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DOCUMENTAZIONE

ENGLISH
ENGLISH

TECNICA

USER’S MANUAL

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HYDRAULIC PRESSES

PH 1890 - PH 2090 - PH 2590 PH 2890

TECHNICAL DOCUMENTATION

DOCUMENTATION TECHNIQUE

TECHNISCHE DOKUMENTATION

DOCUMENTACION TECNICA DOCUMENTAÇÃO TÉCNICA
DOCUMENTACION
TECNICA
DOCUMENTAÇÃO
TÉCNICA

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TABLE OF CONTENTS

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TABLE OF CONTENTS

USER’S MANUAL

HYDRAULIC PRESSES

PH 1890 - PH 2090 - PH2590 PH 2890 - PH 3590

MANUFACTURER

SACMI IMOLA Via Selice Provinciale, 17/A 40026 IMOLA (Bologna) - ITALIA

PUBLISHED ON

October 31, 2003

VERSIONS

PH1890A - PH2090A - PH2590B - PH2890B

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TABLE OF CONTENTS

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TABLE OF CONTENTS

1
1
 

Page

GENERAL INFORMATION

1

- 1

1.1 INTRODUCTION

1 - 1

 

1.2 WHERE TO KEEP THE MANUAL

1 - 1

1.3 HOW TO USE THE MANUAL

1 - 1

1.4 USERS OF THE MANUAL

1 - 1

1.5 WARRANTY

1 - 2

1.6 SUPPLEMENTS

1 - 2

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

1

- 2

1.8 TARGA PER L'IDENTIFICAZIONE DELLA MACCHINA

1 - 5

2
2

MAIN FEATURES

2

- 1

2.1

MACHINE DESCRIPTION

2 - 1

2.1.1

MAIN MACHINE ASSEMBLIES

2 - 1

2.1.2

INTENDED, PROHIBITED AND MISUSE OF THE MACHINE

2 - 7

2.2

OVERALL DIMENSIONS

2 - 8

2.3

TECHNICAL DATA

2 - 10

2.3.1

SPECIFICATIONS

2 - 10

2.3.2

AIRBORNE NOISE LEVELS

2 - 12

2.3.3

DUST SUCTION HOODS

2 - 13

2.3.4

RATING PLATE

2 - 14

2.4

DIAGRAMS

2 - 15

2.4.1

HYDRAULIC AND PNEUMATIC DIAGRAMS

2 - 15

2.5

OPERATION

2 - 23

2.5.1

COMPRESSED AIR SUPPLY

2 - 23

2.5.2

FAST HEATING

2 - 23

2.5.3

HEAT EXCHANGER SYSTEM

2 - 23

2.5.4

OIL LEAK CIRCUIT

2 - 24

2.5.5

MAIN PUMP RUNNING - SAFETY BAR INTERLOCKS ACTIVATED (RAISED)

2 - 24

2.5.6

POSITION TRANSDUCER - SETTINGS

2 - 25

2.5.7

SAFETY BAR INTERLOCKS INACTIVATED (LOWERED)

2 - 26

2.5.8

ENCODER RESETTING

2 - 26

2.5.9

DIE-SET CONTROL CIRCUIT

2 - 26

3
3

SAFETY EQUIPMENT AND PRECAUTIONS

3 - 1

3.1

SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE

3 - 1

3.2

NORME GENERALI

3

- 3

3.3

INSTALLATION

3

- 4

3.4

HANDLING PROCEDURES

3 - 4

3.5

PERSONNEL TRAINING

3 - 5

3.6

OPERATING INSTRUCTIONS

3 - 6

3.6.1

CLEANING

3

- 7

3.7

MAINTENANCE

3 - 8

3.8

MACHINE NOT IN USE

3 - 8

3.9

DECOMMISSIONING THE MACHINE

3 - 8

4
4

INSTALLATION PROCEDURES

4

- 1

4.1

HOW TO LIFT AND PLACE THE PRESS IN POSITION

 

4 - 1

4.2

CONNECTIONS

4 - 1

4.2.1

EARTH CONNECTION

4 - 2

4.2.2

INSTALLING AND REMOVING THE DIE-SET

4

- 3

4.2.3

CONNECTING THE DIE-SET HEATER

4 - 12

4.2.4

CONNECTING THE MAGNETIC LOCK

4 - 13

4.2.5

CONNECTING THE DUST EXTRACTION SYSTEM

4 - 13

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5
5

START-UP PROCEDURES

 

Page 5 - 1

5.1

GENERAL

5 - 1

5.2

PRELIMINARY CHECKS

5 - 1

5.2.1

CHECKING THE CONNECTIONS:

 

5 - 1

5.2.2

MOTOR M3

5 - 1

5.2.3

MOTOR M11

5

- 1

5.2.4

MOTOR M1

5 - 1

5.2.5

SETTING THE PRESSURE

5 - 2

5.2.6

TOP DEAD-CENTER POSITION

5 - 2

5.2.7

SAFETY DEVICES

5

- 2

5.2.8

AUXILIARY EQUIPMENT PRESSURE

5

- 2

5.2.9

FILLER-BOX

5

- 2

5.2.10

KNOCKOUT CONTROL (SPE ONLY)

