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USER’S MANUAL

014AZ011A HYDRAULIC PRESSES

PH 1890 - PH 2090 - PH 2590 PH 2890

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014AZ011A TABLE OF CONTENTS



























014AZ011A TABLE OF CONTENTS USER’S MANUAL

HYDRAULIC PRESSES

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

PUBLISHED ON October 31, 2003



























014AZ011A TABLE OF CONTENTS



























014AZ011A TABLE OF CONTENTS 1

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

2

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

3

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

4

INSTALLATION PROCEDURES .......................................................................... ............................................................................................................... ..................................... 4 - 1 4.1 HOW TO LIFT AND PLACE THE PRESS IN POSITION .............. .................... ............. ............. ............. .............. ............. ........... ..... 4 - 1 4.2 CONNECTIONS CONNECTIONS ............ ................... .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ........... .... 4 - 1 4.2.1 EARTH CONNECTION CONNECTION ..... 4 2




























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






























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

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





























014AZ011A GENERAL INFORMATION 1

GENERAL INFORMATION

1.1

INTRODUCTION

E0004P

1

WARNING!

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

1.2

E0004P

WHERE TO KEEP THE MANUAL

WARNING!

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

1.3

HOW TO USE THE MANUAL

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





























014AZ011A 1 1.5

GENERAL INFORMATION WARRANTY

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

E0004P

ATTENTION!

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

1.6

SUPPLEMENTS

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

1.7 1.7

LEGE LEGEND ND OF THE THE S SAF AFET ETY YS SYM YMBO BOLS LS USED USED ON THE THE M MAC ACHI HINE NE AND/ AND/OR OR IN THE THE MANUAL

DANGER SYMBOLS

General danger





























014AZ011A GENERAL INFORMATION

Danger of entanglement in moving parts E0010P

Risk of explosion E0035P

WARNING SIGNS O2

It is forbidden to use oxygen to recharge the accumulators E0034D

ALERT SYMBOLS

E0005O

E0006O

Heavy duty gloves must be worn

The indicated point must be effectively grounded

OTHER SYMBOLS

1































014AZ011A GENERAL INFORMATION

1

SYMBOLS

This symbol indicates the machine version with SMU system. C1819

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

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

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

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

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































014AZ011A GENERAL INFORMATION 1.8 1.8

TARG TARGA A PE PER R L'ID L'IDE ENTIF NTIFIC ICAZ AZIO ION NE DEL DELLA MACC MACCH HINA INA

C1812

1































014AZ011A 1

GENERAL INFORMATION































014AZ011A MAIN FEA F EATURES TURES 2

MAIN FEATURES

2.1

MACHINE DE DESCRIPTION

2

The press is a fully automatic machine especially designed to press ceramic powder to produce floor and wall tiles or other similar products. Either mechanical or isostatic compacting can be employed depending on the type of die-set installed. In addition, the machine can produce tiles with powders that have different characteristics (double layer). The distinctive feature of the machine is that it uses hydraulic power to perform the whole work-cycle: from loading the die set and performing the press-stroke, to the removal and ejection of the work-pieces. The most important machine assemblies are described below (the references are given in figure 2.1.1). 2.1. 2.1.1 1

MAIN MACHI CHINE ASSEMBLIES

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

HYDRAULIC SYSTEM A pressure booster 7, located inside the upper part of the crosshe ad, generates the pressure directly within the cylinder so that the programmed press-strokes can be carried out.

A number of control assemblies hold the valves and the logic elements required to operate the machine parts and control contro l the operating pressures. These assemblies are located on the machine body near the actual points of use. These control assemblies are listed below:































014AZ011A MAIN FEA FE ATURES

2

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

DCL C1821

FILLER-BOX (DCL TYPE) The filler box is used to load the powder and eject the formed tiles. It includes a support frame which can be removed from the press so as to rapidly replace the die-set from the back of the press. During this stage the mechanical parts move at a speed which is lower than that set by current safety standards (16 mm/sec) — this avoids h azardous situations for the operator from arising. The support frame holds up and guides the mobile part of the filler box which includes the actual body and a powder feed hopper. The latter is mounted over the mobile part of the filler box and a nd may be fed with powder delivered directly

































