Manuale PH 3020 - en

D O C U M E N TA Z I O N E
T E C N I C A
USER’S MANUAL
014AZ008A
HYDRAULIC PRESSES
PH 3020
TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇÃO TÉCNICA
LISH
ENG
014AZ008A
TABLE OF CONTENTS
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TABLE OF CONTENTS
USER’S MANUAL
HYDRAULIC PRESSES
PH 3020
MANUFACTURER
SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
PUBLISHED ON
20.10.2003 - 20.05.2004
VERSIONS
PH3020B
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TABLE OF CONTENTS
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TABLE OF CONTENTS
Page
1 GENERAL INFORMATION ........................................................................................................................1 - 1
1.1 INTRODUCTION ........................................................................................................................ 1 - 1
1.2 WHERE TO KEEP THE MANUAL ............................................................................................. 1 - 1
1.3 HOW TO USE THE MANUAL .................................................................................................... 1 - 1
1.4 USERS OF THE MANUAL ......................................................................................................... 1 - 1
1.5 WARRANTY ............................................................................................................................... 1 - 2
1.6 SUPPLEMENTS ......................................................................................................................... 1 - 2
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE A
ND/OR IN THE MANUAL ........................................................................................................... 1 - 2
1.8 MACHINE IDENTIFICATION PLATE ..........................................................................................1 - 4
2 MAIN FEATURES ......................................................................................................................................2 - 1

2.1 MACHINE DESCRIPTION ......................................................................................................... 2 - 1
2.1.1 MAIN MACHINE ASSEMBLIES ................................................................................................. 2 - 1
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ................................................. 2 - 5
2.2 OVERALL DIMENSIONS ........................................................................................................... 2 - 6
2.3 TECHNICAL DATA .................................................................................................................... 2 - 7
2.3.1 SPECIFICATIONS ......................................................................................................................2 - 7
2.3.2 AIRBORNE NOISE LEVELS ...................................................................................................... 2 - 9
2.3.3 DUST SUCTION HOODS ........................................................................................................ 2 - 10
2.3.4 RATING PLATE ....................................................................................................................... 2 - 11
2.4 DIAGRAMS .............................................................................................................................. 2 - 12
2.4.1 HYDRAULIC AND PNEUMATIC DIAGRAMS ......................................................................... 2 - 12
2.5 OPERATION ............................................................................................................................ 2 - 19
2.5.1 COMPRESSED AIR SUPPLY ................................................................................................. 2 - 19
2.5.2 FAST HEATING ....................................................................................................................... 2 - 19
2.5.3 HEAT EXCHANGER SYSTEM ................................................................................................ 2 - 19
2.5.4 OIL LEAK CIRCUIT .................................................................................................................. 2 - 20
2.5.5 MAIN PUMP RUNNING - SAFETY BARS ENGAGED (RAISED) ........................................... 2 - 20
2.5.6 POSITION TRANSDUCER - SETTINGS ................................................................................. 2 - 21
2.5.7 SAFETY BARS DISENGAGED (LOWERED) .......................................................................... 2 - 22
2.5.8 ENCODER RESETTING .......................................................................................................... 2 - 22
2.5.9 DIE-SET CONTROL CIRCUIT ................................................................................................. 2 - 22
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3 SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 1
3.1 SAFETY DEVICES ......................................................................................................................3 - 1
3.1.1 SAFETY GUIDELINES ............................................................................................................... 3 - 1
3.1.2 SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE ............................................. 3 - 1
3.4 HANDLING PROCEDURES ...................................................................................................... 3 - 3
3.2.1 LIFTING PROCEDURES ........................................................................................................... 3 - 3
3.2.2 HANDLING ..................................................................................................................................3 - 3
3.2.3 PLACING THE LOAD ................................................................................................................. 3 - 3
3.3 INSTALLATION ...........................................................................................................................3 - 4
3.3.1 GUIDELINES ...............................................................................................................................3 - 4
3.4 PERSONNEL TRAINING ........................................................................................................... 3 - 5
3.4.1 END-USER ..................................................................................................................................3 - 5
3.4.2 OPERATORS ............................................................................................................................. 3 - 5
3.4.3 MAINTENANCE STAFF ............................................................................................................. 3 - 5
3.5 OPERATING INSTRUCTIONS .................................................................................................. 3 - 6
3.5.1 SAFETY RULES ........................................................................................................................ 3 - 6
3.5.2 OPERATION IN AUTOMATIC MODE ........................................................................................3 - 6
3.5.3 OPERATION IN MANUAL MODE ...............................................................................................3 - 6
3.5.4 OPERATION IN SETUP MODE ................................................................................................. 3 - 6
3.5.5 INSTALLATION MODE ...............................................................................................................3 - 7
3.5.6 CLEANING ..................................................................................................................................3 - 8
3.6 MAINTENANCE ......................................................................................................................... 3 - 9
3.6.1 GENERAL SAFETY RULES ...................................................................................................... 3 - 9
3.6.2 NOTES REGARDING MAINTENANCE ................................................................................... 3 - 11
3.7 MACHINE NOT IN USE ........................................................................................................... 3 - 12
3.7.1 GENERAL RULES ................................................................................................................... 3 - 12
3.7.2 PUTTING THE MACHINE OUT OF SERVICE ........................................................................ 3 - 12
3.8 DECOMMISSIONING THE MACHINE .................................................................................... 3 - 13
4 INSTALLATION PROCEDURES ...............................................................................................................4 - 1

4.1 HOW TO LIFT AND PLACE THE PRESS IN POSITION .......................................................... 4 - 1
4.2 CONNECTIONS ......................................................................................................................... 4 - 1
4.2.1 EARTH CONNECTION ............................................................................................................. 4 - 2
4.2.2 INSTALLING AND REMOVING THE DIE-SET ..........................................................................4 - 3
4.2.3 CONNECTING THE DIE-SET HEATER .................................................................................. 4 - 11
4.2.5 CONNECTING THE DUST EXTRACTION SYSTEM .............................................................. 4 - 12
4.2.4 CONNECTING THE MAGNETIC LOCK .................................................................................. 4 - 12
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5 START-UP PROCEDURES ...................................................................................................................... 5 - 1
5.1 GENERAL .................................................................................................................................. 5 - 1
5.2 PRELIMINARY CHECKS ........................................................................................................... 5 - 1
5.2.1 CHECKING THE CONNECTIONS: ........................................................................................... 5 - 1
5.2.2 MOTOR M3 ................................................................................................................................ 5 - 1
5.2.3 MOTOR M11 ...............................................................................................................................5 - 1
5.2.4 MOTOR M1 ................................................................................................................................ 5 - 1
5.2.5 SETTING THE PRESSURE ...................................................................................................... 5 - 2
5.2.6 TOP DEAD-CENTER POSITION ............................................................................................... 5 - 2
5.2.7 SAFETY DEVICES ......................................................................................................................5 - 2
5.2.8 AUXILIARY EQUIPMENT PRESSURE ......................................................................................5 - 2
5.2.9 FILLER-BOX ...............................................................................................................................5 - 2
5.2.10 KNOCKOUT CONTROL (SPE ONLY) ........................................................................................5 - 2
5.3 ADJUSTMENT PROCEDURES ................................................................................................. 5 - 3
5.3.1 KNOCKOUT ADJUSTMENT ...................................................................................................... 5 - 3
5.3.2 PRELIMINARY ADJUSTMENTS TO THE HYDRAULIC SYSTEM ............................................5 - 3
5.3.3 FILLER-BOX SPEED SETTING (DCL) ...................................................................................... 5 - 4
5.3.4 PLUNGER BRAKING ADJUSTMENT ........................................................................................5 - 5
5.3.5 PLUNGER PARALLELISM ERROR .......................................................................................... 5 - 5
5.3.6 PLUNGER MOTION SETTING .................................................................................................. 5 - 5
5.3.7 SETTING THE PRESS-CYCLE ................................................................................................. 5 - 5
5.3.8 DE-AERATION ADJUSTMENT ................................................................................................. 5 - 6
5.3.9 ADJUSTING THE DIE-SET PROTECTION DEVICE FOR LACK OF POWDER ...................... 5 - 6
5.3.10 AUTOMATIC CYCLE ................................................................................................................. 5 - 6
5.3.11 SWITCHING ON THE FILLER-BOX SPEED CONTROLLER ................................................... 5 - 6
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6 OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1
6.1 CONTROLS ................................................................................................................................ 6 - 1
6.1.1 CONTROLLER ........................................................................................................................... 6 - 2
6.1.2 ELECTRICAL CABINET ............................................................................................................. 6 - 8
6.2 START-UP AND SHUTDOWN PROCEDURES ........................................................................ 6 - 9
6.2.1 ROUTINE START-UP PROCEDURE ........................................................................................ 6 - 9
6.2.2 MACHINE SHUT DOWN .............................................................................................................6 - 9
6.2.3 STOPPING THE MACHINE IN EMERGENCIES ...................................................................... 6 - 9
6.2.4 SHUTDOWN DURING A POWER FAILURE ............................................................................. 6 - 9
6.2.5 SHUTDOWN DURING AUTOMATIC OPERATION ................................................................. 6 - 9
6.3 PRESSURE-LOAD GRAPHS .................................................................................................. 6 - 10
6.4 AUTOMATIC CYCLE ............................................................................................................... 6 - 11
6.4.1 FILLER-BOX START-UP ......................................................................................................... 6 - 12
6.4.2 POWDER INFEED ................................................................................................................... 6 - 12
6.4.3 FILLER-BOX OPERATION ...................................................................................................... 6 - 12
6.4.4 DIE-SET DOWNSTROKES ...................................................................................................... 6 - 12
6.4.5 FAST DOWNSTROKE ............................................................................................................. 6 - 13
6.4.6 DOWNSTROKE WITH BRAKE APPLIED ............................................................................... 6 - 13
6.4.7 DELAY TIME FOR THE 1ST PRESS STROKE ...................................................................... 6 - 13
6.4.8 FIRST PRESS-STROKE .......................................................................................................... 6 - 14
6.4.9 1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER (WITH OR WITHOUT
ACCUMULATORS) .................................................................................................................. 6 - 14
6.4.10 1ST SEPARATE PRESS-STROKE ......................................................................................... 6 - 14
6.4.11 DEAERATION .......................................................................................................................... 6 - 15
6.4.12 SECOND PRESS-STROKE (LAST PRESS-STROKE) ........................................................... 6 - 15
6.4.13 SECOND DIRECT PRESS-STROKE ...................................................................................... 6 - 15
6.4.14 PRESS-STROKE WITH PRESSURE BOOSTER ................................................................... 6 - 15
6.4.15 SECOND SEPARATE PRESS-STROKE ................................................................................ 6 - 16
6.4.16 DIE-SET UPSTROKE .............................................................................................................. 6 - 16
6.4.17 CYLINDER PRESSURE RECOVERY ..................................................................................... 6 - 16
6.4.18 UPSTROKE WITH BRAKE APPLIED ...................................................................................... 6 - 16
6.4.19 FAST UPSTROKE ................................................................................................................... 6 - 17
6.4.20 KNOCK-OUT ............................................................................................................................ 6 - 17
6.4.21 SFS CYCLE: UPPER FORMING DIE (OPTIONAL) ................................................................ 6 - 17
6.4.22 MOBILE DIE ............................................................................................................................. 6 - 17
6.4.23 DIE OVER-TRAVEL ................................................................................................................. 6 - 17
6.4.24 BRUSH OPERATION ............................................................................................................... 6 - 18
6.4.25 MOVEMENTS IN MANUAL MODE .......................................................................................... 6 - 18
6.4.26 MOVEMENTS IN SET-UP MODE ........................................................................................... 6 - 18
6.4.27 RESETTING THE ENCODERS ............................................................................................... 6 - 19
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7 ADJUSTMENT PROCEDURES ................................................................................................................ 7 - 1
7.1 SETTING THE VARIABLE DELIVERY PUMP .......................................................................... 7 - 1
7.2 SETTING AND ZERO-SETTING THE POSITION ENCODER ................................................. 7 - 6
7.2.1 PLUNGER TRANSDUCERS ...................................................................................................... 7 - 6
7.2.2 FILLER BOX ENCODER.............................................................................................................7 - 6
8 MACHINE MAINTENANCE ...................................................................................................................... 8 - 1

8.1 MAINTENANCE SCHEDULE......................................................................................................8 - 1
8.1.1 LUBRICATING THE KNOCKOUT FEELER PINS ......................................................................8 - 4
8.1.2 VACUUM .................................................................................................................................... 8 - 5
8.2 SPECIAL MAINTENANCE ......................................................................................................... 8 - 6
8.2.1 SERVICING THE PLUNGER BUSHES ......................................................................................8 - 6
8.2.2 FILLING THE RESERVOIR ........................................................................................................8 - 6
8.2.3 DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND RESERVOIR .......................... 8 - 6
8.2.4 DRAINING OIL FROM THE HOSES AND HYDRAULIC CONTROL ASSEMBLIES .................8 - 8
8.2.5 OIL RECIRCULATION AND FILTERING ................................................................................... 8 - 9
8.2.6 REPLACING PROPORTIONAL VALVES YV22a AND YV22b FOR THE KNOCKOUT ......... 8 - 10
8.2.7 CHECKING ACCUMULATOR PRECHARGE .......................................................................... 8 - 11
8.3 TORQUES (NUTS & BOLTS) .................................................................................................. 8 - 12
8.4 SERVICING THE HEAT EXCHANGER ................................................................................... 8 - 13
8.4.1 REPLACING THE GASKET ..................................................................................................... 8 - 13
8.4.2 SECURING THE STAY BOLTS ............................................................................................... 8 - 14
9 DECOMMISSIONING ................................................................................................................................ 9 - 1
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GENERAL INFORMATION 1
1 GENERAL INFORMATION
1.1 INTRODUCTION
WARNING!
E0004P
Carefully read the entire User’s Manual before working on the machine and/or the packaging of the various parts.
This manual contains important information for safeguarding the operators, maintenance staff as well as the machine itself.
SACMI reserves the right to modify the machine and manual without giving prior notice.
Copyright. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI.
The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,
reproduced, disclosed or transferred.
1.2 WHERE TO KEEP THE MANUAL
WARNING!
E0004P
This manual is to be considered an essential part of the machine and must be kept along with it even if the machine
is sold. Always keep the manual near the machine where it can be easily consulted. The manual must always be at hand
so that the operator and maintenance staff is able to rapidly consult it at all times.
1.3 HOW TO USE THE MANUAL
The lay out of this manual allows it to be easily consulted as all the information and instructions provided are grouped
together and divided into chapters and paragraphs. The user has to simply refer to the table of contents.
The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to the
operator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and
are written in italics, as shown below.
WARNING!
E0004P
Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must be carefully read in its entirety as it contains
important information and warnings regarding safety.
1.4 USERS OF THE MANUAL
In this manual the machine operators are categorized as follows:

- Operator: this is the person responsible for supervising and operating the machine.
- Routine maintenance men.
For a more detailed description, see the paragraph dealing with OPERATOR TRAINING in chapter 3 - SAFETY
EQUIPMENT AND PRECAUTIONS.
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1.5 WARRANTY
SACMI shall be held responsible only for the machine as it was configured at the time of delivery.
Any operations that alter the configuration of the machine or operating cycle must be carried out by SACMI personnel
or duly authorized by SACMI S Engineering Dept.
SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.
E0004P
ATTENTION!
The machine operators and maintenance staff are not responsible for carrying out operations under warranty, special
maintenance and repairs. These operations are to be performed only by the manufacturers specially trained
technicians. For this reason, these types of operations are not dealt with in this manual.
1.6 SUPPLEMENTS
Information regarding the electric and electronic components is given in three handbooks provided separately. These
handbooks are entitled:
- USE OF THE MICROPROCESSOR-BASED CONTROL SYSTEM (Instructions B Manual)
- ELECTRONIC CARDS
- LIST OF DEVICES
The above mentioned handbooks supplement this manual.
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE
MANUAL
DANGER SYMBOLS
General danger
E0004P
Hot surfaces - danger of being burnt