5

- 3

5.3

ADJUSTMENT PROCEDURES

5 - 4

5.3.1

KNOCKOUT ADJUSTMENT

5 - 4

5.3.2

PRELIMINARY ADJUSTMENTS TO THE HYDRAULIC SYSTEM

5

- 5

5.3.3

ADJUSTING THE SPEED OF THE FILLER-BOX

5

- 6

5.3.4

PLUNGER BRAKING ADJUSTMENT

5

- 8

5.3.5

PLUNGER PARALLELISM ERROR

5 - 8

5.3.6

PLUNGER MOTION SETTING

5 - 8

5.3.7

SETTING THE PRESS-CYCLE

5 - 8

5.3.8

DE-AERATION ADJUSTMENT

5 - 9

5.3.9

ADJUSTING THE DIE-SET PROTECTION DEVICE (FOR LACK OF POWDER)

5 - 9

5.3.10

AUTOMATIC CYCLE

5 - 9

5.3.11

SWITCHING ON THE FILLER-BOX SPEED CONTROLLER

5 - 10

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6
6

OPERATING INSTRUCTIONS

Page 6 - 1

6.1

CONTROLS

6 - 1

6.1.1

CONTROLLER

6 - 2

6.1.2

ELECTRICAL CABINET

6 - 8

6.2

START-UP AND SHUTDOWN PROCEDURES

6 - 9

6.2.1

ROUTINE START-UP PROCEDURE

6 - 9

6.2.2

MACHINE SHUT DOWN

6

- 9

6.2.3

STOPPING THE MACHINE IN EMERGENCIES

6 - 9

6.2.4

SHUTDOWN DURING A POWER FAILURE

6 - 9

6.2.5

SHUTDOWN DURING AUTOMATIC OPERATION

6

- 9

6.3

PRESSURE-LOAD GRAPHS

6 - 10

6.4

AUTOMATIC CYCLE

6 - 14

6.4.1

FILLER-BOX START-UP

6 - 15

6.4.2

POWDER INFEED

6 - 16

6.4.3

FILLER-BOX OPERATION

6 - 16

6.4.4

DIE-SET DOWNSTROKES

6 - 17

6.4.5

FAST DOWNSTROKE

6 - 19

6.4.6

DOWNSTROKE WITH BRAKE APPLIED

6 - 19

6.4.7

DELAY TIME FOR THE 1ST PRESS STROKE

6 - 19

6.4.8

FIRST PRESS-STROKE

6 - 20

6.4.9

1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER (WITH OR WITHOUT ACCUMULATORS)

6 - 20

6.4.10

1ST SEPARATE PRESS-STROKE

6 - 20

6.4.11

DEAERATION

6 - 21

6.4.12

SECOND PRESS-STROKE (LAST PRESS-STROKE)

6 - 21

6.4.13

SECOND DIRECT PRESS-STROKE

6 - 21

6.4.14

PRESS-STROKE WITH PRESSURE BOOSTER

6 - 21

6.4.15

SECOND SEPARATE PRESS-STROKE

6 - 22

6.4.16

DIE-SET UPSTROKE

6 - 22

6.4.17

CYLINDER PRESSURE RECOVERY

6 - 22

6.4.18

UPSTROKE WITH BRAKE APPLIED

6 - 23

6.4.19

FAST UPSTROKE

6 - 23

6.4.20

KNOCK-OUT

6 - 23

6.4.21

SFS CYCLE: UPPER FORMING DIE (OPTIONAL)

6 - 24

6.4.22

MOBILE DIE

6 - 24

6.4.23

DIE OVER-TRAVEL

6 - 24

6.4.24

BRUSH OPERATION

6 - 25

6.4.25

MOVEMENTS IN MANUAL MODE

6 - 26

6.4.26

MOVEMENTS IN SET-UP MODE

6 - 26

6.4.27

RESETTING THE ENCODERS

6 - 27

7
7

ADJUSTMENT PROCEDURES

7 - 1

7.1

SETTING THE VARIABLE DELIVERY PUMP

7 - 1

7.2

SETTING AND ZERO-SETTING THE POSITION ENCODER

7 - 6

7.2.1

PLUNGER TRANSDUCERS

7 - 6

7.2.2

FILLER BOX ENCODER (DCL)

7 - 6

7.2.3

ALM ENCODER (DCL)

7

- 6

7.2.4

KNOCKOUT ENCODER (SPE)

7 - 7

7.2.5

FILLER-BOX ENCODER (DCP)