014AZ011A MAIN FEA F EATURES TURES

2

SPE C1820

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

































014AZ011A 2

MAIN FEA FE ATURES

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


































Figure 2.1.1/A - OVERALL VIEW OF THE SMU C1819

1 2 3 4 5 6 7 9

2

SMU

7

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

32

20 5 18 27 28

15

































014AZ011A 2

MAIN FEA FE ATURES

SPE

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

32

1 2 3 4 5 7 8 9 10 11

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

7

20 5

18 27 28

































014AZ011A MAIN FEA F EATURES TURES 2.1. 2.1.2 2

2

INTE INTEND NDED ED,, PROH PROHIB IBIT ITED ED AND AND MIS MISUS USE E OF THE THE MAC MACHI HINE NE

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

E0004P

WARNING!

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



































014AZ011A 2 2.2

MAIN FEA FE ATURES OVERALL DIMENSIONS

DCL

Figure 2.2/A - OVERALL DIMENSIONS

1700

C1821

Ø1500 V




































1700

DCP

Figure 2.2/B - OVERALL DIMENSIONS

Ø1500

V

200

2



































014AZ011A 2

MAIN FEA FE ATURES

2.3

TECHNICAL DATA

2 .3 .1

SPECIFICATIONS

PERFORMANCE Max. soft clay filling

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

mm mm mm

PH 1890

PH 2090

PH 2590

PH 2890

32 50 74

32 50 74

32 50 74

32 50 74



































014AZ011A MAIN FEA F EATURES TURES HYDRAULIC SYSTEM Hydraulic oil: system capacity viscosity at 40°C viscosity index greater than FZG test stage Max. operating pressure in hydraulic power unit Accumulators Main circuit capacity

PH 1890

l cSt.

bar l

95 0 46 11 0 11 180 20+20+20

PH 2090

PH 2590

2

PH 2890

950 1100 1100 46 46 46 110 110 1 10 11 11 11 180 180 230 20+20+20 20+20+2024.5+24.5+24.5



































014AZ011A 2 2 . 3 .2

MAIN FEA FE ATURES AIRBORNE NO NOISE LE LEVELS

Test conditions: - Operating Operating conditions conditions (refer (refer to ISO/DIS ISO/DIS 11202 11202 specificati specification, on, paragraph paragraph 9.5): - a wooden test piece was used - a sound-proof system provided - Type Type of proc proces ess: s: manufacture of ceramic products - Work cy cycle:






































2





































014AZ011A 2

MAIN FEA FE ATURES






































2































































































































































































































































































































































































































































































































































































































































































































































































































































014AZ011A 4

INSTALLATION INSTALLATION PROCEDURES PROCED URES

C1819

SMU

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

E0004P

WARNING!

Never carry out any type of operation while the machine is running.

9) Move Move the the plunge plungerr until until it rest rests s on the die-set die-set 10) Secure the upper upper part of the die-set die-set to the the plunger plunger 11) Hook up the die-set die-set and connect it to the pneumatic pneumatic system so that it can operate (see (see the CONNECTING CONNECTING THE DIE-SET HEATER and the MAGNETIC LOCK CONNECTIONS paragraphs). 12) Bring the die-set die-set to the required temperature temperature within within the limits determined determined by the die-set die-set manufacturers manufacturers 13) Center Center the punche punches s 14) Secure the punches punches in place with permanent permanent magnets or electromagnets electromagnets,, in the latter case a mechanical emergency locking device must be installed 15) Loosen and then then retighten retighten the fixing screws screws of the die and/or and/or dies. 16) Move the punches punches a number number of times times to make sure sure they move move freely 17) Make sure sure any magnetic magnetic locks locks installed installed are properly properly set

4.2. 4.2.3 3

E0004P

CONN CONNEC ECTI TING NG THE THE DIEDIE-SE SET T HEAT HEATER ER

IMPORTANT!

