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D O C U M E N TA Z I O N E T E C N I C A
USERS MANUAL
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HYDRAULIC PRESSES
PH 690 - PH 1000 - PH 1500
TECHNICAL DOCUMENTATION DOCUMENTATION TECHNIQUE TECHNISCHE DOKUMENTATION DOCUMENTACION DOCUMENTAO TECNICA TCNICA
ENG
LISH
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TABLE OF CONTENTS
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TABLE OF CONTENTS
USERS MANUAL
HYDRAULIC PRESSES
PH 690 - PH 1000 - PH 1500
MANUFACTURER SACMI IMOLA Via Selice Provinciale, 17/A 40026 IMOLA (Bologna) - ITALIA
DATE OF PUBLICATION 28.10.2003 - 20.05.2004
VERSIONS PH690A - 1000A - 1500A

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TABLE OF CONTENTS
1 Page GENERAL INFORMATION ........................................................................................................................1 - 1 1.1 INTRODUCTION ........................................................................................................................ 1 - 1 1.2 WHERE TO KEEP THE MANUAL ............................................................................................. 1 - 1 1.3 HOW TO USE THE MANUAL .................................................................................................... 1 - 1 1.4 USERS OF THE MANUAL ......................................................................................................... 1 - 1 1.5 WARRANTY ............................................................................................................................... 1 - 2 1.6 SUPPLEMENTS ......................................................................................................................... 1 - 2 1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL ........................................................................................................................ 1 - 2 1.8 MACHINE IDENTIFICATION PLATE ..........................................................................................1 - 5 MAIN FEATURES ......................................................................................................................................2 - 1 2.1 MACHINE DESCRIPTION ......................................................................................................... 2 - 1 2.1.1 MAIN DEVICES ...........................................................................................................................2 - 1 2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ................................................. 2 - 7 2.2 OVERALL DIMENSIONS ........................................................................................................... 2 - 8 2.2.1 PH 690 OVERALL DIMENSIONS ...............................................................................................2 - 8 2.2.2 PH 1000 - 1500 OVERALL DIMENSIONS .................................................................................2 - 9 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 - 16 2.4 DIAGRAMS .............................................................................................................................. 2 - 17 2.4.1 HYDRAULIC/PNEUMATIC SYSTEM DIAGRAM .................................................................... 2 - 17 2.5 MACHINE OPERATION ........................................................................................................... 2 - 27 2.5.1 COMPRESSED AIR SUPPLY ................................................................................................. 2 - 27 2.5.2 FAST HEATING ....................................................................................................................... 2 - 28 2.5.3 HEAT EXCHANGER AND FILTRATION SYSTEM ................................................................. 2 - 28 2.5.4 MAIN PUMP RUNNING - SAFETY BAR INTERLOCKS ACTIVATED (HIGH POSITION) ..... 2 - 29 2.5.5 PRESSURE TRANSDUCER - SETTINGS .............................................................................. 2 - 31 2.5.6 SAFETY BAR INTERLOCKS INACTIVATED (DOWN) ........................................................... 2 - 32 2.5.7 ENCODER RESETTING .......................................................................................................... 2 - 32 2.5.8 DIE-SET CONTROL CIRCUIT ................................................................................................. 2 - 33
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3 Page SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 1 3.1 SAFETY DEVICES ......................................................................................................................3 - 1 3.1.1 SAFETY GUIDELINES ............................................................................................................... 3 - 1 3.1.2 SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE ............................................. 3 - 1 3.2 SAFETY RULES FOR HANDLING .............................................................................................3 - 3 3.2.1 LIFTING PROCEDURES ........................................................................................................... 3 - 3 3.2.2 HANDLING PROCEDURES ...................................................................................................... 3 - 3 3.2.3 PLACING THE LOAD ................................................................................................................. 3 - 3 3.3 INSTALLATION ...........................................................................................................................3 - 4 3.3.1 GUIDELINES ...............................................................................................................................3 - 4 3.4 OPERATOR TRAINING ............................................................................................................. 3 - 5 3.4.1 END-USER ..................................................................................................................................3 - 5 3.4.2 OPERATORS ............................................................................................................................. 3 - 5 3.4.3 MAINTENANCE STAFF ............................................................................................................. 3 - 5 3.5 OPERATING INSTRUCTIONS .................................................................................................. 3 - 6 3.5.1 SAFETY GUIDELINES ............................................................................................................... 3 - 6 3.5.2 AUTOMATIC OPERATION ........................................................................................................ 3 - 6 3.5.3 MANUAL OPERATION ...............................................................................................................3 - 6 3.5.4 SET-UP MODE ...........................................................................................................................3 - 6 3.5.5 INSTALLATION MODE ...............................................................................................................3 - 7 3.5.6 CLEANING ..................................................................................................................................3 - 8 3.6 MAINTENANCE ......................................................................................................................... 3 - 9 3.6.1 GENERAL SAFETY RULES ...................................................................................................... 3 - 9 3.7 MACHINE NOT IN USE ........................................................................................................... 3 - 12 3.7.1 GENERAL RULES ................................................................................................................... 3 - 12 3.7.2 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED .............................................. 3 - 12 3.8 DISMANTLING ......................................................................................................................... 3 - 13 INSTALLATION ........................................................................................................................................ 4 - 1 4.1 HOW TO LIFT AND PLACE THE PRESS IN POSITION .......................................................... 4 - 1 4.2 HOOKING UP AND CONNECTING THE MACHINE .................................................................4 - 1 4.2.1 EARTHING THE MACHINE ........................................................................................................4 - 2 4.2.2 INSTALLING AND REMOVING THE DIE-SET ..........................................................................4 - 3 4.2.3 CONNECTING THE DIE-SET HEATER .................................................................................... 4 - 4 4.2.4 MAGNETIC LOCK CONNECTIONS .......................................................................................... 4 - 5 4.2.5 DUST EXTRACTION SYSTEM ................................................................................................. 4 - 5
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5 Page START-UP PROCEDURE ........................................................................................................................ 5 - 1 5.1 GENERAL .................................................................................................................................. 5 - 1 5.2 PRELIMINARY CHECKS ........................................................................................................... 5 - 1 5.2.1 CHECKS TO BE MADE ............................................................................................................. 5 - 1 5.2.2 MOTOR M11 ...............................................................................................................................5 - 1 5.2.3 MOTOR M1 ................................................................................................................................ 5 - 1 5.2.4 SETTING THE PUMP PRESSURE ........................................................................................... 5 - 2 5.2.5 TOP DEAD CENTER POSITION ............................................................................................... 5 - 2 5.2.6 SAFETY DEVICES ......................................................................................................................5 - 2 5.2.7 AUXILIARY CIRCUIT PRESSURE .............................................................................................5 - 2 5.2.8 FILLER BOX ............................................................................................................................... 5 - 3 5.3 MACHINE ADJUSTMENTS ........................................................................................................5 - 4 5.3.1 ADJUSTING THE KNOCKOUT ................................................................................................. 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 MOTION SETTING .................................................................................................. 5 - 8 5.3.6 SETTING THE PRESS-CYCLE ................................................................................................. 5 - 8 5.3.7 ADJUSTING THE DIE-SET PROTECTION DEVICE (FOR LACK OF POWDER) ................... 5 - 8 5.3.8 ADJUSTING THE PLUNGER SHOCK ABSORBERS ............................................................... 5 - 9 5.3.9 AUTOMATIC WORK CYCLE ......................................................................................................5 - 9 5.3.10 SWITCHING ON THE CONTROLLER TO MAINTAIN THE PRE-SET SPEEDS ................... 5 - 10 OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1 6.1 CONTROLS................................................................................................................................ 6 - 1 6.1.1 CONTROLLER ........................................................................................................................... 6 - 2 6.1.2 ELECTRICAL CABINET ............................................................................................................. 6 - 9 6.2 START UP AND SHUT DOWN PROCEDURES ..................................................................... 6 - 10 6.2.1 DAILY START UP .................................................................................................................... 6 - 10 6.2.2 STOPPING THE MACHINE ..................................................................................................... 6 - 10 6.2.3 EMERGENCY STOP ............................................................................................................... 6 - 10 6.3 DIAGRAMS ILLUSTRATING PRESS OPERATION ................................................................ 6 - 11 6.4 AUTOMATIC CYCLE ............................................................................................................... 6 - 14 6.4.1 FILLER-BOX START ................................................................................................................ 6 - 14 6.4.2 POWDER INFEED ................................................................................................................... 6 - 17 6.4.3 FIRST DIE-SET DOWNSTROKE ............................................................................................ 6 - 17 6.4.4 FILLER-BOX OPERATION ...................................................................................................... 6 - 19 6.4.5 SECOND DIE-SET DOWNSTROKE ....................................................................................... 6 - 20 6.4.6 ADDITIONAL DIE-SET DOWNSTROKE (OPTIONAL) ........................................................... 6 - 21 6.4.7 FAST DOWNSTROKE ............................................................................................................. 6 - 21 6.4.8 DOWNSTROKE WITH BRAKE APPLIED ............................................................................... 6 - 21 6.4.9 DELAY TIME FOR THE 1ST PRESS STROKE ...................................................................... 6 - 21 6.4.10 FIRST PRESS-STROKE .......................................................................................................... 6 - 22 6.4.11 1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER (WITH OR WITHOUT ACCUMULATORS) .................................................................................................................. 6 - 22
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6.4.12 6.4.13 6.4.14 6.4.15 6.4.16 6.4.17 6.4.18 6.4.19 6.4.20 6.4.21 6.4.22 6.4.23 6.4.24 6.4.25 6.4.26 6.4.27 6.4.28 7 1ST SEPARATE PRESS-STROKE ......................................................................................... DEAERATION .......................................................................................................................... SECOND PRESS-STROKE (LAST PRESS-STROKE) ........................................................... SECOND DIRECT PRESS-STROKE ...................................................................................... PRESS-STROKE WITH PRESSURE BOOSTER ................................................................... SECOND SEPARATE PRESS-STROKE ................................................................................ DIE-SET UPSTROKE .............................................................................................................. CYLINDER PRESSURE RECOVERY (ONLY FOR PH 1500) ................................................ UPSTROKE WITH BRAKE APPLIED ...................................................................................... FAST UPSTROKE ................................................................................................................... EJECTION ................................................................................................................................ SFS CYCLE: UPPER FORMING DIE (OPTIONAL) ................................................................ MOBILE DIE (OPTIONAL) ....................................................................................................... DIE OVER-TRAVEL ................................................................................................................. BRUSH OPERATION ............................................................................................................... MOVEMENTS IN MANUAL MODE .......................................................................................... RESETTING THE ENCODERS ............................................................................................... Page 6 - 22 6 - 23 6 - 23 6 - 23 6 - 23 6 - 24 6 - 24 6 - 24 6 - 25 6 - 25 6 - 25 6 - 25 6 - 26 6 - 26 6 - 27 6 - 28 6 - 29
ADJUSTMENTS ........................................................................................................................................ 7 - 1 7.1 SETTING THE PH 690 - PH 1000 VARIABLE DELIVERY PUMP ............................................ 7 - 1 7.2 SETTING THE PH 1500 VARIABLE DELIVERY PUMP ............................................................7 - 5 7.3 SETTING AND RESETTING THE POSITION ENCODER ........................................................ 7 - 8 7.3.1 PLUNGER TRANSDUCERS ...................................................................................................... 7 - 8 7.3.2 FILLER-BOX ENCODER (DCL) ................................................................................................. 7 - 8 7.3.3 ALM ENCODER (DCL) ...............................................................................................................7 - 8 7.3.4 FILLER-BOX ENCODER (DCP) .................................................................................................7 - 9 MACHINE MAINTENANCE ...................................................................................................................... 8 - 1 8.1 SCHEDULED MAINTENANCE .................................................................................................. 8 - 1 8.2 SPECIAL MAINTENANCE ......................................................................................................... 8 - 4 8.2.1 SERVICING THE PLUNGER BUSHES ......................................................................................8 - 4 8.2.2 FILLING THE RESERVOIR ........................................................................................................8 - 4 8.2.3 DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND LINES ..................................... 8 - 6 8.2.4 CHECKING ACCUMULATOR PRECHARGE ............................................................................ 8 - 8 8.3 TORQUES (NUTS AND BOLTS) ............................................................................................... 8 - 9 8.4 SERVICING THE HEAT EXCHANGER ................................................................................... 8 - 10 8.4.1 REPLACING THE GASKETS .................................................................................................. 8 - 10 8.4.2 SECURING THE TIE RODS .................................................................................................... 8 - 11 8.5 SERVICING THE FIXED DELIVERY PUMPS ......................................................................... 8 - 12 8.6 VACUUM .................................................................................................................................. 8 - 14 DECOMMISSIONING ................................................................................................................................ 9 - 1
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GENERAL INFORMATION
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1.1
GENERAL INFORMATION
INTRODUCTION
E0004P
WARNING!
Carefully read the entire Users 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
E0004P
WARNING!
This manual is to be considered an essential part of the machine and must be kept along with it even if the machine is sold. Always keep the manual near the machine where it can be easily consulted. The manual must always be at hand so that the operator and maintenance staff is 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 operators safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and are written in italics, as shown below.
E0004P
WARNING!
Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must be carefully read in its entirety as it contains important information and warnings regarding safety.
1.4
USERS OF THE MANUAL
In this manual the machine operators are categorized as follows: - Operator: this is the person responsible for supervising and operating the machine. - Routine maintenance men. For a more detailed description, see the paragraph dealing with OPERATOR TRAINING in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.
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1.5
GENERAL INFORMATION
WARRANTY
SACMI shall be held responsible only for the machine as it was configured at the time of delivery. Any operations that alter the configuration of the machine or operating cycle must be carried out by SACMI personnel or duly authorized by SACMIS Engineering Dept. SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.
E0004P
ATTENTION!
The machine operators and maintenance staff are not responsible for carrying out operations under warranty, special maintenance and repairs. These operations are to be performed only by the manufacturers specially trained technicians. For this reason, these types of operations are not dealt with in this manual.
1.6
SUPPLEMENTS
Information regarding the electric and electronic components is given in three handbooks provided separately. These handbooks are entitled: - USE OF THE MICROPROCESSOR-BASED CONTROL SYSTEM (Instructions B Manual) - ELECTRONIC CARDS - LIST OF DEVICES The above mentioned handbooks supplement this manual.
1.7
LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL
DANGER SYMBOLS
General danger
E0004P
Hot surfaces - danger of being burnt

E0002P
Danger - hands can be crushed

E0003P
High tension - danger of being electrocuted

E0007P
Danger of entanglement in moving parts

E0010P
Risk of explosion
E0035P
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WARNING SYMBOLS
O2
It is forbidden to use oxygen to recharge the accumulators

E0034D
ALERT SYMBOLS
Heavy duty gloves must be worn

E0005O
The indicated point must be effectively grounded

E0006O
ADDITIONAL SYMBOLS
A list of tools required to carry out maintenance is provided.

E0009C
SYMBOLS
This symbol indicates the machine version with SMU system.

C1819
Available for the PH 690 - PH 1000 - PH 1500. Any description or illustration in the Users Manual which has this symbol next to it refers to this machine version only.
This symbol indicates the machine version with conventional knockout with rods (TRADITIONAL LIFT SYSTEM).
C2086
Available for the PH 690 - PH 1000 - PH 1500. Any description or illustration in the Users Manual which has this sy`rol next to it efers to this machine version only.
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GENERAL INFORMATION
This symbol indicates the machine version with linear loading device (DCL)
C1821
Available for the PH 1500. The descriptions and/or figures accompanied by this symbol refer only to this machine version.
This symbol indicates the machine version with connecting rod/crank mechanism loading device (DCP)
Available for the PH 690 - PH 1000 - PH 1500. The descriptions and/or figures accompanied by this symbol refer only to this machine version.
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GENERAL INFORMATION
1.8 MACHINE IDENTIFICATION PLATE
PH1000 PH1500
PH690
TIPO TYPE MATRICOLA No. SE R I A L N U M B E R ANNO YE A R
VIA
SELICE
PROVINCIALE
17/A
IMOLA
I TA L I A
E0021
E0004P
WARNING!
The machine described in this Users Manual is designed to operate independently and is therefore equipped with all the safety devices called for by the 98/37/EEC directive solely in the configuration determined by SACMI, consisting of: - hydraulic press PH - fixed part of filler-box CAL - mobile part of filler-box CAF - CAS - powder feeder ALM - ACP - FIXED HOPPER - tile collector The installation and lay out of the parts mentioned above are described in paragraph 3.5 RULES FOR OPERATION in this manual. The safety requirements are not considered satisfied if parts other than those mentioned above are installed or if the parts are installed in a way that differs from that described in paragraph 3.5 RULES FOR OPERATION in this manual (if not expressly approved by SACMI).
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GENERAL INFORMATION
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2.1
MAIN FEATURES
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 - OVERALL VIEW). 2.1.1 MAIN DEVICES
MAIN DEVICES MACHINE FRAMEWORK (PH 690) The self-supporting frame 1 includes the machine base, two columns and the crosshead 3. The latter houses a hydraulic cylinder within which a double-acting piston 4 slides . The cylinder is attached to the plunger 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. Two spring shock absorbers 17 move the plunger up during de-aeration. MACHINE FRAMEWORK (PH 1000 - PH 1500) The self-supporting frame 1 includes the machine base, four columns and the crosshead 3. The latter houses a hydraulic cylinder within which a double-acting piston 4 slides . The cylinder is attached to the plunger 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. Two spring shock absorbers 17 move the plunger up during de-aeration.
HYDRAULIC SYSTEM Pressure boosters 7, located inside the upper part of the crosshead, generate the pressure directly within the cylinder so that the programmed press-strokes can be carried out. Several plates (located on the machine body, near the points of use) hold the valves required to control the operating pressures as well as the logic elements used to operate the working parts of the press. The following control plates are provided: - Logic element plate 20 used to control and monitor the pressure required to perform the press cycle. - Accumulator plate 21 used to control the upward and downward strokes of the machine. It is also provided with a brake unit which limits the speed of the plunger when the die set is being closed. - The service plate 22 used to operate the ejector and filler-box. The hydraulic power unit 27 provides the oil required to operate the actuators, filters the oil and controls the oil temperature. A fixed or variable-displacement axial-piston pump draws the oil from the reservoir and delivers it to the hydraulic circuit at the required pressure and flow rate. The hydraulic lines are pressurized to keep out ceramic particles and extraneous matter. The oil-water heat exchanger is located in the hydraulic power unit and maintains the oil temperature within the correct operating range. The circuit is provided with a motor-and-pump unit 28 which filters and cools down the oil. The hydraulic lines 18 are provided with the fittings, pipes and hoses required to join the hydraulic parts to one another.
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MAIN FEATURES
DCP
POWDER FILLER-BOX (PH 690 - PH 1000 - PH1500) The box feeder is used to fill the die-set and eject the finished tiles. The unit features an assembly (mount 9 and geared motor 14) which can be removed from the press so that the die-set can be quickly replaced from the rear. While the latter is being performed the speed of the moving parts is lower than that allowed for by current regulations (16 mm/s) in order to safeguard the operator. The structure sustains and guides a mobile part which consists of the filler-box body 10. The hopper 11 is mounted over the mobile part. This hopper can be fed directly from the main hopper or a mixer. The hydraulic motor and gear-box unit mounted on the unit operates the mobile assembly with the aid of a crank mechanism. With this arrangement, the linear motion is turned into a reciprocating one. The stroke of the mobile part, the speed and stop time of the hydraulic motor are adjustable. All of the devices which join the filler box to the press come with quick couplings (electrical, hydraulic, pneumatic and mechanical).
DCL
C1821
POWDER FILLER-BOX (DCL TYPE FOR PH 1500) 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.
TRADITIONAL LIFT SYSTEM

C2086
TRADITIONAL HYDRAULIC EJECTOR (as an alternative to the SMU hydraulic ejector) PH 690 The device comes with hydraulic cylinders which raise the mobile part of the die at the end of each press-stroke. Its function is to remove the finished workpiece from the die set. The tiles are ejected from the filler-box as soon as they have been brought to the same level as the die. The lower punches in the die set then move down creating a cavity which will then be filled with the material to be compacted. The depth of the cavity can be adjusted manually or automatically after the thickness of the tiles has been set. The two single acting hydraulic cylinders are operated by separate solenoid valves. A mechanical device is used to re-position the cylinders.
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2
PH 1000 - 1500 The device comes with hydraulic cylinders which raise the mobile part of the die at the end of each press-stroke. Its function is to remove the finished workpiece from the die set. The tiles are ejected from the filler-box as soon as they have been brought to the same level as the die. The lower punches in the die set then move down creating a cavity which will then be filled with the material to be compacted. The depth of the cavity can be adjusted manually or automatically after the thickness of the tiles has been set. The two single acting hydraulic cylinders are operated by separate solenoid valves. A hydraulic device is used to re-position the cylinders.
C1819
SMU
SMU HYDRAULIC EJECTOR (as an alternative to the traditional hydraulic ejector) The SMU system features a base plate and a punch holder which incorporates the tile ejector. The system is basically used to remove the finished tiles from the die set. The tile is brought to the same level as the die and is then ejected from 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.
INTAKE, FILTER AND EXHAUST OPENING FOR THE AIR IN THE DIE SET (only with SMU) The air which flows in and out of the lower part of the die set passes though a filtration 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. Covers 29 are provided to 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; - a computer terminal to display the set parameters, operating data and fault messages; - a number of electronic cards. The following are connected to the controller: - a plunger positioner 33: equipment that incorporates a linear encoder which records the position of the plunger and transmits data to the computer system. - electrical wiring 30: the latter is based on the same principle as the hydraulic system. It includes all of the electrical and electromechanical parts found on the press: miniature switches, proximity sensors and related cams, connecting cables, terminals, etc The machine can be equipped with a personal computer (optional) that processes and displays data retrieved by the microprocessor-based controller along with historical data in real time.
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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 distinct 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 is warmed up by electric heating elements to prevent the powder from sticking. Three temperature probes continuously measure the temperature of the punches and die. Three separate instruments can thus control and monitor this important variable.
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MAIN FEATURES
FIGURE 2.1.1/A - PH 690 OVERALL VIEW 1 2 3 4 5 6 7 8 9 10 11 14 15 16 17 18 20 21 22 27 28 29 30 31 32 33 34 35 Framework Plunger Crosshead and hydraulic cylinder Hydraulic cylinder 16 Die-set air filtration Conventional hydraulic ejector (as an alternative to the SMU ejector) Pressure booster SMU proportional knockout (as an alternative to the traditional ejector) Filler-box mount Filler box Hopper Filler-box geared motor Mechanical lock and safety guards Suction hoods Spring shock-absorber Hydraulic lines Logic element plate Accumulator and brake control assembly Knockout and filler-box control assembly Hydraulic power unit Cooling unit (motor-driven pump) Covers Electrical wiring Microprocessor-based control system Electrical cabinet Plunger position control Die-set Control keyboard
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MAIN FEATURES
FIGURE 2.1.1/B - OVERALL VIEW OF PH1000 - PH1500 1 2 3 4 5 Framework Plunger Crosshead and hydraulic cylinder Hydraulic cylinder Die-set air filtration
20
4 3
32
31
17
35
28 34 1 8 6

6 7 8 15 30
27
18
21 33 16
29
14 10
9 10 11 14 15 16 17 18 20 21 22 27 28 29 30 31 32 33 34 35
11 22
5 9
Conventional hydraulic ejector (as an alternative to the SMU ejector) Pressure booster SMU hydraulic ejector (as an alternative to the traditional ejector) Filler-box mount Filler box Hopper Filler-box geared motor Mechanical lock and safety guards Suction hoods Spring shock-absorber Hydraulic lines Logic element plate Accumulator and brake control assembly Ejector and filler-box control Hydraulic power unit Cooling unit (motor-driven pump Covers Electrical wiring Microprocessor-based control system Electrical cabinet Plunger position control Die-set Control keyboard
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MAIN FEATURES
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE
INTENDED USE OF THE MACHINE The machine is specially designed to compact ceramic powder for the production of tiles. The emergency stop devices installed have priority over any command to start the machine. As a result, if the machine is remote controlled it can always be stopped from the machine. In addition, the shut-down signals transmitted from the machines and equipment located before and after the area where the press-cycle is carried out is always read. The machine can be restarted only from the push-button panel installed on the machine. However, the run command will not be executed if the trigger from the machines connected to it is not provided.
E0004
WARNING!
If the machine is remote controlled the operators must be properly instructed regarding its use.
The machine can operate in two modes: manual or automatic. These modes of operation can be selected by using the selector switch located on the control panels. UNINTENDED AND PROHIBITED OPERATIONS The machine must be used only for the tasks it was expressly designed for unless otherwise authorized by the Manufacturer. The Manufacturer will not be held responsible for any injury to persons or damage to the machine caused by failure to observe this safety precaution. MISUSE OR ERRONEOUS USE The manufacturer shall not be held responsible for any injury to persons or damage to the machine deriving from incorrect and erroneous use of the machine. Generally speaking, the most common causes of incorrect use are listed below: - personnel not adequately trained to perform the required operations - fatigue (above all during the night shift) or distraction - negligence caused by superficiality or wrong habits. Remember that the machine is to be controlled and run exclusively by expert well trained personnel who are able to: - correctly operate the machine under normal conditions - and face any emergencies, this is fundamental!
2-7
014AZ002A
2
2.2
2.2.1
MAIN FEATURES
OVERALL DIMENSIONS
PH 690 OVERALL DIMENSIONS
1000 850 1200 330
200
5400
PH 690
5000
530 MAX140 3350 550 790

