocessor system cards: see INSTRUCTIONS C - To replace the EPROMs which store the machine program: see INSTRUCTIONS C - Before welding, disconnect the machine from the electrical cabinets by unplugging the cables.

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PH 339.85.089 Rev. 00 Date 10.12.01

3

MAIN FEATURES OF THE ELECTRIC SYSTEM

The electric system basically consists of three parts: 1) The microprocessor system that controls and monitors machine operation 2) The switchboard that supplies power to the main points of use 3) Machine wiring

1) Microprocessor system for controlling and monitoring machine operation This system controls and monitors plant operation. Its function is to control and monitor all the parts that make up the machine. The microprocessor system consists of a number of cards, each of which is provided to carry out a specific task. Power Supply Card (AL): This card supplies power to the various parts inside the system as well as outside to the sensors. CPU Card: This card stores the main microprocessor and the machine program to be run. Miscellaneous Card (VA) This is the CPU card support; it is used to dialog with the operator keyboards. It stores the set workcycle programs. Encoder/Analog Input Card (EIA) It serves for the dual task of reading the encoders located along the axes as well as the pressures and temperatures present. Analog Input Card (IA): It is used to read the pressures and temperatures. Encoder Input Card (IE): It is used to read the encoders located along the axes. Digital Input Cards (IDM): The function of these cards is to acquire the state of the limit switches and proximity sensors. Digital Output and Relay Output cards (OD, OR): These cards are used to pilot the machine actuators. Digital and Analog Output Cards (ODA) The function of these cards is to pilot the proportional valves that control the positions and speeds of the axes along with certain machine actuators. All the electronic cards are tested at 60°C for not less than 48 hours. An emergency circuit is also provided in the control system. This circuit controls all the safety devices independently, i.e. safety bar, shutdown button located on the machine control keyboard, external shutdown buttons, etc..

2) Switchboard that supplies power to the main points of use This part houses all the devices that control the electric motors. The controls for the motors are protected with magnetic thermal cut-outs (for power outputs less than 11 kW) with mixed coordination (Ir, type 2, Iq type 1). Y-D starters are used with power outputs greater than 15 kW. All the power components are mounted on a bus bar. 7

PH 339.85.089 Rev. 00 Date 10.12.01

3) Electric wiring of the machine The electric wiring of the machine has been studied in depth and is designed to satisfy installation and maintenance requirements. Connectors are used for each individual part so that they can be easily unplugged/plugged in when the machine is installed at the customer’s factory and when maintenance needs to be carried out. All the materials employed for machine wiring have been carefully examined and selected taking into account the aggressive agents found in the work area (oil, dust, etc..). The entire electric system is tested according to current safety regulations. The entire electric system has been designed and developed in compliance with current international electrical codes and regulations regarding safety of machinery.

MAIN LAWS AND SAFETY STANDARDS USED AS REFERENCES European Standard

CENELEC HD 420 Auxiliary control equipment for voltages that do not exceed 1000 V General prescriptions

Italian Standard European Standard International Standard

CEI EN 60204-1 (CEI 44-5) CENELEC EN 60204 IEC 204-1 Safety of machinery- Electric equipment of machinery

Italian Standard European Standard International Standard

CEI 64-8 CENELEC HD 384 IEC 364 Electric systems that use a rated voltage that does not exceed 1000 V alternating current and 1500 V direct current.

European Standard

EN954-1 Safety of machinery- Parts regarding the safety devices in the control system (being approved).

European Standard

EN292-1 Safety of machinery - Terminology, Basic methods

European Standard

EN292-2 Safety of machinery - Specifications and technical principles

European Directive

89/392/EEC Machine directive

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PH 339.85.089 Rev. 00 Date 10.12.01

MACHINE FEATURES OF THE SACMI PLC/MICROPROCESSOR CONTROL SYSTEM The controller comes equipped with a 25 line, 80 character 10-inch display unit. This display shows all information and parameters required to operate the machine. Use the keyboard provided to enter data for new work cycles. The following pages are shown on the display:

1) “DATA” PAGE The following data is provided: - data regarding the work-cycle which has just been completed; - data recorded by the transducers installed in the machine; - production data (partial and total). 2) “INFORMATION AND LANGUAGE SELECTION” PAGE The machine parameters are displayed: mechanical, hydraulic and electronic. The screensaver function can either be enabled or disabled (for terminal versions starting from 2.0) and the language in which all the messages are displayed can be changed. It is also possible to reset any absolute encoders installed on the machine. 3) “ACTUAL LOADING DATA” PAGE All the data regarding the cycle that has just been completed is shown here: - length of the various cycle stages; - temperature of the die-sets. 4) “ACTUAL PRESS CYCLE DATA” PAGE All the data regarding the cycle that has just been completed is shown here: - length of the various cycle stages; - pressures, speeds and positions reached 5) “ACTUAL DIE-SET DATA” PAGE All the operating data related to the proportional ejector (optional) is given on this page. 6) “PROGRAMS” PAGE The list of the programs stored in the system is shown on this page (a “program” consists of all the machine operating data). Up to 128 programs can be stored in the computer’s memory. Each program is identified by a name (consisting of: number of the set size, maximum pressure and thickness set). Operations can be performed with the stored programs (write, read, cancel). 7) “LOADING SET UP” PAGE The values for the following items related to the automatic cycle can be displayed and set from this page: - positions and speed of the filler-box; - positions and delay times for die-set downstrokes. 8) “PRESS CYCLE SET UP” PAGE The values for the following items of the automatic cycle can be displayed and set from this page: - positions and speed of the plunger; - number of press-strokes; - de-aerations; - pressures (and everything concerning the press-cycle); - times (length of various cycle stages, delay times, ...).

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PH 339.85.089 Rev. 00 Date 10.12.01

9) “DIE-SET SET UP” PAGE The values for the following items of the automatic cycle can be displayed and set from this page: - the size and production batch; - die-set blowing; - SFS control - temperatures of the die-sets. - the limit switches and the speed of the proportional ejectors (optional) 10) “FITTINGS SET UP” PAGE The values for the following items of the automatic cycle can be displayed and set from this page: - ALM control - brush control; - internal synchronizer (allows the press to be run at a predetermined number of cycles per minute); - external synchronizer (allows the press to be synchronized with an external device). 11) “PRINT ROUTINE” Regardless of the page actually being displayed, the production data, set data, fault messages and some of the actual values can be printed out at any time. 12) “HELP” PAGE The Help page, which provides the following information, is displayed when the HELP key is pressed with any page active: - a scheme of the pages will appear on the top of the display and the title of the page currently active will flash; - some useful information for the operator is given at the bottom of the display. The cursor can be moved to access the page indicated by the flashing cursor by using the keys on the terminal keyboard. 13) “I/O PAGE” (INPUTS/OUTPUTS) The inputs and outputs, along with their current state, are shown on this page. 14) “STATE OF EXECUTION” PAGE The current operating state of all the machine axes are displayed here. 15) “STATISTICS” PAGE Some historical machine data regarding the amount of time the machine stopped, number of times the machine stopped, pressure, thickness, time taken by the filler-box to carry out the strokes and the setting reached during the die-set upstroke is shown here in histogram form. 16) “FAULTS” PAGE The last 20 fault messages displayed are shown here in chronological order. The following information is provided: - date; - time; - message. 17) “PRODUCTION DATA” PAGE Production data is shown here in the following form: - daily data - weekly data - monthly data - production batch data

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PH 339.85.089 Rev. 00 Date 10.12.01

More than 220 self-diagnostic messages can be displayed including scheduled maintenance messages (in this case, the messages are shown to inform the operator that the maintenance operation has to be performed). Example:

2044 OIL LEVEL (SL1)

(machine shut-down)

Input SL1 has stayed off for 6 s. The pump is stopped. Check the oil level in the reservoir. Check level sensor SL1, the INPUT card (when the oil is above the level, Led SL1 must be on) and the cables/connectors.

REGULATORS The program automatically corrects the pressure in the cylinder. This regulator controls the length of the press-stroke so that the set pressure is reached. The temperature of the die-sets is controlled by a PI type regulator.

TELE-SERVICE The keyboard for setting and displaying data is remote controlled when tele-service is used. Any data item can be set/displayed with this service, for example a new set of parameters can be entered (pressures, times, temperatures, etc.). All the data transmitted to the machine’s display are shown (including fault messages). When the remote control is activated, the machine keyboard for setting data is disabled whereas the display remains active. This feature allows technical support to be provided to Sacmi engineers on the customer’s premises from Imola when starting up the machine or troubleshooting it on site when it is being repaired/tested.

11

24

0

12

5

I

1

R

6

2

I

7

3

12

8

13

9

14

10

15

11

20

16

21

22

18

A2

A1

P

SC

SL

WD

R

+5

19-23

MAN SET UP AUT

27

30

I 28

25

31

–

+

26

29

4

4

I

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PH 339.85.089 Rev. 00 Date 10.12.01

MACHINE CONTROL KEYBOARD SMC 085-11-442

PH 339.85.089 Rev. 00 Date 10.12.01

4.1

DESCRIPTION OF THE KEYS

FUNCTION Pump start Alarm reset Automatic cycle start Semi-automatic loading start Semi-automatic press-cycle start (16) Plunger upstroke Plunger downstroke Plunger upstroke at low speed Plunger downstroke at low speed Self-learning for plunger upstroke/downstroke+press-cycle(5) YV32 and YV318 operation check(12) Pump stop Reset Automatic cycle stop Braking force increase Braking force decrease Brakingforcedecreasebeyondthelimitswitch(3)(4) Braking force increase beyond the limit switch(3)(4) Assign analog braking input offset(3)(4) Assign analog braking input gain(3)(4) Control of the SPE proportional solenoid valves (15) Filler-box forward Filler-box reverse Filler-box encoder mechanical zero setting, Crank connecting rod(11) Punches in Punches out Upper die-set de-magnetized Upper die-set magnetized Thickness increase(1) Thickness decrease(1) Die-sets up (13) YV21 de-energized, Last dieset downstroke(2) YV21 energized, Last dieset downstroke(2) Die-sets down (14) SPE die-set lift 2+2(6) SPE emergency upstroke 2+2(7) Downstroke after SPE lifting 2+2(8) SPE emergency downstroke 2+2(9) SPE self-learning procedure 2+2(10) Bottom punch holder assembly de-magnetised (optional) Bottom punch holder assembly magnetised (optional) Lower die-set de-magnetized Lower die-set magnetized Engage proportional knockout Release proportional knockout ALM in semi-automatic mode C.P. in semi-automatic mode Oil leak recovery pump Start/Stop ALM forward ALM reverse C.P. in manual mode Shutdown

1ST KEY

28* 28* 28* 25 30 25 30 26+31 27+29 28 26 31 28 and 31 26 and 28 25 and 26 30 and 31 28 29 27 26+31 25 30 31 26 26 31 25 27 29 30 25 25 30 30 28 31 26 31 26 28 28 28 28 29 27 27 or 29

2ND KEY+ Ø 1 2 2 2 3 3 3 3 3 3 4 5 6 7 7 7 7 7 7 7 8 8 8 9 9 11 11 12 12 13 13 13 13 13 13 13 13 13 14 14 15 15 16 16 17 18 20 21 21 22 24

KEY SWITCH

PUMP

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

ON ON ON ON ON ON ON ON ON

AUT

ON

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

OFF ON ON

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

ON ON ON

ON ON ON ON ON ON ON ON ON

ON ON ON ON ON ON 13

PH 339.85.089 Rev. 00 Date 10.12.01

Note: * Use key F8 on the computer terminal to select the type of work-cycle. + wo keys need to be used for most operations. However, some of them can be performed by pressing only one key. In these cases, the number of the key which has to be pressed appears in the column marked “2ND KEY”. (1) Operation not possible with 4-cylinder S.P.E. (2) Operation possible with 2-cylinder S.E. only (3) Operation not possible in proportional presses (4) Available only with version 13.01.01 or later versions (5) ONLY FOR PROPORTIONAL PHs The following conditions must be satisfied: filler-box hooked up, safety bar down, limit switch for end of filler-box’s return stroke triggered (input SQ59 off), die-set down, plunger raised with encoders zero set. (6) The following data items must be set as indicated: DIE-SET LOCKED = NO and DIE-SET DISASSEMBLY = 2. The following conditions must be satisfied: safety bar up, limit switch for end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders blocked and the selflearning procedure for SPE 2 + 2 carried out. (7) The following data items must be set as indicated: DIE-SET SECURED = NO and DIE-SET DISASSEMBLY = 3. The following conditions must be satisfied: safety bar up, limit switch for end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders blocked and the “DIESET ENCODER NOT RESET MESSAGE” displayed. (8) The following data items must be set as indicated: DIE-SET SECURED = NO and DIE-SET DISASSEMBLY = 2. The following conditions must be satisfied: safety bar up, limit switch for end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders blocked and the selflearning procedure for SPE 2 + 2 carried out. (9) The following data items must be set as indicated: DIE-SET SECURED = NO and DIE-SET DISASSEMBLY = 3. The following conditions must be satisfied: safety bar up, limit switch for end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders blocked and the “DIESET ENCODER NOT RESET MESSAGE” displayed. (10) The following data items must be set as indicated: DIE-SET LOCKED = NO and DIE-SET DISASSEMBLY = 1. The following conditions must be satisfied: safety bar up, limit switch for end of filler-box’s return stroke triggered (input SQ59 off) die-set encoders not blocked, “DIESET ENCODER NOT RESET MESSAGE” displayed and die-set down. (11) ONLY WITH VERSION PH 13.xx.yy The “FILLER-BOX ENCODER NOT RESET” should not be displayed when the filler-box is in the reset position. From version PH13.08.01 onwards, the user can reset the encoder zero-point offset for the filler box by performing the procedure below: Press keys 25, 30 and 8 with the mode selector turned to SET-UP and the PUMP OFF. Once this operation has been completed, the filler box will stop exactly when the encoder emits the zero-set pulse. (12) ONLY FOR PROPORTIONAL PHs The following conditions must be satisfied: filler-box hooked up, safety bar down, limit switch for end of filler-box’s return stroke triggered (SQ59) and the plunger raised with the encoders zero set. YV303 is de-energized and YV32 is fully opened during the downstroke if MOTION UPSTROKE, 1ST DEAERATION = 0, YV32 is fully opened during the upstroke if MOTION UPSTROKE, 1ST DEAERATION = 100. In the mean time, YV318 is opened to an extent equal to a % of the value set for 1ST PRESS-STROKE SPEED. Once 5 sec. have gone by, YV32 is brought back to the middle position (closed) and YV318 is closed. (13) With a proportional rod-type lift (optional), the upstroke is interrupted in SET-UP mode as soon as one of the two keys is released. With the SPE and the AX axis-control card, the die-set upstroke is allowed only when the dieset is completely down.

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PH 339.85.089 Rev. 00 Date 10.12.01

(14) With a proportional rod-type lift (optional), the downstroke in SET-UP mode is interrupted as soon as one of the two keys is released. Downstroke with the mode selector turned to MAN: - 2-downstroke cycle use keys 30 and 13 for the 1st die-set downstroke use keys 31 and 13 for the last die-set downstroke - 3-downstroke cycle use keys 26 and 13 for the first die-set downstroke use keys 30 and 13 for the second die-set downstroke use keys 31 and 13 for the last die-set downstroke (15) With the SPE and the AX card, the proportional valves open (during upstroke and downstroke) to an extent proportional to the upstroke and downstroke speed. (16) If a double plunger encoder is provided, and the “SEMI-AUTOMATIC PRESS CYCLE - MAN” cycle has been selected, it will be possible to raise or lower the safety bar and execute the semiautomatic pressing cycle after performing the loading operations in semi-automatic mode (safety bar down).

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PH 339.85.089 Rev. 00 Date 10.12.01

4.2

DESCRIPTION OF THE LEDs

+5

Keyboard supply (+5V)

R

Reset

WD

Watch-dog

SL

Serial line (comes on if the keyboard is not hooked up to the PLC)

SC

Scan control (comes on to indicate that a key is malfunctioning)

B

Comes on when a key is pressed

A1 A2

16

}

Keyboard address (both of them on —> first keyboard)

PH 339.85.089 Rev. 00 Date 10.12.01

COMPUTER TERMINAL

PAG DEL CHAR

DEL LINE

G

2

-

1

0

B

DESCRIPTION 25 line x 80 column electroluminescent display Function keys

C

Numeric keypad

D

Write key switch

E

Print routine display

F

Deletes last character typed in

G

Deletes last line typed in

H

Cursor keys

B

F1

F2

F3

F4

F5

F6

F7

F8

C

5 4

.

6

3

E N T E R

F

END

H

QUIT HOME SCREEN

E

+

A2

8 7

9

5.1 A

A

B

A1

-

SL

SC

R

WD

+5

OFF

D

WRITE

ON

PAG

SMC 085-11-409

5

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PH 339.85.089 Rev. 00 Date 10.12.01

5.2

DESCRIPTION OF THE LEDs

+5

Keyboard supply (+5 V)

R

Reset

WD

Watch-dog

SL

Serial line (comes on if the keyboard is not hooked up to the PLC)

SC

Scan control (comes on to indicate that a key is malfunctioning)

B

Comes on when a key is pressed

A1 A2

18

}

Keyboard address (both on —> first keyboard)

PH 339.85.089 Rev. 00 Date 10.12.01

5.3

PAGE LAY-OUT

Information about machine operations is given on the display. A number of pages are provided. The following items appear on each page:

1

2 4

3 5

6

7

1 -Fault messages 2 -No. of the operating program 3 -Date and time 4 -Description of the work-cycle 5 -Machine status 6 -Data input and read-out 7 -Description of the function keys Items 1, 2, 3, 4 and 5 appear on every page whereas items 6 and 7 change from page to page. The first page displayed (DATA) is given as an example.

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PH 339.85.089 Rev. 00 Date 10.12.01

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PH 339.85.089 Rev. 00 Date 10.12.01

5.4

NO. OF THE OPERATING PROGRAM

This number indicates the program the press is being run on. If an asterisk (*) appears to the right of the number, it means that changes have been made to the program which have not been saved yet. If the number of the operating program is ø, it means that this program has not been saved yet (this may happen when the system is turned on for the first time or when the operating program has been deleted).

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PH 339.85.089 Rev. 00 Date 10.12.01

5.5

DATE AND TIME

If DATE and TIME need to be corrected, proceed as directed below: 1) turn the key on the computer terminal to “ON”; 2) switch off the system and then turn it on again; 3) press the DEL CHAR key while DATE and TIME are displayed; 4) respond to the software-generated questions as they appear: QUESTION

RESPONSE (example)

YEAR

00 ENTER

MONTH DAY OF MONTH

24 ENTER

HOUR

15 ENTER

MINUTE

28 ENTER

SECOND

0 ENTER

In this way the following is obtained:

22

1 ENTER

DATE TIME

01/24/00 15:28:00

JANUARY 24, 2000

PH 339.85.089 Rev. 00 Date 10.12.01

5.6

DESCRIPTION OF THE WORK-CYCLE

The F8 key is used to select the type of work-cycle when the machine is started (press keys 28 and 2 on the machine control keyboard). This can be done only if the key switch is turned to AUT and the press is not in automatic mode or being reset. The standard cycle is the automatic one. In this case the following items appear at the beginning of the second line on the display. CYCLE = AUTOMATIC (LOADING + PRESS CYCLE) If the F8 key is pressed, the following will appear after one second: CYCLE = SEMI-AUTOMATIC LOADING If the F8 key is pressed again, the following will appear after one second: CYCLE = SEMI-AUTOMATIC PRESS CYCLE If the F8 key is pressed again, the system will go back to the standard work-cycle. If a double plunger encoder is provided, and the “SEMIAUTOMATIC PRESS CYCLE - MAN” cycle has been selected, it will be possible to raise or lower the safety bar and to execute the semiautomatic pressing cycle after performing the loading operations in semi-automatic mode (safety bar down).

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PH 339.85.089 Rev. 00 Date 10.12.01

5.7

MACHINE STATUS

The state of the press is indicated on the right-hand side of the second line displayed. The various modes in which the machine can operate are described below: MAN SET UP AUT RESETTING CYCLE CYCLE (flashing)

Key switch (on the keyboard) turned to MAN Key switch (on the keyboard) turned to SET UP Key switch (on the keyboard) turned to AUT The machine is being automatically reset (key switch turned to AUT) Press running in automatic mode (key switch turned to AUT) Press being stopped (key switch turned to AUT)

NOTE: If the key switch (on the keyboard) is turned during RESETTING or CYCLE, the press will stop running.

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PH 339.85.089 Rev. 00 Date 10.12.01

5.8

LIST OF PAGES

The pages related to press functioning are listed below:

As already mentioned, the DATA page is displayed when the system is turned on. To shift to other pages, press a function key (e.g. to shift from the DATA to the PROGRAMS page, press the F2 key). The operating and production data for the press is given on the pages which appear on the left-hand side of the diagram above. The pages on the right side show the values entered for the machine cycle. These settings can be changed if necessary. The help key (F1) can be used with any page active. By pressing this key, the user can gain access to the “Help” page on which the following information is provided: a list of the pages provided (similar to the one shown above) is given at the top of the page - the title of the page currently in use flashes. In addition, useful information for the operator is given at the bottom of the page. The user can gain access only to the pages which (in the list of the pages provided) are joined together by a straight line. Press one of the ↑ ↓ ← → keys to change the page whose title is flashing. To access another page by using the Help page, press the keys mentioned above until the title of the required page flashes. After doing this, press ENTER or the F1 key.

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PH 339.85.089 Rev. 00 Date 10.12.01

The STOPPAGES page can be accessed from the HELP page. The list of the faults that can be set by the operator is given on this page. This feature allows the operator to enter the amount of time the machine stops for the reasons listed below and obtain a detailed report regarding the causes of machine stoppages in the form of statistical charts.

Use the ↑ ↓ arrow keys to select the cause of machine stoppage. To make the item selected operative use the ← or → keys. NOTE: It is possible to select the cause of the stoppage only if there is no shutdown. If a stoppage message is displayed, it is possible to enter a new cause of the stoppage by using the functions described above.

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PH 339.85.089 Rev. 00 Date 10.12.01

5.9

DATA INPUT & READ-OUT

The contents of the pages (except for the first and second lines) are described below: 5.9.1 “DATA” The DATA video-page is the first one displayed.

a) The data related to the work-cycle which has just been completed appears in the first square on the left. The title shows the size of the tiles being produced (to change these three settings, gain access to the FITTINGS page). b) The data related to the transducers installed in the machine is shown in the square to the right. This data is updated in real time.

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PH 339.85.089 Rev. 00 Date 10.12.01

c) The production data is shown in the bottom square. The TOTALS cannot be reset whereas the PARTIAL values can. To do this, turn the key switch to “ON” and press the F6 key. The system will then ask the operator to CONFIRM the operation. If key “1” is pressed, all the partial values will be set to zero.

If the data does not need to be reset, press “0” or F6.

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5.9.2

“INFORMATION AND LANGUAGE SELECTION” PAGE

Press the F7 key (INFO) to go from “DATA” to “INFORMATION AND LANGUAGE SELECTION”. The typical parameters of the press are displayed here. They are divided into two parts. The hydraulic and mechanical settings appear on the left-hand side while the electronic ones are shown on the right.

These parameters will not change. Press the F2 key to return to the “DATA” page. Press the F6 key to activate the screensaver function. This is extremely useful as the screen will automatically be switched off after the keyboard has not been used for fifteen minutes thus prolonging its service life. To turn the screen back on, simply press any key. The language used to display all the messages can be changed from this page. Press the F3 key.

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At this point the messages are displayed in the language selected by simply pressing any function key (except F1). INSTRUCTIONS FOR SELECTING ITALIAN Go to the DATA page (if the procedure is not known, then simply turn the controller off and then on again: the DATA page will be the first to appear) then press F7 followed by F3 and finally by F2.

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5.9.3

AXES CONFIGURATION RESET

This page is shown in some machine. Press F5 from INFO to go to this page. The ENCODERS RESET function is used to reset some of the encoders on the press. To RESET AN ENCODER means determining the end stop position of the axis (plunger etc..) ENCODER NO. = XX This indicates the number of the encoder to be reset. The numbers are given in the list of the encoders the press is provided with shown on the display. These may be: 1 - PLUNGER 4 - PROP. KNOCKOUT (only with proportional rod-type knockout) To reset the plunger axis move the plunger fully up (to the mechanical end stop), raise the safety bar, turn the mode selector to SET UP and set ENCODER NUMBER = 1. NOTE The press or the auxiliary equipment that is installed on it may be provided with encoders which have to be RESET in a different way. For information concerning the RESET procedure for an encoder refer to the chapter ADJUSTMENTS in the USER’S MANUAL for the press.

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5.9.4

“ACTUAL LOADING DATA” PAGE

Press the F3 key (LOAD.) to go from the “DATA” page to the “ACTUAL LOADING DATA” page. a) The temperatures of the die-sets are displayed in the top block. The set value is shown to the right (SET). If a flashing square appears to the right of SET it means the corresponding heater is on. In addition, the time (expressed in percentage) each heater for the die-set stays on is shown for the HEAT-UP TIME data item. b) The operating times for the different steps into which the filler-box stroke is subdivided are shown in the left-hand block. The times were measured at the end of the previous cycle. These times are calculated only during the automatic or semi-automatic loading cycles. c) With the rod-crank mechanism filler box: the gains for the filler-box valve opening (forward and return strokes respectively) are displayed in the right block. In addition, the two OFFSET values (i.e. the minimum values required to move the filler-box) for the forward and return strokes are given on the right-hand side of this block. If a linear filler-box is employed, along with the OFFSET value for the return stroke (in the middle and to the right), some other filler-box data items cannot be modified. d) The filler-box encoder setting at the end of the first die-set downstroke (during the work-cycle just performed) and the length of the downstroke are shown in the square below. The latter is divided into two parts: the first is the time from when the solenoid valve is de-energized and sensor SQ3 is inactivated; the second is from when SQ3 is inactivated and SQ6 is activated. Only one time is given when a proportional knockout is employed. e) The actual operating state of the brush is shown at the bottom. Press the F2 key (DATA) to go from this page back to the “DATA” page; press the F4 key (PRESS CY.) to shift to the “ACTUAL PRESS CYCLE DATA” page or press the F5 key (DIE-SETS) to go to the “ACTUAL DIE-SET DATA” page.