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



























014AZ011A INSTALLATION INSTALLATION PROCEDURES PROCE DURES

4

4.2. 4.2.4 4 CONN CONNEC ECTI TING NG THE THE MAGN MAGNET ETIC IC LOCK OCK - Join the cables and connector XJ6 as shown in figure 4.2.4 - DIE-SET WIRING DIAGRAM

E0004P

WARNING!

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

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

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

922 921

XJ6

510

D

511 514

E 515

516 517

912 911

C0524

4.2. 4.2.5 5

CONN CONNEC ECTI TING NG THE THE DUST DUST EX EXTR TRAC ACTI TION ON SY SYST STEM EM

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



























014AZ011A 4

INSTALLATION INSTALLATION PROCEDURES PROCED URES



























014AZ011A START-UP PROCEDURES 5

START-UP PROCEDURES

5.1

GENERAL

5

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

5.2

PRELIMINARY CHECKS

The numbers or symbols which identify the hydraulic, pneumatic or electric components refe r to the HYDRAULIC AND PNEUMATIC DIAGRAMS. The functions of the pushbuttons and selector switches are shown in the figures in the CONTROLS paragraph in chapter 6 - OPERATING INSTRUCTIONS chapter. 5.2. 5.2.1 1 CHECKING ING THE THE CONNEC NECTION IONS: MAKE THE FOLLOWING CHECKS: - Make sure sure that that the die-set heating heating elements elements are properly properly earthed. earthed. - Check the magnetic magnetic lock lock of the upper and lower lower punches for for efficiency. efficiency. The lights lights built into into buttons11 and 15 should come on. - Check that that the press is connected connected to the the workshop workshop earth earth electrodes. electrodes. Check the connecting cable between the plunger and the cross-head for condition. - Make sure sure that the the oil level level in the reservoir reservoir on the top of of the press press is correct. correct. - Make sure that that the pressure pressure in the hydraulic hydraulic system system is within within the correct correct operating operating range as indicated indicated in the SPECIFICATIONS paragraph. - Make sure sure that the the tile thickness thickness gauge gauge leads are properly properly connected. connected. - Make sure that that the filler-box filler-box limit limit switches switches and the interloc interlocks ks on the safety safety bar are properly properly wired wired and set to their their correct operating positions. - Make sure sure that the device device which which warns that that the filter filter is clogged clogged is properly properly wired. wired. - Check the the powder detector detector (located (located on on the filler-box filler-box feed feed hopper) for for efficiency. efficiency. - Check that that the controller controller and the tile tile transfer transfer (placed immediat immediately ely before before the press) are properly properly connected connected (conditions when the machine is started up and stopped).

5 .2 . 2 MOTOR M3 Press button 20 on the control keyboard to start “oil leak collector” pump motor M3 and make sure it runs in the right direction.

5 .2 . 3 MOTOR M11 Start motor driven pump M11 that cools down and filters the oil by pressing push-button 0 found on the keyboard. Check the direction of rotation.

5 .2 . 4 MOTOR M1 After pump M11 has run for at least three minutes, completely loosen the kno b on safety valve 111. Start main motor a fter approx. two seconds by pressing M1 by pressing push-button 0 located on the control keyboard. Turn off the motor after push-button 4. Check the direction of rotation of the motor after it has run for a short time. Wait for the motor to stop. Restart motors M11 and M1, let them run for a few seconds and then stop them. Idle the motor for a few minutes so that the air in the ducts and controls can be eliminated. Keep key 28 on the control keyboard pressed and gradually tighten the knob on the valve 111 to bring the pressure in the circuit to 100 bar. Make sure that there are



























014AZ011A START-UP PROCEDURES

5

5. 2. 5 SETTING THE PRESSURE VARIABLE DISPLACEMENT PUMP PRESSURE Set the safety pressure by following the directions given in the ADJUSTING THE VARIABLE DISPLACEMENT PUMP paragraph found in chapter 7 - ADJUSTMENT PROCEDURES. 5.2. .2.6 TOP DEAD-CE -CENTER PO POSITIO ITION N Raise the plunger to its top dead-center po sition by using keys 3 & 25 on the control keyboard. The main cylinder should reach its top dead-center position while the pressure in the hydraulic power unit (shown on pressure gauge 13) increases until the preset value entered during the test procedure (equal to operating pressure) is obtained. See chapter 7, ADJUSTMENT PROCEDURES. 5. 2. 7 SAFETY DEVICES Lower the safety bar. The filler-box is now able to perform its movements. Before performing any movements, check emergency stop buttons 24 for efficiency. 5.2. 5.2.8 8 AUXI AUXILI LIAR ARY Y EQUI EQUIPM PMEN ENT T PRES PRESSU SURE RE Set the initial operating pressure to 150 bar. Enter this value onto the “FILLING SET UP” video page. 5. 2. 9