2020
1920
1300
3000
700
1060 1490
1060
TRADITIONAL EJECTOR
1000
AREA DI SERVIZIO MINIMA MINIMUM SERVICE AREA MINIMALES BEDIENFELD
2870
1830
820
1870
1750
1020
500
1200 2060
1100
1390
C1241
2-8
1450
3860
MINIMO PER ESTRAZIONE MINIMUM FOR WITHDRAWING MINDESTAUSSTO
014AZ002A
MAIN FEATURES
2.2.2 PH 1000 - 1500 OVERALL DIMENSIONS
I
1500
M
200
P O
PH 1000
MINIMO PER ESTRAZIONE MINIMUM FOR WITHDRAWING MINDESTAUSSTO MINIMO PARA DESMOLDEO
D R
A
600
140
F
00
770
1920
B C
B1
900
TRADITIONAL EJECTOR
H
2450 1300
910
810
AREA DI SERVIZIO MINIMA MINIMUM SERVICE AREA MINIMALES BEDIENFELD AREA DE SERVICIO MINIMA
450 1600
3900
L
2905
C1240
600
A B B1 C D E F G H I L M N O P R
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
PH 1000 3170 210 380 2250 3920 4530 1550 1720 1370 1300 1500 525 700 5000 5700 3200
PH 1500 3850 330 330 2340 4180 4650 1600 1900 1405 1700 1700 880 500 6000 6500 4000
1270
1900
2-9
014AZ002A
2
2.3
2.3.1
MAIN FEATURES
TECHNICAL DATA
SPECIFICATIONS
PERFORMANCE Max. soft clay filling
with traditional lift system with SMU (standard) with SMU (special available on request)
Max. plunger stroke Column diameter Distance between columns Distance between press table and plunger Max. withdrawing force Max. pressing force Max. cylinder pressure Cycles per minute Strokes per cycle ELECTRICAL SYSTEM Voltage: Aux. circuitry Die-set heating Solenoid valves Power: Main motor with fixed delivery pump with variable delivery pump Heat exchanger pump motor Die-set heater (standard punches) Die Controller Magnetic lock Sound-proof booth fan Enea cooling (optional) Sacmi exchanger (optional) In-line filler-box control Double loading control Auxiliary circuits
mm mm mm mm mm mm mm kN kN bar up to
PH 690 40 35 50 140 220 1300 550 96 6000 306 34 1-2-3 PH 690 110 50 24 45 45 7.5 10 + 10 4 1 1.6 0.25 7 9 7 2.5 1
PH 1000 60 35 50 140 200 1550 600 96 10000 352 25 1-2-3 PH 1000 110 50 24 55 55 7.5 10 + 10 4 1 1.6 0.25 7 9 7 2.5 1
PH 1500 60 35 50 140 240 1600 600 96 15000 340 25 1-2-3 PH 1500 110 50 24 75 55 7.5 10 + 10 4 1 1.6 0.25 7 9 7 2.5 1
(regulated) (50 Hz) (50 Hz) (50 Hz) (50 Hz) (50 Hz) (50 Hz)
V ac V ac V kW kW kW kW kW kW kW kW kW kW kW kW kW
2 - 10
014AZ002A
MAIN FEATURES
2
HYDRAULIC SYSTEM PH 690 PH 1000 PH 1500 Hydraulic oil: system capacity l 380 600 800 Cleanliness rating at press inlet in accordance with ISO 4406:1999 Specifications see Lubrication guide for machinery used in the ceramic industry 200.02.A01 Max. operating pressure in the hydraulic power unit bar 170 180 180 Accumulators Main circuit: capacity l 20+20 20+20 20+20 precharge pressure bar 110 110 110 Aux. circuit: capacity l 12 12 12 SMU die control: capacity l 2.5 2.5 2.5 precharge pressure bar 110 110 110 Main filter Filtration capacity 10 10 10 Filter cartridge in tank Filtration capacity 250 250 250 Plate type filter cartridge Filtration capacity 10 10 10 Cooling system: Heat to be dissipated with fixed delivery pump kcal/h 30000 45000 52000 with variable delivery pump kcal/h 25000 33000 32000 Water consumption at 20 with fixed delivery pump l/1' 50 65 70 with variable delivery pump l/1' 28 30 30 Water pipe connection diameter Hoses, Inside diameter Max. pressure Pressurization, Max. pressure (with plunger raised) KNOCKOUT Gearbox lubrication: EP oil viscosity WEIGHTS Weight mm bar bar PH 690 1"1/2-3/8" 40/10 4 1.5 PH 1000 ISO VG 320 1"1/2-3/8" 40/10 4 1.5 PH 1500 ISO VG 320 1"1/2-3/8" 40/10 4 1.5
ISO VG 320
Press body Hydraulic power unit Aux. equipment (controller, electrical cabinet, filler-box, etc.)
kg kg kg
17000 890 2800
27000 890 2800
38500 890 2800
E0004P
ATTENTION!
All the specifications of the oil to be used in he hydraulic system are given in Instructions manual 200.02.A01 LUBRICATION GUIDE FOR MACHINERY USED IN THE CERAMIC INDUSTRY.
2 - 11
014AZ002A
2
2.3.2
MAIN FEATURES
AIRBORNE NOISE LEVELS
Test conditions - Operating conditions :( in compliance with ISO/DIS 11202 standard, point 9.5): - Simulation: pressing on wooden element. - Sound-proof booth provided - Type of operation: Pressing of ceramic material. - Operating cycle: Die-set loading, one or more press-strokes with air vent, press-cycle for final product formation. - Test conditions: PH 690 Cycles/minute Hydraulic power unit pressure (bar) Operating pressure (bar) 15.4 170 280 PH 1000 14 180 300 PH 1500 17.2 180 300
- Test environment: Press testing division, SACMI Imola. Instruments employed Class 1 instruments (IEC 804) Sound pressure level (ISO/DIS 11202) Sound power level (ISO 3746) Values measured: PH 690 LpA (dBA) LwA (dBA) LpA LwA P1 P2 72.5 74.5 92 PH 1000 72 76 95 PH 1500 73.5 75.5 94
Continuous A-weighted sound pressure level. Acoustic power level in dB weighted A.
P1 = Occasional control post P2 = Noisiest position of the ideal machine perimeter measured at floor level.
Figure 2.3.2 - POINTS WHERE NOISE LEVEL IS MEASURED
P2
PH690 PH1000
2 - 12
C1071
C1071
P1
P1 P2
PH1500
014AZ002A
MAIN FEATURES
2.3.3 DUST SUCTION HOODS
PH 690 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 symbol S250 S260 S270 S150 P004 P002 P003 P010
NO. of outlets 1 1 4 1 1 1 2 1
Outlet diameter (mm) 120 120 100 100 80 70 60 50
Total delivery qt (m3/h) 814 814 2260 565 543 416 610 212
Height from floor (m) +2.0 +2.0 +1.4 +6.4 +1.0 +0.2 +0.2 +0.8
Front hood Rear hood Brushes (1) Hopper (19) Rear powder level limit Front powder level limit Powder level limit, Brushes (1) Powder level limit, Cleaning NOTES:
(1) Outlets present on the RPR tile roller conveyor (19) Point of use not shown in the drawing
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.
S260
P004
S250 P002
P010
P003 S270 S270 P003
S270 S270
C2103
2 - 13
014AZ002A
2
MAIN FEATURES
PH 1000 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 symbol S250 S260 S270 S150 P004 P002 P010
NO. of outlets 2 1 4 1 1 1 1
Outlet diameter (mm) 90 120 100 100 120 50 50
Total delivery qt (m3/h) 916 814 2260 565 1220 212 212
Height from floor (m) +2.0 +1.7 +1.4 +6.7(2) +0.3 +0.2 +0.8
Front hood Rear hood Brushes (1) Hopper (19) Rear powder level limit Front powder level limit Powder level limit, Cleaning NOTES:
(1) Outlets present on the RPR tile roller conveyor (2) +6.2 m for service floor H = 5000 (19) Point of use not shown in the drawing
P004
S260
P010 S250 P002 S250
S270
S270
S270
S270
C2104
2 - 14
014AZ002A
MAIN FEATURES
2
PH 1500 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 symbol S250 S260 S270 S150 P004 P002 P010
NO. of outlets 2 1 4 1 1 1 1
Outlet diameter (mm) 90 120 100 100 120 70 50
Total delivery qt (m3/h) 916 814 2260 565 1220 416 212
Height from floor (m) +2.0 +2.0 +1.4 +6.7(2) +0.3 +0.2 +0.8
Front hood Rear hood Brushes (1) Hopper (19) Rear powder level limit Front powder level limit Powder level limit, Cleaning NOTES:
(1) Outlets present on the RPR tile roller conveyor (2) +6.2 m for service floor H = 5000 (19) Point of use not shown in the drawing
Left version
P004
S260
S250 P002 S270 S270
P010 S250 S270
S270
C2102
2 - 15
014AZ002A
2
2.3.4
MAIN FEATURES
RATING PLATE
Figure 2.3.4 - RATING PLATE PH 690
V N
E0012
Hz Cod. Com.
In
V N
E0012
Hz Cod. Com.
In
PH 1000 - 1500
V N
E0012
Hz Cod. Com.
In
V N
E0012
Hz Cod. Com.
In
2 - 16
014AZ002A
MAIN FEATURES
2.4
2.4.1
DIAGRAMS
HYDRAULIC/PNEUMATIC SYSTEM DIAGRAM
A block diagram is provided in order to highlight the different separate areas in the machine. The hydraulic and pneumatic parts are listed according to the identification numbers they have been assigned with so that their functions can be easily and properly found.
Block diagram A B C D E F G H I L M N O P Q R S T U Prefilling tank Press-stroke control Upstroke, downstroke and braking control Services control Knockout control SMU die control (optional) Filler-box proportional control (optional) 3rd die-set downstroke (optional) SFS control (optional) Mirror-finished die-set control (optional) Automatic rod lock control (optional for PH 690) Hydraulic power unit with fixed delivery pump Hydraulic power unit with variable delivery pump (optional) Hopper gate control Blower circuit (optional) Mobile brush pneumatic control (optional) Mobile brush pneumatic system (optional) Filler-box motor Filler-box double speed control (optional)
2 - 17
014AZ002A
YV11a
YV11r YV11b
2 - 18
P P P
75
271
74
73
72
A B P
272 275 120 119 277 267 YV192 223 222 YV221 YV38 YV19 YV41 T T 224 13 36 SQ61 SQ60 194 T YV40 BP1 T YV70 SP2 118 117 116 131 YV173 273 265 266 264
71
YV290
125
126
Q
M2 M
269 269 270 269 269 270
MAIN FEATURES
124 28 YV47a 27 18
C
174 109 115 108
123
S
114
247 M 90 YV31d YV31s BQ3 OPT YV47 YV32d YV32s YV53
M15 132
92
122
BQ1
SFS
258
184
184
82 144
179
179 179 180 181 189 179 SQ6 189 181 180
SMU
SQ3 154
101
STAMPO DIE-SET STAMPO
101
SQ50a 48
H2O 112 YV279 M11 58 M P SP1 H2O
Figure 2.4/A - PH 690 HYDRAULIC AND PNEUMATIC SYSTEM
ESTRATTORE
KNOCKOUT
130
146
1a
55
2a 42
YV129s
136
SQ59a 49 M 57 M1 SP3 78 BT4 79 248
56
O
R
A 58
M11
N
P M 67 10 M 57 49 M1 BT4 SP3 78 79 SP1 248 48
H2O
145 23 145 24 24 142 141 43 143 242 61 140 T YV21 YV20a YV129 251 252 SP4 YV22 183 YV20b YV20s SQ20s 5 YV20a 12
155 62
250
249
141
H2O
YV172
YV193
142
337
338
YV279 112a
183
339
169
143
YV135
140
336
YV170
188
111
248
M E F
C2204
75 P P P
271
74
73
72
A B P
272 275 120 119 277 267 YV192 223 222 YV221 YV38 YV19 YV41 T T 224 13 36 SQ61 SQ60 194 T YV40 BP1 T YV70 SP2 118 117 116 131 YV173 273 265 266 264
71
YV290
125
126
Q
M2 M
269 269 270 269
124
C
27 18 174 109 115 247 M 90 114 YV32d BQ3 OPT YV47 YV32s YV53 YV31d YV31s M15 132 92 108
123
269 270
122
BQ1
SFS
258
184
184
82
179
179 179 180 181 189 179 SQ6 189 181 180
SMU
SQ3
144 154 SQ50a 48 R
101
STAMPO STAMPO
101
H2O 112 YV279 M11 58 M P SQ59a SP1 H2O
ESTRATTORE
130
146
1a
55
2a
YV129s
136 42
49 M 57 M1
78 BT4 SP3
79
248
Figure 2.4/B - PH 1000 HYDRAULIC AND PNEUMATIC SYSTEM DIAGRAM
56
O
R T A 58 M11 H2O
N
P 12 67 10 M T P SQ20s 49 78 M1 BT4 79 M 48
145 23 145 24 24 142 141 43 143 242 61 140 T YV21 YV129 251 YV22 YV20a 183 YV20b
155 62
250
249
H2O
141
YV172
YV193
142
YV11a
YV20a
YV11r YV11b
337
57
338
SP3 112a 5 YV20s 188 252 SP4 6 111
SP1
248
YV279
183
339
169
143
MAIN FEATURES
YV135
140
336
YV170
248
M E
C2205
014AZ002A
2
2 - 19
014AZ002A
338 242 140 61 183 YV20b
143
YV11r YV11b
2 - 20
B P
272 275 120 119 277 267 YV192 YV221 YV38 YV19 YV41 194 13
PC
75
271
74
73
72
A R
264 266 YV173 265 273
71
YV290
125 118 117 116 131
126 223 222

Y
SP2 YV70 YV40 224 SQ60 SQ61
BP1
V P
36
Q
M2 M 269 269
PEL
MAIN FEATURES
SM
PEL
124
C
27 18
Y
270 269
123 174 109 108 115 247

PS
M15 132 92 M
S
R
114
269 270
PS
90 YV31d
B P
122 BQ3
OPT
A
YV31s
YV32d
YV32s
YV53
A A R
R
BQ1 YV47 144

T
SFS
184 258
T
P1
184 154
SQ50a YV99
BT4
T U
82
HO
2
112
179
SMU
48
179 179 179 SQ6

STAMPO
SQ3 180 181 189 189 181 180 SP1 79
YV279 HO
2
101
STAMPO
101
M11 M 49 58 78
Figure 2.4/C - PH 1500 HYDRAULIC AND PNEUMATIC SYSTEM
ESTRATTORE
130
146 SQ59a
1a
55
P
P
SP3
YV129s 42
2a
136
M1
O
A
A
56
R
R
144 154
T P1
SQ50a
T U
BT4
82
HO
2
145 23 145 24 24 142 YV20a 43
SP1 12 67 M11 10 58 49 78 79
48
155 62 141
250
249
YV279
HO
2
141
YV172
YV193
142
337
P
SQ20s
5 112a
P
M1 M
SP3
183 YV21 YV20a YV129 251

P
339 YV22
169
N
YV20s
188 252
P
143
YV135
140
336
YV170
111
SP4
P P
T T T
M E F
248
C2206
014AZ002A
MAIN FEATURES
Figure 2.4/D - LOGIC ELEMENT ASSEMBLY
120 131 YV38 YV41 119 116 118 YV40 117
SP2 YV19 BP1 YV70

C0531
2 - 21
014AZ002A
2
MAIN FEATURES
Figure 2.4/E - PH 690 BRAKE UNIT CONTROL
Figure 2.4/F - PH 1000 - PH 1500 BRAKE UNIT CONTROL
2 - 22
014AZ002A
MAIN FEATURES
Figure 2.4/G -FILLER-BOX AND LIFT CONTROL ASSEMBLY Figure 2.4/H - SERVICE CONTROL ASSEMBLY Figure 2.4/I - SMU CONTROL ASSEMBLY YV21 YV22
YV11r - YV11b YV11a 10 5 112a 111 62

C2082
C2207
242 61 23
188
C2096
Figure 2.4/L
FILLER-BOX DOUBLE FILLER-BOX PROPORTIONAL CONTROL SPEED CONTROL
YV20s - SQ20s YV20a
Figure 2.4/M - SMU CONTROL ASSEMBLY
YV20b
SP4 252
YV129
141
140 12 YV20a 183 251 43

C2084
145
C2085
142
2 - 23
014AZ002A
2
MAIN FEATURES
Figure 2.4/N - SFS CONTROL ASSEMBLY Figure 2.4/O - MIRROR FINISHED DIE-SET CONTROL ASSEMBLY
141 337 140
YV172
C2089
339
155 YV193 183 142

C2088
338 249
250
143
145
C2096
Figure 2.4/P - 3 DIE-SET DOWNSTROKE CYLINDER CONTROL ASSEMBLY

RD
Figure 2.4/Q - AUTOMATIC ROD LOCK CONTROL ASSEMBLY YV135
YV170 169
C2208
C2087
2 - 24
014AZ002A
MAIN FEATURES
LIST OF THE HYDRAULIC/PNEUMATIC COMPONENTS
005 006 010 012 013 018 023 024 027 028 036 042 043 048 049 055 056 057 058 061 062 067 071 072 073 074 075 078 079 082 090 092 101 108 109 111 112 112a 114 115 116 117 118 119 120 122 123 124 125 126 130 131 132 136 140 141 142 143 144 145 146 Check valve, Services Check valve, Service control assembly discharge Valve (pilot-operated), Low pressure Accumulator, Filler-box and lift control Pressure gauge, Pump and cock Accumulator, Press-stroke and upstroke Flow control Flow control, Filler-box at fast speed Accumulator, Press-stroke and upstroke Accumulator, Stabilized braking Pressure gauge, Cylinder and cock Hydraulic motor, Filler-box Check valve, Filler-box braking Heat exchanger Suction filter, Main pump Cylinder, 1st die-set downstroke and ejection Cylinder, 2nd knockout stroke Flexible coupling Main pump Restrictor, Non return valve Restrictor and pilot-operated check valve Pressure gauge, Service pressure and cock Safety valve, Pressurization Air filter, Pressurization circuit Pressure reducer, Air in the pressurization circuit Check valve, Air in the pressurization circuit Pressure gauge, Air in the pressurization circuit Filtration unit pump Filter Check valve, Delivery line filtration Flow rate control, Slow upstroke Pressure relief valve, Brake system Plunger shock absorber Logic element, Upstroke Logic element, Downstroke Pressure relief valve Pilot-operated valve, Line pressure Safety valve, Hydraulic circuit Logic element, Check valve, Accumulator control assembly Logic element, Accumulator shut-off during press-cycle Logic element, Flow booster (1st press-stroke) Logic element, Cylinder pressure Logic element, Cylinder drain Logic element, Booster drain Logic element, Pressure booster Plunger Rod Cylinder Booster assembly Prefilling tank Cylinder, Rack drive Logic element, Booster supply, 2nd press-stroke Flow control, Plunger braking Cylinder, Knockout rod clamping Pressure reducer, Mirror finished die-set Accumulator, Mirror finished die-set Pressure gauge, Mirror finished die-set Drain cock, Mirror finished die-set Cock, Main pump suction line Restrictor, Non return valve, Mirror-finished die set Cylinder, Knockout return stroke 154 155 Service cock, Suction system Shut off cock, Mirror-finished die set circuit with check valve 169 Twin restrictor, 3rd downstroke control 174 Logic element, Braking 179 Cylinder, Die over-travel 180 SMU knockout cylinder 181 Cylinder, Loading adjustment, 2nd SMU downstroke 183 Check valve, Die hydraulic release 184 SFS cylinder 188 Pressure reducer, Filler-box lift unit 189 Cylinder, Additional downstroke control 194 Pressure relief valve, Brush drive 222 Flow control and silencer, Gate cylinder 223 Flow control and silencer, Gate cylinder 224 Gate cylinder 242 Twin throttle valve, 2nd downstroke 247 Check valve, Cylinder downstroke 248 Cock, System drain 249 Restrictor, SFS delivery line 250 Restrictor, SFS accumulator 251 Check valve, Hydraulic die release 252 Proportional filter (10 um) 258 Change-over valve 264 Air filter, Brush unit 265 Pressure gauge, Brush unit 266 Pressure reducer, Brush unit 267 Oiler, Brush unit 269 Flow control, Brush drive cylinder 270 Brush drive cylinder 271 Coalescence filter for pressurization 272 Air filter, Hopper assembly 273 Pressure reducer, Hopper assembly 275 Pressure gauge, Hopper assembly 277 Oiler, Hopper assembly 336 Pressure relief valve 337 Accumulator, SFS circuit 338 Pressure gauge, SFS circuit 339 Drain cock, SFS circuit BP1 Transducer, Cylinder pressure BQ1 Position transducer, Plunger BQ3 Transducer, Brake setting BT4 Thermocouple, Hydraulic power unit reservoir M1 Motor, Main pump M11 Motor, Recirculating pump M15 Motor, Brake system M2 Brush motor SP1 Pressure switch, Main filter service SP2 Pressure switch, Cylinder (safety) SP3 Pressure switch, Air pressurization SP4 Pressure switch, Filler-box valve filter service SQ3 Sensor, Die-sets up SQ20s Proximity switch, YV20s monitoring (optional) SQ50a Miniature switch, Suction line cock SQ59a Limit switch, Filler-box backwards SQ6 Sensor, Die-sets down SQ60 Sensor, Hopper gate open SQ61 Sensor, Hopper gate closed YV11a Solenoid valve (pilot-operated), Pressure off YV11b/R Solenoid valve (pilot-operated), Low pressure YV19 Solenoid valve, 2nd press-stroke (direct) YV20a Solenoid valve, Filler-box YV20s Solenoid valve, Filler box interlock 2 - 25
014AZ002A
2
YV21 YV22 YV31d YV31s YV32d YV32s YV38 YV40
MAIN FEATURES
Solenoid valve, 2nd die-set downstroke Solenoid valve, 1st die-set downstroke Solenoid valve, Slow downstroke Solenoid valve, Slow upstroke Solenoid valve, Plunger downstroke Solenoid valve, Plunger upstroke Solenoid valve (pilot-operated), Pressure booster Solenoid valve (pilot-operated), Flow booster (1st press-stroke) YV41 Solenoid valve, Flow booster (2nd press-stroke) YV47 Solenoid valve, Brake system YV47a Solenoid valve, Brake system YV53 Solenoid valve, Accumulator shut-off YV70 Solenoid valve, Main cylinder drain YV99 Solenoid valve, Pump control drainage YV129 Solenoid valve, Die over-travel control YV129s Pneumatic solenoid valve, Rack rotation YV135 Solenoid valve, Knockout rod lock YV170 Solenoid valve, 3rd die-set downstroke (optional) YV172 Solenoid valve, SFS die-set cylinder drain YV173 Solenoid valve, Air blower YV192 Solenoid valve, Brush operation YV193 Solenoid valve, SFS punch return YV221 Solenoid valve, Hopper gate control YV279 Solenoid valve, Cooling water YV290 Solenoid valve, Pressurization control
2 - 26
014AZ002A
MAIN FEATURES
2.5 MACHINE OPERATION
The numbers and symbols used to identify the hydraulic, pneumatic and electric components in the descriptions below refer to figures 2.4/A and 2.4/B - HYDRAULIC/PNEUMATIC DIAGRAM. 2.5.1 COMPRESSED AIR SUPPLY
FIXED DELIVERY PUMP The unit consists of filter 72, coalescence filter 271, pressure reducer 73, check valve 74, pressure gauge 75 and valve YV290. The compressed air is used to pressurize the tank and to put the hydraulic oil contained in it under constant pressure. The pressure reducer must be set so that a pressure of 1 to 1.2 bar is provided inside tank 126. Safety valve 71 is used to prevent any over-pressure within the tank from occurring. The safety valve is set and sealed during machine testing. A unit (which consists of filter 272, pressure reducer 273, pressure gauge 275, oiler 277 and solenoid valve YV221) controls cylinder 224 to operate the feed hopper gate, provided that this optional device is installed. Another unit (which consists of filter 264, pressure reducer 266, pressure gauge 265, oiler 267, solenoid valve YV192, pressure reducer 194 and flow controls 269) controls cylinder 270 to operate the movable brush, provided that this optional device is installed. VARIABLE DELIVERY PUMP The unit consists of filter 72, coalescence filter 271, pressure reducer 73, check valve 74, pressure gauge 75 and valve YV290. The compressed air is used to pressurize the tank and to put the hydraulic oil contained in it under constant pressure. The pressure reducer must be set so that a pressure of 1 to 1.2 bar is provided inside tank 126. Safety valve 71 is used to prevent any over-pressure within the tank from occurring. The safety valve is set and sealed during machine testing. Pressure switch SP3, which keeps pressurization under control, is mounted on the suction line of pump 58. It prevents the main pump from being started up if the pressure in the air lines is insufficient. If this happens, a fault message will be displayed. A unit (which consists of filter 272, pressure reducer 273, pressure gauge 275, oiler 277 and solenoid valve YV221) controls cylinder 224 to operate the feed hopper gate, provided that this optional device is installed. Another unit (which consists of filter 264, pressure reducer 266, pressure gauge 265, oiler 267, solenoid valve YV192, pressure reducer 194 and flow controls 269) controls cylinder 270 to operate the movable brush, provided that this optional device is installed.
2 - 27
014AZ002A
2
2.5.2
MAIN FEATURES
FAST HEATING
In order for the press to run efficiently, the oil temperature must be kept at around 40C. When the machine begins to run, the oil is normally at ambient temperature; therefore it is necessary to heat it up to at least 30C before starting an automatic work-cycle. However, the machine can be started up. NOTE: With temperatures lower than 5C, use an external heater. To heat up the oil, start up the pump with the safety bar raised. If the temperature is below 30, YV11b/r will be energized and the oil heating circuit will begin to operate. VARIABLE DELIVERY PUMP The pump will circulate the oil at a pressure of 150 bar (set for valve 10). The electrical power dissipated is then turned into heat. FIXED DELIVERY PUMP The pump will circulate the oil at a pressure of 60 bar (set for valve 10). The electrical power dissipated is then turned into heat. The power dissipated in pressure relief valve 10 will cause the oil to be warmed up in a short time (10 to 15 minutes approximately). If the oil temperature is found to be <2C, the controller will not allow main motor M1 to start running.
2.5.3
HEAT EXCHANGER AND FILTRATION SYSTEM
FIXED DELIVERY PUMP The system consists of a pump-and-motor unit M11-78, a plate-type heat exchanger 48 and a filter 79. Pump 78 draws oil from the reservoir of the hydraulic power unit and delivers it to filter 79 and then heat exchanger 48. The oil is then cooled down and returned to the reservoir. Filter 79 is equipped with pressure switch SP1 which signals when the filter is clogged. Check valve 82 prevents the oil from flowing back to the filter when the filter elements are being replaced. Drive motor M1 will stop if motor M11 shuts off. As a result, the automatic cycle will be interrupted. The heat exchanger has to be started up first before main motor M1 can be started. VARIABLE DELIVERY PUMP The system consists of a pump-and-motor unit M11-78, a plate-type heat exchanger 48 and a filter 79. Pump 78 draws oil from the reservoir of the hydraulic power unit and delivers it to filter 79 and then heat exchanger 48. The oil is then cooled down and returned to the reservoir. Filter 79 is equipped with pressure switch SP1 which signals when the filter is clogged. Check valve 82 prevents the oil from flowing back to the filter when the filter elements are being replaced. Valve YV279 controls the flow rate of the cooling water. The microprocessor based control system measures the oil temperature through thermocouple BT4. The latter is installed on the hydraulic power unit reservoir. When the temperature increases and reaches 41 C, YV279 is energized. When the temperature decreases and drops down to 39 C, YV279 is de-energized. Drive motor M1 will stop if motor M11 shuts off. As a result, the automatic cycle will be interrupted. The heat exchanger has to be started up first before main motor M1 can be started.
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MAIN FEATURES
2.5.4 MAIN PUMP RUNNING - SAFETY BAR INTERLOCKS ACTIVATED (HIGH POSITION)
FIXED DELIVERY PUMP The microprocessor-based control system is energized along with the motor control board when the main switch is turned to its on position. a) The following units start running when key 0 is pressed: - Fan motor in the sound-proof housing (if installed); - Motor-and-pump unit for the heat exchanger and filtration unit (M11-78). b) When key 0 is pressed again (at least 5 seconds have to go by between operations a and b) the following starts running: - Main pump and motor (M1-58).
Unit M1-58 is started up under no-load conditions in a pre-determined sequence as solenoid valve YV11a is energized.