7

- 7

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MACHINE MAINTENANCE8 - 1

8 - 1

8.1

MAINTENANCE SCHEDULE

8

- 1

8.1.1

LUBRICATING THE KNOCKOUT FEELER PINS

8

- 4

8.1.2

VACUUM

8 - 4

8.2

SPECIAL MAINTENANCE

8 - 5

8.2.1

SERVICING THE PLUNGER BUSHES

8

- 5

8.2.2

FILLING THE RESERVOIR

8

- 5

8.2.3

DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND RESERVOIR

8 - 5

8.2.4

DRAINING OIL FROM THE HOSES AND HYDRAULIC CONTROL ASSEMBLIES

8

- 7

8.2.5

OIL RECIRCULATION AND FILTERING

8 - 8

8.2.6

REPLACING PROPORTIONAL VALVES YV22a AND YV22b FOR THE KNOCKOUT (ONLY SPE)

8 - 9

8.3

TORQUES (NUTS & BOLTS)

8 - 10

8.4

SERVICING THE HEAT EXCHANGER

8 - 11

8.4.1

REPLACING THE GASKETS

8 - 11

8.4.2

SECURING THE STAY BOLTS

8 - 12

DECOMMISSIONING9 - 1

9 - 1

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GENERAL INFORMATION

1
1

1 GENERAL INFORMATION

1.1 INTRODUCTION

INFORMATION 1 1 GENERAL INFORMATION 1.1 INTRODUCTION E 0 0 0 4 P WARNING! Carefully read

E0004P

WARNING!

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

1.2 WHERE TO KEEP THE MANUAL

WARNING!disclosed or transferred. 1.2 WHERE TO KEEP THE MANUAL E 0 0 0 4 P This

E0004P

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

1.3 HOW TO USE THE MANUAL

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

WARNING! E 0 0 0 4 P Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must

WARNING!

E0004P

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

1.4 USERS OF THE MANUAL

In this manual the machine operators are categorized as follows:

- Operator: this is the person responsible for supervising and operating the machine.

- Routine maintenance men.

For a more detailed description, see the paragraph dealing with OPERATOR TRAINING in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.

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GENERAL INFORMATION014AZ011A 1.5 WARRANTY SACMI shall be held responsible only for the machine as it was configured

1.5 WARRANTY

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

damages deriving from the use of non-original spare parts. E 0 0 0 4 P ATTENTION!

E0004P

ATTENTION!

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

1.6 SUPPLEMENTS

Information regarding the electric and electronic components is given in three handbooks provided separately. These handbooks are entitled:

- USE OF THE MICROPROCESSOR-BASED CONTROL SYSTEM (Instructions B Manual)

- ELECTRONIC CARDS

- LIST OF DEVICES

Information regarding unpacking and handling the machine is given in two handbooks provided under separate cover. These handbooks are entitled:

- HANDLING OPERATIONS

- UNPACKING OPERATIONS

The above mentioned handbooks supplement this manual.

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

DANGER SYMBOLS

General dangerUSED ON THE MACHINE AND/OR IN THE MANUAL DANGER SYMBOLS E 0 0 0 4 P

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THE MANUAL DANGER SYMBOLS General danger E 0 0 0 4 P E 0 0 0

E0002P

SYMBOLS General danger E 0 0 0 4 P E 0 0 0 2 P E

E0003P

danger E 0 0 0 4 P E 0 0 0 2 P E 0 0

E0007P

Hot surfaces - danger of being burnt

Danger - hands can be crushed

High tension - danger of electric shock

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GENERAL INFORMATION

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1

Danger of entanglement in moving parts014AZ011A GENERAL INFORMATION 1 E0010P Risk of explosion E0035P WARNING SIGNS O 2 E0034D It is

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Risk of explosionINFORMATION 1 Danger of entanglement in moving parts E0010P E0035P WARNING SIGNS O 2 E0034D It

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WARNING SIGNS

O 2
O
2

E0034D

It is forbidden to use oxygen to recharge the accumulators

ALERT SYMBOLS

E0005O E0006O
E0005O
E0006O

Heavy duty gloves must be worn

The indicated point must be effectively grounded

OTHER SYMBOLS

A list of tools required to carry out maintenance is provided.Heavy duty gloves must be worn The indicated point must be effectively grounded OTHER SYMBOLS E

E0009C

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GENERAL INFORMATION014AZ011A SYMBOLS C1819 This symbol indicates the machine version with SMU system. The descriptions and/or figures

SYMBOLS

C1819014AZ011A GENERAL INFORMATION SYMBOLS This symbol indicates the machine version with SMU system. The descriptions and/or

This symbol indicates the machine version with SMU system.

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

C1820by this symbol refer only to this machine version. This symbol indicates the machine version with

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

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

C1821by this symbol refer only to this machine version. This symbol indicates the machine version with

This symbol indicates the machine version with linear loading device (DCL)

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

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

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

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GENERAL INFORMATION

1
1

1.8 TARGA PER L'IDENTIFICAZIONE DELLA MACCHINA

C1812 TIPO TYPE MATRICOLA No. SERIAL NUMBER ANNO YEAR VIA SELICE PROVINCIALE 17/A IMOLA -
C1812
TIPO
TYPE
MATRICOLA No.
SERIAL NUMBER
ANNO
YEAR
VIA
SELICE
PROVINCIALE
17/A
IMOLA
-
ITALIA
E0021
E 0 0 0 4 P ATTENZIONE! Le macchine descritte nel presente manuale istruzioni sono

E0004P ATTENZIONE!