FILLER-BOX

DCL C1821

5.2. 5.2.9. 9.1 1 Fill Filler er-b -box ox (DCL (DCL)) Make sure: - The fillerfiller-box box is properly properly positioned positioned and secured secured.. - The slid slide e plate plate is level level with with the the die. die. - The fille filler-bo r-box x guides guides are align aligned ed and center centered. ed. - The mobile mobile part of of the filler-box filler-box is is properly properly adjusted. adjusted. - The brush brush is prope properly rly adjus adjusted ted (if (if provide provided). d). - The powder powder feeder feeder (ALM) (ALM) is properly properly adjusted adjusted (if (if provided). provided). - All electric electric connecti connections ons have been properly properly made. made. - The safe safety ty guards guards are secu secured red in in place. place.

Set the values for the end of the forward and return strokes (distance in mm in relation to the zero setting of the guides). Zero set the filler-box encoder by pressing keys 28 and 5. Carry out some filler-box strokes in manual mode to see whether the values for the end of the forward and return strokes are correct. Make sure limit switch SQ59 is properly set. Limit switch SQ59 provides the trigger for the plunger to move down. It should be triggered only once the mobile part of the filler-box is out of the danger zone.






























5

DCP 5.2. 5.2.9. 9.2 2

Fill Filler er-b -box ox (DCP (DCP))

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

SPE C1820

5.2. 5.2.10 10 KNOC KNOCKO KOUT UT CONT CONTRO ROL L (SP (SPE E ONL ONLY) Y) Move the encoders that monitor the position of the mobile part of th e die-set down and secure in place. With the plunger raised and safety bar up, select SET-UP mode and go to the DIE-SET/SPE page. Set DIE-SET REMOVAL = 3 and make sure DIE-SET LOCKED = NO. Loosen the screws to bleed the air located over the knockout cylinders and control assemblies. Press the keys that move the die-set up and down a number of times until the air has been bled. Install the die-set as directed in the INSTALLING AND REMOVING THE DIE-SET paragraph. Release the encoders. Set values A and B for the end of the upstroke as well as the upstroke and downstroke speeds. Zero set the knockout





























014AZ011A 5

START-UP PROCEDURES

5.3

ADJUSTMENT P PR ROCEDURES

5 . 3 .1

KNOCKOUT ADJUSTMENT

C1819

SMU

5.3.1.1 5.3.1. 1 Adju Adjusti sting ng the the SMU SMU knock knockou outt Set the pressure for the cylinder (which holds the die) to approx. 80 bar when a die-set with through-punches is used (50 bar with a mirror-finished die set). To set the pressure, work on relief valve 140 and observe the reading given on pressure gauge 142. Adjust the knockout speed by using restrictor 61. To adjust the speed for the first die-set downstr oke work on restrictor 23 until a suitable speed is obtained. To adjust the speed for the second die-set downstroke, work on restrictor 242 until the die set rests on the base plate without banging on it. Check the first die-set downstroke by pressing buttons 13 and 30 once or twice so that the lower punch is ready to perform the second downstroke. Measure the distance between the lower punch and the upper surface of the die. If the distance is not correct, allow the die-set to rest on the base plate again by pressing push buttons 13 and 30. Push buttons 26 or 31, while keeping button 12 pressed, to increase or decrease the t he soft filling setting until the desired value is reached.

