Вы находитесь на странице: 1из 127

USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

USE&MAINTENANCE
MANUAL

CONSTRUCTOR
GAROLL SRL

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 1


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

1 INTRODUCTION
Through this manual GAROLL s.r.l. provides its customers with all the information
necessary to ensure correct maintenance and use of the high pressure casting module
for the HPC Series.
Any instructions, drawings, tables, and anything else contained in this handbook, are
confidential technical information and cannot be reproduced in whole or in part
without written approval by GAROLL s.r.l., which is the exclusive proprietor of the same
and which reserves the right to make all the modifications it considers necessary.
Technicians and machine control and maintenance operators are forbidden from
divulging the information contained herein and from using the manuals for purposes
other than those strictly linked to correct use of the machine.
We advise you to keep this book in good condition in an easy-to-access place to allow
rapid consultation, if necessary.
For any additional information, please contact GAROLL s.r.l. - the service department
technicians will be glad to help you.

WORK ORDER: XX/XXXX


DATE OF MANUFACTURE: 2008
CUSTOMER: Vitruvit, Thessaloniki

These user instructions were written to broaden knowledge of the system in order to
exploit its intended use to the full.
GAROLL cannot foresee all the circumstances that could cause a potential hazard
while the machine is being used and maintained. Consequently, the safety messages in
this manual and those shown on machine plates may not include all possible safety
precautions.
This manual provides important instructions on safe, professional and economic use of
the system. If you observe these instructions, you will avoid needless risks, while reducing
repair and down-time costs, and, at the same time, increasing the system’s reliability
and life.
This manual must be integrated with the instructions in the national legal regulations on
accident prevention and environmental protection.
This manual must always be available in the place where the system is installed.
This manual must be read and applied by anyone charged to carry out work with and
on the system, for example:
- use including preparation, troubleshooting during the operating cycle, removal
of production waste, care, disposal of consumables and auxiliary materials
- Maintenance
In addition to this manual and to the current regulations in the country of destination
and in the place of use concerning prevention of accidents, the laws on safety and
professional use must also be observed.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 2


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

2 GENERAL WARNINGS
2.1 INTRODUCTION
Before attempting any job on the system and/or on the packing of parts, carefully read
the instruction manual to the letter.
This manual contains information which is important for the safety of both machine
control operators and routine maintenance operators, and the machine itself.
GAROLL reserves the right to make any technical modifications to the machines and
manuals without notice.
Property rights reserved, reproduction forbidden. GAROLL protects its rights under law
regarding drawings and technical documentation.
For any further copies of this manual, contact GAROLL’s Customer Servicing
department.

Storing the manual


This manual is an essential part of the machine and must always accompany it even if
the machine is sold. The manual must always be kept near the machine, in a place
known to and easily accessible by the personnel.
The operator and maintenance person must be able to obtain and consult the manual
at all times.

How to search and consult the manual


Information and instructions are contained and arranged in chapters and sections and
are easy to trace by consulting the index. Any information preceded by a warning,
obligation or prohibition sign must be carefully read.
The essential notes for the health and safety of operators are contained in a box,
highlighting warning, obligation and/or prohibition signs in italics as illustrated below.
We particularly urge you to read the section “general safety regulations” several times,
as it contains important information and warnings on safety.

Addressees of this manual


For the purpose of this manual, machine personnel are split into the following
categories:
Machine control operator:
He/she is responsible for surveying, using and controlling the machine.
Machine routine maintenance operators.
For a precise definition of these operators, see section QUALIFICATIONS AND SKILLS OF
USERS.

Guarantees
GAROLL considers itself responsible for the system in its original configuration.
Any intervention that changes the machine’s configuration or operating cycle must be
executed or approved by GAROLL’s technical department.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 3


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

GAROLL does not consider itself responsible for the consequences of using non-original
spare parts.
All servicing jobs under guarantee, extraordinary maintenance and repair jobs are not
to be performed either by the operator or maintenance persons but must be carried
out strictly by the machine manufacturer’s technical specialists. Therefore, these
operations are not described in this manual.

Reference standards
The system was designed and built by GAROLL S.R.L. to conform to the technical
prescriptions contained in DPR 459/96, Machine Directives 89/392/EEC, 91/368/EEC,
93/44/EEC, 93/68/EEC and in the following harmonized standards:
EN 292-1
Machine safety.
Fundamental concepts, general design principles.
Part 1: basic terminology and methods.
EN 292-2
Machine safety.
Fundamental concepts, general design principles.
Part 2: specifications and technical principles.
EN 349
Machine safety.
Minimum distances to avoid crushing parts of the body.
EN 418
Machine safety.
Emergency stop equipment, functional aspects.
Design principles.
EN 60204-1
Safe use of the machine.
Machine electrical equipment.
EN 746
The machine conforms to the standards concerning Safety and Health in the Work
Place in observance of D.P.R. 547/55 and of Decree Law 626/94.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 4


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

Key to safety signs on the machine and/or in the instructions manual


In this instructions manual, the following names and symbols are used for particularly
important signs. The symbols are always located on the left side of the page so that
they can be seen immediately.

N.B.
Notes on economic use of the system.
WARNING!
Sign or prohibition aimed at preventing damage.

DANGER!
Sign or prohibition aimed at preventing damage to objects or persons.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 5


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3 GENERAL SAFETY INSTRUCTIONS


3.1 INSTALLATION

Before beginning work, put the machine in a safe condition.


Carry out the jobs observing safety regulations and measures, and following the
machine manufacturer’s instructions.
When you have finished the jobs, make sure the machine is able to work safely and, in
particular, make sure that the protective and safety devices are fully efficient.
Incorrect installation can cause damage to persons or things, and GAROLL cannot be
held liable for such damage.

3.2 SAFETY DEVICES

The system is provided with electrical and/or mechanical safety devices which protect
both operators and the machine.
We therefore warn the user not to remove these devices or tamper with them.
GAROLL declines all liability due to tampering or incorrect use.

3.3 CHECKS, REPAIRS AND MAINTENANCE

Any check, repair or maintenance jobs must not be carried out on moving parts.
Operators must be warned of this prohibition by means of clearly visible notices.
Before attempting any operation, turn off power to the machine.
To ensure the machine is efficient and operates correctly, you must observe GAROLL’s
instructions and carry out scheduled maintenance of the machine.
In particular, we recommend you periodically to check the efficiency of all safety
devices and insulation of electrical cables, which must be replaced if damaged.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 6


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.4 LIVE PARTS

Performing jobs on live parts or in their immediate vicinity is forbidden.

3.5 EXPERT PERSONNEL

Jobs concerning assembly, dismantling and maintenance in general must be entrusted


to expert, technical qualified personnel, and provided that suitable tools or devices are
used and that the relevant instructions are observed.

3.6 PUTTING THE MACHINE OUT OF SERVICE

When no longer in use, the machine must be electrically isolated. The electrical panels
must not be powered and restoring power with normal commands must be disabled.
The machine is now ready for a general in-depth overhaul followed by dismantling and
disposal of all the system’s parts. All current legal regulations and the immediate
environment must be observed and respected during all dismantling operations and all
operations involving disposal of exhausted substances.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 7


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4 HANDLING INSTRUCTIONS
4.1 SLINGING HANDLES

To ensure lifting and suspension operations are correctly performed:


-use equipment of the most suitable type and carrying capacity cover sharp edges
check the hook safety device

Before beginning to lift:


- allow all operators to reach the safe area and prevent people accessing the
handling area
- make sure the load is stable
- check if there is any material that could fall when being lifted
- lift vertically and gradually to prevent swinging and dynamic stress

4.2 TRANSFER

As lifting and load transfer aids, use rods, levers, and grapnels placed at a safe
distance:
-never use hands only.

The operator must:


- have a general view of the path to be followed
- give instructions to the crane driver while staying in a visible position
- interrupt the manoeuvre in the event of dangerous situations.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 8


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.3 LAYING DOWN THE LOAD

Before laying down the load, makes sure the floor is flat and of sufficient capacity to
support the load in question.
Do not lay down loads near to shed exits, fire protection systems, passages, control
panels or electrical lines.
The load must be laid down on appropriate cross-pieces to make it stable and facilitate
removing the slinging.
Do not superimpose containers in poor condition or containing projecting materials.
Do not stack materials to a height whereby stability is at risk.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 9


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

5 QUALIFICATION AND SKILLS OF USERS


5.1 THE USER COMPANY

It is the responsibility of the user Company to ensure that operators:


- conform to the requirements listed below
- read and understand the manual
- receive training suitable for their duties and to carry them out safely
- receive training specifically aimed at using the machine correctly

5.2 THE OPERATOR

The operator must have at least:


-a knowledge of the machine’s technology and specific experience of running the
machine
-basic general culture and basic technical culture of a sufficient level to enable
him/her to read
and understand the contents of the manual including correct interpretation of the
drawings.

Mechanical knowledge (in the electrical, mechanical and pneumatic fields) sufficient
to enable him/her to carry out the jobs entrusted to him/ her as specified in this manual
- knowledge of accident prevention regulations:
- general regulations (hygiene and safety in work place, preventing accidents in
work place)
- specific regulations (for the type of machine)
- current regulations in the country where the machine is installed

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 10


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

5.3 THE MAINTENANCE OPERATOR

Maintenance persons must be selected according to the criteria listed for operators.
Moreover, they must have the specific, specialised technical knowledge (mechanical,
electrical
and pneumatic) to safely perform the duties allotted to them as specified in this
manual.

Duties and limits of operator and maintenance persons.


The use and maintenance operations, split according to purpose (use, routine
maintenance, extraordinary maintenance) are indicated in various parts of the
manual.
Each worker must limit his/her work to his/her specific duties (mechanical, electrical and
pneumatic duties).

Operator’s duties
The operator must not access the electrical equipment installed inside the electrical
panel and must not remove protective devices for live parts of components installed on
the machine, such as:
- motor terminal boards
- terminal board for solenoid-valves and servo-controlled adjustment valves
- terminal boards for electrical connector blocks pressure-switches
- the operator may only use the controls and instruments on the machine control
panel

The operator or machine controller must not carry out any work on the electrical
equipment.
Routine maintenance persons must not modify cables and electrical connections.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 11


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

6 MAINTENANCE INSTRUCTIONS

Running the machine while removing, modifying or tampering with guards, protective
devices and safety devices is always forbidden.
Before doing any job on the machine, always consult the manual which indicates the
correct procedures and contains important information on safety.
In case of doubt, consult GAROLL’s Customer Servicing Department.

Before attempting any maintenance operation, put the machine in a safe condition
and, when you have finished, make sure that the machine is able to work safely and, in
particular, that the safety devices are fully efficient.
Precautions for handling acid or basic solutions (scale removers or disinfectants).

6.1 SAFETY DURING THE MANIPULATION OF ACID OR BASIC


SUBSTANCES
Strictly observe the instructions on the safety and toxicology chart of the product being
handled

Operator:
Equip the operator handling solutions with the following equipment:
- Gas mask with filters for acid vapours
- Anti-spray goggles
- Rubber gloves
- Body protection clothes that can be slipped off when necessary

Machine:
- immediately wash with water the parts of the machine that came into contact
with the chemical solutions.

Environment:
- immediately wash with water the areas of the work place affected by any leaks
of chemical solutions.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 12


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

Avoid direct contact between basic and acid solutions – this may cause toxic gasses.

7 RANGES OF APPLICATIONS
The system is capable of casting various types of ceramic sanitary-ware, which are
agreed together with Garoll during the project and realization phases:
- Shower trays
- Console washbasins
- Wall-mount washbasins
- Pedestals

7.1 INTENDED USES


The system was designed and built for making products with the characteristics
indicated in the technical specifications agreed with GAROLL s.r.l.

7.2.1 NON-INTENDED AND NON-PERMITTED USES

No other uses are allowed unless specifically approved by the Manufacturer.


Consequently, the Manufacturer is relieved of all liability due to failure to observe these
prescriptions.

7.2.2 INCORRECT OR IMPROPER USES

The Manufacturer is not liable for any consequences due to incorrect or improper use
of the system.
The most frequent cases of such use are normally due to:
- inadequate training of personnel
- tiredness (especially during night shifts) or distraction
- neglect due to an overly casual approach or incorrect habits.
N.B.: Supervision and operation control must be entrusted to expert, well-trained
personnel able to correctly use the system under normal operating conditions and (very
important) to handle any emergencies.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 13


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

7.2.3 OPERATING AND ENVIRONMENTAL LIMITS


The casting system was developed for casting ceramic sanitary-ware. The following
conditions must be observed to ensure this is performed correctly and in a way not
endangering things and/or people and the immediate environment:

Safety devices must be fitted and be perfectly efficient;

Electrical panels must be powered at the correct tension and all earth connections
must conform to safety regulations;

Conveyors and/or manipulators must be efficient in common with all accessories


assisting operation.

The pneumatic system must be fed at correct pressure and flow-rate at the delivery
point (see technical specifications)

Use only trolleys and setting plates for pieces of correct shape and mass to avoid any
subsequent damage to equipment during robot manipulation of said setting plates.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 14


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

7.3 OPERATOR’S AREA AND DANGEROUS ZONES

GAROLL considers itself responsible for the system in its original configuration.
Any intervention that changes the machine’s configuration or operating cycle must be
executed or approved by GAROLL’s technical department.
GAROLL does not consider itself responsible for the consequences of using non-original
spare parts.

All servicing jobs under guarantee, extraordinary maintenance and repair jobs are not
to be performed either by the operator or maintenance persons but must be carried
out strictly by the machine manufacturer’s technical specialists. Therefore, these
operations are not described in this manual.

In view of this, the operator must stay in the appropriate areas indicated on the floor
and avoid hazardous areas indicated with suitable signs and safety prescriptions. It is
the sole responsibility of the client to demarcate walkways, safe and non-safe areas
and to display appropriate danger signs in accordance with local legislation.

Access to the more dangerous areas is prevented by fixed guards and guards that can
only be removed intentionally (with appropriate tools and subject to authorisation).

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 15


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

During the maintenance operations all risks and safety hazards must be avoided in a
normal professional way.

7.4 SAFETY DEVICES AND SIGNALS

Protective panels: the areas considered as high risk are protected by protective panels
designed to prevent any action by the operator that might cause damage to things
and/or persons and to the immediate environment. Panels must remain locked at all
times and should only be accessed by suitably qualified technicians.

Motor protection: all motors are provided with overload protection to prevent damage
during overloading or malfunctioning.

Emergency: All control panels and portable pendants are equipped with red
emergency buttons. In the event of an emergency, this device makes it possible to
manually disable the system. Pressing any emergency button disables all equipment in
the casting cell.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 16


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

Safety signs: make sure all safety symbols are legible. Clean or replace them if text
and/or figures are difficult to read. To clean the signs, use a cloth, water and soap. Do
not use solvents, petrol etc.
Replace damaged, missing and/or difficult to read signs.
If necessary, ask GAROLL’s Customer Servicing department for new signs or for
information regarding their correct use.
Safety signs in and around the casting cell must conform to local safety legislation and
it’s the sole responsibility of the client to display this signs in appropriate places.
If sings are worn and/or deteriorated, the client must replace them under his/her own
responsibility. GAROLL is not liable for damage to things and/or people due to non
replacement of faulty signs.

7.5 HAZARDS AND RESIDUAL RISKS

There is a special category of incident that the system manufacturer is unable to


analyse and thus foresee. The repeatability through time and the cause is almost
always accidental but arises through poor maintenance.
Here is an example to better explain the above concept: faulty pipe leaks water
without the user or maintenance person noticing the problem – this leak could reach a
motor and trip its protective device. This type of incident may seem small or negligible,
but, in common with other similar accidents it occurs very frequently.

The operator must wear adherent clothes, so to avoid entanglements with moving
parts. See next section about personal protective equipment.
The system produce quite a high level of noise and personnel should wear hearing
protection.
It is also forbidden to insert body parts or any object during handling.

Water is an integral part of the process and may cause dangerous situations if in
contact with electrical equipment,
All safety fences and safety barriers must be kept in a good condition at all times.
Safety barriers and emergency buttons must be tested regularly.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 17


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

8 PERSONAL PROTECTIVE EQUIPMENT


It is not the duty of the system manufacturer to indicate the clothes and protection
devices most suitable to ensure safety and freedom from harm of the personnel.

However, personnel must be equipped to face all the risks and unforeseen events that
the person responsible for safety has noted. If, due to special production needs,
unknown products have to be used, ask for all the necessary information to make sure
they are handled safely in order to avoid damage to things and/or people, and to the
immediate environment.

Garoll would be very glad to help, explain and suggest any personal protective
equipment which may be considered necessary to avoid damage to things and/or
persons, and to the immediate environment.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 18


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

1. THE TECHNOLOGY
The HPC machine is a unit for forming ceramic articles by high pressure casting.
The machine was designed to allow use of micro-porous resin moulds.

Main work phases:


1. Closing and fixing of mould. All parts of the mould are brought together and closed
by high pressure in order to deform the closing surfaces to the degree set on the
hydraulic closing cylinders or hammers. Closing surfaces has to connect parallel to
each other and at the same amount of compression to prevent any leakage of slip
during the casting process. Leakages of slip during the casting cycle can damage a
mould very seriously.

2. Mould filling. After closing the press and compressing the mould closing surface in
high pressure slip is injected into the model forming cavity of the porous resin mould.

3. Forming of thickness. During filling of the mould with slip, thickness formation on the
casting surface immediately starts even before pressure is applied. Water from the slip is
absorbed into the porous resin and leaves a skin on the casting surface which is the
external face of the piece being cast. Due to casting pressure inside the casting cavity,
water in the slip passes through the skin or formed thickness into the porous mould.
Thickness dimension is in proportion to the time the mould is under pressure and to
the pressure value used. During the whole thickness formation process the mould acts
as a filter to keep the residual particles on the mould surface and only allowing the
water to exit from the forming cavity. During the later part of thickness formation the
water has to pass first through the already formed skin before arriving to the resin. Slip
rheology and particle size distribution of the slip plays a very important role in the
filtering or transport of water through the skin of the piece itself towards the mould.

4. Draining. After the thickness formation process, excess slip is discharged from the
mould by injecting compressed air into the newly formed piece.

5. Hardening. After draining all residual liquid slip from the piece, air is slowly injected
into the piece and maintained at medium pressure for a few minutes. This pressure on
the inside walls of the piece will force the last water towards the outside into the resin
mould and will ensure mechanical strength of the piece.

6. Piece opening and demoulding. This phase consists of two similar but independent
steps. First the mould has to be opened and for this the first detachment happens from
the “non-demoulding side” of the press. The piece is now only suspended on the
remaining half of the mould. The second step is to demould the now suspended piece
from the other part or “demoulding side”. The piece is made to detach from the mould
by injecting compressed air in the mould rear circuit in order to create a counter
pressure flow of air from the resin surface. This air pressure forces out the water that

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 19


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

resides in the mould pores which, in turn, produces a water curtain between mould
surface and piece thus enabling the piece to detach.
Demoulding robots or automatic manipulators are installed to mechanically demould
the piece.