Le macchine descritte nel presente manuale istruzioni sono progettate per il funzionamento indipendente e quindi

possiedono i requisiti essenziali di sicurezza richiesti dalla direttiva 89/392/CEE esclusivamente nella configura- zione standard prevista dalla SACMI e costituita da:

- pressa idraulica

PH

- carrello parte fissa

CAL

- carrello parte mobile CAF - CAS

- dispositivo alimentazione polveri

nell'installazione descritta al paragrafo NORME PER L'UTILIZZO del presente manuale istruzioni.

ALM - ACP - TRAMOGGIA FISSA

L'installazione di dispositivi diversi da quelli sopra descritti o secondo modalità diverse da quanto indicato al paragrafo NORME PER L'UTILIZZO del presente manuale istruzioni (se non specificatamente approvato dalla SACMI) comportano la perdita dei requisiti essenziali di sicurezza.

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GENERAL INFORMATION

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MAIN FEATURES

2
2

2 MAIN FEATURES

2.1 MACHINE DESCRIPTION

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

2.1.1 MAIN MACHINE ASSEMBLIES

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

HYDRAULIC SYSTEM

A pressure booster 7, located inside the upper part of the crosshead, generates the pressure directly within the cylinder

so that the programmed press-strokes can be carried out.

A number of control assemblies hold the valves and the logic elements required to operate the machine parts and control

the operating pressures. These assemblies are located on the machine body near the actual points of use.

These control assemblies are listed below:

- Logic element assembly 20. Used to control the pressure required to perform the press cycle.

- Accumulator control assembly 21. Used to control the upward and downward movements of the plunger. The assembly also includes a brake, which reduces the speed of the plunger while the die set is being closed.

- Aux. equipment control assembly 22 which is used to operate the filler box and any other optional equipment (i.e.

top forming die-sets, etc

) installed.

- Knockout control assemblies 23 (only with SPE) used to control the tile ejection system.

- SMU control assembly 24 (only with SMU) mounted on the aux. equipment control assembly.

The hydraulic system 27 provides the amount of oil needed to operate the actuators, controls the operating temperature and filters the oil. The oil is drawn out of the reservoir by a variable-displacement, axial-piston pump and delivered to the hydraulic circuit at the required flow rate and pressure. The hydraulic circuit is kept under pressure so as to prevent the highly abrasive dust produced from getting in. The hydraulic power unit is provided with an oil/water heat exchanger which keeps the temperature of the oil within the normal operating limits. The circuit is also provided with a pump-and-motor assembly which is used to cool down and circulate the oil within the heat exchanger. The hydraulic piping 18 includes all the parts, pipes and hoses which link up the various units. The oil-leak collector 28 is used to collect any oil leaks at ambient pressure. A pump, located in the hydraulic power unit, will then send the oil collected to a pressurized tank.

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MAIN FEATURES014AZ011A DCP FILLER-BOX (DCP TYPE) The filler box is used to load the powder and eject

DCP014AZ011A MAIN FEATURES FILLER-BOX (DCP TYPE) The filler box is used to load the powder and

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

C1821to electrical, hydraulic, pneumatic or mechanical parts. DCL FILLER-BOX (DCL TYPE) The filler box is used

DCL

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

C1819to electrical, hydraulic, pneumatic or mechanical parts. SMU SMU HYDRAULIC KNOCKOUT The SMU system 6 features

SMU

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

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MAIN FEATURES

2
2

C1820014AZ011A MAIN FEATURES 2 SPE UNIVERSAL/ELECTRONIC KNOCKOUT (SPE) This system consists of three control assemblies linked

SPE

UNIVERSAL/ELECTRONIC KNOCKOUT (SPE) This system consists of three control assemblies linked together through pins. The external ones incorporate the tile ejection system while the central one acts as a support. Basically, this system 8 is used to knock the tiles out of the die- set so that they are level with the die. The tiles are then ejected by the filler box. The mobile part of the die-set is connected to the four cylinder rods with two quick couplings. The cylinders are series connected hydraulically through an intermediate duct. Each pair is controlled by a proportional valve. Two position transducers record the position of the mobile part of the filler box. An axis control card piloted by the microprocessor regulates movement of the mobile part in real time. The encoder signals are processed and valves are piloted for this purpose. As a result, the speed of the die-set, as it moves up and down, as well as the upper limit switch are kept under control. The four cylinders are also used for the die-set overtravel when the lower punches are cleaned and to make replacement easier. The punches are then moved down recreating the cavity that receives the material to be pressed. The soft filling height is automatically determined after setting the desired tile thickness. The knockout comes with four special cylinders used to raise the die-set, thus making the assembly and disassembly operations easier to perform. This operation can be performed by placing gauged spacers between the die-set mobile block and the fixed section of the die-set to make the die-set stiff. In addition, the knockout has an independent circuit that collects any oil that has leaked out of the main cylinders.