SPE C1820

5.3.1.2 5.3.1. 2 Adju Adjusti sting ng the the SPE SPE knocko knockout ut Enter the settings for the die-set and knockout ( upper stop limits A and B) and then set the upstroke and downstroke do wnstroke speeds (0 to 100%). If desired, enable the KNOCKOUT BTW PUNCHES function. IF KNOCKOUT BTW PUNCHES <>0, “delayed die-set upstroke” will be ignored. Set the intermediate and last downstroke in the same way. Make sure the die-set gently rests on the base plate. Lastly, check the settings for moving near the die-set as follows:

1) Move Move the the diedie-set set up. 2) Make sure the punches are close to the die-set. If this is not so, move the cursor to the upper stop limit limit and press the “+” and “-” keys on the keyboard to adjust the height of the cylinders on the left-hand side (cylinders 180a1 and 180a2) 3) Check the right-ha right-hand nd side side (cylinde (cylinders rs 180b1 and 180b2). If the die-set has been properly constructed it should be close to the die. If this is not the case, set the max. offset (B-A) until proper conditions are achieved.






























5

5.3.2 5.3.2 PREL PRELIM IMIN INARY ARY ADJUS ADJUSTM TMEN ENTS TS TO THE THE HYD HYDRA RAUL ULIC IC SY SYST STEM EM The press was properly set before leaving the factory. The information given below should be used to make sure that the settings have not been altered. LOGIC ELEMENT ASSEMBLY Component

Operated by

Prel Prelim imin inar ary y ad adju just stme ment nt PH 1890/PH 2090


12 0 11 9 11 8 11 7 11 6 13 1

YV38 YV70 YV70 YV19 YV40 YV41

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

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

ACCUMULATOR CONTROL ASSEMBLY Component

Operated by



115 108 109 174

YV53 YV32s YV32d YV47

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

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






























5 5.3. 5.3.3 3

ADJU ADJUST STIN ING G THE THE SP SPEE EED D OF OF THE THE FILL FILLER ER-B -BOX OX

DCL C1821

5.3.3.1 5.3.3. 1 Filler Filler-b -box ox spe speed ed sett settin ing g (DCL (DCL)) SETTING (DCL) Once the filler-box has been inspected for proper operation, set the speeds for each of the 5+5 steps which form the total stroke of the filler box (expressed in % from 0 to 100). This indicates the actual aperture of the control valve. An optimal speed range is thus determined in order to suit the product to be obtained. To properly load the powder, determine the position in which the filler-box must be when the die-set performs its first downstroke. Simulate a number of filler-box cycles in semi-automatic mode. Press pushbuttons 8 & 27 to check the filler-box for proper operation before loading the working material. If the value entered for the FILL.-BOX APPROACH POS. data item during the filler-box re turn stroke is greater than zero, plunger downstroke will be triggered once the FILL.-BOX APPROACH POS. setting has been passed. As soon as the filler-box reaches the end of its return stroke, the ALM cycle will start. The filler-box will reach the value set fo r the FILL.BOX APPROACH POS. data item after the grid has be en loaded. The filler-box will run at the set APPROACH SPEED. When set to manual mode, the filler-box runs at a constant speed equal to that set for SPEED IN MANUAL MODE. When set to automatic and semi-automatic mode s, the filler-box runs at the set speeds. A cycle can carried out with the ALM stationary. Loading takes place while the ALM is stationary. In this case, the grid is loaded thro ugh filler-box operation. In this case, the FILLING STROKE will equal the APPROACH STROKE.

POWDER INFEED (DCL) Properly set the ALM feeder (see relevant manual). Select the desired type of loading: grid loaded while the ALM is stationary or grid loaded with ALM running. Set the time for the “DELAYED LOADING” data item. This is the length of time the hopper gate stays open. Set the “GATE CLOSING DELAY” time. This is the amount of time which elapses from when the hopper reaches the position in which the gate closes and the gate actually closes. A special cycle can be selected if double rows of tiles have to be pressed. This is done by setting 2-ROW FILLING = YES. In this case, three values have to be enter ed in the PLC. The first refers to the th e point at which the gate closes during the stroke for loading the ALM after the first row has been loa ded. The second refers to the point at which the gate opens o pens during the loading stroke to load the second row while the last one refers to the point at which the g ate closes after the second row has been loaded. Move the filler-box completely backward and let powder into the feed hopper. Set the number of strokes to be performed perfor med (from right to left) during each ea ch cycle (set 1 or 2 strokes. If 50 is entered en tered the ACP will move non-stop). Fill the die-set a few times in semi-automatic mode and make the required modifications (if the loading cycle is found to be inaccurate). After this preliminary phase has been completed, leave the die cavities full of powder. The ALM can carry out an overtravel during du ring its return stroke to zero set the filler-box encoder. This may also be useful when installing and removing the grid.






