E0002P
Danger - hands can be crushed

E0003P
High tension - danger of electric shock

E0007P
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GENERAL INFORMATION 1
Danger of entanglement in moving parts

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

E0034D
ALERT SYMBOLS
Heavy duty gloves must be worn

E0005O
The indicated point must be effectively grounded

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

E0009C
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1.8 MACHINE IDENTIFICATION PLATE
C2212
E0004P
WARNING!
The machine described in this User’s Manual satisfies all the essential safety requirements specified in standard
98/37/CE solely in the standard configuration determined by SACMI, consisting of:
- hydraulic press PH
- fixed part of filler-box CAL
- mobile part of filler-box CAF
- powder feeder ALM
- Tile collector
The installation and lay out of the parts mentioned above are described in the RULES FOR OPERATION
paragraph in this manual.
The safety requirements are not considered satisfied if parts other than those mentioned above are installed or
if the parts are installed in a way that differs from that described in the RULES FOR OPERATION paragraph in
this manual (if not expressly approved by SACMI).
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MAIN FEATURES 2
2 MAIN FEATURES
2.1 MACHINE DESCRIPTION
The press is a fully automatic machine especially designed to press ceramic powder to produce floor and wall tiles or
other similar products. Either mechanical or isostatic compacting can be employed depending on the type of die-set
installed. In addition, the machine can produce tiles with powders that have different characteristics (double layer).
The most remarkable feature of the machine is that it uses hydraulic power: from loading the die set and performing the
press-stroke, to the removal and ejection of the work-pieces. The main machine units are described below (the
references are given in figure 2.1.1).
2.1.1 MAIN MACHINE ASSEMBLIES
FRAMEWORK
The machine includes the framework (1), base, four columns and crosshead (3) which contains a hydraulic cylinder.
The latter houses a hydraulic cylinder within which a double-acting piston (4) slides. The cylinder is attached to the
plunger (2) so that it can be effectively driven.
The upper part of the crosshead is designed to contain the hydraulic oil required for machine operation.
The plunger (2) slides on the columns through bronze wear-resistant bushes. The main cylinder operates the plunger.
HYDRAULIC SYSTEM
A pressure booster (7), located inside the upper part of the crosshead, generates the pressure directly within the cylinder
so that the programmed press-strokes can be carried out.
A number of control assemblies hold the valves and the logic elements required to operate the machine parts and control
the operating pressures. These assemblies are located on the machine body near the actual points of use.
These control assemblies are listed below:

- Logic element assembly (20). Used to control the pressure required to perform the press cycle.
- Accumulator control assembly (21) used to control upstrokes and downstrokes. In addition, it includes a brake, which
reduces the speed of the plunger while the die set is closing.
- Aux. equipment control assembly (22) which is used to operate the filler box and any other optional equipment (i.e.
top forming die-sets, etc..) installed.
- Knockout control assemblies (23) used to control the tile ejection system.
The hydraulic system (27) provides the amount of oil needed to operate the actuators, controls the operating
temperature and filters the oil. The oil is drawn out of the reservoir by a variable-displacement, axial-piston pump and
delivered to the hydraulic circuit at the required flow rate and pressure.
The hydraulic circuit is kept under pressure so as to prevent the highly abrasive dust produced from getting in.
The hydraulic power unit is provided with an oil/water heat exchanger which keeps the temperature of the oil within the
normal operating limits. The circuit is also provided with a pump-and-motor assembly (28) which is used to cool down
and circulate the oil within the heat exchanger.
The hydraulic lines (18) are provided with the fittings, pipes and hoses required to join the hydraulic parts to one another.
The oil-leak collector (19) is used to collect any oil leaks at ambient pressure. A pump, located in the hydraulic power
unit, will then deliver the oil collected into a pressurized tank.
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2 MAIN FEATURES
FILLER-BOX
The filler box is used to load the powder and eject the formed tiles. It includes a support frame which can be removed
from the press so as to rapidly replace the die-set from the back of the press. During this stage the mechanical parts
move at a speed which is lower than that set by current safety standards (16 mm/sec) - this avoids hazardous situations
for the operator from arising.
The support frame holds up and guides the mobile part of the filler box which includes the actual body and a powder
feed hopper. The latter is mounted over the mobile part of the filler box and may be fed with powder delivered directly
from the main hopper or through a mixer.
The electric motor mounted on the support frame drives the mobile part of the filler box through the use of cogged belts.
The speed and stroke of the filler box as well as the point at which the motor stops can all be set.
All the parts which link the filler box to the press are provided with quick couplings for connection to electrical, hydraulic,
pneumatic or mechanical parts.
UNIVERSAL/ELECTRONIC KNOCKOUT
This system consists of three control assemblies linked together through pins. The external ones incorporate the tile
ejection system while the central one acts as a support. Basically, this system (8) is used to knock the tiles out of the
die-set so that they are level with the die. The tiles are then ejected by the filler box.
The mobile part of the die-set is connected to the four cylinder rods with two quick couplings. The cylinders are series
connected hydraulically through an intermediate duct. Each pair is controlled by a proportional valve.
Two position transducers record the position of the mobile part of the filler box. An axis control card piloted by the
microprocessor regulates movement of the mobile part in real time. The encoder signals are processed and valves are
piloted for this purpose. As a result, the speed of the die-set, as it moves up and down, as well as the upper limit switch
are kept under control. The four cylinders are also used for the die-set overtravel when the lower punches are cleaned
and to make replacement easier. The punches are then moved down recreating the cavity that receives the material
to be pressed.
The soft filling height is automatically determined after setting the desired tile thickness.
The knockout comes with four special cylinders used to raise the die-set, thus making the assembly and disassembly
operations easier to perform. This operation can be performed by placing gauged spacers between the die-set mobile
block and the fixed section of the die-set to make the die-set stiff.
In addition, the knockout has an independent circuit that collects any oil that has leaked out of the main cylinders.
INTAKE, FILTER AND EXHAUST OPENING FOR THE AIR IN THE DIE SET
The air which flows in and out of the lower part of the die set passes though the filter unit (5).
GUARDS AND SUCTION HOODS

The mechanical lock (15) prevents the plunger from accidentally moving down while the die set is being cleaned and
maintenance operations are carried out. A number of covers (29) protect the working parts. The suction hoods (16) draw
the dust out of the process zone.
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MAIN FEATURES 2
MICROPROCESSOR-BASED CONTROLLER
The microprocessor-based controller (31) is used to program the work-cycle that the press will perform automatically.
The controller consists of the following parts:
- a control keyboard;
- a computer terminal to display the set-up parameters, operating data and fault messages;
- electronic cards;
The following are connected to the controller:
- a plunger positioner (33) consisting of two transducers that record the position of the plunger.
- the electrical wiring (30) is based on the same principle as the hydraulic system. It includes all of the electrical and
electro-mechanical parts of the press: miniature switches, proximity sensors and related cams, connecting cables,
terminals, etc...
- a personal computer that processes and displays data retrieved by the microprocessor-based controller along with
historical data in real time.
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 is warmed up by electric heating elements so as to prevent the powder
from sticking.
Three temperature probes continuously measure the temperature in the punches and die. Three separate instruments
can thus control and monitor this important variable.
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2 MAIN FEATURES
Figure 2.1.1 - OVERALL VIEW OF THE PRESS 7
1 Framework 32
2 Plunger
20
3 Crosshead and hydraulic
cylinder 5 18
4 Hydraulic cylinder
5 Air filtering in the die-set
27 19
7 Pressure booster
8 SPE hydraulic knockout 28
9 Filler-box mount (CAL)
10 Mobile part of filler box (CAF)
11 Hopper (ALM)
15
2 C2212
35
29 30 22
31
36
11
9 10
15 Mechanical lock and safety guards

16 Suction hoods
3 18 Hydraulic lines
21 19 Oil leak collector
20 Logic element control assembly
21 Accumulator control assembly
22 Aux. equipment control assembly
33 23 Knockout control assembly
27 Hydraulic power unit
16 28 Cooling unit (motor-driven pump)
29 Covers
4 34 30 Electrical wiring
31 Microprocessor-based control system
32 Electrical control center
33 Plunger position control
34 Die-set
C2583
35 Control keyboard
36 Operator interface cabinet (optional)
1 23
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MAIN FEATURES 2
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE
INTENDED USE OF THE MACHINE

The equipment described in this manual is designed to manufacture ceramic tiles.
The emergency stop buttons have priority over all controls, therefore if the press is started from a distance, it can always
be stopped by using the dedicated controls on the machine. Furthermore the machines placed before and after the press
may send pulses which will stop the press in case of malfunctioning. The press must be restarted from its control panel.
The restart procedure will only take place if trigger pulses are received from the machines in line.
WARNING!
E0004P
If the machine is remote controlled, it is the customer’s responsibility to provide the operators with adequate
training.
The machine can operate in manual or automatic mode. To enable the desired mode of operation, use the relevant
selector switch located on the control panels.
UNINTENDED AND PROHIBITED OPERATIONS

No other tasks except those specified by the Manufacturer are to be performed. For this reason, the Manufacturer shall
not be held responsible for the consequences deriving from the failure to observe the instructions contained herein.
MISUSE OR ERRONEOUS USE

The manufacturer shall not be held responsible for any injury to persons or damage to the machine deriving from
incorrect and erroneous use of the machine. Generally speaking, the most common causes of incorrect use are listed
below:
- personnel not adequately trained to perform the required operations
- fatigue (above all during the night shift) or distraction
- negligence caused by superficiality or wrong habits.
Remember that the machine is to be controlled and run exclusively by expert well trained personnel who are able to:
- correctly operate the machine under normal conditions
- and face any emergencies, this is fundamental!
2-5
2
2.2
1700
2-6
1721,5 ø 1500
1620
= =
200
2000
ø 120
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6500
5890
4951
6000 (min. 5000)
MAIN FEATURES
4000
180
Figure 2.2 - OVERALL DIMENSIONS
OVERALL DIMENSIONS
2250
125
800
-85
1900
1570
1445
1185+15
700
Min. 2055 Max. 2185
750
990
240
2640 1180
1925 = = 2940
= =
4865 625 825
1805 1695 1200 1000
3250 2200
1675 1575
1200 1200 2170
2085 1885
2000 1250
600
1570
310
1300
5000
2170
2170
3800
145 910 145
250
590
500 500
1200
1790
1310
1200
1150
1150
200
250
500
2170
400
1000
Min. 1500
Max. 3500
1800 600
2140 800
2514,5
510
1925
Min. 1825 Max. 3825 680 C2576
014AZ008A
MAIN FEATURES 2
2.3 TECHNICAL DATA
2.3.1 SPECIFICATIONS
PERFORMANCE PH3020
Max. soft clay filling with SPE mm 74
Max. plunger stroke mm 180
Column diameter mm 390
Distance between columns mm 2250
Distance between press table and plunger mm 800
Max. knockout force kN 150
Max. pressing force kN 30000
Max. cylinder pressure bar 382
Cycles per minute up to 20
Strokes per cycle 1-2-3
ELECTRICAL SYSTEM PH 3020

Voltage: Aux. circuitry Vac 110
Die-set heaters Vac 50
Solenoid valves (regulated) V 24
Power: Main motor (50 Hz) kW 90
Heat exchanger pump motor (50 Hz) kW 7,5
Die-set heater (standard punches) (50 Hz) kW 20 + 20
Die (50 Hz) kW 10
Controller (50 Hz) kW 1
Oil leak collector pump (50 Hz) kW 0.18
Magnetic lock kW 2.5
Sound-proof booth fan kW 0.25
Enea cooling (optional) kW 7
Sacmi exchanger (optional) kW 9
In-line filler-box control kW 7
Double loading control kW 2.5
Auxiliary circuits kW 2.5
2-7
014AZ008A
2 MAIN FEATURES
HYDRAULIC SYSTEM PH 3020
Hydraulic oil: system capacity l 1100
Cleanliness rating at press inlet in accordance with ISO 4406:1999 19/17/13
Specifications see “Lubrication guide for machinery used in the ceramic industry” 200.02.A01
Max. hydraulic power unit operating pressure bar 230
Accumulators Main circuit : capacity l 24,5 + 24,5 + 24,5
precharge pressure bar 130
Aux. circuit : capacity l 20
Pilot valve circuit capacity l 1
Main filter Filtering capacity µm 12
Reservoir filter cartridge: Filtering capacity µm 250
Filter cartridge (plate type): Filtering capacity µm 6
Cooling system : Heat to be dissipated kW 64
Kcal/h 55000
Water used at 20 degrees C l/1' 45
Water pipe connection diameter 1"1/2
Hoses, Inside diameter mm 40
Max. pressure bar 4
Pressurisation: Max. pressure (with plunger raised) bar 1.5
WEIGHTS
Weight Press body kg 83000
Hydraulic power unit kg 890
Aux. equipment (controller, electrical cabinet, filler-box, etc.) kg 3000
ATTENTION!
E0004P
All the specifications of the oil to be used in he hydraulic system are given in Instructions manual 200.02.A01
“LUBRICATION GUIDE FOR MACHINERY USED IN THE CERAMIC INDUSTRY”
2-8
014AZ008A
MAIN FEATURES 2
2.3.2 AIRBORNE NOISE LEVELS
Test conditions:
- Operating conditions (refer to ISO/DIS 11202 specification, paragraph 9.5):
- a wooden test piece was used
- a sound-proof system provided
- Type of process:
manufacture of ceramic products
- Work cycle:
die-set loading, one or more press-strokes and deaeration and final formation of product
- Test conditions:
PH 3020
Cycles/minute 14
Hydraulic power unit pressure (bar) 230
Operating pressure (bar) 300
- Test environment
Testing department at Sacmi Imola
Test instruments used

Class 1 (IEC 804)
Sound pressure level (ISO/DIS 11202)

Sound power level (ISO 3746)
Values measured
PH 3020
LpA P1 74
(dBA) P2 78.5
LwA 96
(dBA)
LpA Continuous A-weighted sound pressure level.