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5.9.5

“ACTUAL PRESS CYCLE DATA” PAGE

To go to the “ACTUAL PRESS CYCLE DATA” page from the “DATA” page, press the F4 key (PRESS CYCLE). a) The times and the pressures (expressed in ms and bar respectively) for each individual workcycle stage are displayed in the left-hand square. These values were measured at the end of the cycle which has just been performed. In addition, the TILE THICKNESS value is shown in the THICK. column. This value is measured at the end of the first press-stroke, the end of the second press-stroke and at the end of the third one, if performed. With “proportional” presses, the first number on the left represents, for each press-stroke, the time taken to reach half the set pressure (if mode = 1 or = 2) or the time to reach the thickness set for S1/P1 (if mode = 0). With “proportional” presses only, the number which appears on each Deaeration line and in the THICKNESS column is the plunger stroke performed during deaeration. b) Some data items related to plunger braking are displayed on the top right-hand side. - For “conventional” presses only - setting of the brake logic-element stem: “40” and “470” correspond to the maximum and minimum braking forces applied respectively. To change these settings, press keys 26 or 31 and 7 on the machine control keyboard provided that: SPEED CONTROL ON = NO (on the PRESS CYCLE SET UP page) - The pressure in the plunger upstroke chamber (expressed in bar) is given in real time for “proportional” presses. - plunger speed at the end of the downstroke measured at the IMPACT POSITION. - speed after the plunger has passed the point where the brake is applied during the upstroke (only if braking during upstroke is selected on the PRESS CYCLE SET UP page) - maximum speed reached by the plunger during the previous upstroke or downstroke. - Max. speed the plunger has reached. The downstroke speed appears to the left; the upstroke speed appears to the right (only from version PH13.09.01 onwards). 33

PH 339.85.089 Rev. 00 Date 10.12.01

c) The following items are given in the square below: - maximum stroke carried out by the plunger during the cycle which has just been performed and, on the right (optional) the same value measured by the 2nd encoder BQ7 - distance between the upper and lower punches - difference between the thickness measured during the cycle which has just been performed and the set point (TILE THICKNESS on the PRESS CYCLE SET UP page). d) The amount of material (expressed in sq.m) or number of tiles to be produced in order to complete the current production batch is given in the square below. e) The current pump pressure setting is indicated here. For “proportional” presses, the proportional solenoid valves offset values determined during the self-learning procedure are displayed on the bottom of the page on the right side as follows: YV32 offset to perform the plunger downstroke, YV32 offset to keep the plunger stationary, YV32 offset to perform the plunger upstroke, YV318 offset. To go to the “DATA” page from this page press the F2 key (DATA), press the F3 key (LOAD.) to go to the “ACTUAL LOADING DATA” page or press the F5 key (DIE-SETS) to go to the “ACTUAL DIESET DATA” page.

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5.9.6

“ACTUAL DIE-SET DATA” PAGE

The “ACTUAL DIE-SET DATA” page can be accessed from the “ACTUAL LOADING DATA” and “ACTUAL PRESS CYCLE DATA” pages by pressing the F5 key (DIE SETS) - if the press is equipped with a proportional knockout. With a two-cylinder S.E. the data is as follows: The values of the two die set encoders are updated in real time and given for the DIE SETTING data item. The corresponding analog values are given for the ANALOG data item. The length of the upstroke is shown below the latter. The soft filling height (FILLING HEIGHT) along with the ratio between the thickness of the tiles and that of the soft filling (TILE THICKNESS / FILLING HEIGHT), expressed in percentage, are also displayed. With a four-cylinder S.P.E. or 2 + 2 cylinders the data is as follows: The values of the two die set encoders BQ4 and BQ5 are updated in real time and given for the DIE SETTING data item. The soft filling height (FILLING HEIGHT) along with the ratio between the thickness of the tiles and that of the soft filling (TILE THICKNESS / FILLING HEIGHT), expressed in percentage, are also displayed. Furthermore the movements of the knockout are shown in terms of time (ms) and speed (mm/s)

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With the SPE, the following data is displayed in the bottom section: STATE = Axis control card code AXIS CONTROL CARD ERROR= fault code from axis control card CONTROL = Analog datum signal from axis control card to proportional solenoid valve, side A and B: from 0 (max. datum signal during downstroke) to 4095 (max. reference signal during upstroke) (only with AX card) DIE SETTING = encoder setting as seen from axis control card (only with axis control card AP210) SPEED BTW PUNCHES = SPE average speed during upstroke between the punches measured by the axis control card (only with AP210 axis control card) PUSH = pushing force (expressed in bar) measured by the two SPE pressure transducers (only with AX card) ZERO POSITION - each time the die-set encoder is reset the following is displayed: distance between the “zero-set” signal and end-stop for side A, side B and cycle counter. The data provided during the penultimate reset procedure are displayed on the line underneath. CMD = Axis card control (only with AX card) STEP = Axis control card step (only with AX card) OFFSET = offset indicated by the SPE proportional valves expressed in % of max. opening (only with AX card) SPOOL = Position of SPE proportional solenoid valve spools, side A and B. The value can range from -100.0% (max. opening during downstroke) to 100.0% (max. opening during upstroke) (only with AX card) UPSTROKE CHAMBER PRESSURE = pressure transducer (set in bar) for the SPE bottom chambers (only with card AX) DOWNSTROKE = pressure transducer (set in bar) for SPE top chambers (only with AX card) Press the F2 key (DATA) to go back to the “DATA” page.

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5.9.7

“I/O” PAGE

This page can be accessed from the “DATA” page by pressing the F5 key and then F3. The values of all the PLC inputs are displayed here.

The state of the inputs is displayed here. SL4 Digital input (ON-OFF) A symbol ( ) appears next to the identification number of the input to indicate that the input is closed. The symbol is not shown if the input is open.

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Press F4 to go to the output page.

The state of the outputs is displayed. Two types of solenoid valves are provided. YV32S Digital output (ON-OFF) A symbol ( ) appears next to the identification number of the output to indicate that it is on. The symbol is not shown if the input is off. YV20A = XXXX Analog output (proportional valve) A number XXXX that ranges from 0 to 255 is shown next to the identification number of the output. “0” indicates that the solenoid valve is off. Numbers 1 to 255 indicate the valve is on. The values of the individual outputs the electronic equipment has turned on in that precise moment are also given. NOTE: Numbers 1 to 255 represent the output current (0-20 mA) that the card supplies to the corresponding channel. The number ranges from 0 to 4095 in some analog outputs. NOTE: Press the F4 key to go to the second output page.

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5.9.8

“FAULTS” PAGE

This page can be accessed from the DATA page by pressing the F5 key and then F4. The last 20 faults which caused machine shutdown or stoppage are shown here. The date and time are given with each one.

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5.9.9

“STATISTICS” PAGES

These pages can be accessed from the DATA page by pressing F5 and then F5 again. Bar charts that illustrate some statistics regarding the production run are given on these pages. The number of cycles taken into consideration in drawing up the graphs is given on the next to last line, on the right. To zero set the data, turn the WRITE key to ON and then press F6. When the system asks the operator to CONFIRM, press “1”. Press the PAG↓ or PAG↑ keys to scroll the pages. To print out the graphs displayed, press the F7 key (a CENTRONICS type printer has to be parallel connected to the output on the back of the card rack and the WRITE key needs to be turned to ON).

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The first chart displayed shows the ten causes of machine stoppage or shutdown which resulted in the most downtime (shown in order of time).

Note: - The complete straight line represents the machine downtime before the alarm was reset. - The lines which are cut off represent the machine downtime after the alarm was reset.

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The second chart displayed shows the ten causes of machine stoppage or shutdown which resulted in the greatest number of stoppages (shown in the order of number of stoppages).

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The third chart represents the percentage of defective pieces in relation to the total number produced for each thickness error band. The central bar represents the pieces whose thickness error is less than 10 hundredths of a millimeter.

Set value

Deviation from set value (mm)

Percentage in relation to total cycles

Percentage of each band in relation to total cycles

Total number of cycles performed

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The fourth chart shows the percentage of pieces in relation to the total number produced that fall within each pressure error band. The central bar represents the pieces whose pressure deviates by less than 4 bar.

Percentage of each band in relation to total cycles

Set value

Deviation from set value (bar)

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Percentage in relation to total cycles

Total number of cycles performed

PH 339.85.089 Rev. 00 Date 10.12.01

The fifth chart represents the percentage of cycles in relation to the total number performed for each error band regarding the time taken by the filler-box to carry out the forward stroke. The middle bar represents the cycles with errors that are less than 20 ms.

Set value

Deviation from set value (ms)

Percentage in relation to total cycles

Percentage of each band in relation to total cycles

Total number of cycles performed

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The sixth chart shows the percentage of cycles in relation to the total number performed for each error band regarding the time taken by the filler-box to carry out the return stroke. The middle bar represents the cycles with errors that are less than 20 ms.

Set value

Deviation from set value (ms)

Percentage in relation to total cycles

Percentage of each band in relation to total cycles

Total number of cycles performed

If the machine is equipped with a proportional knockout, the related statistics are provided. The following is shown: - graph showing the errors of cylinder A found after the die-set has completed its upstroke; - the same for cylinder B. If three downstrokes are carried out or with a four-cylinder S.P.E. the following is shown: - graph showing the errors of cylinder A found after the die-set has completed its first downstroke; - the same for cylinder B.

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5.9.11

“STATE OF EXECUTION” PAGE

This page can be accessed from the DATA page by pressing F5 and then F6. The state of execution of the program is shown on this page in numeric form. The numbers for each machine axis increase while the cycle is being carried out. In the event of machine shut down, the numbers are decoded and a fault message is displayed in the block so that the operator can understand what the machine was doing at the time of shut down. NOTE: The message is cleared as soon as the Reset button is pressed. The meaning of each digit is given on the following pages:

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0 X X X X H 1st 2nd 3rd

{

FILLER-BOX

1st) Coding of the main stage 01 = RETURN STROKE IN MANUAL 02 = FORWARD STROKE IN MANUAL 0A = RESETTING 1E = START OF AUTOMATIC CYCLE 20 = AUTOMATIC CYCLE IN PROGRESS 2nd) Not used. 3rd) Coding of operation in progress 0 = FORWARD STROKE F = RETURN STROKE

0 X X X X H 1st 2nd 3rd

{

DIE SETS

1st) Coding of the main stage 01 = UPSTROKE 02 = DOWNSTROKE 03 = UPPER PUNCHES IN 04 = UPPER PUNCHES OUT 05 = OVERTRAVEL 0A = RESETTING 14 = LOADING IN SEMI-AUTOMATIC 15 = PRESS-CYCLE IN SEMI-AUTOMATIC 1E = START OF AUTOMATIC CYCLE 1F = END OF RESETTING DURING AUTOMATIC CYCLE 20 = AUTOMATIC CYCLE IN PROGRESS 2nd) Coding of filler-box operation in progress 1 = FILLER-BOX FORWARD STROKE 2 = FILLER-BOX RETURN STROKE 3 = 2ND FORWARD STROKE (Optional) 4 = 2ND RETURN STROKE (Optional) 3rd) Coding of the secondary stage 1 = START OF LAST PRESS-STROKE 2 = START OF DELAY TIME FOR DIE-SET UPSTROKE 3 = END OF REMOVAL 4 = SYNCHRONIZATION 5 = END OF SYNCHRONIZATION 6 = FILLER-BOX START 7 = FIRST DIE-SET DOWNSTROKE 8 = LAST DIE-SET DOWNSTROKE 9 = THICKNESS CONTROL START A = SECOND DIE-SET DOWNSTROKE

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0 X X X X H 1st 2nd 3rd

{

PLUNGER

1st) Coding of the main stage 01 = SLOW UPSTROKE 02 = SLOW DOWNSTROKE 03 = UPSTROKE 04 = DOWNSTROKE 0A = RESETTING 14 = SEMI-AUTOMATIC PRESS-CYCLE 1E = START OF AUTOMATIC CYCLE 20 = AUTOMATIC CYCLE IN PROGRESS 2nd) Coding of the secondary stage 1 = PLUNGER DOWNSTROKE 2 = BRAKING DURING PLUNGER DOWNSTROKE 3 = DE-AERATION 4 = START OF PRESS-STROKE 5 = END OF PRESS-STROKE 6 = DELAY TIME FOR PLUNGER UPSTROKE 7 = PLUNGER UPSTROKE 3rd) Coding of number of press-strokes 0 = FIRST PRESS-STROKE 1 = SECOND PRESS-STROKE 2 = THIRD PRESS-STROKE

0 X X X X H 1st 2nd 3rd

{

POWDER LOADING

1st) Coding of the main stage 01 = IN MANUAL MODE 02 = IN SEMI-AUTOMATIC MODE 03 = IN AUTOMATIC MODE 2nd) Not used. 3rd) Coding of type of operation 0 = LEFT-HAND MOVEMENT F = RIGHT-HAND MOVEMENT

0 X X X X H 1st 2nd 3rd

{

ALM

1st) Coding of the main stage 01 = IN AUTOMATIC MODE 02 = IN SEMI-AUTOMATIC MODE 03 = RESETTING 2nd) Not used.

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3rd) Coding of secondary stage 1 = HOPPER GATE OPENING 2 = LOADING 3 = HOPPER GATE CLOSING 4 = ALM FORWARD

0 X X X X H 1st 2nd 3rd

{

BRUSH

1st) Coding of the main stage 00 = BRUSH PROGRAM NOT BEING EXECUTED FF = BRUSH PROGRAM BEING EXECUTED 2nd) Coding of secondary stage 1 = STOP BEFORE REVERSING 2 = REVERSE ROTATION 3rd) Coding of type of operation 0 = COUNTER-CLOCKWISE OPERATION F = CLOCKWISE OPERATION

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5.9.11

“PRODUCTION DATA” PAGE

This page can be accessed from the “DATA” page by pressing the F5 key and then F7. The production data is shown in the following forms: Day: current value along with that of the day before; Week: current value along with that of the week before; Month: current value along with that of the month before; Batch: current value along with that of the previous batch;

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5.9.12

“PROGRAMS” PAGE

To go to the “PROGRAMS” page from the “DATA” page, press the F2 key (PROGRAM). This page provides a list of the programs stored in the computer’s memory. A “PROGRAM” refers to all the machine operating data. Up to 128 programs can be stored in the computer’s memory. Each program is identified by a name. For example, program 4 has three exits for 330 mm x 330 mm tiles which are 10 mm thick while the maximum pressure for the press-cycle is set at 200 bar. The name of the program can be displayed in full. To do this, press the “←” or “→” key. To display other programs press the PAG↓ or PAG↑ keys. To perform operations with the stored programs, press the F7 key after turning the key switch on the computer terminal to ON.

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The functions which can be selected are given on the last line: WRITE This function is used to store the data of the operating program. Press the F2 key. The following appears on the bottom of the display:

Now type in the number of the program. The latter will be the back-up copy of the program being used (in the example above, the program in use is one deriving from program 32). If 26 is keyed in and the ENTER key is pressed, the program being used will be assigned number 26. As a result, the operating program will be the one numbered 26. 53

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READ This function is used to run the machine with the data for a program stored in the memory. This function cannot be used when the press is cycling in automatic mode. The following message will appear when the F3 key is pressed. READ PROGRAM NUMBER? Key in the number of the program required (e.g. 4) and then press the ENTER key. The following question will be displayed: SAVE PROGRAM NUMBER 26 (Ø = no, 1 = yes)? This allows the operator to save the old operating program (26 in the example) before loading the one required (4 in the example). CLEAR This function is used to delete a program. To do this, press the F4 key. The following message will appear: CANCEL PROGRAM NUMBER? Type in the number and then press the ENTER key. If the back-up copy of the operating program is deleted, the new program will be identified by ø.

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5.9.13

“LOADING SET UP” PAGE

To go to the “LOADING SET UP” page from the “PROGRAMS” page press the F3 key (LOAD.). This page shows the settings related to the press loading cycle. The top half of the page will show one of the following displays: 1) With program version PH13.xx.yy and linear filler-box: the end of the two filler-box strokes (END OF RETURN STROKE and FORWARD) must be set (in mm) in relation to the zero setting of encoder BQ2. The FILLER-BOX CONTROL ON data item should only be set to YES if a fault is to be signaled when the traveling time error exceeds 5% in relation to the set FILLER-BOX FORWARD STROKE TIME and the FILLER-BOX RETURN STROKE TIME. FILL.-BOX APPROACH POS.: if a value greater than the END OF RETURN STROKE is entered for this data item, the trigger pulse for the plunger downstroke is provided as soon as the fillerbox has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. Once the filler-box reaches the END OF RETURN STROKE during the press-cycle the ALM cycle will start. After the grid has been loaded, the filler-box starts traveling again at the speed set for SPEED until the value set for FILL.-BOX APPROACH POS. is reached. The filler-box strokes are divided into steps - or zones - (a maximum of 5 steps for the forward stroke and 5 for the return stroke). The filler-box speed in each of these zones can also be set. For the forward stroke enter: - end of zone 1 position - end of zone 2 position - end of zone 3 position - end of zone 4 position (the end of zone 5 position is the same as the End of Forward Stroke) - speed for the 5 forward stroke zones

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For the return stroke enter: - end of zone 1 position - end of zone 2 position - end of zone 3 position - end of zone 4 position (the end of zone 5 position is the same as the End of Return Stroke) - speed for the 5 return stroke zones Example with linear filler-box: end of return stroke = 175 mm, approach setting = 430 mm and end of forward stroke = 1185 mm end of zone positions during forward stroke = 520 700 700 1050 forward stroke speed = 35 55 55 85 70 This means that: from the end of the return stroke to the approach setting, the filler-box travels at the approach speed. zone 1) from the approach setting up to 520 mm the filler-box travels at 35% of its full speed zone 2) from 520 mm up to 700 mm the filler-box travels at 55% of its full speed zone 3) from 700 mm up to 1050 mm the filler-box travels at 85% of its full speed zone 4) from 1050 mm up to the end of the forward stroke the filler-box travels at 70% of its full speed end of zone positions during return stroke = 1000 685 520 430 return stroke speed = 70 85 80 70 60 This means that: zone 1) from the end of the forward stroke up to 1000 mm the filler-box travels at 70% of its full speed zone 2) from 1000 mm up to 685 mm the filler-box travels at 85% of its full speed zone 3) from 685 mm up to 520 mm the filler-box travels at 80% of its full speed zone 4) from 520 mm up to 430 mm the filler-box travels at 70% of its full speed zone 5) from 430 mm up to the end of the return stroke the filler-box travels at a 60% of its full speed When in the mode selector is turned to MAN, the filler-box travels at a constant speed which equals that set for SPEED IN MANUAL MODE. 2) With program version PH13.xx.yy and connecting rod-and-crank mechanism filler-box with proportional solenoid valve: Set the end of the filler-box return stroke as a percentage. FILLER-BOX CONTROL ON should only be set to YES if the filler-box speed is to be automatically controlled according to the operating times set for F-B FORWARD RUN TIME and F-B RETURN TIME. Once this function has been activated, check the F-STROKE GAIN and RET. STROKE GAIN settings which are found on the “ACTUAL LOADING DATA” page. These settings must fall between 140 and 160. If they do not, change the setting for GAIN (RP2) until the desired values are reached. If the value entered for FILL.-BOX APPROACH POS. is greater than the END OF RETURN STROKE value, the following cycle will be carried out: - without ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. At the same time, the APPROACH DELAY TIME starts to elapse. Once the filler-box reaches the END OF RETURN STROKE, during the press-cycle, it stops for the amount of time set for the APPROACH DELAY TIME data item. After this time has elapsed the filler-box starts traveling again at the speed set for the SPEED data item until the value set for FILL.-BOX APPROACH POS. is reached; - with ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. Once the filler-box reaches the END OF RETURN STROKE, during the press-cycle, the ALM cycle will start. After the grid has been loaded, the filler-box starts traveling again at the speed set for SPEED until the value set for FILL.-BOX APPROACH POS. is reached.

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The filler-box strokes are divided into set steps - or zones - (a maximum of 5 steps for the forward stroke and 5 for the return stroke). The filler-box speed in each of these zones can also be set. For the forward stroke enter: - end of zone 1 position - end of zone 2 position - end of zone 3 position - end of zone 4 position (the end of zone 5 position is the same as the End of Forward Stroke) - speed for the 5 forward stroke zones For the return stroke enter: - end of zone 1 position - end of zone 2 position - end of zone 3 position - end of zone 4 position (the end of zone 5 position is the same as the End of Return Stroke) - speed for the 5 return stroke zones When the mode selector is turned to MAN, the filler-box travels at a constant speed which equals that set for the first zone of the forward stroke. 3) With program version PH13.xx.yy and connecting rod-and-crank mechanism filler-box without proportional solenoid valve: Set the end of the filler-box return stroke as a percentage. Set FILLER-BOX CONTROL ON = NO. The values set for F-B FORWARD RUN TIME and F-B RETURN TIME are only used for the STATISTICS PAGES. Set FILL.-BOX APPROACH POS. = 0.0%. GAIN (RP2) has no relevance. The filler-box strokes are divided into set steps - or zones - (a maximum of 5 steps for the forward stroke and 5 for the return stroke). The filler-box speed in each of these zones can also be set. If a value between 0 and 76% is set the filler box travels at low speed (YV20B off). If a value between 77 and 100% is set the filler box will travel at high speed (YV20B on). For the forward stroke enter: - end of zone 1 position - end of zone 2 position - end of zone 3 position - end of zone 4 position (the end of zone 5 position is the same as the End of Forward Stroke) - speed for the 5 forward stroke zones For the return stroke enter: - end of zone 1 position - end of zone 2 position - end of zone 3 position - end of zone 4 position (the end of zone 5 position is the same as the End of Return Stroke) - speed for the 5 return stroke zones When the mode selector is turned to MAN, the filler-box travels at a constant speed which equals that set for the first zone of the forward stroke.

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PH 339.85.089 Rev. 00 Date 10.12.01

4) With program version PH11.xx.yy or earlier and connecting rod-crank mechanism fillerbox with proportional solenoid valve:

The illustration above shows the set-points relating to the filler-box strokes, the encoder position for the end of the return stroke and the filler-box speed during the 8 forward steps and 8 return steps. Enter the following: FILLER-BOX CONTROL ON = YES Also enter the length of time required for the filler-box forward and return strokes for F-B FORWARD RUN TIME and F-B RETURN TIME respectively. In this way the filler-box speed is automatically controlled according to the set operating times. When this control has been activated, check the F-STROKE GAIN and RET. STROKE GAIN settings which are found on the “ACTUAL LOADING DATA” page. These settings must fall between 140 and 160. If they do not, change the setting for GAIN (RP2) until the desired values are reached. If the value entered for FILL.-BOX APPROACH POS. is greater than “0”, the filler-box approach cycle will be carried out: - without ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. At the same time, the APPROACH DELAY TIME starts to elapse. Once the filler-box reaches the end of its return stroke, it stops for the amount of time set for the APPROACH DELAY TIME data item. After this time has elapsed the filler-box starts traveling again at the speed set for the APPROACH SPEED data item until the value set for FILL.-BOX APPROACH POS. is reached; - with ALM: the trigger pulse for the plunger downstroke is provided as soon as the filler-box has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. Once the filler-box reaches the end of its return stroke, the ALM cycle will start. After the grid has been loaded, the filler-box starts traveling again at the speed set for SPEED. Finally, the GAIN (RP2) data item is used to control the speed of hydraulic filler-box operated by the proportional solenoid valve. 58

PH 339.85.089 Rev. 00 Date 10.12.01

5) With program version PH11.xx.yy or earlier and connecting rod-crank mechanism fillerbox without proportional solenoid valve: Set FILLER-BOX CONTROL ON = NO. If a value between 0 and 76% is set for the 16 steps, the filler box travels at low speed. If a value between 77 and 100% is set, the filler box will travel at high speed. Set FILL.-BOX APPROACH POS. = 0.0%. The GAIN (RP2) setting has no effect. 6) With program version PH11.xx.yy or earlier and linear filler-box: The following data should be entered in the FILLER-BOX block: The data items END OF RETURN STROKE and FORWARD represent the two filler-box strokes in mm in relation to the zero setting of the encoder. The FILLER-BOX CONTROL ON data item is used to select whether a fault is to be signaled when the traveling time error exceeds 5% in relation to the set TIME. FILL.-BOX APPROACH POS.: if a value greater than “0” is entered for this data item, the trigger pulse for the plunger downstroke is provided as soon as the filler-box has passed the value set for FILL.-BOX APPROACH POS. during its return stroke. Once the filler-box reaches the end of its return stroke, the ALM cycle will start. After the grid has been loaded, the filler-box starts traveling again at the speed set for SPEED until the value set for FILL.-BOX APPROACH POS. is reached. In manual mode the filler-box moves at a speed set for SPEED IN MANUAL MODE. In automatic or semi-automatic mode, the filler-box travels at the set speeds. If the value set for FILL.-BOX APPROACH POS. is greater than “0”, the steps go from the FILL.-BOX APPROACH POS. to the END OF FORWARD STROKE. The last part of the return stroke is performed at the same speed as that set for the eighth step of the return stroke. If the FILL.-BOX APPROACH POS. = 0, the steps start from the end of the return stroke and go to the end of the forward stroke. All the steps have the same length.