5

DCP 5.3.3.2 5.3.3. 2 Fille Fillerr-bo box x speed speed settin setting g SETTING (DCP) Two different systems can be used:

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































014AZ011A 5

START-UP PROCEDURES

5.3. .3.4 PLUNGER GER BR BRAKIN KING ADJU ADJUS STMENT To check the value entered for plunger br aking, observe the logic element setting, which should be a pprox. 80. If it is not, allow the plunger to rest on the powder, press buttons 7 and 26 at the same time to increase the braking force or buttons 7 and 31 to decrease it until 80 is read. At the beginning, inactivate the brake control (SPEED CONTROL ON = NO) and set an adequate braking action (e.g., BRAKING SPACE = 90.00) in order to have safe braking during the first stage. After filling the die-set with powder, perform some downstrokes, adjust the braking action and change the logic element setting until the desired braking force is obtained. Once the machine has been started up, the automatic brake control can be activated. To do this, check that the braking space is ≥ 35.00 (if it is less than 35.00, the automatic brake control cannot be switched on).After th e die-set has been filled with powder, determine the correct speed at which the punches should come into contact with the powder and then type YES for the SPEED CONTROL data item and enter the value previously read for the IMPACT SPEED. From this time on, the controller will correct the brake settings until the desired one is obtained so that th e impact speed will be kept constant throughout the work-cycle.

5.3. .3.5 PLUNGER GER PA PARALLELISM ISM ER ERROR The press is equipped with two encoders that record th e position of the plunger. The parallelism error during the presscycle can be established by simply comparing these measurements. This will prevent de formed products resulting from excessive inclination from being produced. The maximum allowable error can be set from the microprocessor controller (PRESSING SET-UP page). If a message indicating incorrect plunger inclination appears, check the loading state.

5.3. .3.6 PLUNGER GER MOTION SETTING ING Read the setting entered to begin the th e press-stroke (punches on the powder) . Slowly lower the plunger until the punches come into contact with the powder, read the plunger encoder setting (expressed in “mm” and which refers to the end of its upward stroke) and enter the setting for the IMPACT POS. Turn the key switch to “WRITE” to enter a sufficiently long temporary value to indicate that there is no powder (STOP, NO POWDER = 180.00). In this case, the control will no longer be active. Enter a setting for the end of the upward stroke (plunger up). Remember that the last setting should allow the filler-box to move freely. Enter YES for UPSTROKE BRAKING ON as well as the value for end of braking while
































5

5.3.8 .3.8 DE-AERATIO ATION N ADJUSTMENT Adjust de-aeration proportioner 89 by working on the limit screw. The system can be adjusted so that the plunger p lunger carries out a de-aeration stroke that ranges from 0 to 3.4 mm.

5.3.9 5.3.9 ADJUS ADJUSTIN TING G THE THE DIE-S DIE-SET ET PRO PROTE TECT CTIO ION N DEVI DEVICE CE (FO (FOR R LACK LACK OF OF POWD POWDER ER)) Inspect the automatic thickness gauge for proper functioning. The tile must not be too thin, as this may severely damage the die-set. Enter the setting for PLUNGER SHUTDOWN when there is not enough powder. It should be equal to the max. allowable stroke for the plunger during the press-cycle. Make sure the plunger can move down a fu rther 0.5 mm approx. in relation to a tile of the desired thickness. Once this setting has been entered, make sure the relevant fault message is actually displayed when the plunger moves below the preset level.