LwA Acoustic power level in dB weighted A.
P1 = Occasional control post

P2 = Noisiest position of the ideal machine perimeter measured at floor level
Figure 2.3.2 - POINTS WHERE NOISE LEVEL WAS MEASURED

C2216
P2
P1
2-9
014AZ008A
2 MAIN FEATURES
2.3.3 DUST SUCTION HOODS
Dust is let into the atmosphere during normal machine operation. The press is equipped with suction hoods designed
to capture the dust particles. These hoods are to be connected to a suitable suction system. A drawing illustrating the
points where the hoods are installed along with the air delivery rates required for proper operation is given below.
Suction outlet ID NO. of Outlet diameter Total delivery rate Height from floor
symbol outlets (mm) qt (m3/h) (m)
Front hood S250 2 150 2560 +2.0

Rear hood S260 1 150 1280 +2.0
Brushes (1) S270 4 100 2260 +1,4
Hopper (19) S150 1 100 565 +6.7 (2)
Double loading, powder
P003 2 100 1080 -0.1
level limit (opt.)
Rear powder level limit P004 6 80 2160 -0.1
Front powder level limit P002 1 70 416 +0.2
Powder level limit - Cleaning P010 1 50 212 +0.8
(1) Outlets present on tile roller conveyor - rpr-

(2) + 6.2 for service floor h = 5000
(19) Use not shown in drawing
C2217
P004
P004
P003
P003
NOTE: Suction system vacuum before

reaching the press must fall
within “130 and 150” mm of H2O
(= “0.0126 and 0.0145” bar).
S260
NOTE: Use anti-static tubes to connect
the hoods to the suction system.
S250
P002 P010
S250
S270
S270 S270
S270
2 - 10
014AZ008A
MAIN FEATURES 2
2.3.4 RATING PLATE
Figure 2.3.4 - RATING PLATE
C2212
2 - 11
014AZ008A
2 MAIN FEATURES
2.4 DIAGRAMS
2.4.1 HYDRAULIC AND PNEUMATIC DIAGRAMS
The schematic is presented as a block diagram in order to highlight the different separate areas in the machine. The
hydraulic and pneumatic parts are numbered and listed so that the functions can be well identified.
Block diagram
A PREFILLING TANK
B HOPPER GATE CONTROL
C PRESS-STROKE CONTROL
D UPSTROKE, DOWNSTROKE, BRAKING AND PRESSURE CONTROL
E AUX. EQUIPMENT CONTROL ASSEMBLY
F KNOCKOUT CONTROL
G MECHANICAL LOCK CONTROL
H SPE TYPE KNOCKOUT
I HYDRAULIC POWER UNIT
L BLOWER CIRCUIT (OPTIONAL)
M SFS CONTROL (OPTIONAL)
P MIRROR-FINISHED DIE-SET (OPTIONAL)
Q DIE RELEASE CONTROL (OPTIONAL)
R MOBILE BRUSH PNEUMATIC CONTROL (OPTIONAL)
S MOBILE BRUSH PNEUMATIC SYSTEM (OPTIONAL)
T FIXED AND MOBILE BRUSH HYDRAULIC CONTROL (OPTIONAL)
V THIRD DIE-SET DOWNSTROKE CONTROL (OPTIONAL)
2 - 12
Figure 2.4.1/A - HYDRAULIC & PNEUMATIC SYSTEM SCHEMATIC
YV290
75 271 73 72
74
71
A C B L T 264
272
ASPIRAZIONE POMPA 125
DELLO EXCHANGER
AIR-OILSCAMBIATORE 126 275 273 YV173 265 266
ARIAPUMP
- OLIOINTAKE 120 117 116 131
119 118
277 267
SP2 194
YV221
220
YV38 YV70 YV19 YV40 YV41 223 222
224
36 YV192
219
BP1 SQ61 SQ60
YV32m D 18a 18b 18

G
382 R
124 89 YV39
195 195
383
384 269 269
174 109 108 115 385
123
247 M15 132 92
M
90 270 270
YV313 269 269
122 YV107 YV31d YV31s YV47 YV32d YV32s YV53
153
BQ3
YV171a YV171i
184 184 S
258
7 60
59
179 179
069
388 388 144 SQ50a BT4

145 12 154
250 249 67 10
I
H 180a1 141 YV99 M3 M
386 386 180b1 386 386 84 82
142 YV172 YV193 YV11r 112 105
85
180b2 338 H2O
180a2 112a 54 SL4
143 337 86 SL3 YV279
H2O
YV304b YV304a BP6 183 188 48
140 339 SP1
BP7 111 M11
YV298
YV22b YV22b 196 198 4 M
336
S
U
166 49 78
YV22a 153 79
SP5 58
POMPA
DELIVERY
SP3
YV25 13
PUMPSCAMBIATORE
YV22s
AIR-OIL EXCHANGER
F 252 M M1
MANDATA
DELLO
ARIA - OLIO
MAIN FEATURES
P Q M E
C2190
2
014AZ008A
2 - 13
014AZ008A
2 MAIN FEATURES
Figure 2.4.1/B - LOGIC ELEMENT ASSEMBLY
YV70 220
YV38
BP1
SP2
YV19
YV40
YV41
120
119
118
117
116
C1827
131
Figure 2.4.1/C - BRAKE CONTROL ASSEMBLY
18a 18
89
YV39
18b
YV32m
YV107
YV31d
247
132 YV31s
108
115 M15
92
C2582 174
YV53 YV47
90
153 YV325s
YV32d 258 109
2 - 14
014AZ008A
MAIN FEATURES 2
Figure 2.4.1/D - AUX. EQUIPMENT -

SPE CONTROL ASSEMBLY 141
YV172
YV193
337
YV129 SP5
250
12
339
249
336
188
140 252
112a
10
C2581
153 YV11r 143 183 338 251 142
Figure 2.4.1/E - SPE PROPORTIONAL KNOCKOUT CONTROL ASSEMBLIES (REAR VIEW)
198
YV22a
166
196
BP7
BP6
YV304a
C2125 YV304b
YV22b YV25 YV22s
2 - 15
014AZ008A
2 MAIN FEATURES
Figure 2.4.1/F - SPE PROPORTIONAL KNOCKOUT (FRONT VIEW)
180a2
180a1
180b2
C1816
180b1
2 - 16
014AZ008A
MAIN FEATURES 2
LIST OF THE HYDRAULIC AND PNEUMATIC COMPONENTS (SMU - SPE)
004 Check valve, Accumulator, Aux. equipment control 154 Suction system cock
007 Manual check valve, Accumulator control assembly drain 166 Reducer valve, Intermediate duct between cylinders
010 Valve (pilot-operated), Low pressure control 180a1 and 180a2
012 Accumulator, Aux. equipment (filler-box and lift control) 174 Logic element, Braking
013 Pressure gauge, Pump and cock 179 Cylinder, Die over-travel
018 Accumulator, Press-stroke and upstroke 180a1 Knock-out cylinder
018a Accumulator, Press-stroke and upstroke 180a2 Knock-out cylinder
018b Accumulator, Press-stroke and upstroke 180b1 Knock-out cylinder
036 Pressure gauge, Cylinder and cock 180b2 Knock-out cylinder
048 Heat exchanger 183 Check valve, Die hydraulic release
049 Suction filter, Main pump 184 SFS cylinder
054 Check valve, Oil leak recovery pump 188 Pressure reducer, Aux. equipment circuit
058 Main pump 194 Pressure relief valve, Brush drive
059 Pressure relief valve, Brush rotation 195 Hydraulic motor, Brush
060 Restrictor, Brush rotation 196 Pressure gauge, Intermediate duct between knockout cylinders
067 Pressure gauge, Aux. equipment pressure and cock 198 Pressure gauge, SPE return stroke chamber 2 + 2
069 Check valve (hydraulic release), Die upstroke cylinders
071 Safety valve, Pressurisation 219 Check valve, Pilot system accumulator
072 Air filter, Pressurisation circuit 220 Pilot system accumulator, Logic element control
073 Pressure reducer, Air in the pressurisation circuit assembly
074 Check valve, Air in the pressurisation circuit 222 Flow control and silencer, Gate cylinder
075 Pressure gauge, Air in the pressurisation circuit 223 Flow control and silencer, Gate cylinder
078 Filtering unit pump 224 Gate cylinder
079 Filter 247 Check valve, Cylinder downstroke
082 Check valve, Filtering unit delivery line 249 Restrictor, SFS delivery line
084 Coupling (oil collector pump) 250 Restrictor, SFS accumulator
085 Oil collector pump 252 Proportional filter (10 µm)
086 Filter, Oil collector pump suction line 258 Change-over valve
089 De-aeration proportioner 264 Air filter, Brush ass’y
090 Flow rate control, Slow upstroke 265 Pressure gauge, Brush ass’y
092 Logic element, Booster supply, 2nd press-stroke 266 Pressure reducer, Brush ass’y
105 Oil leak collection tank 267 Oiler, Brush ass’y
108 Logic element, Upstroke 269 Flow regulator, Brush drive cylinder
109 Logic element, Downstroke 270 Cylinder, Brush drive
111 Pressure relief valve 271 Coalescent filter, Pressurisation system
112 Pilot-operated valve, Line pressure 272 Air filter, Hopper assembly
112a Safety valve, Hydraulic circuit 273 Pressure reducer, Hopper assembly
115 Logic element, Accumulator shut-off during press-cycle 275 Pressure gauge, Hopper assembly
116 Logic element, Flow booster (1st press-stroke) 277 Oiler, Hopper assembly
117 Logic element, Cylinder pressure 336 Pressure relief valve
118 Logic element, Cylinder drain 337 Accumulator, SFS circuit
119 Logic element, Booster drain 338 Pressure gauge, SFS circuit
120 Logic element, Pressure booster 339 Drain cock, SFS circuit
122 Plunger 382 Actuator air filter, Pneumatic lock
123 Rod 383 Actuator pressure reducer, Pneumatic lock
124 Cylinder 384 Actuator pressure gauge, Pneumatic lock
125 Booster assembly 385 Oiler, Pneumatic lock
126 Prefilling tank 386 Throttle, Cylinder speed regulation, Pneumatic lock
132 Flow control, Plunger braking 388 Pneumatic actuators, Mechanical lock
134 Pressure relief valve, Plunger protection BP1 Transducer, Cylinder pressure
140 Pressure reducing valve, Mirror finished die-set BP6 pressure transducer, SPE upstroke
141 Accumulator, Mirror finished die-set BP7 pressure transducer, SPE downstroke
142 Pressure gauge, Mirror finished die-set BQ3 Position transducer, Brake logic-element
143 Drain cock, Mirror finished die-set BQ4 Cylinder A encoder, Proportional knockout
144 Cock, Main pump suction line BQ5 Cylinder B encoder, Proportional knockout
145 Restrictor, Non return valve, Mirror-finished die set BQ6 Plunger encoder (R.H.)
153 Cock, Accumulator and brake control assembly drain BQ7 Plunger encoder (L.H.)
153a Cock, Aux. equipment control assembly drain BQ10 ALM encoder
BT4 Thermocouple, Hydraulic power unit reservoir
M1 Motor, Main pump
M3 Motor, oil leak recovery pump
M11 Motor, Recirculating pump
2 - 17
014AZ008A
2 MAIN FEATURES
M15 Motor, Brake system
M20 Motor, Linear filler-box (optional)
SL3 Min. oil leak level
SL4 Max. oil leak level
SP1 Pressure switch, Main filter service
SP2 Pressure switch, Cylinder (safety)
SP3 Pressure switch, Air pressurization
SP5 Pressure switch, Proportional valve filter clogged
(knockout)
SQ3 Sensor, Die-sets up
SQ6 Sensor, Die-sets down
SQ11a Micro-contact, Mechanical lock, Right lock normally
open
SQ11b Micro-contact, Mechanical lock, Left lock normally open
SQ11c Micro-contact, Mechanical lock, Right lock normally
closed
SQ11d Micro-contact, Mechanical lock, Left lock normally closed
SQ12a Micro-contact, Lock application, Right mechanical lock
normally closed
SQ12b Micro-contact, Lock application, Left mechanical lock
normally closed
SQ50a Micro-contact, Suction line cock safety
SQ60 Sensor, Hopper gate open
SQ61 Sensor, Hopper gate closed
YV11r Solenoid valve, Quick oil heating
YV19 Solenoid valve (pilot-operated), 2nd press-stroke (direct)
YV22a Proportional solenoid valve, Cylinders 180a1 and 180a2
control
YV22b Proportional solenoid valve, Cylinders 180b1 and 180b2
control
YV22s Safety solenoid valve
YV25 Solenoid valve, Slow SE die-set movement
YV31d Solenoid valve, Slow downstroke
YV31s Solenoid valve, Slow upstroke
YV32d Solenoid valve, plunger downstroke
YV32m Solenoid valve, Booster upstroke
YV32s Solenoid valve, plunger upstroke
YV38 Solenoid valve (pilot-operated), Pressure booster
YV39 Solenoid valve, deaeration
YV40 Solenoid valve (pilot-operated), Flow booster, 1st press-
stroke
YV41 Solenoid valve, Flow booster, 2nd press-stroke
YV53 Solenoid valve, Accumulator shut-off
YV70 Solenoid valve, Main cylinder drain
YV99 Solenoid valve, Pump control drainage
YV104 Solenoid valve, Oil leak compensation
YV107 Solenoid valve, Automatic plunger upstroke
YV171a Solenoid valve, Brush hydraulic motor control
YV171i Solenoid valve, Brush hydraulic motor control
YV172 Solenoid valve, SFS die-set cylinder drain
YV173 Solenoid valve, Die-set blower
YV192 Solenoid valve, Brush drive
YV193 Solenoid valve, SFS punch return stroke
YV221 Solenoid valve, Hopper gate control
YV279 Solenoid valve, Cooling water
YV290 Solenoid valve, Pressurization control
YV298 Solenoid valve, Lower die-set release
YV304a Solenoid valve, Pressure restoration, Intermediate duct
between cylinders 180a1 and 180a2
Solenoid valve, Pressure restoration, Intermediate duct
between cylinders 180b1 and 180b2
YV313 Solenoid valve, Actuator control, Pneumatic lock
2 - 18
014AZ008A
MAIN FEATURES 2
2.5 OPERATION
The identification numbers and symbols of the hydraulic, pneumatic and electrical components mentioned below refer
to the HYDRAULIC AND PNEUMATIC DIAGRAM.
2.5.1 COMPRESSED AIR SUPPLY
The unit consists of filter 72, pressure reducer 73, check valve 74, pressure gauge 75, valve YV290 and pressurisation
system air filter 271. The compressed air is used to pressurise the tank and to put the hydraulic oil contained in it under
constant pressure.
The pressure reducer must be set so that a pressure of 1 to 1.2 bar is provided inside tank 126. Safety valve 71 is used
to prevent any over-pressure within the tank from forming.
Pressure switch SP3, which keeps pressurisation under control, is mounted on the suction line of pump 58. It prevents
the main pump from being started up if the pressure in the air lines is insufficient. If this happens, a fault message will
be displayed. A unit (which consists of filter 272, pressure reducer 273, pressure gauge 275, lubricator 277 and solenoid
valve YV221) controls cylinder 224 to operate the feed hopper gate, provided that this optional device is installed. An
additional assembly – which includes filter 264, pressure reduce 266, pressure gauge 265, lubricator 267, solenoid valve
YV192, pressure reducer 194 and flow regulators 269 – controls cylinders 270 that drive the mobile brush (optional).
In addition, the mechanical lock control unit includes a filter 382, pressure reducer 383, pressure gauge 384, oiler 385
and valve YV313. This valve controls the pneumatic actuators 388 whose speed is regulated by throttles 386.
2.5.2 FAST HEATING
In order for the press to run efficiently, the oil temperature must be kept at around 40°C. When the machine begins to
run, the oil is normally at ambient temperature, therefore it is necessary to heat it up to at least 30°C before starting an
automatic work-cycle. However, the machine can be started up.
NOTE: With temperatures lower than 5°C, use an external heater.
To heat the oil, start up the pump with the safety bar raised. If the temperature is below 30°, valve YV11r will be energised
and the oil heating circuit will begin to operate. The pump will circulate the oil at a pressure of 150 bar (set for valve 10).
The electrical power dissipated is then turned into heat. The power dissipated in pressure relief valve 10 will cause the
oil to be warmed up in a short time (10 to 15 minutes approx.). If the oil temperature is found to be <2°C, the controller
will not allow drive motor M1 to start running.
2.5.3 HEAT EXCHANGER SYSTEM
The system consists of pump-and-motor unit M11-78, plate-type heat exchanger 48 and filter 79.
Pump 78 draws the oil from the tank of the hydraulic power unit and delivers it to filter 79 and heat exchanger 48. The
oil is then cooled down and returned to the tank.
Filter 79 is provided with pressure switch SP1 which indicates when it is clogged.
Check valve 82 is used to prevent the oil from going back into the filter when the filter elements are being replaced.
The flow rate of the cooling water is controlled by valve YV279.
The microprocessor based system measures the oil temperature thanks to thermocouple BT4 (located on the hydraulic
power unit’s reservoir). After the temperature rises and reaches 41°C, YV279 will be energised; after it reaches 39°C,
YV279 will be de-energised.
Drive motor M1 will stop if motor M11 shuts off. As a result, the automatic work-cycle will be interrupted. First run the
heat exchanger to bring motor M1 back into operation.
2 - 19
014AZ008A
2 MAIN FEATURES
2.5.4 OIL LEAK CIRCUIT
The oil leaks from the gasket of the main cylinder’s 124 rod from the booster are collected in tank 105.
A level control inside tank 105, called “first level control” (SL3), starts motor-pump unit M3-85 when the maximum level
is present. The oil drawn in by the pump flows through filter 86 and is sent to the hydraulic power unit reservoir. Check
valve 54 stops the oil from flowing back to tank 105. When the level control detects the minimum level, it stops the pump.
The “second level control” (SL4) inside tank 105 transmits a signal processed by the microprocessor control system
that shuts down the machine if the oil cannot be pumped into the hydraulic power unit reservoir (e.g. coupler between
the motor and pump broken as suction filter 86 is clogged, thermal relay contact for motor M3 open, etc...).
2.5.5 MAIN PUMP RUNNING - SAFETY BARS ENGAGED (RAISED)
The microprocessor-based control system is energised along with the motor starters when the master switch is turned
to its “on” position.
a) the following units start running when key “0” is pressed:

- Fan motor in the sound-proof housing (if installed);
- Motor-and-pump assembly for the filtering unit and heat exchanger M11-78.
b) if key “0” is pressed again (at least five seconds must elapse between operations A and B), the following unit will start
running:
- Main pump and motor M1-58.
Unit M1-58 is started up under no-load conditions in a pre-determined sequence when solenoid valve YV99
controls the drainage of the pump pressure regulator.
Filter 49 and pressure switch SP3 are installed on the suction line of pump 58. The pressure switch indicates when filter
49 is clogged. In fact, if the pressure in the suction line falls below the allowable levels, pressure switch SP3 will change
over and transmit a signal to the microprocessor system which, in turn, will cause the motor which drives the main pump
to stop running. A fault message will appear on the screen of the microprocessor system. The delivery line of pump 78
is fitted with filter 79 and pressure switch SP1. The latter indicates when filter 79 is clogged. The pressure in the circuit
is around 20 bar (see the instructions for the variable delivery pump).
As soon as solenoid valve YV22s is energised, oil is delivered to solenoid valves YV22a and YV22b which keep the
die-set in position.
2 - 20
014AZ008A
MAIN FEATURES 2
2.5.6 POSITION TRANSDUCER - SETTINGS
The encoders are digital position transducers which continuously monitor the position of the plunger, the filler-box and
the knockout. These allow the microprocessor based control system to determine the position of the various axes so
that the operations set by the user can be performed. In particular:
Encoders 1 and 2 (plunger position) “BQ6” and “BQ7”
The following settings can be entered for the plunger (see Instructions B manual):
- Plunger stoppage due to lack of powder
- Plunger down position (trigger pulse to start the press-stroke)
- Braking space
- Plunger raised position (automatic mode)
- End of braking during plunger upstroke
- Plunger parallelism error: this value, expressed in mm, represents maximum plunger inclination during the press-
cycle.
Encoder 3 (filler box position) “BQ2”
The following settings can be entered for the filler-box (see the Instructions B manual):
- Position filler-box reaches when fully back
- Position filler-box reaches when fully forward
- Approach setting
- Filler-box speed during the forward stroke
- Filler-box speed during the return stroke
- Approach speed
- Filler box position for first die-set downstroke
- Filler-box speed in manual mode
Encoders 4 and 5 (knockout position) “BQ4” and “BQ5” (only with SPE)
The following settings can be entered for the knockout (see the Instructions B manual):
- Upper end-stops A and B
- Speed during upstroke
- Speed during downstroke
- Tile knockout between punches
- Knockout timing with filler-box during loading
Encoder 6 (ALM position) “BQ10” (only with DCL)
The following settings can be entered for the filler-box cycle (see the Instructions B manual):
- Position ALM reaches when back
- Position ALM reaches when forward
- ALM speed during forward stroke
- ALM speed during return stroke
- Position ALM reaches when the hopper gate is opened
- Position ALM reaches when the hopper gate is closed
2 - 21
014AZ008A
2 MAIN FEATURES
2.5.7 SAFETY BARS DISENGAGED (LOWERED)
When the safety bars are pushed down, the press cycle valves are enabled. The press is able to run in automatic mode
if the filler box and tile ejector are installed at the front of the machine.
Throughout operation valve 111, at the pressure valve set for 112a acts as a safety device for the hydraulic circuit (the
work and safety pressure valves are given in paragraph 7 - ADJUSTMENT PROCEDURES).
Keep in mind that once the maximum and safety pressures have been set, the pins fir the two valves should be secured
with the lock nuts provided to prevent them from coming loose during operation due to the vibrations created. This
practice will prevent the set pressure values from being modified. The pressure of valve 112 is defined as the line
pressure. It can be adjusted when valve YV99 is energized.
2.5.8 ENCODER RESETTING
To perform this operation, press keys 28 & 5 at the same time. This is to be done whenever the microprocessor based
system is disconnected. The encoders must be reset in order to start the machine cycling in automatic mode.
“ENCODER NOT RESET” will appear on the display of the microprocessor control system so as to inform the operator
when this is to be done.
2.5.9 DIE-SET CONTROL CIRCUIT
Press push buttons 13 & 25 to energize solenoid valves YV22s, YV25 and proportional valves YV22a and YV22b.
Solenoid valve YV22s delivers oil to valves YV22a and YV22b which, in turn send oil to cylinders 180a1, 180a2, 180b1
and 180b2. The latter are used for the upward and downward movement. The cylinders on each side are joined to one
another by an intermediate duct which ensures perfect timing. The pressure in the intermediate duct is restored by
solenoid valves YV304a and YV304b. During each cycle the latter join the intermediate chambers to the reduced
pressure line. This is accomplished through reducer 166.
In order for the cylinders to be precisely positioned, the gauges 196 and 198 should read the values given on the plate.
Check periodically. If this does not happen, proceed as directed in paragraph 4.2.2 - INSTALLING AND REMOVING
THE DIE-SET.
The speed and timing are controlled by the axis control card. The latter, in turn, is controlled by the microprocessor
according to the position of the cylinders. Transducers BQ4 and BQ5 are used to monitor this position.
2 - 22
014AZ008A
SAFETY EQUIPMENT AND PRECAUTIONS 3
3 SAFETY EQUIPMENT AND PRECAUTIONS

3.1 SAFETY DEVICES
WARNING!
E0004P
3.1.1 SAFETY GUIDELINES
The machine is provided with a number of electrical and/or mechanical safety devices in order to safeguard the
operators and the machine itself.
These devices must never be removed, disabled or altered in any way.
Some illustrations provided in the manual show the machine, or parts of it, with the guards removed. This is simply for
added clarity. Never actually use the machine with the guards removed or safety devices disabled.
Warning signs are provided on the machine to indicate any hazards in the zone where the sign is attached.
Always take all necessary safety precautions before working on the machine.
SACMI shall not be held responsible for any personal injury or property damage resulting from failure to observe these
precautions or use the safety devices provided.
3.1.2 SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE
The operator may be injured, cut or get caught in moving machine parts while working in the area where the powder
is loaded or in the area around the die set. A number of barrier guards have been provided to prevent the operator from
gaining access to these hazardous areas:
- Fixed guards mounted on the front of the press
- Front safety bars with mobile guard
- Fixed guards on the powder infeed system
None of the fixed guards can be removed without using special tools. Furthermore, they will not stay in position unless
suitable fasteners are used. The mobile guard is basically a grid which moves when the safety bar when the safety bar
is operated. In any case, the size of the steel mesh is such as to prevent access to the hazardous area.
When the safety bar is raised, two limit switches - located on the front part of the machine - prevent any powered
movements from being performed. Moreover, two mechanical locks are engaged to prevent the plunger from abruptly
moving down.
The front of the press must be safeguarded by installing the tile collector equipped with fixed safety guards that prevent
access to the area where the die-set is found and limit switches (SQ53a and SQ53b) that signal it is present in its work
position.
Two interlocking devices SQ66 and SQ66a, which are triggered by the powder infeed system, are found at the rear of
the machine. When the feeder is not operated and the area at the rear of the die-set is clear, only the plunger can move
slowly down (at a speed of less than 16 mm/sec) by using self-maintained pushbuttons.
The press is also provided with two red emergency stop buttons (on a yellow background). One button is located on
the control panel while the other is to be found at the rear of the press. These buttons are to be pressed whenever an
emergency situation arises, causing the machine to stop and the oil in the hydraulic accumulators as well as in the pump
to be drained.
The machine is to be reset whenever an emergency stop button has been pressed.
In the event that electricity to the machine is cut off, the accumulators on the press-cycle and service control assembly
must be manually discharged with cocks 153.
A pressure relief valve 112a is provided in the hydraulic circuit. This valve is factory set to the highest allowable value
to ensure top machine performance. In addition, this acts as a safety feature as it prevents the system from exceeding
the set value and consequential system malfunctioning. A safety valve 71 is installed on the reservoir. This valve serves
to prevent the pressurization pressure from exceeding 2.25 bar. This valve is factory set and sealed and therefore cannot
be modified.
3-1
014AZ008A
The following safety standards were used as references
EN 292-1 Safety of machinery - Basic concepts, general principles for design.

Part 1: Basic terminology, methodology.
EN 292-2 Safety of machinery - Basic concepts, general principles for design.
Part 2: Technical principles and specification.
EN 294 Safety of machinery - Safe distances to prevent danger zones being reached by the upper limbs.
EN 349 Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.
EN 418 Safety of machinery - Emergency stop equipment, functional aspects. Principles for design.
EN 953 Safety of machinery - Guards. General requirements for the design and construction of fixed and movable guards.
EN 982 Safety of machinery - Safety requirements for fluid power systems and their components. Hydraulics.
EN 983 Safety of machinery - Safety requirements for fluid power systems and their components. Pneumatics.
EN 1088 Safety of machinery - Interlocking devices associated with guards. Principles for design and selection.
Pr EN 12692: 1999 Machines and plants for manufacturing light-and-heavyweight ceramics and refractories.
Safety of presses
3-2
014AZ008A
3.4 HANDLING PROCEDURES
WARNING!
E0004P
3.2.1 LIFTING PROCEDURES
SLINGING THE LOAD

To properly and safely lift the machine, always follow the directions below:
- Use adequate lifting equipment.
- Cover all sharp edges.
- Check the safety device the hook is provided with.
- Do not move the load unless it is securely slung.
Before lifting:
- Make sure all personnel are away from the machine.
- Make sure the load does not sway.
- Make sure all parts which may fall are secured in position.
- Lift the machine vertically in order to prevent collision with anything placed nearby
3.2.2 HANDLING
During handling operations, the load must remain on a perfectly horizontal plane regardless of the type of equipment
being used.
The load should always be lifted and handled with the aid of sticks, levers and grapples. Never use your hands!
The person in charge of handling and lifting must always:
- Know where the machine is to be carried.
- Instruct the crane operator from a visible position.
- Stop the operations if hazardous situations occur (e.g. personnel passing by).
3.2.3 PLACING THE LOAD
Before the load is placed in position, make sure the floor is level and strong enough.
Do not place the loads in areas where they could create a hazard, prevent the use of equipment or obstruct emergency
exits:
- factory exits,
- Fire extinguishers
- Passageways
- Control panels
- Power lines
The load is to be placed on suitable supports in order to keep it stable and help the personnel remove the sling. Never
place containers in bad condition with protruding parts on top of each other. Never stack parts to a height which may
affect stability.
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3.3 INSTALLATION
3.3.1 GUIDELINES
E0004P
WARNING!
The machine must be placed on concrete foundations as specified by SACMI. In particular, the foundations should be
able to resist the stress applied when the press is operated. The customer should provide the ducts and conduits for
the hydraulic lines and electrical wiring. These are to be made in non-slip sheet metal and should conform to current
engineering regulations. If the machine comes with a conventional knockout, the well must be provided with fixed covers
which can only be removed by using specific tools.
Make sure there is enough space around the machine so that it can be operated and serviced easily.
The area surrounding the machine must always be kept free of obstacles, clean, dry and well-lit.
The lighting in the areas around the machine and, in particular, in the work zone should be efficient and have a level
of illumination not less than 300 lux.
The customer must make sure that fire-fighting equipment is provided in the area where the machine is installed and
that there is a system for protection against voltage fluctuation in the electricity supply line. These must conform to laws
currently in force in the country where the machine is installed. Machine installation and start up is to be done by the
manufacturer or persons authorized by the manufacturer therefore instructions regarding these steps are not given in
this manual.
WARNING!
E0007
Connect the machine to an effective earth-ground.
WARNING!
E0007
The electrical wiring does not come with a differential protective device unless expressly requested.
WARNING!
E0007
If electronic converters are present in the electrical control cabinet, the differential protective devices installed on the
cabinet’s power supply line must be “B” type as specified by current safety standards.
E0004P
WARNING!
SACMI shall not be held responsible for any property damage or personal injury resulting from improper installation.
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3.4 PERSONNEL TRAINING
E0004P
WARNING!
3.4.1 END-USER
The factory supervisor should see that the machine operators:

- meet the requirements listed below;
- have fully understood the instructions contained in the manual;
- are well trained on how to safely carry out their tasks;
- have received specific instructions on how to operate the machine correctly.
3.4.2 OPERATORS
The machine operators should:

- understand the instructions provided and have specific experience in operating this type of machine
- be sufficiently educated so as to be able to read and fully understand the contents of this manual as well as the
drawings provided
- know all the safety rules and regulations in force in the country where the machine is installed i.e.:
- general rules (regarding hygiene and on-the-job safety as well as work accident prevention)
- specific rules (for the type of product being manufactured)
Operator tasks
The operator is only authorised use the controls and instruments provided on the machine’s control panel.
3.4.3 MAINTENANCE STAFF
The maintenance staff should be employed on the basis of the same criteria.
In addition, they must be qualified in specific technical fields (mechanical, electric, hydraulic and pneumatic) so that they
can safely carry out the operations they are responsible for (as specified in the manual).
Tasks for the maintenance staff