C2086
WITH PH 690 TRADITIONAL LIFT SYSTEM Solenoid valve YV22 is de-energized draining cylinders 55. As a result the lower punches move downwards. PH 1000 - PH 1500 Solenoid valve YV22 is de-energized sending oil to the upper chamber of cylinders 55. As a result the lower punches move downwards.
C1819
SMU
WITH SMU LIFT SYSTEM Solenoid valve YV22 is de-energized sending oil to the upper chamber of cylinders 180. As a result the lower punches move downwards. VARIABLE DELIVERY PUMP The microprocessor-based control system is energized along with the motor control board when the main switch is turned to its on position. a) The following units start running when key 0 is pressed: - Fan motor in the sound-proof housing (if installed); - Motor-and-pump unit for the heat exchanger and filtration unit (M11-78). b) When key 0 is pressed again (at least 5 seconds have to go by between operations a and b) the following starts running: - Main pump and motor (M1-58).
Unit M1-58 is started up under no-load conditions in a pre-determined sequence as solenoid valve YV11a is energized.
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2
MAIN FEATURES

C2086
WITH PH 690 TRADITIONAL LIFT SYSTEM Solenoid valve YV22 is de-energized draining cylinders 55. As a result the lower punches move downwards. PH 1000 - PH 1500 Solenoid valve YV22 is de-energized sending oil to the upper chamber of cylinders 55. As a result the lower punches move downwards.
C1819
SMU
WITH SMU LIFT SYSTEM Solenoid valve YV22 is de-energized sending oil to the upper chamber of cylinders 180. As a result the lower punches move downwards. Filter 49 and pressure switch SP3 are installed on the suction line of pump 58. The pressure switch indicates when filter 49 is clogged. In fact, if the pressure in the suction line falls below the allowable levels, pressure switch SP3 will detect it and transmit a signal to the microprocessor system which, in turn, will cause the main pump-motor unit to stop running. A fault message will appear on the screen of the microprocessor system.
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MAIN FEATURES
2.5.5 PRESSURE TRANSDUCER - SETTINGS
The encoders are digital position transducers which continuously detect the position of the plunger and filler-box. The data entered into the microprocessor based control system provides the machine with information. Consequently, the machine will perform the programmed operations when the positions of the plunger and filler-box (detected by the transducers) coincide with the settings. Encoders 1 and 2 (plunger position) BQ6 and BQ7 The following settings can be entered for the plunger (see Instructions B manual): - Plunger stoppage due to lack of powder - Plunger down position (trigger pulse to start the press-stroke) - Braking space - Plunger raised position (automatic mode) - End of braking during plunger upstroke - Plunger parallelism error: this value, expressed in mm, represents maximum plunger inclination during the press-cycle.
Encoder 3 (filler-box position) BQ2 The following settings can be entered for the filler-box (see Instructions B manual): - Filler-box back position - Filler-box forward position - Approach value - Filler-box speed during the forward stroke - Filler-box speed during the return stroke - Approach speed - First die-set downstroke position - Filler-box speed in manual mode When sensor SQ2 is triggered by the cam integral with the mobile part of the filler-box it provides the zero point for the encoder.
DCL
C1821
Encoder 6 (ALM position) BQ10 (only with DCL) The following settings can be entered for the filler-box (see Instructions B manual): - Position of ALM when back - Position of ALM when forward - ALM speed during forward stroke - ALM speed during return stroke - ALM position when hopper gate is opened - ALM position when hopper gate is closed When sensor SQ10 is triggered by the cam integral with the mobile part of the filler-box it provides the zero point for the encoder. Sensors SQ3 and SQ6 detect when the die-set is in its highest and lowest positions. Indicator lights on the rack of the microprocessor based control system indicate the state of the inputs and outputs, solenoid valves, miniature switches, sensors, contactors, etc. during machine operation.
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2
2.5.6
MAIN FEATURES
SAFETY BAR INTERLOCKS INACTIVATED (DOWN)
FIXED DELIVERY PUMP When the safety bar is lowered, limit switch SQ51 is inactivated while limit switch SQ52 is triggered, transmitting a signal to the microprocessor system. The latter will de-energize solenoid valve YV11a and energize YV11b/r. The pressure in the circuit will be adjusted to the pressure in relief valve 10 which is set to 60 bar. The pressure can then be read on gauge 13. VARIABLE DELIVERY PUMP When the safety bar is lowered, limit switch SQ51 is inactivated while limit switch SQ52 is triggered, transmitting a signal to the microprocessor system. The latter will de-energize solenoid valve YV11a. At this point, the pressure in the circuit will be brought to the operating pressure of relief valve 112. This pressure is given on gauge 13. Valve 111 is set according to the value of valve 112a. The latter acts as a protection device for the hydraulic circuit. (The operating pressure and safety values are given in chapter 7 - ADJUSTMENTS). Once the pressures for the relief and safety valves have been set, it is good practice to tighten the adjusters (by using the locknuts) on the two valves. By doing this, vibrations will be prevented and the adjusters will not come loose, as a result, the pressure settings can be maintained over long periods. The pressure level of valve 112 is referred to as line pressure.
2.5.7
ENCODER RESETTING
To perform this operation, press keys 28 & 5 at the same time. This is to be done whenever the microprocessor based system is disconnected. The encoders must be reset in order to start the machine cycling in automatic mode. The display of the microprocessor control system will inform the operator when this operation must be done. The message ENCODER NOT RESET will appear. As an absolute encoder is used for the plunger it does not have to be zero set whenever the controller is shut off. This needs to be done only if the encoders are physically moved, if the IE card is replaced or is the encoders 0 point has to be changed (see the procedure given in the Instructions B manual).
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MAIN FEATURES
2.5.8 DIE-SET CONTROL CIRCUIT
C1819
SMU
WITH SMU LIFT SYSTEM Press pushbuttons 13 & 25 to energise solenoid valves YV22 and YV21. Solenoid valve YV22 delivers oil to the bottom part of cylinders 180 used to raise the lower punches. Simultaneously, the upper part of cylinders 180 is joined to the drain through YV22. Adjust flow control 61, located under solenoid valve YV22 to adjust the speed at which the upward movement takes place. To adjust the downstroke speed, work on throttle 23. Solenoid valve YV21 delivers oil to die-set upstroke cylinders 181 through flow control 242. The latter is used to adjust the speed for the last downstroke. As a result the lower punches reach the same level as the die. The upstroke speed is determined by a fixed gigler.

C2086
WITH TRADITIONAL LIFT SYSTEM PH 690 Press pushbuttons 13 & 25 to energise solenoid valves YV22 and YV21. Solenoid valve YV22 delivers oil to cylinder 55 used to raise the lower punches. Adjust flow control 61, located under solenoid valve YV22 to adjust the speed at which the upward movement takes place. To adjust the downstroke speed, work on the throttle located on the line in the point where the pipe used to connect the cylinder for the first downstroke starts. Solenoid valve YV21 delivers oil to die-set upstroke cylinders 56 through flow control 242. The latter is used to adjust the speed for the last downstroke. As a result the lower punches reach the same level as the die. The upstroke speed is determined by a fixed gigler. PH 1000 - PH 1500 Press pushbuttons 13 & 25 to energise solenoid valves YV22 and YV21. Solenoid valve YV22 delivers oil to the bottom part of cylinder 55 used to raise the lower punches. Simultaneously, the upper part of cylinder 55 is joined to the drain through YV22. Adjust flow control 61, located under solenoid valve YV22 to adjust the speed at which the upward movement takes place. To adjust the downstroke speed, work on throttle 23. Solenoid valve YV21 delivers oil to the die-set upstroke cylinder through flow control 242. The latter is used to adjust the speed for the last downstroke. As a result the lower punches reach the same level as the die. The upstroke speed is determined by a fixed gigler.
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2
MAIN FEATURES
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SAFETY EQUIPMENT AND PRECAUTIONS
3
3.1

SAFETY DEVICES
E0004P
WARNING!
SAFETY GUIDELINES
3.1.1
The machine is provided with a number of electrical and/or mechanical safety devices in order to safeguard the operators and the machine itself. These devices must never be removed, disabled or altered in any way. Some illustrations provided in the manual show the machine, or parts of it, with the guards removed. This is simply for added clarity. Never actually use the machine with the guards removed or safety devices disabled. Warning signs are provided on the machine to indicate any hazards in the zone where the sign is attached. Always take all necessary safety precautions before working on the machine. SACMI shall not be held responsible for any personal injury or property damage resulting from failure to observe these precautions or use the safety devices provided.
3.1.2
SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE
The operator may be injured, cut or get caught in moving machine parts while working in the area where the powder is loaded or in the area around the die set. A number of barrier guards have been provided to prevent the operator from gaining access to these hazardous areas: - Fixed guards on the powder infeed system - Fixed side guards mounted near the press columns - Fixed guards mounted on the front of the press - Fixed guards on the working parts of the filler box infeed system - Front safety bar with mobile guard None of the fixed guards can be removed without using special tools. Furthermore, they will not stay in position unless suitable fasteners are used. The mobile guard is basically a grid which moves when the safety bar is operated. In any case, the size of the steel mesh is such as to prevent access to the hazardous area. When the safety bar is raised, limit switches SQ51 and SQ52, located at the front of the machine, prevent any powered movements from being performed. Moreover, two mechanical locks are engaged to prevent the plunger from abruptly moving down. Two interlocking devices SQ66 and SQ66a, which are triggered by the powder infeed system, are found at the rear of the machine. If the powder infeed system is not present (i.e., when the area where the die-set operates can be accessed from the rear), the plunger can only carry out a slow downstroke (less than 16 mm/s). This movement is controlled by self-maintaining buttons. The front of the press must be safeguarded by installing the tile collector equipped with fixed safety guards that prevent access to the area where the die-set is found and limit switches SQ53a and SQ53b that signal it is present in its work position. The press is also provided with two red emergency stop buttons (on a yellow background). One button is located on the control panel while the other is to be found at the rear of the press. These buttons are to be pressed whenever an emergency situation arises, causing the machine to stop and the oil in the largest accumulators as well as the main pump to be drained. The machine is to be reset whenever an emergency stop button has been pressed. The hydraulic system is provided with a pressure relief valve 112a set to the maximum allowable value. This ensures trouble-free operation and prevents the pressure in the hydraulic system from exceeding the permitted levels in the presence of malfunctioning. In addition, a safety valve 71 is on the hydraulic reservoir so as to prevent the pressure from exceeding 2.25 bar. The pressure setting cannot be changed as the valve is sealed.
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Reference standards EN 292-1 Safety of machinery - Basic concepts, general principles for design. Part 1: Basic terminology, methodology. EN 292-2 Safety of machinery - Basic concepts, general principles for design. Part 2: Technical principles and specification. EN 294 Safety of machinery - Safe distances to prevent danger zones being reached by the upper limbs. EN 349 Safety of machinery - Minimum gaps to avoid crushing of parts of the human body. EN 418 Safety of machinery - Emergency stop equipment, functional aspects. Principles for design. EN 953 Safety of machinery - Guards. General requirements for the design and construction of fixed and movable guards. EN 982 Safety of machinery - Safety requirements for fluid power systems and their components. Hydraulics. EN 983 Safety of machinery - Safety requirements for fluid power systems and their components. Pneumatics. EN 1088 Safety of machinery - Interlocking devices associated with guards. Principles for design and selection. PrEN 12692: 1999 Machines for ceramic industry Safety of presses
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3.2 SAFETY RULES FOR HANDLING
E0004P
WARNING!
3.2.1
LIFTING PROCEDURES
To safely and correctly lift and handle the machine always: - use the most suitable lifting equipment with an adequate lift capacity; - cover all sharp edges; - make sure the safety device for the lift hook works properly; - do not shift the load from its initial position while lifting. Before lifting: - make sure all personnel is safely away and that no one can enter the area where the machine is being moved - make sure the load is stable - make sure there is no material which may fall when the parts are lifted - gradually lift in a vertical manner in order to avoid swaying and irregular movements. 3.2.2 HANDLING PROCEDURES
During handling operations, the load must remain on a perfectly horizontal plane regardless of the type of equipment being used. To facilitate the lifting and handling operations use bars, levers and ramps from a safe distance. Never use your hands. The person in charge must: - have a clear view of where the machine is to be moved - give instructions to the crane operator from a position where he/she can be clearly seen - stop the operation immediately if dangerous conditions arise (for example people passing by). 3.2.3 PLACING THE LOAD
Before placing the machine make sure the floor is perfectly level and is able to support the weight of the machine. Do not place the loads in areas where they could create a hazard, prevent the use of equipment or obstruct emergency exits: - factory exits, - fire fighting equipment, - passage areas, - control panels - power lines. The machine must be placed on suitable bars to make it stable so that the slings can be easily removed. Do not place worn containers or those with protruding parts on top of each other. Do not stack material at a dangerous height.
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3.3
3.3.1

INSTALLATION
GUIDELINES
E0004P
WARNING!
Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations in force in your country. The machine is to be installed on adequate concrete foundations as specified by SACMI. In particular, these concrete foundations should be able to withstand the static and dynamic loads applied by the press during operation. Cover the electrical conduit and raceways for the hydraulic lines and electrical wiring with non-slip cover plates made in compliance with current safety regulations. If the press comes equipped with a conventional knockout, the point of access to the pit where the knockout is installed must be covered up with fixed cover plates, i.e. that can be removed with the aid of suitable tools. Make sure there is enough space around the machine so that it can be operated and serviced easily. The area surrounding the machine must always be kept free of obstacles, clean, dry and well-lit. The lighting in the areas around the machine and, in particular, in the work zone should be efficient and have a level of illumination not less than 300 lux. The customer must make sure that fire-fighting equipment is provided in the area where the machine is installed and that there is a system for protection against voltage fluctuation in the electricity supply line. These must conform to laws currently in force in the country where the machine is installed. The manufacturer or authorized people is to install and commission the machine, therefore the respective instructions are not given in this user's manual.
E0007
WARNING!
Connect the machine to an effective earth-ground.
E0007
WARNING!
The electrical wiring does not come with a differential protective device unless expressly requested.
E0007
WARNING!
If electronic converters are present in the electrical control cabinet, the differential protective devices installed on the cabinets power supply line must be B type as specified by current safety standards.
E0004P
ATTENTION!
SACMI shall not be held responsible for any property damage or personal injury resulting from improper installation.
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3.4 OPERATOR TRAINING
E0004P
WARNING!
3.4.1
END-USER
The company using this equipment must see that their personnel: - match the requirements listed below - read and understand the manual in its entirety - are adequately instructed and trained on how to safely carry out their tasks - receive specific training on how to operate this machine correctly. 3.4.2 OPERATORS
The machine operator must: - understand the technology employed and have specific experience in operating this type of machine - be well educated enough to read and fully understand the contents of this manual as well as properly interpret the drawings provided - know all the safety rules and standards - general (hygiene and on-the-job safety, accident prevention) - specific (for the type of product handled by the machine) in force in the country where the machine is installed. Operator tasks The operator is only authorised use the controls and instruments provided on the machines control panel. 3.4.3 MAINTENANCE STAFF
The maintenance staff must be selected according to the same criteria as that indicated for the operators. In addition, they must be trained in specific technological areas (mechanical, electric, hydraulic and pneumatic) so that they can carry out the operations they are responsible for (as specified in the manual) in complete safety using suitable tools and equipment. Tasks for the maintenance staff The maintenance staff are responsible for carrying out the routine maintenance operations described in this manual. It is important that the members of staff carry out only the tasks in the areas they are specifically responsible for (mechanical, electric, pneumatic, etc.).
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3.5
3.5.1

OPERATING INSTRUCTIONS
SAFETY GUIDELINES
E0004P
WARNING!
The machine is equipped with electric and/or mechanical safety devices that safeguard the operating personnel as well as the machine. The press can be run within the limits determined by the manufacturer as long as these devices are operative and efficient. These limits are specified in the following chapters. In addition, these devices must not be removed or tampered with under any circumstances whatsoever. The control systems and safety devices installed can ensure operator safety only if a powder loading system approved by SACMI is used. In addition, only die-sets that employ one of the following systems for locking the upper punches can be used: mechanical, with permanent magnets and electromagnets, in the latter case a mechanical emergency system that prevents falling must be provided. The manufacturer of the pressing tool shall be held responsible for any damage or injury resulting from the pressing tool. The press can operate in three different modes by setting the mode selector to the desired position: automatic, manual and set-up. 3.5.2 AUTOMATIC OPERATION
When the press is running in automatic no operations need to be carried out by the operator. Hazardous areas (dieset area) are fully protected by fixed and mobile guards which make these areas totally inaccessible. In particular, the following are provided: - Fixed guards are mounted on the powder infeed system - Fixed guards at the sides of the press near the columns. The guards include an access door which can be opened with special tools, thus allowing the operator to visually check machine functioning without gaining access to hazardous areas of the machine. - Fixed guards are on the working parts of the filler box infeed system. The strokes of the filler box should be set when the machine is stopped. - Front safety bar with mobile guard. This bar is wired up to the microprocessor-based control system. When the bar is completely down, it prevents the operator from gaining access to the work areas during the production run. All the guards have been placed at a safe distance as recommended by current safety standards (EN 294). The front of the press must be safeguarded by installing the tile collector equipped with fixed safety guards that prevent access to the area where the die-set is found (figure 3.5.5) and limit switches that signal it is present in its work position. If the front safety bar is raised, two mechanical locks are engaged to prevent the plunger from abruptly moving down. This arrangement prevents the press from performing any hazardous powered movements which may harm the operating personnel. Moreover, the plunger can be raised so as to disengage the mechanical locks and allow single parts of the die-set to be moved so as to perform routine cleaning. 3.5.3 MANUAL OPERATION
When set to manual mode, the operator can control some movements of the press directly, for example to carry out semiautomatic cycles, test runs, etc... All the safety devices used during the automatic cycle must be on and operating. 3.5.4 SET-UP MODE
This mode of operation can be used only by the maintenance staff. When the machine is in set-up mode, the plunger can move up and down only at a low speed (less than 16 mm/s) so that the die-set can be replaced. In this case, the rear box feeder or the front tile transfer system can be moved to access the machine. However, no operations can be performed while the machine is running under any circumstances. Instructions on how to install the die-set are given in chapter 4, INSTALLATION. The press is equipped with two emergency stop buttons. One is located on the control panel while the other is placed at the back of the machine. Pressing one of these buttons immediately stops the machine and discharges the pump. In the event of an emergency always press one of these two buttons.
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3
WARNING!
E0004P
The operator who sets the press to set-up mode must keep the key to the selector switch in his/her pocket until special machine servicing has been completed. It is therefore important that just one copy of the key is available in the workshop to prevent more than one person from working on the machine at the same time. As most of the safety devices are inactivated, machine and personnel safety are at the hands of the operator who must be informed and clearly understand what he/she is responsible for.
3.5.5
INSTALLATION MODE
The diagram below shows the layout foreseen by the manufacturer for correct operation. The tile collector and handling device, is not an integral part of the machine however, safety is compromised if it is not present. The signal transmitted by the sensor must be in series with the other limit switches installed on the press. This collector should be equipped with an arm that activates the right and left safety guards of the press and be placed near the die-set, with less than 25 mm play on each side, to prevent access to the danger zone from the bottom. In addition it must be fitted with two limit switches SQ53a and SQ53b, hooked up as shown in the wiring diagram, that detect when the device is in place in its work condition. When the arm of the tile collector is not in place, therefore not in its work condition, the press can run only in SET-UP mode. The signal from these limit switches should be in series with the other limit switches installed in the press.
Figure 3.5.5 - RULES FOR OPERATION
POWDER FEED SYSTEM
TILE COLLECTOR
SQ53a SQ53b
C1327
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3
3.5.6