5.3.1 .3.10 0 AUTOMATIC CYCLE Check the oil level with the plunger lowered and make sure that the die-sets have reached the desired temperature. Read the die-set temperatures. With the temperature properly set, make sure the die-set moves freely. Thoroughly clean the die and start the automatic work- cycle by pressing pushbuttons 28 & 2 at the same time. During the first workstages keep the process zone under control so that emergency stop button 24 can be pressed immediately in case of malfunctioning. If there are no problems, allow the machine to run for a few minutes. Stop the work-cycle by pressing push-button 6 then check the finished product and correct as required. If tiles are to be ejected during the last cycle, enter YES for “EJECTION WHEN STOPPING”. If not, enter NO.

NOTE: The corrections which require work on the press body or filler box should be made with the machine stopped. The set data set or hydraulic parts can be corrected while the machine is running. When good-quality products are obtained, duplicate the program (see the Instructions B manual) and make any adjustments required to increase productivity.
































5 5.3.11 5.3 .11

SWITC SWITCHI HING NG ON THE THE FILLE FILLERR-BOX BOX SPE SPEED ED CONT CONTRO ROLL LLER ER

DCL C1821

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

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































014AZ011A OPERATING INSTRUCTIONS 6

OPERATING IN INSTRUCTIONS

6.1

CONTROLS

6

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

CONTROLLER ELECTRICAL CABINET































014AZ011A 6

OPERATING INSTRUCTIONS

6. 1. 1 CONTROLLER The programmable logic controller comes with a microprocessor system. Use the computer terminal provided to: - set up the work work cycle and make make modifications modifications to the programmed programmed work stages even when when the machine machine is cycling. cycling. - display display messag messages es and typic typical al process process variable variables; s; - store store and retriev retrieve e the data relat related ed to each each pre-set pre-set press press cycle; cycle; - automati automaticall cally y localise localise and and “diagno “diagnose” se” faults faults;; - monitor monitor the operatin operating g pressure pressures; s; - automati automaticall cally y gauge gauge tile thicknes thickness; s; - automatically automatically control control the the machine machine in the event event of system failure.

Figure 6.1.1/A - CONTROLLER

SYSTEM CARDS

































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

SYSTEM CONFIGURATION Location of cards

1-4 5 6 7 8 9 10 11-12-13 14-15-16 17-18

AL CPU VA IA IE IE AX ID OD ODA

POWER SUPPLY (rectified supply voltage) Central processing unit MISCELLANEOUS ANALOG INPUT ENCODER INPUT ENCODER INPUT AXES DIGITAL INPUTS (24 Vdc signals) DIGITAL OUTPUTS (energise the 24Vdc outputs) ANALOG & DIGITAL OUTPUTS

C1471

6

































014AZ011A 6


Figure 6.1.1/C1 - (CONTROLLER) COMPUTER TERMINAL

Figure 6.1.1/D1 - (CONTROLLER) MACHINE CONTROL KEYBOARD

9 0 4 - 1 1 - 5 8 0 C M S

2 4 4 - 1 1 - 5 8 0 C M S

9 2 G A P

N O E T I R W

5 +

T I U Q

D

F F O

G A P

E M O H

1 2 R D L C B A A W S S

N E E R C S

-

+

H

– 1 3 8

5 2

0 3

I 2

D N E L R E A D H C

E

6 + 2

L E N E I D L

F

G

E N T E R

9 6 3 .

T U A N A M P U T E S

7 2 3 2 9 1

5 R D L C P 1 2 + A A W S S

































014AZ011A OPERATING INSTRUCTIONS Figure 6.1.1/C2 - (CONTROLLER) COMPUTER TERMINAL A B C D E F G H

25 line ine x 80 col column umn, elec lectro tro-lu -lumine mines scent cent displ splay unit nit Function keys Numeric keypad Write enable key switch N o t u se d Deletes last character typed in Deletes last line typed in Cursor control keys C0628

ELECTRO-LUMINESCENT DISPLAY UNIT The press comes with an electro-luminescent display unit on which the following are displayed: - fault fault messag messages es - mach machin ine e dat data a - produc productio tion n data data - actual actual setti settings ngs - list of the the program programs s stored stored set points points and any modifi modificati cations ons made made to them