The maintenance staff are responsible for carrying out the routine maintenance operations described in this manual.
It is important that the members of staff carry out only the tasks in the areas they are specifically responsible for
(mechanical, electric, pneumatic, etc.).
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3.5 OPERATING INSTRUCTIONS
3.5.1 SAFETY RULES
E0004P
WARNING!
The machine comes equipped with electrical and/or mechanical safety devices which safeguard the press and the
operator. The press must be used in accordance with the instructions provided by the manufacturer otherwise these
devices cannot ensure maximum safety. Moreover, the safety devices and guards provided MUST NOT be removed
or inactivated under any circumstances. The Manufacturer shall not be liable for any damage or injury if the machine
operator fails to observe these precautions. The controls and devices the machine is provided with will only guarantee
maximum safety if a powder infeed system approved by SACMI is used. Furthermore, only die sets, which employ a
suitable upper punch lock, are to be used. The upper punch locking system may use permanent magnets or be of the
mechanical or electro-mechanical type. In this case, a special mechanical system is used to prevent the punches from
inadvertently moving down. The manufacturer of the die-set is responsible for any risks that derive from the tools.
The press can operate in three modes. Simply turn the selector switch located on the control panel to automatic, manual
and set-up.
3.5.2 OPERATION IN AUTOMATIC MODE
When the machine runs in automatic mode the personnel do not need to perform any operations. A number of barrier
guards have been provided to prevent the personnel from gaining access to the hazardous areas (i.e. around the die-
set). In particular:
- Fixed guards are mounted on the powder infeed system
- Fixed guards at the sides of the press near the columns. The guards include an access door which can be opened
with special tools, thus allowing the operator to visually check machine functioning without gaining access to
hazardous areas of the machine.
- Fixed guards are on the working parts of the filler box infeed system. The strokes of the filler box should be set when
the machine is stopped.
- Front safety bar with mobile guard. This bar is wired up to the microprocessor-based control system. When the bar
is completely down (safety bars down), it prevents the operator from gaining access to the work areas during the
production run.
All the guards have been placed at a safe distance as recommended by current safety standards (EN 294).
The front guards also include a tile ejector. The latter, in turn, should be provided with fixed covers so as to prevent
access to the die-set (figure 3.5.5).
If the front safety bar is raised, two mechanical locks are engaged to prevent the plunger from abruptly moving down.
This arrangement prevents the press from performing any hazardous powered movements which may harm the
operating personnel.
3.5.3 OPERATION IN MANUAL MODE
If all the safety devices used during operation in automatic mode are operative, the filler-box, knockout and plunger can
be operated manually. If the safety bar is raised the filler-box cannot be moved. The knockout can still carry out
movements.
3.5.4 OPERATION IN SETUP MODE
Only the maintenance personnel can operate the machine in this mode. The plunger moves slowly up and down (< 16
mm/s) so as to replace the die-set. In this case, the filler-box slide at the rear or the front tile ejector is to be removed
so as to gain access to the machine. Do not perform any operations with the machine running. To install the die-set,
see chapter 4 - INSTALLATION PROCEDURES.
The press is also provided with two emergency stop buttons . One button is located on the control panel while the other
is to be found at the rear of the press. These buttons are to be pressed whenever an emergency situation arises, causing
the machine to stop and the oil in the pump to be drained.
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014AZ008A
WARNING!
E0004P
The operator who sets the press to set-up mode must keep the key to the selector switch in his/her pocket until
special machine servicing has been completed. It is therefore important that just one copy of the key is available
in the workshop to prevent more than one person from working on the machine at the same time. As most of the
safety devices are inactivated, machine and personnel safety are at the hands of the operator who must be
informed and clearly understand what he/she is responsible for.
3.5.5 INSTALLATION MODE
The diagram below shows the layout foreseen by the manufacturer for correct operation. The tile collector and handling
device, is not an integral part of the machine however, safety is compromised if it is not present. The signal transmitted
by the sensor must be in series with the other limit switches installed on the press. This collector should be equipped
with an arm that activates the right and left safety guards of the press and be placed near the die-set, with less than 25
mm play on each side, to prevent access to the danger zone from the bottom. In addition it must be fitted with two limit
switches SQ53a and SQ53b, hooked up as shown in the wiring diagram, that detect when the device is in place in its
work condition. When the arm of the tile collector is not in place, therefore not in its work condition, the press can run
only in SET-UP mode. The signal from these limit switches should be in series with the other limit switches installed in
the press.
Figure 3.5.5 - RULES FOR OPERATION
FILLER-BOX
TILE KNOCKOUT
SQ53a
SQ53b
C2219
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014AZ008A
3.5.6 CLEANING
Stop the machine to clean it. Follow the procedure below:

- Stop the moving parts of the tile collector and back up the mobile arm so that the front of the die-set can be accessed.
- Fully raise the plunger by pressing buttons 25 & 3 located on the control panel.
- Use the lever found to the side to raise the safety arms.
E0004P
WARNING!
When cleaning the die-set, the personnel must wear adequate clothing for protection against heat. For more
thorough cleaning, perform the same procedures as recommended for maintenance.
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3.6 MAINTENANCE
3.6.1 GENERAL SAFETY RULES
WARNING!
E0001
Never inspect, repair or service moving parts. Clear warning signs should be attached near the parts in question to warn
operators of the danger.
E0004P
WARNING!
Before attempting to carry out any operations on the machine, discharge the accumulators and wait until they are empty.
O2
E0004P
WARNING!
E0034D
The accumulators are to be precharged using only dry nitrogen in tanks with reducer. Use of compressed air and/or
oxygen is severely forbidden.
WARNING!
E0007 E0010
Before performing any operations on the machine, including the replacement of components of the control panel or
electrical cabinet, the maintenance staff must shut off the electricity supply by using the main switch located on the
control panel. This switch should then be locked out with a padlock so that the machine cannot be accidentally started
up.
WARNING!
E0007
The electrical cabinets and junction boxes installed on-board the machine contain live parts.
As laid down by the EN 60204-1 directive, access to the electrical cabinet should only be possible with a special tool.
This tool should be kept by one member of staff qualified and trained to work on live parts.
When the electrical cabinet is energised, the only task that this member of staff should perform is to reset the circuit
breakers.
WARNING!
E0007
Wherever “plug-outlet” connections are present, whether they are in the electrical control cabinets or junction boxes on-
board the machine, they are to be disconnected only with the machine stopped and after shutting off power from the
supply mains.
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014AZ008A
WARNING!
E0007
Specific tools are to be used to connect and disconnect the conductors inserted in “spring” terminals.
WARNING!
E0017
When working on the machine never climb up on any part other than the service floor or ladders. The machine guards
and enclosing barriers are not designed to bear the weight of a person. If climbed on, they may collapse causing personal
injury and equipment damage.
E0004P
WARNING!
It may be necessary to temporarily remove or disable certain safety devices when making adjustments or servicing the
machine. Once these operations have been completed, it is highly important that the safety devices are put back in place
and reactivated before the machine is started up.
WARNING!
E0002 E0005
During operations, the electric motors can reach extremely high temperatures which would cause burning if touched.
Always take the necessary safety precautions when working on the motors.
WARNING!
E0007 E0009
In order to ensure that the machine operates efficiently, safely and in a trouble-free manner always follow SACMI’s
instructions carefully. Carry out the scheduled maintenance operations exactly as described and at the time intervals
recommended.
In particular, regularly check all the safety devices for proper functioning. Also check the insulation of the electrical cables
and replace if necessary.
E0004P
WARNING!
The user must restore the markings (conductors, terminals, devices, etc..), monitor signals and nameplates when no
longer legible or if removed for any reason.
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014AZ008A
3.6.2 NOTES REGARDING MAINTENANCE
To ensure machine efficiency and trouble-free operation, keep to the instructions outlined by SACMI when performing
the routine maintenance described in chapter 8 - MACHINE MAINTENANCE. In particular, periodically check all the
safety devices and the emergency stop buttons for proper functioning. Make sure the electrical cables are well insulated
and replace them if damaged. Check that the ground electrodes are efficient. The maintenance personnel should have
the qualifications indicated in the PERSONNEL TRAINING paragraph contained in this chapter. Before performing any
maintenance, carry out the following operations:
1) Fully raise the plunger by pressing buttons 25 & 3 located on the control panel.
2) Use the side lever to raise the safey arms.
3) Press key 4 to shut off the main pump.
4) Press the emergency stop button.
5) Disconnect the supply by using the main switch. The latter can be locked in its “OFF” position so as to prevent the
machine from being accidentally started up. Use a padlock (not provided).
6) Drain the oil from the accumulators with the manual valves. Use cock 153 for brake control assembly accumulators
18, 18a, 18b and cock 153a for service control assembly accumulator 12.
E0004
WARNING!
Before attempting to carry out any operations wait until the accumulators have been completely drained.
7) If accumulators 141 and 337 are present they must be discharged through valves 143 and 339.
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014AZ008A
3.7 MACHINE NOT IN USE
E0004P
WARNING!
3.7.1 GENERAL RULES
When the machine is no longer to be used, make it inoperative by shutting off the electricity and air supplies etc.
Use suitable safety devices.
Thoroughly clean the entire machine, especially the working parts, and if necessary apply a protective lubricant.
Close the electrical control cabinet doors and any machine access doors to prevent any parts being tampered with or
dust getting in.
3.7.2 PUTTING THE MACHINE OUT OF SERVICE
If the machine is to remain inoperative for a certain period of time, proceed as follows:
1) Fully raise the plunger by pressing buttons 25 & 3 located on the control panel.
2) Use the side lever to raise the safey arms.
3) Press key 4 to shut off the main pump.
4) Press the emergency stop button.
5) Drain the oil from the accumulators with the manual valves. Use cock 153 for brake control assembly accumulators
18, 18a, 18b and cock 153a for service control assembly accumulator 12.
6) If accumulators 141 and 337 are present they must be discharged through valves 143 and 339.
E0004
WARNING!
Before attempting to carry out any operations wait until the accumulators have been completely drained.
7) Disconnect the machine from the mains by unplugging the power cable.
3 - 12
014AZ008A
3.8 DECOMMISSIONING THE MACHINE
When decommissioning the press, refer to Chapter 9, DECOMMISSIONING.
3 - 13
014AZ008A
3 - 14
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INSTALLATION PROCEDURES 4
4 INSTALLATION PROCEDURES Figure 4.1 - LIFTING AND

PLACING THE PRESS
Only SACMI personnel are authorized to install and
commission the machine.
4.1 HOW TO LIFT AND PLACE THE

PRESS IN POSITION
Use ropes and other suitable equipment when lifting the

press. Always follow the safety regulations in force in your
country.
To properly place the press, refer to the foundation plan
provided.
E0004P
IMPORTANT
Follow the instructions given for lifting the machine
in chapter 3 - SAFETY EQUIPMENT AND
PRECAUTIONS.
The load must always remain perfectly horizontal
(regardless of the type of equipment used for hoisting)
while being moved.
C2584
EQUIPMENT:
E0009C
- Pair of ropes PH 3020 kg 83.000

- Pair of safety clamps
4.2 CONNECTIONS
The connections must be performed by qualified personnel. Carefully follow the instructions provided by the
manufacturer.
E0004P
WARNING!
As there are a number of electronic converters inside the electrical cabinet, make sure the ground fault circuit
interrupters on the power supply are of the B type (as recommended by CEI 64-8 specifications, par. 532.2.1.4
thereby ensuring adequate protection against leakage currents.
4-1
014AZ008A
4 INSTALLATION PROCEDURES
4.2.1 EARTH CONNECTION
E0004P
WARNING!
The machine (electrical control cabinet – press body – power unit - filler-box) has to be effectively earthed. Hook
the machine up to the external protective circuit. The connection point marked PE (EN60445) is found beside the
main shut off switch (see figure 4.2/B). The cross-section of the cable must be at least half that of the cabinet’s
power cable.
In addition, hook up the connection points on the machine frame marked with symbol (417-IEC-5019)
to the earth bar at the bottom of the electrical control cabinet (see figure 4.2/A).
The cross-section of the cables must be at least half that of the largest heater cable.
Connect the copper bar in the electrical control cabinet to the machine C and the cross-head to the plunger A-B.
Join earth wires D and E as shown in the DIE-SET WIRING DIAGRAM figure.
The points where the earth connections are to be made should be free of paint. Any paint present should be removed
before the relative screws are tightened in order to ensure perfect electrical continuity.
E0004P
WARNING!
Failure to earth the machine may cause serious personal injury as well as equipment damage.
Figure 4.2/A - EARTH BAR IN ELECTRICAL Figure 4.2/C - EARTH CONNECTION

CONTROL CABINET
B
Figure 4.2/B - EARTH CONNECTION
C
C2783
F
EARTH BAR IN
ELECTRICAL CONTROL
CABINET
4-2
014AZ008A
4.2.2 INSTALLING AND REMOVING THE DIE-SET
4.2.2.1 Removing and installing the die-sets in presses

REMOVING THE DIE-SET
Preliminary operations:
DIE-SET LIFT = 0 is set on the DIE-SETS/SPE page.
E0004P
WARNING!
If the die-set comes with magnetic punches, they have to be disengaged before the die-set is removed, otherwise
it will be very difficult to take them out.
To disengage the upper and lower magnetic punches, proceed as follows:

Select “UPPER AND LOWER MAGNETIC PUNCHES = YES”. Press keys 31 - 15 and 31 - 11. The LEDs built into keys
15 and 11 will go out as soon as the magnetic locks have been disengaged. At this point, “YES” disappears from the display.
To remove the die-set, proceed as directed below:
1) Make sure the die-set is fully down and the plunger is completely up.
2) Raise the safety arms and fit the adjustable spacers between the upper part of the die-set and the lower pads
(“isostatic” pads are to be removed).
The spacers must be properly positioned, each spacer should correspond to a knockout cylinder.
E0004P
WARNING !
The spacers must be properly positioned between the upper and lower parts. Take care not to damage the punches
when performing this operation.
3) Store the pressure value given on gauge 196.

4) Work on reducer valve 166 and bring the pressure to 0 bar. Check the value given on gauge 196.
5) Turn the key switch to SET-UP.
6) Press keys 28 and 16 to start the cycle for LOCKING/UNLOCKING the die-set. The machine will automatically
carry out the cycle.
7) With the spanner provided, release the die-set by working on the devices provided for this purpose found on the
left-hand (cylinder 180a1) and right-hand (cylinder 180b2) sides. Make sure they are completely opened by turning
them at least four and a half times.
8) Set reducer valve 166 to the value previously memorized.
9) Press keys 28 and 16 to complete the cycle for LOCKING/UNLOCKING the die-set.
10) Go to the SPE/DIE-SET page and set DIE-SET REMOVAL = 1
11) Make sure DIE-SET LOCKED = NO
12) Make sure the encoders are free and have been zero set.
13) With the filler-box connected to the press, make certain the mobile part is not over the die-set.
14) Carry out the SELF-LEARNING procedure.
Press die-set key (13) and the green key (28) at the same time. The procedure is automatically executed.
The procedure is considered completed only if an upstroke and downstroke have been carried out without any
faults and is memorized while power is being delivered.
15) Loosen and remove the screws that secure the die-set mounting plate to the knockout.
16) Place four spacers between the block for the mobile part and the die. They should be high enough to assure the
mobile part is secured to the fixed part of the die-set. Place the spacers in the corners of the block or in the point
foreseen by the die-set manufacturer.
4-3
014AZ008A
17) Block the die-set encoder.
20) Carry out the upstroke.
Press the die-set key (13) and up arrow key (25) at the same time to carry out the upstroke.
E0004P
IMPORTANT!
The movement can be reversed during the upstroke and downstroke by pressing the down arrow key (30) or up
arrow key (25) and then the die-set key (13). The cylinders will move either up or down after a brief pause as
required.
21) When the die-set is fully up, place two spacers (supplied with the machine) 70 mm up between the knockout and
table track.
22) Move the knockout cylinders down so that the die-set can rest on the spacers and the plugs can be removed from
the die-set.
Press die-set key (13) and the down arrow key (30) at the same time to execute the downstroke.
23) Bring the equipment (fork lift truck) for transfering the die-set near the die-set.
24) Lift the die-set up being careful not to damage the knockout cylinder plugs and die-set sensing cylinders.
25) Move the die-set away from the press bed.
DIE-SET INSTALLATION
Preliminary operations:
a) Fully raise the plunger
b) Raise the safety arms
c) Select “SET-UP” mode
d) Thoroughly clean the parts of the press and the knockout which come into contact with the die set and lubricate with oil
e) Thoroughly clean the two die-set feelers with gasoline making sure they are able to move in a regular manner.
E0004P
WARNING!
DO NOT clean the two die-set feelers with oil or grease
f) Remove the die-set from the packing container by using adequate lifting equipment and place it on two support
blocks so that it is at least 10 cm from the floor.
E0004P
WARNING!
When moving the die-set, refer to the safety instructions concerning the handling of overhead loads.
Do not use levers, shims etc... to lift the die-set.
g) Move the die-set near the press by using a fork lift truck.
h) Check the fasteners for efficiency and completely open them by using a suitable spanner.
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014AZ008A
To install the die-set proceed as follows:
1) Make sure the knockout cylinders are fully down. Block the encoders that monitor when the mobile part of the die-
set is down with the stop levers provided.
2) Load the die-set onto the fork of the lift truck. Gently raise the die-set making sure the fork is properly positioned
in relation to the load’s centre of gravity .
3) Move the lift truck close to the press so that the die-set can be transferred from the fork to the four spacers (h =
58) on the knockout. Be careful not to damage the knockout cylinder plugs and die-set sensing cylinders.
4) Place the die-set in the middle of the press. Make sure it is properly centered back-forth and to the right-left.
5) Make sure the four gauged spacers are on the die-set between the die and block. The spacers should be in the
corners of the block or in the points foreseen by the die-set manufacturer. If a mobile die is used, connect the
hydraulic die support line and pressurize it so that the die can be moved fully up and then put in the spacers.
8) Carry out the UPSTROKE.
Press the die-set key (13) and up arrow key (25) at the same time to carry out the upstroke. Make certain the plugs
correctly enter the boxes for locking the die-set during the upstroke.
E0004P
IMPORTANT!
required.
9) Remove the four spacers (h = 70) on the knockout.