7. Washing. This is the final phase of the cycle and cleans the mould in counter current
direction to clear out any slip particles that may have entered the pores near the
casting surface of the mould. The washing cycle prepares the mould for casting of the
next cycle. Correct washing parameters ensures the correct “dryness” of the mould
surface to enhance proper thickness formation.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 20


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

2. ADJUSTMENT BEFORE STARTING THE SYSTEM


2.1 SAFETY PROCEDURE FOR CELL ACCESS DURING ANY WORK PERFORMED
BY TECHNICIANS INSIDE THE SAFETY FENCE

Any unauthorised access to the casting cell causes the hardware security intervention
of the separate equipment (Robot and presses). This is to prevent any injury or damage
to people and equipment. To restore the cell it is necessary to identify and reset the
emergency cause and to re-enable on each press the motors button. For the robot it is
necessary to resume the program from the interrupted point.

Procedure for SAFE ACCESS into the cell:


Safe access is required for mould changes, mould washing with hypochlorite,
scheduled maintenance and breakdown repairs.
- Turn off the auto start to all presses.
- Wait for all presses to complete casting cycles. .
- Wait for the robot to complete any manipulation that may still be in progress.
- Stop the robot at the end of its working sequence.
- Turn the safety key on the press panel to the safety position to prevent the
possibility to start any equipment. This safety key allows the operator to
manipulate the press movement in manual mode but any auto start is disabled.
Robot movement is also inhibited by the safety key.
- Open the cell entrance gate (All the equipment go in safety).
- Take care that all equipment has stopped.
- Install moulds from the front part of the machine with proper tools and in safe
condition. There is a safety access gate next to every press to allow safe entry.
- Perform any other maintenance work that necessitated the stoppage.

SAFE RESTARTING OF EQUIPMENT


- Remove all tools from the cell.
- Direct all personnel out of the cell and close the gate
- Enable the robot and the press motors of the equipment.
- Enable the auto start to the presses.
- The cell is back in automatic mode.
- It is not recommended to “bridge” the safety switches on the fence gates to
perform mould changes on a single press while the rest of the cell is functional.
Robot movement is unpredictable and can cause serious injury to personnel.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 21


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

2.2 VERTICAL SETTING AND CLOSURE PRE-LOADING REGULATION


2.2.1 VERTICAL SETTING

It is of the utmost importance to first regulate the verical setting of the press before
attempting the set the pre-load. The vertical adjustment is very much part of the
eventual setting of mould closure and compression.

After installation of EVERY new mould on the press, the vertical adjustment has to be
controlled.
A: Main nut for adjustment of Horizontal
position.
B: Locking nut for locking Horizontal position
C: Locking nut for locking Vertical position
D: Locking bolts for locking piston end of
hydraulic cylinder.

E: Left cylinder
F: Right cylinder

- Enter MANUAL mode.


- Start only the hydraulic pump as described in the manual operation of the press
on the SERVICES manual page of the touch pendant. This is to ensure that the
hydraulic cylinders can be pushed to the set vertical position during lateral
movement of the press. This will further ensure that the press is in the locked
vertical position when you make the control measurement.
- Drive the press to an open position of approximately 200mm between mould
closing surfaces.
- Measure the distance between the mobile and fixed part in the four corners of
the mould holding frame of the press.
- Compare the 4 readings and determine if the mould frames are parelel or if the
mobile part needs any adjustment.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 22


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

- If the measures in the lower part of the press is bigger than the readings in the
higher part, the two cylinders E and F needs to be extended until the measures in
lower and higher parts are equal (to a tolerance of 0,5mm).
- If the contrary is true and the lower part measures are smaller than the higher
part measures, the two cylinders E and F needs to be shortened.
- Move the mobile part of the press untill the rotating position and rotate slightly
towards horizontal. This will allow the piston to be free from hydraulic pressure that
will allow it to be turned. If the press is left in the vertical position, the piston is
locked at the end of the cylinder stroke.
- Unscrew the locking bolts D to release the screw thread on the end of the piston.
- Ensure that the main nut A and Locking nut B are tightly locked together.
- Unlock the locking nut C by turning it anti-clockwise.
- To extend the cylinder stroke, turn the piston anti-clockwise using the correct key
on the big nut A (because A and B are locked it can be used to turn the piston).
- To shorten the cylinder stroke, turn the piston clockwise using the correct key on
the big nut A.
- Rotate back to vertical and control the measures again. Repeat this adjustment
untill the mobile and fixed sides of the press is paralel.
- When the setting is done, lock the locking bolts D tight.
- Lock the big locking nut C by turning it clockwise until it locks onto the metal
frame.

2.2.2 CLOSURE PRE-LOADING REGULATION

Always perform this task only after proper regeneration of the mould for approximately
10 minutes. This ensures the mould is at the correct flexibility and temperature. Also first
set the correct vertical adjustment of the mould carrier before adjusting the pre-load
on the hdraulic hammers.

The closure pre-loading is the deformation dimension of the closing surface of every
single mould part. It allows the sealing of the mould by means of hydraulic tightness
when the slip is under pressure inside the mould during the casting cycle. The
adjustment of the pre-load setting on the hammers is on the one hand to ensure some
compression of the resin on the closing surface of the mould but on the second hand to
prevent permanent deformation of the mould if the hammers could not be locked at a
certain point. It guarantees the tightness of the mould closing but at the same time
deforms the closing surfaces to the minimum.
The correct pre-load setting for each mould has to be found in order to prevent leaking
and consequent damage to moulds. On presses where several different moulds are

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 23


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

used it is useful to install and work with moulds that are of more or less the same casting
life or age. This means that when a mould is new it has a specific pack thickness (the
thickness of the complete mould measured from back to back of the aluminium
plates). As the mould age the pack thickness will reduce due to the constant
compression and decompression of the mould during closing and opening the press in
the normal casting cycles.
The pre-loading values should be in the range of 1 to 2,5mm but ideally for a new
mould it should be around 1,5mm.
A: Hydraulic hammer locking nut
B: Hydraulic hammer setting nut
C: Hydraulic cylinder closing face

D: Lock the locking nut A in clockwise


direction
E: Lock the setting nut B in the anti clockwise
direction
F: Hydraulic hammer cylinder body.

Pre-loading regulation sequence.


- Unlock all the locking nuts (A) and open them 3 to 4 turns.
- Open all setting nuts to near the locking nut position.
- Close the press mobile part until the two halves of the resin mould are in contact.
- Read the position of the mobile part on the display screen and verify that it is the
same as in setup configuration.
- Close the hydraulic hammers in low pressure as described in 4.2.1.4 Manual
Movement of press.
- Control that none of the setting nuts are in contact with the hydraulic cylinder
body (F).
- Systematically adjust all setting nuts to touch the hydraulic hammer body and
then carefully unscrew it to the desired free space between setting nut and
cylinder body.
- Lock the setting nut and locking nuts together as in the second figure.
- A thin plate thickness gauge can be used to determine the space between the
nut and the cylinder body. An easy rule of thumb is 1 rotation of the nut = 1,5mm.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 24


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

On all mould parts the cylinders must be set at exactly the same deformation values.
Different values can cause mould carrier non alignment with consequential damage to
the mobile part carrier guides as well as for the moulds.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 25


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3. AUTOMATIC CYCLE SET-UP


After mould installation it is necessary to carefully change the setup parameters for the
casting cycle of the press in order to achieve the optimum results for the particular
shape that is to be cast. This includes the casting cycle parameters in the setup pages
as well as the configuration parameters in the configuration setup pages.

Push the SETUP button for the press you wish to select. A password entry screen will appear.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 26


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

1. Touch the blue rectangle once.


1. A flashing rectangular box will appear in the blue rectangle.
2. Touch <CLR> once to delete any incorrect typing.
3. Touch the corresponding numbers of the password on the keypad.
4. Confirm the password by pressing <ENTER> for approximately 2 seconds.
5. If the password is correct, you will obtain access to the parameter setting pages.
6. If the password is not accepted, repeat from point 1.

The <MAIN> key at the top of the page returns you to the main
selection screen.

Knowing the password will give you access to the machine set-up and manual
movement pages. This access must be reserved only for machine maintenance and

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 27


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

adjustment personnel. If this confidentiality is lost, we advise you to contact us so we


can reprogram a new code.
3.1 HOW TO INTRODUCE OR MODIFY DATA ON THE SETUP PAGES

All setup screens contain data relevant to some part of the process. The setup pages
are located in sequence and can be found by touching the <FOLLOW> key or the
<PREC> key to return to previous pages. To change any parameter, touch the block
containing the value for that parameter. A numerical keypad similar to the password
input pad will appear. The parameter value that you touched will be highlighted.

1. Touch the <CLR> key.


2. The original value in the parameter box will return to 0.
3. Touch the corresponding numbers of the new value you wish to enter on the
keypad.
4. Touch the <DEL> key to move one character backwards to delete any incorrect
input.
5. Confirm the new value by pressing <ENTER>.
6. The keypad will disappear and you will only see the setup screen.
7. Control if the parameter is now of the correct value.

Pay attention when entering or changing parameter values.


Incorrect values can cause unpredicted behaviour of the
equipment!

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 28


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.2 PRESSURE CASTING SYSTEM TECHNOLOGICAL PARAMETERS


NOTE:
There are several columns on each of the setup screens. The heading for each column
is described below:
3.2.1 TIME or DURATION
The cycle phase is time controlled and finishes only when the time set for each
parameter in this column elapses. There are some conditional parameters that are not
controlled by time and thus without the possibility to set any time value. All time values
are set in seconds.

3.2.2 DELAY
With the complex layout and design of the press, it may be necessary to delay some
functions on one circuit while the process continues on the other circuit. Delays are set
to equalise the conditions in two moulds which may be of variable shape and size. All
delay values are set in seconds.

3.2.3 RAMP
The ramp setting is the time over which the pressure can change from Low to High or on
the other hand from High to Low. This setting ensures that no sudden pressure changes
can occur inside the mould or cast piece which may damage the mould and/or cause
the cast piece to have defects after the process. Ramp is set in time (seconds) and
initial and final pressures (bar).

3.2.4 INITIAL PRESSURE


This is the first or starting pressure of any phase and measured in bar.

3.2.5 FINAL PRESSURE


This is the pressure achieved after the time of any parameter has elapsed. Ramp
settings are normally included inside the total setting of any parameter and are
therefore part of the total time of the specific parameter.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 29


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3 IDENTIFICATION OF THE MOULD ON THE MACHINE

The presses are set up to allow for various configuration of installation. In the above
diagram the layout means:
- Mould 1/1 and Mould 2/1 are the two moulds on the <Left/Down> configuration
in setup. All pages referring to <Left/Down> will change configuration for the
mould/moulds installed in the lower part of the press.
- Mould 2/1 and Mould 2/2 are the two moulds on the <Right/Up> configuration in
setup. All pages referring to <Right/Up> will change configuration for the
mould/moulds installed in the upper part of the press.
- Always take care to open the correct manual valves on the Air/Water and
Draining circuits on the top manifolds that feed the Demoulding and Non
Demoulding sides of the press. From setup it is important to address the correct
part of the mould in each phase of demoulding.

In the following pages the setup of the press parameters will be described in detail.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 30


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.1 TECHNOLOGICAL CYCLE PHASE PAGE C1

3.3.1.1 Initial Draining


After the mould is closed it is possible to blow air into the casting cavity of each mould
to disperse any water that may still be on the mould surface. The air enters through the
draining air inlet pipes into the cavity. All discharge valves on the resin parts of the
moulds are open at this stage and water is forced to the back of the mould and
drained to the floor. This leaves the mould casting surface more dry for casting and
avoid any possibility to have drops of water on the casting surface. For the final 5
seconds of this setting the slip draining valve to the floor is also opened to force any
accumulated water in the filling circuit to the floor.

PARAMETERS:
1. Time or Duration
Total duration of this phase in seconds.
2. Pressure
Pressure into the circuit is regulated by the proportional valve in the control panel at the
end of the press.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 31


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.1.2 Slip Recirculation


Slip is recirculated in the feeding circuit prior to the filling of the moulds. The main
purpose of this is to transport fresh and hot slip to the manifold next to the press. Slip is
pumped from the slip pump to the main manifold and returns to the return tank. It also
removes the slip in the circuit that has already been under pressure during the previous
cycle. Time duration and Pressure in bar can be set for this parameter

PARAMETERS:
1. Time or Duration
Total duration of this phase in seconds.
2. Pressure
Pressure to the pneumatic slip pump is regulated by the proportional valve in the
control panel at the end of the press.

3.3.1.3 Slip Filling with Pump


After mould composition, initial draining and recirculation, the moulds can now be filled
with slip to start the casting cycle. The slip pump transfers slip from the heated slip tank
into the moulds. Ensure that the mould is completely filled during the filling phase.

PARAMETERS:
1. Time or Duration
Total duration of this phase in seconds.
2. Ramp
This is the gradual change from initial pressure to final pressure of filling. Ramp is set in
seconds and must be shorter or equal to the filling time of the mould.
3. Initial Pressure
The pressure to the pneumatic slip pump is regulated by the proportional valve in the
control panel at the end of the press. This is the pressure at the start of the filling phase.
4. Final Pressure
Pressure of compressed air supply of the filling pump at end of ramp time – this value will
be maintained until end of filling phase.

3.3.1.4 Proportional Air Slip Valve Norgren Ramp


This is a secondary proportional valve that controls the volume flow of air to the slip
pump. This is to maintain constant pressure at low pressure from the pneumatic slip
pump.

PARAMETERS:
1. Ramp
This is the time of gradual change from initial pressure setting to final pressure of this flow
control valve. Ramp is set in seconds and must be shorter or equal to the filling time set
in the Slip Filling With Pump parameter.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 32


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

2. Initial Pressure
The initial setting of the valve on a scale of 0 to 100%. The settings can be 1, 2, 3 and 4
and each increment represents 25% of flow.
3. Final Pressure
The final setting of the valve on a scale of 0 to 100%. The settings can be 1, 2, 3 and 4
and each increment represents 25% of flow. The use of this valve in conjunction with the
inline proportional valve is to ensure control over the flow of air at lower pressure from
the proportional valve.

3.3.1.5 Delay Filling Mould with Valves 450 & 451


If the two moulds installed on the press are of diverse nature, it is possible to delay the
filling to any one at the beginning of filling. This may be necessary if for example there is
a larger mould installed in one position that requires longer time for filling. It is then
possible to delay the start of filling for the smaller piece to ensure the filling in both
pieces are completed at almost the same moment.

PARAMETERS:
1. Time
This is the time set for the active delay on the mould you require to have a delay. If the
moulds are almost equal in size the delay setting for both moulds should be 0.

3.3.1.6 Offset of filling


Filling offset is the threshold pressure value (in bar) used to allow the cycle to continue
to the next phase. It is like a second security to ensure the moulds are completely filled.
Offset pressure is set slightly lower than the Final Pressure of filling and the filling phase
will continue until this parameter is met before stepping to the next phase. Even if filling
time have elapsed, the cycle will remain in Filling until this condition is met.

PARAMETERS:
1. Final Pressure
This setting is a conditional interlock value that must be met to ensure the Slip Filling With
Pump is completed successfully.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 33


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.2 TECHNOLOGICAL CYCLE PHASE PAGE C2

3.3.2.1 Thickness Formation with Slip Pump


Directly after the moulds are filled, the cycle switch over to thickness formation with slip
pump. This is a phase where thickness formation on the mould surface takes place but
the pressure in the circuit is still relatively low. It adds the further benefit that water that is
forced out of the slip into the resin mould can be replaced by fresh slip into the circuit
without forfeiting any volume on the stroke of the injector.

PARAMETERS:
1. Time
This is the total time in seconds for the phase.
1. Ramp
This is the time of gradual change from initial pressure setting to final pressure of this
phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time
parameter.
2. Initial Pressure
The initial pressure setting at the start of the phase.
3. Final Pressure
The final pressure setting for the end of the phase (the end of Ramp Pressure).

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 34


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.2.2 Thickness Formation with Injector N1


The real thickness formation under pressure starts from this phase. Where the slip pump
effectively works until 5bar, the injector can increase the pressure to the desired top
limit. The injector is hydraulically operated and forces slip through the filling circuit
towards the mould to maintain high pressure as water is filtered to the resin mould. The
injector takes over from the thickness with slip pump. Take care to set the initial pressure
equal to the final pressure of N1 to avoid sudden pressure changes in the mould. Any
sudden changes may lead to damage of the mould and/or defects to the piece being
cast.

PARAMETERS:
1. Time
This is the total time in seconds for the phase.
1. Ramp
This is the time of gradual change from initial pressure setting to final pressure of this
phase. As the pressure during this phase is high, it is important to set a ramp time that
does not apply sudden pressure changes inside the mould. 120 seconds should be the
minimum ever used to reach final pressure. Take care to set the initial pressure equal to
the final pressure of thickness with slip pump to avoid sudden pressure changes in the
mould. Any sudden changes may lead to damage of the mould and/or defects to the
piece being cast. Ramp is set in seconds and must be shorter or equal to the time set in
the Time parameter. Ramp is included in total time of this phase.
2. Initial Pressure
The initial pressure setting at the start of the phase.
3. Final Pressure
The final pressure setting for the end of the phase.

3.3.2.3 Thickness Formation with Injector N2


Sometimes it may be necessary to set also a second thickness formation time after N1.
Some pieces are sensitive and need a reduction in pressure towards the end of
thickness formation. On the other hand some pieces may require a more gentle first
thickness formation and higher pressure on the second phase. N2 takes over
immediately from N1. Take care to set the initial pressure equal to the final pressure of
N1 to avoid sudden pressure changes in the mould. Any sudden changes may lead to
damage of the mould and/or defects to the piece being cast.

PARAMETERS:
1. Time
This is the total time in seconds for the phase. This time setting can be varied to make
less or more thickness formation depending on the piece requirements.
2][ Ramp
This is the time of gradual change from initial pressure setting to final pressure of this
phase. As the pressure during this phase is high, it is important to set a ramp time that
does not apply sudden pressure changes inside the mould. 120 seconds should be the

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 35


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

minimum ever used to reach final pressure. Ramp is set in seconds and must be shorter
or equal to the time set in the Time parameter. Ramp is included in total time of this
phase.
2. Initial Pressure
The initial pressure setting at the start of the phase.
3. Final Pressure
The final pressure setting for the end of the phase.

3.3.2.4 Offset of Draining Pressure


Draining offset is the threshold pressure value (in bar) used to enable start of mould
draining. At the end of the thickness formation phase (at high pressure), the cycle must
change over to the next phase which is draining of the remaining slip from the mould
cavity. To effect the draining, compressed air has to be pushed into the cavity to force
out the slip. To safely introduce the compressed air into the piece, the high pressure of
thickness formation first has to be released. Draining offset is the pressure threshold
below which the draining phase can safely begin.

PARAMETERS:
1. Final Pressure
This is only a control parameter or interlock to allow the next phase to begin if it
becomes true.

3.3.2.5 Delay Start Draining N1


It is possible to place a delay on the start of draining. It is to effect some natural
decompression inside the piece after thickness formation and before draining.