CLEANING
Stop the machine to clean the die set area. Follow the procedure below: - Stop the moving parts of the tile collector and back up the mobile arm so that the front of the die-set can be accessed. - Fully raise the plunger by pressing buttons 25 & 3 located on the control panel. - Raise the safety bar.
E0004P
WARNING!
When cleaning the die-set, the personnel must wear adequate clothing for protection against heat. For more thorough cleaning, perform the same procedures as recommended for maintenance.
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3.6
3.6.1
MAINTENANCE
GENERAL SAFETY RULES
WARNING!
E0001
Never inspect, repair or service moving parts. Clear warning signs should be attached near the parts in question to warn operators of the danger.
E0004P
WARNING!
Before attempting to carry out any operations on the machine, discharge the accumulators and wait until they are empty.
O2
E0004P
E0034D
WARNING!
The accumulators are to be precharged using only dry nitrogen in tanks with reducer. Use of compressed air and/or oxygen is severely forbidden.
E0007
E0010
WARNING!
Before performing any operations on the machine, including the replacement of components of the control panel or electrical cabinet, the maintenance staff must shut off the electricity supply by using the main switch located on the control panel. This switch should then be locked out with a padlock so that the machine cannot be accidentally started up.
E0007
WARNING!
The electrical cabinets and junction boxes installed on-board the machine contain live parts. As laid down by the EN 60204-1 directive, access to the electrical cabinet should only be possible with a special tool. This tool should be kept by one member of staff qualified and trained to work on live parts. When the electrical cabinet is energised, the only task that this member of staff should perform is to reset the circuit breakers.
E0007
WARNING!
Wherever plug-outlet connections are present, whether they are in the electrical control cabinets or junction boxes onboard the machine, they are to be disconnected only with the machine stopped and after shutting off power from the supply mains.
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3
E0007
WARNING!
Specific tools are to be used to connect and disconnect the conductors inserted in spring terminals.
WARNING!
E0017
When working on the machine never climb up on any part other than the service floor or ladders. The machine guards and enclosing barriers are not designed to bear the weight of a person. If climbed on, they may collapse causing personal injury and equipment damage.
E0004P
WARNING!
It may be necessary to temporarily remove or disable certain safety devices when making adjustments or servicing the machine. Once these operations have been completed, it is highly important that the safety devices are put back in place and reactivated before the machine is started up.
E0002
E0005
WARNING!
During operations, the electric motors can reach extremely high temperatures which would cause burning if touched. Always take the necessary safety precautions when working on the motors.
E0007
E0009
WARNING!
In order to ensure that the machine operates efficiently, safely and in a trouble-free manner always follow SACMIs instructions carefully. Carry out the scheduled maintenance operations exactly as described and at the time intervals recommended. In particular, regularly check all the safety devices for proper functioning. Also check the insulation of the electrical cables and replace if necessary.
E0004P
WARNING!
The user must restore the markings (conductors, terminals, devices, etc..), monitor signals and nameplates when no longer legible or if removed for any reason.
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3
3.6.2 NOTES REGARDING MAINTENANCE In order to guarantee top machine performance and efficiency, the scheduled maintenance operations indicated by SACMI must be carried out, as stated in chapter 8, MAINTENANCE. In particular, the following should be periodically performed: make sure all the safety devices and emergency stop buttons are in the right position and operate properly, check the insulation of the cables, replacing them if damaged and make sure the machine is effectively grounded. The maintenance staff is to be qualified as dictated in the OPERATOR TRAINING paragraph in this chapter. Before carrying out any operations, proceed as follows: 1) Move the plunger fully up by using buttons 25 and 3 located on the control keyboard. 2) Raise the safety bar by activating the lever on the side at the same time. 3) Press key 4 to shut off the main pump. 4) Press the emergency stop button. 5) Disconnect the machine from the mains electricity supply by turning the main switch to OFF. The main switch can be locked with a pad lock and key (not supplied with the machine) in the power off position to prevent it from being accidentally started. 6) Discharge service accumulator 12 by changing over die-set solenoid valves YV22 manually until the knockout no longer moves. 7) Discharge the upper accumulators by changing over cylinder pressure solenoid valve YV19 and/or downstroke and upstroke solenoid valves YV32s and YV32d simultaneously. 8) If accumulators 141 and 337 are present they must be discharged through valves 143 and 339.
E0004P
WARNING!
Before attempting to carry out any operations wait until the accumulators have been completely discharged.
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3.7

MACHINE NOT IN USE
E0004P
ATTENTION!
GENERAL RULES
3.7.1
When the machine is no longer to be used, make it inoperative by shutting off the electricity and air supplies etc. Use suitable safety devices. Thoroughly clean the entire machine, especially the working parts, and if necessary apply a protective lubricant. Close the electrical control cabinet doors and any machine access doors to prevent any parts being tampered with or dust getting in.
3.7.2
WHAT TO DO WHEN THE MACHINE IS NO LONGER USED
If the machine is no longer going to be used, it should be made inoperative by performing the following operations: 1) Move the plunger fully up by using buttons 25 and 3 located on the control keyboard. 2) Raise the safety bar by activating the lever on the side at the same time. 3) Press key 4 to shut off the main pump. 4) Discharge service accumulator 12 by changing over die-set solenoid valves YV22 manually until the knockout no longer moves. 5) Discharge the upper accumulators by changing over cylinder pressure solenoid valve YV19 and/or downstroke and upstroke solenoid valves YV32s and YV32d simultaneously. 6) If accumulators 141 and 337 are present they must be discharged through valves 143 and 339.
E0004P
WARNING!
Before attempting to carry out any operations wait until the accumulators have been completely discharged.
7) Disconnect the machine from the mains by unplugging the power cable.
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3.8 DISMANTLING
If the press is to be dismantled, follow the instructions given in chapter 9 - DECOMMISSIONING THE MACHINE.
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INSTALLATION
4 INSTALLATION
The machine is to be installed and started up only by persons authorized by SACMI. Figure 4.1 - LIFTING AND POSITIONING THE MACHINE
4.1
HOW TO LIFT AND PLACE THE PRESS IN POSITION
Use sling ropes and other suitable equipment when hoisting the press. Always follow the safety regulations in force in your country. To properly place the press, refer to the foundation plan provided before hand.
E0004P
WARNING!
Follow the instructions for hoisting the machine given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS. The load must always remain perfectly horizontal, regardless of the type of equipment used for hoisting, while it is being moved.
C0535
EQUIPMENT
E0009C
PH 690 PH 1000 PH 1500
kg 18.000 kg 27.000 kg 39.000
- Pair of slings - Pair of safety clamps
4.2
HOOKING UP AND CONNECTING THE MACHINE
The machine must be hooked up and connected only by specially trained personnel. Carefully follow the instructions provided by the manufacturer.
E0004P
WARNING!
As there are several electronic converters inside the electrical cabinet, make sure the ground fault circuit interrupters on the power supply are of the B type (as called for by CEI 64-8 standard article 532.2.1.4), thereby ensuring adequate protection against leakage currents.
4-1
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4
4.2.1
INSTALLATION
EARTHING THE MACHINE
E0004P
WARNING!
The machine (electrical control cabinet - press body - power unit - filler-box) has to be effectively earthed. Hook the machine up to the external protective circuit. The connection point marked PE (EN60445) is found beside the main shut off switch (see figure 4.2/B). The cross-section of the cable must be at least half that of the cabinets power cable.
In addition, hook up the connection points on the machine frame marked with symbol to the earth bar at the bottom of the electrical control cabinet (see figure 4.2/A). The cross-section of the cables must be at least half that of the largest heater cable.
(417-IEC-5019)
Connect the copper bar in the electrical control cabinet to the machine C and the cross-head to the plunger A-B. Join earth wires D and E as shown in the DIE-SET WIRING DIAGRAM figure. The points where the earth connections are to be made should be free of paint. Any paint present should be removed before the relative screws are tightened in order to ensure perfect electrical continuity.
E0004P
WARNING!
Failure to earth the machine may cause serious personal injury as well as equipment damage.
Figure 4.2/A - EARTH BAR IN ELECTRICAL CONTROL CABINET
Figure 4.2/C - EARTH CONNECTION
B
Figure 4.2/B - EARTH CONNECTION
C
C2783
F
EARTH BAR IN ELECTRICAL CONTROL CABINET
4-2
014AZ002A
INSTALLATION
4.2.2 INSTALLING AND REMOVING THE DIE-SET
The die-set can be installed on the press only by expert personnel as indicated in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS. Only die-sets which incorporate the punch locking systems listed below can be used: 1) mechanical lock 2) locking by means of permanent magnets 3) locking by means of electromagnets with a mechanical safety system The die-set can be installed either from the front or back of the machine. In both cases, enough space must be left free to move around so that the die-set can be manoeuvred conveniently. This can be done, for example, by removing the box feeder or the tile transfer system. Preliminary operations: a) move the plunger to its top dead center position b) raise the front safety bar c) select set-up mode d) thoroughly clean the mating surfaces of the press and die-set and lubricate them with oil. Two systems can be employed to bring the die-set inside the press: - by using a fork lift truck - with special equipment for example, carts fitted with lift systems and a roller surface.
E0004P
WARNING!
Whenever moving the die-set always observe the safety precautions for handling hanging loads.
Perform the following operations regardless of the means used to move the die-set. 1) Remove the die-set from the packaging using adequate lift systems. Place the die-set on 2 shims so that it is raised approximately 10 cm from the floor. 2) Protect the forks of the truck to prevent damaging the die-set. 3) Place the forks under the die-set Slightly raise it, making sure the forks lift it symmetrically in relation to the center of gravity. 4) Make sure the press and die-set are thoroughly clean. 5) Bring the die-set under the plunger, making sure the it is perfectly centered in relation to the press elements: press columns and plunger for centering lengthwise and crosswise). 6) Remove the forks of the truck from the press or the roller surface from the lower part of the die-set. To do this, raise the die-set in one of the following ways: a) if the die-set is mounted on SMU, it is provided with four rests so that it can be easily raised b) if the press is fitted with quick change devices, the die-set can be hooked to the plunger and then moved up c) if the press or die-set are not provided with autonomous lift devices, hydraulic cylinders can be used as long as they conform with current safety regulations.
E0004P
WARNING!
Devices that are not suitable for lifting the die-set for example, levers, shims, etc.. must never be used.
4-3
014AZ002A
4
INSTALLATION
7) Secure the base plate of the die-set to the press bed. 8) Move the front bar down.
NOTE: the machine is in set-up mode therefore it can run at a maximum speed of 16 mm/s.
E0004P
WARNING!
Never carry out any type of operation while the machine is running.
9) Move the plunger until it rests on the die-set. 10) Secure the upper part of the die-set to the plunger. 11) Hook up the die-set and connect it to the pneumatic system so that it can operate (see the CONNECTING THE DIE-SET HEATER and the MAGNETIC LOCK CONNECTIONS paragraphs). 12) Bring the die-set to the required temperature within the limits determined by the die-set manufacturers. 13) Center the punches. 14) Secure the punches in place with permanent magnets or electromagnets, in the latter case a mechanical emergency locking device must be installed. 15) Loosen and then retighten the fixing screws of the die and/or dies. 16) Move the punches a number of times to make sure they move freely. 17) Make sure any magnetic locks installed are properly set.
4.2.3
CONNECTING THE DIE-SET HEATER
E0004P
WARNING!
Make the connections as illustrated in figure 4.2.4 - DIE-SET WIRING DIAGRAM

The connections must be properly performed. Failure to do so may result in severe damage to the columns and cylinder. - Do not reverse the wires between the upper and lower heating element. - Connect both wires of the upper heating elements to the die set. Do not connect one wire to the die set and the other to the plunger. - Do not ground the secondary winding of the die-set heater transformers. - Make sure connection of the grounding cables is efficient.
4-4
014AZ002A
INSTALLATION
4.2.4 MAGNETIC LOCK CONNECTIONS
- Join the cables and connector XJ6 as shown in figure 4.2.4 - DIE-SET WIRING DIAGRAM.
E0004P
WARNING!
Reversing one or more wires may severely damage the machine.

Figure 4.2.4 - DIE SET WIRING DIAGRAM HEATER 510-511 Upper punch cables 514-515 Lower die cables 516-517 Lower punch cables D E MAGNETIC LOCK 911-912 Lower plate cable 921-922 Connector XJ6 (upper plate cables)
Lower punch holder-die ground cable Machine base-die ground cable VERSION WITH TRADITIONAL LIFT SYSTEM
921 922 XJ6
510 511 514 515 912 516 517 911

C0523
VERSION WITH SMU LIFT SYSTEM

921 510 511 514 515 516 517
922 XJ6 D E 912 911
C0524
4.2.5
DUST EXTRACTION SYSTEM
Join the various suction outlets to an efficient suction system sized according to the data provided by SACMI.
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4
INSTALLATION
4-6
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START-UP PROCEDURE
5
5.1
START-UP PROCEDURE
GENERAL
After the press, filler-box and die set have been properly installed, the following conditions will be present: the plunger will be raised and the safety bar will be up (limit switch SQ51 is activated while limit switch SQ52 is inactivated).
5.2
PRELIMINARY CHECKS
The numbers which identify the hydraulic, pneumatic and electric components in the descriptions below refer to figure 2.4.1/A HYDRAULIC/PNEUMATIC DIAGRAM. The functions of the pushbuttons and selector switches are illustrated in the figures in paragraph 6.1 - CONTROL DEVICES paragraph given in chapter 6 - OPERATING INSTRUCTIONS. 5.2.1 CHECKS TO BE MADE
PERFORM THE FOLLOWING: - Make sure the die-set heating elements are grounded and properly connected. - Make sure the upper and lower magnetic lock are properly set (the leds in buttons 11 and 15 must be on). - Make sure the press body is effectively grounded. Check the braid that connects the plunger to the crosshead for condition. - Make sure the oil level in the reservoir (on the top of the press) is correct. - Make sure the pressure in the hydraulic system is within the correct operating range indicated in paragraph 2.3.1 SPECIFICATIONS. - Make sure the tile thickness gauge is properly connected. - Make sure the filler-box limit switches and interlocks on the safety bar are properly wired and work as required. - Make sure the device that indicates filter clogged is properly wired. - Check the powder detector (located on the filler box feed hopper) for efficiency. - Make sure the controller and the tile transfer (placed immediately before the press) are properly connected (these conditions are to be fully satisfied when the machine is started or stopped). 5.2.2 MOTOR M11
Start motor-driven pump M11 to cool down the oil by pressing push-button 0 located on the control keyboard. Check the direction of rotation. 5.2.3 MOTOR M1
After pump M11 has run for at least three minutes, completely loosen the knob on safety valve 112a. Start main motor M1 by pressing pushbutton 0 located on the control keyboard. Turn off the motor after it has run for approximately two seconds by pressing pushbutton 4. While the motor is running check the direction in which it runs. Wait for it to stop and then restart motors M11 and M1. Allow the motor to run for a few seconds and then stop it. Repeat this operation several times and let the motor run if there are no troubles. Idle the motor for a few minutes, so that the air in the ducts and control assemblies can be let out. Keep key 28, on the control keyboard, pressed and gradually tighten the knob on valve 112a to increase the pressure in the circuit to approximately 100 bar. Make sure no oil leaks from the hose fittings.
5-1
014AZ002A
5
5.2.4
START-UP PROCEDURE
SETTING THE PUMP PRESSURE
FIXED DELIVERY PUMP Proceed as follows: - Disconnect solenoid valve YV11b/r (oil heating). - Start the main pump with the safety bar raised. - Completely loosen pressure control valve 112a. - Gradually tighten valve 112a while keeping button 28 pressed until the desired pressure is read on the gauge. Once the value has been reached, fully tighten the adjustment screw. Operating pressure (bar) 170 180
PH 690 PH 1000 - PH 1500
- Connect solenoid valve YV11b/r. As the oil has not reached the required temperature yet, the heating cycle will start. - Loosen pressure relief valve 10 completely, relieve the pressure in the upper accumulators and tighten valve 10 until the desired oil pressure (60 bar) is read on gauge 13. Once the value has been reached, fully tighten the adjustment screw. VARIABLE DELIVERY PUMP Set the safety pressure - operating pressure by following the instructions given in ADJUSTING THE VARIABLE DELIVERY PUMP in chapter 7 - ADJUSTMENTS. 5.2.5 TOP DEAD CENTER POSITION
Bring the plunger into its top dead center position by using the keys 3 and 25 on the control keyboard. The main cylinder should reach its top dead center position while the pressure in the hydraulic power unit, shown on pressure gauge 13, increases until the value set during testing, which is equal to the operating pressure, is reached. 5.2.6 SAFETY DEVICES
Lower the safety bar. The filler box can now perform its movements. Before starting operation, make sure the emergency stop buttons 24 work efficiently. 5.2.7 AUXILIARY CIRCUIT PRESSURE
Completely loosen the adjustment screw of pressure reducer valve 188. Make sure the pressure read in the auxiliary circuit (pressure gauge 67) does not exceed 50 bar. If it does, manually discharge accumulator 12 by activating solenoid valves YV21 and YV22. Press the button 28 used to apply pressure and tighten the screw of valve 188 until the pressure required in the auxiliary circuit (140 bar) is read on gauge 67.
5-2
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START-UP PROCEDURE
5.2.8 FILLER BOX
DCL
C1821
FILLER-BOX (DCL) Make sure: - The filler-box is correctly positioned and secured in place. - The slide plate is perfectly level with the die surface. - The filler-box guides are aligned and centered. - The mobile part of the filler-box is properly adjusted. - The brush is properly adjusted (if present). - The powder feeder (ALM) is properly adjusted. - All electrical connections have been properly made. - The safety guards are in place. Set the values for the end of the forward and return strokes (they represent the distance in millimeters in relation to the home position of the guides). Press keys 28 and 5 to zero set the filler-box encoder. Move the filler-box in manual mode to verify that the values entered for the end of the forward and return stroke are correct. Make sure limit switch SQ59 has been properly set. Limit switch SQ59 that provides the signal for the plunger to move down should be triggered only when the mobile part of the filler-box is out of the danger zone.
DCP
FILLER-BOX (DCP) FILLER-BOX ACTUATED BY A NON-PROPORTIONAL VALVE Set filler box control = NO. Set the speeds of the 10 filler box steps (from the 1st forward step to the fifth return step) to 100%. Start up the filler box by pressing keys 8, 27 and 29 at the same time. Block the flow regulator in this position. Operate the filler-box so that any air bubbles present can be eliminated from the hydraulic circuit. Carry out a few cycles in semi-automatic mode (press key F8 to select a semi-automatic loading cycle and then press buttons 28 and 2) making sure that the filler box always reaches the end of its stroke safely, i.e. the limit switch should be effectively triggered. Make sure that the filler box encoder setting shown on the display is lower than the value set for the end of the return stroke (usually a few mm). FILLER-BOX ACTUATED BY A PROPORTIONAL VALVE Set filler box control = NO. Set the GAIN item (RP2) to its max. value and set the speeds of the 10 filler box steps (from the 1st forward step to the fifth return step) to 100%. Start up the filler box by pressing keys 8, 27 and 29 at the same time. In any case, it must be greater than the presumed working speed. Block the flow regulator in this position. Set the GAIN item (RP2) to 50% and then operate the filler box so that any air bubbles can be removed from the hydraulic circuit. Carry out a few cycles in semi-automatic mode (press key F8 to select a semi-automatic loading cycle and then press buttons 28 and 2) making sure that the filler box always reaches the end of its stroke safely, i.e. the limit switch should be effectively triggered. Make sure that the filler box encoder setting shown on the display is lower than the value set for the end of the backward stroke (usually a few mm). Under the conditions described above (speed 100% and RP2 = 50%), the speed of the filler box must be at least equal to the max. operating speed required to produce tiles of the correct size. If it is not, increase RP2 until the desired speed is reached (Maximum acceptable value RP2 = 70%).
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5.3
5.3.1
START-UP PROCEDURE
MACHINE ADJUSTMENTS
ADJUSTING THE KNOCKOUT
C1819
SMU
ADJUSTING THE SMU KNOCKOUT Set the pressure for the cylinder (which holds the die) to approx. 80 bar when a die-set with through-punches is used (50 bar with a mirror-finished die set). To set the pressure, work on relief valve 253 and observe the reading given on pressure gauge 142. Set the speed at which the tiles are ejected by adjusting restrictor 61. To adjust the speed for the first die-set downstroke work on restrictor 23 until a suitable speed is obtained. To set the speed for the second die-set downstroke, adjust restrictor 242 until the die set rests on the base plate without banging on it. Check the first die-set downstroke by pressing buttons 13 and 30 once or twice so that the lower punch is ready to perform the second downstroke. Measure the distance between the lower punch and the upper surface of the die. If the distance is not correct, allow the die-set to rest on the base plate again by pressing push buttons 13 and 30. Push buttons 26 or 31, while keeping button 12 pressed, to increase or decrease the soft filling setting until the desired value is reached.