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PH 339.85.089 Rev. 00 Date 10.12.01

SERVICE BLOCK SERVICE PRESSURE: this value is entered for the aux. equipment circuit through the use of solenoid valve YV64. NOTE: with certain types of PH (when the control assembly is not provided with pressure transducer BP2 and the related control for the aux. equipment YV64) “0” needs to be entered to inactivate the aux. equipment pressure control. SERVICE PRESS. 2nd RECHARGING: if YES is entered, the pressure is recuperated at the beginning of the last de-aeration if it was below the minimum set threshold (a fault signal is given before the die-set upstroke). With the linear filler-box or double-loading filler-box, the pressure in the auxiliary equipment is recuperated during the filler-box stroke. EJECTION DURING STOPPAGE: if YES is entered, the tiles are ejected at the end of the press stop cycle. DIE-SET BLOCK DIE-SET UPSTROKE DELAY TIME: - with WAIT FOR LOWER DIE-SET = NO: if the die-set is provided with a SMU device or a conventional Knockout, this time starts from the beginning of the last press-stroke. If the die-set is provided with a proportional knockout, the time starts from the end of the last press-stroke. - with WAIT FOR LOWER DIE-SET = YES: the data item becomes DIE UPSTROKE DELAY TIME and the time starts to elapse from when the plunger moves up again according to the setting PLUNGER TRAVEL, DIE-SETS UP PUNCHES EJECTION DELAY (only with SFS type upper die-set): - with WAIT FOR LOWER DIE-SET = NO: the delay time starts from the end of the last pressstroke. - with WAIT FOR LOWER DIE-SET = YES: the delay time starts from the beginning of the last press-stroke. 1st DOWNSTROKE POSITION: this is the position the filler-box reaches during its forward stroke when the first downstroke is performed. With a three-downstroke cycle and filler box NOT designed for double loading, the user can set the position of the filler box for the 2nd downstroke (GLAZE FALL POSITION). This setting can be entered if the glaze must fall during the forward (0) or return (1) stroke. FILLER-BOX/PLUNGER BLOCK F.BOX SETTING AT PLUNGER START (ONLY with linear filler-box) If miniature switch SQ59 is activated, the plunger will begins its downstroke at the set moment during the return stroke of the linear filler-box. Otherwise the press signals a fault. If a mobile die is installed, this setting must be made so that the grid is outside the die itself. Set O to turn off this function. F.BOX START ADVANCE FILLER-BOX SAFETY SETTING (ONLY with proportional presses and linear filler-box). When the PLUNGER UP - FILLER-BOX START ADVANCE setting is exceeded during the plunger upstroke, the filler-box starts to move. When the filler-box arrives at the FILLER-BOX SAFETY SETTING, check that the plunger has arrived at the setting for the end of its upstroke. Otherwise the filler-box movement is blocked and the message “F.BOX/PLUNGER COLLISION” is shown. Set FILLER-BOX START ADVANCE = 0 to turn off this function.

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PH 339.85.089 Rev. 00 Date 10.12.01

From this page, press F2 (PROGRAM) to go back to the PROGRAMS page. Instructions on how to change the set data are given below: 1) First of all move the cursor next to the data item to be modified by pressing one of the following keys: ↓ to shift to the next data item PAG ↓ to shift to the next data block END to shift to the last data item on the page ↑ to shift to the previous data item PAG ↑ to shift to the previous data block HOME to shift to the first data item on the page 2) The set points can be changed in two ways: a -enter a new value by using the following keys: 0, 1, 2, 3, 4, 5, 6, 7, 8, 9 - to indicate a negative number . to indicate decimal points DEL CHAR to delete the last number entered DEL LINE to delete the entire data item entered ENTER to make the data operative b -By using the “-” and “+” keys found above the ENTER key: - keep it pressed to decrease the value + keep it pressed to increase the value 3) The second to last line on the display provides all the information necessary to enter the data: a) MIN = 0.0 MAX. = 40.0 These items indicate the minimum and maximum settings for the data item pointed out by the cursor. b) +/If this symbol appears, it means that the data item pointed out by the cursor can be changed in the same way as directed for “b” given at point 2) above. c) FILLER-BOX ENCODER = 0.0% Useful information on how to change the data item pointed out by the cursor is displayed. In the example above, the filler-box encoder setting is shown. This value is useful to set the end of the filler-box’s return stroke. If no messages appear on the second to last line, it means that the data item cannot be changed because the WRITE key switch is turned to OFF. With the WRITE key turned to OFF, changes can be made to the functions below by following the directions given for “b” at point 2) above: MOULD UPSTROKE DELAY/DIE UPSTROKE DELAY The FILL.-BOX APPROACH POS. data item can be modified only if the mode selector is turned to SET-UP.

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5.9.14

“PRESS-CYCLE SET UP” PAGE

To go to the “PRESS CYCLE SET UP” page from “PROGRAMS” press the F4 key (PRESS CY.). The data set for the press cycle is given on this page. 1) Presses with proportional hydraulic system

a) The following information is displayed in the first square on the left-hand side: Some important settings for the plunger stroke and three data items regarding tile thickness: The tiles are produced according to the TILE THICKNESS setting. Perform the following steps to enter the required settings: - enter the maximum allowable value for the IMPACT POSITION data item, e.g. 140.00 mm; - enter the maximum allowable value for the THICKNESS SETTING data item, e.g. 40.00 mm; - lower the plunger in manual mode until it rests on the powder contained in the die-set; - with the cursor on the IMPACT POSITION data item, read the actual setting of the plunger encoder given on the second to last line on the screen; - enter a value which is lower than that of the encoder for the IMPACT POSITION data item: For example: if the PLUNGER ENCODER = 106.80 mm, set IMPACT POSITION to 105.00 mm. Also set PRESSING START POS. to 105.00 mm ; - allow the machine to perform one press-cycle; - with the cursor on the SHUTDOWN POSITION data item read the value given for the MAX. PLUNGER STROKE data item and enter a value greater than it for the SHUTDOWN POSITION data item; - do the same for the SHUTDOWN POSITION 1ST data item; - with the cursor on the THICKNESS CALIBRATION data item, read the value displayed for the TILE THICKNESS data item given on the second to last line on the screen; - measure the actual thickness of the tile; - enter the same value as the measured one for the THICKNESS CALIBRATION data item; 62

PH 339.85.089 Rev. 00 Date 10.12.01

- enable the automatic thickness gauge by entering a value higher than 0 for THICKNESS CTRL COEFF. - enter a value which corresponds to the desired thickness for the TILE THICKNESS data item. NOTE: This procedure must be performed whenever the die-set is replaced! NOTE: If a program is called up after the die-set has been replaced, perform this procedure after reading the program! Automatic thickness control: - With a SMU system having a conventional lift mechanism or 2-cylinder S.E.: The recommended value for THICKNESS CONTROL PULSE is 200. If the press has to perform too many cycles in order to reach the thickness set for the TILE THICKNESS data item, increase the setting, e.g. to 300. If the thickness of the tiles produced is not always the same, decrease the value, for example to 100. - With a 4-cylinder S.P.E. Enter a value greater than 0 in THICKNESS CTRL COEFF. The recommended value is 50%; if the press needs too great a number of cycles to reach the thickness set in TILE THICKNESS increase the value. If the thickness is unstable, decrease the value. PLUNGER UP POSITION is the position the plunger reaches when it completes its upward movement during the automatic cycle. The plunger reaches its mechanical end-stop during the semi-automatic cycle or when the machine is stopped. END STOP PRECISION is used to more precisely position the plunger at the value set for PLUNGER UP POSITION. If Ø is entered, minimum precision is obtained. On the other hand, if 100 is entered, the plunger positioning is extremely precise while the production output is reduced (because the plunger slows down to a greater extent). IMPACT POSITION: when this plunger setting is reached, braking finishes. PRESSING START POS. when this plunger setting is reached, the first press-stroke delay time starts to elapse (DEL. in ms). When the delay time has elapsed, the first press-stroke starts. If the first press-stroke is to stop at the set thickness, enter PRESS STROKE START THICKNESS, which is the thickness of the soft filling height at which the first press-stroke should start. FINAL PRESSURE: enter the pressure of the last press-stroke TOLERANCE: enter the tolerance for the pressure of the last press-stroke to the right of the symbol ±. If zero is entered for the tolerance, the last press-stroke will finish when the final pressure is reached. If, on the other hand, the tolerance is 5 bar, the last press-stroke will finish when the tile thickness is reached; as long as the pressure is between “final pressure - tolerance” and final pressure + tolerance” (see figure 1). - The PLUNGER PARALLELISM data item may appear in some machines. This value, expressed in mm, represents maximum plunger inclination during the press-cycle. THICKNESS LIMIT FAULT: this indicates the thickness limit beyond which the press stops working (recommended value = 0.40 mm) b) The following are shown in the “braking” block: - plunger braking during the first press-stroke; - speed when the plunger is moving down to the IMPACT POSITION; - braking during upstroke; if this function is enabled, braking will start when the plunger rests on the tile and stops when the value set for END OF BRAKING UPWARDS is reached. Also enter the plunger speed during the part of the stroke with braking.

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c) Press cycle: The press-stroke parameters are entered here. PRESS-STROKE MODE: (0=to thickness, 1 = to pressure, 2 = to set time) this data item can only be set when the machine is in SET-UP mode; type O can only be used for the first press-stroke. Type O: the press-stroke finishes when the soft filling height set in the SP/PR column is reached. Type 1: the press-stroke finishes when the cylinder pressure has reached the setting in the SP/ PR column. Type 2: the press-stroke finishes after a time controlled by the control system, in order to obtain cylinder pressure equal to the setting in the SP/PR column, has elapsed. Pressure or thickness SET-POINT for each intermediate press-stroke. PRESS-STROKE TREND: S1/P1 = thickness/pressure at the first point on the line shown on the graph (this can only be set for type 0; otherwise it is fixed at half the set pressure). T1 = first time at which the pressure, as shown on the line, reaches value S1/P1. T2 = total length of pressure trend. Example 1 (see figure 2): 1st press-stroke set to type 0 with THICKNESS AT START OF PRESS-STROKE = 15.00, SP/PR = 12.00, S1/P1 = 13.00, T1 = 2000, T2 = 3000. This means that the press-stroke starts when the soft filling height reaches 15 mm. The press will adjust YV318 in order to reach a soft filling height of 13 mm in 2 seconds and then 12 mm in another second. Example 2 (see figure 3): last press-stroke set to type 1 with FINAL PRESSURE = 250 bar, S1/P1 = 125, T1 = 2000, T2 = 3000. This means that the press will adjust YV318 in order to reach a cylinder pressure of 125 bar in 2 seconds and then 250 bar in the next second. - Select whether the press-stroke is to be performed without the booster (in this case it is performed with the direct press-stroke solenoid valve). - Delay time before first press-stroke. PRESS-STROKE SPEED: this is the extent to which YV318 opens during the press-stroke, expressed as a percentage. YV318 controls the delivery rate to the press-cycle control assembly. d) The data items regarding deaeration should be set in the right-hand block. DEAERATION block: MOTION UPSTR.: the speed for the deaeration upstroke should be entered here. Enter Ø to perform the upstroke at a slow constant speed (through YV31S), enter 100 to perform a fast upstroke (through YV32). STROKE: the deaeration upstroke is set here. DURAT.: set the amount of time the deaeration setting should last SPE. DOWNSTR: set the speed of the downstroke after deaeration. e) The CYLINDER PRESSURE REGAINED function allows energy to be saved.

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Soft filling height

Fig. 1

Final thickness

Tolerance

Tolerance

Final pressure

Cylinder pressure

Thickness

Fig. 2

Thickness at start of pressstroke

S1/P1 SP/PR

T1

T2

time

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Pressure

Fig. 3

SP/PR or final pressure (=PR)

PR/2

T1

66

T2

time

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2) Presses with traditional hydraulic system

a) The following information is displayed in the first square on the left-hand side: Some important settings for the plunger stroke and three data items regarding tile thickness: The tiles are produced according to the TILE THICKNESS setting. Perform the following steps to enter the required settings: - enter the maximum allowable value for the IMPACT POSITION data item, e.g. 140.00 mm; - enter the maximum allowable value for the THICKNESS SETTING data item, e.g. 40.00 mm; - lower the plunger in manual mode until it rests on the powder contained in the die-set; - with the cursor on the IMPACT POSITION data item, read the actual setting of the plunger encoder given on the second to last line on the screen; - enter a value which is lower than that of the encoder for the IMPACT POSITION data item: For example: if the PLUNGER ENCODER = 106.80 mm, set IMPACT POSITION to 105.00 mm. Also set PRESSING START POS. to 105.00 mm ; - allow the machine to perform one press-cycle; - with the cursor on the SHUTDOWN POSITION data item read the value given for the MAX. PLUNGER STROKE data item and enter a value greater than it for the SHUTDOWN POSITION data item; - do the same for the SHUTDOWN POSITION 1ST data item; - with the cursor on the THICKNESS CALIBRATION data item, read the value displayed for the TILE THICKNESS data item given on the second to last line on the screen; - measure the actual thickness of the tile; - enter the same value as the measured one for the THICKNESS CALIBRATION data item; - enable the automatic thickness gauge by entering a value higher than 0 for THICKNESS CTRL COEFF. - enter a value which corresponds to the desired thickness for the TILE THICKNESS data item. NOTE: This procedure must be performed whenever the die-set is replaced! NOTE: If a program is called up after the die-set has been replaced, perform this procedure after reading the program! 67

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Automatic thickness control: - With a SMU system having a conventional lift mechanism or 2-cylinder S.E.: The recommended value for THICKNESS CONTROL PULSE is 200. If the press has to perform too many cycles in order to reach the thickness set for the TILE THICKNESS data item, increase the setting, e.g. to 300. If the thickness of the tiles produced is not always the same, decrease the value, for example to 100. - With a 4-cylinder S.P.E. Enter a value greater than 0 in THICKNESS CTRL COEFF. The recommended value is 50%; if the press needs too great a number of cycles to reach the thickness set in TILE THICKNESS increase the value. If the thickness is unstable, decrease the value. PLUNGER UP POSITION is the position the plunger reaches when it completes its upward movement during the automatic cycle. The plunger reaches its mechanical end-stop during the semi-automatic cycle or when the machine is stopped. IMPACT POSITION: when this plunger setting is reached, braking finishes. FINAL PRESSURE: enter the pressure of the last press-stroke. - The PLUNGER PARALLELISM data item may appear in some machines. This value, expressed in mm, represents maximum plunger inclination during the press-cycle. THICKNESS LIMIT FAULT: this indicates the thickness limit beyond which the press stops working (recommended value = 0.40 mm) b) The following are shown in the “braking” block: - plunger braking during the first press-stroke; - braking space during the last part of the plunger downstroke - speed control during plunger downstroke and related speed to the IMPACT POSITION; - braking during upstroke; if this function is enabled, braking will start when the plunger rests on the tile and stops when the value set for END OF BRAKING UPWARDS is reached. c) Press cycle: The press-stroke parameters are entered here. - pressure for each intermediate press-stroke - select whether the press-stroke is to be performed without accumulators (separate) - select whether the press-stroke is to be performed without booster (in this case it is performed with the direct press-stroke solenoid valve) - delay time before the first press-stroke (for presses with piloted de-aeration also enter the delay time before the second and third press-strokes). d) The length of time each deaeration stroke lasts is set in the right-hand block. e) In some types of press, the CYLINDER PRESSURE REGAINED data item is set in the block at the bottom of the screen. This function allows energy to be saved. With this page active, press F2 (PROGRAMS) to go back to the PROGRAMS page. The data should be input in the same way as described for the LOADING SET-UP page. Also note the following: with the WRITE key switch turned to OFF, the following data items can be modified using method b) described in point 2) above: 1ST PRESS-STROKE DEAERATION LENGTH 68

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5.9.15

“DIE-SET SET UP” PAGE

To go to the “DIE-SET SET UP” page from “PROGRAMS” press the F5 key (DIE-SETS). The set points related to the die-set are displayed on this page. a) The following items appear in the SIZE block along with the three size parameters: TYPE OF BATCH: enter Ø to set the production batch in m2, enter 1 to set it in terms of the number of tiles produced. PRODUCTION BATCH: as soon as the press has produced the tiles which correspond to the set value, the press will stop and BATCH COMPLETED will appear on the display. TILE CODE indicates the type of product. SHRINKAGE: this specific pressure is calculated by referring to the unfired tiles. Kiln production (sq.m produced) is determined by referring to the shrinkage (difference btw die cavity and fired tiles expressed in %) b) Die-set temperature: To turn off a heater, enter ø for the related set point. c) SFS BLOCK: DIE-SET TYPE: enter - 1 if a SFS upper die-set is installed, 0 if the lower die is fixed or 1 if the lower die is mobile. DOUBLE EFFECT: enter YES if there is a double-acting die-set or NO if it is single-acting. PUNCHES INSIDE: enter 1 to move the upper punches back in when the filler-box starts, 2 to move them in when the filler-box is at the end of its forward-stroke and 3 to move them in when the filler-box is at the end of its return stroke. WAIT LOWER DIE: enter YES to enable the “lock/unlock die” operation when the lower mobile die remains locked in its low position at the end of the press-cycle. After the plunger has moved back up again - performing a movement equal to PLUNGER TRAVEL, DIE-SETS UP - the lower punch upstroke is performed. After the MOULD UPSTROKE DELAY time has elapsed (LOADING SET-UP page) the lower die is unlocked and moves up to the upper end-stop thus energising the 2 sensors SQ63A/B. 69

PH 339.85.089 Rev. 00 Date 10.12.01

d) Two data items regarding maintenance of the die-sets are given in this block along with the type of material the punches are constructed in. First of all, the operator has to enter the expected service life of the die-set for the “NO. OF CYCLES DIE-SET LIFE” data item. Each time the die-set is changed as the production cycle is modified jot down the value given for the “CYCLES PERFORMED WITH DIE-SET” data item shown on the “ACTUAL LOADING DATA” page regarding the die-set being removed. Once the die-set has been installed, enter the value for “NO. OF CYCLES PERFORMED”. As soon as the die-set reaches the number of cycles entered for “NO. OF CYCLES DIE-SET LIFE” the following message appears: “REPLACE DIE-SET”. e) Two data items regarding the upper and lower die-sets are given in the MAGNETIC LOCK block. Enter YES if the related magnetic lock is provided on the press. Two other data items are provided for demagnetizing the die-sets: enter YES before demagnetizing the die-set (these settings are operative ONLY with program version PH 11.01.01.7TR or later). If the press is provided with the magnetic lock set UPP. = YES and LOW. = YES. Magnetising procedure: with the key switch turned to SET UP press the “magnetisation” keys (see chap. DESCRIPTION OF KEYS) and make sure the related leds come on. Adjust the current control device of the magnetism (AJ1 and AJ2) (see INSTRUCTIONS FOR ADJUSTING THE ELECTRICAL EQUIPMENT); turn the key switch to MAN. Demagnetising procedure: with the key switch turned to SET UP set DEMAGNETISATION UPP. = YES AND LOW. = YES, press the related keys (see DESCRIPTION OF KEYS) and make sure the related leds go out (they flash for more than a minute). To release a magnetic lock, first demagnetise it and then set UPP. = NO (or LOW. = NO). The two data items LOW. 1, which relate to the magnetic lock of the bottom punch holder (optional), appear at the bottom. f)

As far as DIE-SET BLOWING is concerned, the operator can set the stages in which the solenoid valve (YV173) for die-set blowing is activated. Set DURING PRESS. = YES to operate the blower during the press-0cycle. Enter the plunger encoder value at which blowing is terminated during the upstroke for the OFF POS. data item. Enter the blowing value for the SFS pusher to clean the mobile die (YV178) on the line below. It is energized during the plunger downstroke at the value set for ON. POS. and is de-energized at the value set for OFF POS. If a linear filler-box is used, the DOUBLE-ROW BLOWER data item is also provided. If a value > 0 is entered, YV175 is energized when the filler-box starts running and is de-energized once the filler-box has exceeded the set value. Two additional data items, NO. CYCLES and LENGTH have been added to the DIE-SET BLOWING block for the PH 4200. These data items concern YV 174 (PH 4200 base blowing). This solenoid valve is energized for two seconds whenever the automatic cycle is started and periodically every n cycles, where n = NO. CYCLES. The length is the value entered for the LENGTH data item.

g) Setting the proportional ejector (2-cylinder S.E. optional): The setting the die-set has to reach during its upstroke along with the speed (expressed in percentage) at which the die-set carries out the upstrokes and downstrokes are to be entered here. DIESET SELF-LEARNING is a procedure to be carried out whenever the die-set is changed so that the punches and die are aligned during knockout. Proceed as follows: 1 - Reset the machine and then reset the encoders. Next, enter the desired values for UPPER LIMIT A and B. 2 - With the safety bar raised, enter DIESET SELF-LEARNING = YES. 3 - Carry out DIE-SET UPSTROKE and wait until the led of key 13 flashes. 4 - Make sure the punches are at exactly the same level as the die (they must be perfectly aligned); if they are not, move the cursor to the UPPER LIMIT A data item and use the “-” and “+” keys on the terminal keyboard to adjust the height of cylinder A. Do the same for cylinder B. 70

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5 - To end the procedure, enter DIESET SELF-LEARNING = NO To remove the tiles between the punches enter KNOC. = YES. Finally, set how far the punch should move up during overtravel in relation to the die. Press the F2 key (PROGRAM) to go back to the PROGRAMS page from this page. Follow the directions given on the LOADING SET UP page to set the following data items. ENABLE SPS WAIT LOWER DIE UPP. MAGNETIC LOCK LOW. MAGNETIC LOCK UPP. DEMAGNETIZATION LOW. DEMAGNETIZATION DIESET SELF-LEARNING END STOP (UP) A END STOP (UP) B KNOC. These data items can be modified only if the mode selector is turned to SET-UP.

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5.9.16

“S.P.E. DIE-SET SET-UP” PAGE

The “S.P.E. DIE-SET SET-UP” page can be accessed from the “DIE-SET SET-UP” page by pressing F5 (S.P.E.). This page (which is optional) shows the proportional knockout setpoints. a) Settings: First of all, enter the number of SPE downstrokes (which can be changed only in SETUP mode and with the die-set down) - 2-downstroke cycle

die-set setting

soft filling height upper end stop

time die-set upstroke

72

first die-set downstroke

last die-set downstroke

PH 339.85.089 Rev. 00 Date 10.12.01

- 3-downstroke cycle die-set setting

base material thickness upper end stop

glaze thickness

time die-set upstroke

first die-set downstroke

second die-set downstroke

last die-set downstroke

b) Set the speed for the various movements of the die-set. c) Set the following: If the knockout between the punches is required, set KNOCKOUT BTW PUNCHES = number other than Ø (only with SPE). With the AX card activated, go to data item KNOCKOUT BTW PUNCHES to set the required knockout force (in bar), 0 = upstroke btw punches off. With the 4-cylinder SPE, the following settings need to be entered for KNOCKOUT BTW PUNCHES: - 1 for standard knockout force 1 for a lower knockout force 2 for a higher knockout force 0 knockout btw punches off Set DIE-SET ENGAGED = YES only if the die-set has actually been engaged. With the 2+2 cylinder SPE, data item DIE-SET DISASSEMBLY is provided. Enter Ø unless the die-set is to be operated for the disassembly procedures as described in paragraph 4.1. For the punch overtravel, set PUNCH EXTRA-RUN = YES and raise the die-set (see DESCRIPTION OF THE KEYS). A setting beyond the upper end-stop can be entered so that the die-set can perform its overtravel. With the SPE, if the die-set, when fully up, is not level with the die on either side, the user can enter the difference between the settings for cylinder A and cylinder B on the SPE. If, for example, cylinder A is flush with the die but cylinder B is below the edge of the die, set MAX. MISALIGNMENT (B-A) = 0.20 mm With an electronically controlled rod-type lift (optional), enter the data required for the DEAD STROKE. First reset the encoder of the die-set with mechanical end-stops (key in 4 on the same video-page as that used to reset the plunger encoder), attach the die-set, then enter the setting to be read with the die-set down during the DEAD STROKE + 1 mm (for example, if the reading is 12.00 mm, enter 13.00 mm). To set the UPPER END-STOP, enter the dead stroke + the required stroke (e.g. to travel 30 mm, enter 30 + 13 = 43 mm).

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d) Movements of the knockout which are timed with the FILLER BOX. The knockout can perform up to five movements during the filler box return stroke starting from the 1st downstroke position. For each movement set the following: the filler box setting when it starts moving, the extent the die-set moves, the filler box return stroke setting at the point where 1st downstroke takes place, the die-set travel speed. An explanatory diagram is given below: filler box return

die-set setting

die-set stroke

REAR END STOP last downstroke

END

RETURN

START

FRONT END STOP

Filler box setting

SPEED

With a 4-cylinder S.P.E. the speed of each movement can be calculated automatically so as to smooth the powder in such a way as to give it a “wedge” shape instead of a “step” shape (AUT = YES). Die-set setting

REAR END STOP

END

START

END STOP FORWARDS

Filler box setting

RETURN

From this page it is possible to go back to the PROGRAMS page by pressing F2 (PROGRAM.)