PARAMETERS:
1. Time
Time is set in seconds.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 36


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.3 TECHNOLOGICAL CYCLE PHASE PAGE C3 – RAMPS FOR LOWER MOULD

3.3.3.1 Ramp Draining N1 Mould 1


This is the ramp setting for the start of the Draining phase. The duration of the Draining
phase is set on another page of the setup parameters. This sets the variable pressure
from start to end of draining.

PARAMETERS:
1. Ramp Time
This is the time in seconds for the ramp during the 1st draining phase.
2. Initial Pressure
This is the starting pressure applied inside the piece when Draining N1 starts.
3. Final Pressure
The final pressure setting at the end of the ramp and will be maintained until the end of
the draining phase.
4. Water Off/On
Normally draining is effected by pushing compressed air into the cavity to force out the
slip at the draining (filling) point in the mould. In some cases but very rare it may be
possible to pump water into the cavity during draining to enable better draining of the
residual slip.
3.3.3.2 Internal Washing with Water Mould 1

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 37


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

It is possible to pump water also after the first draining into the mould to rinse out any
slip that have not drained during the 1st draining phase. This can be used if slip viscosity
is not suitable to drain fast and some slip remains on the internal walls of the piece. If
used at all, it should be very briefly as too much water will damage the internal of the
piece. Ensure that the selector switch for Internal Washing with Air is set to the Off
position to prevent water to end up in return slip.

PARAMETERS:
1. Time
This is the total time in seconds for the phase.

3.3.3.3 Internal Washing with Air Mould 1


If the piece is washed internally with water as described in the previous point, it is
necessary to blow some air through the piece once more before the hardening phase.
This is important to remove any liquid residue (slip/water) that may remain in the bottom
part of the piece.

This setting can also be used as a secondary draining after Draining N1. In some cases
where slip is slow to drain you may need a secondary draining curve at different
pressures to clean the piece internally before hardening.

PARAMETERS:
1. Ramp Time
This is the time in seconds for the ramp during the 1st draining phase.
2. Initial Pressure
This is the starting pressure applied inside the piece when Internal Washing with Air
starts.
3. Final Pressure
The final pressure setting at the end of the ramp and will be maintained until the end of
the Washing with Air phase.
4. To Return Circuit Off/On
This switch is toward the bottom of the page. This is the selector switch to send slip to the
return tank (ON) or directly to the floor (OFF).

3.3.3.4 Ramp for Hardening Mould 1


When the piece is completely drained of residual slip, air pressure is applied inside the
internal room of the piece with compressed air. This is to force some moisture out of the
piece into the resin mould and to give the piece some mechanical strength. This phase
describes the change from end of draining pressure to hardening pressure inside the
piece. The duration of hardening is set on Setup page C5.

PARAMETERS:
1. Ramp Time
This is the total time in seconds for the ramp at the start of hardening phase.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 38


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

2. Initial Pressure
This is the starting pressure applied inside the piece when Hardening starts.
3. Final Pressure
The final pressure setting at the end of the ramp and will be maintained until the end of
the Hardening phase.

3.3.3.5 Ramp for Decompression Hardening Mould 1


At the end of Hardening the pressure inside the piece has to be released gently to
avoid any structural damage to the piece. By decompression you gently change from
hardening pressure to normal atmospheric pressure to avoid any damage or
deformation to the piece during opening of the press.

PARAMETERS:
1. Ramp Time
This is the total time in seconds for the Decompression phase.
2. Initial Pressure
This is the starting air pressure applied inside the piece when Decompression starts.
3. Final Pressure
This is the final pressure inside the piece at the end of Decompression.

3.3.3.6 Ramp Draining N3 Mould 1


After hardening there may again be some slip in the bottom of the piece that has run
down from the internal walls of the piece. This needs to be drained before the piece is
demoulded from the press.

PARAMETERS:
1. Ramp Time
This is the time of gradual change from initial pressure setting to final pressure of this
phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time
parameter on Setup page C7 – Draining N3.
2. Initial Pressure
This is the starting air pressure applied inside the piece when Draining N3 starts.
3. Final Pressure
The final air pressure setting at the end of the ramp and will be maintained until the end
of the Draining N3 phase.
4. Water Off/On
It is possible in this phase to wash again the piece internally with water. With the switch
ON the piece will have water and with the switch OFF the piece will be drained with air.
When water is selected, the Initial and Final pressures do not apply as only air pressure is
controlled by a proportional valve.

5. To Return Circuit Off/On


This switch is toward the bottom of the page. This is the selector switch to send slip to the
return tank (ON) or directly to the floor (OFF) when water is selected.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 39


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.3.7 Ramp Draining N4 Mould 1


This is similar to Draining N3 as well as to the Internal Washing with Air. A secondary
gentle flushing of air through the internal room of the piece may be necessary to
remove the last of any residual slip (or water if Draining N3 was set to flush with water).

PARAMETERS:
1. Ramp Time
This is the time of gradual change from initial pressure setting to final pressure of this
phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time
parameter on Setup page C7 – Draining N4.
2. Initial Pressure
This is the starting air pressure applied inside the piece when Draining N4 starts.
3. Final Pressure
The final air pressure setting at the end of the ramp and will be maintained until the end
of the Draining N4 phase.
4. Water Off/On
It is possible in this phase to wash again the piece internally with water. With the switch
ON the piece will have water and with the switch OFF the piece will be drained with air.
When water is selected, the Initial and Final pressures do not apply as only air pressure is
controlled by a proportional valve.
5. To Return Circuit Off/On
This switch is toward the bottom of the page. This is the selector switch to send slip to the
return tank (ON) or directly to the floor (OFF) when water is selected.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 40


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.4 TECHNOLOGICAL CYCLE PHASE PAGE C4 – RAMPS FOR UPPER MOULD

3.3.4.1 Ramp Draining N1 Mould 2


This is the ramp setting for the start of the Draining phase. The duration of the Draining
phase is set on another page of the setup parameters. This sets the variable pressure
from start to end of draining.

PARAMETERS:
1. Ramp Time
This is the time in seconds for the ramp during the 1st draining phase.
2. Initial Pressure
This is the starting pressure applied inside the piece when Draining N1 starts.
3. Final Pressure
The final pressure setting at the end of the ramp and will be maintained until the end of
the draining phase.
4. Water Off/On
Normally draining is effected by pushing compressed air into the cavity to force out the
slip at the draining (filling) point in the mould. In some cases but very rare it may be
possible to pump water into the cavity during draining to enable better draining of the
residual slip.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 41


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.4.2 Internal Washing with Water Mould 2


It is possible to pump water also after the first draining into the mould to rinse out any
slip that have not drained during the 1st draining phase. This can be used if slip viscosity
is not suitable to drain fast and some slip remains on the internal walls of the piece. If
used at all, it should be very briefly as too much water will damage the internal of the
piece. Ensure that the selector switch for Internal Washing with Air is set to the Off
position to prevent water to end up in return slip.

PARAMETERS:
1. Time
This is the total time in seconds for the phase.

3.3.4.3 Internal Washing with Air Mould 2


If the piece is washed internally with water as described in the previous point, it is
necessary to blow some air through the piece once more before the hardening phase.
This is important to remove any liquid residue (slip/water) that may remain in the bottom
part of the piece.

This setting can also be used as a secondary draining after Draining N1. In some cases
where slip is slow to drain you may need a secondary draining curve at different
pressures to clean the piece internally before hardening.

PARAMETERS:
1. Ramp Time
This is the time in seconds for the ramp during the 1st draining phase.
2. Initial Pressure
This is the starting pressure applied inside the piece when Internal Washing with Air
starts.
3. Final Pressure
The final pressure setting at the end of the ramp and will be maintained until the end of
the Washing with Air phase.
4. To Return Circuit Off/On
This switch is toward the bottom of the page. This is the selector switch to send slip to the
return tank (ON) or directly to the floor (OFF).

3.3.4.4 Ramp for Hardening Mould 2


When the piece is completely drained of residual slip, air pressure is applied inside the
internal room of the piece with compressed air. This is to force some moisture out of the
piece into the resin mould and to give the piece some mechanical strength. This phase
describes the change from end of draining pressure to hardening pressure inside the
piece. The duration of hardening is set on Setup page C6.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 42


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

PARAMETERS:
1. Ramp Time
This is the total time in seconds for the ramp at the start of hardening phase.
2. Initial Pressure
This is the starting pressure applied inside the piece when Hardening starts.
3. Final Pressure
The final pressure setting at the end of the ramp and will be maintained until the end of
the Hardening phase.

3.3.4.5 Ramp for Decompression Hardening Mould 2


At the end of Hardening the pressure inside the piece has to be released gently to
avoid any structural damage to the piece. By decompression you gently change from
hardening pressure to normal atmospheric pressure to avoid any damage or
deformation to the piece during opening of the press.

PARAMETERS:
1. Ramp Time
This is the total time in seconds for the Decompression phase.
2. Initial Pressure
This is the starting air pressure applied inside the piece when Decompression starts.
3. Final Pressure
This is the final pressure inside the piece at the end of Decompression.

3.3.4.6 Ramp Draining N3 Mould 2


After hardening there may again be some slip in the bottom of the piece that has run
down from the internal walls of the piece. This needs to be drained before the piece is
demoulded from the press.

PARAMETERS:
1. Ramp Time
This is the time of gradual change from initial pressure setting to final pressure of this
phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time
parameter on Setup page C8 – Draining N3.
2. Initial Pressure
This is the starting air pressure applied inside the piece when Draining N3 starts.
3. Final Pressure
The final air pressure setting at the end of the ramp and will be maintained until the end
of the Draining N3 phase.
4. Water Off/On
It is possible in this phase to wash again the piece internally with water. With the switch
ON the piece will have water and with the switch OFF the piece will be drained with air.
When water is selected, the Initial and Final pressures do not apply as only air pressure is
controlled by a proportional valve.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 43


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

5. To Return Circuit Off/On


This switch is toward the bottom of the page. This is the selector switch to send slip to the
return tank (ON) or directly to the floor (OFF) when water is selected.

3.3.4.7 Ramp Draining N4 Mould 2


This is similar to Draining N3 as well as to the Internal Washing with Air. A secondary
gentle flushing of air through the internal room of the piece may be necessary to
remove the last of any residual slip (or water if Draining N3 was set to flush with water).

PARAMETERS:
1. Ramp Time
This is the time of gradual change from initial pressure setting to final pressure of this
phase. Ramp is set in seconds and must be shorter or equal to the time set in the Time
parameter on Setup page C8 – Draining N4.
2. Initial Pressure
This is the starting air pressure applied inside the piece when Draining N4 starts.
3. Final Pressure
The final air pressure setting at the end of the ramp and will be maintained until the end
of the Draining N4 phase.
4. Water Off/On
It is possible in this phase to wash again the piece internally with water. With the switch
ON the piece will have water and with the switch OFF the piece will be drained with air.
When water is selected, the Initial and Final pressures do not apply as only air pressure is
controlled by a proportional valve.
5. To Return Circuit Off/On
This switch is toward the bottom of the page. This is the selector switch to send slip to the
return tank (ON) or directly to the floor (OFF) when water is selected.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 44


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.5 TECHNOLOGICAL CYCLE PHASE PAGE C5 – DRAINING & HARDENING LOWER MOULD

3.3.5.1 Draining 1 - Mould 1 through YV230 and YV231


During the 1st draining phase after thickness formation, air is injected into the mould to
force out the remaining liquid slip inside the piece. The filling valve to the mould, YV450,
and return valves YV420 and YV470 are opened during this step. Slip is drained to the
return tank through these valves by injecting air via YV230 and/or YV231 to force the slip
out of the piece. It is important to drain the piece as quick as possible with the minimum
possible air pressure.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV230 while air is injected through YV231 or delay
the opening of YV231 while air is injected through YV230. These two valves work in
parallel and can also open simultaneously without any delay setting on either of them.
To set a delay depends on the design and geometry of the piece to determine the
time of draining air through each of YV230 and YV231. Delay is set in seconds.
2. Time
The total time in seconds these valves will be opened during the Draining 1 phase. Any
delays set may lengthen the total time of Draining 1.
3.3.5.2 Internal Washing with Air - Mould 1 through YV230 and YV231

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 45


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

This is also referred to as 2nd draining. During the Internal Washing with Air phase after 1st
draining, air is injected into the mould to force out the remaining liquid slip (or water if
water on time was selected on page C3) inside the piece. The filling valve to the mould,
YV450, and return valves YV420 and YV470 are opened during this step. Slip is drained
to the return tank through these valves by injecting air via YV230 and/or YV231 to force
the slip out of the piece. It is important to drain the piece as quick as possible with the
minimum possible air pressure.
NOTE: If Internal Washing with Water time was selected on page C3, only the discharge
valve YV460 at the bottom of the press will open when air is injected into the mould
(YV450, YV420 and YV470 closed). This is to avoid water to be drained to the slip return
tank. Please take care that the selector switch toward the bottom of page C3 is in the
OFF position to ensure that water drains to the floor and not to the slip return tank.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV230 while air is injected through YV231. Delay is
set in seconds.
2. Time
The total time in seconds this valve will be opened during the Internal Washing with Air
phase.

3.3.5.3 Hardening - Mould 1 through YV230 and YV231


During the hardening phase after draining and internal washing with air, air is injected
into the mould to pressurise the piece internally. This is done to force some water out of
the walls of the newly cast piece into the resin mould. It ensures mechanical strength of
the piece. The filling valve to the mould, YV450, is opened during this phase but the
return valves YV420 and YV470 are closed. Compressed air is injected via YV230 and/or
YV231 to pressurise the piece internally. The total hardening or consolidation time for
different pieces may vary due to their shape and size.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV230 while air is injected through YV231 or delay
the opening of YV231 while air is injected through YV230. These two valves work in
parallel and can also open simultaneously without any delay setting on either of them.
To set a delay depends on the design and geometry of the piece to determine the
time of hardening air through each of YV230 and YV231.
2. Time
The total time in seconds these valves will be opened during the Hardening phase. Any
delays set may lengthen the total time of Hardening.

3.3.5.4 Detachment in Hardening - Mould 1 through YV280

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 46


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

It is possible to initiate some detachment on the non-demoulding side of the mould


during the hardening phase. Take in consideration that the pressure applied through
YV280 can only be the same of the current pressure during the hardening phase. This
means that the pressure internally and on the mould surface will be exactly the same.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV280 during the hardening phase until only the
last few seconds of hardening. For example, if hardening is 200 seconds and you wish to
set this parameter for the last 15 seconds during hardening, you have to set a 185
second delay.
2. Time
The total time in seconds YV280 will be opened during the Hardening phase.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 47


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.6 TECHNOLOGICAL CYCLE PHASE PAGE C6 – DRAINING & HARDENING UPPER MOULD

3.3.6.1 Draining 1 - Mould 2 through YV232 and YV233


During the 1st draining phase after thickness formation, air is injected into the mould to
force out the remaining liquid slip inside the piece. The filling valve to the mould, YV451,
and return valves YV421 and YV471 are opened during this step. Slip is drained to the
return tank through these valves by injecting air via YV232 and/or YV233 to force the slip
out of the piece. It is important to drain the piece as quick as possible with the minimum
possible air pressure.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV232 while air is injected through YV233 or delay
the opening of YV233 while air is injected through YV232. These two valves work in
parallel and can also open simultaneously without any delay setting on either of them.
To set a delay depends on the design and geometry of the piece to determine the
time of draining air through each of YV232 and YV233. Delay is set in seconds.
2. Time
The total time in seconds these valves will be opened during the Draining 1 phase. Any
delays set may lengthen the total time of Draining 1.
3.3.6.2 Internal Washing with Air - Mould 2 through YV232 and YV233

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 48


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

This is also referred to as 2nd draining. During the Internal Washing with Air phase after 1st
draining, air is injected into the mould to force out the remaining liquid slip (or water if
water on time was selected on page C4) inside the piece. The filling valve to the mould,
YV451, and return valves YV421 and YV471 are opened during this step. Slip is drained
to the return tank through these valves by injecting air via YV232 and/or YV233 to force
the slip out of the piece. It is important to drain the piece as quick as possible with the
minimum possible air pressure.
NOTE: If Internal Washing with Water time was selected on page C4, only the discharge
valve YV461 at the bottom of the press will open when air is injected into the mould
(YV451, YV421 and YV471 closed). This is to avoid water to be drained to the slip return
tank. Please take care that the selector switch toward the bottom of page C4 is in the
OFF position to ensure that water drains to the floor and not to the slip return tank.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV232 while air is injected through YV233. Delay is
set in seconds.
2. Time
The total time in seconds this valve will be opened during the Internal Washing with Air
phase.

3.3.6.3 Hardening - Mould 2 through YV232 and YV233


During the hardening phase after draining and internal washing with air, air is injected
into the mould to pressurise the piece internally. This is done to force some water out of
the walls of the newly cast piece into the resin mould. It ensures mechanical strength of
the piece. The filling valve to the mould, YV451, is opened during this phase but the
return valves YV421 and YV471 are closed. Compressed air is injected via YV232 and/or
YV233 to pressurise the piece internally. The total hardening or consolidation time for
different pieces may vary due to their shape and size.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV232 while air is injected through YV233 or delay
the opening of YV233 while air is injected through YV233. These two valves work in
parallel and can also open simultaneously without any delay setting on either of them.
To set a delay depends on the design and geometry of the piece to determine the
time of hardening air through each of YV232 and YV233.
2. Time
The total time in seconds these valves will be opened during the Hardening phase. Any
delays set may lengthen the total time of Hardening.

3.3.6.4 Detachment in Hardening - Mould 2 through YV290

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 49


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

It is possible to initiate some detachment on the non-demoulding side of the mould


during the hardening phase. Take in consideration that the pressure applied through
YV290 can only be the same of the current pressure during the hardening phase. This
means that the pressure internally and on the mould surface will be exactly the same.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV290 during the hardening phase until only the
last few seconds of hardening. For example, if hardening is 200 seconds and you wish to
set this parameter for the last 15 seconds during hardening, you have to set a 185
second delay.
2. Time
The total time in seconds YV290 will be opened during the Hardening phase.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 50


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.7 TECHNOLOGICAL CYCLE PHASE PAGE C7 – DRAINING 3&4 LOWER MOULD

3.3.7.1 Draining 3 - Mould 1 through YV230 and YV231


During the 3rd draining phase after hardening, air is injected into the mould to allow the
draining of any liquid slip inside the piece. The filling valve to the mould, YV450, and
return valves YV420 and YV470 are opened during this step. Slip is drained to the return
tank through these valves by injecting air via YV230 and/or YV231 to force the slip out
of the piece. It is important to drain the piece as quick as possible with the minimum
possible air pressure. Normally very low pressure is required for Draining 3.

As described in the Ramps page for this mould circuit (C3), it is possible to wash the
piece once again internally with water in this phase. If water is selected on page C3
only the discharge valve YV460 at the bottom of the press will open when water is
injected into the piece (YV450, YV420 and YV470 closed). This is to avoid water to be
drained to the slip return tank. Please take care that the selector switch toward the
bottom of page C3 is in the OFF position to ensure that water drains to the floor and not
to the slip return tank.