C2086
ADJUSTING THE TRADITIONAL ROD-TYPE KNOCKOUT Set the speed at which the tiles are ejected by adjusting restrictor 61. To adjust the speed for the first die-set downstroke, work on restrictor 23 until the movements are performed at the required speed. Set the speed for the second downstroke by adjusting restrictor 242 until the die-set gently rests on the lower plate without banging it. Check the first die-set downstroke by pressing buttons 13 & 30 once or twice so that the lower punch is set for the second downstroke. Measure the distance between the lower punch and the top surface of the die. If the distance is incorrect, allow the die-set to rest again on the base plate by pressing buttons 13 & 30 and buttons 26 or 31 (keeping button 12 pressed) in order to increase or decrease the soft filling setting until the desired value is reached.
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START-UP PROCEDURE
5.3.2 PRELIMINARY ADJUSTMENTS TO THE HYDRAULIC SYSTEM
The press is factory set before shipment. However, the information below is supplied to ensure that the original settings have not been accidentally altered. LOGIC ELEMENT CONTROL ASSEMBLY Preliminary adjustment Component Operated by PH 690 120 119 118 117 116 131 YV38 YV70 YV70 YV19 YV40 YV41 Fully open Open by 2 turns Fully open Fully open Open by 2.5 turns Open by 4 turns
Preliminary adjustment PH 1000 Open by 6 turns aperto 2 turns Fully open Open by 3.5 turns Open by2.5 turns Open by 5 turns
Preliminary adjustment PH 1500 Open by 6 turns Open by 2 turns Open by 10 turns Open by 3.25 turns Open by 2.25 turns Open by 5 turns
ACCUMULATOR CONTROL ASSEMBLY Preliminary adjustment Component Operated by PH 690 115 108 109 174 114 90 92 YV53 YV32s YV32d YV47 Fully open Open by 5.5 turns Open by 8 turns Open by 5 turns Fully open Open by 5.5 giri Open by 1 and 2/3 turns
Preliminary adjustment PH 1000 Open by 6 turns Open by 5 turns Open by 6 turns Open by 8.5 turns Open by 6 turns Open by 5.5 turns Open by 1 and 2/3 turns
Preliminary adjustment PH 1500 Open by 6 turns Open by 7.5 turns Open by 8.5 turns Open by 8.5 turns Open by 6 turns Open by 6.5 turns /
5-5
014AZ002A
5
5.3.3
START-UP PROCEDURE
ADJUSTING THE SPEED OF THE FILLER-BOX
DCL
C1821
FILLER-BOX SPEED SETTING (DCL) SETTING (DCL) Once the filler-box has been inspected for proper operation, set the speeds for each of the 5+5 steps which form the total stroke of the filler box (expressed in % from 0 to 100). This indicates the actual aperture of the control valve. An optimal speed range is thus determined in order to suit the product to be obtained. To properly load the powder, determine the position in which the filler-box must be when the die-set performs its first downstroke. Simulate a number of filler-box cycles in semi-automatic mode. Press pushbuttons 8 & 27 to check the filler-box for proper operation before loading the working material. If the value entered for the FILL.-BOX APPROACH POS. data item during the filler-box return stroke is greater than zero, plunger downstroke will be triggered once the FILL.-BOX APPROACH POS. setting has been passed. As soon as the filler-box reaches the end of its return stroke, the ALM cycle will start. The filler-box will reach the value set for the FILL.-BOX APPROACH POS. data item after the grid has been loaded. The filler-box will run at the set APPROACH SPEED. When set to manual mode, the filler-box runs at a constant speed equal to that set for SPEED IN MANUAL MODE. When set to automatic and semi-automatic modes, the filler-box runs at the set speeds. If the setting for FILL.-BOX APPROACH POS. is greater than zero, the 8 + 8 steps go from the FILL.-BOX APPROACH POS. to END OF FORW STROKE settings. The last step of the return stroke is performed at the speed used for the eighth step of the return stroke. The cycle can be set while the ALM is not working. Loading takes place while the ALM is stationary. In this case, the grid is loaded through filler-box operation. In this case, the FILLING STROKE will equal the APPROACH STROKE. POWDER INFEED (DCL) Properly set the ALM feeder (see relevant manual). Select the desired type of loading: grid loaded while the ALM is stationary or grid loaded with ALM running. Set the time for the DELAYED LOADING data item. This is the length of time the hopper gate stays open. Set the GATE CLOSING DELAY time. This is the amount of time which elapses from when the hopper reaches the position in which the gate closes and the gate actually closes. A special cycle can be selected if double rows of tiles have to be pressed. This is done by setting 2-ROW FILLING = YES. In this case, two values have to be entered in the PLC. The first refers to the point at which the gate closes during the stroke for loading the ALM. This gate opens again after the time set for OPENING DELAY has elapsed. Once the second value is reached, the time set for GATE CLOSING DELAY starts elapsing after which the gate closes definitively. Move the filler-box completely backward and let powder into the feed hopper. Set the number of strokes to be performed (from right to left) during each cycle (set 1 or 2 strokes. If 3 strokes are set the ACP will move non-stop). Fill the die-set a few times in semi-automatic mode and make the required modifications (if the loading cycle is found to be inaccurate). After this preliminary phase has been completed, leave the die cavities full of powder. The ALM can carry out an overtravel during its return stroke to zero set the filler-box encoder. This may also be useful when installing and removing the grid. Timed filler-box and knockout operations can also be carried out during loading. In particular, the knockout can perform up to 5 movements during the filler-box return stroke, starting from the 1st downstroke position. The following are set for each movement: filler-box setting at the start of the movement, degree to which the die-set moves, filler-box return stroke setting up to setting for 1st downstroke and die-set speed during the movement.
5-6
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START-UP PROCEDURE
5
DCP
FILLER-BOX SPEED SETTING SETTING (DCP) Two different systems can be used: FILLER-BOX ACTUATED BY A NON-PROPORTIONAL VALVE Once the filler box has been inspected for proper operation, set the speed levels for the 5 + 5 steps which form the total stroke of the filler box. These are expressed in %: - the filler-box will run at the min. speed if a value between 0 and 75% is set - the filler-box will run at the max. speed if a value between 75% and 100% is set An optimal speed range is thus determined in order to suit the product to be obtained. To properly load the powder, determine the position in which the filler box should be when the die-set performs its first downstroke. Press keys 8 and 27 at the same time to simulate various filler box cycles in semi-automatic mode to check the filler box for proper functioning before loading the powder. FILLER-BOX ACTUATED BY A PROPORTIONAL VALVE (OPTIONAL) Once the filler box has been inspected for proper operation, set the speed levels for the 5 + 5 steps which form the total stroke of the filler box. These are expressed in % from 0 to 100 which represent the degree to which the control valve is open in relation to its maximum opening. An optimal speed range is thus determined in order to suit the product to be obtained. To properly load the powder, determine the position in which the filler box should be when the die-set performs its first downstroke. Press keys 8 and 27 at the same time to simulate various filler box cycles in semi-automatic mode to check the filler box for proper functioning before loading the powder. POWDER INFEED (DCP) Two different systems can be used: FILLER-BOX WITH HOPPER AND ACP After the ACP device has been properly set up (see relevant manual), put powder into the filler box infeed hopper. Set the number of strokes to be carried out (from right to left) per cycle (1 or 2 strokes). If 3 is entered, the ACP will operate non-stop. FILLER-BOX WITH ALM MOBILE HOPPER Properly set the ALM device (see relevant manual). Set the delayed loading. This is the amount of time the hopper stays open before moving backwards. Set the gate closing delay. This is the amount of time which elapses from when the hopper reaches the position in which the gate closes (on the sensor) and the actual closure of the gate. Move the filler-box completely backward and place powder in the feed hopper. Set the number of strokes to be carried out (from right to left) per cycle (1 or 2 strokes). If 3 is entered, the ACP will operate non-stop. Fill the die-set a few times in semi-automatic mode and make the required modifications (if the loading cycle is found to be inaccurate). After this preliminary phase has been completed, leave the die cavities full of powder.
5-7
014AZ002A
5
5.3.4
START-UP PROCEDURE
PLUNGER BRAKING ADJUSTMENT
To check the value entered for plunger braking, observe the braking logic element value, which should be approx. 80. If it is not, allow the plunger to rest on the powder, press buttons 7 and 26 at the same time to increase the braking force or buttons 7 and 31 to decrease it until approximately 80 is read. At the beginning, inactivate the brake control (speed control on = NO) and set an adequate braking action (e.g.. braking space = 90.00) in order to have safe braking during the first stage. After filling the die-set with powder, perform some downstrokes, adjust the braking action and change the braking logic element setting until the desired braking force is obtained. Once the machine has been started up, the automatic brake control can be activated. To do this, check that the braking space is 70.00 (if it is less than 70.00, the automatic brake control cannot be switched on). After the die-set has been filled with powder, read the speed at which the punches come into contact with the powder. If it is suitable for the presscycle, type in YES for speed control on and enter the impact speed setting previously read. From this time on, the controller will correct the brake settings until the impact speed remains constant throughout the cycle. 5.3.5 PLUNGER MOTION SETTING
Read the setting for start of pressing (punches on the powder). Slowly lower the plunger until the punches come into contact with the powder, read the plunger encoder setting (expressed in mm and referred to the end of its upward stroke) and enter the setting given for start of pressing. Turn the key switch to WRITE to enter a high temporary safety value for indicating lack of powder (stoppage due to lack of powder = 140.00). In this case, the control will no longer be activated. Enter a setting for the end of the upward stroke (plunger up). Remember that the last setting should allow the filler box to move freely. Enter YES to brake during upstroke as well as the value for end of braking while the plunger moves up again. Allow the plunger to move up and down in manual mode with the die cavity full of powder. 5.3.6 SETTING THE PRESS-CYCLE
Enter the data related to the press-cycle. Enter the number of press-strokes per cycle, the pressure settings (expressed in bar) for the first, second and (if necessary) third press-strokes, the delay time (expressed in milliseconds) for the first press-stroke as well as the first and (if necessary) second de-aeration. These settings must be compatible with the size of the tiles to be obtained. Fill the die-set with new powder in semi-automatic mode (with selector 23 set to automatic, select semi-automatic loading by pressing key F8; then press pushbuttons 28 and 2 respectively). After making sure that the powder is evenly distributed in the die cavities, perform a press-cycle in semi-automatic mode with selector switch 23 set to automatic (to select the semi-automatic mode, press key F8 and push buttons 28 and 2 respectively). Fill the die-set ten times approx. and perform the same number of press-cycles in semi-automatic mode in order to eliminate the air in the hydraulic system and allow the automatic pressure regulators to make the required corrections. Once the tile has been properly formed, measure its thickness and adjust the height of the soft filling by pressing push buttons 26 (+) or 31 (-) with the die-set down and push-button 12 pressed to obtain tiles of the desired thickness. Once the desired thickness has been reached (thickness control on = NO, enter the measured tile thickness for the thickness displayed). Perform other press-cycles in semiautomatic mode and make sure that the measured thickness corresponds to that actually read. If it does, the automatic thickness gauge can be switched on (thickness control on = YES, tile thickness = desired thickness). 5.3.7 ADJUSTING THE DIE-SET PROTECTION DEVICE (FOR LACK OF POWDER)
Inspect the automatic thickness gauge for proper functioning. The tile must not be too thin as this may severely damage the die-set. Enter the setting for plunger stoppage because of lack of working material. This should be equal to the max. allowable stroke for the plunger during the press-cycle. Make sure that the plunger can move down an additional 0.5 mm in relation to a tile of the desired thickness. Once this setting has been entered, make sure that a fault message is actually displayed when the plunger moves below the preset level.
5-8
014AZ002A
START-UP PROCEDURE
5.3.8 ADJUSTING THE PLUNGER SHOCK ABSORBERS
With the plunger in its uppermost position and the safety bar raised, loosen the locknut and lower spring shock absorber pads 101. Fill the die-set with fresh powder, allow the punches to rest on it and raise the pads until they come into contact with the plunger. Bring the cylinder into its uppermost position, raise the safety bar and the pads by approx. half a turn and then secure the pads in place by using the locknuts provided. NOTE: Adjust the height of the shock absorbers whenever the punches or die-set are replaced.
5.3.9
AUTOMATIC WORK CYCLE
With the plunger completely down, check the oil level and make sure that the die-set has reached the desired temperature. Observe the displayed die-set temperature. With the temperature properly set, make sure that the die-set moves freely. Thoroughly clean the die and start the automatic work-cycle by pressing push buttons 28 and 2. During the initial work stages, keep the process zone under control so that emergency stop button 24 can be readily pressed in case of malfunctioning. If there are no problems, allow the machine to run for a few minutes. Stop the work cycle by pressing push-button 6 then check the finished product and make the required corrections. If tiles are to be ejected during the last cycle, enter ejection when stopping = YES, if not, ejection when stopping = NO. NOTE: the corrections which require adjustments to the press body and the filler box must be carried out with the machine turned off. Corrections to the data entered into the controller or any adjustments to the hydraulic components must be performed with the machine running. When good quality products are obtained, duplicate the program (see par. 4.9.5, Instructions B manual) and perform further adjustments to increase productivity.
5-9
014AZ002A
5
5.3.10
START-UP PROCEDURE
SWITCHING ON THE CONTROLLER TO MAINTAIN THE PRE-SET SPEEDS
DCL
C1821
SWITCHING ON THE FILLER-BOX SPEED CONTROLLER (DCL) Once the press has been started up and the tiles have been properly formed (i.e. the die-set has been loaded correctly), the speed controller is switched on (FILLER-BOX CONTROL ON = YES). At this point, set the filler-box forward and filler-box return times (this should correspond to the time previously measured to perform the forward and return strokes). The control system sees whether the time error is 5% greater than the set time. If this is the case, a fault message will appear.
DCP
SWITCHING ON THE SPEED CONTROLLER FOR FILLER-BOXES ACTUATED BY PROPORTIONAL VALVES(OPTIONAL) (DCP) The press comes with an electronic device which energizes solenoid valves YV20a to correct any interferences which may affect the speeds set for the powder feeder. When starting up the machine, switch off this control device (filler box control on = NO). When the press has been started up and the tiles are found to be properly formed (the die-set has been properly filled), the control is switched on (filler-box control = YES). Set the times for the filler box forward and return strokes (the times set should be the same as those previously read for the forward and return strokes). Check that the gain for the forward and return strokes falls within 145-155. If they are not, work on RP2 (in the controller) until the desired values are displayed (max. allowable value, RP2 = 70%).
5 - 10
014AZ002A
6
6.1
CONTROLS
The following are used to control and monitor press operations: - CONTROLLER All the controls necessary to operate the press along with the keys used to program the work-cycle are found here. - ELECTRICAL CABINET All the switches used to turn on the motors are located here. Figure 6.1/A - PH 690 CONTROLS
ELECTRICAL CABINET
CONTROLLER
Figure 6.1/B- PH 1000 - PH1500 CONTROLS
ELECTRICAL CABINET
CONTROLLER
E0004P
IMPORTANT!
All information about how to program and use the controller are given in Instructions B manual - Use of the microprocessor control system. The illustrations of the control keyboard and auxiliary control panel are not binding. The background colors and colors and shapes of the keys may vary according to the electric codes in force in the country of installation and color of the machine. However, the number and functions of the keys do not vary even if the colors are different.
6-1
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6
IMPORTANT - CYCLE PROGRAMMING refers to setting all the data required to perform an automatic work-cycle. - To access the programming mode, put the key into the switch found on the controller keyboard. - Only authorized personnel can gain access to the programming mode as altering the programmed data may cause severe damage to the machine. - It is advisable to keep a library of the programs loaded by using the sheets provided. 6.1.1 CONTROLLER
The microprocessor-based programmable logic controller is used to: - set up a work cycle and make modifications to the programmed work stages even when the machine is cycling. These operations are performed from the control keyboard. - display messages and typical process variables; - store and retrieve the data related to each pre-selected press cycle; - self-diagnosis; - automatically regulate the operating pressures; - automatically gauge the tile thickness; - automatically control the machine even in the event of system failure.
Figure 6.1.1/A - CONTROLLER
SYSTEM CARDS
COMPUTER TERMINAL MACHINE CONTROL KEYBOARD
INDICATOR LIGHTS AND SELECTORS
NOTE: A detailed description of each section is given on the following pages.

6-2
014AZ002A
Figure 6.1.1/B - (CONTROLLER) SYSTEM CARDS
SYSTEM CONFIGURATION Card location 1-4 5 6 7 8 9 10 11-12-13 14-15-16 17-18 19 20-21 AL CPU VA IA IE IE ID OD ODA OR POWER SUPPLY (rectified supply voltage) Central processing unit MISCELLANEOUS ANALOG INPUT ENCODER INPUT ENCODER INPUT (not used) DIGITAL INPUT (reads 24 Vdc external signals) DIGITAL OUTPUTS (energize the 24Vdc outputs) ANALOG & DIGITAL OUTPUTS (not used) RELAY OUTPUT
C1463
RACK - PLC
10 11 12 13 14 15 16 17 18 19 20 21
AL
CPU VA IA IE IE ID ID ID OD OD OD
ODA ODA
OR OR
DATA POWER SUPPLY
ALIMENTAZIONE
PROCESSING ELABORAZIONE
INPUTS INGRESSI
OUTPUTS
USCITE
The configuration given above is for reference purposes only. For more detailed information, refer to the INSTRUCTIONS B manual, chapter 2 LIST OF THE DEVICES.
6-3
014AZ002A
17
18
+5 R WD SL SC P A1 A2
25
MAN SET UP AUT
26
I
3 8 9 10 11 16
+
27
I 28
19-23
29
I
7 12 13 14 15 20 21 22
30 31
SMC 085-11-442
Figure 6.1.1/D1 - (CONTROLLER) MACHINE CONTROL KEYBOARD
24
SMC 085-11-409
6-4
+5 R OFF ON WD SL SC B A1 A2 WRITE
7
D
HOME PAG
8 5 +
E
SCREEN
9 6 3
F
QUIT DEL CHAR
Figure 6.1.1/C1 - (CONTROLLER) COMPUTER TERMINAL
4
C
1 0 G
END
2 .
DEL LINE E N T E R
PAG
H F5 F6 F7 F8
F1
F2
F3
F4
014AZ002A
Figure 6.1.1/C2 - (CONTROLLER) COMPUTER TERMINAL A B C D E F G H 25 line x 80 column electro luminescent display Function keys Numeric keypad Write enable key switch Not used Deletes last character typed in Deletes last line typed in Cursor keys
ELECTROLUMINESCENT DISPLAY The press comes with an electro luminescent display on which the following are displayed: - fault messages - machine configuration data - production data - actual settings - list of the programs - set points and any modifications made to them NOTE: To display data, consult MANUAL - B Figure 6.1.1/D2 - (CONTROLLER) MACHINE CONTROL KEYBOARD
OPERATION
Pump start Alarm reset Automatic cycle start Semi-automatic loading start Semi-automatic press cycle start Plunger up Plunger down Slow plunger upstroke Slow plunger downstroke Pump stop Repositioning Automatic cycle stop Braking force increase Braking force decrease Braking force decrease beyond end-stop Braking force increase beyond end-stop Assigns braking analog input offset Assigns braking analog input gain Filler-box forward Filer-box return Zero point of filler-box with connecting rod and crank mechanism encoder Punches in Punches out Upper die-set de-magnetization Upper die-set magnetization Thickness increase Thickness decrease Die-sets up Die-sets down Lower die-set de-magnetization Lower die-set magnetization Proportional knockout hook up End of proportional knockout hook up ALM semi-automatic mode C.P. semi-automatic mode Oil leak recovery pump start/stop ALM forward ALM reverse C.P. manual mode Emergency stop
1ST KEY
1 28* 28* 28* 25 30 25 30 4 28 26 31 28 and 26 and 25 and 30 and 29 27
2ND KEY+ KEY SWITCH
PUMP
2 2 2 3 3 3 3 5 6 7 7 7 7 7 7 8 8 8 9 9 11 11 12 12 13 13 15 15 16 16 17 18 20 21 21 22 24
AUT AUT AUT MAN/AUT MAN SET-UP SET-UP AUT MAN/AUT MAN/AUT SET-UP SET-UP SET-UP SET-UP MAN MAN SET-UP MAN/SET-UP MAN/SET-UP SET-UP SET-UP MAN/AUT MAN/AUT MAN/SET-UP MAN/SET-UP SET-UP SET-UP SET-UP SET-UP AUT AUT MAN MAN MAN
ON ON ON ON ON ON ON ON
31 28 26 31
ON ON ON ON ON
26+31 25 30 31 26 26 31 25 30 31 26 28 28 28 28 29 27 27 or 29
ON ON
ON ON ON ON ON ON
Note: * Press the F8 terminal key to set-up the cycle. + Two keys need to be pressed for almost all of the operations. However, only one key has to be pressed for some operations. In these cases, the number of the key to be pressed is given in the 2ND KEY column.
6-5
014AZ002A
C1421
17
18
+5 R WD
25
MAN SET UP
SL SC P A1 A2
26
I
3 8 9 10 11 16
+
AUT
27
I 28
19-23
29
I
7 12 13 14 15 20 21 22
30 31
SMC 085-11-442
Figure 6.1.1/F1 - (PERSONAL COMPUTER) MACHINE CONTROL KEYBOARD
24
SMC 085-11-449
6-6
B
Q O L ;
(
W S X
+
E D C " =
PAGE UP
R F V 7 8 5 2 "
> @ # %
&
T G B
*
Y H N 9 6 3 "
< ^
U J M + _ P : K
A Z
SPACE
A
CAPS LOCK
ESC TAB
4
1
SHIFT
ALT
INS
1
PAGE DOWN
CTRL BKSP
DEL
E N T E R
Figure 6.1.1/E1 - (PERSONAL COMPUTER) (OPTIONAL)
F1 F9 F10 F11
F2
F3
F4
F5
F6
F7
F8
014AZ002A
Figure 6.1.1/E2 - (PERSONAL COMPUTER) (OPTIONAL) A B C Color monitor Function keys Mouse
COLOR MONITOR The press comes with an electro luminescent display on which the following are displayed: - fault messages - machine configuration data - production data - actual settings - list of the programs - set points and any modifications made to them NOTE: To display data, consult MANUAL - B
Figure 6.1.1/F2 - (PERSONAL COMPUTER) MACHINE CONTROL KEYBOARD

OPERATION
Pump start Alarm reset Automatic cycle start Semi-automatic loading start Semi-automatic press cycle start Plunger up Plunger down Slow plunger upstroke Slow plunger downstroke Pump stop Repositioning Automatic cycle stop Braking force increase Braking force decrease Braking force decrease beyond end-stop Braking force increase beyond end-stop Assigns braking analog input offset Assigns braking analog input gain Filler-box forward Filer-box return Zero point of filler-box with connecting rod and crank mechanism encoder Punches in Punches out Upper die-set de-magnetization Upper die-set magnetization Thickness increase Thickness decrease Die-sets up Die-sets down Lower die-set de-magnetization Lower die-set magnetization Proportional knockout hook up End of proportional knockout hook up ALM semi-automatic mode C.P. semi-automatic mode Oil leak recovery pump start/stop ALM forward ALM reverse C.P. manual mode Emergency stop
1ST KEY
1 28* 28* 28* 25 30 25 30 4 28 26 31 28 and 26 and 25 and 30 and 29 27
2ND KEY+ KEY SWITCH
PUMP
2 2 2 3 3 3 3 5 6 7 7 7 7 7 7 8 8 8 9 9 11 11 12 12 13 13 15 15 16 16 17 18 20 21 21 22 24
AUT AUT AUT MAN/AUT MAN SET-UP SET-UP AUT MAN/AUT MAN/AUT SET-UP SET-UP SET-UP SET-UP MAN MAN SET-UP MAN/SET-UP MAN/SET-UP SET-UP SET-UP MAN/AUT MAN/AUT MAN/SET-UP MAN/SET-UP SET-UP SET-UP SET-UP SET-UP AUT AUT MAN MAN MAN
ON ON ON ON ON ON ON ON
31 28 26 31
ON ON ON ON ON
26+31 25 30 31 26 26 31 25 30 31 26 28 28 28 28 29 27 27 or 29
ON ON
ON ON ON ON ON ON
Note: * Press the F11 terminal key to set-up the cycle. + Two keys need to be pressed for almost all of the operations. However, only one key has to be pressed for some operations. In these cases, the number of the key to be pressed is given in the 2ND KEY column.
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6
Figure 6.1.1/G - (CONTROLLER) SELECTORS AND INDICATOR LIGHTS HL300 SA1 SA2 SA300 Indicator light, Stand-by and automatic start up on (optional) Selector switch, Punch overtravel Selector switch, Rod release Selector switch, Automatic start-up (optional)
HL300
SA1
SA2
SA300
C1136
6-8
014AZ002A
6.1.2 ELECTRICAL CABINET
The electrical cabinet supplies electricity to the motors installed in the hydraulic power unit and press as well as to the die-set heater.
Figure 6.1.2 - ELECTRICAL CABINET A Ammeter QS1 Main switch V Voltmeter (*) Optional
(*)
QS1
C1235
6-9
014AZ002A
6
6.2
6.2.1
START UP AND SHUT DOWN PROCEDURES
DAILY START UP
The machine is started up by pressing key 0 on the keyboard which first starts the recirculation pump and then the main motor.
E0004P
WARNING!
Never press push-button 28 on the controller during start up.

Consult the Instructions B Manual when starting the machine in automatic mode. 6.2.2 STOPPING THE MACHINE
The machine can be stopped in two ways: - from the controller, by pressing key 6; - from the outer shut down circuit (KA300). 6.2.3 EMERGENCY STOP
The machine is provided with two emergency stop buttons. One is located on the machine control keyboard while the other is found on the back of the machine. When pressed, these red mushroom-head buttons stop the machine as well as all of the equipment placed before it. The following takes place when these buttons are pressed: - the hardware of the solenoid valves that control the plunger is disabled; - the hardware of the motors that drive the powder loading system is disabled; - the hardware of the hydraulic power unit motors is disabled. Consequently, the machine immediately shuts down and accumulator 12 of the service control assembly. Accumulators 18 and 27 of the brake control assembly have to be manually discharged with cock 153 and accumulators 141 and 337, if present, through valves 143 and 339. Once the machine has stopped, it can be restarted as follows: - bring the emergency stop button back into its original position; - reset the machine; - carry out the operations given in paragraph 6.2.1.
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014AZ002A
6.3 DIAGRAMS ILLUSTRATING PRESS OPERATION
PH 690 PRESSURE-LOADS GRAPH The total pressure applied by the press results from the pressure exerted by the central cylinder F. The pressure setting for the central cylinder is marked in the P column. The corresponding thrust F can be read in the left-hand column by drawing a horizontal line. Once the total thrust has been found F, the value must be marked at the ordinates in the graph. When the dimensions of the unfired tiles and the number of die cavities are known, the total surface area to be pressed S can be found. The value expressed in sq.cm is recorded at the abscissa. The line which passes through the point (whose co-ordinates are the two values previously found) indicates the specific pressure applied to the tiles.
Figure 6.3/A - PH 690 PRESSURE-LOAD GRAPH
5-200 x 200 6-150 x 200 2-300 x 300 F (kN) 6000