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As far as data set-up is concerned, refer to the paragraph regarding the LOADING SETUP page. The following data items: NO. OF DOWNSTROKES END STOP FILLING HEIGHT BASE THICKNESS GLAZE THICKNESS KNOC. DIE-SET SECURED DIESET DISASSEMBLY PUNCH EXTRARUN MAX. MISALIGNMENT (B - A) NO. CORRECTIONS AUT can only be changed if the Mode selector is turned to SET-UP. With the WRITE key switch turned to OFF the following data item can only be modified with keys -/+ on the keyboard: BASE THICKNESS

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5.9.17

“FITTINGS SET UP” PAGE

To go to the FITTINGS SET UP page from the PROGRAMS page, press the F6 key (FITTINGS). The remaining set points are shown on this page. a) The INSIDE synchronization data item allows the press to be run at a preset speed (expressed in CYCLES PER MINUTE). The second CYCLES PER MINUTE data item allows the strokes of the press to be “halved” with synchronized operation. For example, the press is synchronized and carries out 12 cycles per minute, if the input that pilots inside synchronization (KA301) is activated the press performs 6 cycles per minute. OUTER synchronization allows the press to be timed with an external device. b) As far as the ACP is concerned, enter the number of movements to be performed during each work cycle. The numbers range from 1 to 49, with 0 = Off, 50 = ACP operating continuously. In addition, a delay time can be set between one movement and another The following is to be set if the loading operations are to be performed through an ALM mobile hopper: ALM with encoder 1) TYPE OF ALM CYCLE = 0 The gate opens and the ALM loading stroke starts after a length of time equal to LOAD DELAY has elapsed. The gate moves at the speed (%) entered for the loading stroke . The gate closes when the required position has been reached. The ALM reaches the end of its forward stroke, reverses and then moves back to the end of its backward stroke at the speed entered during the repositioning stage. With two-row loading operations, the gate opens in position 2 during loading and finally closes in position 2. 76

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2) ALM CYCLE FIXED/MOBILE = 1 2.1) APPROACH SETTING = 0 The hopper pauses when it reaches the loading position. When the filler-box arrives back the gate opens (after a delay time set for gate opening delay). The gate closes when the filler-box reaches the position for closing during the forward stroke. 2.2) APPROACH SETTING > 0 The grid is loaded during the filler-box’s approach stroke. The ALM remains stationary in its loading position. First of all the gate opens and then the filler-box approach stroke begins once the loading delay time has elapsed. The gate closes when the filler-box reaches the closing position. 3) ALM CYCLE FIXED/MOBILE = 2 Mixed ALM cycle; this is only possible if APPROACH SETTING > 0. Combined fixed ALM / mobile ALM loading is to be used when the CAF stroke is not sufficient to load the entire grid with the ALM stopped. The cycle is as follows: A) When die-set loading is completed, the CAF brings the front part of the grid under the ALM. B) the ALM gate is opened and stays open C) with the ALM stopped, the CAF moves forward as far as the die-set dimensions will allow (approach setting) and then stops. D) the ALM moves back while keeping its inlet open until the grid loading operation is completed with the CAF stopped. Only set OPEN W/ MCH. STOPPED = YES if the gate is to be opened at the end of the automatic cycle. ALM with sensors ALM CYCLE FIXED/MOBILE = 0 (mobile), 1 (fixed), 2 (mixed only with approach) DELAYED LOADING (from when the gate opens to when the ALM starts its loading cycle). GATE CLOSING DELAY (from when sensor SQ25 is activated to when the gate closes). If a 2 line die-set is used, enter 2-ROW LOADING = YES. In addition, 2 cams have to be placed under SQ25 instead of 1. As a result, during the ALM loading stroke the gate will close once the first cam is reached. The gate will reopen after the time set for OPENING DELAY has elapsed. As soon as the second cam is reached the time set for the GATE CLOSING DELAY data item will start to elapse. Once this time has expired the gate will close definitively. c) The following settings can be entered for the brush: - whether the brush is present or not - whether the brush is fixed or mobile - if the brush is mobile the following can be set: 1) whether the brush has to clean the lower or the upper die-set 2) the point of the filler-box stroke at which the brush moves down 3) the point of the filler-box stroke at which the brush moves up - brush rotation: if this function is enabled, the following modes of operation can be selected: Always CLOCKWISE rotation (REVERSE ROTATION = NO, C.WISE ROTATION = YES); Always COUNTER-CLOCKWISE rotation (REVERSE ROTATION = NO, C.WISE ROTATION = NO) Reverse rotation every h cycles (REVERSE ROTATION = YES, CYCLES BTW REVERSALS = h). The ROTATION ENABLING data item allows the following to be selected: NO = rotation off 1 = rotation on only during filler-box forward stroke 2 = rotation on only during filler-box return stroke 3 = rotation constantly on

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- If a linear filler-box is used: The points at which brushing starts and stops in relation to the filler-box stroke (expressed in mm) can be set in the BRUSH block if a linear filler-box is used. WEAR and MAX (only for proportional presses) If WEAR is set > 0, the upper end-stop for the plunger is lowered in order to automatically compensate for brush wear and obtain optimum cleaning. The operator should set a specific value for brush wear i.e. the number of cycles during which the brush’s radius is reduced by 1/ 100th of a mm. The maximum allowable wear (MAX) should also be set: when this value is reached, the machine stops and the message “REPLACE BRUSH” appears. If a reset operation is performed, the procedure begins again. NOTE: The use of this function may gradually reduce the opening of the die-set until the filler box can no longer go in. d) If the Enea Cooling system is provided (optional), the user can select whether to enable or disable the heat exchanger or cooling fans (only if the Enea Cooling system is controlled by SACMI). e) MDR BLOCK (optional and available for program version PH12.xx.yy and later versions) Basic MDR CYCLE TYPE: 0 = MDR disabled, 1 = rotation always clockwise, 2 = rotation always counter-clockwise, 3 = rotation clockwise, counter-clockwise. MDR SPEED: speed (expressed as a %) of the mixer with rotating diaphragm installed on the ACP. To go to the “PROGRAMS” page from this one, press the F2 key (PROGRAM). To enter the data, follow the instructions given for the “LOADING SET UP” page.

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5.9.18

“PRINT ROUTINE”

The PRINT ROUTINE is displayed (regardless of the page currently being shown) by pressing the <SCREEN> key on the terminal (see chapter 4 “COMPUTER TERMINAL”). The following data can be printed out at any time. - PRODUCTION DATA - SET DATA - FAULTS - ACTUAL DATA While the data is being transmitted to the printer, a dotted line which flashes will appear. Press ESC (key <5>) to go back to the current page. NOTE: In order to print out the data, a printer with a Centronics type parallel input must be connected to the output on the back of the card rack (marked ST). It is advisable to use the printer installation kit (not supplied). A4 continuous form paper should be used. NOTE: A BMOS v. 1.8 operating system or later version is required (see INFO page). 79

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5.10

FAULT MESSAGES

The fault messages are displayed in the area of the display illustrated in the figure. Each message is identified by a four digit number (the first digit indicates the category the message belongs to). The messages are divided into five different categories: 1) SHUTDOWN MESSAGES These messages are displayed when the machine immediately shuts down. Once the trouble has been remedied, clear them by pressing the Reset key. 2) PARTIAL SHUTDOWN MESSAGES These messages are displayed when the machine immediately shuts down. Once the trouble has been remedied, clear them by pressing the Reset key. 3) MACHINE STOPPAGE MESSAGES These messages appear when the machine stops at the end of the work cycle in progress. Manual operations are still enabled. Once the trouble has been remedied, clear them by pressing the Reset key. 4) INFORMATION MESSAGES These messages do not affect the work-cycle or manual operations. Press the Reset key to clear them. 5) MAINTENANCE MESSAGES These messages do not affect the work-cycle or manual operations. Press the Reset key to clear them. NOTE: In some cases, messages are displayed by the operating system. When this happens, the video is completely cleared and the machine shuts down. A detailed description of these messages is given in the following chapter. NOTE: - Some of the messages recommend checking one or more cards for proper functioning (e.g. check the EIA card). Consult the Hardware Manual for the card in question, in particular the TROUBLESHOOTING chapter. - For further information regarding the sensors/actuators consult the LIST OF DEVICES handbook. - The location of the sensors/actuators indicated in the fault messages is given in the SPARE PARTS Manual.

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WHAT TO DO WHEN THE MACHINE STOPS DUE TO MALFUNCTIONING The machine stops immediately when a “shutdown” message is displayed. When a “stoppage” message appears the machine stops after completing the cycle in progress. Read the message shown on the first line at the top of the display and then refer to the FAULT MESSAGES chapter for information regarding what caused the shutdown or stoppage. In some cases the identification symbol of the device that detected the fault is given next to the message. In these cases, check the state of the device in question. If everything is as required, check the electric connections regarding the input in question. Other information regarding the machine is provided on the following pages: Outputs (I/O page) State of all the machine outputs. Information that is useful if an axis or accessory fails to work is given on this page. The state of the outputs is given so that the ones which should have been activated can be easily located. Inputs (I/O page) State of all the machine inputs. The state of all the inputs is given on this page. The operator can verify whether the physical inputs match those read by the controller (by measuring the input voltage of the card: 0V input not activated, 24V input activated). If the actual state does not coincide with the one read, replace the input card. Machine status (STATE) The state of the machine axes is given on this page. The state is given in numeric form for each axis (refer to the chapter that deals with this page for the meaning of the code given). In the event of machine shutdown, the state is decoded and described in the relevant block. Additional information is given on the DATA page. The pressures and settings of the axes are shown on this page. ALWAYS TAKE DOWN ALL THE INFORMATION MENTIONED ABOVE SO THAT IT CAN BE READILY QUOTED WHEN CONTACTING SACMI’s SERVICE DEPARTMENT. MACHINE MALFUNCTIONING CANNOT BE PROPERLY DIAGNOSED IF THIS INFORMATION IS NOT AVAILABLE. A detailed description of the messages is given below, in numeric order.

1001

SHUTDOWN PUSH-BUTTON

(shutdown)

The shutdown push-button on the keyboard has been pressed. If the push-button has not been pressed, check the keyboard power leads. If the power lead is properly connected and is not broken, try replacing the control KEYBOARD. If the keyboard works properly, try replacing the MISCELLANEOUS card. 1002

EXTERNAL SHUTDOWN PUSH-BUTTON (SB1E)

(shutdown)

One of the external shutdown pushbuttons has been pressed. If this is not the case, check the connector blocks of the external shutdown buttons and related wiring connections. Also check the input card (Led SB1E must be on when the machine has not shutdown) and the leads/connectors. 81

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1003

ANALOG/ENCODER CARD NOT WORKING (1)

(shutdown)

The encoder/analog card (EIA) is malfunctioning. If a proportional knockout is provided the fault is to be found in the EIA card in location 6/7. Shut off the controller and replace the card. If the trouble persists, replace the CPU card. Note: This message only appears if a program version earlier than PH12.01.01 is being used. 1004

PUNCHES NOT FIXED (AJ1/AJ2)

(shutdown)

If AJ1 or AJ2 does not appear to the right of the fault message the magnetic lock is enabled but it has not yet been magnetized (see chapter 5.9.16, paragraph “e” in this manual). - (AJ1): The input card has not received the feedback signal that the upper punch locks are magnetized. Check the setting of current control device AJ1 and check the wiring/operation of the upper magnetic lock. Also inspect the input and output cards (see NOTE). - (AJ2): The input card has not received the feedback signal that the lower punch locks are magnetized. Check the setting of current control device AJ2 and check the wiring/operation of the lower magnetic lock. Also inspect the input and output cards (see NOTE). NOTE: For presses using an earlier program version than PH12.01.01, there is only one feedback input signal (the contacts of AJ1 and AJ2 are series connected). This means that, even if the fault message PUNCHES NOT FIXED (AJ1) appears, the operator must check whether the fault is in the upper or lower magnetic lock. Then make the required checks. 1005

CHECK PRESET DATA

(shutdown)

If this message appears when the machine is started up or after the CPU card has been replaced, check all of the set data. If the message appears at any other time, check the battery for proper functioning (located on the POWER SUPPLY card). If it works properly, replace the CPU card and check all of the settings. NOTE: The message can be deleted (with the key switch on the control keyboard turned to SET UP) by pressing the Reset button. 1006

CHECK 24 VEV

(shutdown)

No 24 VEV voltage is being supplied. Press the Reset key. If the message is not cleared, check safety module AJ100: if power is not being supplied (“NETZ” Led off or “POWER” off), check the CPU card, the AL card and the leads/connectors. If power is being delivered but the two signals (S1 and S2) are different or both of them are off, check the internal and external shutdown buttons, input SB1E and the leads/connectors. Check three phase rectifier bridge VC 101 located in the power switchboard. Also check the upper BUS, Section 1. 1007

MODE SELECTOR

(shutdown)

The key on the machine control keyboard was turned during RESETTING, CYCLE or SEMIAUTOMATIC operation. If the key was not turned, check selector SA9, its connection to the machine keyboard and the keyboard power lead. If the lead is properly plugged in and is not broken, replace the control keyboard. If the keyboard works properly, replace the MISCELLANEOUS card. 82

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1008

ANALOG/ENCODER CARD NOT WORKING (2)

(shutdown)

The second encoder/analog card (EIA) in location 10 is malfunctioning. Shut off the controller and replace the card. If the trouble persists, replace the CPU card. If the problem still cannot be resolved, contact SACMI to check the configuration (check the ENCODER data item). NOTE: this message only appears when a program version earlier than PH12.01.01 is being used. 1009

MAIN SWITCH TRIPPING (BTn)

(shutdown)

This fault message is displayed just before the power to the electrical cabinet is cut off. This happens because a fault has been detected in one of the die-set heaters (“n” indicates the heater which is malfunctioning): - output KMn is off and the corresponding input KMn is on. - the temperature measured by thermocouple BTn is higher than 110°C (80°C if the punches are made of rubber). - the temperature measured by BTn is lower than 0°C and output KMn is on. In all these cases, the pumps are stopped after 5 minutes and then power to the electrical cabinet is cut off. With program versions earlier than PH12.01.01: check thermocouple BTn, its input module, the EIA card in location 6/7 and the related leads/connectors. If the problem is the first possibility mentioned, check the output card, contactor KMn, feedback relay KAn in the electrical cabinet and the input card. With program version PH12.01.01 or later: check thermocouple BTn, its conversion card in box 38, the IA card and the related leads/connectors. If the problem is the first possibility mentioned, check the output card, contactor KMn, feedback relay KAn in the electrical cabinet and the input card. 1010

SHORT CIRCUIT YVn

(shutdown)

The OD and ODA cards have a control device which checks that the current supplied from each digital output is correct. If one of these cards detects a faulty output, this message appears. Disconnect the output for YVn from the controller and make sure there are no short circuits in solenoid valve YVn or in the leads/connectors. If there are no shorts in the cable or solenoid valve, check to see whether there is a +24 V supply for the solenoid valves. To do this, check the respective Led on the power supply (see INSTRUCTIONS C - paragraph 3.1) and the AL Led on the card which has the short circuited output. Make sure there are no false contacts in the power supply for the YVn output card. If the short-circuited output is part of the first ODA card, check filler-box limit switches SQ59, SQ53 (Roller conveyor on), SQ66, SQ66A (Filler-box on), SQ51, SQ52 (Safety bar), contact SA9 of the mode selector as well as contacts AJ101, KA102 and KA103. Also check circuit breaker FS101. If the problem persists replace the output card.

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1011

PRESSURE SWITCH/TRANSDUCER ... bar

(shutdown)

The maximum operating pressure for the press cylinder has been exceeded. If “(SP2)” appears to the right of the fault message this means the problem has been detected by pressure switch SP2: check the pressure switch and the ID card (if the pressure is within the set limits led SP2 should always be on) as well as the leads/connectors. If nothing appears to the right of the fault message this means the problem has been detected by pressure transducer BP1. In this case the message appears when the transducer detects pressure which is 20 bar above the maximum allowable. Check transducer BP1, the leads/connectors and With program versions earlier than PH12.01.01: the input module of transducer BP1 (AP301) and the EIA card in location 6/7. With program version PH12.01.01 or later: check the IA card in location 7. 1012

IE CARD

(shutdown)

The IE card does not work. Turn off the controller and replace the card. If the problem persists replace the CPU card. 1013

CONFIG.

(shutdown)

This message is for SACMI personnel only. The press cannot perform any movement. If this message appears when no SACMI engineer is working on the press, contact the Aftersales Service Dept. - SACMI, IMOLA 1014

ANALOG CARD DOES NOT WORK

(shutdown)

The IA card does not work. Turn off the controller and replace the card. If the problem persists, replace the CPU card. 2001

FAN/FILTERING UNIT (KM11)

(shutdown)

Input KM11 has remained inactivated for 30 seconds. The pumps are stopped. Check the thermal cutout and contactors of the fan and filtering unit motors (KM4 and KM11). Check the input card (Led KM11 must be on when the motors are running) and the leads/ connectors. Check the output card (Led KM11 must come on when the motors have to run) and the leads/connectors. If KM11A, KM13 or KM14 are indicated in the fault message, check the additional heat exchanger. 2002

HYDR. UNIT PUMP (KM1D)

(shutdown)

Input KM1D has stayed off for 30 seconds with the main pump running or the input signal has remained on for 2 seconds while the main pump is being turned off. The main pump is stopped. Check the thermal cutout and contactor KM1D. Check the input card (Led KM1D must be on when the motor is running) and the leads/ connectors. Check the output card (Led KM1 must be on when the motor has to run) and the leads/ connectors. 84

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2003

LOW PRESSURIZATION (SP3)

(shutdown)

Input SP3 has stayed off for 6 seconds. The main pump is stopped. Check the main pump suction filter for efficiency. Check pressure switch SP3, the input card (Led SP3 must be on when the operating pressure is within the allowable range) and the leads/connectors. 2004

OIL LEVEL (SL1)

(shutdown)

Input SL1 has stayed off for 6 seconds. The pumps are stopped. Check the oil level in the reservoir. Check level sensor SL1, the input card (Led SL1 must come on when the oil exceeds the maximum level mark) and the leads/connectors. 2005

CONNECT THERMOC. (BT4)

(shutdown)

The machine will shutdown when this message appears and the main pump will stop running. Make sure the thermocouple for the oil is properly connected. With program versions earlier than PH12.01.01:check the input module of thermocouple BT4 (AP304) and the EIA card in location 6/7. With program version PH12.01.01 or later: check conversion card APBT4 (control unit box) and the IA card. 2006

TEMP. TOO LOW (BT4)

(shutdown)

The oil temperature has remained at a temperature which is too low (less than 2° C) for 30 seconds. The main pump is stopped. Check the thermocouple for proper functioning (replace it if necessary). If it works properly, find out what is causing the temperature to be too low. With program versions earlier than PH12.01.01:check the input module of thermocouple BT4 (AP304) and the EIA card in location 6/7. With program version PH12.01.01 or later: check conversion card APBT4 (control unit box) and the IA card. 2007

TEMP. TOO HIGH (BT4)

(shutdown)

The oil has remained at a temperature which is too high (over 55° C) for 30 seconds. The main pump is stopped. Check the thermocouple for proper functioning (replace it if necessary). If it works properly, find out what is causing the temperature to be too high. With program versions earlier than PH12.01.01: check the input module of thermocouple BT4 (AP304) and the EIA card in location 6/7. With program version PH12.01.01 or later: check conversion card APBT4 (control unit box) and the IA card. The temperature level reached appears to the right of the fault message. 2008

CHECK (SP11)

(shutdown)

The input of pressure switch SP11 has stayed off for 6 sec. while motor control KM11 was on. The pumps are stopped. Check the input card (Led SP11 must be on when motor M11 is running) and the leads/connectors. 85

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2009

REPLACE FILTER (SP1)

(shutdown)

Input SP1 has remained inactivated and the oil temperature is above 30°C. The main pump is stopped. Replace the filter in the hydraulic power unit as it is clogged. If the message is still displayed even after the filter has been replaced, check pressure switch SP1, the input card (Led SP1 must be on when the filter is not clogged) and the leads/ connectors. 2010

OIL LEAK LEVEL (SL4)

(shutdown)

Input SL4 has stayed off for 40 seconds. The main pump is stopped. Check the oil leak level in the oil recovery tank. Check level sensor SL4, the input card (Led SL4 must come on when the oil is below the low level mark) and the leads/connectors. 2011

OIL COCK CLOSED (SQ50)

(shutdown)

The pumps are stopped. If this message appears when the oil cock is open, check limit switch SQ50 (which opens the oil passage), the leads/connectors and the input card (Led SQ50 must be on when the cock is open). 2012

HIGH PRESSURE IN THE CYLINDER

(shutdown)

With the safety bar raised, the pressure in the cylinder exceeds 6 bar. The main pump is stopped. Check all the logic elements and solenoid valves of the pressing unit and make sure no faults are present. If there is no pressure in the cylinder, set the pressure transducer of the cylinder (see NOTE). If the problem persists, replace pressure transducer BP1. With program version earlier than PH12.01.01:check the input module of transducer BP1 (AP301) and the EIA card in location 6/7. With program version PH12.01.01 or later: check the IA card in location 7. NOTE: With program version 12.01.01 or later, cylinder pressure = 2 bar is displayed when the machine is turned on if digital input SP3 is on (air pressurization approx. 1.5 bar) and the pressure detected by transducer BP1 is between -3 bar and +7 bar. To set the transducer, it is necessary to eliminate pressurization, turn off the controller and then turn it on again. At this point the pressure displayed is that read by the transducer and the operator can therefore proceed with the setting procedure: see the INSTRUCTIONS FOR SETTING THE TRANSDUCERS Manual. 2013

REPLACE FILTER (SP6)

(shutdown)

Input SP6 has stayed off for 60 seconds and the oil temperature is higher than 30°C. The ENEA COOLING filter needs to be replaced as it is clogged. If the message continues to be shown after the filter has been replaced, check pressure switch SP6 and the input card (with the filter not clogged led SP6 should be on) and the related leads/connectors.

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2014

TEMPERATURE TOO HIGH (ST1)

(shutdown)

Input ST1 has stayed off for 6 sec. The main pump is stopped. Check the flywheel bearings to see if they are properly lubricated. Make sure the bearings work properly. 2021

PUNCHES INSIDE (SQ62)

(shutdown)

During the automatic cycle, SQ62 has not been energised within 0.5 seconds of the moment when the plunger arrived at the top end stop. Check limit switch SQ62 and the related leads/connectors. Check the input card (Led SQ62 must be on when the punches are out). Also check solenoid valve YV193, the leads/connectors and related output card. 2022

HOPPER CLOSING (SQ61)

(shutdown)

SQ61 has not been energized within one second of YV221 being de-energized during gate closing. Check solenoid valve YV221 for proper operation. Check proximity switch SQ61, the input card (with the hopper closed, switch SQ61 must be energized) and the leads/connectors. Check the output card (Led YV221 must go off when the gate has to close) and the leads/ connectors. 2023

LAST DIE-SET D.STROKE (SQ6)

(shutdown)

During the last die-set downstroke SQ6 was de-energised (see NOTE). Check solenoid valve YV21 for proper functioning. Check proximity switch SQ6, the ID card in location 11(when the die-set is lowered, Led SQ6 must be on) and the leads/connectors. Check the OD card in location 16 (during the last die-set downstroke, Led YV21 must go out) and the leads/connectors. NOTE: SQ6 must be activated once the die-set has completed the first downstroke and must remain activated during all the other downstrokes as well as during the press-cycle. With 2-cylinder proportional knockout: if the value of encoder A or B is not lower than 2 mm within 8 seconds from when the signal for the last downstroke was sent: Check proportional solenoid valves YV22A/22B, axis cards AP204/205, the related ODA card, synchronization card AP203, encoder interface module AP206 installed on the SMU, encoders BQ4/5 and: - With program version earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. - With program version PH12.01.01 or later: the IA card and the IE card in location 9. If the message is displayed during the press-cycle, it means encoders BQ4/5 have not read a value less than 0.5 mm during the press-strokes. Shut off the controller and then turn it back on and reset the encoders. With 4-cylinder proportional knockout: if the value of encoder A or B is not lower than 0.8 mm within 8 seconds from when the signal for the last downstroke was sent: Check proportional solenoid valves YV22A/22B, axis cards AP210, the encoder interface card AP207, the serial interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/5 and - With program version earlier than PH12.01.01: the EIA card in location 10. - With program version PH12.01.01 or later: the IE card in location 9. If the message is displayed during the press-cycle, it means encoders BQ4/5 have not read a value less than 0.5 mm during the press-strokes. Shut off the controller and then turn it back on and reset the encoders. 87

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2024

PLUNGER DOWN DUR. DIE-SET UPSTR.

(shutdown)

The plunger is below the value set for its upper-most position when the die-sets begin to move up. 2025

F-BOX FORW DUR. DIE-SET UPSTROKE (SQ59)

(shutdown)

The filler box is not completely back when the die-set starts moving up If “(SQ59)” appears to the right of the fault message, this means the fault has been diagnosed by upper input SQ59. In this case, check filler box safety switch SQ59 and the IDM card in location 11. If nothing appears to the right of the message, this means that the fault has been detected by the filler box encoder. In this case, check the filler-box encoder setting. If the latter does not correspond to the actual position of the filler box: With program version earlier than PH12.01.01:check the EIA card in locations 6/7. With program version PH12.01.01 or later: check the IE card in location 9. 2026

2ND FILLER-BOX FORWARD (KA302)

(shutdown)

The position of the second filler-box or LB type filler-box is not correct when the die-sets start their upstroke. Check the trigger pulse for the plunger downstroke (KA302) and the related input card. 2027

DIE-SET UPSTROKE (SQ3)

(shutdown)

Proximity switch SQ3 is not energized during the die-set upstroke (see NOTE). Check solenoid valves YV21/22 and the related hydraulic lines for proper functioning. Check proximity switch SQ3, the ID card in location 11 (when the die-sets are raised, proximity switch SQ3 must be energized) and the leads/connectors. Check the OD card in location 16 (while the die-sets are moving up, Leds YV21/22 must come on) and the leads/connectors. Check solenoid valve YV64 and the pressure in the service circuit. With a 2-cylinder proportional knockout: if the setting of encoder A or B does not reach the upper end-stop setting less 2 mm within 8 seconds from when the signal for the die-set upstroke was sent: Check solenoid valve YV22S, proportional solenoid valves YV22A/22B, axis cards AP204/ 205 and related ODA card, synchronization card AP203, encoder interface module AP206 installed on the SMU, encoders BQ4/5 and - With program version earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. - With program version PH12.01.01 or later: the IA card and the IE card in location 9. With 4-cylinder proportional knockout: if the setting of encoder A or B does not reach the upper end-stop setting less 0.8 mm within 8 seconds of the signal for the die-set upstroke being sent: Check solenoid valve YV22S, proportional solenoid valves YV22A/22B, axis card AP210, the encoder interface card AP207, the serial interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/5 and - With program version earlier than PH12.01.01: the EIA card in location 10. - With program version PH12.01.01 or later: the IE card in location 9. NOTE: SQ3 should be energized when the die-sets move up (YV21 and YV22 ON) for a max. time of 8 seconds. SQ6 should be de-energised within this time and should be energized when the die-set performs its first downstroke.