INTAKE , FILTER AND EXHAUST OPENING FOR THE AIR IN THE DIE SET The air which flows in and out of the lower part of the die set passes though the filter unit 5.

GUARDS AND SUCTION HOODS The mechanical lock 15 prevents the plunger from accidentally moving down while the die set is being cleaned and maintenance operations are carried out. A number of covers 29 protect the working parts. The suction hoods 16 draw the dust out of the process zone.

MICROPROCESSOR-BASED CONTROLLER The microprocessor-based controller 31 is used to program the work-cycle that the press will perform automatically.

The controller consists of the following parts:

- a control keyboard 35;

- a computer terminal 35 to display the set-up parameters, operating data and fault messages;

- electronic cards;

Furthermore:

- a plunger positioner 33 is connected to the controller. The equipment incorporates one or two encoders which record the position of the plunger and transmits data to the computer system.

- the electrical wiring 30 is based on the same principle as the hydraulic system. It includes all of the electrical and electro-mechanical parts of the press: miniature switches, proximity sensors and related cams, connecting cables, terminals, etc

The machine may come with a personal computer (optional) that processes and displays the data received from the microprocessor along with the historical data in real time.

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2
2

MAIN FEATURES

ELECTRICAL CABINET The electrical cabinet 32 contains the equipment needed to start and stop all of the motors on the press, the transformers for the die-set heaters, contactors, thermal relays, fuses, etc

DIE SET The forming die 34, which is used to give the pressed powder the required shape, consists of two parts. The lower part (attached to the base of the machine) incorporates the die, which rests on a number of supports, and the lower forming punches that are joined to the hydraulic knockout. The upper part, which is attached to the plunger, is provided with the mounting plate for the upper punches. The die as well as the upper and lower punches, are warmed up by electric heating elements so as to prevent the powder from sticking. Three temperature probes continuously measure the temperature in the punches and die. Three separate instruments can thus control and monitor this important variable.

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MAIN FEATURES

2
2

Figure 2.1.1/A - OVERALL VIEW OF THE SMU

C1819 7
C1819
7

SMU

1

Framework

2

Plunger

3

Crosshead and hydraulic cylinder

4

Hydraulic cylinder

5

Air filtering in the die-set

6

SMU hydraulic knockout

7

Pressure booster

9

Filler-box mount (CAL)

15

2

11 9 10
11
9
10
32 20 5 18 27 28 24 35 29 30 22 31
32
20
5
18
27
28
24
35
29
30
22
31

3

4

21 33 6 C1825 34 1 16
21
33
6
C1825
34
1
16

10

Mobile part of filler box (CAF)

11

Hopper (ALM)

15

Mechanical lock and safety guards

16

Suction hoods

17

Spring shock-absorber

18

Hydraulic lines

20

Logic element control assembly

21

Accumulator control assembly

22

Aux. equipment control assembly

24

SMU control assembly

27

Hydraulic power unit

28

Oil leak collector

29

Covers

30

Electrical wiring

31

Microprocessor-based control system

32

Electrical cabinet

33

Plunger position control

34

Die-set

35

Control keyboard

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2
2

MAIN FEATURES

C1820
C1820

SPE

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

1 Framework

2 Plunger

3 Crosshead and hydraulic cylinder

4

Hydraulic cylinder

5

Air filtering in the die-set

7

Pressure booster

8

SPE hydraulic electronic knockout

9

Filler-box mount (CAL)

10 Mobile part of filler box (CAF)

11 Hopper (ALM)

15

7 32 20 5 18 27 28 2 35 8 29 30 22
7
32
20
5
18
27
28
2
35 8
29
30
22

31

11 9 10
11
9
10
3 21 33 16 34 4 C1826 23
3
21
33
16
34
4
C1826
23

1

15

Mechanical lock and safety guards

16

Suction hoods

18

Hydraulic lines

20

Logic element control assembly

21

Accumulator control assembly

22

Aux. equipment control assembly

23

Knockout control assembly

27

Hydraulic power unit

28

Oil leak collector

29

Covers

30

Electrical wiring

31

Microprocessor-based control system

32

Electrical cabinet

33

Plunger position control

34

Die-set

35

Control keyboard

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MAIN FEATURES

2
2

2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE

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

WARNING! E 0 0 0 4 P If the machine is remote controlled, it is

WARNING!

E0004P

If the machine is remote controlled, it is the customer’s responsibility to provide the operators with adequate training.

The machine can operate in manual or automatic mode. To enable the desired mode of operation, use the relevant selector switch located on the control panel.

UNINTENDED AND PROHIBITED OPERATIONS No other tasks except those specified by the Manufacturer are to be performed. For this reason, the Manufacturer shall not be held responsible for the consequences deriving from the failure to observe the instructions contained herein.