When air is selected the pressure setting should always be very low in Draining 3 as it is
generally a very small quantity of slip that is drained. If water is selected, a very short
time should be chosen as too much water can damage the piece internally.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 51


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

PARAMETERS:
1. Delay
It is possible to delay the opening of YV230 while air/water is injected through YV231 or
delay the opening of YV231 while air/water is injected through YV230. These two valves
work in parallel and can also open simultaneously without any delay setting on either of
them. To set a delay depends on the design and geometry of the piece to determine
the time of draining air/water through each of YV230 and YV231. Delay is set in
seconds.
2. Time
The total time in seconds these valves will be opened during the Draining 3 phase. Any
delays set may lengthen the total time of Draining 3.

3.3.7.2 Draining 4 - Mould 1 through YV230 and YV231


During the 4th draining phase after 3rd draining, air is injected into the mould to allow the
draining of any liquid slip inside the piece. The filling valve to the mould, YV450, and
return valves YV420 and YV470 are opened during this step. Slip is drained to the return
tank through these valves by injecting air via YV230 and/or YV231 to force the slip out
of the piece. It is important to drain the piece as quick as possible with the minimum
possible air pressure. Normally very low pressure is required for Draining 4.

As with Draining 3 water can also be used in this phase. It is not recommended and only
very low pressure air should be used. If you select water, the same valve conditions
apply as in Draining 3.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV230 while air is injected through YV231 or delay
the opening of YV231 while air is injected through YV230. These two valves work in
parallel and can also open simultaneously without any delay setting on either of them.
To set a delay depends on the design and geometry of the piece to determine the
time of draining air through each of YV230 and YV231. Delay is set in seconds.
2. Time
The total time in seconds these valves will be opened during the Draining 3 phase. Any
delays set may lengthen the total time of Draining 3.

3.3.7.3 Offset Demoulding Pressure - Mould 1


This is the threshold pressure that will allow the press to open. If the internal pressure is
too high, the press will stay in waiting position until the condition is met.

PARAMETERS:
1. Pressure
Pressure setting in bar. The press can only open when internal pressure is lower than the
set pressure.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 52


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.7.4 Vacuum to Demoulding Part in Detachment – Mould 1


For some types of pieces it may be necessary to apply vacuum in the one half of the
mould from where the robot must take the piece. The purpose of the vacuum in the
mould is to keep the piece supported while the press open and to prevent it to fall
down from the mould while the press rotate to the horizontal position. The vacuum is
applied to the mould via the valve YV350 on the auxiliary vacuum circuit. This is a direct
connection from the vacuum pump to the mould circuit between the mould and valve
YV250. During this auxiliary vacuum in detachment the discharge valve YV251 is also
closed to ensure the vacuum is applied on the back of the piece from the resin mould.

PARAMETERS:
1. Time
This is a time setting in seconds. The vacuum to demoulding part starts at the same time
as Demoulding 1 to the non demoulding side of the mould before the hydraulic
hammers are opened.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 53


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.8 TECHNOLOGICAL CYCLE PHASE PAGE C8 – DRAINING 3&4 UPPER MOULD

3.3.8.1 Draining 3 - Mould 2 through YV232 and YV233


During the 3rd draining phase after hardening, air is injected into the mould to allow the
draining of any liquid slip inside the piece. The filling valve to the mould, YV451, and
return valves YV421 and YV471 are opened during this step. Slip is drained to the return
tank through these valves by injecting air via YV232 and/or YV233 to force the slip out
of the piece. It is important to drain the piece as quick as possible with the minimum
possible air pressure. Normally very low pressure is required for Draining 3.

As described in the Ramps page for this mould circuit (C4), it is possible to wash the
piece once again internally with water in this phase. If water is selected on page C4
only the discharge valve YV461 at the bottom of the press will open when water is
injected into the piece (YV451, YV421 and YV471 closed). This is to avoid water to be
drained to the slip return tank. Please take care that the selector switch toward the
bottom of page C4 is in the OFF position to ensure that water drains to the floor and not
to the slip return tank.

When air is selected the pressure setting should always be very low in Draining 3 as it is
generally a very small quantity of slip that is drained. If water is selected, a very short
time should be chosen as too much water can damage the piece internally.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 54


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

PARAMETERS:
1. Delay
It is possible to delay the opening of YV232 while air/water is injected through YV233 or
delay the opening of YV233 while air/water is injected through YV232. These two valves
work in parallel and can also open simultaneously without any delay setting on either of
them. To set a delay depends on the design and geometry of the piece to determine
the time of draining air/water through each of YV232 and YV233. Delay is set in
seconds.
2. Time
The total time in seconds these valves will be opened during the Draining 3 phase. Any
delays set may lengthen the total time of Draining 3.

3.3.8.2 Draining 4 - Mould 2 through YV232 and YV233


During the 4th draining phase after 3rd draining, air is injected into the mould to allow the
draining of any liquid slip inside the piece. The filling valve to the mould, YV451, and
return valves YV421 and YV471 are opened during this step. Slip is drained to the return
tank through these valves by injecting air via YV232 and/or YV233 to force the slip out
of the piece. It is important to drain the piece as quick as possible with the minimum
possible air pressure. Normally very low pressure is required for Draining 4.

As with Draining 3 water can also be used in this phase. It is not recommended and only
very low pressure air should be used. If you select water, the same valve conditions
apply as in Draining 3.

PARAMETERS:
1. Delay
It is possible to delay the opening of YV232 while air is injected through YV233 or delay
the opening of YV233 while air is injected through YV232. These two valves work in
parallel and can also open simultaneously without any delay setting on either of them.
To set a delay depends on the design and geometry of the piece to determine the
time of draining air through each of YV232 and YV233. Delay is set in seconds.
2. Time
The total time in seconds these valves will be opened during the Draining 3 phase. Any
delays set may lengthen the total time of Draining 3.

3.3.8.3 Offset Demoulding Pressure - Mould 2


This is the threshold pressure that will allow the press to open. If the internal pressure is
too high, the press will stay in waiting position until the condition is met.

PARAMETERS:
1. Pressure
Pressure setting in bar. The press can only open when internal pressure is lower than the
set pressure.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 55


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.8.4 Vacuum to Demoulding Part in Detachment – Mould 2


For some types of pieces it may be necessary to apply vacuum in the one half of the
mould from where the robot must take the piece. The purpose of the vacuum in the
mould is to keep the piece supported while the press open and to prevent it to fall
down from the mould while the press rotate to the horizontal position. The vacuum is
applied to the mould via the valve YV351 on the auxiliary vacuum circuit. This is a direct
connection from the vacuum pump to the mould circuit between the mould and valve
YV260. During this auxiliary vacuum in detachment the discharge valve YV261 is also
closed to ensure the vacuum is applied on the back of the piece from the resin mould.

PARAMETERS:
1. Time
This is a time setting in seconds. The vacuum to demoulding part starts at the same time
as Demoulding 1 to the non demoulding side of the mould before the hydraulic
hammers are opened.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 56


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.9 TECHNOLOGICAL CYCLE PHASE PAGE C9 – DETACHMENT LOWER MOULD

3.3.9.1 Detachment 1 Non-demoulding side – Mould 1


This is the 1st phase of detachment of the piece from the non-demoulding side
(opposite side from where the robot will take the piece from the press). During this
phase the hydraulic hammers are still closed in high pressure. Air (or water) is injected in
the resin mould to start to release the piece from the resin surface. The valve YV280 is
opened and YV281 is closed.

PARAMETERS:
1. Water ON/OFF
It is possible to inject water in the back of the mould to have better release of pieces
with difficult shapes. Take care when using water as too much water can cause
deformation in pieces with hollow casting. If the switch is selected to ON, water will be
used in this phase and when OFF is selected air will be used.
2. Delay
If more than one mould is installed on the machine, it is possible that different times are
required for detachment. Compare the detachment time for every phase and set a
delay time equal to the difference between the time parameter for mould 1 and 2 on
the mould with the shorter of the two times. If the detachment times are equal, no
delay is necessary.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 57


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3. Time
This is the duration of the phase. Time is set in seconds.
4. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.9.2 Detachment 2 Non-demoulding side – Mould 1


This is the 2nd phase of detachment of the piece from the non-demoulding side. During
this phase the hydraulic hammers are opened. Air (or water) is injected in the resin
mould to continue to release the piece from the resin surface. This phase follows
immediately after detachment 1. The valve YV280 is opened and YV281 is closed.
When all hammers are completely open, the mobile part of the press will remain in the
detachment position as set in the setup configuration page.

PARAMETERS:
1. Water ON/OFF
Take care when using water as too much water can cause deformation in pieces with
hollow casting. If the switch is selected to ON, water will be used in this phase and when
OFF is selected air will be used. Normally water is not used after detachment 1 but it
may be required to use.
2. Delay
If more than one mould is installed on the machine, it is possible that different times are
required for detachment. Compare the detachment time for every phase and set a
delay time equal to the difference between the time parameter for mould 1 and 2 on
the mould with the shorter of the two times. If the detachment times are equal, no
delay is necessary.
3. Time
This is the duration of the phase. Time is set in seconds.
4. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.9.3 Detachment 3 Non-demoulding side – Mould 1


This is the 3rd phase of detachment of the piece from the non-demoulding side. Before
this phase the hydraulic hammers are already open and auxiliary inserts completely
detached. Air (or water) is injected in the resin mould to continue to release the piece
from the resin surface. This phase follows immediately after detachment 2 of auxiliary
inserts. The valve YV280 is opened and YV281 is closed.

PARAMETERS:
1. Water ON/OFF
Take care when using water as too much water can cause deformation in pieces with
hollow casting. If the switch is selected to ON, water will be used in this phase and when

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 58


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

OFF is selected air will be used. Normally water is not used after detachment 1 but it
may be required to use.
2. Delay
If more than one mould is installed on the machine, it is possible that different times are
required for detachment. Compare the detachment time for every phase and set a
delay time equal to the difference between the time parameter for mould 1 and 2 on
the mould with the shorter of the two times. If the detachment times are equal, no
delay is necessary.
3. Time
This is the duration of the phase. Time is set in seconds.
4. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.9.4 Detachment 4 Non-demoulding side – Mould 1


This is the 4th phase of detachment of the piece from the non-demoulding side and
follows immediately after demoulding 3. The mobile part of the press will start to move
towards the rotation position (or open position if the piece does not require horizontal
demoulding by the robot). Air (or water) is injected in the resin mould to continue to
release the piece from the resin surface. This phase follows immediately after
detachment 2. The valve YV280 is opened and YV281 is closed.

PARAMETERS:
1. Water ON/OFF
Take care when using water as too much water can cause deformation in pieces with
hollow casting. If the switch is selected to ON, water will be used in this phase and when
OFF is selected air will be used. Water is hardly ever used in the 4th phase of
detachment.
2. Delay
If more than one mould is installed on the machine, it is possible that different times are
required for detachment. Compare the detachment time for every phase and set a
delay time equal to the difference between the time parameter for mould 1 and 2 on
the mould with the shorter of the two times. If the detachment times are equal, no
delay is necessary.
3. Time
This is the duration of the phase. Time is set in seconds.
4. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.9.5 Detachment 1 Demoulding side – Mould 1


This is the 1st phase of detachment of the piece from the demoulding side. During this
phase the robot will be in position already with the demoulding tool or setter plate
almost in contact with the piece. There should always be 2 to 3 mm space between the

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 59


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

tool and the piece to allow the detachment pressure to push the piece away from the
mould. If the tool is pushed against the piece you are almost sure of having
deformation on the part that is still in the half mould. Air (or water) is injected in the resin
mould to release the piece from the resin surface. This phase starts immediately when
the robot is in demoulding position and the signal is received by the press from the
robot. The valve YV250 is opened and YV251 is closed. If auxiliary vacuum is used
through valve YV350, the vacuum is stopped immediately before this 1st detachment
starts.

PARAMETERS:
1. Water ON/OFF
Sometimes when auxiliary vacuum is used, it is necessary to inject some water into the
mould to help with the release of the piece onto the robot tool. If the switch is selected
to ON, water will be used in this phase and when OFF is selected air will be used.
2. Time
This is the duration of the phase. Time is set in seconds.
3. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.9.6 Detachment 2 Demoulding side – Mould 1


This is the 2nd phase of detachment of the piece from the demoulding side. During this
phase the robot will start to move away from the mould gently taking the piece from
the mould. Air is injected in the resin mould to release the piece from the resin surface.
The valve YV250 is opened and YV251 is closed. When the time of this phase have
elapsed, the valveYV250 will close and YV251 will open releasing any residual air that
may be in the mould after detachment is completed.

PARAMETERS:
1. Water ON/OFF
If the switch is selected to ON, water will be used in this phase and when OFF is selected
air will be used. Water is hardly ever used in this phase of detachment.
2. Time
This is the duration of the phase. Time is set in seconds.
3. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.9.7 Detachment 1 Auxiliary Inserts – Mould 1


This is the 1st phase of detachment of the auxiliary inserts from the piece (mobile inserts
that are used to create fixing holes in the back of washbasins). Air (or water) is injected
in the resin insert to release it from the piece. This phase starts immediately after the
hammers are opened in detachment 2 from non demoulding side. The valve YV240 is

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 60


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

opened and YV240A is closed. The inserts can only start to detach when the hammers
are released to avoid any pressure from the closed mould on the barrel of the insert.

PARAMETERS:
1. Water ON/OFF
If the switch is selected to ON, water will be used in this phase and when OFF is selected
air will be used.
2. Time
This is the duration of the phase. Time is set in seconds.
3. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.9.8 Detachment 2 Auxiliary Inserts – Mould 1


This is the 2nd phase of detachment of the auxiliary inserts from the piece. Air (or water)
is injected in the resin insert to release it from the piece. This phase starts immediately
after detachment 1 for auxiliary inserts. The valve YV240 is opened and YV240A is
closed. The inserts can only start to detach when the hammers are released to avoid
any pressure from the closed mould on the barrel of the insert.

PARAMETERS:
1. Water ON/OFF
If the switch is selected to ON, water will be used in this phase and when OFF is selected
air will be used.
2. Time
This is the duration of the phase. Time is set in seconds.
3. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 61


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.10 TECHNOLOGICAL CYCLE PHASE PAGE C10 – DETACHMENT UPPER MOULD

3.3.10.1 Detachment 1 Non-demoulding side – Mould 2


This is the 1st phase of detachment of the piece from the non-demoulding side
(opposite side from where the robot will take the piece from the press). During this
phase the hydraulic hammers are still closed in high pressure. Air (or water) is injected in
the resin mould to start to release the piece from the resin surface. The valve YV290 is
opened and YV291 is closed.

PARAMETERS:
1. Water ON/OFF
It is possible to inject water in the back of the mould to have better release of pieces
with difficult shapes. Take care when using water as too much water can cause
deformation in pieces with hollow casting. If the switch is selected to ON, water will be
used in this phase and when OFF is selected air will be used.
2. Delay
If more than one mould is installed on the machine, it is possible that different times are
required for detachment. Compare the detachment time for every phase and set a
delay time equal to the difference between the time parameter for mould 1 and 2 on
the mould with the shorter of the two times. If the detachment times are equal, no
delay is necessary.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 62


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3. Time
This is the duration of the phase. Time is set in seconds.
4. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.10.2 Detachment 2 Non-demoulding side – Mould 2


This is the 2nd phase of detachment of the piece from the non-demoulding side. During
this phase the hydraulic hammers are opened. Air (or water) is injected in the resin
mould to continue to release the piece from the resin surface. This phase follows
immediately after detachment 1. The valve YV290 is opened and YV291 is closed.
When all hammers are completely open, the mobile part of the press will remain in the
detachment position as set in the setup configuration page.

PARAMETERS:
1. Water ON/OFF
Take care when using water as too much water can cause deformation in pieces with
hollow casting. If the switch is selected to ON, water will be used in this phase and when
OFF is selected air will be used. Normally water is not used after detachment 1 but it
may be required to use.
2. Delay
If more than one mould is installed on the machine, it is possible that different times are
required for detachment. Compare the detachment time for every phase and set a
delay time equal to the difference between the time parameter for mould 1 and 2 on
the mould with the shorter of the two times. If the detachment times are equal, no
delay is necessary.
3. Time
This is the duration of the phase. Time is set in seconds.
4. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.10.3 Detachment 3 Non-demoulding side – Mould 2


This is the 3rd phase of detachment of the piece from the non-demoulding side. Before
this phase the hydraulic hammers are already open and auxiliary inserts completely
detached. Air (or water) is injected in the resin mould to continue to release the piece
from the resin surface. This phase follows immediately after detachment 2 of auxiliary
inserts. The valve YV290 is opened and YV291 is closed.

PARAMETERS:
1. Water ON/OFF
Take care when using water as too much water can cause deformation in pieces with
hollow casting. If the switch is selected to ON, water will be used in this phase and when

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 63


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

OFF is selected air will be used. Normally water is not used after detachment 1 but it
may be required to use.
2. Delay
If more than one mould is installed on the machine, it is possible that different times are
required for detachment. Compare the detachment time for every phase and set a
delay time equal to the difference between the time parameter for mould 1 and 2 on
the mould with the shorter of the two times. If the detachment times are equal, no
delay is necessary.
3. Time
This is the duration of the phase. Time is set in seconds.
4. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.10.4 Detachment 4 Non-demoulding side – Mould 2


This is the 4th phase of detachment of the piece from the non-demoulding side. During
this phase the hydraulic hammers are already open and the mobile part of the press
will start to move towards the rotation position (or open position if the piece does not
require horizontal demoulding by the robot). Air (or water) is injected in the resin mould
to continue to release the piece from the resin surface. This phase follows immediately
after detachment 2. The valve YV290 is opened and YV291 is closed.

PARAMETERS:
1. Water ON/OFF
Take care when using water as too much water can cause deformation in pieces with
hollow casting. If the switch is selected to ON, water will be used in this phase and when
OFF is selected air will be used. Water is hardly ever used in the 4th phase of
detachment.
2. Delay
If more than one mould is installed on the machine, it is possible that different times are
required for detachment. Compare the detachment time for every phase and set a
delay time equal to the difference between the time parameter for mould 1 and 2 on
the mould with the shorter of the two times. If the detachment times are equal, no
delay is necessary.
3. Time
This is the duration of the phase. Time is set in seconds.
4. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.10.5 Detachment 1 Demoulding side – Mould 2


This is the 1st phase of detachment of the piece from the demoulding side. During this
phase the robot will be in position already with the demoulding tool or setter plate
almost in contact with the piece. There should always be 2 to 3 mm space between the

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 64


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

tool and the piece to allow the detachment pressure to push the piece away from the
mould. If the tool is pushed against the piece you are almost sure of having
deformation on the part that is still in the half mould. Air (or water) is injected in the resin
mould to release the piece from the resin surface. This phase starts immediately when
the robot is in demoulding position and the signal is received by the press from the
robot. The valve YV260 is opened and YV261 is closed. If auxiliary vacuum is used
through valve YV351, the vacuum is stopped immediately before this 1st detachment
starts.