10) Allow the knockout cylinders to perform the downstroke so that the die-set can rest on the table and be centered
with the two pins. Press the die-set key (13) and down arrow key (30) at the same time to carry out the downstroke.
11) Remove the die-set from the four spacers found between the die and mobile block. If a mobile die is used, connect
the hydraulic die support line and pressurize it so that the die can be moved fully up and then remove the spacers.
12) Fully tighten all the screws used to fix the die-set mounting plate to the knockout.
13) Release the die-set encoder.
14) Place the spacers between the upper part of the die-set and lower pads (“isostatic” pads are to be removed). The
spacers must be properly positioned, each spacer should correspond to a knockout cylinder.
E0004P
WARNING !
15) Memorise the pressure value read on gauge 196.

16) Set the pressure of reducer valve 166 to 0 bar. Check the value given on pressure gauge 196.
17) Go to the die-set left page and set DIE-SET LIFT = 0.
18) Press keys 28 and 16 to start the cycle for LOCKING/UNLOCKING the die-set. The machine will automatically
carry out the cycle.
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014AZ008A
left-hand (cylinder 180a1) and right-hand (cylinder 180b2) sides. Make sure they are completely closed by
unscrewing them at least four and a half turns.
21) Press keys 28 and 16 to complete the cycle for LOCKING/UNLOCKING the die-set.
22) Go to the die-set lock page and set DIE-SET LOCKED = YES
E0004P
WARNING!
Set only after the die-set has been locked.
23) Remove the spacers.

24) Set the upper and lower stop limits (A and B) as well as the speed at which the upstroke and downstroke are to
be performed.
25) Turn the PLC off and then back on to zero set the encoder for the new die-set.
26) Check the set data by moving the die-set with the machine set to SET-UP
NOTE:
With the “SET-UP” mode enabled, the press operates at a speed lower than 16 mm/s.
E0004P
WARNING!
Do not make any adjustments with the machine running.
27) Turn the key to MANUAL.

28) Make sure reducer valve 166 is properly set.
a) with the oil temperature at approximately 45° C and the die-set raised, reach the value given on pressure gauge
198 being careful to read the gauge only after the accumulator has been recharged;
b) move the die-set down and adjust reducer valve 166 by reading pressure gauge 196. It should read the pressure
given in the chart below:
VALUE READ ON PRESSURE GAUGE 198 SET PRESSURE GAUGE 196 TO

40 BAR 40 BAR
45 BAR 44 BAR
50 BAR 47 BAR
55 BAR 51 BAR
60 BAR 55 BAR
65 BAR 59 BAR
70 BAR 62 BAR
75 BAR 66 BAR
80 BAR 70 BAR
85 BAR 74 BAR
90 BAR 77 BAR
95 BAR 81 BAR
100 BAR 85 BAR
105 BAR 89 BAR
110 BAR 92 BAR
115 BAR 96 BAR
4-6
014AZ008A
29) Allow the plunger to rest on the die-set.
30) Fasten the upper part of the die-set to the plunger.
31) Make the electrical and air connections required to operate the press (refer to paragraphs CONNECTING THE
DIE-SET HEATER and CONNECTING THE MAGNETIC LOCK).
32) Warm the die-set up to the required temperature, as recommended by the manufacturer.
33) Set the punches to the correct position.
34) Secure the punches in place with the permanent magnets or the magnetic locks by turning the key switch to SET-
UP. With MAGNETIC LOCK = YES function active, press keys 26 and 15, 26 and 11. The LEDs built into keys
15 and 11 will come on once the magnetic locks have been applied. When the magnetic locks are applied, also
engage the mechanical fasteners.
35) Loosen and retighten the screws which hold the die/s in place.
36) Move the punches several times to ensure they are not obstructed in any way.
37) Check all the magnetic locks provided for proper operation.
38) After operating a few minutes, check the pressure values to assure they have not been modified in any way
otherwise repeat the procedure indicated at points 28a) and 28b).
4-7
014AZ008A
INSTALLING THE DIE-SET IN THE PRESS USING THE “EMERGENCY PROCEDURE”
E0004P
WARNING!
This procedure should be used only when the die-set encoder cannot be zero set.
This situation occurs when there is a power failure and the die-set has already been removed therefore the die-set
encoder cannot be zero set.
E0004P
IMPORTANT!
This procedure should NOT be used when the die-set is on the press as the encoder can always be zero set.
When removing the die-set, carry out these preliminary steps:

a) Fully raise the plunger
b) Raise the safety arms
c) Select “SET-UP” mode
d) Thoroughly clean the parts of the press and the knockout which come into contact with the die set and lubricate with oil
e) Thoroughly clean the two die-set feelers with gasoline making sure they are able to move in a regular manner.
E0004P
WARNING!
DO NOT use oil or grease
f) Remove the die-set from the packing container by using adequate lifting equipment and place it on two support
blocks so that it is at least 10 cm from the floor.
E0004P
WARNING!
When moving the die-set, refer to the safety instructions concerning the handling of overhead loads.
Do not use levers, shims etc... to lift the die-set.
g) Move the die-set near the press by using a fork lift truck.
h) Check the fasteners for efficiency and completely open them by using a suitable spanner.
To install the die-set proceed as follows:

1) Make sure the knockout cylinders are fully down. Block the encoders that monitor when the mobile part of the die-
set is down with the stop levers provided.
2) Load the die-set onto the fork of the lift truck. Gently raise the die-set making sure the fork is properly positioned
in relation to the load’s centre of gravity .
3) Move the lift truck close to the press so that the die-set can be transferred from the fork to the four spacers (h =
70) on the knockout. Be careful not to damage the knockout cylinder plugs and die-set sensing cylinders.
4-8
014AZ008A
4) Place the die-set in the middle of the press. Make sure it is properly centered back-forth and to the right-left.
5) Make sure the four gauged spacers are on the die-set between the die and block. The spacers should be in the
corners of the block or in the points foreseen by the die-set manufacturer. If a mobile die is used, connect the
hydraulic die support line and pressurize it so that the die can be moved fully up and then put in the spacers.
8) Carry out the UPSTROKE (emergency operation).

Press the die-set key (13) and up arrow key (25) at the same time to carry out the upstroke. Make certain the plugs
correctly enter the boxes for locking the die-set during the upstroke.
E0004P
IMPORTANT!
Make certain the plugs correctly enter the die-set locking boxes while the movement is being carried out.
E0004P
IMPORTANT!
required.
9) Remove the four spacers (h = 70) on the knockout.

10) Allow the knockout cylinders to perform the downstroke so that the die-set can rest on the table and be centered
with the two pins. Press the die-set key (13) and down arrow key (30) at the same time to carry out the downstroke.
E0004P
IMPORTANT!
required.
11) Remove the die-set from the four spacers found between the die and mobile block. If a mobile die is used, connect
the hydraulic die support line and pressurize it so that the die can be moved fully up and then remove the spacers.
12) Fully tighten all the screws used to fix the die-set mounting plate to the knockout.
13) Release the die-set encoder.
14) Place the spacers between the upper part of the die-set and lower pads (“isostatic” pads are to be removed). The
spacers must be properly positioned, each spacer should correspond to a knockout cylinder.
E0004P
WARNING !
4-9
014AZ008A
15) Memorize the pressure value read on gauge 196.
16) Set the pressure of reducer valve 166 to 0 bar. Check the value given on pressure gauge 196.
17) Go to the DIE-SET/SPE page and set DIE-SET REMOVAL = 0.
18) Press keys 28 and 16 to start the cycle for locking/unlocking the die-set. The machine will automatically carry out
the cycle.
left-hand (cylinder 180a1) and right-hand (cylinder 180b2) sides. Make sure they are completely closed by
unscrewing them at least four and a half turns.
21) Press keys 28 and 16 to complete the cycle for locking the die-set.
22) Go to the die-set lock page and set DIE-SET LOCKED = YES
E0004P
WARNING!
Set only after the die-set has been locked.
23) Remove the spacers.

24) Set the upper and lower stop limits (A and B) as well as the speed at which the upstroke and downstroke are to
be performed.
25) Turn the PLC off and then back on to zero set the encoder for the new die-set.
26) Check the set data by moving the die-set with the machine set to manual or SET-UP.
NOTE:
With the “SET-UP” mode enabled, the press operates at a speed lower than 16 mm/s.
E0004P
WARNING!
Do not make any adjustments with the machine running.
Adjust the die-set as directed from step 27 to 38.
4 - 10
014AZ008A
4.2.3 CONNECTING THE DIE-SET HEATER
E0004P
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 to the columns and cylinder.
- Do not reverse the wires between the upper and lower heating element.
- Connect both wires of the upper heating elements to the die set. Do not connect one wire to the die set and the other
to the plunger.
- Do not earth the secondary winding of the die-set heater transformer.
- Make sure that the earth connection is effective.
4 - 11
014AZ008A
4.2.4 CONNECTING THE MAGNETIC LOCK
- 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.
Figura 4.2.4 - DIE SET WIRING DIAGRAM
HEATER
510-511 / 1510-1511 Upper punch cables MAGNETIC LOCK
514-515 Lower die cables 911-912 Lower plate cables
516-517 / 1516-1517 Lower punch cables 921-922 Connector XJ6 (upper plate cables)
D Lower punch holder-die earth cable
E Machine base-die earth cable
XJ6 922
921
510 1510
511 1511
D
514
515 E
912
516 1516
517 911
1517
C1853
4.2.5 CONNECTING THE DUST EXTRACTION SYSTEM
Connect the machine to the dust extraction system. The latter must meet SACMI specifications.
4 - 12
014AZ0008A
START-UP PROCEDURES 5
5 START-UP PROCEDURES
5.1 GENERAL
After the press, filler box and die-set have been properly installed, the plunger must 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 refer 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.
5.2.1 CHECKING THE CONNECTIONS:
MAKE THE FOLLOWING CHECKS:

- Make sure that the die-set heating elements are properly earthed.
- Check the magnetic lock of the upper and lower punches for efficiency. The lights built into buttons 11 and 15 should
come on.
- Check that the press is connected to the workshop earth electrodes.
Check the connecting cable between the plunger and the cross-head for condition.
- Make sure that the oil level in the reservoir on the top of the press is correct.
- Make sure that the pressure in the hydraulic system is within the correct operating range as indicated in the
SPECIFICATIONS paragraph.
- Make sure that the tile thickness gauge leads are properly connected.
- Make sure that the filler-box limit switches and the interlocks on the safety bar are properly wired and set to their correct
operating positions.
- Make sure that the device which warns that the filter is clogged is properly wired.
- Check the powder detector (located on the filler-box feed hopper) for efficiency.
- Check that the controller and the tile transfer (placed immediately before the press) are properly connected (conditions
when the machine is started up and stopped).
5.2.2 MOTOR M3
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 knob on safety valve 111. Start main motor
M1 by pressing push-button 0 located on the control keyboard. Turn off the motor after approx. two seconds by pressing
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
no oil leaks at the hose fittings.
5-1
014AZ008A
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.
5.2.6 TOP DEAD-CENTER POSITION
Raise the plunger to its top dead-center position 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 arms. The filler-box is now able to perform its movements. Before performing any movements, check
emergency stop buttons 24 for efficiency.
5.2.8 AUXILIARY EQUIPMENT PRESSURE
Set the initial operating pressure to 170 bar with pressure relief valve 188. Check the reading given on pressure gauge 67.
5.2.9 FILLER-BOX
Make sure:
- The filler-box is properly positioned and secured.
- The slide plate is level with the die.
- The filler-box guides are aligned and centered.
- The mobile part of the filler-box is properly adjusted.
- The brush is properly adjusted (if provided).
- The powder feeder (ALM) is properly adjusted (if provided).
- All electric connections have been properly made.
- The safety guards are secured in 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 (see paragraph 6.4.27).
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.
5.2.10 KNOCKOUT CONTROL (SPE ONLY)
Move the encoders that monitor the position of the mobile part of the 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
encoders.
5-2
014AZ0008A
5.3 ADJUSTMENT PROCEDURES
5.3.1 KNOCKOUT ADJUSTMENT
Enter the settings for the die-set and knockout (upper stop limits A and B) and then set the upstroke and downstroke
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 the die-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 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-hand side (cylinders 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.
When the oil has reached its normal operating temperature (approx. 45 degrees C), repeat the procedure from point 1.
5.3.2 PRELIMINARY ADJUSTMENTS TO THE HYDRAULIC SYSTEM
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 Preliminary adjustment PH 3020
120 YV38 Open 10 turns

119 YV70 Open 1 turn
118 YV70 Fully open
117 YV19 Open 4.25 turns
131 YV41 Open 9 turns
ACCUMULATOR CONTROL ASSEMBLY
Component Operated by Preliminary adjustment PH 3020

108 YV32s Open 9.5 turns
109 YV32d Open 8.5 turns
5-3
014AZ008A
5.3.3 FILLER-BOX SPEED SETTING (DCL)
SETTING (DCL)
Once correct filler-box operation has been verified, set the speeds for each of the 8+8 steps included in the total stroke
of the filler box (expressed in % from 0 to 100). The speed range most adequate to obtain the desired product is thereby
determined. To properly load the powder, determine the position the filler-box should be in when the die-set performs
its first downstroke. Simulate a number of filler-box cycles in semi-automatic mode. Press pushbuttons 8 & 27 to check
the filler-box for proper operation before loading the working material.
If the value entered for the FILL.-BOX APPROACH POS. data item during the filler-box return stroke is greater than zero,
plunger downstroke will be triggered once the FILL.-BOX APPROACH POS. setting has been passed. As soon as the
filler-box reaches the end of its return stroke, the ALM cycle will start. The filler-box will reach the value set for the FILL.-
BOX APPROACH POS. data item after the grid has been loaded. The filler-box will run at the set APPROACH SPEED.
When set to manual mode, the filler-box runs at a constant speed equal to that set for SPEED IN MANUAL MODE. When
set to automatic and semi-automatic modes, the filler-box runs at the set speeds. A cycle can carried out with the ALM
stationary. Loading takes place while the ALM is stationary. In this case, the grid is loaded through filler-box operation.
In this case, the FILLING STROKE will equal the APPROACH STROKE.
POWDER INFEED (DCL)