60 00
50 00
00 30
2-330 x 330 4-250 x 250 P (bar) 306
6-150 x 150
9-100 x 200
40 00
5000
00 20
254
4000
cm N/
2
203
3000
0 100
153
2000
102
1000
51
200
600
1000
1400
1800
2200
400
800
1200
1600
2000
2400
2600
S (cm2)
2800
C0528
Cylinder cross-section = 1963.5 sq.cm
6 - 11
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6
PH 1000 PRESSURE-LOAD GRAPH The total pressure applied by the press results from the pressure exerted by the central cylinder F. The pressure setting for the central cylinder is marked in the P column. The corresponding thrust F can be read in the left-hand column by drawing a horizontal line. Once the total thrust has been found F, the value must be marked at the ordinates in the graph. When the dimensions of the unfired tiles and the number of die cavities are known, the total surface area to be pressed S can be found. The value expressed in sq.cm is recorded at the abscissa. The line which passes through the point (whose co-ordinates are the two values previously found) indicates the specific pressure applied to the tiles.
Figure 6.3/B - PH 1000 PRESSURE-LOAD GRAPH
2-330 x 330 8-150 x 150 F (kN) 2-300 x 300 7-160 x 160 10.000 5-215 x 215 6-200 x 200
4-270 x 270 5-250 x 250 5-2105x 330 6-200 x 300 P (bar) 352
9000
318
8000
282
7000
248
6000
60
212
50
00 30
00
00
40
00
5000
2 0 00
176
4000
N/ cm
2
142
3000
1 000
106
2000
70
1000
35
1000
1400
1800
2200
2600
3000
3400
1200
1600
2000
2400
2800
3200
3600
3800
200
600
S (cm2)
4000
400
Cylinder cross-section = 2827 sq.cm
800
C0772
6 - 12
014AZ002A
6
PH 1500 PRESSURE-LOAD GRAPH The total pressure applied by the press results from the pressure exerted by the central cylinder F. The pressure setting for the central cylinder is marked in the P column. The corresponding thrust F can be read in the left-hand column by drawing a horizontal line. Once the total thrust has been found F, the value must be marked at the ordinates in the graph. When the dimensions of the unfired tiles and the number of die cavities are known, the total surface area to be pressed S can be found. The value expressed in sq.cm is recorded at the abscissa. The line which passes through the point (whose co-ordinates are the two values previously found) indicates the specific pressure applied to the tiles.
Figure 6.3/C - PH 1500 PRESSURE-LOAD GRAPH
4-275 x 275 7-150 x 300 4-275 x 275 3-330 x 330 5-210 x 315 7-150 x 150 5-220 x 220
9-110 x 220 5-220 x 330 4-275 x 275 2-440 x 440 4-220 x 440 3-360 x 360 1-650 x 650
F (kN) 15000
P (bar) 340
14000
50 00
45 00
40 00
317
35 q cm N/ 00
0 30 0
12000
271
2500
10000
2000
228
8000
1500
179
6000
133
4000
1000 1500 2000 2500 3000 3500 4000 4500 5000
91 S (cm2)
C1250
Cylinder cross-section = 4417 sq.cm
6 - 13
014AZ002A
6
6.4
AUTOMATIC CYCLE
In the descriptions below, the numbers and symbols used to identify the hydraulic, pneumatic and electric components refer to figure 2.4 - HYDRAULIC DIAGRAMS. 6.4.1 FILLER-BOX START
DCP
START OF FILLER-BOX OPERATED BY A TWO-SPEED VALVE Solenoid valves YV20a and YV20b are energized when the two cycle start keys (28 & 2) are pressed. The oil provided by pump 58 and service accumulator 12 passes through valves YV20a and YV20b and starts hydraulic motor 42. The motor combined with the gears drive the filler-box. The microprocessor control system allows eight different speeds for the forward and return strokes to be set. Limit switch SQ59, mounted on the filler-box frame, and must be de-energized after the latter has traveled a few millimeters forward. This will prevent the plunger from moving down until the switch is triggered by the filler-box during its return stroke. This will happen a few millimeters before the filler-box stops in its initial start position, i.e. when the encoder reaches the set value. It is important that the position at which solenoid valves YV20a and YV20b are de-energized and the point where the crank stops are within the operating range of limit switch SQ59 (see figure 6.4.1/A). START OF FILLER-BOX OPERATED BY A PROPORTIONAL VALVE (OPTIONAL) Solenoid valves YV20a and YV20s are energized when the two cycle start keys (28 & 2) are pressed. The oil provided by pump 58 and service accumulator 12 passes through proportional flow control valves YV20a and YV20s and starts hydraulic motor 42. The motor combined with the gears drive the filler-box. The microprocessor control system allows eight different speeds for the forward and return strokes to be set. Limit switch SQ59, mounted on the filler-box frame, and must be de-energized after the latter has traveled a few millimeters forward. This will prevent the plunger from moving down until the switch is triggered by the filler-box during its return stroke. This will happen a few millimeters before the filler-box stops in its initial start position, i.e. when the encoder reaches the set value. It is important that the position at which solenoid valves YV20a and YV20s are de-energized and the point where the crank stops are within the operating range of limit switch SQ59 (see figure 6.4.1/A).
DCL
C1821
FILLER-BOX START-UP (DCL TYPE) Press the two cycle start keys 28 and 2 to start the filler-boxs electric motor (M20). This motor drives the mobile part of the filler-box through the belts provided. Eight different speeds can be set for the forward and return strokes from the microprocessor control system. Limit switch SQ59, located on the fixed filler-box mount, should be released after the box feeder has moved a few millimeters forward, thereby preventing the plunger from moving down until it is triggered by the filler-box while carrying out its return stroke a few millimeters before stopping in the initial start position, i.e. when the encoder reaches the value set for the end of the return stroke.
6 - 14
014AZ002A
Figure 6.4.1/A - FILLER-BOX START-UP ASYNCHRONOUS OPERATION C Cranks range of action T Tolerance to be observed when repositioning the filler-box back 0 Theoretical position of the filler-box when back FC Allowable position when the filler-box is back
T
SQ59 PREMUTO TRIGGERED
0% C
FC
SQ59 NOT NON TRIGGERED PREMUTO
100%
C0351
6 - 15
014AZ002A
6 - 16
YV99 YV40 YV41 YV70 YV53 YV21 YV22 YV20s YV221 YV20a
SQ3
SQ6
YV38
Figure 6.4.1/B - PH 690 - PH 1000 - PH 1500 BAR CHART
YV47 YV47a (solo PH690) (PH690 only) YV19
(solo PH1500) (PH1500 only)
SQ61
SQ60
SQ59
YV32s
YV32d
START CARRELLO FILLER-BOX START
INIZIO PRIMA CADUTA STAMPO E2 = C15 START OF FIRST DIE-SET DOWNSTROKE FINE CADUTA END PRIMA OF FIRST DOWNSTROKE
END OF FILLER-BOX TRAVEL - START OF DOWNSTROKE/HOPPER GATE OPENING FINE CARRELLO - INIZIO DISCESA / APERTURA SERRANDA TRAMOGGINO FINE CADUTA STAMPO END 2 OF SECOND DIE-SET DOWNSTROKE
INIZIO FRENATURA START OF BRAKING ARRIVO SULLA PUNCHES ON POLVERE POWDER INIZIO PRIMA PRESSATA START OF FIRST PRESS-STROKE
elettrovalvola eccitata solenoid valve energized solenoid valve energized if the related options have been selected elettrovalvola eccitata se sono selezionate le relative opzioni
FINE PRESSATA END PRIMA OF FIRST PRESS-STROKE DECOMPRESSIONE-DEAERAZIONE DECOMPRESSION - DE-AERATION FINE END DEAERAZIONE OF DE-AERATION INIZIO PRESSATA DIRETTA START OF DIRECT PRESS-STROKE FINE SALITA END RITARDO OF DELAY TIMESTAMPI FOR DIE-SET UPSTROKE INIZIO PRESSATA MOLTIPLICATORE START OF PRESS-STROKE (WITH PRESSURE BOOSTER)
END OF SECOND PRESS-STROKE FINE 2 PRESSATA FINE SALITA END RITARDO OF DELAY TIMESTAMPI FOR DIE-SET UPSTROKE INIZIO SALITA START OF UPSTROKE
FINE STAMPI END SALITA OF DIE-SET UPSTROKE FINE SALITA FRENATA
END OF UPSTROKE WITH BRAKE APPLIED END SALITA OF UPSTROKE FINE HOPPER GATE CLOSURE CHIUSURA SERRANDA TRAMOGGINO
C2211
014AZ002A
6.4.2 POWDER INFEED
DCP
POWDER INFEED (DCP) The powder can be fed in the following ways: - a feed hopper with a fixed opening; the powder is fed by gravity and no parts are brought into operation during the cycle. - a feed hopper with fully controlled opening; the hopper gate is controlled by sensors located on the filler-box and solenoid valve YV221. The operator can thus adjust the amount of powder loaded onto the mobile grid of the box feeder during its travel by changing the position of the sensors and setting different times for LOADING DELAY TIME and GATE CLOSING DELAY TIME.
DCL
C1821
POWDER INFEED (DCL) The powder can be fed by a hopper. Hopper opening is controlled and can be adjusted: the hopper gate is controlled by the sensors located on the filler-box and solenoid valve YV221. The operator can therefore adjust the amount of powder let into the filler-boxs grid while carrying out its stroke by varying the position of the sensors and adequately setting the times for the LOADING DELAY TIME and GATE CLOSING DELAY TIME data items. 6.4.3 FIRST DIE-SET DOWNSTROKE
C1819
SMU
WITH SMU LIFT SYSTEM While the filler-box moves forward, the encoder records the loading position (the relevant setting can be entered into the microprocessor control system) according to the setting for the first downstroke. At this point, solenoid valve YV22 is de-energized, causing the oil to flow from pump 58 and accumulator 12 to the upper part of cylinders 180. Meanwhile, the oil coming from the lower part of cylinders 180 is drained through solenoid valve YV22. Pilot operated check valve 62 allows the fast downstroke to be performed. The speed for the downstroke can be adjusted with flow regulator 23 (directly mounted on the line). The lower punches stop moving when they reach a limit stop formed by cylinders 181. Solenoid valve YV21 stays on throughout the whole stage. In this way, the die-set performs its 1st downstroke, i.e. the cavity which will be filled with powder (on the grid of the filler box) is created by gravity. It is important that the 1st downstroke setting is correct as it determines when the powder is to be dropped and consequently the lower cavity filled. In addition, this operation depends on a number of other factors, e.g. the speed of the filler-box which is governed by proportional flow control valve YV20a. During this phase, sensor SQ3 must be de-energized (lower punches raised) and the cam brought opposite SQ6. If this does not happen, the machine stops and a fault message will appear on the display.
6 - 17
014AZ002A
6

C2086
PH 690 WITH TRADITIONAL LIFT SYSTEM While the filler-box moves forward, the encoder records the loading position (the relevant setting can be entered into the microprocessor control system) according to the setting for the first downstroke. At this point, solenoid valve YV22 is de-energized draining cylinder 55. Pilot operated check valve 62 allows the fast downstroke to be performed. The speed for the downstroke can be adjusted with flow regulator 23 (directly mounted on the line). The lower punches stop moving when they reach a limit stop formed by cylinders 56. Solenoid valve YV21 stays on throughout the whole stage. In this way, the die-set performs its 1st downstroke, i.e. the cavity which will be filled with powder (on the grid of the filler box) is created by gravity. It is important that the 1st downstroke setting is correct as it determines when the powder is to be dropped and consequently the lower cavity filled. In addition, this operation depends on a number of other factors, e.g. the speed of the filler-box which is governed by proportional flow control valve YV20a. During this phase, sensor SQ3 must be de-energized (lower punches raised) and the cam brought opposite SQ6. If this does not happen, the machine stops and a fault message will appear on the display. PH 1000 - PH 1500 While the filler-box moves forward, the encoder records the loading position (the relevant setting can be entered into the microprocessor control system) according to the setting for the first downstroke. At this point, solenoid valve YV22 is de-energized so that oil flows from pump 58 and accumulator 12 to the top part of cylinders 55. Meanwhile, the oil coming from the lower part of cylinders 55 is drained through solenoid valve YV22. Pilot operated check valve 62 allows the fast downstroke to be performed. The speed for the downstroke can be adjusted with flow regulator 23 (directly mounted on the line). The lower punches stop moving when they reach a limit stop formed by cylinders 56. Solenoid valve YV21 stays on throughout the whole stage. In this way, the die-set performs its 1st downstroke, i.e. the cavity which will be filled with powder (on the grid of the filler box) is created by gravity. It is important that the 1st downstroke setting is correct as it determines when the powder is to be dropped and consequently the lower cavity filled. In addition, this operation depends on a number of other factors, e.g. the speed of the filler-box which is governed by proportional flow control valve YV20a. During this phase, sensor SQ3 must be de-energized (lower punches raised) and the cam brought opposite SQ6. If this does not happen, the machine stops and a fault message will appear on the display.
6 - 18
014AZ002A
6.4.4 FILLER-BOX OPERATION
DCP
FILLER-BOX OPERATION WITH A TWO-SPEED VALVE The encoder detects the position of the filler-box while it is moving. The speed range for the filler-box can be set by entering values for the 5+5 steps of the forward and return strokes in the microprocessor-based control system. A low and high speed can be set: - If a value between 0 and 75% is entered, YV20a is energized and the filler-box runs at low speed. Use the restrictor valve mounted on YV20b to adjust. - if a value between 76% and 100% is entered, YV20a and YV20b are energized. As a result, the highest speed for the filler-box is obtained which can be adjusted through flow control 24. Valves YV20a and YV20b provide a link between accumulator 12 and motor 42 changing the speed according to the values entered and position of the potentiometer. FILLER-BOX OPERATION WITH A PROPORTIONAL VALVE (OPTIONAL) The encoder detects the position of the filler-box while it is moving. It is possible to decide the speed profile for the filler box by entering the set points for the 5+5 steps of the forward and return strokes (1) into the microprocessor-based control system. To vary all the speeds proportionally, set the GAIN (RP2) (2) data item accordingly. Proportional valve YV20a will control the oil flow from accumulator 12 to motor 42 according to the set points entered. NOTE: (1) The set points are values which range from 0 to 100% and provide a speed range for each individual step. (2) The set point works on the voltage output in the microprocessor control system, making the signal which reaches the valve stronger or weaker.
DCL
C1821
FILLER-BOX OPERATION (DCL) The encoder detects the position of the filler-box while it is moving. The speed range for the filler-box is determined by entering the set points for the 5+5 steps of the forward and return strokes (1) in the microprocessor-based control system. NOTE: (1) The set points are values which range from 0 to 100% and provide a speed range for each individual step.
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6.4.5
SECOND DIE-SET DOWNSTROKE
C1819
SMU
WITH SMU LIFT SYSTEM The filler-box continues to move until it reaches the end of its pre-determined stroke. At this point, solenoid valves YV21 and YV20s are de-energized whereas solenoid valve YV20a is assigned the OFF SET value. While solenoid valve YV21 is de-energized, cylinders 181 for the 2nd downstroke are drained. With solenoid valve YV22 de-energized, the oil delivered increases the pressure in the die-set return cylinder 180. As a result, the pressure generated within the cylinder 181 causes the oil to flow out though flow regulator 242 and solenoid valve YV21 so that the die-set can perform its downward movement. Work on plate-mounted flow regulator 242 to govern the movement. During this phase, it is essential that sensor SQ6 continues to be energized by the respective cam. If it is not, the press automatically stops working and a fault message will appear on the display (refer to the Instructions B Manual). The setting entered for the end of the return stroke will cause the filler box to stop in its rest position. Before the filler box stops moving, safety switch SQ59 must be triggered. The respective Led, located on the front panel of the microprocessor control system (KA59) should go out.

C2086
PH 690 WITH TRADITIONAL LIFT SYSTEM The filler-box continues to move until it reaches the end of its pre-determined stroke. At this point, solenoid valves YV21 and YV20s are de-energized whereas solenoid valve YV20a is assigned the OFF SET value. While solenoid valve YV21 is de-energized, cylinders 56 for the 2nd downstroke are drained. Thanks to the springs pressure is exerted on cylinder 56 causing the oil to flow through flow control 242 and YV21. As a result, the die-set carries out its second downstroke. Adjustments are made by working on plate-type flow control 242. During this phase, it is essential that sensor SQ6 continues to be energized by the respective cam. If it is not, the press automatically stops working and a fault message will appear on the display (refer to the Instructions B Manual). The setting entered for the end of the return stroke will cause the filler box to stop in its rest position. Before the filler box stops moving, safety switch SQ59 must be triggered. The respective Led, located on the front panel of the microprocessor control system (KA59) should go out. PH 1000 - PH 1500 The filler-box continues to move until it reaches the end of its pre-determined stroke. At this point, solenoid valves YV21 and YV20s are de-energized whereas solenoid valve YV20a is assigned the OFF SET value. While solenoid valve YV21 is de-energized, cylinders 56 for the 2nd downstroke are drained. The oil pressure delivered by solenoid valve YV22 when de-energized is in cylinder 55 used for the die-set return stroke. As a result, pressure is exerted on cylinder 56 causing the oil to flow through flow control 242 and YV21. As a result, the die-set carries out its second downstroke. Adjustments are made by working on plate-type flow control 242. During this phase, it is essential that sensor SQ6 continues to be energized by the respective cam. If it is not, the press automatically stops working and a fault message will appear on the display (refer to the Instructions B Manual). The setting entered for the end of the return stroke will cause the filler box to stop in its rest position. Before the filler box stops moving, safety switch SQ59 must be triggered. The respective Led, located on the front panel of the microprocessor control system (KA59), should go out.
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6.4.6 ADDITIONAL DIE-SET DOWNSTROKE (OPTIONAL)
An intermediate rest for the lower punches allows the powder to be loaded so that two layers can be formed. The punches first rest on cylinders 189, allowing the die-set to perform its downward stroke. At this point, solenoid valve YV170 is de-energized while solenoid valve YV21 stays on. The powder is then loaded so that a second layer can be formed. The punches rest on the press table after solenoid valve YV21 has been de-energized. The speed at which the additional downstroke is performed is governed by plate-mounted flow regulator 169. The cavity can be filled twice when a second filler box triggers a press-cycle at the end of its stroke. 6.4.7 FAST DOWNSTROKE
The following conditions must be satisfied in order for the plunger to start its downward movement: - Sensor SQ6 activated (lower punches down) - Limit switch SQ59 triggered by the box feeder when fully backward. Under these conditions, the microprocessor control system must receive an electric pulse from solenoid valve YV32d. This will relieve the pressure in the rear part of the cone on logic element 109. At this point, the combined weight of the plunger-and-cylinder assembly and the pressure that the air contained in pre-filling tank 126 exerts generates a pressure in the annular chamber of the cylinder. This pressure will overcome the push of the spring, thus opening logic elements 174 and 109. The oil can thus be drained through the annular chamber. The oil will encounter little resistance along its passage. As a result, the main cylinder will begin its downstroke as the air pushes the oil in the pre-filling tank through the ports in the pressure booster located in the main cylinder. The speed, during this part of the downstroke can be adjusted by opening the cone of logic element 109. To do this, work on the adjuster provided. In any case, as this adjustment is used to bring the upper punches close to the powder to be pressed, it is advisable to select the highest possible speed which can be used. 6.4.8 DOWNSTROKE WITH BRAKE APPLIED
As soon as the plunger exceeds the setting entered for start of braking solenoid valve YV47 will be energized. As a result, the oil under pressure will flow from accumulators 27 and 18 to the back part of the cone of logic element 174. This will cause the nozzle (found beneath the pressure line of solenoid valve YV47) to shut the logic element in a pre-determined time. The oil will have to pass through flow control 132 (which is motor-operated) and because of its small size, slows down the downward movement of the plunger, thus creating a back-pressure for braking. Pressure relief valve 92 is a protective device which reduces the peak pressures; therefore it must not be used to adjust the brake system. To adjust the speed at which the upper punches come into contact with the powder contained in the cavity, it is necessary to set speed control on = YES in the Microprocessor control system. After this has been done, set the impact speed to the desired setting in mm/sec. The automatic speed control can be used only if there is a braking space of 70 mm. The program comes with a corrective function which, when activated, detects the impact speed and compares it to the set one, thus altering the settings of flow control 132 by means of motor M15. The speed control during braking can be turned off by entering speed control on = NO. The braking length can be varied by setting the following data items: - BRAKING IN PRESSING = YES. Braking is shut off by de-energized YV47 when the 2ND PRESS-STROKE WITH BOOSTER is started. - BRAKING IN PRESSING = NO. Braking is shut off by de-energized YV47 when the 1ST PRESS-STROKE is started. 6.4.9 DELAY TIME FOR THE 1ST PRESS STROKE
The plunger will continue to move down at the braking speed until the upper punches come into contact with the powder contained in the die cavities. While the upper punches are being brought near the powder, the encoder will reach the setting entered to start the pressstroke a second before the upper punches come into contact with the powder contained in the die cavities. This time corresponds to the start of the delay time for the 1st press-stroke. The length of the delay time is entered in the microprocessor control system. Throughout this period, the weight of the cylinder and plunger as well as the pressure exerted by the compressed air is applied on the powder contained in the die cavities. In this way, the powder is compacted for the first time and a certain amount of air is let out. This operation is very important to obtain good deaeration in the next process stages.
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6.4.10
FIRST PRESS-STROKE
Once the delay time (for the 1st press stroke) has elapsed, the 1st press stroke will begin. The required pressure is set and measured by pressure transducer BP1. The program which runs the microprocessor-based control system monitors the operating pressure, compares it with the set one and, if there are any deviations, corrects them. The hydraulic circuit will now be examined. The microprocessor-based control system transmits a signal to solenoid valve YV40 (1st press-stroke) which is then energized, allowing logic element 116 to open. The logic element permits the oil which comes from pump 58 and accumulators 18 & 27 to flow to pressure booster assembly 125. The flow rate of the oil can be regulated along with the working speed of the press by turning the adjuster on logic element 116. Accumulators 18 & 27 are brought into action by logic element 115 that is operated by solenoid valve YV53, which is energized. The cylinder chamber filled with oil receives the pressure produced by the piston of the oil flow booster while the plunger moves down. The latter provides pressure through the main cylinder to the plunger. The pressure is shown on the display of the microprocessor-based control system. Remember that the exact pressure value shown on the display does not include any delay time and is therefore more accurate than mechanical pressure gauges. Pressure gauge 36 must always be turned off during normal operation and used only to check or set the displayed value. 6.4.11 1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER (WITH OR WITHOUT ACCUMULATORS)
To allow the machine to perform the 1st press-stroke without pressure booster, set 1st p.stroke w/out f. boost. to YES. The first press-stroke is different from the previous one from a hydraulic standpoint. The program allows for a fixed time during which solenoid valve YV40 is energized, as described in the paragraph above. Once this time has elapsed, solenoid valve YV40 is de-energized and solenoid valve YV19 is energized, thus allowing logic element 117 to open. As the line pressure is higher than that in the section which joins logic element 117 to the cylinder, the oil will flow into the latter. This will allow the press stroke to be completed without having to use the booster, thus saving on oil. Obviously, this type of 1st press-stroke should be performed only when a large amount of oil is needed for the 1st press-stroke (with SFS die-set or any other optional equipment for very thick tiles made from a dry ground mix). Setting 1ST P. STROKE W/OUT P. BOOST. = YES and 1ST SEPARATE PRESS-STROKE = YES, the press-stroke will be performed without the accumulators and pressure booster (see FIRST SEPARATE PRESS-STROKE). 6.4.12 1ST SEPARATE PRESS-STROKE
The function of the 1st press-stroke is to remove the air from the powder to be compacted. If the first press-stroke is too fast or too violent, the air may not be completely released, resulting in defective tiles (grooves in the tiles). It is therefore sometimes necessary to perform the 1st press stroke at a slower speed and with a more steady pressure. This phase is known as 1st separate press-stroke. To perform this stage, set 1ST SEPARATE PRESS-STROKE = YES. The type of 1st press-stroke to be performed depends on the powder to be pressed. Once the delay time for the 1st press-stroke has elapsed, the solenoid of valve YV40, which pilots logic element 116 when opening, is energized. At the same time, the solenoid of valve 53, which pilots logic element 115 when closing, is energized. As a result, accumulators 18 and 27 are shut off. The press-stroke ends when the cylinder reaches the set pressure, without using the accumulators. The action of the main cylinder will be slower and steadier, thus allowing the air to be let out from the powder being pressed. This type of press-stroke requires less energy as the pressure in the pump is proportional with that of the cylinder starting from 0 up to the max. value, whereas the accumulators would have caused the pump to work at the highest pressure.
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6.4.13 DEAERATION
During deaeration, the upper punches move away from the powder just pressed so that the air compressed in the cavity can be released. Once the 1st press stroke has been completed, the time set for deaeration (set from the microprocessor system) starts elapsing. Meanwhile, solenoid valve YV40, which pilots logic element 116 while closing, is de-energized. Solenoid valve YV70 (drain) is also de-energized, allowing logic elements 118 and 119 to open. The first logic element eliminates the pressure applied for the first press-stroke which built up in the main cylinder, thus opening a passage to tank 126. On the other hand, logic element 119 allows the oil contained in tank 126 to be drained into the flow booster. At this point, two spring shock absorbers 101 (located beneath the plunger), which were compressed during the 1st press-stroke, push the plunger upwards, allowing the upper punches to move away from the powder and the air to escape from the cavity through suitably sized openings in the die-set. Note that de-aeration is strictly related to the time set and space left free (upward movement of the plunger, expressed in mm, in relation to the shock absorbers). Obviously, the correct adjustment must be performed in the least amount of time, remembering that the finished tiles must not have any defects in the finish. 6.4.14 SECOND PRESS-STROKE (LAST PRESS-STROKE)
The last press-stroke is performed in two separate stages, which are: - SECOND DIRECT PRESS-STROKE - PRESS-STROKE WITH PRESSURE BOOSTER A pressure of up to 150 bar can be reached during the first stage. If higher pressures are required the second stage must be used. 6.4.15 SECOND DIRECT PRESS-STROKE
Once the de-aeration time has elapsed, the solenoid of valve YV70 is energized, piloting logic elements 118 and 119 while closing. Solenoid valve YV19 is then energized allowing logic element 117 to be opened by the line pressure. As a result, the accumulators will be directly connected to the main cylinder. If the set pressure is < 150 bar, the second press-stroke will end as soon as the set point has been reached. If the set pressure is > 150 bar (once the optimal setting determined by the controller has been reached with the aid of pressure transducer BP1), solenoid valve YV19 will be de-energized thus shutting off the accumulators. The press-stroke with the pressure booster will then begin. 6.4.16 PRESS-STROKE WITH PRESSURE BOOSTER
The first stage of the press-stroke must be performed as described in the SECOND DIRECT PRESS-STROKE paragraph. When the pressure in the main cylinder reaches the optimal value (determined by the control system), solenoid valve YV19 is de-energized, piloting logic element 117 while closing. Solenoid valves YV38 and YV41 are energized thus allowing logic elements 120 and 131 to open. The oil put under pressure in the pump and accumulators 18 and 27 flows to pressure and flow booster 125. MAXIMUM SETTABLE PRESSURE FOR MAIN CYLINDER (bar) 306 352 340
PH690 PH1000 PH1500
If the max. allowable pressure in the main cylinder is exceeded for any reason, pressure switch SP2 (set and sealed during machine inspection at the factory) will come into action to stop the work-cycle. A fault message will appear on the display of the microprocessor control system.
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6.4.17
SECOND SEPARATE PRESS-STROKE
If the second press-stroke has to be carried out at a slower and steadier speed, accumulators 18 and 27 can be shut off by entering 2 for the 2ND SEPARATE PRESS-STROKE = YES data item in the microprocessor based control system. As soon as solenoid valve YV19 is energized, the solenoid of valve YV53 (accumulator shut off) which pilots logic element 115 while closing, will be inactivated. The logic element will prevent the oil (contained in accumulators 18 & 27) from flowing into the pressure lines. As a result, only the oil which comes from main pump 58 will fill the cylinder of the main piston. Solenoid valve YV53 will be energized as soon as the operating time of solenoid valve YV19 has elapsed. During the second half of the press-stroke, where the pressure booster is used, the accumulators are also employed. This kind of press-stroke allows the user to save on energy as the pressure in the pump is proportional with the pressure in the cylinder. The pressure will not remain at its highest level when the accumulators are used. 6.4.18 DIE-SET UPSTROKE
C1819
SMU
WITH SMU LIFT SYSTEM At the beginning of the 2nd press-stroke, the delay time for the die-set upstroke will begin to elapse (the time is set from the micro-processor control system). As soon as the delay time has elapsed, the solenoids of valves YV21 and YV22 will be energized at the same time. The pressurized oil in accumulator 12 will flow into the lower part of cylinders 181 and 180 thus allowing the lower punches to move up after the plunger has begun its upstroke. If the delay time is properly regulated, the punches and plunger will move up at the same time (the tile is taken out between the punches). The longer the delay time, the greater the time required to energize solenoid valves YV22 and YV21. As a result, the lower punches will move up with a certain delay in relation to the plunger upstroke.