PARAMETERS:
1. Water ON/OFF
Sometimes when auxiliary vacuum is used, it is necessary to inject some water into the
mould to help with the release of the piece onto the robot tool. If the switch is selected
to ON, water will be used in this phase and when OFF is selected air will be used.
2. Time
This is the duration of the phase. Time is set in seconds.
3. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.10.6 Detachment 2 Demoulding side – Mould 2


This is the 2nd phase of detachment of the piece from the demoulding side. During this
phase the robot will start to move away from the mould gently taking the piece from
the mould. Air is injected in the resin mould to release the piece from the resin surface.
The valve YV260 is opened and YV261 is closed. When the time of this phase have
elapsed, the valveYV260 will close and YV261 will open releasing any residual air that
may be in the mould after detachment is completed.

PARAMETERS:
1. Water ON/OFF
If the switch is selected to ON, water will be used in this phase and when OFF is selected
air will be used. Water is hardly ever used in this phase of detachment.
2. Time
This is the duration of the phase. Time is set in seconds.
3. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.9.7 Detachment 1 Auxiliary Inserts – Mould 1


This is the 1st phase of detachment of the auxiliary inserts from the piece (mobile inserts
that are used to create fixing holes in the back of washbasins). Air (or water) is injected
in the resin insert to release it from the piece. This phase starts immediately after the
hammers are opened in detachment 2 from non demoulding side. The valve YV241 is

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 65


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

opened and YV241A is closed. The inserts can only start to detach when the hammers
are released to avoid any pressure from the closed mould on the barrel of the insert.

PARAMETERS:
1. Water ON/OFF
If the switch is selected to ON, water will be used in this phase and when OFF is selected
air will be used.
2. Time
This is the duration of the phase. Time is set in seconds.
3. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

3.3.9.8 Detachment 2 Auxiliary Inserts – Mould 1


This is the 2nd phase of detachment of the auxiliary inserts from the piece. Air (or water)
is injected in the resin insert to release it from the piece. This phase starts immediately
after detachment 1 for auxiliary inserts. The valve YV241 is opened and YV241A is
closed. The inserts can only start to detach when the hammers are released to avoid
any pressure from the closed mould on the barrel of the insert.

PARAMETERS:
1. Water ON/OFF
If the switch is selected to ON, water will be used in this phase and when OFF is selected
air will be used.
2. Time
This is the duration of the phase. Time is set in seconds.
3. Final Pressure
This is the pressure set in bar that is applied to the mould when air is used in this phase.
Pressure cannot be set when water is selected.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 66


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.11 TECHNOLOGICAL CYCLE PHASE PAGE C11 – WASHING TOTAL DURATION

3.3.11.1 Filling Circuit


This refers to the slip filling circuit and refers to the part after the valve YV440 to the
mould filling point. If this phase is selected the valve YV450 opened and water will be
injected in the mould filling circuit from valve YV510. The discharge valve YV460 will also
be opened. It is sometimes necessary to clean the filling circuit with water as a hard slip
build-up is possible to form inside the circuit.

PARAMETERS:
1. Water Time On
This is the time in seconds that water will be injected into the filling circuit.
2. Vacuum Time On
This is not used on this model of press.

3.3.11.2 Draining Valve YV230


This is one of the 2 draining air valves of mould 1. It can be cleaned using own
parameters to suit the need of the particular circuit. Some draining circuits require more
cleaning than others. Some circuits with the special plastic sleeved insert only require
cleaning with air.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 67


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

PARAMETERS:
1. Water
This is the time in seconds that water will be injected through this valve YV230.
2. Time
This is the time in seconds that air will be injected through this valve YV230.
3. Pressure
This is the pressure in bar of the air during the air phase. Water pressure is not controlled.

3.3.11.3 Draining Valve YV231


This is the second of the 2 draining air valves of mould 1. It can be cleaned using own
parameters to suit the need of the particular circuit. Some draining circuits require more
cleaning than others. Some circuits with the special plastic sleeved insert only require
cleaning with air.
PARAMETERS:
1. Water
This is the time in seconds that water will be injected through this valve YV231.
2. Time
This is the time in seconds that air will be injected through this valve YV231.
3. Pressure
This is the pressure in bar of the air during the air phase. Pressure was already set for
YV230 and also applies to this valve.

3.3.11.4 Draining Valve YV232


This is one of the 2 draining air valves of mould 2. It can be cleaned using own
parameters to suit the need of the particular circuit. Some draining circuits require more
cleaning than others. Some circuits with the special plastic sleeved insert only require
cleaning with air.

PARAMETERS:
1. Water
This is the time in seconds that water will be injected through this valve YV232.
2. Time
This is the time in seconds that air will be injected through this valve YV232.
3. Pressure
This is the pressure in bar of the air during the air phase. Water pressure is not controlled.

3.3.11.5 Draining Valve YV233


This is the second of the 2 draining air valves of mould 2. It can be cleaned using own
parameters to suit the need of the particular circuit. Some draining circuits require more
cleaning than others. Some circuits with the special plastic sleeved insert only require
cleaning with air.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 68


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

PARAMETERS:
1. Water
This is the time in seconds that water will be injected through this valve YV233.
2. Time
This is the time in seconds that air will be injected through this valve YV233.
3. Pressure
This is the pressure in bar of the air during the air phase. Pressure was already set for
YV232 and also applies to this valve.

The water for the cleaning of the above four valves will start simultaneously if set and
the air will only start when all water cleaning have elapsed. The air again will start
simultaneously.

3.3.11.6 2nd Draining Air


After washing of the mould sections in the press, the draining air circuit is once again
cleaned with air. This is to ensure there is no water remaining in the circuit that could
cause damage to the piece internally later on in the cycle. All the valves, YV230,
YV231, YV232 and YV233 are cleaned simultaneously in this phase.

PARAMETERS:
1. Time
This is the time in seconds that air will be injected through these valves.
2. Pressure
This is the pressure in bar of the air during the air phase.

3.3.11.7 Mould Circuit


All resin parts of the moulds also has to be washed between casting cycles. It is possible
to clean every resin part individually by opening and closing the water, air and vacuum
to the particular part independently from any other resin part. Between casting cycles it
is important to clean out any fine particles of slip that may have penetrated the pores
of the resin during casting. It is important to understand that the times and pressures set
for mould circuit are the global time. These times are divided and shared by the
individual parts depending on the % of each global time you select on the next page
for washing. The reasons for using divided times are twofold. Firstly you have to prevent
any water from one section of mould to fall onto another mould part that has already
been cleaned. Secondly with divided time you have more dedicated pressure and
flow resulting in better cleaning. Depending on the slip used, the phases could run in
parallel and save some time in washing. The sequence of washing is first water, then air
and finally vacuum. The air will force water out of the resin. Vacuum is to dry the mould
surface somewhat in preparation for the next casting cycle. The degree of moisture in
the resin after washing is very important for the performance and thickness formation of
the piece. Controlling the moisture in the resin at this phase also determine the ease of
detachment at the end of the cycle.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 69


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

PARAMETERS:
1. Water On Time
This is the total time in seconds that water will be injected to the distribution manifold
and be available for washing of any resin part. Valves YV520 for lower mould and
YV521 for upper mould are used.
2. Vacuum On Time
This is the total time in seconds that vacuum will be applied to the distribution manifold
and be available to any resin part. Valves YV320 for lower mould and YV321 for upper
mould are used.
3. Air On Time
This is the total time in seconds that air will be injected to the distribution manifold and
be available for washing of any resin part. Valves YV220 for lower mould and YV221 for
upper mould are used.
4. Air Pressure Lower Mould
This is the pressure in bar of the air during the air phase of washing of the lower mould.
5. Air Pressure Upper Mould
This is the pressure in bar of the air during the air phase of washing of the upper mould.

3.3.11.8 Vacuum Tank


It is possible to clean the vacuum tank after each washing cycle to remove any dirt
and residue from it. During aspiration of the pieces some dirty water and slip may reach
the tank and this need to be rinsed out. Valves YV520/YV521 and YV320/YV321 will
transfer water to the vacuum tank. At the end of this cleaning sequence, water will
drain from the bottom of the tank through YV300

PARAMETERS:
1. Water On Time
This is the total time in seconds that water will be injected to the distribution manifold
and be available for washing of the vacuum tank.
2. Vacuum On Time
This is the total time in seconds that vacuum will be applied to the distribution manifold
and be available for washing of the vacuum tank.

3.3.11.9 Mould Regeneration


It is possible to do some continuous washing of the resin parts of the mould. During
regeneration water and air will be injected alternatively. All resin parts receive water
and air simultaneously as per the individual settings for water and air. Water and air will
never be opened simultaneously as it hold some danger in cracking the mould from
behind.

PARAMETERS:
1. Water On Time
This is the total time in seconds that water will be injected to the distribution manifold
and from there to all resin parts simultaneously.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 70


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

2. Air On Time
This is the total time in seconds that air will be injected to the distribution manifold and
from there to all resin parts simultaneously.

When the presses are stopped for any extended time more than one day, it is important
to set the maintenance time for moulds. The moulds will then be automatically
regenerated as per the set points on the maintenance page,

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 71


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.12 TECHNOLOGICAL CYCLE PHASE PAGE C12 – WASHING PROPORTIONAL TIME

3.3.12.1 Washing Non Demoulding Mould 1


This is the washing sequence of the non demoulding part of the lower mould.

PARAMETERS:
1. Water Start/Stop Time
This is the start and stop point in percentage of the global time set for washing of this
section of mould with water through YV520 (water inlet to manifold) and YV280 (valve
from manifold to mould). Water is first in washing sequence.
2. Vacuum Start/Stop Time
This is the start and stop point in percentage of the global time set for applying vacuum
to this section of mould through YV320 (vacuum inlet to manifold) and YV280 (valve
from manifold to mould). Vacuum is last in the washing sequence.
3. Air Start/Stop Time
This is the start and stop point in percentage of the global time set for washing of this
section of mould with air through YV220 (air inlet to manifold) and YV280 (valve from
manifold to mould). Air is second in washing sequence.

3.3.12.2 Washing Non Demoulding Mould 2


This is the washing sequence of the non demoulding part of the upper mould.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 72


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

PARAMETERS:
1. Water Start/Stop Time
This is the start and stop point in percentage of the global time set for washing of this
section of mould with water through YV521 (water inlet to manifold) and YV290 (valve
from manifold to mould). Water is first in washing sequence.
2. Vacuum Start/Stop Time
This is the start and stop point in percentage of the global time set for applying vacuum
to this section of mould through YV321 (vacuum inlet to manifold) and YV290 (valve
from manifold to mould). Vacuum is last in the washing sequence.
3. Air Start/Stop Time
This is the start and stop point in percentage of the global time set for washing of this
section of mould with air through YV221 (air inlet to manifold) and YV290 (valve from
manifold to mould). Air is second in washing sequence.

3.3.12.3 Washing Demoulding Mould 1


This is the washing sequence of the demoulding part of the lower mould.

PARAMETERS:
1. Water Start/Stop Time
This is the start and stop point in percentage of the global time set for washing of this
section of mould with water through YV520 (water inlet to manifold) and YV250 (valve
from manifold to mould). Water is first in washing sequence.
2. Vacuum Start/Stop Time
This is the start and stop point in percentage of the global time set for applying vacuum
to this section of mould through YV320 (vacuum inlet to manifold) and YV250 (valve
from manifold to mould). Vacuum is last in the washing sequence.
3. Air Start/Stop Time
This is the start and stop point in percentage of the global time set for washing of this
section of mould with air through YV220 (air inlet to manifold) and YV250 (valve from
manifold to mould). Air is second in washing sequence.

3.3.12.4 Washing Demoulding Mould 2


This is the washing sequence of the demoulding part of the upper mould.

PARAMETERS:
1. Water Start/Stop Time
This is the start and stop point in percentage of the global time set for washing of this
section of mould with water through YV521 (water inlet to manifold) and YV260 (valve
from manifold to mould). Water is first in washing sequence.
2. Vacuum Start/Stop Time
This is the start and stop point in percentage of the global time set for applying vacuum
to this section of mould through YV321 (vacuum inlet to manifold) and YV260 (valve
from manifold to mould). Vacuum is last in the washing sequence.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 73


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3. Air Start/Stop Time


This is the start and stop point in percentage of the global time set for washing of this
section of mould with air through YV221 (air inlet to manifold) and YV260 (valve from
manifold to mould). Air is second in washing sequence.

3.3.12.5 Washing Auxiliary Circuit Inserts


This is the washing sequence of the auxiliary circuit inserts. The inserts for lower and
upper moulds are set in the same line of the setup page.

PARAMETERS:
1. Water Start/Stop Time
This is the start and stop point in percentage of the global time set for washing of this
section of mould with water through YV520 and YV521 (water inlet to manifolds lower
and upper moulds) and YV240A and YV241A (valve from manifold to inserts lower and
upper moulds). Water is first in washing sequence.
2. Vacuum Start/Stop Time
This is the start and stop point in percentage of the global time set for applying vacuum
to this section of mould through YV320 and YV321 (vacuum inlet to manifolds lower and
upper moulds) and YV240A and YV241A (valve from manifold to inserts lower and
upper moulds). Vacuum is last in the washing sequence.
3. Air Start/Stop Time
This is the start and stop point in percentage of the global time set for washing of this
section of mould with air through YV220 and YV221 (air inlet to manifold) and YV240A
and YV241A (valve from manifold to inserts lower and upper moulds). Air is second in
washing sequence.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 74


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.13 SETUP PAGE C13 – CONFIGURATION

The configuration setup pages address some physical characteristics of the press and
needs to be completed very carefully to avoid damage to the equipment. To arrive in
the configuration pages you have to press the Configure button at the bottom of any
setup page. Once more you will be required to enter a password as described in
Automatic Setup. Some of the parameters on this page is very critical and have to be
tested and controlled in manual after the values were updated.

3.3.13.1 Press in Open Position


This is the position when the press is in the vertical position and the mobile part is driven
fully open. This is normally the demoulding position when pieces are demoulded from
the vertical mobile part by the robot. Take care to use the maximum open position and
do not change the setting. If a smaller value is set after robot programming is done, you
will have a collision by the robot to the mobile part. The press sends a ready signal to
the robot when the parameter value in this setting is met.

PARAMETER:
1. Distance Value in mm. This value is controlled by means of a linear transducer in the
top of the press that accurately reads the travel distance of the press mobile part.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 75


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.13.2 Press in Washing Position


This is the position where you set the mobile part to stop for completion of the washing
cycle.

PARAMETER:
1. Distance Value in mm. This value is controlled by means of a linear transducer in the
top of the press that accurately reads the travel distance of the press mobile part.

3.3.13.3 Press in Demoulding Position


This is the position of the mobile part immediately after the hydraulic hammers were
opened during detachment. It must be tested if it is safe to open the hydraulic
hammers in this position.

PARAMETER:
1. Distance Value in mm. This value is controlled by means of a linear transducer in the
top of the press that accurately reads the travel distance of the press mobile part.

3.3.13.4 Press in Closing Position


This is the position of the mobile part when it is safe to close the hydraulic hammers. This
position is reached during lateral movement of the mobile part when the two mould
parts touch each other and the mould is practically in a closed position by the motor
that drive the mobile part.

PARAMETER:
1. Distance Value in mm. This value is controlled by means of a linear transducer in the
top of the press that accurately reads the travel distance of the press mobile part.

3.3.13.5 Deceleration Space


The movement of the mobile part of the press is controlled by a frequency inverter. This
gives you the possibility to control variable speed settings on the movement.
Deceleration space is the distance required before any open or closed position of the
mobile part to safely slow down.

PARAMETER:
1. Distance Value in mm. This value is controlled by means of a linear transducer in the
top of the press that accurately reads the travel distance of the press mobile part.

3.3.13.6 Slow Demoulding Space


When the press opens after casting, the initial movement of the mobile part is called
the slow demoulding space. The mobile part carefully extracts the piece from the fixed
side of the mould.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 76


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

PARAMETER:
1. Distance Value in mm. This value is controlled by means of a linear transducer in the
top of the press that accurately reads the travel distance of the press mobile part.

3.3.13.7 Offset Locking Low Pressure


This is the threshold level of the hydraulic circuit when the press is in low pressure
hydraulic operation. During closing of the press the hammers will turn and lock on the
press frame. When all hammers are completely locked in low pressure a certain
pressure in the system is reached. Before the system can switch over to high pressure,
the PLC will determine if the pressure is over the offset pressure. Over time the limit of
low pressure will deteriorate as the internal of the pump wears out, when filters are
blocked or when cylinders are leaking oil.

PARAMETER:
1. Pressure in bar. This value is controlled by comparing the actual oil pressure with the
set point.

3.3.13.8 Offset Locking High Pressure


This is the threshold level of the hydraulic circuit when the press is in high pressure
hydraulic operation. After closing the hammers in low pressure and the low pressure
offset is met, the hydraulic circuit will switch over to high pressure and close all hammers
in high pressure. When a static situation is reached, the PLC will control to see if the high
pressure is reached. Filling of the moulds will not commence if the offset is not met.

PARAMETER:
1. Pressure in bar. This value is controlled by comparing the actual oil pressure with the
set point.

3.3.13.9 Presence of Mould 1


This is a selector to set ON if a mould is installed in position 1 (Lower part). If it is set to ON,
all functionality for the mould is possible. If it is set to OFF, all functionality on the circuit is
disabled.

3.3.13.10 Presence of Mould 2


This is a selector to set ON if a mould is installed in position 2 (Upper part). If it is set to
ON, all functionality for the mould is possible. If it is set to OFF, all functionality on the
circuit is disabled.

3.3.13.11 Synchronised Start


Select ON if you want the press to be synchronised with the other presses (ensuring that
presses open one at a time with no robot overlaps). There may be a short waiting time
at the end of each cycle to synchronise presses.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 77


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.13.12 Opening Cylinders ON/OFF


Some presses are equipped with hydraulic cylinders that assist in opening the press from
the closed position during demoulding. Some pieces have more complex geometry
that creates excess friction between the mould surface and the piece. This friction
makes it difficult to drive the press open with only the electric motor. Not all presses are
equipped with this function and is normally used in the casting of water tanks (cisterns).

3.3.13.13 Casting Mould 1 ON/OFF


It is possible to prevent casting on a mould that is installed on the press. Sometimes you
need to stop casting one mould while the other one is casting. Select the switch to ON
to enable casting and OFF to disable casting. When the mould is disabled, all slip
circuits will be disabled but the mould circuit will still be washed every cycle during
washing phase.

3.3.13.14 Casting Mould 2 ON/OFF


It is possible to prevent casting on a mould that is installed on the press. Sometimes you
need to stop casting one mould while the other one is casting. Select the switch to ON
to enable casting and OFF to disable casting. When the mould is disabled, all slip
circuits will be disabled but the mould circuit will still be washed every cycle during
washing phase.

3.3.13.15 Demoulding Mould 1 Fixed/Mobile Side


Select the position of demoulding. If Fixed is selected, mould 1 will be taken by the
robot from the fixed part of the press. The fixed part then becomes the Demoulding side
and the mobile side becomes the Non Demoulding side. If Mobile is selected the
opposite becomes true and the robot will take the piece from the mobile side of the
press. Ensure to test all valves from the manual pages to make sure the correct
functionality of the press is active.