MISUSE OR ERRONEOUS USE The manufacturer shall not be held responsible for any injury to persons or damage to the machine deriving from

incorrect and erroneous use of the machine. Generally speaking, the most common causes of incorrect use are listed below:

- personnel not adequately trained to perform the required operations

- fatigue (above all during the night shift) or distraction

- negligence caused by superficiality or wrong habits.

Remember that the machine is to be controlled and run exclusively by expert well trained personnel who are able to:

- correctly operate the machine under normal conditions

- and face any emergencies, this is fundamental!

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2

MAIN FEATURES

2.2 OVERALL DIMENSIONS DCL Figure 2.2/A - OVERALL DIMENSIONS 1700 C1821 Ø1500 200 C1875 F
2.2 OVERALL DIMENSIONS
DCL
Figure 2.2/A - OVERALL DIMENSIONS
1700
C1821
Ø1500
200
C1875
F
E
K
Minimum service area
M
N
A
L
I
B
D
C
R
MAX S
P
O
T
U
V
Z
G
H
 

PH 1890

PH 2090

PH 2590

PH 2890

A

(mm)

4890

4890

4991

4991

B

(mm)

4300

4300

4321

4321

C

(mm)

700

700

700

700

D

(mm)

590

590

670

670

E

(mm)

2539

2539

2660

2660

F

(mm)

1040

1040

1180

1180

G

(mm)

920

920

929

929

(Minimum for knockout)

H

(mm)

5220

5220

5250

5250

I

(mm)

1165

1165

1095

1095

K

(mm)

2000

2000

2000

2000

L

(mm)

2835

2835

2905

2905

M

(mm)

2860

2860

2860

2860

N

(mm)

1200

1200

1200

1200

O

(mm)

2170

2170

2170

2170

P

(mm)

1150

1150

1150

1150

R

(mm)

730

730

730

730

S

(mm)

160

160

160

160

T

(mm)

6500

6500

6500

6500

U

(mm)

6000

6000

6000

6000

V

(mm)

500

500

500

500

Z

(mm)

4000

4000

4000

4000

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MAIN FEATURES

2
2
1700 DCP Figure 2.2/B - OVERALL DIMENSIONS Ø1500 200 C1876 F E K Minimum service
1700
DCP
Figure 2.2/B - OVERALL DIMENSIONS
Ø1500
200
C1876
F
E
K
Minimum service area
M
N
A
L
I
B
D
C
R
MAX S
P
T
OP
VU
Z
G
H
 

PH 1890

PH 2090

PH 2590

PH 2890

A

(mm)

4890

4890

4991

4991

B

(mm)

4300

4300

4321

4321

C

(mm)

700

700

700

700

D

(mm)

590

590

670

670

E

(mm)

2539

2539

2660

2660

F

(mm)

1040

1040

1180

1180

G

(mm)

920

920

929

929

(Minimum for knockout)

H

(mm)

5220

5220

5250

5250

I

(mm)

1165

1165

1095

1095

K

(mm)

2000

2000

2000

2000

L

(mm)

2835

2835

2905

2905

M

(mm)

2860

2860

2860

2860

N

(mm)

1200

1200

1200

1200

O

(mm)

2170

2170

2170

2170

P

(mm)

1150

1150

1150

1150

R

(mm)

730

730

730

730

S

(mm)

160

160

160

160

T

(mm)

6500

6500

6500

6500

U

(mm)

6000

6000

6000

6000

V

(mm)

500

500

500

500

Z

(mm)

4000

4000

4000

4000

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2
2

MAIN FEATURES

2.3 TECHNICAL DATA

2.3.1

SPECIFICATIONS

PERFORMANCE

 

PH 1890

PH 2090

PH 2590

PH 2890

Max. soft clay filling

with SMU (standard)

mm

32

32

32

32

with SMU (special on request)

mm

50

50

50

50

with SPE

mm

74

74

74

74

Max. plunger stroke

 

mm

160

160

160160

Column diameter

 

mm

320

320

390

390

Distance between the columns

 

mm

1750

1750

1750

1750

Distance between press table and plunger

 

mm

600

600

600600

Max. knockout force

 

kN

90

90

90

90

Max. pressing force

 

kN

18000

20000

25000

27500

Max. cylinder pressure

 

bar

318

352

350

388

Cycles per minute

 

up to

22

22

21

21

Strokes per cycle

 

1 - 2 - 3

1 - 2 - 3

1 - 2 - 3

1 - 2 - 3

ELECTRICAL SYSTEM

 

PH 1890

PH 2090

PH 2590

PH 2890

Voltage:

Aux. circuitry

V c.a.

110

110

110

110

Die-set heating

V c.a.