C2086
WITH TRADITIONAL LIFT SYSTEM At the beginning of the 2nd press-stroke, the delay time for the die-set upstroke will begin to elapse (the time is set from the micro-processor control system). As soon as the delay time has elapsed, the solenoids of valves YV21 and YV22 will be energized at the same time. The pressurized oil in accumulator 12 will flow into the lower part of cylinders 55 and 56, thus allowing the lower punches to move up after the plunger has begun its upstroke. If the delay time is properly regulated, the punches and plunger will move up at the same time (the tile is taken out between the punches). The longer the delay time, the greater the time required to energize solenoid valves YV22 and YV21. As a result, the lower punches will move up with a certain delay in relation to the plunger upstroke. 6.4.19 CYLINDER PRESSURE RECOVERY (ONLY FOR PH 1500)
This option can be turned on from the controller. It is active only if the pressure in the cylinder exceeds the line pressure. Once the last press-stroke has been completed, the oil under pressure in the cylinder flows to the accumulators 18 and 27 which are at a lower pressure. YV19 will be energized so that logic element 117 can open. Oil will be transferred until the pressure in the cylinder drops to a value equal to the line pressure + 30 bar. At this point, YV19 is de-energized closing logic element 117. YV70 is de-energized so that the cylinder chamber can be decompressed, reaching zero. This is done through logic elements 118 and 119.
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6.4.20 UPSTROKE WITH BRAKE APPLIED
To move the plunger up, the pressure in the main cylinder which was used for the last press-stroke has to be eliminated. This is done by de-energizing solenoid valve YV70 which, in turn, opens logic elements 118 and 119. Logic element 118 will open an oil passage from the main cylinder to tank 126. Meanwhile, the solenoid of valve YV32s, which pilots logic element 108 while opening, will be energized, thus allowing the oil which comes from pump 58 and accumulators 18 and 27 to flow into the chamber of the main cylinder. Some of this oil will enter the chamber of the booster, thus allowing the shutter to open. This takes place because solenoid valve YV38 has remained energized. Logic element 120 is still piloted when opening and, as a result, the pressure built up in the chamber of the pressure booster can be relieved in tank 126. At this point, the pilot system pressure (applied to the shutter) will cause the piston in the pressure booster to move up. The oil contained in the pressure booster chamber can flow through the opening in the shutter up to the tank. The oil contained in the flow booster reaches the tank through logic element 119, which is piloted by drain solenoid valve YV70, when de-energized. While the piston of the booster is moving up, the oil passages between the main cylinder and the tank are opened. In this way, the pressure exerted in the upstroke chamber of logic element 108 (piloted by solenoid valve YV32s when opening) can operate the main cylinder and the oil is thus allowed to enter the tank. Solenoid valves YV32s and YV47 are energized at the same time. The latter stays on until the plunger encoder reaches the setting entered for the end of braking during upstroke (only if upstroke braking on = YES is entered). Solenoid valve YV47 pilots logic element 174 while closing and the oil from main pump 58 and accumulators 18 and 27 (through logic element 108) is forced to pass through restrictor 90 before reaching the chamber for main cylinder upstroke. The oil flowing through the restrictor will allow the braking force to be properly adjusted. 6.4.21 FAST UPSTROKE
When the plunger (whose position is recorded by the encoder) is no longer within the predetermined braking range during upstroke, the oil which comes from logic element 108 can enter the chamber for plunger upstroke (because solenoid valve YV47 is de-energized). The plunger will continue to move up at a high speed until the encoder detects the settings for the plunger raised. Solenoid valve YV32s is de-energized and pilots logic element 108 while closing. Meanwhile, solenoid valve YV38 is de-energized and pilots logic element 120 when closing. The plunger will now stop moving. 6.4.22 EJECTION
To remove the finished tiles from the cavity, it is necessary to energize solenoid valves YV21 and YV22. This will cause the lower punches to move up as described in the DIE-SET UPSTROKE paragraph. It is possible to decide when the solenoid valve is to be energized by setting a delay time for the die-set upstroke. The operator can also select whether to take out tiles from between the punches or to freely remove the tiles. As soon as sensor SQ3 has been activated (i.e. the pressed tiles have been removed), the box feeder will start moving to eject the tiles and a new cycle can now begin. 6.4.23 SFS CYCLE: UPPER FORMING DIE (OPTIONAL)
Control cylinders of the SFS system 184 are found in the upper part of the die-set. The system features a three-position solenoid valve YV193, YV172, accumulator 337 and pressure relief valve 336. The tiles are removed when solenoid valve YV193 has been energized (after the delay time for punch removal, set from the microprocessor system and determined before plunger upstroke, has elapsed) thus allowing the oil to flow from accumulator 337 to the upper part of cylinders 184. The speed is adjusted by means of flow control 250. The punches return stroke can be set by setting that solenoid valve YV172 is energized either as soon as the filler-box starts or when the filler-box is forward or when it is at the end of its return stroke. Energizing solenoid valve YV172 will allow the oil to flow from the accumulator to the lower part of cylinders 184. To adjust the speed work on flow control 249.
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6.4.24
MOBILE DIE (OPTIONAL)

C2086
TRADITIONAL LIFT SYSTEM If a mirror finished die-set is installed, the lower die has to be moved in order to bring the upper punches into contact with the powder. To move the die, a special system - consisting of accumulator 141 and relief valve 140 (which controls the max. pressure immediately after it) - has been adopted. During the press-cycle, the upper punch (rigidly mounted on the plunger) moves the lower die downward. The oil which comes from the lower part of cylinders 179 flows back, partially charging accumulator 141; part of the oil is drained through relief valve 140. Once the press-cycle has been completed, accumulator 141 will provide the thrusting force and the oil required to place the die in its highest position. The upstroke speed is adjusted through flow control 145. Check valve 183 is used to prevent the die from moving down because of leakage if the machine remains inoperative for a long period of time.
C1819
SMU
SMU LIFT SYSTEM If a mirror finished die-set is installed, the lower die has to be moved in order to bring the upper punches into contact with the powder. To move the die, a special system - consisting of accumulator 141 and relief valve 253 (which controls the max. pressure immediately after it) - has been adopted. During the press-cycle, the upper punch (rigidly mounted on the plunger) moves the lower die downward. The oil which comes from the lower part of cylinders 179 flows back, partially charging accumulator 141; part of the oil is drained through relief valve 253. Once the press-cycle has been completed, accumulator 141 will provide the thrusting force and the oil required to place the die in its highest position. The upstroke speed is adjusted through flow control 145. Check valve 183 is used to prevent the die from moving down because of leakage if the machine remains inoperative for a long period of time. 6.4.25 DIE OVER-TRAVEL
C1819
SMU
CON ESTRATTORE TIPO SMU This function is used when the lower punches are to be cleaned. Use the selector switch located on the microprocessor system. Turning the selector switch to the on position will energize solenoid valve YV129 which, in turn, will deliver oil to the upper part of cylinders 179 and open check valve 251 thus allowing the die to move down. Under these conditions, the lower punches can be raised so that the user can reach their sides to clean or disassemble them.

C2086
WITH TRADITIONAL KNOCKOUT This function is used when the lower punches are to be cleaned. Use the selector switch located on the microprocessor system. Turning the selector switch to the on position will energize solenoid valve YV129s which, in turn, will trigger rack cylinder 130 thereby increasing the stroke of cylinders 55 and 56. Under these conditions, the user can reach the side of the punches so that they can be cleaned or disassembled. To do this, raise the lower punches.
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6.4.26 BRUSH OPERATION
DCP
BRUSH OPERATION (OPTIONAL) (DCP) The brush is used to keep the punches and die thoroughly clean. An electric motor combined with a belt drive rotates the brush and advances the filler-box. The brush can operate only if the press is set for automatic operation or semiautomatic loading. If the operator has entered rotation enable = 3 rotation will always be enabled. If rotation enable = 1 is entered, rotation will be enabled only when the filler box is performing its forward stroke. If rotation enable = 2 is entered rotation will be enabled only for filler box return. The direction in which the brush operates can be set. When NO is entered for REVERSE ROTATION the direction of rotation can be selected: clockwise = YES, counter-clockwise = NO. In addition, it is also possible for the brush to reverse its direction of rotation from time to time. To do this, enter REVERSE ROTATION = YES and then the number of cycles between one reverse rotation and another. If a mobile brush is used, it can also move up and down. As soon as the brush down value has been reached, solenoid valve YV192 will be energized, causing the brush to lower until it touches the lower die after pneumatic cylinders 270 have been brought into action. As soon as the filler-box encoder exceeds the setting entered for brush raised, solenoid valve YV192 will be de-energized, thus allowing the brush to move up.
DCL
C1821
BRUSH OPERATION (OPTIONAL) (DCL) The brush is used to keep the punches and die thoroughly clean. An electric motor combined with a belt drive rotates the brush and advances the filler-box. The brush can operate only if the press is set for automatic operation or semiautomatic loading. If the operator has entered ROTATION ENABLE = 3 rotation will always be enabled. If ROTATION ENABLE = 1 is entered, rotation will be enabled only when the filler box is performing its forward stroke. If ROTATION ENABLE = 2 is entered rotation will be enabled only for filler box return. The brush may operate constantly in the same direction or reverse after a set number of revolutions. If REVERSE ROTATION = NO is entered the brush always runs in the same direction; CLOCKWISE = YES, COUNTER CLOCKWISE = NO. If REVERSE ROTATION = YES is entered the number of cycles after which the brush reverses operation has to be entered. If a mobile brush is used, it can also move up and down. . As soon as the brush down value has been reached, solenoid valve YV192 will be energized, causing the brush to lower until it touches the lower die after pneumatic cylinders 270 have been brought into action. As soon as the filler-box encoder exceeds the setting entered for brush raised, solenoid valve YV192 will be de-energized, thus allowing the brush to move up.
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6.4.27
MOVEMENTS IN MANUAL MODE
A number of movements in manual mode can be performed by using the relevant keys on the control keyboard. In any case, the movements allowed will not endanger the operator. These movements can be performed provided that the mode key switch on the control keyboard is turned to MAN. Different situations may be encountered: - Safety bar raised and led built into key 15 on. The magnetic lock for the lower punches has been applied. Only the die-set (push buttons 25, 30 and 13) can be moved upward and downward. - Safety bar raised and led built into key 15 off. The magnetic lock for the lower punches has not been applied. The machine is shut-down and the die-set cannot be moved up or down. - Safety bar raised and led built into key 15 off. The magnetic lock has not been applied. The following can be set: A) Magnetic lock = YES if the magnetic lock is to be applied, the machine will be shut down and the die-set cannot move up and down. B) Magnetic lock = NO if the magnetic lock does not have to be used. In this case, only the die-set can move up and down. - Safety bar lowered and filler box installed. The plunger can be moved upward and downward (push buttons 25, 30 and 3), the filler-box can move backward and forward (push buttons 27, 29 and 8), the die-set can be moved upward and downward (push buttons 25, 30 and 13), the ALM can move back and forth (buttons 21, 27 and 29), the ACP can move from right to left (buttons 22, 27 ad 29) ad the upper punches can move up and down (buttons 9, 25 and 30) if the SFS is installed. - Safety bar lowered and filler box mount not attached to the press. The plunger can move up and down (push buttons 25, 30 and 3). In this case, the movements are controlled by solenoid valves YV31s and YV31d. These allow the movements to be performed at speeds lower than 16 mm/sec. The die-set can move upwards and downwards (push buttons 25, 30 and 13). With the key switch is turned to SET UP, only the plunger can move up and down at low speed and the die-set can perform upward and downward movements.
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6.4.28 RESETTING THE ENCODERS
The encoders are automatically reset in the following order when keys 5 and 28 are pressed: PLUNGER ENCODER RESET PROCEDURE(ABSOLUTE) - Move the plunger fully up. - Raise the safety bar and set the machine to set-up. - Enter encoder number 1 = PLUNGER on the ENCODER RESET page. Refer to the Instructions B Manual - USE OF THE MICROPROCESSOR-BASED CONTROL SYSTEM.
DCL
C1821
CAL AND ALM ENCODER RESET PROCEDURE (DCL) - The ALM moves fully back activating sensor SQ10 (ALM encoder BQ10 reset). - If encoder reset sensor SQ2 is activated, the filler-box will move forward at low speed until sensor SQ2 is inactivated. - The filler-box moves back at low speed until reset sensor SQ2 is activated (fully back position) (filler-box encoder BQ2 reset). - The filler-box moves fully back at low speed (set value). - The ALM moves completely forward (set value).
DCP
FILLER-BOX ENCODER RESET PROCEDURE (DCP) - The filler-box reaches the 0 position activating YV20a and YV20s. - The ALM moves completely forward activating SQ23.
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ADJUSTMENTS
7
7.1
ADJUSTMENTS
SETTING THE PH 690 - PH 1000 VARIABLE DELIVERY PUMP
For the reference items, see figures 7.1/A and 7.1/B.
PUMP START-UP - Fill the hydraulic system. - Fill the pump casing by using fitting 2. Be sure that the pump casing is completely full. - Turn the motor on and off, allowing it to run for a few seconds until all the air is let out.
SETTING THE MAX. PRESSURE LIMIT FOR THE SYSTEM In order to prevent the system from malfunctioning, a pressure relief valve is provided. This valve (112a+111) is found on the control assembly of the lift system and filler box. To set the pressure limit, perform the following operations: - Disconnect valve YV11b/r (oil heating) - Start up the main pump with the safety bar raised. - Completely loosen valve 112a. - Completely tighten valve 112 (found on pump 4). - Press pressure control button 28, found on the microprocessor control system; the pressure will reach 10-20 bar. Solenoid valves YV11a and YV11b/r will be de-energized and the pump will reach its max. displacement thus draining the whole delivery line. - Slowly tighten relief valve 112a until the gauge on the pump 13 reads the required pressure. - After the valve has been set, tighten it with the locknut provided.
PH690 PH1000
SAFETY PRESSURE (bar) 230 230
7-1
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7
ADJUSTMENTS
Figure 7.1/A - VARIABLE DELIVERY PUMP PH 690 1 2 3 4 5 6 7 Adjustment screw, Max. displacement limit Pump casing inlet and drain ports Pressure regulator Screw, Pressure control setting Flow control (the screw has to be fully tightened) Flow regulator Pump casing
4
C0540
M M11
112 7 58 49 BT4 SP1 SP3 79 256 78
57
M1
C2092
7-2
014AZ002A
ADJUSTMENTS
Figure 7.1/B - VARIABLE DELIVERY PUMP PH 1000 1 2 3 4 5 6 Adjustment screw, Max. displacement limit Pump casing inlet and drain ports Pressure regulator Screw, Pressure control setting Pump flow Pump casing
4 3
112
M M11
6
58
78 49 BT4 SP1 SP3 79
57
M1
C2108
7-3
014AZ002A
7
ADJUSTMENTS
SETTING THE OPERATING PRESSURE The valve 4 which controls the line pressure 112 is mounted on the pump. To perform this operation, set the pressure limit as described above. Proceed as directed below: - Start up the main pump with the safety bar up. - Apply pressure by pushing button 28, located on the microprocessor control system. The pump provides the max. amount of fluid and the pressure reaches the permissible limit. - Loosen pressure regulating valve 112 and eliminate the pressure from the accumulators. Tighten pressure regulator 112a with button 28 pressed until the gauge reads the desired pressure. Tighten the adjustment screw. Once adjusted, pump displacement will become nearly zero. Under these conditions, the oil will no longer be drained from pressure relief valve 111. - Tighten pressure relief valve screw 112 when the desired position has been reached. PH 690 The max. delivery of the pump must be set to 145 l/min. To set the delivery rate, turn screw 1 which limits the maximum displacement, making sure the current absorbed does not exceed the rated value given on the main motor plate (set with maximum displacement present). PH 1000 The max. delivery of the pump must be set to 181 l/min. To set the delivery rate, turn screw 1 which limits the maximum displacement, making sure the current absorbed does not exceed the rated value given on the main motor plate (set with maximum displacement present).
PH 690 PH 1000
Operating pressure (bar) 170 180
OPERATING CONDITIONS - Motor On; pump running; safety bar raised; max. pump displacement; line pressure = 20 bar. - Press in standby mode; motor on; pump running, safety bar lowered; pump displacement drops, the line pressure will be at the operating pressure previously set. If pump displacement is not zero, it means there is an oil leak somewhere in the system (make sure pressure relief valve 112a has been properly set).
7-4
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ADJUSTMENTS
7.2 SETTING THE PH 1500 VARIABLE DELIVERY PUMP
For the reference items, see figure 7.2. PUMP START-UP - Fill the hydraulic system. - Fill the pump casing by using fitting 4. Be sure that the pump casing is completely full. - Turn the motor on and off, allowing it to run for a few seconds until all the air is let out.
SETTING THE MAX. POWER OUTPUTS FOR THE SYSTEM The variable delivery pump comes with a power control which limits the power absorbed to a level less than or equal to the motor power output (see chart) regardless of the pressure reached. POWER OUTPUT OF HYDRAULIC UNIT MAIN MOTOR (kW at 50 Hz) 55
PH1500
This can be done by adjusting power control 5. Proceed as directed below: - Start up the main pump with the safety bar raised. - Loosen screw 6 of power control 5. - Close valve 112. - If the oil heating cycle has been activated (YV11r energized), disconnect valve YV11r. - Make sure the operating pressure is present. If it is not, adjust it (see paragraph SETTING THE OPERATING PRESSURE) with 112a. - Keep push-button 28, found on the microprocessor control system, pressed (solenoid valve YV99 is energised thus allowing the oil delivery pump to be drained through relief valve 111; the pressure will reach the press operating pressure). - Attach a clamp tester to the supply wires of the motor. - Turn screw 6 on the power control until the value read (in AMPERES) is the same as that given on the motors rating plate divided by 1.732 if a 50 Hz motor is used. On the other hand, if a 60 Hz motor is used, divide by 1.732 and then again by 1.15. The reading should be taken on each supply wire and the reference current corresponds to the average of the readings taken on the three wires. If a clamp tester is not available, use the ammeter in the switchboard remembering that the current reading corresponds to the total value for the three supply wires. As a rule, the max. output currents should be the same as that given on the motors rating plate if a 50 Hz motor is used. On the other hand, if a 60 Hz motor is used, it should equal the rated value divided by 1.15. When measuring under these conditions, the other utilities have to be shut off as the ammeter is on the cabinets line and not the control units motor. NOTE As a rule, the maximum current should be: For 50 Hz - equal to the rated current when the reading is taken on the ammeter in the cabinet; IReading = IRated value - equal to the rated current divided by 1.732 if the reading is taken on each supply wire; IReading = IRated value : 1.732 For 60 Hz - equal to the rated current divided by 1.15 when the reading is taken on the ammeter in the cabinet; IReading = IRated value : 1.15 - equal to the rated current divided by 1.732 and then by 1.15 if the reading is taken on each supply wire; IReading = IRated value : (1.732 x 1.15) - Lock screw 6 in position. After this procedure has been performed, reset the valves 112a, 112 and 10 and reconnect valve YV11r (see the SETTING THE SYSTEM PRESSURE and SETTING THE OPERATING PRESSURE paragraphs).
7-5
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7
ADJUSTMENTS
SETTING THE MAX. PRESSURE LIMIT FOR THE SYSTEM (Oil heating and relief valve) In order to prevent the system from malfunctioning, a pressure relief valve is provided. This valve (112a + 111) is found on the control assembly of the lift system and filler-box. To set the pressure limits, perform the following operations: - Detach connector YV11b/r (oil heating valve). - Start up the main pump with the safety bar raised. - Fully loosen valve 112a (to be set). - Completely tighten valve 112 found on the block secured to the frame of the hydraulic power unit. - Press pressure control pushbutton 28, found on the microprocessor control system; the pressure will reach 10 20 bar. Solenoid valve YV99 will be energized and the pump will reach its max. displacement (indicator 9 in position 11), thus draining the whole delivery line. - Slowly tighten relief valve 112a until the gauge on pump 13 reads the desired pressure to be set. - After the valve has been set, lock it in the correct position. - Attach connector YV11b/r (oil heating valve). As the oil should not yet be at its correct temperature, YV11b/r will see that the oil heating cycle is started again. Completely loosen relief valve 10, relieve the pressure in the upper accumulators, tighten valve 10 until the desired pressure for oil heating (150 bar) has been obtained and then tighten the adjustment screw. SAFETY PRESSURE (bar) 230
PH1500 SETTING THE OPERATING PRESSURE (See figure 7.2)
The valve which controls the operating pressure in the circuit 112 is mounted on a block which is fixed to the frame of the hydraulic power unit. To perform this operation, the pressure limit has to be set as described above. Proceed as directed below: - Start up the main pump with the safety bar up. - Loosen pressure relief valve 112 and relieve the pressure in the accumulators. - Gradually tighten pressure relief valve 112 (with pushbutton 28 pressed) until the desired pressure is read on the gauge and then tighten the adjustment screw. Once adjusted, pump displacement will become nearly zero (meter 9 reads 10 which corresponds to 0). Under these conditions, oil will no longer be drained from pressure relief valve 112a. OPERATING PRESSURE (bar) 180
PH1500
CHECKING THE OPERATING CONDITIONS (See figure 7.2) - With the motor off; pump stationary: displacement meter 9 reads 11 - With the motor on; pump running; safety bar raised: displacement meter 9 reads 10. When the pump delivery tends to drop, the line pressure will be at 20 bar. - Press in stand-by mode; motor on; pump running; safety bar lowered: displacement meter 9 reads 10. Pump displacement drops. The line pressure will be the operating pressure previously set. In these two cases, when pump displacement is not zero, it means that there is oil leakage in the system (make sure that pressure relief valve 112a has been properly set).
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ADJUSTMENTS
Figure 7.2 - REXROTH VARIABLE DELIVERY PUMP PH 1500 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 Displacement regulator body Adjustment screw, Max. displacement limit Adjustment screw, Min. displacement limit Pump casing inlet and drain Power control Adjustment screw, Power control Pressure regulator Adjustment screw, Min. pressure 5 Displacement meter No displacement Max. displacement Pump casing Suction line 1 Delivery line Pressure control valve Driver, Power control Connection with external pilot system XD 18 7 8 6
4 2 3
12 11 10
15
Pos. 10
C0190 C0197
15
Pos. 11
(Pump as seen from above)
YV99
10 YV11R
7
112
15 18
5
112A
6 8 17 3 12
13 5 58 254 49
111
2 13 1 4
SP3
14
M1
7-7
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7
7.3
ADJUSTMENTS
SETTING AND RESETTING THE POSITION ENCODER
The resetting operations must be done each time the encoder or any other related mechanical parts are replaced.
7.3.1
PLUNGER TRANSDUCERS
The encoders mounted on the plunger have a central work zone and two outer non-reading areas (see figure) that are 66 mm and 25.4 mm long respectively. The field of motion of the axis the encoder is used for must be completely centred in the work area. Figure 7.3.1 - RESETTING THE PLUNGER ENCODER
* = Position not read ** = Work zone
Dead zone 66.0 mm (2.60 in.)
**
*
Blank space 28 mm (1.00 in.)
To perform the reset procedure, proceed as directed below: a) Move the plunger fully up in SET-UP mode. b) Raise the safety bar. c) Turn the selector switch to SET-UP. d) Go to the page used to RESET THE ENCODER on the microprocessor terminal. e) Enter encoder number 1 = PLUNGER.
DCL
C1821
7.3.2 FILLER-BOX ENCODER (DCL) If the reset procedure (see par. 6.4.28.2) was not successful, proceed as directed below: a) Move the mobile part of the filler-box (CAF) fully back activating sensor SQ2 but without triggering limit switch SQ20i (approximately 10 mm from the end-stop). b) Loosen the encoder support screws and grub screw that secures the encoder shaft to the flexible coupling. c) Plug the encoder connector into the encoder reset box provided. d) Turn the encoder until the red led that indicates the encoder zero mark has come on. e) Keeping the encoder in place fully tighten the support screws and grub screw. f) Repeat the reset procedure with keys 28 and 5.
DCL
C1821
7.3.3 ALM ENCODER (DCL) If the reset procedure (see par. 6.4.28) was not successful, proceed as directed below: a) Move the ALM fully back activating sensor SQ10. b) Loosen the encoder support screws and grub screw that secures the encoder shaft to the flexible coupling. c) Plug the encoder connector into the encoder reset box provided. d) Turn the encoder until the red led that indicates the encoder zero mark has come on. e) Keeping the encoder in place fully tighten the support screws and grub screw. f) Repeat the reset procedure with keys 28 and 5.
7-8
014AZ002A
ADJUSTMENTS
7
DCP
7.3.4 FILLER-BOX ENCODER (DCP) Software reset procedure: Software reset procedure: - Fully raise the plunger. - Press keys 28 and 5 to automatically reposition the fillerbox. The filler-box will stop in any position (the filler-box stops when the encoders 0 pulse is read, almost surely it will not be when the filler-box is back). - Turn the key selector to MAN and press keys 29 and 8 to move the filler-box back (the filler-box moves at the speed set for the 1st forward step). - Turn the key selector to SET-UP and press keys 26, 31 and 8 simultaneously with the filler-box in this position (limit switch SQ59 should be triggered). The encoders offset value will be stored, i.e. the distance traveled by the fillerbox from the encoders 0 position to the position the fillerbox reaches when fully back. From this point on whenever the filler-box is moved it will return to its back position (encoders 0 position + offset value).
Figure 7.3.4 - FILLER-BOX ENCODER 1 2 3 4 5 6 7 Encoder 7-pin connector Encoder reset box Half flanges and related fixing screws Holes and plugs to access to the coupling Geared motor 1 22 3 Connecting rod CK1
4
CK2
5
The encoder can be zero set in a conventional manner: - With the pump off and key turned to SET-UP, press keys 25, 30 and 8. - Fully raise the plunger. - Raise the safety bar. - Turn off the controller. - Disconnect the lead which runs from the connector 2 on the encoder 1. - Hook up the reset box 3.
C0207
Two green LEDS, located on the box 3, are used for signals CK1 and CK2. A red LED which lights up only when the encoder is being reset is also provided. Set the rod 7 perpendicular to the press, as when the filler box is fully backwards. Loosen the screws which secure the encoder to the half-flange 4. Perform the reset operations by turning the encoder body until the red led comes on. Fully tighten the screws 4. Plug the controller cable into the connector 2. Install the guard, making sure the cable is not in the way. If the operation cannot be done, perform a different procedure. - Remove the two plugs 5 from the metal cylinder which is located just beneath the encoder. - Turn the rod 7 until the screw on the coupling is brought near the hole. - Loosen the screw in the lower part of the coupling and set the rod 7 perpendicular to the machine. Do not turn the encoder coupling. - Tighten the bottom screw. - Loosen the top screw and the screws 4 which secure the encoder to the two half-flanges. - Remove the encoder. - Turn the spindle until the red led comes on. - Re-install the encoder and tighten all the screws.
7-9
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ADJUSTMENTS
7 - 10
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MAINTENANCE
8 MACHINE MAINTENANCE 8
The checks and maintenance operations required to keep the press in top running order are listed below. The first operations dealt with in the chart below, have to be carried out regularly at the stated intervals. The other operations are to be performed when required, i.e. at the operators discretion.
E0004P
WARNING!
Carefully read the precautions given in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS before carrying out any maintenance operations.
8.1
SCHEDULED MAINTENANCE
OPERATIONS INITIAL MAINTENANCE TO BE CARRIED OUT THEREAFTER EVERY
EVERY (HOURS)
(***)
8 1 - GENERAL CLEANING OF DIE-SET AND PRESS 2 - INSPECT CONDITION OF THE FELTS 3 - LUBRICATE PLUNGER BUSHES 4 - CHECK OIL LEVEL IN FILLER-BOX GEARED MOTOR 5 - INSPECT EJECTOR 6 - CHECK NUTS & BOLTS TO SEE IF TIGHT 7 - CHANGE OIL IN HYDRAULIC POWER UNIT 8 - CHANGE OIL IN FILLER-BOX GEARBOX 9 - CLEAN ELECTRICAL CABINET INSIDE 10 - REPLACE FILTER ELEMENTS 11 - CHECK FOR LEAKS 12 - INSPECT VARIABLE DELIVERY PUMP 13 - CHECK EARTH CONNECTIONS FOR CONDITION (**) 14 - CLEAN DIE-SET AIR FILTERS 15 - CHECK SAFETY DEVICES 16 - REPLACE PRESSURIZATION AIR FILTER ELEMENT 17 - CHECK EFFICIENCY OF SUCTION SYSTEM 18 - CHECK EFFICIENCY OF OIL/WATER HEAT EXCHANGER 19 - REPLACE THE PLUNGER UPSTROKE LINE 20 - REPLACE THE BOOSTER UPSTROKE LINE
40
80
200
500
2000 4000
8 hours 80 hours 80 hours 80 hours 80 hours 2000 hours 4000 hours 4000 hours 2000 hours (*) 200 hours 200 hours 80 hours 80 hours 80 hours 4000 hours 500 hours 200 hours
Every 6,000,000 cycles or within 5 years Every 6,000,000 cycles or within 5 years
C2200
(*) (**) (***)
Operation to be carried out only when specified. Inspect after the die-set has been changed. Intervals at which these operations are to be carried out are automatically indicated on
Approximate value
1 - GENERAL CLEANING OF THE PRESS. The filler-box, grid, slide plate and the part of the die set which rests on the table need special attention. 2 - INSPECT THE CONDITION OF THE FELTS which protect the plunger bushes.
8-1
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8
MAINTENANCE
3 - LUBRICATE THE PLUNGER BUSHES (this operation must be done by hand with the grease gun provided. Inject the grease through the fittings provided). 4 - CHECK THE OIL LEVEL IN THE FILLER-BOX GEARED MOTOR. 5 - INSPECT THE EJECTOR. Make sure there are no oil leaks and that the screws are tight. 6 - INSPECT BOLTS AND NUTS TO SEE IF TIGHT. Refer to chart 8.3. 7 - CHANGE THE OIL IN THE HYDRAULIC POWER UNIT. Change the oil, taking care to remove any deposits which may have accumulated in the reservoirs. Only oils which have the characteristics indicated in the Specifications paragraph must be used. The intervals indicated in the chart at which the oil should be changed is given for reference purposes only. Follow the intervals established by the manufacturer of the oil used. 8 - CHANGE THE OIL IN THE FILLER-BOX GEARBOX. 9 - CLEAN THE ELECTRICAL CABINET INSIDE. Clean the electronic and electrical equipment by removing any extraneous matter with a suitable suction device; do not blow in air! Clean the contacts with ether. 10 - REPLACE THE FILTER ELEMENTS Indicators SP1 (filter on main filtration circuit located in hydraulic power unit) and SP4 (filler box filter) will cause fault messages to appear on the controller display screen when the filter elements are clogged. When the message Filter clogged (SP1) is displayed a counter that signals Change filter within XX also appears. The press can continue the production cycle until the time after which the filter has to be changed is reached. Once this time is over, the press will shut down, completing the press-cycle in progress. Operation can be re-started only after the filter has been changed. As a result, the operator can change the filters from the time that spans from the message signaling the filter is clogged is displayed and the press actually shuts down thereby allowing the job to be planned in advance. Each time a filter element is replaced, thoroughly clean the filter housing. Check the condition of the filter gaskets each time the filter housing is opened. The filters monitored by indicator SP1 should be changed only when signaled by the press PLC or whenever the oil is changed. The filters monitored by indicators SP2 and SP4 should be changed when signaled by the press PLC or yearly (when scheduled maintenance is performed). Use only genuine SACMI filters to prevent malfunctions from arising. 11 - CHECK FOR OIL LEAKS. Check the logic elements and valve seats for oil leaks. Check the level in the oil leak collector. 12 - INSPECT THE VARIABLE DELIVERY PUMP. Check the seals for wear. The following conditions should be satisfied for proper operation. Keep the pressure control button pressed and make sure the displacement meter, located on the pump casing, reads zero and that the motor which drives the pump does not consume more power than that set for maximum power absorption. If this is not the case, contact our Customer Service Dept.
8-2
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MAINTENANCE
8
13 - EARTH CONNECTIONS Inspect the earth electrodes of the machine and the earth connections between the crosshead and the plunger. Make the connections, if required. Earth terminals: A - Crosshead B - Plunger C - Machine base F - Earth bar in electrical cabinet
C
F
C2783
Make sure the die-set has been properly earthed (See figure 4.2.4 - DIE SET WIRING DIAGRAM, cables D and E in chapter 4 - INSTALLATION).
E0004P
WARNING!
Remove the paint from the points where the machines earth conductors are attached before tightening the screws provided in order to guarantee adequate electrical continuity. Failure to properly earth the machine parts shown may result in damage to the machine and injury to the operator.
14 - CLEAN THE DIE-SET AIR FILTERS Remove the filters and clean them using compressed air. Check their condition and replace them if necessary (special attention should be given to the filter gaskets while the covers are being closed. 15 - CHECK THE SAFETY DEVICES Check all the safety devices for proper operation: emergency stop buttons, limit switches and barrier guards. 16 - REPLACE THE PRESSURIZATION AIR FILTER ELEMENT Replace the coalescence filter element 271 at least once a year. 17 - CHECK EFFICIENCY OF THE SUCTION SYSTEM Make sure the suction outlets are hooked up and that the systems run according to SACMI specifications. 18 - CHECK EFFICIENCY OF OIL/WATER HEAT EXCHANGER Make sure the oil temperature remains within the allowable range and that it does not increase rapidly. If the exchanger needs to be adjusted, follow the instructions given in paragraph 8.4 - HEAT EXCHANGER MAINTENANCE. 19 - REPLACE THE PLUNGER UPSTROKE LINE Drain the oil from the machine and replace the tube. 20 - REPLACE THE BOOSTER UPSTROKE LINE Drain the oil from the machine, remove the cover of the cross-head and replace the tube.
8-3
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8
8.2
8.2.1
MAINTENANCE
SPECIAL MAINTENANCE
SERVICING THE PLUNGER BUSHES
The bushes do not need to be adjusted. The seals, which stop dust from entering, and the high quality materials used ensure a long service life. When installing, make sure that the oval section marked O and stamped on the bush, is turned towards the center of the press.
PH690
PH1000 - PH1500
C0542
C0306
8.2.2
FILLING THE RESERVOIR
The reservoir is filled with the aid of a portable charge pump. - Loosen the level plug Q (pre-filling tank). - Open the ball valve A (suction line). - Put one end of the suction hose B into the oil can C. - Attach the end of the delivery hose D to point N (suction hose). - Open the ball valve P. - Turn the switch F to start the charge pump. - Make sure that the oil filter G is not clogged (indicator H red). Replace the filter element if necessary (3 absolute m). - The presence of oil in the tube L indicates that the system has been filled to the required level. Once the correct amount of oil has been put in (with the plunger down): - Turn the switch F to stop the pump. - Close the ball valve P. - Remove the hose D from N.
E0004P
ATTENTION!
If the optional filling pump has not been purchased, the customer must see that the oil drawn from the cans is filtered. The filters used should have a 3 absolute degree of filtration to assure the cleanliness rating at the press inlet conforms to ISO 4406:1999 of 19/17/13.
8-4
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MAINTENANCE
Figure 8.2.2 - FILLING THE RESERVOIR A B C D F G H L N P Q Ball valve found on the suction line Pump suction hose Oil can Delivery or drain hose Switch to start the charge pump. Oil filter Indicator (filter clogged) Tube (leaks) Fitting Ball valve Level plug
8-5
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8
8.2.3
MAINTENANCE
DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND LINES
Draining the reservoir - Make sure that the ball valve A is open (suction line). - Put the delivery hose D into the oil can C. - Connect the drain hose D to point N on the suction line. - Open the ball valve P. - This operation can be made faster by pressurizing the circuit (1 bar) using compressed air. - Close the ball valve P. Draining the hoses and hydraulic control assemblies - Attach the hose D to the fitting I)and then put the opposite end into an empty can C. - Pressurize the circuit (1 bar). - Open the needle valve E to drain the hoses and the hydraulic control assemblies. Draining the heat exchanger ad control unit - Attach the hose D to the fitting R and then put the opposite end into an empty can C. - Open the ball valve O. - Drain the exchanger.
8-6
014AZ002A
MAINTENANCE
Figure 8.2.3 - DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND LINES A C D E I N O P Q R Ball valve found on the suction line Oil can Delivery or drain hose Needle valve Fitting Fitting Ball valve Ball valve Level plug Fitting
8-7
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8
8.2.4
MAINTENANCE
CHECKING ACCUMULATOR PRECHARGE
Gas precharge pressure of the accumulators is set to the standard value indicated in paragraph SPECIFICATIONS at the time of machine installation. To check precharge, follow the steps given below: - Drain the oil from all the accumulators installed in the machine with the cocks provided. - Make sure the hydraulic circuit is not under pressure. - Unscrew the cap on the side of inflation valve 38. - Unscrew the control 39. - Open the release 40. - Screw the tester on the inflation valve by hand. - Secure the fitting directing the gauge block by hand. - Tighten the control 39 observing the hand of the gauge. When the hand moves away from 0, continue tightening (1/ 2 a turn is sufficient; there is no need to tighten completely). - Read the inflation pressure given on the gauge (check the values obtained with those foreseen for the various accumulators in paragraph SPECIFICATIONS). To reduce the pressure - Slowly open the release until the desired pressure is reached. To increase the pressure - Take off the knurled cap 41. - Connect the end of the hose (1/4 BSO at 60) to fitting 42. - Connect the other end of the hose to the nitrogen source and put under pressure (it is fundamental to wait for heat exchange caused by movement of the pressures, to become stable before testing or precharging).
E0004P
ATTENTION!
The accumulators are to be precharged using only dry nitrogen in tanks with reducer. Use of compressed air and/ or oxygen is severely forbidden.
- To disassemble, perform the steps in the reverse order. - Make certain the inflation valve on the accumulator is tight. - Tighten the cap on the inflation valve side.
Figure 8.2.4 - CHECKING ACCUMULATOR PRECHARGE 39
41 42
T2543
40 38
8-8
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MAINTENANCE
8.3 TORQUES (NUTS AND BOLTS)
S.R = Resisting cross section (sq.mm) MS = Tightening torque (kgm) V = Pre-load (corresponding to the tightening torque, kg)
NOTE: 12-K class screws must be tightened with a torque wrench. The operation must be done as if they were of the 10K class. Example: A 12-mm dia. screw with a 1.75 pitch (class 12K) must be tightened to 12.28 kgm instead of 14.74 kg. STANDARD THREAD SCREWS
DIAMETER PITCH S.R. 5S
mm. mm. mm2 MS = kgm V = kg
4 0.70 8.11 0.22 227 0.34 363 0.49 511 0.58 613
5 0.80 13.31 0.43 373 0.69 596 0.96 839 1.16 1006
6 1.00 18.68 0.73 523 1.16 837 1.64 1177 1.96 1412
8 1.25 34.57 1.81 978 2.90 1549 4.07 2178 4.89 2613
9 1.25 45.77 2.33 1282 3.73 2050 5.25 2884 6.30 3460
10 1.50 55.28 3.23 1548 5.18 2477 7.28 3483 8.73 4179
12 1.75 79.92 5.46 2238 8.74 3580 12.28 5035 14.74 6042
14 2.00
16 2.00
18 2.50
20 2.50
22 2.50
24 3 338 44.00 9880 60.5 15800 85.3 21740 100.9 26000
110.16 150.49 185.16 236.52 294.16 8.33 3084 13.32 4935 18.74 6940 22.49 8328 12.72 4214 20.36 6742 28.63 9481 34.36 11377 16.02 5184 25.63 8295 36.04 11665 43.25 13998 24.88 6823 35.81 10596 50.36 14900 60.43 17830 33.10 8436 43.36 13178 60.97 18532 73.16 22238
8G
MS V
10K
MS V
12K
MS V
FINE THREAD SCREWS
DIAMETER PITCH S.R. 5S
mm. mm. mm2 MS = kgm V = kg
8 1.00 37.14 1.92 1040 3.08 1664 4.33 2340 5.19 2808
10 1.00 61.87 3.52 1732 5.63 2772 7.91 3898 9.50 4677
12 1.50 83.83 5.68 2347 9.09 3756 12.78 5281 15.34 6338
14 1.50
16 1.50
18 1.50
20 1.50
22 1.50
24 2 374.5 45.7 10800 66.00 17200 91.00 24300 110.0 29200
119.42 161.29 209.44 263.86 324.58 8.83 3344 14.12 5350 19.86 7523 23.83 9005 13.37 4516 21.39 7226 30.08 10161 36.09 12194 17.48 5864 27.96 9383 39.32 13195 47.18 15834 27.16 7688 38.65 11821 54.36 16623 65.23 19948 35.81 9388 52.10 11541 73.82 21249 88.79 21538
8G
MS V
10K
MS V
12K
MS V
8-9
014AZ002A
8
8.4
MAINTENANCE
SERVICING THE HEAT EXCHANGER
CLEANING THE EXCHANGER - Loosen the nuts on the tie rods and move the plate away. - Check the width of the gaskets and replace them if necessary. - Remove the plates from the frame. - If the plates are dirty or covered with calcium deposits, proceed as follows: Type of deposits Solid deposits not stuck to the plates or grilles Cleaning Remove them with running water at low pressure
Soft sludge Hard sludge Hard calcium deposits
Proceed as above Soak the plates, and then proceed as above. Fully immerse the plates (without removing the gaskets and grilles) in a solution containing water and 10% of hydrochloric and nitric acid for about 5 minutes. Thoroughly rinse under running water. Repeat the operation if necessary.
NOTE: Never remove the grilles and the gaskets from their seats unless the gaskets are worn and need to be replaced.
E0004
WARNING:
DO NOT use solvents under any circumstances.
8.4.1
REPLACING THE GASKETS
Check the width of the gaskets measuring it along with the plate. The gasket along with the relative plate should not be less than 4.1 mm. If worn down and less than this value, replace the heat exchanger gaskets and close it taking into consideration a precharge value for the plates for the new heat exchanger. - Remove the square mesh grille from the plate. - Remove the gasket and thoroughly clean the edges of the plate. If the gaskets are difficult to install, slightly raise the curled edge of the plate with the aid of a spatula. - Re-install the grille, making sure that it fits into the inside groove of the gasket.
8 - 10
014AZ002A
MAINTENANCE
8.4.2 SECURING THE TIE RODS
No special tools are required to perform this operation (e.g... torque wrenches). The value n x A, indicated in the diagram, can be exceeded (the plate cluster must be more compact) without causing the heat exchanger to malfunction (see the chart below). Tighten the tie rods in the following order: Secure tie rods 1, 6, 10 and 5. Secure tie rods 2, 7, 9 and 4. Secure tie rods 3 and 8. Repeat this operation until the correct dimension is reached.
Figure 8.4.2 - SECURING THE TIE RODS