3.3.13.16 Demoulding Mould 2 Fixed/Mobile Side


Select the position of demoulding. If Fixed is selected, mould 2 will be taken by the
robot from the fixed part of the press. The fixed part then becomes the Demoulding side
and the mobile side becomes the Non Demoulding side. If Mobile is selected the
opposite becomes true and the robot will take the piece from the mobile side of the
press. Ensure to test all valves from the manual pages to make sure the correct
functionality of the press is active.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 78


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.14 SETUP PAGE C14 – ROTATION

3.3.14.1 Press Rotation Position


This is the position at which the press can safely rotate from vertical to horizontal and
vice versa. When the mobile part reach this point it will stop and the hydraulic cylinders
on the back of the press frame will move the press frame from vertical to horizontal for
the demoulding operation.

PARAMETER:
1. Distance Value in mm. This value is set and confirmed on the next page that appears
when this value is touched for changing.

3.3.14.2 Press Security Position


This is the position where the moulds can safely be changed. From the original rotation
position it is possible to move the mobile part more open while in the press is in
horizontal until the mobile part reaches the safety frame on the top of the press. This
operation is done in manual mode and will be described later in the manual.

PARAMETER:
1. Distance Value in mm. This value is set and confirmed on the next page that appears
when this value is touched for changing.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 79


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.14.3 High Speed Rotation %


In the rotation movement path there are 4 sensors to read the physical position of the
mobile part in rotation. Between the sensors there is a long area of travel when no
sensor is read by the PLC. During this movement it is possible to apply maximum pressure
to the cylinders to enable high speed movement.

PARAMETER:
1. Percentage setting between 0% and 100%.

3.3.14.4 Medium Speed Rotation %


Near the vertical position and near the horizontal position the PLC will read a first signal
from the medium speed sensor. Pressure will be adjusted to slow down the rotation to
the medium speed as set in the parameters. This is the first deceleration of the rotation
movement.

PARAMETER:
1. Percentage setting between 0% and 100%.

3.3.14.5 Low Speed Rotation %


After the medium speed sensor is read, a second sensor is read to slow down the
movement further (both sensors read together). The pressure will be adjusted to slow
down the rotation to the slow speed as set in the parameters. This is final deceleration
and rotation will continue until the mechanical stop is reached at the end of the
cylinder stroke.

PARAMETER:
1. Percentage setting between 0% and 100%.

3.3.14.6 Demoulding Combination


There are several possible configurations to take the piece from the press by the robot.
Depending on the piece geometry it is possible to support the new piece in almost any
possible condition on the open mould for demoulding.

PARAMETERS:
1. V-V: This is vertical and vertical and both pieces are suspended on one of the
vertical surfaces of the press for taking by the robot.
2. V-H: This is vertical and horizontal. The mould 1 piece will be taken from the vertical
on the fixed side of the press and the mould 2 piece will be taken from the horizontal
on the mobile part of the press.
3. H-H: This is horizontal and horizontal. Both pieces are taken from the horizontal on the
mobile part of the press.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 80


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.15 SETUP PAGE C15 – ROTATION

3.3.15.1 Press Rotation Position


If the value is touched on the previous screen to change this parameter, the page
changes automatically to this page to give you a second chance to select and
change the position of rotation. This is only a security measure to prevent the value to
be changed by mistake on the previous page. Ensure that the press can rotate safely in
the position that you select. Slowly rotate the press and look to see if the mobile part is
not touching the hammers or that the two mould halves does not interfere during
rotation.

3.3.15.2 Press Security Position


If the value is touched on the previous screen to change this parameter, the page
changes automatically to this page to give you a second chance to select and
change the security position. This is only a security measure to prevent the value to be
changed by mistake on the previous page. Ensure that the press can safely move to
the security position after you have changed this parameter. Rotate the press horizontal
and select mould change. Move the press to the security position and look if it is
correct.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 81


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.16 FIRST DISPLAY DURING AUTOMATIC OPERATION OF THE CELL

After entering all the setup parameters carefully, it is possible to run the presses in
automatic and to test the cycle introduced in the previous pages. Select the AUTO
START button on the MAIN display page. The press will start in automatic if there are no
alarms present and if the synchronisation conditions with the other presses in the cell are
met. From the MAIN screen select NEXT and the above active display page will appear,
continuously showing the progress of the casting cycle.

3.3.16.1 Main Graphic Window


The progress and shape of the cycle curve is displayed in the main rectangular window
in real time. The X axis is time in minutes and the Y axis is pressure in Bar. The scale of the
X axis is 30 seconds for every longer line on the axis line. The scale of the Y axis is 2 Bar
for every line on the axis line.

3.3.16.2 Phase C1
The description of the current phase in progress of Press C Mould 1 is displayed in the
long rectangle.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 82


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.16.3 Phase C2
The description of the current phase in progress of Press C Mould 2 is displayed in the
long rectangle.

3.3.16.4 Time Set Point


The set duration for the phase in Press C is displayed here.

3.3.16.5 Time Display


The expired time of the phase in Press C is displayed here.

3.3.16.6 Average Pressure Display


The average pressure between Mould 1 and Mould 2 of Press C is displayed in the small
rectangle to the right of the Time Display.

3.3.16.7 Pressure Display Mould 1


The actual pressure in Mould 1 circuit of Press C is displayed in the green rectangle.

3.3.16.8 Pressure Display Mould 2


The actual pressure in Mould 2 circuit of Press C is displayed in the red rectangle.

3.3.16.9 Phase B1
The description of the current phase in progress of Press B Mould 1 is displayed in the
long rectangle.

3.3.16.10 Phase B2
The description of the current phase in progress of Press B Mould 2 is displayed in the
long rectangle.

3.3.16.11 Time Set Point


The set duration for the phase in Press B is displayed here.

3.3.16.12 Time Display


The expired time of the phase in Press B is displayed here.

3.3.16.13 Average Pressure Display


The average pressure between Mould 1 and Mould 2 of Press B is displayed in the small
rectangle to the right of the Time Display.

3.3.16.14 Pressure Display Mould 1


The actual pressure in Mould 1 circuit of Press B is displayed in the yellow rectangle.

3.3.16.15 Pressure Display Mould 2


The actual pressure in Mould 2 circuit of Press B is displayed in the blue rectangle.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 83


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.16.16 Events
The event window will display some communication regarding the process for example
the status of the robot, the status of the press during opening etc.

3.3.16.17 History Columns


There are two columns in the bottom right of the page with the green column
containing data for Press C and the yellow column containing data for Press B.
- Total Cycles – this is the total number of cycles cast from installation of the press.
- Partial Cycles – this is an intermediate counter and can be reset by touching the
number. You can choose when to reset, daily, weekly or monthly to count
production or reset when a new mould is fitted to keep track of mould life.
- Time Last Cycle – shows the total cycle time of the previously completed cycle.
- Time Cycle – shows the cumulative time of the current cycle. This value resets to 0
at the end of washing.
- Temperature of water – shows the temperature of the heated water entering the
manifold of each press.

3.3.16.18 Top Line Buttons


There are several selection buttons on the top line of the page.
- Main – takes you back to the MAIN selection page.
- Press C Vacuum – enables you to do aspiration of a piece from Press C vacuum
pump.
- Press B Vacuum – enables you to do aspiration of a piece from Press B vacuum
pump.
- Alarms – takes you to the alarm page for view of current alarms and to reset
alarms.
- Next – takes you to the second visual display page of automatic operation of the
presses.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 84


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.17 SECOND DISPLAY DURING AUTOMATIC OPERATION OF THE CELL

The second page of automatic operation monitoring is very important. Some specific
conditions regarding the hydraulic system and position of the mobile part is displayed
on this page. The page is divided in two sections, left in green for Press C and right in
yellow for Press B.

3.3.17.1 Washing
Whenever the press is not in cycle, the washing button can be selected to perform a
single washing operation as set in the Setup of Washing on pages C11 and C12 of
technological setup.

3.3.17.2 Simulate Robot


When the press opens after an automatic cycle and for some reason the robot is not
available, it is possible to select this button to do a step by step detachment of the
pieces (first selection = Mould , second selection = Mould 2 and third selection = robot
out of press and press can continue with washing and return to vertical position).

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 85


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.17.3 Jump Cycle


If during any casting cycle a leakage of slip occurs on any mould, it is recommended to
jump the cycle. This means the pressure from the injector is immediately released and
the mould will drain and go directly to opening after draining without hardening. This is
to prevent any damage to the closing surface of the mould.

3.3.17.4 Regeneration of Moulds


To regenerate the mould is to continuously pass water and air through the resin mould
parts to remove dirt from the pores. When the mould is still cold before starting it is
recommended to use regeneration to bring the mould to working temperature via the
hot water that is passing through the resin. Mould regeneration is set on pages C11 and
C12 of technological setup.

3.3.17.5 Top Line Buttons


There are several selection buttons on the top line of the page.
- Main – takes you back to the MAIN selection page.
- Alarms – takes you to the alarm page for view of current alarms and to reset
alarms.
- Previous – takes you to the first visual display page of automatic operation of the
presses.

3.3.17.6 Active Displays


There are several active displays that indicate the current status of the press.
- Hammers - in the top part of the page is a series of green lights for Press C
hammers and yellow lights for Press B hammers. If the light is clear the hammer is
open and when there is a small black dot in the light, the hammer is closed.
- Water Temperature – displays the water temperature where it enters the manifold
of each press. The left display is Press C and the right display is Press B.
- Locking Bar – displays the active hydraulic pressure of each press.
- Position Press – displays the actual position of the mobile part of the press.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 86


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.18 SEMI-AUTOMATIC OPERATION OF THE CELL

It is possible to perform several functions in semi-automatic mode. Semi-automatic


movement is using all parameters from automatic movement and performs the singular
selected operation. Semi-automatic movement is useful to test movement before
running a full automatic cycle. Semi-automatic should be used to determine if the open
and closed positions of the press as well as the rotation position of the mobile part are
correct as set and tested in manual mode.

3.3.18.1 Rotation of Press


By selecting Vertical Rotation the press will rotate to the absolute vertical position. By
selecting the Horizontal Rotation the press will rotate to the absolute horizontal position.
The mobile part has to be in the rotation position in order for these buttons to work.

3.3.18.2 Translation of Press


By selecting Closing Machine the mobile part will move to the closed position and
when reaching the closed position, the hydraulic hammers will close. When selecting
Opening Machine, the hammers will open (if closed at the moment) and the mobile
part will move to the open position.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 87


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

3.3.18.3 Main
Selecting the button in the top left corner returns you to the Main selection page.

3.3.18.4 Active Displays


There are several active displays to note:
- Translation of Mobile – the blue rectangle above the figure of the press shows the
actual position of the mobile part.
- FC Forward - this indicator is to the left of the upper corner of the picture of the
press on the screen. It always appears grey and when the press reach the
completely open position the indicator will light up.
- NC Limit – The completely closed position of the mobile part. It will have a black
dot when the press reaches the closed position.
- Rotation Position – this is the position set to rotate the press for demoulding or
mould changes.
- Press in Vertical Position – the mobile is in perfect vertical and it is safe to open or
close the press. If the press is not in vertical position, the hammer heads can
touch the female flanges on the mobile frame.
- Press in Horizontal Position – the mobile part is in perfect horizontal position and
ready to demould.

It is not desirable to close the press in semi-automatic before long stoppages. In semi-
automatic the hammers will close and therefore leave the moulds compressed if the
press is left in this condition for a long time.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 88


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4 MANUAL MOVEMENTS AND MANIPULATION OF THE PRESS


It is possible to simulate all functions and movements of the press in manual mode. It is
very important to test and prove that all connections of circuits are indeed correct and
that the parameters chosen for movement positions are correct.

As in the setup sequence, it is necessary to press the Manual button on the touch panel
to enter the manual screens. A password selector screen will appear. Enter the Manual
password and Enter.

On all manual screens there are the same series of buttons on the right of the screen.
This buttons are to navigate to the different functions as described in the next section.

Carefully test all functionality of the installation.

IMPORTANT:
Actions by the operator in this mode can cause hazardous or unsafe situations. When
entering the manual mode please ensure that no personnel are inside the island and all
staff present being made aware that the machine is not in safety mode. Therefore, one
must be wholly familiar with the machine and have full knowledge of all operations
being carried out. Consequently, we recommend that all such operations be carried
out STRICTLY by trained personnel. To this end, access to the MANUAL operating mode
is protected by an ACCESS CODE (password) which must be known by trained
personnel only.

Active Menu Buttons on all pages


 PRINC. – Takes you back to the MAIN selection screen
 SETUP – Takes you to the SETUP screens (via password entry)
 ROTATION – This screen
 MOVEMENT – Takes you to the manual movement of mobile part screen
 FILLING – Left button takes you to filling of mould 1 and right button to filling of
mould 2
 DRAINING – Left button takes you to draining of mould 1 and right button to
draining of mould 2
 MOULD NON DEMOULDING – Left takes you to the mould circuit of mould 1 non
demoulding side and right button takes you to mould circuit mould 2 non
demoulding side.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 89


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

 MOULD DEMOULDING – Left takes you to the mould circuit of mould 1


demoulding side and right button takes you to mould circuit mould 2 demoulding
side.
 SERVICE – Takes you to the services page
 TOOLS – Takes you to the robot tool management page
 ALARMS – Takes you to an overview of current alarms

All the above active buttons appear on all the manual pages to enable navigation to
any point of the equipment from anywhere.

When some function is activated in manual it will automatically terminate if you exit the
manual pages.

For the purposes of this manual copies are included from Press C setup and manual
pages. The diagrammatic colour on the ProFace panel is yellow and for that reason
reference is made to yellow sensor indicators on the screen pages. In some presses the
yellow indicators may be represented by green indicators.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 90


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.1 MANUAL OPERATION – ROTATION PAGE C1

4.1.1 Active Buttons on this page


4.1.1.1 Right Arrow
When pressed, the mobile part of the press will start to rotate towards the horizontal
position. For ability of this switch, the mobile part has to be in the rotation position, the
hydraulic pump has to be on (SERVICES) and the hydraulic high pressure must be
selected (SERVICES). When only the button is pressed continuously, the rotation
movement will be at low speed. A secondary hidden button can be pressed
simultaneously to make the rotation movement in high speed (this point is located at
the top right hand corner of the picture of the press frame). Slow speed rotation is
possible over the complete rotation curve. High speed is only available between the
vertical and horizontal slowdown sensors.

4.1.1.2 Up Arrow
When pressed, the mobile part of the press will start to rotate towards the vertical
position. Exactly the same conditions as in 4.1.1.1 apply for this button regarding
position and speed.

Take care that the rotation position selected and set in configuration is safe and that no
parts of the press will collide with any other part during rotation.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 91


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.1.2 Active Displays on this page


4.1.2.1 Press in Rotation Position
This the yellow indicator at the top left of the picture. When it is only yellow, the mobile
part is in the rotation position (as set in the configuration setup as well as by the position
sensor on the horizontal beam of the press). When there is a black dot in the yellow
indicator, the press is out of the rotation position.

4.1.2.2 Vertical Position


This indicator is located just below the Rotation Position indicator. When it is only yellow,
the mobile part is in the vertical position (as read by the vertical position sensor on the
rotation axis of the press). When there is a black dot in the yellow indicator, the press is
out of the vertical position.

4.1.2.3 Horizontal Position


This indicator is located at the bottom right hand corner of the picture. When it is only
yellow, the mobile part is in the horizontal position (as read by the horizontal position
sensor on the rotation axis of the press). When there is a black dot in the yellow
indicator, the press is out of the horizontal position.

4.1.2.4 Slowdown Indicators


These indicators are located at the right hand back of the diagonal part of the picture.
The upper one is the slowdown indicator towards the vertical position and the lower
one is the slowdown indicator towards horizontal position of the press. When both
indicators have black dots in the yellow indicators, the press is somewhere between
vertical and horizontal. In this condition it is possible to rotate in high speed. When
rotating towards vertical and the vertical slowdown sensor is read, the press will change
over to medium speed mode until also the vertical sensor is read. The press will then
change to low speed mode and while you continue to press the button will continue to
rotate until the mechanical stop is reached at the end of the cylinder stroke. The same
condition applies in the horizontal direction.

4.1.2.5 Linear Position of Carriage


This is the blue rectangular display at the centre bottom of the page. This window
displays the physical position of the carriage as read by the linear transducer in the top
of the press.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 92


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.2 MANUAL OPERATION – MOVEMENTS PAGE C2

4.2.1 Active Buttons on this page


4.2.1.1 Change Mould
When you want to do a mould change, it is possible to drive the mobile part (when in
the horizontal position) approximately another 120mm more open. At this position the
mould frame enters a security position preventing accidental rotation of the mobile
part. The mobile part is prevented by a mechanical stop to rotate. Personnel can now
safely work under the mould carrier frame to detach the previous mould and attach a
new mould. Extreme care must be taken during mould change operations to prevent
injury to people or damage to equipment and moulds. Forklifts used must be of the
correct capacity and forklift operators must be well trained and qualified. Before
detaching the previous mould from the press, ensure that the forklift is supporting the
mould well before starting to unscrew the mould holding bolts.

4.2.1.2 Left Arrow (Press Closing)


Before attempting to move the mobile part in any direction, select the SERVICES page
and enable the hydraulic pump. This is necessary to enable hydraulic pressure to the
rotating cylinders during lateral movement. Lateral movement cannot take place
without the mould frame being in the vertical position. At any time when the lateral
movement button is pressed, the PLC will activate the hydraulic unit in high pressure to

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 93


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

resume pressure on the rotating cylinder to ensure the mould frame is vertical when it
moves. This is to prevent that the hammer heads touch the female slots on the closing
frame as well as to ensure that mould halves always touch only when they are perfectly
parallel. To close the press, continuously push the Left Arrow until the mobile part is
against the fixed part. There is a hidden button in the top right corner of the press frame
picture on the screen that can be pressed simultaneously with the closing button to
enable high speed movement. The lateral movement is by means of an overhead
electric motor and gearbox that drive the carriage by two chains and sprockets. The
motor is controlled by a frequency inverter that control high and low speed as well as
acceleration and deceleration. The deceleration space as set in configuration setup
will apply also in manual movement.

4.2.1.3 Right Arrow (Press Opening)


As described in the closing operation, all the same conditions apply with regard to the
control of this function. To open the press, you have to continuously press the right
arrow.

4.2.1.4 Hammers Closing Button


The hydraulic hammers are closed by pressing the top button on the left once. An
arrow will appear showing that the hammers are closing. For the hammers to be closed
the following conditions must be true:
- The press must be in the closed position as set in configuration setup. Since the
hammers also make a rotation movement, it is not allowed to activate
movement when the press is not completely in the closed position. The hammers
can however also be activated when the press is open more than 700mm.
- The hydraulic pump must be activated on SERVICES page
- The low pressure switch must be activated on SERVICES page

4.2.1.5 Hammers Opening Button


The hydraulic hammers are opened by pressing the lower button on the left once. An
arrow will appear showing that the hammers are opening. For the hammers to be
opened, the same conditions as in closing must be true.