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2028

1ST DIE-SET D.STROKE (SQ3/SQ6)

(shutdown)

Proximity switch SQ3 is not de-energized or proximity switch SQ6 is not energized within 1 second of the first downstroke signal (see NOTE). Check solenoid valve YV22 and related hydraulic lines for proper functioning. Check proximity switches SQ3/SQ6, the ID card in location 11 (after the first downstroke, SQ6 should be energized and SQ3 de-energized) and the leads/connectors. Check the OD card in location 16 (Led YV22 should go out after the first downstroke) and the leads/connectors. With a 2-cylinder proportional knockout: 2-downstroke cycle: if the setting of encoder A or B is not lower than FCA/2 (FCA = Upper end-stop) within 8 seconds from when the signal for the first downstroke was sent, 3-downstroke cycle: if the first downstroke setting (with 0.4 mm tolerance) has not been reached within 8 seconds from when the signal for the first downstroke was sent: check proportional solenoid valves YV22A/22B, axis cards AP204/205 and related ODA card, synchronization card AP203, encoder interface card AP206 installed on the SMU, encoders BQ4/5 and - With program version earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. - With program version PH12.01.01 or later: the IA card and the IE card in location 9. With 4-cylinder proportional knockout: if the first downstroke setting (with 0.8 mm tolerance) has not been reached within 8 seconds from when the signal for the first downstroke was sent: Check proportional solenoid valves YV22A/22B, axis card AP210, encoder interface card AP207, serial interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/5 and - With program version earlier than PH12.01.01: the EIA card in location 10. - With program version PH12.01.01 or later: the IE card in location 9. NOTE: SQ6 should be energized when the first die-set downstroke has been performed and should remain energized for the rest of the downstrokes and during the press-cycle. SQ3 should be energized as soon as the die-set starts to move down. 2029

HOPPER OPEN (SQ60)

(shutdown)

SQ60 has not been energized within 1 second of YV221 being energized during gate opening. Check solenoid valve YV221 for proper functioning. Check proximity switch SQ60, the input card (with the hopper open, proximity switch SQ60 must be energized) and the leads/connectors. Check the output card, (Led YV221 must come on when the gate has to open) and the leads/ connectors. 2030

2ND F-BOX TRIGGER P. (KA304)

(shutdown)

Digital input KA304 has not come on within 15 seconds from when the signal for starting the 2nd filler-box cycle was sent (KA401). Make sure the second filler box/filler-box for double loading works properly. Check the trigger pulse contact for the intermediate die-set downstroke (KA304), the input card (Led KA304 must be on when the trigger pulse is provided) and the leads/connectors.

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2031

2ND DIE-SET D.STROKE (SQ6)

(shutdown)

During the second die-set downstroke (in a 3-downstroke cycle) SQ6 has been deenergized for more than 1 second. Check proximity switch SQ6, the ID card in location 11 (LED SQ6 should be on) and the leads/connectors. Check solenoid valve YV170 and related hydraulic lines for proper functioning. Check the OD card in location 16 and the leads/connectors. With a 2-cylinder proportional knockout: 3-downstroke cycle: if the first downstroke setting less 0.4 mm has not been reached within 8 seconds from when the signal for the second downstroke was sent: (Note: If the set glaze thickness is lower than 0.8 mm, the fault message is not shown) check proportional solenoid valves YV22A/22B, axis cards AP204/205 and related ODA card, synchronization card AP203, encoder interface card AP206 installed on the SMU, encoders BQ4/5 and - With program version earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. - With program version PH12.01.01 or later: the IA card and the IE card in location 9. With 4-cylinder proportional knockout: if the second downstroke setting (with 0.8 mm tolerance) has not been reached within 8 seconds of the signal for the second downstroke being sent: Check proportional solenoid valves YV22A/22B, axis card AP210, encoder interface card AP207, serial interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/5 and - With program version earlier than PH12.01.01: the EIA card in location 10. - With program version PH12.01.01 or later: the IE card in location 9. 2032

2ND F-BOX TRIGGER P. (KA302)

(shutdown)

Digital input KA302 has not come on within 15 seconds of the second die-set downstroke. Check that the second filler box functions and moves properly. Check the trigger pulse contact for the last die-set downstroke (KA302), the input card (Led KA302 must be on when the last die-set downstroke is triggered) and the leads/connectors. 2033

DIE DOWN (SQ63)

(shutdown)

SQ63 has not been energized within 0.5 seconds from when = the plunger reached its uppermost position. Check sensor SQ63 and the leads/connectors. Check the input card (with the die up, Led SQ63 must be on). Check solenoid valve YV172, the leads/connectors and related output card. 2034

REPLACE FILTER (SP5)

(shutdown)

Digital input SP5 is off and the oil temperature is higher than 30°C. The knockout filter must be replaced as it is clogged. If the message is still displayed after the filter has been replaced, check pressure switch SP5, the ID card in location 12 (when the filter is not clogged, Led SP5 should be on) and the leads/connectors.

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2035

DIE-SET DEVIATION > 2 mm

(shutdown)

With a 2-cylinder proportional knockout: during their upstroke, both proportional knockout cylinders have exceeded the setting for UPPER END-STOP (DIE-SET SET-UP page) by more than 3 mm. Try reducing the UPSTROKE SPEED. Check proportional solenoid valves YV22A/22B, axis cards AP204/205 and related ODA card, synchronization card AP203, encoder interface card AP206 installed on the SMU, encoders BQ4/5 and - With program version earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. - With program version PH12.01.01 or later: the IA card and the IE card in location 9. With 4-cylinder proportional knockout: during their upstroke one or two of the proportional knockout cylinders have exceeded the setting for UPPER END-STOP (DIE-SET SET-UP page) by more than 2 mm. Try reducing the UPSTROKE SPEED. Check solenoid valve YV22S, proportional solenoid valves YV22A/22B, axis card AP210, encoder interface card AP207, serial interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/5 and - With program version earlier than PH12.01.01: the EIA card in location 10. - With program version PH12.01.01 or later: the IE card in location 9. 2036

DIE-SET PARALLELISM ERROR

(shutdown)

An excessive difference was found between the value of the right-hand side and the lefthand side while the proportional knockout was moving. With 2-cylinder proportional knockout: 1) When moving down cylinder B has exceeded cylinder A by more than 2.5 mm (setting A > setting B). Cylinder A shut down; check proportional valve A. 2) When moving down cylinder A has exceeded cylinder B by more than 2.5 mm (setting B > setting A). Cylinder B shut down; check proportional valve B. 3) When moving up cylinder A has exceeded cylinder B by more than 2.5 mm (setting A > setting B). Cylinder B shut down; check proportional valve B. 4) When moving up cylinder B has exceeded cylinder A by more than 2.5 mm (setting B > setting A). Cylinder A shut down; check proportional valve A. 5) A misalignment of more than 10.5 mm has been detected between the two cylinders (YV22S is de-energized). Proportional valve malfunctioning; check the Moog and ODA cards. Encoder stopped or not working. With 4-cylinder proportional knockout: 0) A misalignment of more than 5 mm has been detected between the two cylinders.

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2037

DIE-SET UP. ERROR (A=..., B=...)

(shutdown)

At the filler-box start, the difference between the value measured by one of the two encoders and the upper end-stop is > 0.4 mm. The values measured for cylinders A and B of the proportional knockout are indicated in brackets. Try reducing the setting for UPSTROKE SPEED. With 2-cylinder proportional knockout: Check solenoid valve YV22S, proportional solenoid valves YV22A/22B, axis cards AP204/205 and related ODA card, synchronization card AP203, encoder interface card AP206 installed on the SMU, encoders BQ4/5 and - With program version earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. - With program version PH12.01.01 or later: the IA card and the IE card in location 9. With 4-cylinder proportional knockout: Check solenoid valve YV22S, proportional solenoid valves YV22A/22B, axis card AP210, encoder interface card AP207, serial interface card AP208, the OD card in location 14, the ID card in location 13, encoders BQ4/ 5 and - With program version earlier than PH12.01.01: the EIA card in location 10. - With program version PH12.01.01 or later: the IE card in location 9. 2038

DIE-SET ENCODER RESET

(shutdown)

The die-set encoder reset procedure has failed. Check the proportional solenoid valves of the die-set (YV22A, YV22B) for proper operation. Make sure the aux. equipment circuit is under pressure. Make sure the SPE is under pressure (solenoid valves YV22S, YV25). With proportional 2+2 or 4-cylinder knockout: 0) No zero-set pulse is emitted from one or both encoders. 1) During the first 1 mm upward travel, the encoder on side A has not recorded an adequate movement 2) During the first 1 mm upward travel, the encoder on side B has not recorded an adequate movement 3) During the first 1 mm upward travel, a parallelism error has been found. 4) During the upward travel, the encoder on side A has not recorded an adequate movement. 5) During the upward travel, the encoder on side B has not recorded an adequate movement 6) During the upward travel, a parallelism error has been found. 7) During the upward travel, the die-set has moved up too quickly. 8) At the end of the reset procedure, the value recorded by one or both encoders is not within +0.5 and -0.5 mm. 9) The zero-point signal of one encoder is not recorded. To locate the fault, refer to item “Zero Position” on the Die-Set display 12) With the SPE encoders not reset, when solenoid valve YV 25 (YV22S in the 4-cylinder SPE) is energised to deliver oil to the SPE, the die-set has moved up more than 2.5 mm. Solenoid valve YV25 or YV22S is de-energised. The proportional solenoid valve has got stuck during upstroke. Check card AX. With proportional 2-cylinder knockout: Check the “ANALOG” value on the ACTUAL DIE SETTINGS video-page. If the setting of encoder is less than 0.5 mm or higher than 1.5 mm at the end of a reset procedure the ENCODER MUST BE SET UP. (See SETUP PROCEDURES FOR THE PROPORTIONAL KNOCKOUT ENCODER). 1) At the end of the reset procedure, the analog value read by one or both encoders is not between 0.5 mm and 1.5 mm. Check the point of contact between the encoder sensor and the mobile part of the dieset. Check the encoder setting on the relevant card installed on the die-set. Make sure there are no blockages which could prevent the knockout from moving down (e.g. 92

PH 339.85.089 Rev. 00 Date 10.12.01

powder built up under the die-set). 3) While the cylinders were moving during the second downstroke (YV21), the value read by one or both encoders has not exceeded the 0.2 mm setting (digital value). Check for any jammed parts and for hydraulic pressure in the auxiliary equipment control assembly. Encoder blocked, not working or not connected to electricity supply. Make sure the thickness gauge is adjusted correctly to a setting greater than 0.2 mm. 4) The values read by each of the two encoders for the second downstroke cylinders with YV21 energized differs by more than 0.5 mm (digital value). Check for any jammed parts. The operator has released the encoder but the locking system has remained engaged. An encoder has blocked during operations. 5) The value read by one or both encoders has reached 12 mm (digital value). Encoder not reset (the reset pulse for one or both encoders is not read). 6) A misalignment between the two cylinders of more than 3.5 mm has been detected. Proportional valves connected the wrong way round or malfunctioning. Make sure the hydraulic lines have been completely drained. Make sure the die-set can move freely on both sides without obstructions or excessive friction. 7) A misalignment between the two cylinders of more than 4.5 mm has been detected. YV22S is de-energized. A proportional valve is malfunctioning (blocked during upstroke); check the Moog and ODA cards. 8) Both encoders have read a value of more than 14 mm (YV22S is de-energized). Both proportional valves are malfunctioning (both blocked during upstroke); check the Moog and ODA cards. 9) The electrical signal sent by one of the proportional valves has exceeded 16 mm. Valve malfunctioning (blocked during downstroke) or not connected; check the Moog and ODA cards. Check for any jammed parts. 10) After an electrical signal equal to zero has been sent by a proportional valve, the dieset does not move down. Check for any jammed parts. Proportional valve blocked. 11) During the last stage of the die-set resetting procedure and after a 12 mm electrical signal has been sent by the proportional valves, one or neither of the cylinders have reached a setting equal to half the signal sent (6 mm). Check for any jammed parts. 12) With the die-set not yet reset and following a reset signal, the die-set is found to move up more than 2.5 mm (digital value) as soon as YV22S is energised. YV22S is then deenergised. Proportional valve blocked during upstroke; check the Moog and EIA cards. 2039

PERFORM DIE-SET LEARNING

(shutdown)

Perform the die-set self-learning procedure. See the DIE-SET SET UP page. 2040

CHECK DIE-SET ENCODER

(shutdown)

A fault has been detected in one of the die-set encoders (the difference between the analog value and the digital one is > 1 mm). Check the encoder interface card AP206 installed on the SMU, encoders BQ4 and BQ5 and With program version earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. With program version PH12.01.01or later: the IA card and the IE card in location 9.

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2041

DIE SETTING NOT REACHED

(shutdown)

During the die-set learning procedure one of the two encoders has reached the value set for UPPER END STOP ± 2 mm. Check the proportional solenoid valves of the die-set for proper functioning. Check solenoid valve YV64, YV225 and the pressure of the service circuitry. Otherwise reduce the UPPER END STOP setting A or B. 2042

CONTROL UP: PERFORM DIE-SET SELF-LEARNING

(shutdown)

The control used to perform the die-set upstroke (or the first downstroke in the case of a 3downstroke cycle) is too far up. Try performing a die-set self-learning procedure. (See the DIE-SET SET-UP page). If the problem persists replace the solenoid valves in the die-set. 2043

AXES CARD ERROR

(shutdown)

The card which controls the proportional knockout has emitted a fault signal. Make sure there are no faults in the die-set (excessive friction, etc...). Check to see whether the dieset encoders work properly. 0) Check signal KA 1006 and the IDM card in location 13. If the problem persists, replace axis card control AP210 in the controller. 1) The die-set is blocked. Try moving down the die-set with the key switch turned to Set Up and make sure there are no obstacles which prevent the die-set from moving. If the dieset is still blocked, try moving the die-set upwards in Set Up mode. 2) The AX card does not work. Check the first module. 3) The AX card does not work. Check the second module. 4) When solenoid valve YV25 is energised (YV22S in the 4-cylinder SPE) to deliver oil to the SPE, the AX card indicates that there are problems with the feedback of proportional solenoid valve A (left-hand side). Solenoid valve YV25 or YV22S is de-energised. Proportional valve A stuck. Check the AX card and the spool signal. 5) When solenoid valve YV25 (YV22S in 4-cylinder SPE) is energised to deliver oil to the SPE, the AX card indicates that there are problems with the feedback of proportional solenoid valve B (right-hand side). Solenoid valves YV25 and YV22S are de-energised. Proportional valve B has got stuck. Check the AX card and the spool signal. 2044

DIE-SET ENCODER BLOCKED (SQ4)

(shutdown)

The proportional knockout cannot be moved because the encoders are blocked. Release them. If the message continues to appear, check the two sensors SQ4 and SQ5, the wiring and IDM card in location 13. 2045

RESET PRESSURE

(shutdown)

While the proportional knockout pressure was being reset, one of the two encoders read a value greater than 0.6 mm (the die-set was not fully down and therefore the reset procedure was not performed). Make sure the die-set can reach the zero setting. Check encoders BQ4/ 5, the IE card in location 9 and axis card AP210.

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2046

KNOCKOUT BETWEEN PUNCHES

(shutdown)

The die-set moves up more slowly than the plunger. Try reducing the plunger speed. If the problem persists, try disabling the “knockout between punches” function to see whether a different fault message appears. 2047

ENCODER FAULTY (BQ4A)

(shutdown)

Check BQ4A = position of rod-type knockout (linear absolute encoder) and the related electrical wiring. Check card IE, location 9. 2048

TIME-OUT, KNOCKOUT UP

(shutdown)

The rod-type knockout has not completed its upward movement within the preset time. Check YV25S = slow upward movement of the rod-type knockout, YV21G/YV21H= knockout interlock solenoid valve, YV21P = proportional solenoid valve to control rod-type knockout. Check card OD, location 14, card OD, location 16, and card ODA, location 17. Check BQ4A = position of rod-type knockout (linear absolute encoder) and card IE, location 9. 2049

TIME-OUT, KNOCKOUT DOWN

(shutdown)

The rod-type knockout has not completed its downward movement within the preset time. Check YV25D = slow downward movement of rod-type knockout, YV21G/YV21H= knockout interlock solenoid valve, YV21P= proportional solenoid valve to control the rod-type knockout. Check card OD (location 14) card OD (location 16) card ODA (location 17). Check BQ4A= position of the rod-type knockout (linear absolute encoder) and card IE, location 9. 2050

WRONG KNOCKOUT MOTION (BQ4A)

(shutdown)

The rod-type knockout has moved in the wrong direction. Proportional valve YV21P may be blocked. Check YV21P= proportional solenoid valve to control the rod-type knockout and card ODA, location 17. Check BQ4A= position of the rod-type knockout (linear absolute encoder) and card IE, location 9. 2053

SAFETY BAR UP

(shutdown)

The safety bar has been raised. If the message appears when the safety bar is down, press the Reset key. If the message remains on the screen, check limit switches SQ51and SQ52 for secure mounting and proper operation. Also check the ID card in location 11 and the leads/connectors. This message only appears if LEDS SQ51 and SQ52 (on the ID card in location 11) are on with mode selector SA9 turned to MANUAL or AUTOMATIC.

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2054

ENCODER FAULTY (BQ6)

(shutdown)

A fault has been detected in the system which monitors the setting of a plunger encoder (the name of the encoder is specified in brackets). Check the encoder, connecting lead and the encoder card (IE) in location 9 for proper functioning. Try turning off the control system, removing the IE card and putting it back in and then turning the system on again. 2055

PUNCHES OVERTRAVEL/LIFT RODS

(shutdown)

The lift rod or punch over-travel selectors have been turned on. If neither of these selectors have been turned on, check the input card in location 12 (Led SA1 must be on if no contacts are energized) and the leads/connectors. With 4-cylinder proportional knockout: data item PUNCH OVERTRAVEL = YES has been set on the S.P.E. die-set set-up page. Enter NO for this setting. 2056

CHECK (SQ68/SQ67)

(shutdown)

The device for changing the die-set is activated (it is out). If this is not the case, check sensors SQ68A, SQ68B, SQ67A, SQ67B (when the hook is in, sensors SQ67 are energized and SQ68 de-energized, whereas when the hook is out sensors SQ67 are deenergized and SQ68 energized). Check the ID cards and the leads/connectors. 2057

REPLACE FILTER (SP4)

(shutdown)

Input SP4 has stayed off for 0.5 seconds with the oil temperature higher than 30°C. Replace the filter located on the proportional solenoid valve in the filler-box as it is clogged. If the message is still displayed even after the filter has been replaced, check pressure switch SP4, the ID card in location 11 (Led SP4 must be on when the filter is not clogged) and the leads/connectors. 2058

PLUNGER ENCODER/ACTUATOR

(shutdown)

Approx. 300 msecs. have elapsed since the plunger downstroke began and the plunger speed is still lower than 4mm/sec. In “proportional” PHs, this fault message may be displayed during the first few plunger downstrokes just before reaching the impact position. In this case, try restarting the machine because during each attempt the control system tries to soften the brake ramp. Check the plunger encoder, its mount and the leads/connectors. Make sure the plunger can reach the START PRESS STROKE setting when it moves down. Check solenoid valve YV32D and the related hydraulic lines for proper functioning. The first ODA card has to be energized while the plunger is moving down (19th led of the card should be on). If it is not, check filler box limit switch SQ59, circuit breaker FS101, contactors KA102/102A, KA103/103A, mode selector SA9, safety module AJ101 and With program version earlier than PH12.01.01: check the EIA card in location 6/7 if an incremental encoder is installed or the IE card in location 9 if an absolute encoder is installed. With program version PH12.01.01 or later: check the IE card in location 8.

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2059

F-BOX ENCODER/ACTUATOR

(shutdown)

200 msecs. have elapsed since the filler-box forward stroke signal was sent but the fillerbox encoder value has not changed. Check encoder BQ2, its mount and the leads/connectors. With rod-crank mechanism filler-box: check proportional solenoid valve YV20 (see NOTE), the related electrical wiring and hydraulic lines for proper functioning. Check the pressure in the service circuit. Check solenoid valve YV20S and related electrical wiring. Also inspect YV20 control card AP201 and the OD card in location 16. If solenoid valve YV20S does not work, also check circuit breaker FS101, mode selector SA9 and contactors KA102/102A, KA103/103A. NOTE: if proportional valve YV20 is not installed, check solenoid valve YV20A and the related electrical wiring; If the proportional solenoid valve is installed, YV20A becomes YV20S - With program version earlier than PH12.01.01: check the EIA card in locations 6/7. - With program version PH12.01.01 or later: check the IE card in location 10. With linear filler-box: check digital output KA20E on the ODA card (LED on = filler-box moving) and the related electrical wiring. Check relays KA20E/20I, inverter U20 and motor M20. - With program version earlier than PH12.01.01: check the EIA card in locations 6/7. - With program version PH12.01.01 or later: check the IE card in location 10. 2060

PWD FEED SHUTOFF AT... c.mm

(shutdown)

There is no powder in the die-set. The plunger has reached a value higher than the one set for the STOP DUE TO LACK OF PWD data item. Alternatively, the plunger has reached a value higher than that set for the STOP DUE TO LACK OF PWD - 1ST data item during the first press-stroke. The setting of the plunger encoder which caused the alarm is indicated in the message. 2061

FILLER-BOX RETURN

(shutdown)

Check proportional solenoid valve YV20 and the related hydraulic lines for proper functioning, including card VT11023. If the proportional solenoid valve is not provided, check solenoid valve YV20A. Check encoder E2, its mount, the EIA card and the leads/connectors. Check the output card (when the solenoid valve has to operate, Led YV20A must come on) and the leads/connectors. Check the pressure in the service circuit. With a filler box for double loading, check signals KA302 and SQ59 coming from the filler box itself (when the filler box is fully back, led KA302 on the ID card should come on and led SQ59 should go out). Also check the ID card and the KA59 relay. 2062

FILLER-BOX FORWARD

(shutdown)

Check proportional solenoid valve YV20 and the related hydraulic lines for proper functioning, including card VT11023. If the proportional solenoid valve is not provided, check solenoid valve YV20A. Check encoder E2, its mount, the EIA card and the leads/connectors. Check the output card (Led YV20A must come on when the solenoid valve has to operate) and the leads/connectors. Check the pressure in the service circuit. With a filler box for double loading, check signals KA302 and SQ59 coming from the filler box itself (when the filler box starts moving, led KA302 on the ID card should go out and led SQ59 should come on). Also check the ID card and the KA59 relay. 97

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2063

F-BOX ENCODER RESET

(shutdown)

The filler-box encoder reset procedure has failed. With connecting rod/crank filler-box: the encoder zero-point has not been found within 8 seconds of the signal to reset the filler-box. Check the encoder for proper functioning. Check proportional solenoid valveYV20 (see NOTE), its electrical wiring and related hydraulic lines, the service circuit pressure, solenoid valve YV20S and related wiring, YV20 control card AP201 and the OD card in location 16. If solenoid valve YV20S is not energized check circuit breaker FS101, mode selector SA9 and contactors KA102/102A, KA103/103A. NOTE: if proportional solenoid valve YV20 is not installed, check solenoid valve YV20A and related electrical wiring; If the proportional valve is installed, YV20A will be identified as YV20S - With program version earlier than PH12.01.01: check the EIA card in locations 6/7. - With program version PH12.01.01 or later: check the IE card in location 10. With linear filler-box: with the reset sensor energised the encoder zero point has not been found. Check that the encoder is working properly. Check digital outputs KA20E (led on = filler-box moving) and KA201 (filler-box forwards/backwards) on the ODA card. Also inspect the related wiring, relays KA20E/20I, inverter U20 and motor M20. - With program version earlier than PH12.01.01: check the EIA card in locations 6/7. - With program version PH12.01.01 or later: check the IE card in location 10. 2064

PLUNGER DOWN AT F-BOX START

(shutdown)

The plunger is below the value set for its upper-most position when the filler-box begins its forward/return strokes. If an absolute encoder is installed, check that the value read by the encoder when the plunger is against the end-stop is 0. If this is not the case, repeat the plunger encoder reset procedure (see AXES RESET page). If the fault persists, try replacing the IE card in location 8. 2065

FILLER-BOX BACKWARD (KA302 - SQ59)

(shutdown)

When the automatic or semi-automatic cycle is started, the filler-box for double loading is not fully back. When the filler-box is fully back, input SQ59 should be off and input KA302 should come on. Check cards ID in locations 11 and 13. 2066

1ST DOWNSTROKE SIGNAL (KA305)

(shutdown)

The signal for the first die-set downstroke sent from the PLC controlled filler-box was not received within 15 seconds of the filler-box start. Check the connection for the first die-set downstroke signal and the input card in location 13 (when the request is provided Led KA305 must come on). 2067

3RD DOWNSTROKE SIGNAL (KA306)

(shutdown)

The signal for the third die-set downstroke was not received from the filler-box for double loading. Check the connection for the third die-set downstroke signal and the input card (when the request is provided Led KA306 must come on).

98

PH 339.85.089 Rev. 00 Date 10.12.01

2068

WAIT FOR F-BOX TO GO BACK (KA302)

(shutdown)

Digital inputs SQ59 and KA302 have not changed over within 15 seconds of the last downstroke (when the filler-box arrives at the rear end-stop, led SQ59 should go out and led KA302 should come on). Make sure that the digital input cards in location 11 and 13 receive the filler-box forwards/ backwards signals SQ59 and plunger down trigger pulse KA302. Also check contactor KA59 and the related press/filler-box leads/connectors. 2069

CHECK (SQ51/SQ52)

(shutdown)

One of the two limit switches for the safety bar is faulty. Check the two limit switches, the ID card in location 11 and the related leads/connectors (when the safety bar is down Leds SQ51 and SQ52 for the input card must be on). After checking, push the safety bar up and press the Reset button. 2070

CHECK (YV20S)

(shutdown)

Check solenoid valve YV20S and its monitoring device (SQ20S) for proper functioning. When the filler-box is operating (output YV20S energized), input SQ20S must be off whereas when the filler-box is stopped (YV20S de-energized) input SQ20S must be on. Check the ID input card in location 12. 2071

CHECK (SQ58)

(shutdown)

The ejector cylinder is malfunctioning. Check the sensor indicated in the fault message and the ID input card in location 13 (when the sensor is activated the corresponding Led of the card must be on) and the leads/connectors. 2072

FAULT, FILLER-BOX DRIVE (U20)

(shutdown)

Digital input U20 on the ID card in location 13 is not energized. The converter that drives the linear filler-box is malfunctioning or is not energized. Check the two miniature switches SQ20A and SQ20I which, when triggered, shut off the power supply to the converter. Check the converter and consult the Instruction Manual to locate what is causing the fault. If the converter is not faulty, check the input card (when the converter is running, Led U20 must be on) and the leads/connectors. 2073

CHECK (AJ101)

(shutdown)

Press the Reset button. If the message remains on the screen, check safety module AJ101. If no power is delivered (“NETZ” Led off or “POWER” off) check magnetic-thermal cutout FS100. If power is being delivered but the two signals (S1 and S2) are different or they are both off, check limit switches SQ51, SQ52 and SQ66/SQ66A as well as sensors SQ53A/ SQ53B, which monitor the roller conveyor (optional), for secure mounting and proper operation. If Leds S1 and S2 stay on and the message remains on the screen, check the input card (Led AJ101 must be on when the safety bar is down) and the leads/connectors.