nxA
10
C0315
n = number of plates that make up the exchanger
TIGHTENING THE TIE ROD (1 PLATE) New gaskets A 3.75 Minimum 3.5
NOTE: - The first value was used when the heat exchanger was constructed and for exchangers overhauled with new gaskets. - The min. tightness is the min. allowable value. To compensate for a plate that has worn down in relation to another, do not exceed this value as when the space between plates is reduced the section for oil and water flow is also decreased causing greater loses and reducing efficiency of the exchanger.
8 - 11
014AZ002A
8
8.5
MAINTENANCE
SERVICING THE FIXED DELIVERY PUMPS
These operations must be carried out by well trained personnel, especially when the most important parts of the pump are to be replaced. Disassembling: Thoroughly clean the pump outside and wash it with diesel fuel if necessary. Do not disassemble the pump in dusty environments or near grinding wheels. Secure the pump to a work bench with the drain port A turned downwards. Mark the body B and head assembly C for future reference purposes. Remove the mounting bolts D and pull off the head assembly C. The head assembly is provided with a reference pin which is used to determine when the perforated plate is to be reinstalled. Remove the gasket E. Take out the perforated plate F. Fit a rubber ring on the shaft G in order to protect the cylinder block surface. Secure the block P by applying a shim and a screw. Remove the tab I, snap ring L, part M and shims V. Be careful not to damage the gaskets N and O. Remove all equipment from the casing with the aid of a puller. Attach the puller to the threaded section at the end of the shaft. Remove the cylinder block P. It is not necessary to mark the pistons and related cylinders. Remove the Belleville washers Q observing their position. Remove the pistons R from their housing. Use an electric screwdriver to loosen all the screws S. It is advisable not to remove the bearings T and U, as the whole unit will have to be set-up if a single bearing is replaced. Replace the piston rings: - Remove worn or damaged rings. - Fit the upper and lower piston rings. When observing the pistons from the top, make sure the marks can be clearly seen on both faces. Assembling: Fit the pistons R back into place and tighten the screws S after applying Loctite on their surfaces to prevent them from loosening. Replace the Belleville washers and the shim Q making sure they are correctly positioned. Grease the central bore in the block P (do not use standard Belleville washers). Make sure that all the parts are assembled as shown in the diagram. Put the pistons R in place in the cylinder block P and insert the pin G in the central hole in the block. Fit the rubber ring. Use a screw and washer to secure the cylinder block P. Heat the casing B up to approx. 80C. Prepare all the tools required to install the front part of the pump so that it can be installed before the casing cools down. Place the impeller in the pre-heated casing so that the bearings can be fully pushed home. A heat shield should be used to protect the operator. Finish assembling the lower part of the pump by installing the gasket O, the shims required and the part M. The last part to be fitted is the snap ring L. Remove the rubber ring, the screw and the washer. Install the perforated plate F and the gasket E. Install the head assembly C and insert the dowel W in the hole provided by referring to the marks made during the disassembly procedure. Fully tighten the bolts D on the head assembly.
8 - 12
014AZ002A
MAINTENANCE
Figure 8.5 - FIXED DELIVERY PUMP
C0500
8 - 13
014AZ002A
8
8.6
MAINTENANCE
VACUUM
If hydraulic components need to be replaced without draining the oil from the press, put the hydraulic circuit under vacuum with the equipment supplied with the machine. Proceed as follows: - drain the hydraulic accumulators.
E0004P
WARNING!
Before attempting any operations, wait for the hydraulic accumulators to be completely drained.
- disconnect the pressurization circuit from the air line and wait until air no longer flows out of the circuit; - connect tube A to fitting B for the vacuum device and tube C to fitting D of the vacuum device; - wait a few minutes. To avoid damaging the hydraulic circuit the time the press is kept under vacuum should be as short as possible, in any case less than 60 minutes. In addition, cover any openings in the hydraulic circuit to prevent pollutants from entering. NOTE: drain the oil from the press when replacing valves with large diameters directly connected to the reservoir.
Figure 8.1.2 - VACUUM
12
C2138
8 - 14
014AZ002A
DECOMMISSIONING
9 DECOMMISSIONING 9
When the machine is to be dismantled, follow the directions given below: 1) rest the plunger on the mechanical stop and secure it in this position so that it can not move in any way 2) disconnect the machine from the supply mains with the main switch and then unplug the power cable 3) if present, discharge accumulators 141 and 337 through valves 143 and 339
E0004P
WARNING!
Wait until the accumulators have been completely discharged before working on the press.
4) 5) 6) 7) 8) 9) 10) drain the hydraulic fluid in the press as instructed for scheduled maintenance disconnect all the machine parts from the power supply disconnect the water lines for cooling down the oil disconnect the hydraulic lines remove the filler-box remove the control unit for the electrical connections discharge all the accumulators of the gas under pressure that is present in them by using the tool for checking gassing, available on request 11) remove all the accumulators 12) remove all the hydraulic control units 13) the press can be moved as directed for installing it. Refer to the relevant chapter. When dismantling, parts of the machine (hydraulic control units, accumulators, etc.) have to be moved with suitable lift devices. These operations are to be carried out only by expert personnel observing the safety regulations currently in force. In addition, whenever the upper part of the machine has to be reached, all the safety devices and gear called for by current safety regulation are to be used.
9-1
014AZ002A
9
DECOMMISSIONING
9-2

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

PH 690 - PH 1000 - PH 1500

PH 690 - PH 1000 - PH 1500

DATE OF PUBLICATION 28.10.2003 - 20.05.2004

VERSIONS PH690A - 1000A - 1500A

WHERE TO KEEP THE MANUAL

HOW TO USE THE MANUAL

USERS OF THE MANUAL

Hot surfaces - danger of being burnt

Danger - hands can be crushed

High tension - danger of being electrocuted

Danger of entanglement in moving parts

It is forbidden to use oxygen to recharge the accumulators

Heavy duty gloves must be worn

The indicated point must be effectively grounded

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

This symbol indicates the machine version with SMU system.

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

TRADITIONAL LIFT SYSTEM

530 MAX140 3350 550 790

AREA DI SERVIZIO MINIMA MINIMUM SERVICE AREA MINIMALES BEDIENFELD

MINIMO PER ESTRAZIONE MINIMUM FOR WITHDRAWING MINDESTAUSSTO

PERFORMANCE Max. soft clay filling

17000 890 2800

27000 890 2800

38500 890 2800

Continuous A-weighted sound pressure level. Acoustic power level in dB weighted A.

Figure 2.3.2 - POINTS WHERE NOISE LEVEL IS MEASURED

ID symbol S250 S260 S270 S150 P004 P002 P003 P010

Outlet diameter (mm) 120 120 100 100 80 70 60 50

P003 S270 S270 P003

ID symbol S250 S260 S270 S150 P004 P002 P010

Outlet diameter (mm) 90 120 100 100 120 50 50

P010 S250 P002 S250

ID symbol S250 S260 S270 S150 P004 P002 P010

Outlet diameter (mm) 90 120 100 100 120 70 50

S250 P002 S270 S270

P010 S250 S270

Figure 2.3.4 - RATING PLATE PH 690

269 269 270 269 269 270

247 M 90 YV31d YV31s BQ3 OPT YV47 YV32d YV32s YV53

STAMPO DIE-SET STAMPO

H2O 112 YV279 M11 58 M P SP1 H2O

Figure 2.4/A - PH 690 HYDRAULIC AND PNEUMATIC SYSTEM

SQ59a 49 M 57 M1 SP3 78 BT4 79 248

269 269 270 269

144 154 SQ50a 48 R

H2O 112 YV279 M11 58 M P SQ59a SP1 H2O

Figure 2.4/B - PH 1000 HYDRAULIC AND PNEUMATIC SYSTEM DIAGRAM

SP3 112a 5 YV20s 188 252 SP4 6 111

338 242 140 61 183 YV20b

125 118 117 116 131

126 223 222

SP2 YV70 YV40 224 SQ60 SQ61

123 174 109 108 115 247

BQ1 YV47 144

179 179 179 SQ6

SQ3 180 181 189 189 181 180 SP1 79

Figure 2.4/C - PH 1500 HYDRAULIC AND PNEUMATIC SYSTEM

145 23 145 24 24 142 YV20a 43

183 YV21 YV20a YV129 251

120 131 YV38 YV41 119 116 118 YV40 117

SP2 YV19 BP1 YV70