4.2.2 Active Displays on this page


4.2.2.1 Press in Rotation Position
This the yellow indicator at the top left of the picture. When it is only yellow, the mobile
part is in the rotation position (as read on the linear transducer and as set in the
configuration setup). When there is a black dot in the yellow indicator, the press is out of
the rotation position.

4.2.2.2 Vertical Position


This indicator is located just to the right of the press mould frame in the picture. When it
is only yellow, the mobile part is in the vertical position (as read by the vertical position

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 94


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

sensor on the rotation axis of the press). When there is a black dot in the yellow
indicator, the press is out of the vertical position.

4.2.2.3 Rotation Position Sensor


This indicator is located above the press picture on the screen and is the left of the two
sensors in the centre. It displays yellow when the press is in this position and have a
black dot on the yellow when the press is out of this position.

4.2.2.4 Mould Changing Position Sensor


This indicator is located above the press picture on the screen and is the right of the
two sensors in the centre. It displays yellow when the press is in this position and have a
black dot on the yellow when the press is out of this position.

4.2.2.5 Press Completely Open (fc forw)


This indicator is to the left of the upper corner of the picture of the press on the screen. It
always appears grey and when the press reach the completely open position the
indicator will display yellow.

4.2.2.6 Hammers Open or Closed Sensors


The press is equipped with 14 closing hammers for locking the fixed and mobile parts
together. There is a sensor indicator for every one of the hammers. 7 are located above
the hammer closing button and 7 are located below the hammer opening button.
When the hammers are open, the sensor indicators will be yellow and when the
hammers are in the closed position the yellow indicator will have a black dot in it.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 95


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.3 MANUAL OPERATION – FILLING CIRCUIT LOWER MOULD PAGE C3

4.3.1 Active Buttons on this page


4.3.1.1 Injector Forward
Select the black box next to the FORWARD by pressing it once. To enable any
movement of the injector the hydraulic circuit has to be switched on and low pressure
activated on the SERVICES page. Under no circumstances may the injector be pushed
forward if the slip feeding valve YV410 is open. This is to protect the pneumatic pump.

4.3.1.2 Injector Backward


It is not suggested to select the BACKWARD movement of the injector. Normally the
injector will move backward during the filling of the press. If BACKWARD is selected
without any valves on the circuit open it will cause suction inside the injector that may
suck air into the circuit during the next start.

4.3.1.3 Slip Pump


To start the slip pump by touching the pump figure once. Always ensure that slip feed
pipes to the pump is in a good order without any perforation (caused by the
movement of the pipe during any pump action). Check that the manual valve at the
tank is open to feed slip to the pump.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 96


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.3.1.4 Slip Feed Valve YV410


This is the main slip feeding valve to the slip distribution manifold. When the valve on the
screen is touched it will turn light blue from grey indicating that it is open.

4.3.1.5 Slip Feed Valve YV440


This is the main slip feeding valve to the lower mould circuit. When the valve on the
screen is touched it will turn light blue from grey indicating that it is open.

4.3.1.6 Slip Feed Valve YV450


This is the main slip feeding valve to the lower mould. When opened, the mould can be
filled with slip. When the valve on the screen is touched it will turn light blue from grey
indicating that it is open.

4.3.1.7 Slip Discharge Valve YV460


This is the slip discharge valve from the lower mould circuit. When opened, slip will drain
to the floor. When the valve on the screen is touched it will turn light blue from grey
indicating that it is open.

4.3.1.8 Slip Draining Valve YV420


This is the main slip returns valve from the lower mould circuit. When this valve is
opened, slip will pass to the returns line.. When the valve on the screen is touched it will
turn light blue from grey indicating that it is open.

4.3.1.2 Slip Draining Valve YV470


This is the decompression control valve. When it is closed while YV420 is opened, slip will
bypass through the manual decompression valve. If YV470 is opened together with
YV420, slip will pass directly to the slip returns tank. When the valve on the screen is
touched it will turn light blue from grey indicating that it is open.

4.3.1.9 Water Feed Valve YV510


This is water inlet valve into the slip circuit for cleaning purposes only. When the valve on
the screen is touched it will turn light blue from grey indicating that it is open.

4.3.2 Active Displays on this page


4.3.2.1 Injector Forward
When the FORWARD button is touched, a black downward arrow in the button will
indicate that the injector is in forward pressure.

4.3.2.2 Injector Forward


When the BACKWARD button is touched, a black upward arrow in the button will
indicate that the injector is in backward pressure.

4.3.2.3 Slip Pump


The + in the pump figure will change to X showing that the pump is activated.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 97


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.3.2.4 Pressure Indicator


The pressure indicator on the upper part of the screen will display the active pressure in
the slip circuit at any given moment.

4.3.2.5 Valve Indicators


All valves turns light blue when activated or open and grey when deactivated or
closed.

NOTE:
Take care of the following:
- Avoid opening water and return valves at the same time. This may cause water
to enter your slip tanks at the back and seriously affecting slip rheology.
- Never activate the injector FORWARD while the slip valve YV410 is open. The
pneumatic pump can be damaged seriously.
- Always leave the injector in the FORWARD position after cleaning the circuit with
water. This will prevent that you have an injector full of water at the start of a
cycle.
- Always clean the complete slip circuit with water when the plant is to be stopped
for an extended period. This will prevent that slip becomes solid inside the lines.
- It is suggested to clean the slip circuit weekly at least to prevent build-up inside
the lines.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 98


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.4 MANUAL OPERATION – FILLING CIRCUIT UPPER MOULD PAGE C4

4.4.1 Active Buttons on this page


4.4.1.1 Injector Forward
Select the black box next to the FORWARD by pressing it once. To enable any
movement of the injector the hydraulic circuit has to be switched on and low pressure
activated on the SERVICES page. Under no circumstances may the injector be pushed
forward if the slip feeding valve YV410 is open. This is to protect the pneumatic pump.

4.4.1.2 Injector Backward


It is not suggested to select the BACKWARD movement of the injector. Normally the
injector will move backward during the filling of the press. If BACKWARD is selected
without any valves on the circuit open it will cause suction inside the injector that may
suck air into the circuit during the next start.

4.4.1.3 Slip Pump


To start the slip pump by touching the pump figure once. Always ensure that slip feed
pipes to the pump is in a good order without any perforation (caused by the
movement of the pipe during any pump action). Check that the manual valve at the
tank is open to feed slip to the pump.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 99


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.4.1.4 Slip Feed Valve YV410


This is the main slip feeding valve to the slip distribution manifold. When the valve on the
screen is touched it will turn light blue from grey indicating that it is open.

4.4.1.5 Slip Feed Valve YV441


This is the main slip feeding valve to the lower mould circuit. When the valve on the
screen is touched it will turn light blue from grey indicating that it is open.

4.4.1.6 Slip Feed Valve YV451


This is the main slip feeding valve to the lower mould. When opened, the mould can be
filled with slip. When the valve on the screen is touched it will turn light blue from grey
indicating that it is open.

4.4.1.7 Slip Discharge Valve YV461


This is the slip discharge valve from the lower mould circuit. When opened, slip will drain
to the floor. When the valve on the screen is touched it will turn light blue from grey
indicating that it is open.

4.4.1.8 Slip Draining Valve YV421


This is the main slip returns valve from the lower mould circuit. When this valve is
opened, slip will pass to the returns line.. When the valve on the screen is touched it will
turn light blue from grey indicating that it is open.

4.4.1.2 Slip Draining Valve YV471


This is the decompression control valve. When it is closed while YV421 is opened, slip will
bypass through the manual decompression valve. If YV471 is opened together with
YV421, slip will pass directly to the slip returns tank. When the valve on the screen is
touched it will turn light blue from grey indicating that it is open.

4.4.1.9 Water Feed Valve YV511


This is water inlet valve into the slip circuit for cleaning purposes only. When the valve on
the screen is touched it will turn light blue from grey indicating that it is open.

4.4.2 Active Displays on this page


4.4.2.1 Injector Forward
When the FORWARD button is touched, a black downward arrow in the button will
indicate that the injector is in forward pressure.

4.4.2.2 Injector Forward


When the BACKWARD button is touched, a black upward arrow in the button will
indicate that the injector is in backward pressure.

4.4.2.3 Slip Pump


The + in the pump figure will change to X showing that the pump is activated.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 100


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.4.2.4 Pressure Indicator


The pressure indicator on the upper part of the screen will display the active pressure in
the slip circuit at any given moment.

4.4.2.5 Valve Indicators


All valves turns light blue when activated or open and grey when deactivated or
closed.

NOTE:
Take care of the following:
- Avoid opening water and return valves at the same time. This may cause water
to enter your slip tanks at the back and seriously affecting slip rheology.
- Never activate the injector FORWARD while the slip valve YV410 is open. The
pneumatic pump can be damaged seriously.
- Always leave the injector in the FORWARD position after cleaning the circuit with
water. This will prevent that you have an injector full of water at the start of a
cycle.
- Always clean the complete slip circuit with water when the plant is to be stopped
for an extended period. This will prevent that slip becomes solid inside the lines.
- It is suggested to clean the slip circuit weekly at least to prevent build-up inside
the lines.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 101


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.5 MANUAL OPERATION – DRAINING CIRCUIT LOWER MOULD PAGE C5

4.5.1 Active Buttons on this page


4.5.1.1 Controlled Air Valve YV220
Air through this valve is controlled by the proportional valve as set in C11.

4.5.1.2 Non Controlled Air Valve YV202


Air through this valve is not controlled by the proportional valve but is coming directly
from the compressed air circuit and controlled by a pressure regulating valve.

4.5.1.3 Water Valve YV520


Through this valve water is pumped through the draining circuit.

4.5.1.4 Draining Valves YV230 and YV231


Air will enter the hollow part of the cast piece through these two valves.

4.5.2 Active Displays on this page


All valves change from grey to light blue when opened and from light blue to grey
when closed.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 102


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.6 MANUAL OPERATION – DRAINING CIRCUIT UPPER MOULD PAGE C6

4.6.1 Active Buttons on this page


4.6.1.1 Controlled Air Valve YV221
Air through this valve is controlled by the proportional valve as set in C11.

4.6.1.2 Non Controlled Air Valve YV203


Air through this valve is not controlled by the proportional valve but is coming directly
from the compressed air circuit and controlled by a pressure regulating valve.

4.6.1.3 Water Valve YV521


Through this valve water is pumped through the draining circuit.

4.6.1.4 Draining Valves YV232 and YV233


Air will enter the hollow part of the cast piece through these two valves.

4.6.2 Active Displays on this page


All valves change from grey to light blue when opened and from light blue to grey
when closed.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 103


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.7 MANUAL OPERATION – MOULD CIRCUIT NON DEMOULDING LOWER MOULD PAGE C7

4.7.1 Active Buttons on this page


4.7.1.1 Controlled Air Valve YV220
Air through this valve is controlled by the proportional valve as set in C11.

4.7.1.2 Non Controlled Air Valve YV202


Air through this valve is not controlled by the proportional valve but is coming directly
from the compressed air circuit and controlled by a pressure regulating valve. It is not
recommended to send high pressure air to the mould circuit if only one mould section is
selected. This option should be used only if more than 2 mould halves are selected and
opened through YV250, YV260, YV280 or YV290.

4.7.1.3 Water Valve YV520


Through this valve water is pumped into the back of the selected mould circuit.

4.7.1.4 Vacuum Supply Valve YV320


It is possible to apply vacuum to the back of the mould circuit to allow cleaning with
chemicals on the mould casting surface. To have the most efficient use of this
application, ensure that only one mould section is open at any given time during the
cleaning with chemicals.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 104


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.7.1.5 Vacuum Tank Discharge Valve YV300


During vacuum application to any mould circuit some water will accumulate in the
vacuum tank. This water can be drained afterwards by stopping the vacuum pump
and by opening the discharge valve YV300.

4.7.1.6 Vacuum Pump


Stop and start the vacuum pump by touching the figure of the pump on the screen.

4.7.1.7 Air/Water Supply to Resin Inserts YV240A


The resin inserts are mini mould parts and need the same air, water and vacuum circuit
connected as all the normal mould parts.

4.7.1.8 Discharge Valve from Resin Inserts YV240B


Pressure discharge from the resin inserts. The YV240A and YV240B are working in the
opposite and when YV240A is open, YV240B will be closed and vice versa.

4.7.1.9 Air/Water Supply to Non Demoulding Lower Mould YV280


Air, water and vacuum are applied to the back of the mould via this valve. When
YV280 is open, the discharge valve YV281 will close automatically.

4.7.1.10 Discharge Valve from Non Demoulding Lower Mould YV281


Air Pressure discharge from the back of the resin mould. The YV280 and YV281 are
working in the opposite and when YV280 is open, YV281 will be closed and vice versa.

4.7.1.11 Auxiliary Vacuum Supply to Non Demoulding Lower Mould YV350


It is possible to apply vacuum directly to the mould circuit when this side of the press is
used as DEMOULDING side. In that case the manual selector valve on the auxiliary
vacuum circuit must be selected towards this section of the mould.

4.7.2 Active Displays on this page


4.7.2.1 All Valves
All valves change from grey to light blue when opened and from light blue to grey
when closed.

4.7.2.2 Vacuum Pump


The + in the pump figure will change to X showing that the pump is activated.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 105


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.8 MANUAL OPERATION – MOULD CIRCUIT NON DEMOULDING UPPER MOULD PAGE C8

4.8.1 Active Buttons on this page


4.8.1.1 Controlled Air Valve YV221
Air through this valve is controlled by the proportional valve as set in C11.

4.8.1.2 Non Controlled Air Valve YV203


Air through this valve is not controlled by the proportional valve but is coming directly
from the compressed air circuit and controlled by a pressure regulating valve. It is not
recommended to send high pressure air to the mould circuit if only one mould section is
selected. This option should be used only if more than 2 mould halves are selected and
opened through YV250, YV260, YV280 or YV290.

4.8.1.3 Water Valve YV521


Through this valve water is pumped into the back of the selected mould circuit.

4.8.1.4 Vacuum Supply Valve YV321


It is possible to apply vacuum to the back of the mould circuit to allow cleaning with
chemicals on the mould casting surface. To have the most efficient use of this
application, ensure that only one mould section is open at any given time during the
cleaning with chemicals.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 106


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.8.1.5 Vacuum Tank Discharge Valve YV300


During vacuum application to any mould circuit some water will accumulate in the
vacuum tank. This water can be drained afterwards by stopping the vacuum pump
and by opening the discharge valve YV300.

4.8.1.6 Vacuum Pump


Stop and start the vacuum pump by touching the figure of the pump on the screen.

4.8.1.7 Air/Water Supply to Resin Inserts YV241A


The resin inserts are mini mould parts and need the same air, water and vacuum circuit
connected as all the normal mould parts.

4.8.1.8 Discharge Valve from Resin Inserts YV241B


Pressure discharge from the resin inserts. The YV241A and YV241B are working in the
opposite and when YV241A is open, YV241B will be closed and vice versa.

4.8.1.9 Air/Water Supply to Non Demoulding Upper Mould YV290


Air, water and vacuum are applied to the back of the mould via this valve. When
YV290 is open, the discharge valve YV291 will close automatically.

4.8.1.10 Discharge Valve from Non Demoulding Upper Mould YV291


Air Pressure discharge from the back of the resin mould. The YV290 and YV291 are
working in the opposite and when YV290 is open, YV291 will be closed and vice versa.

4.8.1.11 Auxiliary Vacuum Supply to Non Demoulding Upper Mould YV360


It is possible to apply vacuum directly to the mould circuit when this side of the press is
used as DEMOULDING side. In that case the manual selector valve on the auxiliary
vacuum circuit must be selected towards this section of the mould.

4.8.2 Active Displays on this page


4.8.2.1 All Valves
All valves change from grey to light blue when opened and from light blue to grey
when closed.

4.8.2.2 Vacuum Pump


The + in the pump figure will change to X showing that the pump is activated.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 107


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.9 MANUAL OPERATION – MOULD CIRCUIT DEMOULDING LOWER MOULD PAGE C9

4.9.1 Active Buttons on this page


4.9.1.1 Controlled Air Valve YV220
Air through this valve is controlled by the proportional valve as set in C11.

4.9.1.2 Water Valve YV520


Through this valve water is pumped into the back of the selected mould circuit.

4.9.1.3 Vacuum Supply Valve YV320


It is possible to apply vacuum to the back of the mould circuit to allow cleaning with
chemicals on the mould casting surface. To have the most efficient use of this
application, ensure that only one mould section is open at any given time during the
cleaning with chemicals.

4.9.1.4 Vacuum Tank Discharge Valve YV300


During vacuum application to any mould circuit some water will accumulate in the
vacuum tank. This water can be drained afterwards by stopping the vacuum pump
and by opening the discharge valve YV300.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 108


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.9.1.5 Vacuum Pump


Stop and start the vacuum pump by touching the figure of the pump on the screen.

4.9.1.6 Air/Water Supply to Demoulding Lower Mould YV250


Air, water and vacuum are applied to the back of the mould via this valve. When
YV250 is open, the discharge valve YV251 will close automatically.

4.9.1.7 Discharge Valve from Demoulding Lower Mould YV251


Air Pressure discharge from the back of the resin mould. The YV250 and YV251 are
working in the opposite and when YV250 is open, YV251 will be closed and vice versa.

4.9.1.8 Auxiliary Vacuum Supply to Demoulding Lower Mould YV351


It is possible to apply vacuum directly to the mould circuit when this side of the press is
used as DEMOULDING side. In that case the manual selector valve on the auxiliary
vacuum circuit must be selected towards this section of the mould.

4.9.2 Active Displays on this page


4.9.2.1 All Valves
All valves change from grey to light blue when opened and from light blue to grey
when closed.

4.9.2.2 Vacuum Pump


The + in the pump figure will change to X showing that the pump is activated.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 109


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.10 MANUAL OPERATION – MOULD CIRCUIT DEMOULDING UPPER MOULD PAGE C10

4.10.1 Active Buttons on this page


4.10.1.1 Controlled Air Valve YV221
Air through this valve is controlled by the proportional valve as set in C11.

4.10.1.2 Water Valve YV521


Through this valve water is pumped into the back of the selected mould circuit.

4.10.1.3 Vacuum Supply Valve YV321


It is possible to apply vacuum to the back of the mould circuit to allow cleaning with
chemicals on the mould casting surface. To have the most efficient use of this
application, ensure that only one mould section is open at any given time during the
cleaning with chemicals.

4.10.1.4 Vacuum Tank Discharge Valve YV300


During vacuum application to any mould circuit some water will accumulate in the
vacuum tank. This water can be drained afterwards by stopping the vacuum pump
and by opening the discharge valve YV300.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 110


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.10.1.5 Vacuum Pump


Stop and start the vacuum pump by touching the figure of the pump on the screen.

4.10.1.6 Air/Water Supply to Demoulding Lower Mould YV260


Air, water and vacuum are applied to the back of the mould via this valve. When
YV260 is open, the discharge valve YV261 will close automatically.