99

PH 339.85.089 Rev. 00 Date 10.12.01

2074

WRONG DIE-SET OP. (A=..., B=...)

(shutdown)

The value of one or both die-set encoders has exceeded the Upper End Stop (FCA) setting by more than 0.5 mm or has fallen below it by more than 1 mm during the filler-box forward stroke (up until the first downstroke). Refer to fault message 2037 for trouble-shooting instructions. 2075

CHECK (SQ53/SQ54)

(shutdown)

One of the 2 sensors that detect when the roller deck is in front of the press is malfunctioning. Check the 2 sensors, the ID card in location 13 and the leads/connectors (when the roller deck is connected Leds SQ53 and SQ54 on the ID card must be off). After checking, move the roller deck back and press the Reset key. 2076

FILLER-BOX DID NOT START (KA302 - SQ59)

(shutdown)

Digital inputs SQ59 and KA302 failed to change-over within 30 sec. from the moment in which the start signal was sent to the PLC controlled filler-box from contact KA20A (when the filler-box begins to move, led SQ59 should light up and led KA302 should go out). Make sure the start signal from KA20A reaches the filler-box controller (led YV20S on card OD in location 16 ON = filler-box start). In addition, check contactors KA102/102A, KA103/ 103A, relay KA20A and the leads/connectors for the relative press/filler-box. Make sure the digital input cards in locations 11 and 13 receive the filler-box forward/back signals from SQ59 and the signals for the plunger downstroke from KA302. In addition, check contactor KA59 and the leads/connectors for the relative press/filler-box. 2077

F.BOX/PLUNGER COLLISION

(shutdown)

The linear filler-box has exceeded the safety position (set for the FILLER-BOX SAFETY SETTING data item on the LOADING SET- UP page) and the plunger is lower than the value set for PLUNGER UP (PRESS CYCLE SET-UP page). Decrease the value set for F.BOX START ADVANCE. If this is not enough to solve the problem, try reducing the value set for PLUNGER UP or adjust the UPPER END-STOP PRECISION data item. 2081

MIXER (KM22A)

(shutdown)

Digital input KM22 has not come on within 300 msecs. of the KM22A signal being sent. Check the thermal cutout and ACP contactor KM22A for proper functioning. Check the input card (Led KM22 must be on when the motor is running) and the leads/ connectors. Check the output card (Led KM22A must be on when the motor has to run) and the leads/ connectors 2082

HOMOGENIZER (KM21A)

(shutdown)

Digital input SQ21 has not come on within 20 seconds of the KM21A signal being sent. Check the thermal cutout and the ACP contactor. Check sensors SQ21 and SQ22 (when KM21A is energized SQ21 has to be activated) and the related input card. Check the output card (when the motor has to run, Led KM21A must be on) and the leads/ connectors. 100

PH 339.85.089 Rev. 00 Date 10.12.01

2083

MIXER (KM22B)

(shutdown)

Digital input KM22 has not come on within 300 msecs. of the KM22B signal being sent. Check the thermal cutout and ACP contactor KM22B for proper functioning. Check the input card (Led KM22 must be on when the motor is running) and the leads/ connectors. Check the output card (Led KM22B must be on when the motor has to run) and the leads/ connectors. 2084

HOMOGENIZER (KM21B)

(shutdown)

Digital input SQ22 has not come on within 20 secs. of the KM12B signal being sent. Check the thermal cutout and the ACP contactor. Check sensors SQ21 and SQ22 (when KM21B is energized SQ22 has to be activated). Check the output card (when the motor has to run, Led KM21B must be on) and the leads/ connectors. 2085

MOBILE HOPPER (KM23I)

(shutdown)

The ALM failed to complete its loading stroke correctly. ALM with encoder: - If the ALM does not reach the setting for the end of the forward stroke within 15 secs., - If the ALM accidentally performs an overtravel beyond the setting for end of backstroke and does not return to the end of backstroke setting within 15 seconds, check ALM encoder BQ10, the IE card in location 10 and the leads/connectors. ALM with sensors: If limit switch SQ24 is not energised within 15 seconds (the ALM must be at the maximum distance from the press) check sensor SQ24 and the input card (with the ALM at the maximum distance from the press, led SQ24 should be on). Check contactor KM231 and the OR output card (when the ALM moves away from the press, led KM231 should be on) and the leads/connectors. 2086

MOBILE HOPPER (KM23A)

(shutdown)

ALM with encoder: if the ALM does not reach the setting for the end of the backstroke within 15 seconds; check ALM encoder BQ10, the IE card in location 10 and the leads/connectors. ALM with sensors: if limit switch sensor SQ23 is not energised within 15 seconds (the ALM should be near the press). Check sensor SQ23 and the input card (with the ALM near the press, led SQ23 should be on). Check contactor KM23A and the OR output card (when the ALM moves near the press, led KM23A should be on) and the leads/connectors. 2087

MOBILE HOPPER (SQ23/SQ24)

(shutdown)

- With the fixed ALM, limit switch SQ23 is not energized at the filler-box start (the ALM should be near the press). Make sure that digital input SQ23 on the ID card in location 12 is on. - Limit switch SQ24 has not been energised within 15 seconds during a manual operation or ALM reset procedure. Try increasing the ALM speed. 101

PH 339.85.089 Rev. 00 Date 10.12.01

2088

MOBILE HOPPER (U23)

(shutdown)

Digital input U23 on the ID card in location 11 is not energized. The inverter which drives the ALM is malfunctioning. Check inverter U23, the input card (Led U23 must be on when the inverter is running) and the leads/connectors. 2089

MOBILE HOPPER (SQ25)

(shutdown)

Sensor SQ25 was not activated during the ALM loading cycle. Check sensor SQ25, the input card and the leads/connectors. Check the related cam: SQ25 must be energized before the ALM activates SQ24. 2090

REDUCE ALM OPENING DELAY TIME

(shutdown)

This fault message is provided with 2-LINE LOADING of the ALM when the second cam for SQ25 or limit switch SQ24 is activated before the time set for OPENING DELAY for the gate has elapsed. Decrease the value set for the OPENING DELAY data item found on the FITTINGS SET UP page. 2091

MOBILE HOPPER (SQ24S)

(shutdown)

Sensor SQ24S was activated while the ALM was being moved back in manual mode or being reset. Check sensor SQ24S and the input card (when the ALM is at the end of its backwards overtravel stroke, Led SQ24S must be on) and the leads/connectors. If the return stroke of the filler-box is to be carried out in manual mode, move the ALM to the end of its backwards overtravel position with the manual control for the back stroke before carrying out the operation. If a semi-automatic loading cycle is required, move the ALM forwards before carrying out the operation. 2092

FILLER-BOX FORWARD

(shutdown)

If the ALM has to be moved back in manual mode or be reset, move the filler-box fully back before carrying out the operation. 2093

MOBILE HOPPER

(shutdown)

- With the fixed ALM, the value read by the ALM encoder BQ10 differs from the rear endstop value by more than 20 mm. Check encoder BQ10, the IE card in location 9 and the leads/connectors. - The ALM has not reached the rear end-stop position within 25 seconds during a manual operation or while being reset. Try increasing the ALM speed. - With an ALM with sensors, make certain limit switches SQ23 and SQ24 are not activated at the same time. Check the ID card in location 12.

102

PH 339.85.089 Rev. 00 Date 10.12.01

2096

MOBILE HOPPER (SQ10)

(shutdown)

- The position of the ALM during the filler-box return stroke, with the filler-box nearly at the end of the backstroke, is not correct (reset sensor SQ10 should be energized). - Reset sensor SQ10 was not energized within 25 seconds while the ALM was being operated in manual mode or was being reset. Try increasing the ALM speed, check reset sensor SQ10, the IE card in location 9 and the leads/connectors. - The ALM encoder zero-point was not found with reset sensor SQ10 energized. Check the ALM encoder BQ10 and the leads/connectors. 2097

ALM ACTUATOR/ENCODER

(shutdown)

The ALM encoder value has not changed after 0.75 secs. following the signal for the ALM to move. Check the encoder for proper functioning, check the ODA card in location 18, the OR card in location 20 (when the ALM needs to move, one of outputs KM23A/KM23I should be energized), relays KA23A/KA23I, the IE card in location 10, inverter U23, motor M23 and the leads/connectors. 2098

CHECK (U24)

(shutdown)

With the pump running, mode selector SA9 in the manual or automatic position and safety modules AJ100 and AJ101 in operating mode, digital input U24 is off. Make sure inverter U24 is in operating mode and check the ID card in location 12 (with inverter U24 in operating mode, digital input U24/KM22AB should be on) and the leads/ connectors. 2101

CARRY OUT LOADING

(shutdown)

A press-cycle has been attempted before carrying out a loading cycle. 2102

CYLINDER PRESSURE TRANSDUCER (BP1)

(shutdown)

The pressure measured by transducer BP1 before the plunger begins its downstroke is more than 20 bar. Check pressure transducer BP1, the leads/connectors and With program versions earlier than PH12.01.01: check the input module of transducer BP1 (AP201) and the EIA card in locations 6/7. With program version PH12.01.01 or later: check the IA card in location 7.

103

PH 339.85.089 Rev. 00 Date 10.12.01

2103

PLUNGER DOWNSTROKE

(shutdown)

- If the plunger encoder value does not reach the IMPACT POSITION setting within 8 seconds during a downstroke in manual mode; - if the plunger encoder value does not reach the IMPACT POSITION - BRAKING SPACE setting (both data items can be set) within 8 seconds in automatic mode; Check that the setting for IMPACT POSITION can be reached. Also check solenoid valve YV32D and related hydraulic lines for proper operation, inspect the plunger encoder and make sure it is securely mounted, check the leads/connectors, the ODA card (when solenoid valve YV32D is energised, the corresponding green LED should be on) and With program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if the incremental encoder is installed or the IE card in location 9 if the absolute encoder is installed. With program versions from PH12.01.01 onwards, check card IE in location 8. In proportional presses, check proportional solenoid valve YV32, card ODA (location 17), potentiometer card AP32. This problem may arise when the press has started moving up after receiving a downstroke signal. In this case, replace YV32 and/or card ODA - location 17 (YV32D or YV32S with non-proportional presses). 2104

EXCESSIVE BRAKING

(shutdown)

- The plunger encoder value does not reach the setting for IMPACT POSITION while the plunger is moving down. - The plunger encoder value does not reach the setting for PLUNGER UP while the plunger is moving up. Make sure that the setting for IMPACT POSITION can be reached. Check solenoid valves YV32D and YV32S and related hydraulic lines for proper operation. Also check the plunger encoder and make sure it is securely mounted, check the leads/connectors, the ODA card (when solenoid valve YV32D is energised, the green LED should be on) and With program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if the incremental encoder is installed or the IE card in location 9 if the absolute encoder is installed. With program version PH12.01.01 or later: check the IE card in location 8. If this problem arises during the upstroke with a proportional press, decrease the value set for UPPER END-STOP PRECISION. 2105

BRAKING

(shutdown)

Make sure that the braking space set is sufficient so that the solenoid valve can work properly. Check solenoid valve YV47 and the related hydraulic lines for proper functioning. Inspect the plunger encoder, its mount, card EIA and the leads/connectors. Check the output card (when the solenoid valve has to operate, Led YV47 must come on) and the leads/connectors. 2106

DIE-SETS UP (SQ3/SQ6)

(shutdown)

The die-set is not down when the plunger begins its downstroke. Proximity switch SQ6 is inactivated or SQ3 is activated. Check proximity switch SQ6, the input card (Led SQ6 must be on when the die-sets are down) and the leads/connectors. Do the same for SQ3. The same fault message will appear on the display when the filler box is moved manually and the PROPORTIONAL KNOCKOUT is 0.4mm higher than the set value. In this case move the die-set manually so as to bring it into the correct position. 104

PH 339.85.089 Rev. 00 Date 10.12.01

2107

F-BOX FORW. DUR. PLUNGER DOWNSTROKE

(shutdown)

The filler-box is not all the way back when the plunger begins to move down. Check the filler box encoder setting which should be lower than the REAR END STOP. Try increasing the REAR END STOP setting. If the problem persists check YV20 and card VT 11023. 2108

F.BOX SAFETY SW. (SQ59)

(shutdown)

The filler-box is not completely back when the plunger begins its downstroke. Check limit switch SQ59, its mount, the input card (Led SQ59 must be off when the fillerbox is fully back) and the leads/connectors. If limit switch SQ59 is working correctly, check the filler box encoder. 2109

2ND F.BOX SAFETY SW. (KA302)

(shutdown)

When the plunger begins its downstroke the trigger pulse from the 2nd filler-box or the LB type filler-box is not provided. Check limit switch KA302, its mount, the input card (Led KA302 must be on when the 2nd filler-box or LB type filler-box is fully back) and the leads/ connectors. 2110

PLUNGER UPSTROKE

(shutdown)

In manual mode: the manual upstroke keys have been kept pressed for more than 8 seconds. In automatic mode: if upstroke with braking has been selected and plunger encoder has not reached the “end of braking during upstroke” setting; check that the setting for END OF BRAKING DURING UPSTROKE can be reached, check solenoid valves YV32S and YV47 and related hydraulic lines for proper functioning. Check the plunger encoder, its mount and the leads/connectors. Also check the OD card in location 16 (when solenoid valve YV32S is energised, the related green LED should be on) and With program versions earlier than PH12.01.01: check the EIA card in locations 6/7 if the incremental encoder is installed or the IE card in location 9 if the absolute encoder is installed. With program versions from PH12.01.01 onwards: check card IE in location 8. In proportional presses, check proportional solenoid valve YV32, card ODA (location 17), potentiometer card AP32. The problem may arise when the press has started moving down after receiving an upstroke signal. In this case, replace YV32 and/or card ODA - location 17 (YV32D or YV32S with non-proportional presses).

105

PH 339.85.089 Rev. 00 Date 10.12.01

2111

PLUNGER ENCODER RESET

(shutdown)

The plunger encoder reset procedure has failed. With incremental encoder: the encoder zero-point has not been found with reset sensor SQ1 energised. With absolute encoders: - If only one encoder is installed: the encoder value is > 5 mm with the safety bar raised - if both encoders are installed: the difference between the values of the two encoders is > 5 mm. Check solenoid valves YV31D and YV31S for proper functioning. Inspect the plunger encoder, its mount, the plunger reset sensor, the EIA card and the leads/ connectors. Check the reset signal for the plunger encoder (see the USER’S MANUAL). If the machine has a double plunger encoder or just one absolute encoder they are to be reset (see AXES RESET). If the message continues to appear, try replacing the IE card. If led HL7 on the IE card does not come on when the encoder is reset, try replacing the CPU card. 2112

1ST PRESS STROKE

(shutdown)

The set pressure has not been reached within 4 seconds. Check solenoid valve YV40 and the related hydraulic lines for proper functioning. Check pressure transducer BP1, the ODA card (when the solenoid valve is energized, green LED YV40 should be on) and the leads/connectors. With program versions earlier than PH12.01.01: check the input module of transducer BP1 (AP301) and the EIA card in locations 6/7. With program version PH12.01.01 or later: check the IA card in location 7 and, if the proportional press-stroke is delivered, also check solenoid valve YV318, related hydraulic lines and the ODA card in location 17. 2113

EJECTOR FORWARD (SQ58)

(shutdown)

The ejector cylinder is forward (SQ58 inactivated) when the plunger begins its downstroke. Check sensor SQ58, the ID input card in location 13 (when the ejector cylinder is back, Led SQ58 must be on) and the leads/connectors. 2114

DIRECT PRESS STROKE

(shutdown)

The set pressure was not reached within 4 seconds. Check solenoid valve YV19 and the related hydraulic lines for proper functioning. Check pressure transducer BP1, the ODA card (when the solenoid valve is energized, green LED YV19 should be on) and the leads/connectors. With program versions earlier than PH12.01.01: check the input module of transducer BP1 (AP301) and the EIA card in locations 6/7. With program version PH12.01.01 or later: check the IA card in location 7 and, if the proportional press-stroke is delivered, also check solenoid valve YV318, related hydraulic lines and the ODA card in location 17.

106

PH 339.85.089 Rev. 00 Date 10.12.01

2115

BOOSTED PRESS STROKE

(shutdown)

The set pressure was not reached within 4 seconds. Check solenoid valves YV38/41 and the related hydraulic lines for proper functioning. Check pressure transducer BP1, the ODA card (when the solenoid valves are energized, green LEDs YV38/41 should be on) and the leads/connectors. With program versions earlier than PH12.01.01: check the input module of transducer BP1 (AP301) and the EIA card in locations 6/7. With program version PH12.01.01 or later: check the IA card in location 7 and, if the proportional press-stroke is delivered, also check solenoid valve YV318, related hydraulic lines and the ODA card in location 17. 2116

PRESSURE NOT RECUPERATED

(shutdown)

The press was not able to restore the correct pressure. PH400 - PH3590: If the cylinder pressure is not lower than the pump pressure + 30 bar (the set pump pressure is approx. 200 bar) within 2 seconds after the end of the press-stroke; PH4200: if the cylinder pressure is not lower than the pressure in the accumulators as detected by transducer BP3 + 4 bar within 2 seconds after the end of the press-stroke; Check solenoid valves YV19 and YV19A and the related hydraulic lines for proper functioning. Check pressure transducers BP1 and BP3 (BP3 only with PH4200), the ODA card (when the solenoid valves are energised, green LEDs YV19 and YV19A should be on), the leads/ connectors and With program versions earlier than PH12.01.01: check the input module of transducer BP1 (AP301) and the EIA card in locations 6/7. With program version PH12.01.01 or later: check the IA card in location 7 and, if the proportional press-stroke is delivered, also check solenoid valve YV318, related hydraulic lines and the ODA card in location 17. 2117

CHECK (SQ67/SQ68)

(shutdown)

Sensors SQ67A/B and SQ68A/B have remained de-energised for more than 5 seconds. The die-set changer has not been correctly activated or inactivated. Check pneumatic valve YV292 and proximity sensors SQ67A/B, SQ68A/B: when the hook is used, only sensors SQ68A/B must be activated, when the hook is not used only sensors SQ67A/B have to be activated. Check the input card and the leads/connectors. 2118

CHECK (BQ1)

(shutdown)

The plunger has carried out a stroke which is longer than the allowable one. Reset the plunger encoder (see the USER’S MANUAL).

107

PH 339.85.089 Rev. 00 Date 10.12.01

2119

POWDER IN DIE-SET BELLOWS

(shutdown)

With 2-cylinder proportional knockout: the difference between the analog and digital values during the press-cycle is greater than 1 mm and the encoder value is > 0.6 mm. Check encoder interface card AP206 installed on the SMU for proper operation. Also check encoders BQ4/5 and - With program versions earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. - With program version PH12.01.01 and later: the IA card and the IE card in location 9. With 4-cylinder proportional knockout: the value of one or both encoders is > 0.6 mm during the press-cycle. Check axis card AP210, encoder interface card AP207, serial interface card AP208, encoders BQ4/5 and - With program versions earlier than PH12.01.01: the EIA card in location 10. - With program version PH12.01.01 and later: the IE card in location 9. 2120

INCORRECT PLUNGER PARALLELISM

(shutdown)

The max. difference (value to be entered in INCORRECT PLUNGER PARALLELISM on the PRESS CYCLE SET-UP page) on the diagonal of the plunger has been exceeded. The detected value is the difference between encoders BQ6 and BQ7. 2121

REPLACE FILTER (SP7)

(shutdown)

With the oil temperature higher than 30°C, digital input SP7 has stayed off for more than 2.5 seconds. Replace the filter of the control line of proportional solenoid valves YV32 and YV318 as it is clogged. If the message is still displayed on the screen after the filter has been replaced, check pressure switch SP7 and the input card (LED SP7 should be on if the filter is not clogged) and the leads/connectors. 2122

ACCUMULATOR CHARGE

(shutdown)

While the accumulators were being re-charged, the line pressure is less than the pressure of the accumulators or the pressure of the accumulators has not reached the required value within 5 sec. Make sure there is no pressure loss in the main hydraulic circuit line or line for the accumulators. Check pressure transducers BP2 and BP4, the cables and IA card. Carry out the self-learning procedure for YV309 again (see message 2124). 2123

PERFORM PLUNGER LEARNING (YV32)

(shutdown)

For program version PH 13.03.01.7TR and later The self-learning cycle for calculating the offset values for proportional valves (YV32, YV318) has been stopped in an incorrect manner. The various cases are examined below. The number that appears on the right side of the message is given. 1. The mode selector switch has been turned from the MAN position or the plunger has not moved down 1 mm with YV31D energized. Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16. If the plunger moves down but the encoder does not count, check plunger encoder BQ6 and the IE card in location 8.

108

PH 339.85.089 Rev. 00 Date 10.12.01

2. The mode selector switch has been turned from the MAN position or the plunger has not moved down 15 mm (19 mm for P1-14200) with YV318 open 35%. Check proportional solenoid valve YV318, the relative cables and OD card in location 17. Check the solenoid valve for the booster downstroke: solenoid valve YV32M (it should be energized during this stage), solenoid valve YV40 (it should be energized during this stage) and solenoid valve YV70/71 (it should be energized during this stage). 3. The mode selector switch has been turned from the MAN position or the plunger has not reached the IMPACT POSITION - 40 mm with YV31D energized. Check the value set for the IMPACT POSITION data item on the press-cycle set-up page. Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16. 4. During the stage in which the offset value for YV32 is determined, the cylinder pressure has exceeded 10 bar to keep the plunger stationary. Check proportional solenoid valve YV318 (it should be closed during this stage), the relative cables and ODA card in location 17. Check the solenoid valve used to put the cylinder under pressure: solenoid valve YV19 (it should be de-energized during this stage), logic element 117 (it should be closed during this stage), solenoid valve YV40 (it should be de-energized during this stage), logic element 116 (it should be closed during this stage), solenoid valve YV41 (it should be de-energized during this stage), logic element 131 (it should be closed during this stage), solenoid valve YV38 (it should be de-energized during this stage), logic element 120 (it should be closed during this stage), solenoid valve YV70 (it should be de-energized during this stage) and logic element 118 (it should be opened during this stage). 5. During the stage in which the offset value for YV32 is determined, the mode selector switch was turned from the MAN position to keep the plunger stationary or the plunger did not move down with YV31D energized. Decrease the value set for the IMPACT POSITION data item on the press-cycle set-up page. Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16. 6. During the stage in which the offset value for YV32 is determined, the mode selector switch was turned from the MAN position to keep the plunger stationary or the plunger did not move up with YV31S energized. Check the solenoid valve for the slow upstroke, the relative cables and OD card in location 16. 7. The mode selector switch was turned from the MAN position or the plunger did not move up with YV31S energized. The plunger should move up to 26 mm (30 mm for P1-14200). Check the solenoid valve for the slow upstroke, the relative cables and OD card in location 16. 8. The mode selector switch was turned from the MAN position or the plunger did not move 1 mm down with YV31D energized. The plunger should move up to 26 mm (30 mm for P1-14200). Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16. 9. During the stage in which the offset value for YV318 is determined, the command to the solenoid valve has exceeded the maximum allowable value (4095 valve points, given on page 110). Check proportional solenoid valve YV318, the relative cables and ODA card in location 17. Check pressure transducer BP5 for the upstroke chamber, the relative cables and IA card in location 7. Check the solenoid valves used to charge the upstroke chamber during this stage: solenoid valve YV19 (it should be energized during this stage), solenoid valve YV70 (it should be energized during this stage). 10. During the stage in which the offset value for YV318 is determined, the pressure in the cylinder has exceeded 10 bar or the plunger has reached the IMPACT POSITION - 10 mm. In the latter case increase the value entered for the IMPACT POSITION data item on the press-cycle set-up page. Otherwise check proportional solenoid valve YV318, the relative cables and ODA card in location 17. Check pressure transducer BP5 for the upstroke chamber, the relative cables and IA card in location 7. Check the solenoid valves used to charge the upstroke chamber during this stage: solenoid valve YV19 (it should be energized during this stage), solenoid valve YV70 (it should be energized during this stage). If the pressure in the cylinder has exceeded 10 bar and the plunger 109