50

50

50

50

Solenoid valves

(regulated)

V

24

24

24

24

Power:

Main motor

(50 Hz)

kW

75

75

75

90

Heat exchanger pump motor

(50 Hz)

kW

7.5

7.5

7.5

7.5

Die-set heater (standard punches)

(50 Hz)

kW

10 + 10

10 + 10

10 + 10

10 + 10

Die

(50 Hz)

kW

4

4

4

4

Controller

(50 Hz)

kW

1

1

1

1

Oil leak collector pump

(50 Hz)

kW

0.18

0.18

0.18

0.18

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MAIN FEATURES

2
2

HYDRAULIC SYSTEM

PH 1890

PH 2090

PH 2590

PH 2890

Hydraulic oil:

system capacity

l

950

950

1100

1100

viscosity at 40 C

cSt.

46

46

46

46

viscosity index greater than

110

110

110

110

FZG test stage

11

11

11

11

Max. operating pressure in hydraulic power unit

 

bar

180

180

180

230

Accumulators

Main circuit

capacity

l

20+20+20

20+20+20

20+20+2024.5+24.5+24.5

 

precharge pressure

bar

110

110

110

130

 

Aux. circuit

capacity

l

12

12

12

12

Pilot valve circuit

capacity

l

1

1

1

1

SMU die control

capacity

l

2,5

2,5

2,5

2,5

 

precharge pressure

bar

110

110

110

110

Main filter

Filtering capacity

µ

12

12

12

12

Filter cartridge in tank

Filtering capacity

µ

250

250

250

250

Filter cartridge (plate type)

Filtering capacity

µ

6

666

Cooling system

Heat to be dissipated

kW

52

52

52

64

 

Kcal/h

45000

45000

45000

55000

 

Water used at 20 C

l/1'

40

40

40

50

Water pipe connection diameter

 

1"1/2

1"1/2

1"1/2

1"1/2

Hoses, Inside diameter

mm

40

40

40

40

Max. pressure

bar

4

4

4

4

Pressurisation,

Max. pressure (with plunger raised)

bar

1.5

1.5

1.5

1.5

FILLER BOX-EJECTOR ASSEMBLY

 

PH 1890

PH 2090

PH 2590

PH 2890

Gearbox lubrication: EP oil viscosity

 

ISO VG 320

ISO VG 320 ISO VG 320 ISO VG 320

WEIGHTS

Weight

Press body

kg

51000

51000

64000

64000

Hydraulic power unit

kg

890

890

890

890

Aux. equipment (controller, electrical cabinet, filler-box, etc.)

kg

2800

2800

2800

2800

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MAIN FEATURES014AZ011A 2.3.2 AIRBORNE NOISE LEVELS Test conditions: - Operating conditions (refer to ISO/DIS 11202 specification,

2.3.2 AIRBORNE NOISE LEVELS

Test conditions:

- Operating conditions (refer to ISO/DIS 11202 specification, paragraph 9.5):

- a wooden test piece was used

- a sound-proof system provided

- Type of process:

manufacture of ceramic products

- Work cycle:

die-set loading, one or more press-strokes and deaeration and final formation of product

- Test conditions:

PH 1890 PH 2090 PH 2590 PH 2890 Cycles/minute 14.7 14.7 14.6 14 Hydraulic power
PH 1890
PH 2090
PH 2590
PH 2890
Cycles/minute
14.7
14.7
14.6
14
Hydraulic power unit pressure (bar)
180
180
180
220
Operating pressure (bar)
300
300
300
300
- Test environment
Testing department at Sacmi Imola
Test instruments used
Class 1 (IEC 804)
Sound pressure level (ISO/DIS 11202)
Sound power level (ISO 3746)
Noise levels measured
PH 1890
PH 2090
PH 2590
PH 2890
P1
72.5
72.5
72
74
L pA
(dBA)
P2
76.5
76.5
75
78.5
96
96
94
96
L wA
(dBA)
Continuous A-weighted sound pressure level.
L pA
Acoustic power level in dB weighted A.
L wA
P1 = Occasional control post
P2 = Noisiest position of the ideal machine perimeter measured at floor level
FIGURE 2.3.2 - POINTS WHERE NOISE LEVEL WAS MEASURED
PH 1890 - PH 2090
PH 2590
PH 2890
P2
C0834
C0834
C0834
P2
P1
P1
P2
P1
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MAIN FEATURES

2
2

2.3.3 DUST SUCTION HOODS

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

Suction outlet

ID

No. of

Outlet diameter

Total delivery

Height from floor

symbol

outlets

(mm)

rate q t (m 3 /h)

(m)

Front hood

S250

2

150

2540

+3.3

Rear hood

S260

2

150

2540

+2.5

Rear powder level limit

P004

6

80

2160

-0.1

Front powder level limit (optional)

P002

2

100

1080

-0.1

Powder level limit, Cleaning

P010

1

50

141

+0.8

S260

P004 C306 S250 P010 P002 S250 S270 S270 S270 S270
P004
C306
S250
P010
P002
S250
S270
S270
S270
S270

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

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

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MAIN FEATURES014AZ011A 2.3.4 RATING PLATE C1812 2 - 14