6

































































014AZ011A OPERATING INSTRUCTIONS Figure 6.1.1/E2 - (PERSONAL COMPUTER) (OPTIONAL) A B C

Color display Function keys Mouse

COLOR DISPLAY The press comes with an electro-luminescent electro-lumi nescent display unit on which the following are displayed: - faul faultt mess messag ages es - mach machiine data ata - prod produc ucti tion on data data - actu actual al sett settin ings gs - list list of of the the progr programs ams store stored d - set point points s and any any modific modificatio ations ns made made to them them NOTE: To read out data, consult the INSTRUCTIONS B MANUAL.

6



































014AZ011A 6 6. 1. 2

OPERATING INSTRUCTIONS ELECTRICAL CABINET

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

Voltmeter Ammeter



































014AZ011A OPERATING INSTRUCTIONS 6.2

START-UP -UP AND SHUTDOWN PROCEDURES

6.2. 6.2.1 1

ROUT OUTINE INE ST START-UP PR PROCEDURE URE

6

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



































014AZ011A 6 6.3

OPERATING INSTRUCTIONS PRESSURE-LOAD GRAPHS

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



































014AZ011A OPERATING INSTRUCTIONS

6

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



































014AZ011A 6


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






































6





































014AZ011A 6







































6





































014AZ011A 6







































6























































































































































































































































































































































































































































































































































































































































































































































































014AZ011A 8

MACHINE MAINTENANCE

8.4. .4.2 SECURI URING THE STAY BOLT OLTS No special tools are required to perform this operation (e.g. torque wrenches). The value n x A, indicated in th e diagram, can be exceeded (the plate cluster must be more compact) without causing the heat exchanger to malfunction (see the chart below). Tighten the stay bolts in the following order:

- Secu Secure re stay stay bolt bolts s 1, 6, 10, 5. - Secu Secure re stay stay bolt bolts s 2, 7, 9, 4. - Secu Secure re stay stay bolt bolts s 3, 8. Repeat the operations until the required value is obtained.

Figure 8.4.2 - SECURING THE STAY BOLTS nxA

1

6

2

7

3

8

4

9

5

10

C0315

n = number of plates which form the heat exchanger.

TIGHTENING THE STAY BOLT FOR 1 PLATE

A

New gaskets

minimo

3.75

3.5

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



























014AZ011A DECOMMISSIONING 9

9

DECOMMISSIONING

When the machine is not to be used any longer and is to be dismantled proceed as follows: 1) Move the the plunger plunger to the end-stop end-stop and lock it in place place so as as to prevent prevent it from from moving moving down. down. 2) Turn off off the machine with the the main main shut off switch switch and and then unplug the power power cable cable 3) If pres present ent,, dra drain in accu accumul mulat ator ors s 141 and 337 through valves 143 and 339. 4) Drain all all the hydraulic hydraulic fluid fluid from the the press by by following following the same same procedures procedures as recommend recommended ed for routine routine maintenance. 5) Discon Disconnect nect the mach machine ine from from the the elect electric ricity ity supp supply. ly. 6) Discon Disconnect nect the water water line lines s for for oil oil cooli cooling. ng. 7) Disc Discon onnec nectt the the hydr hydraul aulic ic line lines. s. 8) Remo Remove ve the the fil fille lerr box box.. 9) Discon Disconnect nect the the contro controll unit unit electr electrica icall connec connectio tions. ns. 10) Blow off the pressurised pressurised gas in all the accumulators accumulators by using using the tester-inflator tester-inflator available available on request. request. 11) Remove Remove the the accumul accumulato ators. rs. 12) Remove the hydraulic hydraulic control assemblies. assemblies. 13) The press may be moved in the same way as during installati installation, on, therefore therefore refer to the relevant chapter. chapter. When disassembling the machine, lift equipment must be used to remove certain parts (e.g. hydraulic control assemblies, accumulators, etc..). These operations are to be performed by qualified personnel observing current safety regulations. Use all personal safety gear called for by current safety standards when working above shoulder height.



























014AZ011A 9

DECOMMISSIONING

Machine Maiternance

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