PH 339.85.089 Rev. 00 Date 10.12.01

has reached the material, decrease the value entered for the IMPACT POSITION data item on the press-cycle set-up page. Check logic element YV303 which should be open during this stage. 11. Once the stage in which the offset value for YV318 is determined has been completed, the command to the solenoid valve is either too high or null. Check proportional solenoid valve YV318, the relative cables and ODA card in location 17. Check pressure transducer BP5 for the upstroke chamber, the relative cables and IA card in location 7. Check the solenoid valves used to charge the upstroke chamber during this stage: solenoid valve YV19 (it should be energized during this stage), solenoid valve YV70 (it should be energized during this stage). 12. During the stage in which the offset value for YV32 (downstroke) is determined, the plunger has reached the IMPACT POSITION - 10 mm. Increase the value entered for the IMPACT POSITION data item on the press-cycle set-up page. Otherwise check proportional solenoid valve YV32, the relative cables and ODA card in location 17. Check solenoid valve YV303 used for plunger movement (it should be energized during this stage) and ODA card in location 17. 13. During the stage in which the offset value for YV32 (downstroke) is determined, the pressure in the cylinder has exceeded 10 bar. Check proportional solenoid valve YV318 (it should be closed during this stage), the relative cables and ODA card in location 17. Check the solenoid valves used to put the cylinder under pressure: solenoid valve YV19 (it should be de-energized during this stage), logic element 117 (it should be closed during this stage), solenoid valve YV40 (it should be de-energized during this stage), logic element 116 (it should be closed during this stage), solenoid valve YV41 (it should be de-energized during this stage), logic element 131 (it should be closed during this stage), solenoid valve YV38 (it should be de-energized during this stage), logic element 120 (it should be closed during this stage), solenoid valve YV70 (it should be deenergized during this stage) and logic element 118 (it should be opened during this stage). 14. The mode selector switch was turned from the MAN position or the plunger did not reach the IMPACT POSITION - 20 mm with YV31D energized. Check the value entered for the IMPACT POSITION data item on the press-cycle set-up page. Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16. 15. During the stage in which the offset value for YV32 (upstroke) is determined, the plunger has reached 19 mm (23 mm for P1-14200). Check proportional solenoid valve YV32, the relative cables and ODA card in location 17. Check solenoid valve YV303 used for plunger movement (it should be energized during this stage) and ODA card in location 17. 16. During the stage in which the offset value for YV32 (upstroke) is determined, the pressure in the cylinder has exceeded 10 bar. Check proportional solenoid valve YV318 (it should be closed during this stage), the relative cables and ODA card in location 17. Check the solenoid valves used to put the cylinder under pressure: solenoid valve YV19 (it should be de-energized during this stage), logic element 117 (it should be closed during this stage), solenoid valve YV40 (it should be de-energized during this stage), logic element 116 (it should be closed during this stage), solenoid valve YV41 (it should be de-energized during this stage), logic element 131 (it should be closed during this stage), solenoid valve YV38 (it should be de-energized during this stage), logic element 120 (it should be closed during this stage), solenoid valve YV70 (it should be deenergized during this stage) and logic element 118 (it should be opened during this stage). 17. The mode selector switch was turned from the MAN position or the plunger did not reach the mechanical end-stop at the end of the self-learning cycle. The booster may not have moved up. Make sure the solenoid valves allow upward movement: solenoid valve YV32M (it should be de-energized during this stage) and solenoid valve YV71 (it should be de-energized during this stage). 18. The self-learning procedure has been interrupted because solenoid valve YV32 has got stuck during the upstroke or downstroke (with solenoid valve YV303 energised and a signal sent to YV32 so that the valve over-center is closed, the plunger travels at a speed > 40 mm/s). 110

PH 339.85.089 Rev. 00 Date 10.12.01

For program versions PH 12.xx.01.7TR The self-learning cycle for calculating the offset values for proportional valve YV32 has been stopped in an incorrect manner. The various cases are examined below. The number that appears on the right side of the message is given. 1. Not used. 2. Not used. 3. The mode selector switch has been turned from the MAN position or the plunger has not reached the IMPACT POSITION - 40 mm with YV31D energized. Check the value set for the IMPACT POSITION data item on the press-cycle set-up page. Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16. 4. During the stage in which the offset value for YV32 is determined, the cylinder pressure has exceeded 10 bar to keep the plunger stationary. Check the solenoid valve used to put the cylinder under pressure: solenoid valve YV19 (it should be de-energized during this stage), logic element 117 (it should be closed during this stage), solenoid valve YV307 (it should be de-energized during this stage), solenoid valve YV70 (it should be de-energized during this stage) and logic element 118 (it should be opened during this stage). 5. During the stage in which the offset value for YV32 is determined, the mode selector switch was turned from the MAN position to keep the plunger stationary or the plunger did not move down with YV31D energized. Decrease the value set for the IMPACT POSITION data item on the press-cycle set-up page. Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16. 6. During the stage in which the offset value for YV32 is determined, the mode selector switch was turned from the MAN position to keep the plunger stationary or the plunger did not move up with YV31S energized. Check the solenoid valve for the slow upstroke, the relative cables and OD card in location 16. 7. The mode selector switch was turned from the MAN position or the plunger did not move up with YV31S energized. The plunger should move up to 30 mm. Check the solenoid valve for the slow upstroke, the relative cables and OD card in location 16. 8. Not used. 9. Not used. 10. Not used. 11. Not used. 12. During the stage in which the offset value for YV32 (downstroke) is determined, the plunger has reached the IMPACT POSITION - 10 mm. Increase the value entered for the IMPACT POSITION data item on the press-cycle set-up page. Otherwise check proportional solenoid valve YV32, the relative cables and ODA card in location 17. Check solenoid valve YV303 used for plunger movement (it should be energized during this stage) and ODA card in location 17. 13. During the stage in which the offset value for YV32 (downstroke) is determined, the pressure in the cylinder has exceeded 10 bar. Check the solenoid valves used to put the cylinder under pressure: solenoid valve YV19 (it should be de-energized during this stage), logic element 117 (it should be closed during this stage), solenoid valve YV307 (it should be de-energized during this stage), solenoid valve YV70 (it should be deenergized during this stage) and logic element 118 (it should be opened during this stage). 14. The mode selector switch was turned from the MAN position or the plunger did not reach the IMPACT POSITION - 20 mm with YV31D energized. Check the value entered for the IMPACT POSITION data item on the press-cycle set-up page. Check the solenoid valve for the slow downstroke, the relative cables and OD card in location 16. 15. During the stage in which the offset value for YV32 (upstroke) is determined, the plunger has reached 4 mm. Check proportional solenoid valve YV32, the relative cables and ODA card in location 17. Check solenoid valve YV303 used for plunger movement (it should be energized during this stage) and ODA card in location 17. 111

PH 339.85.089 Rev. 00 Date 10.12.01

16. During the stage in which the offset value for YV32 (upstroke) is determined, the pressure in the cylinder has exceeded 10 bar. Check the solenoid valves used to put the cylinder under pressure: solenoid valve YV19 (it should be de-energized during this stage), logic element 117 (it should be closed during this stage), solenoid valve YV307 (it should be de-energized during this stage), solenoid valve YV70 (it should be deenergized during this stage) and logic element 118 (it should be opened during this stage). 17. The mode selector switch was turned from the MAN position or the plunger (encoder BQ6) did not reach the mechanical end-stop at the end of the self-learning cycle. 2124

PERFORM YV309 LEARNING

(shutdown)

The self-learning procedure for proportional solenoid valve YV309 needs to be carried out. Set NO. OP. SETTING = 2 (on PC page N) with the key turned to Set-up and then press keys 28 and 7. The procedure takes a few minutes. Once completed, press the Reset key to clear the message. 2125

START OF PRESS-STROKE SETTING NOT REACHED

(shutdown)

During its downstroke the plunger had exceeded the IMPACT POSITION setting but has not reached the START OF PRESS-STROKE POS. (or START OF PRESS-STROKE THICKNESS) - 5 mm - within 5 seconds. Check that the value set for START OF PRESS-STROKE POS. can be reached (for example it could be something in the die-set or soft filling that is preventing the downstroke from being performed). 2126

PERFORM SELF-LEARNING (YV32)

(shutdown)

The proportional solenoid valve self-learning procedure must be performed before switching the press over to automatic or semi-automatic mode (refer to the “self-learning for plunger upstroke/downstroke...” item in the DESCRIPTION OF THE KEYS). 3001

UPPER PUNCH HEATING (KM5)

(stoppage)

The heater is turned on (OUT KM5 and KM5B = ON) but feedback input KM5 is off. Check the contacts on contactors KM5 and KM5B (optional) for heating the upper punches as they fail to close. 3002

UPPER DIE HEATING (KM6)

(stoppage)

Check the contact on contactor KM6 for heating the upper die as it fails to close. 3003

LOWER DIE HEATING (KM7)

(stoppage)

Check the contact on contactor KM7 for heating the lower die as it fails to close. 3004

LOWER PUNCH HEATING (KM8)

(stoppage)

Check the contacts on contactors KM8 and KM8B (optional) for heating the lower punches as they fail to close. 112

PH 339.85.089 Rev. 00 Date 10.12.01

3005

CONTACTS STUCK IN CONTACTOR (KM5)

(stoppage)

The heater is off (OUT KM5 and KM5B = OFF) but feedback input KM5 is on. Contactor KMn does not work; its contacts fail to open. 3006

CONTACTS STUCK IN CONTACTOR (KM6)

(stoppage)

See message no. 3005. 3007

CONTACTS STUCK IN CONTACTOR (KM7)

(stoppage)

See message no. 3005. 3008

CONTACTS STUCK IN CONTACTOR (KM8)

(stoppage)

See message no. 3005. 3009

TEMP. TOO HIGH (BT5)

(stoppage)

The temperature measured by thermocouple BTn is higher than 110°C (80°C if the punches are made of rubber). The temperature is too high. Check the thermocouple for proper functioning (replace it if necessary). If it works properly, find out what is causing the overtemperature. If it does not work properly, (even after the thermocouple has been replaced), check the input module of the thermocouple and then try replacing the analog card. NOTE: n = 5 upper punches n = 6 upper die n = 7 lower die n = 8 lower punches 3010

TEMP. TOO HIGH (BT6)

(stoppage)

See message no. 3009. 3011

TEMP. TOO HIGH (BT7)

(stoppage)

See message no. 3009. 3012

TEMP. TOO HIGH (BT8)

(stoppage)

See message no. 3009.

113

PH 339.85.089 Rev. 00 Date 10.12.01

3013

BRUSH NOT WORKING (KM2A/KM2B )

(stoppage)

Feedback digital input KM2 is off after a signal for brush rotation has been sent (KM2A or KM2B = ON). Check the thermal cutout and contactors KM2A and KM2B. Check the input card (input KM2 must be closed when the motor is running) and the leads/ connectors. Check the output card (Led KM2A or KM2B must be on when the motor has to run) and the leads/connectors. 3014

LACK OF POWDER IN HOPPER (AD1K1)

(stoppage)

Digital input AD1K1 is off. Check the powder level in the hopper. Check level sensor AD1K1, the input card (Led AD1K1 must come on when the powder exceeds the maximum level) and the leads/connectors. If Led AD1K1 is off when the powder exceeds the maximum level adjust the sensitivity of the powder detector amplifier (AD1). 3015

EXTERNAL STOP (KA300)

(stoppage)

Digital input KA300 is off. The line after the press has stopped. Check signal KA300. If the line after the press has not stopped, check the input card (when the line is running Led KA300 must be on) and the leads/connectors. 3016

STOP PUSH-BUTTON

(stoppage)

The automatic cycle stop push-button (located on the keyboard) has been pressed. If the push-button has not been pressed, check the keyboard lead. If the lead is properly connected and is not broken, try replacing the control KEYBOARD. If the keyboard works properly, try replacing the MISCELLANEOUS card. 3017

STOP. DUE TO EXT. SYNCH. (KA301)

(stoppage)

The outer synchronization contact has remained closed (when the filler-box starts its travel) for more than the maximum allowable time (2 minutes). Check contact KA301, the input card (Led KA301 must be off when the press is running) and the leads/connectors. 3018

BATCH COMPLETED

(stoppage)

The production batch has been completed as set for the “PRODUCTION BATCH” data item.

114

PH 339.85.089 Rev. 00 Date 10.12.01

3019

SERVICE-ACCUMULATORS

(stoppage)

The service pressure has remained lower than the set value - 5 bar for three consecutive cycles. Check solenoid valve YV64 for proper functioning. Check the output card (Led YV64 must come on when the solenoid valve has to operate) and the leads/connectors. Check pressure transducer BP2, its input module, the EIA card and the leads/connectors. See the INSTRUCTIONS FOR SETTING THE PRESSURE TRANSDUCER. Make sure the SERVICE PRESSURE setting is higher than the operating pressure of the accumulators. 3020

DECREASE RP2

(stoppage)

Decrease the value set for the GAIN (RP2) data item to prevent the gain for opening the fillerbox valve from becoming too low. This value is given on the ACTUAL LOADING DATA video-page. If the problem persists check YV20 and card VT 11023. If the problem persists check the EIA card and the leads/connectors. 3021

INCREASE RP2

(stoppage)

Increase the value set for the GAIN (RP2) data item to prevent the gain for opening the fillerbox valve from becoming too high. This value is given on the ACTUAL LOADING DATA video-page. If the problem persists check YV20 and card VT 11023. If the problem persists check the EIA card and the leads/connectors. 3022

PLUNGER LEAKS

(stoppage)

The plunger has moved down more than 5 mm during the loading cycle. 3023

THICKNESS ERROR > 40 c.mm

(stoppage)

A tile thickness deviation greater than 0.4 mm has been indicated. The thickness is automatically adjusted (the 0.4 mm threshold can be entered). If the thickness measured does not correspond to the actual thickness, check the plunger encoder, its mount, the EIA/IE card (EIA if an incremental encoder is installed, IE if an absolute one is installed) and the leads/connectors. With SMU and 2-cylinder proportional knockout: Check the automatic filling height control, motor M9 and contactors KKM9A/KM9B, the OR output card (either output KM9A or KM9B has to be activated when the filling height is adjusted), the leads/connectors and, only for 2-cylinder proportional knockout: - With program versions earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. - With program version PH12.01.01or later: the IA card and the IE card in location 9. With SMU and 4-cylinder proportional knockout: Check axis card AP210, encoder interface card AP207, serial interface card AP208, encoders BQ4/5 and - With program versions earlier than PH12.01.01: the EIA card in location 10. - With program version PH12.01.01or later: the IE card in location 9.

115

PH 339.85.089 Rev. 00 Date 10.12.01

3024

CHECK THERMOCOUPLE (BTn)

(stoppage)

The die-set heater is on (OUT KMn = ON) but the temperature measured by thermocouple BTn is lower than 1°C. The temperature measured by a thermocouple for the die-sets is not correct. Check the connections of the thermocouple indicated in the message. Check the input module in question. 3025

WRONG DIE-SET OP. (A=..., B=...)

(stoppage)

At the filler-box start the value of one or both die-set encoders has exceeded the setting for Upper End Stop (FCA) by more than 0.4 mm or has fallen below the setting by more than 0.6 mm. 3026

CONNECT THERMOC. (BT5)

(stoppage)

See whether the thermocouple is properly connected. If the message is not cleared, With program versions earlier than PH12.01.01: check the input module of thermocouple BT5 (AP305), the EIA card in locations 6/7 and the leads/connectors. With program version PH12.01.01or later: check the IA card in location 7 and the leads/ connectors. 3027

CONNECT THERMOC. (BT6)

(stoppage)

See whether the thermocouple is properly connected. If the message is not cleared, With program versions earlier than PH12.01.01: check the input module of thermocouple BT6 (AP306), the EIA card in locations 6/7 and the leads/connectors. With program version PH12.01.01or later: check the IA card in location 7 and the leads/ connectors. 3028

CONNECT THERMOC. (BT7)

(stoppage)

See whether the thermocouple is properly connected. If the message is not cleared, With program versions earlier than PH12.01.01: check the input module of thermocouple BT7 (AP307), the EIA card in locations 6/7 and the leads/connectors. With program version PH12.01.01or later: check the IA card in location 7 and the leads/ connectors. 3029

CONNECT THERMOC. (BT8)

(stoppage)

See whether the thermocouple is properly connected. If the message is not cleared, With program versions earlier than PH12.01.01: check the input module of thermocouple BT8 (AP308), the EIA card in locations 6/7 and the leads/connectors. With program version PH12.01.01or later: check the IA card in location 7 and the leads/ connectors. 3030

PUMP STOP PUSH-BUTTON

(stoppage)

The pump stop button on the keyboard has been pressed. If it has not, check the keyboard power cord. If the cord is properly plugged in and is not broken, try replacing the control KEYBOARD. If the keyboard works properly, try replacing the MISCELLANEOUS card. 116

PH 339.85.089 Rev. 00 Date 10.12.01

3031

LOW PRESSURIZATION/FILTER (SP3)

(stoppage)

Digital input SP3 is off. Check the suction filter of the main pump. Make sure the pressurization pressure is sufficient. Check the ID card in location 11 and the leads/connectors. 3032

CLEANING

(stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page. 3033

DIE-SET CHANGE

(stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page. 3034

SCHEDULED MAINTENANCE

(stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page. 3035

SPECIAL MAINTENANCE/REPAIRS

(stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page. 3036

CHECK TILE/ADJUST MACHINE

(stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page. 3037

PAUSE/WORKSHIFT CHANGE

(stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page. 3038

OTHER PROBLEMS

(stoppage)

Cause of machine stoppage requested by the operator on the “STOPPAGES” page. 3039

TURN SELECTOR SA293 TO ON

(stoppage)

Open the controller and turn selector SA293 to engage the proportional knockout. 3040

DIE-SET NOT DOWN

(stoppage)

One of the die-set cylinders moved more than 2 mm while the proportional knockout was being hooked. Repeat the procedure for hooking the proportional knockout.

117

PH 339.85.089 Rev. 00 Date 10.12.01

3041

PLUNGER LEAKS

(stoppage)

With 2-cylinder proportional knockout: the plunger moved by more than 1 mm while the proportional knockout was being engaged. With 4-cylinder proportional knockout: the plunger moved by more than 2 mm while the proportional knockout was being engaged. 3042

CHECK (KM3)

(stoppage)

Output KM3 is energised but feedback digital input KM3 is off. The oil leak recovery motor has failed. Input KM3 must be closed when the motor is running. Check the input card and the leads/connectors. Check the output card (when the motor has to run, output KM3 must be activated) and the leads/connectors. 3043

FILLER-BOX BACKWARD

(stoppage)

The filler-box is further back than its END OF BACKSTROKE setting when the plunger starts to move down or the ALM begins its forward stroke. Bring the filler-box into the correct position. 3044

REPOSITION

(stoppage)

Before starting the automatic CYCLE perform an automatic repositioning procedure. 3045

REPLACE BRUSH

(stoppage)

The maximum allowable brush wear set on the FITTINGS SET-UP page has been reached. Replace the brush, press Reset and start up again. 3046

CHECK (SQ59)

(stoppage)

Miniature switch SQ59 has been energised (input SQ59 off) at the end of the filler-box forward stroke (after the first downstroke with a double-loading filler-box) in automatic or semi-automatic mode. Check the filler-box back miniature switch and related ID card (with the filler-box forward the miniature switch should be inactivated an the input should be on). 3049

CHECK (FILLER BOX FORWARD/BACK TIME)

(stoppage)

The time the linear filler box requires to complete its forward and backward stroke deviates more than 10% from the pre-determined time Set the correct time for the filler-box forward and return stroke. If the press does not need to stop, set FILLER BOX CONTROL ON = NO 4001

CYCLE TIME GREATER THAN SYNCH. TIME

(message)

The time required for the press to perform a complete cycle is greater than the time set for a synchronized cycle. The number of cycles per minute set cannot be carried out. 118

PH 339.85.089 Rev. 00 Date 10.12.01

4002

WAIT FOR SYNCH. TIME

(message)

The press is stationary and is waiting for the internal synchronization time to elapse. 4003

WAIT FOR EXTERNAL SYNCH.

(message)

The press is stationary and is waiting for external synchronization contact KA301 to open. 4004

LOADING CORRECTION NOT ALLOWED

(message)

Loading cannot be corrected as the die-sets are not down. 4005

TEMP. TOO HIGH (BT5): ... °C

(message)

The temperature of the die-set is high. Do not touch the die-set without wearing heavy duty work gloves. 4006

TEMP. TOO HIGH (BT6): ... °C

(message)

The temperature of the die-set is high. Do not touch the die-set without wearing heavy duty work gloves. 4007

TEMP. TOO HIGH (BT7): ... °C

(message)

The temperature of the die-set is high. Do not touch the die-set without wearing heavy duty work gloves. 4008

TEMP. TOO HIGH (BT8): ... °C

(message)

The temperature of the die-set is high. Do not touch the die-set without wearing heavy duty work gloves. 4009

F-BOX FORW. RUN TIME

(message)

The time taken for the filler-box to perform its forward stroke differs from the set value (FBOX FORW. RUN TIME) by more than 5%. 4010

FILLER BOX RETURN TIME

(message)

The time taken for the filler-box to perform its return stroke differs from the set value (FILLER BOX RETURN TIME) by more than 5%. 4011

OIL TEMPERATURE

(message)

The temperature of the oil is less than 30° C. If the safety bar is raised, under these conditions, the oil will automatically be heated up by solenoid valve YV11R. It is possible to stop the oil from being heated by lowering the safety bar and pressing the Reset key on the control keyboard. 119

PH 339.85.089 Rev. 00 Date 10.12.01

4012

FILTER CLOGGED (SP5)

(message)

Digital input SP5 is off. Make sure that the filter on the die-set proportional solenoid valve is not clogged. Check pressure switch SP5, the ID card in location 12 (Led SP5 must be on when the filter is not clogged) and the leads/connectors. 4013

FILTER CLOGGED (SP4)

(message)

Digital input SP4 is off. Make sure that the filter on the filler-box proportional solenoid valve is not clogged. Check pressure switch SP4, the input card (Led SP4 must be on when the filter is not clogged) and the leads/connectors. 4014

WAIT FOR END OF MOBILE HOPPER CYCLE

(message)

The press is stationary and is waiting for the ALM to stop moving. 4015

THICKNESS ERROR > 25 c.mm

(message)

Tile thickness is wrong. The thickness is automatically adjusted. The deviation falls within 0.25 and 0.4 mm; the max. threshold (0.4 mm) can be entered. 4016

POWDER IN DIE-SET BELLOWS

(message)

With 2-cylinder proportional knockout: the difference between the analog and digital values during the press-cycle is more than 1 mm and the encoder value is between 0.3 and 0.6 mm. Check encoder interface card AP206 installed on the SMU, encoders BQ4/5 and - With program versions earlier than PH12.01.01: input modules AP327/328 and the EIA card in location 10. - With program version PH12.01.01or later: the IA card and the IE card in location 9. With 4-cylinder proportional knockout: the value of one or both the encoders is between 0.3 mm and 0.6 mm during the press-cycle. Check axis card AP210, encoder interface card AP207, serial interface card AP208, encoders BQ4/5 and - With program versions earlier than PH12.01.01: the EIA card in location 10. - With program version PH12.01.01or later: the IE card in location 9. 4017

CHECK PLUNGER SETTING

(message)

This message is displayed after a program has been read. Go to the PRESS CYCLE SET UP page and check the data in the square that deals with the PLUNGER. 4018

TOO MUCH TIME TAKEN TO SET DIE-SET

(message)

The difference between the value of one or both die-set encoders and the Upper End Stop is > 0.2 mm. The upward movement of the proportional knockout is not very precise and it takes it longer to reach the value set for the UPPER LIMIT data item. To avoid slowing down the cycle, set the upstroke of the proportional knockout. 120

PH 339.85.089 Rev. 00 Date 10.12.01

4019

1ST DIE-SET D.STROKE

(message)

An error greater than 0.4 mm was detected after the proportional knockout completed its first downstroke. 4020

FILLER-BOX FORWARD

(message)

A semi-automatic ALM cycle was requested with the filler-box forwards. Move the filler-box fully back and try again. 4021

LAST DIE-SET D.STROKE

(message)

With the proportional knockout carrying out three downstrokes, an incorrect self-learning value for the encoder of the die-set on the cylinders for the last downstroke (YV21) was detected. Shut the controller off, turn it back on and then carry out an automatic resetting cycle. If the message is not cleared, check the die-set for the last downstroke. 4022

FILLER-BOX ENCODER NOT RESET

(message)

Carry out an automatic resetting cycle to zero set the filler-box encoder. 4023

DIE-SET ENCODER NOT RESET

(message)

Carry out an automatic resetting cycle to zero set the die-set encoder. 4024

PLUNGER ENCODER NOT RESET

(message)

Carry out an automatic resetting cycle to zero set the plunger encoder. 4025

FILLER-BOX SAFETY GUARD (SQ66)

(message)

The filler-box has been moved from its seat. Make sure limit switches SQ66/SQ66A are correctly installed and efficient. Check contact SQ66, the input card (Led SQ66 should be on when the filler-box is detached) and the cables/connectors. If either a DAF or DXP filler-box is used, check safety module AJ101. 4026

CONTROL UP PERFORM DIE-SET LEARNING

(message)

Carry out the self-learning procedure for the die-set. See the DIE SET SET UP chapter. 4027

WAIT FOR AUTO. RESTART (KA300)

(message)

The press is in standby ready to start automatically. No trigger pulse has been sent from the next machine in line (KA300). When the trigger pulse is emitted the machine will restart.

121

PH 339.85.089 Rev. 00 Date 10.12.01

4028

CONTROL UP DURING 1ST DOWNSTROKE

(message)

It is advisable to perform a die-set self-learning procedure. See DIE-SET SET-UP chapter. 4029

CARD NOT ENERGIZED (ODA 17)

(message)

During the downward movement of the plunger the ODA card is not energized. Check the 1st ODA card, the filler box miniature switch SQ59 as well as miniature switches SQ66, SQ66A, SQ51, SQ52, SQ53A and SQ53B (optional), contactors KA102, KA103, circuit breaker FS101, mode selector SA9 and safety module AJ101. 4030

INCORRECT PRESSING

(message)

The pressure reached during the last press stroke deviates more than 15 bar in relation to the set value. If the message continues to appear check the solenoid valves (YV19, YV41, YV38), pressure transducer BP1, the leads/connectors and With program versions earlier than PH12.01.01: the input module of transducer BP1 (AP301) and the EIA card in locations 6/7 With program version PH12.01.01or later: check the IA card in location 7 and, if the proportional press-stroke is delivered, solenoid valve YV318, the related hydraulic lines and the ODA card in location 17. 4031

CHECK HEAT EXCHANGER

(message)

HEAT EXCHANGER = NO has been set on the FITTINGS SET-UP page but the feedback digital input KM11A of the heat exchanger is on. 4032

PLUNGER LEAKS

(message)

The plunger is kept up by the PLC because otherwise it would move down to rest on the dieset because of too much leakage. Check the cylinder seal and the hydraulic lines for the downstroke. 4033

WAIT

(message)

Wait before performing any machine operation. 4034

DIE-SET NOT LOCKED

(message)

The proportional knockout is not locked. Lock the die-set. 4035

HYDRAULIC JOINT OIL TEMP.

(message)

To ensure top performance of the hydraulic joint in the power unit, wait 10 minutes before starting the pump.