2.3.4 RATING PLATE

C1812
C1812
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MAIN FEATURES

2
2

2.4

DIAGRAMS

2.4.1 HYDRAULIC AND PNEUMATIC DIAGRAMS

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

Block diagram

A

PREFILLING TANK

B

HOPPER GATE CONTROL

C

PRESS-STROKE CONTROL

D

UPSTROKE, DOWNSTROKE, BRAKING AND PRESSURE CONTROL

E

AUX. EQUIPMENT CONTROL ASSEMBLY

F

SPE TYPE KNOCKOUT CONTROL

G

SMU TYPE KNOCKOUT CONTROL

H

SPE KNOCKOUT

I

HYDRAULIC POWER UNIT

L

BLOWER CIRCUIT (OPTIONAL)

M

SFS CONTROL (OPTIONAL)

P

MIRROR-FINISHED DIE-SET (OPTIONAL)

Q

DIE RELEASE CONTROL (OPTIONAL)

R

MOBILE BRUSH PNEUMATIC CONTROL (OPTIONAL)

S

MOBILE BRUSH PNEUMATIC SYSTEM (OPTIONAL)

T

FIXED AND MOBILE BRUSH HYDRAULIC CONTROL (OPTIONAL)

U

OPTIONAL FILLER-BOX (OPTIONAL)

V

THIRD DIE-SET DOWNSTROKE CONTROL (OPTIONAL)

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2
2

MAIN FEATURES

C2341

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

72

73

71

74

YV290

SPE

271

75

C B L T 272 264 273 265 266 275 YV173 120 118 117 116
C
B
L
T
272
264
273
265
266
275
YV173
120
118
117 116
131
119
277
267
SP2
194
YV221
220
YV38
YV70
YV19
YV40
YV41
223
222
224
V
36
YV192
P
219
BP1
SQ61
SQ60
YV32m
D
18a 18b 18
R
89
YV39
195
195
269
269
115
174
108
109
247
M15
132 92
M
270
270 269
90
269
YV107
YV31d
YV31s
YV32d
YV32s
YV53
YV47
B
P
BQ3
YV171a
YV171i
S
258
60
7
59
42
SQ59a
BT4
T
144
SQ50a
U
145
12
I
250
249
67
154
141
10
YV99
M3
M
82
84
YV172
YV193
142
YV20a
112
105
85
YV11r
H
O
338
2
112a
SL 4
143
337
YV279
YV20s
86
SL 3
H
O
183
188
54
2
48
140
339
M11
SP1
111
YV298
205
4
M
336
49
78
SP4
79
SP5
58
13
SP3
252
M1
M
P
Q
M
U
E
A 125 126 124 123 122 184 184 179 179 069 BQ5 BQ5 180a1 H
A
125
126
124
123
122
184
184
179
179
069
BQ5
BQ5
180a1
H
180b1
180b2
180a2
198
YV304b
YV304a
YV22b
196
YV22a
BP6 BP7
166
YV22s
YV25
F
C1820 ASPIRAZIONE POMPA AIR-OIL DELLO SCAMBIATORE EXCHANGER ARIA - OLIO INTAKEPPUM
C1820
ASPIRAZIONE POMPA
AIR-OIL
DELLO SCAMBIATORE
EXCHANGER
ARIA - OLIO
INTAKEPPUM
MANDATA POMPA AIR-ILO DELLO SCAMBIATORE EXCHANGER ARIA - OLIO DELIVERYPPUM
MANDATA POMPA
AIR-ILO
DELLO SCAMBIATORE
EXCHANGER
ARIA - OLIO
DELIVERYPPUM
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MAIN FEATURES

2
2

C2342

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

72

73

71

74

YV290

271

75

C B L T 272 264 273 265 266 275 YV173 120 118 117 116
C
B
L
T
272
264
273
265
266
275
YV173
120
118
117 116
131
119
277
267
SP2
194
YV221
220
YV38
YV70
YV19
YV40
YV41
223
222
224
V
36
YV192
P
219
BP1
SQ61
SQ60
YV32m
D
18a 18b 18
R
89
YV39
195
195
269
269
115
174
108
109
247
M15
132 92
M
270
270 269
90
269
YV107
YV31d
YV32d
YV53
CADUTA3a
YV31s
YV32s
YV47
B
P
BQ3
YV171a
YV171i
ASTESBLOC.
S
258
60
7
59
CADUTA2a
42
CADUTA1a
SQ59a
BT4
T
144
SQ50a
U
145
12
I
250
249
67
154
10
141
YV99
M3
M
82
84
YV172
YV193
142
112
105
YV20a
85
338
YV11r
H
O
2
112a
SL 4
143
337
169
242
61
23
YV20s
86
YV279
SL 3
183
188
H
O
54
2
48
339
140
M11
SP1
111
YV170
YV135
YV21
YV22
336
205
4
M
49
78
SP4
251
79
58
YV129
13
SP3
M1
M
V
G
P
M
U