4.10.1.7 Discharge Valve from Demoulding Lower Mould YV261


Air Pressure discharge from the back of the resin mould. The YV260 and YV261 are
working in the opposite and when YV260 is open, YV261 will be closed and vice versa.

4.10.1.8 Auxiliary Vacuum Supply to Demoulding Lower Mould YV361


It is possible to apply vacuum directly to the mould circuit when this side of the press is
used as DEMOULDING side. In that case the manual selector valve on the auxiliary
vacuum circuit must be selected towards this section of the mould.

4.10.2 Active Displays on this page


4.10.2.1 All Valves
All valves change from grey to light blue when opened and from light blue to grey
when closed.

4.10.2.2 Vacuum Pump


The + in the pump figure will change to X showing that the pump is activated.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 111


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.11 MANUAL OPERATION – SERVICES PAGE C11

4.11.1 Active Buttons on this page


4.11.1.1 Oil Pump
The hydraulic oil pump is started and stopped with this switch. To the left the switch is off
and to the right the switch is on. By starting the pump, the circuit will have only the
pump pressure active which is less than 20Bar.

4.11.1.2 Low Pressure Enable


With the pump started the low pressure can be enabled (to do hammer adjustment for
example). Low pressure ends at approximately 50Bar. When the switch is enabled the
figure will change colour to light blue ad when it is disabled it will be grey.

4.11.1.3 High Pressure Enable


This switch enables high pressure. If activated it is possible to test the hydraulic functions
in high pressure. High pressure ends at approximately 160Bar. When the switch is
enabled the figure will change colour to light blue ad when it is disabled it will be grey.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 112


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.11.1.4 Multiplier Enable


This switch will multiply the current high pressure of the system by 2. Multiplied pressure is
the pressure necessary for closing the hammers during the casting cycle. Multiplied
pressure ends at approximately 320Bar. When the switch is enabled the figure will
change colour to light blue ad when it is disabled it will be grey.

4.11.1.5 Grease Pump Conveyor Robot


This switch enables the lubrication pump on the robot track movement. When the
switch is enabled the figure will change colour to light blue ad when it is disabled it will
be grey.

4.11.1.6 Hydraulic Inserts Outside the Mould


For moulds equipped with the hydraulic type piston insert to make the water overflow
hole in the piece, this switch will push the piston out of the resin to the ready for cast
position. Button activated will show a green light and deactivated will show a red light.

4.11.1.7 Hydraulic Inserts Inside the Mould


This switch will draw the insert back into the mould as in the demoulding position for the
cast piece. Button activated will show a green light and deactivated will show a red
light.

4.11.1.8 Pneumatic Inserts Lower Mould


This switch will push the insert out of the mould to the normal casting position when
activated and withdraw back inside the mould to demoulding position when
deactivated. Button activated will show a green light and deactivated will show a red
light.

4.11.1.9 Pneumatic Inserts Upper Mould


This switch will push the insert out of the mould to the normal casting position when
activated and withdraw back inside the mould to demoulding position when
deactivated. Button activated will show a green light and deactivated will show a red
light.

4.11.1.10 Vacuum Pump


It is possible to start the vacuum pump from this page to enable manual aspiration of
pieces at the aspiration pipe on the tool supports. Stop and start the vacuum pump by
touching the figure of the pump on the screen.

4.11.1.11 Aspiration Piece


This valve should be opened to enable aspiration of a piece while in the same time the
vacuum pump is enabled.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 113


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.11.1.12 Slip Pressure Set point


Enter a value in the rectangular box to control the set point of slip movement during
any manual operation of the slip injector or pump. Touch the box, a small input screen
will appear, clear the old value and type the new value. Press ENTER when the new
value is typed.

4.11.1.13 Air Pressure Set point Mould 1


Enter a value in the rectangular box to control the set point of air movement during any
manual operation of the draining or mould circuit of MOULD 1. This set point also
determines the maximum level of air available to the slip pump. Touch the box, a small
input screen will appear, clear the old value and type the new value. Press ENTER when
the new value is typed.

4.11.1.14 Air Pressure Set point Mould 2


Enter a value in the rectangular box to control the set point of air movement during any
manual operation of the draining or mould circuit of MOULD 2. This set point also
determines the maximum level of air available to the slip pump. Touch the box, a small
input screen will appear, clear the old value and type the new value. Press ENTER when
the new value is typed.

4.11.2 Active Displays on this page


4.11.2.1 All Valves
All valves change from grey to light blue when opened and from light blue to grey
when closed.

4.11.2.2 Vacuum Pump


The + in the pump figure will change to X showing that the pump is activated.

4.11.2.3 Temperature of Water


The current temperature of water entering the manifold is displayed in °C.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 114


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.12 MANUAL OPERATION – TOOLS PAGE C12

The casting cell is equipped with 4 overhead tool storage areas from where the robot
can automatically pick up and deposit tools during manipulation of pieces from the
press. If different model moulds are installed on the presses it becomes necessary to
place the correct manipulating tools in these storage spaces to enable automatic
operation.

IMPORTANT:
The only time this mode should be entered is when tools are changed on the storage
supports. This is a potentially dangerous situation and if care is not taken, damage to
equipment or injury to persons can occur. Only competent persons should be in control
of the panel during this operation.

It is important to realise that the lock must be closed on the tool before the robot
release the tool on the storage position.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 115


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

4.12.1 Active Buttons on this page


4.12.1.1 Tool 1&2 Lock and Unlock
Drive the robot to the tool to be changed and lock the tool changer head of the robot
on the tool. Press the unlock button on the press panel. It is now possible to drive the
tool with the robot to a safe position near the floor to take down the old tool from the
robot and to place a new tool on the robot. When a new tool is attached to the robot,
drive the robot back to the storage position and stop the movement of the robot when
the tool rests safely on the rack. Press the locking button on the press panel. When the
locking arm is safely in position on the tool, release the tool changer head from the tool
and drive the robot back to Home Position.

4.12.2 Active Displays on this page


4.12.2.1 Lock sensor
When the locking arms above the tools are locked onto the tool the indicator will have
a black dot in the centre.

4.12.2.2 Unlock sensor


When the locking arms above the tools are unlocked (tool should be held up by the
robot) the indicator will have a black dot in the centre.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 116


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

5. SLIP TANK OPERATION AND SETUP

From the MAIN page, select SLIP Tank button. A selection page with two options will
appear. From here you can select to monitor the slip tank where it is possible to see the
actual status of the circuit. It is also possible to select the Setup page to change the
process parameters relating to the slip circuit. If Setup is selected, a password keypad
will appear and only after entering the correct password, will you be able to edit the
setup parameters.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 117


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

5.1 Slip Tank Monitoring

5.1 Active Buttons on this page


5.1.1 Heating Enable
When ON is selected, the temperature of the slip in the tank will be controlled as per
the set point in Slip Tank Setup. When OFF, the heating will be disabled but the
motorised valve will remain in the last position of operation. If you need to disable the
heating it is preferred that you first reduce the set point to near ambient temperature.
After about 5 minutes you can then turn off the heating.

5.1.2 Agitator in Automatic


When ON is selected, the agitator of the slip tank will rotate as per the time and
direction set points in Slip Tank Setup. When OFF is selected, the agitator will remain in
the stationary position.

5.1.3 Vitreous China


This is the speed as set in the frequency inverter parameter A0069 (slow speed). Select
this switch ON when vitreous china slip is used.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 118


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

5.1.4 Fireclay
This is the speed as set in the frequency inverter parameter A0070 (high speed). Select
this switch ON when fireclay slip is used. Fireclay requires higher speed due to the
density and coarser particles.

5.1.5 Automatic Filling


Select On to enable automatic filling of the tank. Between casting cycles the tank level
will be controlled by the level sensor and the filling valve will open and close to
maintain the slip level as per the set point in Slip Tank Setup.

5.1.6 Manual Filling


It is possible to manually fill the tank after it was cleaned. The slip feed valve will open
when ON is selected. Pease observe the tank level as automatic control is OFF.

5.2 Active Displays on this page


5.2.1 Maximum Level
This is the maximum level of slip allowed in the tank. Above this level an alarm will sound
and you have to inspect if the tank is not overflowing.

5.2.2 Set Point Level


This is the level set for the desired level to have in the tank. Optimally it should be in the
region of 90cm.

5.2.3 Alarm Level


This is the low level set for the tank. Below this level the volume of slip in the tank is too
little and you must urgently follow up why the tank is not filling.

5.2.4 Temperature Set Point Slip


This is the set point for heating the slip to a workable temperature. The maximum is 49°C
to prevent mould damage with too hot slip.

5.2.5 Tank Actual Level


The actual level of slip in the tank will be indicated in the upper part of the tank
diagram in a numerical value. A schematically live graph is also showing the level of
material in the tank diagram.

5.2.6 Temperature
The real temperature is displayed in the small rectangle right from the tank diagram.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 119


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

6. MOULD MAINTENANCE

This section about mould maintenance is only about keeping moulds wet and
workable. Refer to the separate manual on mould treatment and cleaning for clear
views on cleaning the moulds in a safe and efficient way.

It is important to keep the moulds wet during times of extended stoppage. It is


furthermore very important to clean the moulds very well with Sodium Hypochlorite prior
to an extended stoppage as mould maintenance is intended to keep moulds wet and
not to necessarily clean them. When Mould Maintenance is selected, the press will not
be able to start until mould maintenance is deactivated.

The page is divided in two halves and for the purpose of this manual will address the
functions only once as they are identical for the two presses.

6.1 Water Set Time


This is the set point in seconds for feeding water to the mould circuit. Depending on
your water pressure this value may vary between 10 seconds and 30 seconds.

6.2 Air Set Time


This is the set point in seconds to feed air to the mould circuit.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 120


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

6.3 Air Pressure


This is the pressure set point for the duration of the air in mould maintenance.

6.4 Number of Regeneration Cycles


Mould maintenance is regeneration of the moulds at a time different than set in the
washing setup. At this setting you can select the number of regeneration cycles.

6.5 Waiting Time in Hours


This is the time delay in hours between mould maintenance cycles.

6.6 Waiting Time in Minutes


This is the additional waiting time in minutes added to the hours in 6.5.

6.7 Opening Machine


This is a button for semi-automatic opening of the press.

6.8 Closing Machine


This is a button for semi-automatic closing of the press. When the press is left
unattended for an extended time it is recommended to close the press (by drive motor
only but without the hydraulic hammers closing).

6.9 Start Mould Maintenance


By pressing the big black button at the bottom of the screen, the automatic times
regeneration of the moulds will be activated. The button will flash green when
activated. When this function is activated, it is not possible to start the press or perform
semi-automatic functions until it is deactivated again.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 121


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

7. FIRST START PROCEDURE

Before the press is started in the morning (after overnight or extended stoppage), it is
recommended to perform the FIRST START PROCEDURE. This procedure automatically
prepares the casting circuits for casting. Water from previous circuit cleaning is
displaced from the slip circuits, the injector is filled with fresh slip and moulds are
regenerated and washed several times to bring them to casting condition and
temperature. By selecting the correct parameters you can prepare the press in a
proper manner before starting to cast.

7.1 Air Set Point


This is the set point of air pressure in the air circuit from proportional valve during this
operation.

7.2 Slip Pressure Set Point


This is the set point of slip pressure during this operation.

7.3 First Recirculation YV470/471


The procedure flush the slip circuit properly with fresh slip prior to filling the injector. This is
to remove the residual water that was left in the slip circuit when the FINAL WASHING

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 122


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

procedure was executed previously. Slip is pumped from the slip tank via the slip feed
line through to the return lines and into the return tank. The duration of this step is set in
seconds. The small light on the right will indicate if the phase is active and have a small
black dot when it is not active.

7.4 Cycle Number For Injector Movement and Draining With YV420/421
After the first circulation of slip through the slip circuit, the injector needs to be filled and
emptied several times to ensure it is free from any residual water and also to guarantee
it is filled with fresh slip prior to starting. Set here the number of filling and emptying of
the injector. During the last filling the injector will remain full and ready for casting. This is
effected by opening and closing only the valves YV420/421 while the rest of the circuit
remains open all the time (excluding the valves to the moulds). The small light on the
right will indicate if the phase is active and have a small black dot when it is not active.
The two lights at the bottom of this block indicates the injector position (UP and DOWN).

7.5 Recirculate with YV450/451


After the circuit is properly flushed and prepared the last step in the slip line cleaning is
to flush the line until the mould filling points. Slip is now pumped towards the mould
through valves YV450/451 and discharged on the floor through YV460/461. The duration
of this step is set in seconds. The small light on the right will indicate if the phase is active
and have a small black dot when it is not active.

7.6 Regeneration Cycles Number


After all slip lines have been flushed, the moulds can be prepared for casting. Several
cycles of regeneration can be selected. Regeneration times and pressure will be as per
the setup in the WASHING page of SETUP. Ideally 6 to 10 regeneration cycles should be
selected to heat up the moulds properly.

7.7 Washing Cycles Number


After regeneration some washing cycles are selected to ensure the correct moisture
content inside the resin as well as the proper cleaning of the draining circuits. Ideally 2
to 4 washing cycles should be selected.

7.8 Second Circulation with YV470/471


After regeneration and washing the slip circuit is once again flushed with fresh slip. The
press should now be ready to start casting.

7.9 Start Procedure


At the top of the two columns there are a green and yellow button FIRST START. When
the button is pressed it will change colour to violet for the duration of the procedure.

7.10 MAIN and FOLLOW


The MAIN button returns to the main page and FOLLOW takes you to FINAL WASHING.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 123


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

8. FINAL WASHING PROCEDURE

Before the press is left unattended for an extended period it is very important to clear all
the slip circuits of slip and to leave the circuit completely empty as old slip can cause
blockages and problems when the press is restarted.

8.1 Air Set Point


This is the set point of air pressure in the air circuit from proportional valve during this
operation.

8.2 Slip Pressure Set Point


This is the set point of slip pressure during this operation.

8.3 Cycle Number For Injector Movement and Draining With YV470/471
To clear the circuit of slip, it has to be flushed with water. To ensure the injector is
completely clear of slip it has to be flushed several times with water. At the end of the
last filling the injector will push the water out of the circuit and remain in the down
position during the stoppage. The small light on the right will indicate if the phase is
active and have a small black dot when it is not active. The two lights at the bottom of
this block indicates the injector position (UP and DOWN).

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 124


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

8.4 Regeneration Cycles Number


After all slip lines are cleaned, the moulds must be cleaned with water to avoid any
residual slip to harden on the mould surface. Ideally 6 to 10 regeneration cycles should
be selected to clean the moulds properly.

8.5 Washing Cycles Number


After regeneration some washing cycles are selected to ensure the proper cleaning of
the draining circuits. Ideally 2 to 4 washing cycles should be selected.

8.6 Start Procedure


At the top of the two columns there are a green and yellow button FINAL WASHING.
When the button is pressed it will change colour to violet for the duration of the
procedure.

8.7 MAIN and PREVIOUS


The MAIN button returns to the main page and PREVIOUS takes you to FIRST START.

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 125


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

9. ROUTINE CLEANING AND MAINTENANCE


For the equipment to function well and to ensure the maximum life from resin moulds, it
is extremely important to follow a proper inspection and maintenance plan on the
equipment. Attached are typical lists of daily, weekly and monthly inspection and
maintenance. It is very important to note that this is merely a guide and additional
points from your own experience should be added to the list.

The following list is typically an operators list that should be controlled daily. It can be
part of his day to day work and could be done during the first start or mould cleaning in
the morning.
DAILY INSPECT
1 Inspect water circuit temperature
2 Inspect water circuit filters for accumulation of sediment
3 Inspect moulds surfaces for cleanliness
4 Inspect air/water pipe connections on moulds for leakages

5 Inspect and correct water pressure on slip casting tank heating jacket

6 Inspect vacuum tank filter for presence of water and drain if necessary
7 Inspect moulds for any leaking or surface damage
8 Control and record slip rheology (Density, Viscosity, Thixotropy 1 and 5 minutes)
9 Cast plaster test mould and record the thickness formation during 1 hour
10 Control and record the thickness formation of pieces
11 Inspect finishing tools and replace if worn

12 Clean all slip circuits and draining circuits if press is stopped overnight (Final Washing)

Flush all slip circuits and fill injector with fresh slip every morning before first casting (First
13
start)

14 Clean moulds every 3rd day with Hypochlorite if working 24 hour shifts

15 Clean moulds every 2nd day with Hypochlorite if not working continuous shifts.
Set presses on auto mould regeneration maintenance if press is stopped over night or
16
weekend

17 Inspect plaster setter surfaces for damage or deformation. Repair if possible or change.

Remove all draining circuit inserts and replace the heat shrink black tube. Replace
18
inserts and test for leaks

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 126


USE AND MAINTENANCE MANUAL

HPC 201T Date: 25/03/2009

The following list is typically a maintenance technician’s list and could partially be
shared by the operator. The company can decide the responsibilities and roles of
operators and technicians.
WEEKLY INSPECT
1 Lubrication of mobile part of Press 201.
2 Inspect hydraulic circuit for leakages in high and low pressure
3 Check hydraulic tank level
Inspect compressed air line filters for presence of oil as it can damage moulds from
4
behind
Test compressed air proportional valve setting to actual pressure on manifold with
5
portable manometer
6 Clean machine and robot exterior and apply wax for protection
7 Test one by one every control valve on filling circuit of press
8 Test one by one every control valve on draining circuit of press
9 Test one by one every control valve on mould circuit of press
Check black plastic tubes on draining circuit inserts for any perforations. Change if
10
required.
11 Perform chemical washing on all moulds as per the prescribed recipe
12 Test Hydraulic pressure on injector and clean the transducers for slip.
13 Confirm actual vs. set positions of all linear transducers on mobile parts of the Press
Measure plaster setter level and replace if 3mm consumption reached. Adjust Robot
14
level accordingly
Inspect and clean all robot tool changers with dry cloth. Wipe after cleaning with oiled
15
cloth
16 Inspect and clean filters on vacuum circuit on robot
Inspect all slip feeding hoses for correct inclination during washing position to prevent
17
water in slip
18 Clean slip casting tank, agitator and circuits to eliminate any build-up of dry material

The following list is typically a maintenance technicians.


MONTHLY INSPECT
1 Regulate all hydraulic hammers for uniform mould compression
2 Inspect electric cables in the island and look for any damage on housings
Inspect Fast in screws and apply grease in the centre screw for protection against
3
corrosion
4 Inspect oil level in gearboxes of Press mobile parts
5 Inspect chain tension on mobile part Press 201T
6 Confirm the sensor connections on hydraulic circuit for clean filter monitoring
7 Test all security gates and optical beams on the Island
8 Clean insides of electrical panels with blower or vacuum cleaner
9 Clean robot panel and heat exchanger elements on the back of panel
10 Check paintwork and repair if necessary to avoid rust
11 Check robot as per robot standard maintenance instructions in robot manual
12 Open and clean venturi for piece demoulding and remove all slip dust

USE AND MAINTENANCE MANUAL – POROUS RESIN MOULDS Pag. 127