122

PH 339.85.089 Rev. 00 Date 10.12.01

4036

ALM ENCODER NOT RESET

(message)

Perform an automatic reset procedure to set the ALM encoder back to zero. 4037

ROLLER CONVEYOR LIMIT SWITCHES (SQ53)

(message)

The roller conveyor has been moved away from the press. Check miniature switches SQ53A/SQ53B, the ID card in location 13 (with the roller conveyor in the work position, digital input SQ53A should be off) and the leads/connectors. 4038

SELF-LEARNING IN PROGRESS

(message)

The press is carrying out the self-learning cycle to calculate the offset values for the proportional valves (YV32, YV318). Turn the mode selector switch to stop the cycle. 4039

YV32 OFFSET VALUE TOO HIGH ·[O/D/S]

(message)

The offset values for YV32, determined during the self-learning procedure, are too high. If (S) appears on the right side of the message it means the upstroke offset value is too high. (D) appears to signal the downstroke offset value is too high. (O) appears to signal the zero offset value is too high. Carry out the self-learning cycle again with hot oil. If the message is still displayed, replace YV32 (plunger proportional solenoid valve). 4040

CHECK (BP5)

(message)

While the plunger is moving up, the value in the upstroke chamber read by the pressure transducer is < 10 bar. Check pressure transducer BP5, its cables and the IA card in location 7. 4044

ALLOW DIE-SET TO PERFORM LAST DOWNSTROKE

(message)

Turn the mode selector to MAN or SETUP and allow the die-set to perform the downstroke in manual mode. Now it is possible to change the press over to automatic or semi-automatic. If the message does not disappear, replace the AX card. 4048

WAIT FOR TRIGGER PULSE FROM D.I.P. (KA311)

(message)

The press is waiting for a trigger pulse from the D.I.P to indicate that the KA311 is ready to operate. As soon as the trigger pulse has been emitted (input KA311 signal high) the press restarts cycling. If this does not happen, make sure the DIP electrical cabinet disables the signal. Check the IDM card on the press (location 11) and the cables/wiring connectors. 4900

MEMORY READ

(message)

This message appears for a few seconds when the machine is turned on.

123

PH 339.85.089 Rev. 00 Date 10.12.01

4901

INVALID DATA IN SERIAL EEPROM

(message)

If this message appears when the machine is turned on, contact the CUSTOMER SERVICE DEPT - SACMI IMOLA. 4902

INVALID DATA AFTER SERIAL EEPROM READ

(message)

If this message appears when the machine is turned on, contact the CUSTOMER SERVICE DEPT - SACMI IMOLA. 4903

SACMI BMOS V.1.X - MINIMUM BMOS V.1.Y

(message)

A CPU card with at least a BMOS v. 1.Y operating system has to be installed in order to run the program. Check the version. If it is earlier than 1.Y, replace the CPU card. If this is not the case, shut off the system and then turn it back on. 4904

CHECK CONFIGURATION

(message)

If this message appears when the machine is turned on, contact the CUSTOMER SERVICE DEPT - SACMI IMOLA. 4905

ID 13 CARD

(message)

The ID card is not present in location 13. Program execution is interrupted. 4910

ERROR DURING PRINTING

(message)

Make sure the printer is properly hooked up to the machine controller, power is supplied and that it is ON-LINE. Remember that the CPU card must have an operating system that is at least BMOS 1.8. 4911

EEPROM FAILURE

(message)

If this message appears, contact the CUSTOMER SERVICE DEPT - SACMI IMOLA. 4912

PROGRAM NOT AVAILABLE

(message)

The user tried to store a back-up copy of the operating program in an area (in the computer’s memory) which is already occupied by another program. Enter a different program number. 4913

WRONG PROGRAMMED DATA

(message)

An error was found while a program was being read. Try to read the program again. If the fault message is not cleared, erase the program.

124

PH 339.85.089 Rev. 00 Date 10.12.01

4916

OPERATION NOT ALLOWED

(message)

A program cannot be read if the machine is set to RESETTING or CYCLE 5001

REPLACE FILTER (SP1) WITHIN ...h

(message)

Make sure the filters in the hydraulic power unit are not clogged. Check pressure switch SP1 and the input card (with the filters clean, Led SP1 should be on) and the cables/wiring connectors. NOTE: to erase the message, turn the key switch on the keyboard to SETUP and press the RESET key. The number to the right of the message indicates the number of hours the pump can operate with the filter clogged. 5002

SCHEDULED MAINTENANCE (80 hrs)

(message)

This message appears after the main pump has operated for 80 hours. The maintenance operations which are described in the INSTRUCTIONS MANUAL need to be performed. NOTE: To clear the message, turn the key switch on the machine control keyboard to “SET UP” and press the Reset key. 5003

SCHEDULED MAINTENANCE (message)

(200 h)

See message no. 5002. 5004

SCHEDULED MAINTENANCE (message)

(500 h)

See message no. 5002. 5005

SCHEDULED MAINTENANCE (message)

(2000 h)

See message no. 5002. 5006

SCHEDULED MAINTENANCE (message)

(4000 h)

See message no. 5002. 5007

REPLACE DIE-SET

(message)

The die-set has already carried out the number of cycles set for the “DIE-SET LIFE IN CYCLES” data item on the DIE SET SET-UP page. It needs to be replaced. NOTE: The message is cleared by turning the key on the machine control keyboard to SET UP and pressing the Reset key.

125

PH 339.85.089 Rev. 00 Date 10.12.01

5008

SCHEDULED MAINTENANCE (6,000,000 CYCLES)

(message)

See message no. 5002. 5009

CLOGGED FILTER (SP6)

(message)

Check to see whether the ENEA COOLING filter is clogged. Check pressure switch SP6, the input card (if the filters are not clogged, led SP6 should come on) as well as the leads/connectors. Note: the message can be cancelled by turning the selector key on the keyboard to SETUP and pressing the RESET key. 5010

AT END OF BATCH LOAD PROGRAM NO. Perform the operation requested by the controller.

126

(message)

PH 339.85.089 Rev. 00 Date 10.12.01

5.11

OPERATING SYSTEM MESSAGES

The machine shuts down and the screen is cleared when these messages are displayed. The list of messages is given below: KEYBOARD ERROR [PE\OE\FE] Improper communication with the machine control keyboard. Shut off the electrical power and then turn it on again. If the trouble does not re-occur it can be ignored, otherwise check the power cord that hooks the keyboard up to the miscellaneous card or replace the keyboard and/or “Miscellaneous” (VA) card. Parameter: PE (parity error), OE (overrun error), FE (framing error). INVALID MEMORY The program is not valid. Shut off the power supply, make sure the card located on the CPU is properly plugged in and then turn the power supply back on. If the trouble persists, contact SACMI quoting the alpha-numeric code stamped on the card. POWER SUPPLY/FUSES nnV The protection device on the AL card has come into action or the fuses have blown. The message provides information about the voltages not provided. Check the fuses for condition and make sure there are no shorts in the conductors indicated. OVERFLOW PROG n LINE nn An instruction has been executed whose result exceeds the set limits. The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears. DIVIDE ERROR PROG n LINE nn A division by 0 has been performed. The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears. PROG n PC nnnn:nnnn

COD nn

An instruction not acknowledged was executed. The version of the operating system is probably prior to the one required by the program. The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears and the version of the operating system. OVERFLOW STACK PROG n LINE nn The pointer stack is outside the allowable limits. The problem cannot be solved by the customer. Contact SACMI quoting the message as it appears.

127

PH 339.85.089 Rev. 00 Date 10.12.01

TABLE OF CONTENTS

1

INTRODUCTION ................................................................................................................. 5

2

WARNINGS ......................................................................................................................... 6

3

MAIN FEATURES OF THE ELECTRIC SYSTEM ............................................................... 7

4

MACHINE CONTROL KEYBOARD .................................................................................. 12 4.1 DESCRIPTION OF THE KEYS ............................................................................... 13 4.2 DESCRIPTION OF THE LEDs ................................................................................ 16

5

COMPUTER TERMINAL ................................................................................................... 17 5.1 DESCRIPTION ........................................................................................................ 17 5.2 DESCRIPTION OF THE LEDs ................................................................................ 18 5.3 PAGE LAY-OUT ....................................................................................................... 19 5.4 NO. OF THE OPERATING PROGRAM ................................................................... 21 5.5 DATE AND TIME ..................................................................................................... 22 5.6 DESCRIPTION OF THE WORK-CYCLE ................................................................. 23 5.7 MACHINE STATUS .................................................................................................. 24 5.8 LIST OF PAGES ...................................................................................................... 25 5.9 DATA INPUT & READ-OUT ..................................................................................... 27 5.9.1 “DATA” ......................................................................................................... 27 5.9.2 “INFORMATION AND LANGUAGE SELECTION” PAGE............................ 29 5.9.3 AXES CONFIGURATION RESET .............................................................. 31 5.9.4 “ACTUAL LOADING DATA” PAGE .............................................................. 32 5.9.5 “ACTUAL PRESS CYCLE DATA” PAGE ..................................................... 33 5.9.6 “ACTUAL DIE-SET DATA” PAGE ................................................................ 35 5.9.7 “I/O” PAGE .................................................................................................. 37 5.9.8 “FAULTS” PAGE .......................................................................................... 39 5.9.9 “STATISTICS” PAGES ................................................................................. 40 5.9.11 “STATE OF EXECUTION” PAGE ................................................................ 47 5.9.11 “PRODUCTION DATA” PAGE ..................................................................... 51 5.9.12 “PROGRAMS” PAGE .................................................................................. 52 5.9.13 “LOADING SET UP” PAGE ......................................................................... 55 5.9.14 “PRESS-CYCLE SET UP” PAGE ................................................................ 62 5.9.15 “DIE-SET SET UP” PAGE ........................................................................... 69 5.9.16 “S.P.E. DIE-SET SET-UP” PAGE ................................................................. 72 5.9.17 “FITTINGS SET UP” PAGE ......................................................................... 76 5.9.18 “PRINT ROUTINE”...................................................................................... 79 5.10 FAULT MESSAGES ................................................................................................. 80 5.11 OPERATING SSTEM MESSAGES ....................................................................... 127

128

PH 339.85.089 Rev. 00 Date 10.12.01

FAULT MESSAGES LIST 1ST DIE-SET D.STROKE ....................................................................................................................... 121 1ST DIE-SET D.STROKE (SQ3/SQ6) ...................................................................................................... 89 1ST DOWNSTROKE SIGNAL (KA305) .................................................................................................... 98 1ST PRESS STROKE ............................................................................................................................. 106 2ND DIE-SET D.STROKE (SQ6) .............................................................................................................. 90 2ND F-BOX TRIGGER P. (KA302) ............................................................................................................ 90 2ND F-BOX TRIGGER P. (KA304) ............................................................................................................ 89 2ND F.BOX SAFETY SW. (KA302) ......................................................................................................... 105 2ND FILLER-BOX FORWARD (KA302) .................................................................................................... 88 3RD DOWNSTROKE SIGNAL (KA306) .................................................................................................... 98

A ACCUMULATOR CHARGE ..................................................................................................................... 108 ALLOW DIE-SET TO PERFORM LAST DOWNSTROKE ....................................................................... 123 ALM ACTUATOR/ENCODER .................................................................................................................. 103 ALM ENCODER NOT RESET ................................................................................................................ 123 ANALOG CARD DOES NOT WORK ........................................................................................................ 84 ANALOG/ENCODER CARD NOT WORKING (1) ..................................................................................... 82 ANALOG/ENCODER CARD NOT WORKING (2) ..................................................................................... 83 AT END OF BATCH LOAD PROGRAM NO. ........................................................................................... 127 AXES CARD ERROR ............................................................................................................................... 94

B BATCH COMPLETED ............................................................................................................................. BOOSTED PRESS STROKE .................................................................................................................. BRAKING ................................................................................................................................................ BRUSH NOT WORKING .........................................................................................................................

115 107 104 114

C CARD NOT ENERGIZED (ODA 17) ....................................................................................................... 122 CARRY OUT LOADING .......................................................................................................................... 103 CHECK (AJ101) ........................................................................................................................................ 99 CHECK (BP5) ......................................................................................................................................... 124 CHECK (BQ1) ......................................................................................................................................... 108 CHECK (FILLER BOX FORWARD/BACK TIME) .................................................................................... 118 CHECK (KM3) ......................................................................................................................................... 119 CHECK (SP11) ......................................................................................................................................... 85 CHECK (SQ51/SQ52) ............................................................................................................................... 99 CHECK (SQ53/SQ54) ............................................................................................................................. 100 CHECK (SQ58) ......................................................................................................................................... 99 CHECK (SQ59) ....................................................................................................................................... 118 CHECK (SQ67/SQ68) ............................................................................................................................. 107 CHECK (SQ68/SQ67) ............................................................................................................................... 96 CHECK (U24) .......................................................................................................................................... 103 CHECK (YV20S) ....................................................................................................................................... 99 CHECK 24 VEV......................................................................................................................................... 82 CHECK CONFIGURATION ..................................................................................................................... 124 CHECK DIE-SET ENCODER ................................................................................................................... 93 CHECK HEAT EXCHANGER .................................................................................................................. 123 CHECK PLUNGER SETTING ................................................................................................................. 121 CHECK PRESET DATA ............................................................................................................................. 82 CHECK THERMOCOUPLE (BTn) .......................................................................................................... 116 CHECK TILE/ADJUST MACHINE ........................................................................................................... 118 CLEANING .............................................................................................................................................. 117 129

PH 339.85.089 Rev. 00 Date 10.12.01

CLOGGED FILTER (SP6) ....................................................................................................................... 127 CONFIG. ................................................................................................................................................... 84 CONNECT THERMOC. (BT4) ................................................................................................................... 85 CONNECT THERMOC. (BT5) ................................................................................................................. 116 CONNECT THERMOC. (BT6) ................................................................................................................. 116 CONNECT THERMOC. (BT7) ................................................................................................................. 116 CONNECT THERMOC. (BT8) ................................................................................................................. 117 CONTACTS STUCK IN CONTACTOR (KM5) ......................................................................................... 113 CONTACTS STUCK IN CONTACTOR (KM6) ......................................................................................... 113 CONTACTS STUCK IN CONTACTOR (KM7) ......................................................................................... 114 CONTACTS STUCK IN CONTACTOR (KM8) ......................................................................................... 114 CONTROL UP DURING 1ST DOWNSTROKE ....................................................................................... 122 CONTROL UP PERFORM DIE-SET LEARNING ................................................................................... 122 CONTROL UP: PERFORM DIE-SET SELF-LEARNING .......................................................................... 94 CYCLE TIME GREATER THAN SYNCH. TIME ...................................................................................... 119 CYLINDER PRESSURE TRANSDUCER (BP1) ..................................................................................... 103

D DIE DOWN (SQ63) ................................................................................................................................... 90 DIE SETTING NOT REACHED ................................................................................................................. 94 DIE-SET CHANGE .................................................................................................................................. 117 DIE-SET DEVIATION > 2 mm ................................................................................................................... 91 DIE-SET ENCODER BLOCKED (SQ4) .................................................................................................... 94 DIE-SET ENCODER NOT RESET.......................................................................................................... 121 DIE-SET ENCODER RESET .................................................................................................................... 92 DIE-SET NOT DOWN ............................................................................................................................. 118 DIE-SET NOT LOCKED .......................................................................................................................... 123 DIE-SET PARALLELISM ERROR ............................................................................................................. 91 DIE-SET UP. ERROR (A=..., B=...) ........................................................................................................... 92 DIE-SET UPSTROKE (SQ3) ..................................................................................................................... 88 DIE-SETS UP (SQ3/SQ6) ....................................................................................................................... 104 DIRECT PRESS STROKE ...................................................................................................................... 106

E EJECTOR FORWARD (SQ58) ................................................................................................................ 106 ENCODER FAULTY (BQ4A) .................................................................................................................... 95 ENCODER FAULTY (BQ6) ........................................................................................................................ 96 EXCESSIVE BRAKING ........................................................................................................................... 104 EXTERNAL SHUTDOWN PUSH-BUTTON (SB1E) .................................................................................. 81 EXTERNAL STOP (KA300) .................................................................................................................... 114

F F-BOX ENCODER RESET ....................................................................................................................... 98 F-BOX ENCODER/ACTUATOR ................................................................................................................ 97 F-BOX FORW DUR. DIE-SET UPSTROKE (SQ59) ................................................................................. 88 F-BOX FORW. DUR. PLUNGER DOWNSTROKE .................................................................................. 105 F-BOX FORW. RUN TIME ....................................................................................................................... 120 F.BOX SAFETY SW. (SQ59) ................................................................................................................... 105 F.BOX/PLUNGER COLLISION ............................................................................................................... 100 FAN/FILTERING UNIT (KM11) .................................................................................................................. 84 FAULT, FILLER-BOX DRIVE (U20) ........................................................................................................... 99 FILLER BOX RETURN TIME .................................................................................................................. 120 FILLER-BOX BACKWARD ...................................................................................................................... 119 FILLER-BOX BACKWARD (KA302 - SQ59) ............................................................................................. 98 FILLER-BOX DID NOT START (KA302 - SQ59) ..................................................................................... 100 FILLER-BOX ENCODER NOT RESET ................................................................................................... 121 FILLER-BOX FORWARD ......................................................................................................... 97, 102, 121 130

PH 339.85.089 Rev. 00 Date 10.12.01

FILLER-BOX RETURN ............................................................................................................................. 97 FILLER-BOX SAFETY GUARD (SQ66) .................................................................................................. 122 FILTER CLOGGED (SP1) ....................................................................................................................... 125 FILTER CLOGGED (SP4) ....................................................................................................................... 120 FILTER CLOGGED (SP5) ....................................................................................................................... 120

H HIGH PRESSURE IN THE CYLINDER ..................................................................................................... 86 HOMOGENIZER (KM21A) ...................................................................................................................... 100 HOMOGENIZER (KM21B) ...................................................................................................................... 101 HOPPER CLOSING (SQ61) ..................................................................................................................... 87 HOPPER OPEN (SQ60) ........................................................................................................................... 89 HYDR. UNIT PUMP (KM1D) ..................................................................................................................... 84 HYDRAULIC JOINT OIL TEMP. .............................................................................................................. 123

I ID 13 CARD ............................................................................................................................................ 125 IE CARD .................................................................................................................................................... 84 INCORRECT PLUNGER PARALLELISM ............................................................................................... 108 INCORRECT PRESSING ....................................................................................................................... 122 INCREASE RP2 ...................................................................................................................................... 115 INVALID DATA AFTER SERIAL EEPROM READ ................................................................................... 124 INVALID DATA IN SERIAL EEPROM ...................................................................................................... 124

K KNOCKOUT BETWEEN PUNCHES ......................................................................................................... 95

L LACK OF POWDER IN HOPPER (AD1K1) ............................................................................................ 114 LAST DIE-SET D.STROKE ..................................................................................................................... 121 LAST DIE-SET D.STROKE (SQ6) ............................................................................................................ 87 LOADING CORRECTION NOT ALLOWED ............................................................................................ 119 LOW PRESSURIZATION (SP3) ................................................................................................................ 85 LOW PRESSURIZATION/FILTER (SP3) ................................................................................................. 117 LOWER DIE HEATING (KM7) ................................................................................................................. 113 LOWER PUNCH HEATING (KM8) .......................................................................................................... 113

M MAIN SWITCH TRIPPING (BTn) .............................................................................................................. 83 MEMORY READ ..................................................................................................................................... 124 MIXER (KM22A) ...................................................................................................................................... 100 MIXER (KM22B) ...................................................................................................................................... 101 MOBILE HOPPER .................................................................................................................................. 102 MOBILE HOPPER (KM23A) ................................................................................................................... 101 MOBILE HOPPER (KM23I) ..................................................................................................................... 101 MOBILE HOPPER (SQ10) ...................................................................................................................... 103 MOBILE HOPPER (SQ23/SQ24) ............................................................................................................ 101 MOBILE HOPPER (SQ24S) ................................................................................................................... 102 MOBILE HOPPER (SQ25) ...................................................................................................................... 102 MOBILE HOPPER (U23) ........................................................................................................................ 102 MODE SELECTOR ................................................................................................................................... 82

O OIL COCK CLOSED (SQ50) ..................................................................................................................... 86 OIL LEAK LEVEL (SL4) ............................................................................................................................ 86 OIL LEVEL (SL1) ...................................................................................................................................... 85 131

PH 339.85.089 Rev. 00 Date 10.12.01

OIL TEMPERATURE ............................................................................................................................... 120 OPERATION NOT ALLOWED ................................................................................................................ 125 OTHER PROBLEMS ............................................................................................................................... 118

P PAUSE/WORKSHIFT CHANGE .............................................................................................................. 118 PERFORM DIE-SET LEARNING .............................................................................................................. 93 PERFORM PLUNGER LEARNING (YV32) ............................................................................................ 109 PERFORM SELF-LEARNING (YV32) .................................................................................................... 112 PERFORM YV309 LEARNING ............................................................................................................... 112 PLUNGER DOWN AT F-BOX START ....................................................................................................... 98 PLUNGER DOWN DUR. DIE-SET UPSTR. ............................................................................................. 88 PLUNGER DOWNSTROKE .................................................................................................................... 104 PLUNGER ENCODER NOT RESET ...................................................................................................... 122 PLUNGER ENCODER RESET ............................................................................................................... 106 PLUNGER ENCODER/ACTUATOR .......................................................................................................... 96 PLUNGER LEAKS ................................................................................................................. 115, 118, 123 PLUNGER UPSTROKE .......................................................................................................................... 105 POWDER IN DIE-SET BELLOWS .................................................................................................. 108, 120 PRESSURE NOT RECUPERATED ........................................................................................................ 107 PRESSURE SWITCH/TRANSDUCER ... bar ........................................................................................... 84 PROGRAM NOT AVAILABLE ................................................................................................................. 125 PUMP STOP PUSH-BUTTON ................................................................................................................ 117 PUNCHES INSIDE (SQ62) ....................................................................................................................... 87 PUNCHES NOT FIXED (AJ1/AJ2) ............................................................................................................ 82 PUNCHES OVERTRAVEL/LIFT RODS .................................................................................................... 96 PWD FEED SHUTOFF AT... c.mm ............................................................................................................ 97

R REDUCE ALM OPENING DELAY TIME ................................................................................................. 102 REPLACE BRUSH .................................................................................................................................. 118 REPLACE DIE-SET ................................................................................................................................ 127 REPLACE FILTER (SP1) .......................................................................................................................... 86 REPLACE FILTER (SP1) WITHIN ...h ..................................................................................................... 125 REPLACE FILTER (SP4) .......................................................................................................................... 96 REPLACE FILTER (SP5) .......................................................................................................................... 90 REPLACE FILTER (SP6) .......................................................................................................................... 86 REPLACE FILTER (SP7) ........................................................................................................................ 108 REPOSITION .......................................................................................................................................... 119 RESET PRESSURE ................................................................................................................................. 94 ROLLER CONVEYOR LIMIT SWITCHES (SQ53) .................................................................................. 123

S SACMI BMOS V.1.X - MINIMUM BMOS V.1.Y ........................................................................................ 124 SAFETY BAR UP ...................................................................................................................................... 95 SCHEDULED MAINTENANCE .............................................................................................. 118, 126, 127 SCHEDULED MAINTENANCE (80 hrs) ................................................................................................. 126 SELF-LEARNING IN PROGRESS .......................................................................................................... 123 SERVICE-ACCUMULATORS .................................................................................................................. 115 SHORT CIRCUIT YVn ............................................................................................................................... 83 SHUTDOWN PUSH-BUTTON .................................................................................................................. 81 SPECIAL MAINTENANCE/REPAIRS ..................................................................................................... 118 START OF PRESS-STROKE SETTING NOT REACHED ...................................................................... 112 STOP PUSH-BUTTON ............................................................................................................................ 115 STOP. DUE TO EXT. SYNCH. (KA301) ................................................................................................... 115

132

PH 339.85.089 Rev. 00 Date 10.12.01

T TEMP. TOO HIGH (BT4) ............................................................................................................................ 85 TEMP. TOO HIGH (BT5) .......................................................................................................................... 114 TEMP. TOO HIGH (BT5): ... °C ................................................................................................................ 119 TEMP. TOO HIGH (BT6) .......................................................................................................................... 114 TEMP. TOO HIGH (BT6): ... °C ................................................................................................................ 119 TEMP. TOO HIGH (BT7) .......................................................................................................................... 114 TEMP. TOO HIGH (BT7): ... °C ................................................................................................................ 119 TEMP. TOO HIGH (BT8) .......................................................................................................................... 114 TEMP. TOO HIGH (BT8): ... °C ................................................................................................................ 120 TEMP. TOO LOW (BT4) ............................................................................................................................ 85 TEMPERATURE TOO HIGH (ST1) ........................................................................................................... 87 THICKNESS ERROR > 0.25 mm ............................................................................................................ 120 THICKNESS ERROR > 0.4 mm .............................................................................................................. 115 THICKNESS ERROR > 25 c.mm ............................................................................................................ 120 THICKNESS ERROR > 40 c.mm ............................................................................................................ 115 TIME-OUT, KNOCKOUT DOWN ............................................................................................................... 95 TIME-OUT, KNOCKOUT UP ..................................................................................................................... 95 TOO MUCH TIME TAKEN TO SET DIE-SET .......................................................................................... 121 TURN SELECTOR SA293 TO ON .......................................................................................................... 118

U UPPER DIE HEATING (KM6) ................................................................................................................. 113 UPPER PUNCH HEATING (KM5) ........................................................................................................... 113

W WAIT ....................................................................................................................................................... 123 WAIT FOR AUTO. RESTART (KA300) .................................................................................................... 122 WAIT FOR END OF MOBILE HOPPER CYCLE .................................................................................... 120 WAIT FOR EXTERNAL SYNCH. ............................................................................................................ 119 WAIT FOR F-BOX TO GO BACK (KA302) ................................................................................................ 99 WAIT FOR SYNCH. TIME ....................................................................................................................... 119 WAIT FOR TRIGGER PULSE FROM D.I.P. (KA311) .............................................................................. 123 WRONG DIE-SET OP. (A=..., B=...) ................................................................................................ 100, 116 WRONG KNOCKOUT MOTION (BQ4A) ................................................................................................... 95 WRONG PROGRAMMED DATA ............................................................................................................. 125

Y YV32 OFFSET VALUE TOO HIGH ·[O/D/S] ............................................................................................ 124

133