Properly set the ALM feeder (see relevant manual).
Select the desired type of loading: grid loaded while the ALM is stationary or grid loaded with ALM running.
Set the time for the “DELAYED LOADING” data item. This is the length of time the hopper gate stays open.
Set data item “GATE CLOSING POSITION”, i.e. the value at which the gate closes.A special cycle can be selected
if double rows of tiles have to be pressed. This is done by setting 2-ROW FILLING = YES. In this case, two values have
to be entered in the PLC. The first refers to the point at which the gate closes during the stroke for loading the ALM.
The gate opens again after the time set for OPENING DELAY. Once the second value is reached, the time set for
“GATE CLOSING DELAY” starts elapsing after which the gate definitively closes.
Move the filler-box completely back and let powder into the feed hopper.
Set the number of strokes to be performed (from right to left) during each cycle (set 1 or 2 strokes. If 3 is entered the
ACP will move non-stop).
Fill the die-set a few times in semi-automatic mode and make the required modifications (if the loading cycle is found
to be inaccurate). After this preliminary phase has been completed, leave the die cavities full of powder.
The ALM can carry out an overtravel during its return stroke to zero set the filler-box encoder. This may also be useful
when installing and removing the grid.
Timed filler-box and knockout operations can also be carried out during loading. In particular, the knockout can perform
up to 5 steps during the filler-box return stroke, starting from the 1st downstroke position. The following are set for each
step: filler-box setting at the start of the step, degree to which the die-set moves, filler-box return stroke setting at setting
for 1st downstroke and die-set speed during the step.
5-4
014AZ0008A
5.3.4 PLUNGER BRAKING ADJUSTMENT
To check the value entered for plunger braking, read the logic element value, which should be approximately 80. If it
is not, allow the plunger to rest on the powder, press buttons 7 and 26 at the same time to increase the braking force
or buttons 7 and 31 to decrease it until approximately 80 is read. At the beginning, inactivate the brake control (SPEED
CONTROL ON = NO) and set an adequate braking action (e.g., BRAKING SPACE = 90.00) in order to obtain 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 the 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 the impact speed will
be kept constant throughout the work-cycle.
5.3.5 PLUNGER PARALLELISM ERROR
The press is equipped with two encoders that record the position of the plunger. The parallelism error during the press-
cycle can be established by simply comparing these measurements. This will prevent deformed 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.
5.3.6 PLUNGER MOTION SETTING
Read the setting entered to begin the press-stroke (punches on powder). Slowly lower the plunger until the punches
rest on the powder, read the plunger encoder setting (expressed in millimeters and which refers to the end of its upward
stroke) and enter the value for the IMPACT POSITION.
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 the plunger moves up again. Allow the plunger to move up
and down in manual mode with the die cavity full of powder.
5.3.7 SETTING THE PRESS-CYCLE
Enter the data related to the press-cycle. Enter the number of press-strokes per cycle, the pressure settings (expressed
in bar) for the first, second and (if necessary) third press-strokes. In addition, enter the delay time (expressed in
milliseconds) for the first and second press-strokes (if three press-strokes are performed, the delay time for the second
one is also valid for the third press-stroke), the first and, if necessary, second de-aeration stage. These values should
be suitable for the size and types of tiles to be obtained. Fill the die-set with powder in semi-automatic mode (with selector
23 set to automatic, select semi-automatic loading by pressing key F8; then press pushbuttons 28 and 2 respectively).
After making sure the powder is evenly distributed in the die cavities, perform a press-cycle in semi-automatic mode
with selector 23 turned to automatic (to select the semi-automatic mode. Press key F8 and pushbuttons 28 and 2
respectively. Fill the die-set approximately ten times and perform the same number of press-cycles in semi-automatic
mode in order to eliminate the air in the hydraulic system and allow the automatic pressure regulators to make the
required corrections. Once the tile has been properly formed, measure its thickness and adjust the level of the soft filling
by changing the value set for BASE THICKNESS. After tiles with the required thickness are produced (THICKNESS
CTRL IMPULSE = 0, the displayed thickness should equal the measured one), perform other press-cycles in semi-
automatic mode and make sure the measured thickness corresponds to the one given. If it does, the automatic thickness
control can be switched on (THICKNESS CTRL IMPULSE > 0 and TILE THICKNESS = desired thickness).
5-5
014AZ008A
5.3.8 DE-AERATION ADJUSTMENT
Adjust de-aeration proportioner 89 by working on the limit screw. The system can be adjusted so that the plunger carries
out a de-aeration stroke that ranges from 0 to 3.4 mm.
5.3.9 ADJUSTING THE DIE-SET PROTECTION DEVICE FOR LACK OF POWDER
Inspect the automatic thickness gauge for proper functioning. The tile must not be too thin, as this may severely
damage the die-set. Enter the setting for PLUNGER 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 further
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.
5.3.10 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 work-stages
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: Any adjustments to the press and the filler-box must be carried out with the machine stopped. Corrections
to the data entered into the controller or any adjustments to the hydraulic components must be performed with the
machine running.
When good-quality products are obtained, duplicate the program (see the Instructions B manual) and make any
adjustments required to increase productivity.
5.3.11 SWITCHING ON THE FILLER-BOX SPEED CONTROLLER
Once the press has been started up and the tiles have been properly formed (i.e. the die-set has been loaded correctly),
the speed controller is switched on (FILLER-BOX CONTROL ON = YES). At this point, set the FILLER-BOX FORWARD
and FILLER-BOX RETURN times (this should correspond to the time previously measured to perform the forward and
return strokes).
The control system sees whether the time error is 5% greater than the set time. In this case, a fault message will appear.
If greater than 10% the press will shut down.
5-6
014AZ008A
OPERATING INSTRUCTIONS 6
6 OPERATING INSTRUCTIONS
6.1 CONTROLS
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.
- OPERATOR INTERFACE CABINET
Houses the PC used to control and program press operation.
- ELECTRICAL CABINET
Contains all the control equipment for the motors, heaters and magnetic locks.
Figure 6.1 - CONTROLS
ELECTRICAL CABINET
C2212
CONTROLLER
OPERATOR INTERFACE CABINET (OPTIONAL)
IMPORTANT!
E0004P
All information about how to program and use the controller are given in INSTRUCTIONS MANUAL B - USE OF
THE MICROPROCESSOR CONTROL SYSTEM.
The illustrations of the control keyboard and auxiliary control panel are not binding.
The background colors and colors and shapes of the keys may vary according to the electric codes in force in the
country of installation and color of the machine.
However, the number and functions of the keys do not vary even if the colors are different.
IMPORTANT
- “PROGRAMMING” refers to all the information required to perform a work-cycle in automatic mode.
- Programming can be performed only by certain PC operators with a special password or key.
- Only authorised personnel can perform programming procedures as altering the stored data may result in severe
damage to the machine.
- It is advisable to keep a file of the programs loaded by using the sheets provided.
6-1
014AZ008A
6.1.1 CONTROLLER
The programmable logic controller comes with a microprocessor system.

Use the computer terminal provided to:
- set up the work cycle and make modifications to the programmed work stages even when the machine is cycling.
- display messages and typical process variables;
- store and retrieve the data related to each pre-set press cycle;
- automatically localise and “diagnose” faults;
- monitor the operating pressures;
- automatically gauge tile thickness;
- automatically control the machine in the event of system failure.
Figure 6.1.1/A - CONTROLLER
C2212
COMPUTER
TERMINAL
(OPTIONAL)
•
•
•
SYSTEM CARDS
MACHINE CONTROL KEYBOARD
NOTE: A detailed description of each section is given on the following pages.
6-2
014AZ008A
Figure 6.1.1/B - (CONTROLLER) C2228

SYSTEM CARDS
SYSTEM CONFIGURATION
Location of cards
1 SAL POWER SUPPLY (rectified supply voltage)

2 CPU Central processing unit
3 VA MISCELLANEOUS
4 OA ANALOG OUTPUT
5 AX AXES
6 IA ANALOG INPUT
7 IE ENCODER INPUT
8 IE ENCODER INPUT
9 (not used)
10-11-12 ID DIGITAL INPUTS (24 Vdc signals)
13-14-15-16-17-18 OD DIGITAL OUTPUTS (energise the 24Vdc outputs)
19 (not used)
20-21 OR RELAY OUTPUTS
C2580 RACK - PLC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
SAL CPU VA OA AX IA IE IE
ID ID ID OD OD OD OD OD OD OR OR
The configuration given above is for reference purposes only. For more detailed information, refer to the
INSTRUCTIONS B manual, Chapter 2 “LIST OF THE DEVICES”.
6-3
6-4
014AZ008A
6
TERMINAL
Figure 6.1.1/C1 - (CONTROLLER)
OPERATING INSTRUCTIONS
+5
WRITE
R
OFF ON
WD
SL
SC
B
7 8 9 - A1
A2
D
A
4 5 6 + E SCREEN HOME PAG
C
1 2 3 E F DEL
CHAR
QUIT
N
T
0 - . E
R G
DEL
LINE END PAG
SMC 085-11-409
B F1 F2 F3 F4 F5 F6 F7 F8
CONTROL KEYBOARD
Figure 6.1.1/D1 - (CONTROLLER) MACHINE
17 18 25 26
+5
I R I R
MAN +
SET UP AUT
WD
0 1 2 3 8 9 10 11 16 SL
27 I 29
SC 28
P
SMC 085-11-442
A1
I A2 19-23 –
24 4 5 6 7 12 13 14 15 20 21 22 30 31
014AZ008A
Figure 6.1.1/C2 - (CONTROLLER)

COMPUTER TERMINAL
A 25 line x 80 column, electro-luminescent display unit

B Function keys
C Numeric keypad
D Write enable key switch
E Not used
F Deletes last character typed in
G Deletes last line typed in
H Cursor control keys C1736
ELECTRO-LUMINESCENT DISPLAY UNIT

The press comes with an electro-luminescent display unit on which the following are displayed:
- fault messages
- machine data
- production data
- actual settings
- list of the programs stored
- set points and any modifications made to them
NOTE: To read out data, consult the INSTRUCTIONS B MANUAL.
FUNCTION 1ST KEY 2ND KEY+ KEY SWITCH PUMP Figure 6.1.1/D2 -
Pump start Ø (CONTROLLER) MACHINE
Alarm reset 1
Automatic cycle start 28* 2 AUT ON
CONTROL KEYBOARD
Start of semi-automatic loading 28* 2 AUT ON
Semi-automatic press cycle start (16) 28* 2 AUT ON
Plunger upstroke 25 3 MAN/AUT ON
Plunger downstroke 30 3 MAN ON
Plunger upstroke at low speed 25 3 SET-UP ON
Plunger downstroke at low speed 30 3 SET-UP ON
Pump stop 4
Repositioning 28 5 AUT ON
Automatic cycle stop 6
Braking force increase 26 7 MAN/AUT
Braking force decrease 31 7 MAN/AUT
Braking decrease beyond end-stop (3) (4) 28and 31 7 SET-UP
Braking increase beyond end-stop (3) (4) 26and 28 7 SET-UP
Braking analog input offset setting (3) (4) 25and 26 7 SET-UP
Braking analog input gain setting (3) (4) 30and 31 7 SET-UP
Plunger+press-cycle up/down self-setting procedure (5) 28 7 MAN ON
YV21p self-setting procedure (12) 28 7 MAN ON
YV21p offset reset (15) 28 7 SET-UP OFF
Filler box forward 29 8 MAN ON
In-line filler-box forward beyond end-stop (17) 26+29 8 MAN ON
Filler box return 27 8 MAN ON
In-line filler-box back beyond end-stop (17) 27+31 8 MAN ON
Filler-box with crank and connecting
rod mechanism encoder zero setting (11) 26 + 31 8 SET-UP ON
Punches in 25 9 MAN/SET-UP ON
Punches out 30 9 MAN/SET-UP ON
Upper die-set release 31 11 SET-UP
C1736
Upper die-set lock 26 11 SET-UP
Differentiated booster forward 29 10 MAN ON
Differentiated booster back 27 10 MAN ON
Lower die up 25 10 SET-UP ON
Lower die down 30 10 SET-UP ON
Tile thickness increase (1) 26 12 MAN/AUT
Tile thickness decrease (1) 31 12 MAN/AUT
Die-set upstroke (13) 25 13 MAN/SET-UP ON
YV21 last die-set downstroke de-energized (2) 27 13 SET-UP ON
YV21 last die-set downstroke energized (2) 29 13 SET-UP ON
Die-set downstroke (14) 30 13 MAN/SET-UP ON Rear
SPE 2+2 die-set lift (6) 25 13 SET-UP ON
SPE 2+2 emergency upstroke (7) 25 13 SET-UP ON emergency
Downstroke after SPE 2+2 die-set lift (8) 30 13 SET-UP ON stop button
SPE 2+2 emergency downstroke (9) 30 13 SET-UP ON
SPE 2+2 self-setting procedure (10) 28 13 SET-UP ON
Lower punch holder release
(optional) 31 14 SET-UP
Lower punch holder lock
(optional) 26 14 SET-UP
Lower die-set release 31 15 SET-UP
Lower die-set lock 26 15 SET-UP
Proportional knockout engagement 28 16 SET-UP ON
Proportional knockout disengagement 28 16 SET-UP ON
ALM in semi-automatic mode 28 17 AUT ON
CP in semi-automatic mode 28 18 AUT ON
Oil-leak collector pump start/stop 20
ALM forward 29 21 MAN ON
ALM forward beyond end-stop (17) 26+29 21 MAN ON
ALM back 27 21 MAN ON
ALM back beyond end-stop (17) 27+31 21 MAN ON
CP in manual mode 27 or 29 22 MAN
Emergency stop button 24
6-5
014AZ008A
Figure 6.1.1/E1 - (PERSONAL COMPUTER) (OPTIONAL) Figure 6.1.1/F1 - (PERSONAL COMPU-

TER) MACHINE CONTROL KEYBOARD
SMC 085-11-442
29
26
31
–
+
28
25
30
I
27
AUT
19-23
MAN
SET UP
WD
SC
+5
SL
A1
A2
R
22
18
17
21
20
16
11
15
14
10
13
9
12
8
7
3
2
6
I
R
1
5
I
0
4
I
24
C2137
6-6
014AZ008A
Figure 6.1.1/E2 - (PERSONAL COMPUTER) (OPTIONAL)
A Color display
B Function keys
C Mouse
COLOR DISPLAY
The press comes with an electro-luminescent display unit on which
the following are displayed:
- fault messages
- machine data
- production data
- actual settings
- list of the programs stored
- set points and any modifications made to them
C2118
NOTE: To read out data, consult the INSTRUCTIONS B MANUAL.
Figure 6.1.1/F2 - (PERSONAL COMPUTER)

MACHINE CONTROL KEYBOARD
FUNCTION 1ST KEY 2ND KEY+ KEY SWITCH PUMP
Pump start Ø
Alarm reset 1
Automatic cycle start 28* 2 AUT ON
Start of semi-automatic loading 28* 2 AUT ON
Semi-automatic press cycle start (16) 28* 2 AUT ON
Plunger upstroke 25 3 MAN/AUT ON
Plunger downstroke 30 3 MAN ON
Plunger upstroke at low speed 25 3 SET-UP ON
Plunger downstroke at low speed 30 3 SET-UP ON
Pump stop 4
Repositioning 28 5 AUT ON
Automatic cycle stop 6
Braking force increase 26 7 MAN/AUT
Braking force decrease 31 7 MAN/AUT
Braking decrease beyond end-stop (3) (4) 28and 31 7 SET-UP
Braking increase beyond end-stop (3) (4) 26and 28 7 SET-UP
Braking analog input offset setting (3) (4) 25and 26 7 SET-UP
Braking analog input gain setting (3) (4) 30and 31 7 SET-UP
Plunger+press-cycle up/down self-setting procedure (5) 28 7 MAN ON
YV21p self-setting procedure (12) 28 7 MAN ON
YV21p offset reset (15) 28 7 SET-UP OFF
Filler box forward 29 8 MAN ON
In-line filler-box forward beyond end-stop (17) 26+29 8 MAN ON
Filler box return 27 8 MAN ON
In-line filler-box back beyond end-stop (17) 27+31 8 MAN ON
Filler-box with crank and connecting
rod mechanism encoder zero setting (11) 26 + 31 8 SET-UP ON
Punches in 25 9 MAN/SET-UP ON
Punches out 30 9 MAN/SET-UP ON
Differentiated booster forward 29 10 MAN ON
Differentiated booster back 27 10 MAN ON
Lower die up 25 10 SET-UP ON
Lower die down 30 10 SET-UP ON
Rear
Upper die-set lock 26 11 SET-UP emergency
Tile thickness increase (1) 26 12 MAN/AUT stop button
Tile thickness decrease (1) 31 12 MAN/AUT
Die-set upstroke (13) 25 13 MAN/SET-UP ON
YV21 last die-set downstroke de-energized (2) 27 13 SET-UP ON
YV21 last die-set downstroke energized (2) 29 13 SET-UP ON
Die-set downstroke (14) 30 13 MAN/SET-UP ON
SPE 2+2 die-set lift (6) 25 13 SET-UP ON
SPE 2+2 emergency upstroke (7) 25 13 SET-UP ON Note: * Use F11 on the computer
Downstroke after SPE 2+2 die-set lift (8) 30 13 SET-UP ON
SPE 2+2 emergency downstroke (9) 30 13 SET-UP ON
terminal to set up the type
SPE 2+2 self-setting procedure (10) 28 13 SET-UP ON of cycle.
Lower punch holder release
+
(optional) 31 14 SET-UP Almost all the operations
Lower punch holder lock
(optional) 26 14 SET-UP require the use of two keys.
Lower die-set release 31 15 SET-UP
Lower die-set lock 26 15 SET-UP
Some keys, however, only
Proportional knockout engagement 28 16 SET-UP ON need one key to be pressed.
Proportional knockout disengagement 28 16 SET-UP ON
ALM in semi-automatic mode 28 17 AUT ON In this case, the number of
CP in semi-automatic mode 28 18 AUT ON
Oil-leak collector pump start/stop 20 the key to be pressed is
ALM forward 29 21 MAN ON
ALM forward beyond end-stop (17) 26+29 21 MAN ON indicated in the "2nd KEY"
ALM back
ALM back beyond end-stop (17)
27
27+31
21
21
MAN
MAN
ON
ON
column.
CP in manual mode 27 or 29 22 MAN
Emergency stop button 24
6-7
014AZ008A
6.1.2 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 heaters and the magnetic locks.
Figure 6.1.2 - ELECTRICAL CABINET
V Voltmeter
A Ammeter
V A
QS1
C2130
6-8
014AZ008A
6.2 START-UP AND SHUTDOWN PROCEDURES
6.2.1 ROUTINE START-UP PROCEDURE
The machine is started up from the control panel by pressing button “0”. The circulating pump will start running the first
time this button is pressed while the main motor comes into operation when the button is pressed again.
WARNING!
E0004P
Never press Enable button 28 on the controller during the start up procedure.
To start the automatic cycle, refer to the Instructions B Manual.
6.2.2 MACHINE SHUT DOWN
The machine can be stopped in two ways:

- from the controller, by pressing key 6;
- from the outer shutdown circuit (KA300).
6.2.3 STOPPING THE MACHINE IN EMERGENCIES
The machine is provided with two emergency stop buttons - one is located on the control panel while the other is to be
found on the rear of the machine. When these red, mushroom-shaped buttons are pressed in, the machine and related
equipment placed before it stop cycling. When the stop button is pressed:
- the solenoid valves which control the plunger are de-energised;
- the motors which drive the powder infeed system are stopped;
- the motors which drive the hydraulic power unit are shut off.
As a result, the machine immediately shuts down. The accumulators must be drained with the manual valves provided:
in particular accumulators 18, 18a and 18b with valve 153, accumulator 12 with cock 153a and accumulators 141 and
337, if present have to be drained with valves 143 and 339.
To restart the machine, proceed as follows:
- Pull out the emergency stop button;
- Reset the machine;
- Close valves 153, 153A, 143 and 339.
- Carry out the procedure described in paragraph 6.2.1. ROUTINE START-UP PROCEDURE.
6.2.4 SHUTDOWN DURING A POWER FAILURE
In the event of a power failure the press automatically switches over to safe conditions. In fact, if there is a power
shortage, valve YV107, directly connected to the power supply, is de-energized. As a result, the oil in the accumulators
flows to the upstroke chamber and the plunger reaches the top end-stop at low speed (< 16 mm/s).
YV313 is simultaneously de-energized. as a result, when the plunger has moved completely down, the locks are
automatically applied as they are pushed by cylinders 338.
6.2.5 SHUTDOWN DURING AUTOMATIC OPERATION
If the press shuts down while running in automatic mode, the plunger automatically reaches the end-stop so that it can
be locked in place. In fact, YV31s is energized in these cases joining the accumulators to the upstroke chamber. As a
result, the plunger is pushed up to the end-stop.
6-9
014AZ008A
6.3 PRESSURE-LOAD GRAPHS
The total force applied by the press results from the pressure exerted by the central cylinder (F). The pressure exerted
by the central cylinder is indicated in column “P”. The corresponding 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.
Figure 6.3 - PRESSURE-LOAD GRAPH
Superfice
Cylinderpistone = cm
surface area = cm
2
7854
2
7854 C2585
30000
6000 N/cm2 5000 4000
28000 / 2 / 2 357
3000 N/cm2
26000 3500 N/cm2 331
5500 N/cm2
24000 4500 N/cm2 306
force [kN] kN]
2500 N/cm 2
22000 280
di pressatura
20000 255
2000 N/cm2
18000 229
Pressing
16000 204
forza
14000 178
12000 153
10000 127
8000 102
6000 76
4000 51
10000
10500
11000
11500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
9500
superfice
Surface area [cm[cm
2
] 2]
6 - 10
6.4
YV99
YV70
YV53
YV47
YV41
YV40
YV39
YV38
YV19
SQ61
SQ60
SQ59
YV25
YV32s
YV221
YV107
YV32d
YV22s
YV22a
YV22b
YV32m
YV304b
YV304a
FILLER-BOX START
Solenoid
elettrovalvola
elettrovalvola
valve
Solenoid valve
START OF FIRST DIE-SET DOWNSTROKE
eccitata
eccitata
END OF FIRST DOWNSTROKE
Figure 6.4.1/A - BAR CHART
energized
energized
se sono
END OF FILLER-BOX TRAVEL - START OF DOWNSTROKE
AUTOMATIC CYCLE
HOPPER GATE OPEN
if relative
END OF SECOND DIE-SET DOWNSTROKE
selezionate
END OF AUX. EQUIPMENT RECHARGE
options
START OF BRAKING
are also indicated in the HYDRAULIC SCHEMATIC.
le relative
PUNCHES ON POWDER
T1
haveopzioni
START OF FIRST PRESS-STROKE
END OF FIRST PRESS-STROKE

DECOMPRESSION
been selected
DE-AERATION
T2
END OF DE-AERATION + T2
START OF DIRECT PRESS-STROKE
START OF DELAY TIME FOR DIE-SET UPSTROKE
PRESSURE IN KNOCKOUT INTERMEDIATE DUCT REGENERATED
START OF PRESS-STROKE (PRESSURE BOOSTER ASSISTED)
END OF SECOND PRESS-STROKE
END OF DELAYED DIE-SET UPSTROKE
START OF UPSTROKE
END OF DIE-SET UPSTROKE

END OF UPSTROKE WITH BRAKE APPLIED
OPERATING INSTRUCTIONS
C2230
END OF UPSTROKE
HOPPER GATE CLOSED
6
In the description that follows the ID numbers and the symbols of the hydraulic, pneumatic and electrical components
6 - 11
014AZ008A
014AZ008A
6.4.1 FILLER-BOX START-UP
Press cycle start keys 28 and 2 at the same time. Electric motor M20 that drives the filler-box will start running. This motor
drives the mobile part of the filler-box through a series of belts.
The microprocessor control system allows five different speeds for the forward and return strokes to be set. Limit switch
SQ59, mounted on the filler-box frame, must be de-energized after the latter has traveled a few millimeters forward. As
a result, the plunger will not be able to move down until the switch is triggered by the filler-box during its return stroke.
This will happen a few millimeters before the filler-box stops in its initial start position, i.e. when the encoder reaches
the value set for the end of the return stroke.
6.4.2 POWDER INFEED
The powder may be fed through a hopper with an adjustable gate. Sensors, located on the filler box, and solenoid valve
YV221 are used to control the hopper gate.
The operator can thus adjust the amount of powder fed to the mobile grid on the box feeder during its travel by changing
the operating position of the sensors as well as the settings for “DELAYED LOADING” and “GATE CLOSING DELAY”.
6.4.3 FILLER-BOX OPERATION
The encoder detects the position of the filler-box while it is traveling. It is possible to decide the speed range for the filler-
box by entering the set points for the 5+5 steps of the forward and return strokes (1) in the microprocessor control system.
NOTE:
(1) The set points are values which range from 0 to 100% and provide a speed range for each individual step.
6.4.4 DIE-SET DOWNSTROKES
The die-set downstrokes are carried out in an identical manner by operating cylinders 180a1, 180a2, 180b1 and 180b2.
YV22s, YV22a, YV22b and YV25 are energized to move the die-set down. As a result, oil flows from pump 58 and
accumulator 12 to the upper part of cylinders 180b1 and 180a2. Simultaneously, the oil in the lower part of cylinders
180a1 and 180b2 is drained. An intermediate duct joins the cylinders together from a hydraulic standpoint, thereby
guaranteeing perfect timing. Whenever the die-set rests on the end plate, valves YV304a and YV304b are energized
to restore the pressure in the intermediate duct. In fact, these valves see that the oil flows at the pressure set by reducer 166.
Use the DOWNSTROKE SPEED data item to adjust the speed at which the die-set moves down. The lower punches
stop moving when the microprocessor detects (through encoders) the set values have been reached.
In this way, the die-sets perform the downstrokes. The cavity that has been created is then filled with the powder coming
from the grid of the filler box. It is important for the 1ST D.STROKE POSITION to be correct as it determines when the
powder is to be dropped and when the lower cavities are to be filled.
In addition, this operation is related to a number of factors, such as the speed of the filler-box. During this stage, the
mobile part of the die-set is controlled by the position transducers. The microprocessor-based controller sees whether
the actual position matches with the set one. If this is not the case, the machine will stop and the relevant fault message
will appear on the display.
During this stage, the mobile part of the die-set should move to its lowest position. If it does not, the press automatically
stops working and a fault message will appear on the display. The setting entered (for the end of the return stroke) will
cause the filler box to stop in its “rest” position. Before the filler box stops moving, safety switch SQ59 must be triggered.
The respective indicator light, located on the front panel of the microprocessor control system, should come on (KA59).
6 - 12
014AZ008A
6.4.5 FAST DOWNSTROKE
The following conditions must be satisfied in order for the plunger to start the downstroke:
- the lower punches should be fully down (recorded by position transducers)
- limit switch SQ59 triggered by the filler-box when fully back
Under these conditions, the microprocessor control system should receive an electric pulse from solenoid valve
YV32d. This will relieve the pressure in the rear part of downstroke logic element 109. Simultaneously, YV32m is
energized to drain the upstroke chamber of the booster.
At this point, the weight of the plunger-and-cylinder assembly combined with the pressure in pre-filling tank 126,
pressurises in the annular chamber of the cylinder. This pressure will overcome the push of the spring, thus opening
logic elements 174 and 109.
The oil is then drained from the annular chamber. The oil will encounter little resistance along the path it follows. As
a result, the main cylinder will begin its downstroke as the air pushes the oil through the ports in the main cylinder
pressure booster and into the pre-filling tank . The speed during this stage of the downstroke can be adjusted by
working on the regulator and opening logic element 109. As this adjustment serves to bring the upper punches as close
to the powder as possible, it is advisable to select the highest speed capable of meeting your specific working
requirements.
6.4.6 DOWNSTROKE WITH BRAKE APPLIED
As soon as the plunger exceeds the set point at which braking starts, solenoid valve YV70 is energised. This solenoid
valve closes logic elements 118 and 119 and shuts off the drain circuits of the main cylinder and booster. Simultaneously,
YV47, which gradually closes logic element 174, is also energized. In this way, the oil is forced through motor-operated
flow control 132. As the latter is quite small (DN = 14), the plunger will slow down as it is lowered, causing a back pressure.
As a result the brake is applied.
Pressure relief valve 92 is a protective device which reduces the peak pressures, therefore it must not be used to set
the braking system. To adjust the speed at which the upper punches come into contact with the powder in the cavities,
select “SPEED CONTROL ON” = YES and set the “SPEED” to the desired value expressed mm/s. The automatic control
of the impact speed can only be used if there is a braking space ≥ 35 mm.
The program comes with a corrective function which, when activated, reads the impact speed and compares it to the
set one. If necessary, motor M15 comes into operation to adjust flow control 132.
The speed control can be turned off during braking by selecting “SPEED CONTROL ON = NO”. The length of braking
can be changed by selecting:
- BRAKING DURING P.CYCLE = YES: Braking is disabled by de-energising solenoid valve YV47 at the start of the 2ND
BOOSTED PRESS-STROKE.
- BRAKING DURING P.CYCLE = NO: Braking is disabled by de-energising solenoid valve YV47 at the start of the 1ST
PRESS-STROKE.
6.4.7 DELAY TIME FOR THE 1ST PRESS STROKE
The plunger continues moving down at the speed (with the brake applied) until the upper punches come into contact
with the powder contained in the die cavities.
While the upper punches are approaching the powder, the encoder reaches the value set to start the press-stroke just
before the upper punches come into contact with the powder. At this point, the delay time for the 1st press-stroke starts
elapsing. The length of the delay time is set in the microprocessor control system. Throughout this stage, the weight
of the cylinder and plunger as well as the pressure exerted by the compressed air are applied to the powder contained
in the die cavities. In this way, the powder is compacted for the first time and a certain amount of air is let out. This
operation is very important to obtain good de-aeration during the next process stages.
6 - 13
014AZ008A
6.4.8 FIRST PRESS-STROKE
The 1st press stroke begins as soon as the delay time is over. The required pressure is set and measured by transducer
BP1. The program which runs the microprocessor-based control system checks the pressure reached, compares it
to the set one and corrects any deviations.
The hydraulic circuit will now be examined.
The microprocessor-based control system transmits a signal to solenoid valve YV40 (1st press-stroke) which is then
energised, allowing logic element 116 to open. The logic element permits the oil received from pump 58 and
accumulators 18, 18a and 18b to flow to pressure booster 125. The flow rate of the oil can be regulated along with the
working speed of the press by turning the adjuster on logic element 116. The accumulators 18 and 18b are brought
into action by logic element 115. The latter is operated by solenoid valve YV53, which is energised.
The cylinder chamber which has been filled with oil is put under pressure by the piston of the flow booster while the
plunger moves down. The oil transmits the pressure through the main cylinder to the plunger.
The pressure is shown on the display of the microprocessor-based control system. Remember that the pressure value
shown on the display does not take any delay time into consideration and is therefore more accurate than any readings
taken by mechanical pressure gauges. The pressure gauge 36 must always be turned off during normal operation and
should only be used to read out or set the value.
6.4.9 1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER (WITH OR WITHOUT ACCUMULATORS)
If “1ST PRESS-STROKE WITHOUT PRESSURE BOOSTER = YES is entered the first press-stroke is different from
the previous one from a hydraulic standpoint. The program allows for a fixed time during which solenoid valve YV40
is energised, as described in the paragraph above. Once this time has elapsed, solenoid valve YV40 is de-energised
and solenoid valve YV19 is energised, thus allowing logic element 117 to open. As the line pressure is higher than that
in the section between logic element 117 and the cylinder, the oil will flow into the latter. This will allow the press stroke
to be completed without having to use the booster. Obviously, this type of 1st press-stroke should be performed only
when a large amount of oil is needed (i.e. with SFS die-sets or any other optional equipment, for very thick tiles made
from a dry ground mix, etc..).
Selecting “1ST PRESS STROKE WITHOUT PRESSURE BOOSTER = YES” and “1ST SEPARATE PRESS-STROKE
= YES” will allow the press-stroke to be performed without the accumulators and pressure booster (see 1st SEPARATE
PRESS-STROKE).
6.4.10 1ST SEPARATE PRESS-STROKE
The function of the 1st press-stroke is to remove the air from the powder to be compacted. If the first press-stroke is
too fast or too abrupt, the air may not be completely released, resulting in defective tiles (i.e. grooves). It may be
necessary to perform the 1st press stroke at a slower speed and a steadier pressure. This phase is known as “1st
separate press-stroke”.
To perform this stage, select “1ST SEPARATE PRESS-STROKE = YES”. The type of 1st press-stroke to be performed
depends on the powder to be pressed.
Once the delay time for the 1st press-stroke has elapsed, solenoid valve YV40, which opens logic element 116, is
energised. At the same time, solenoid valve YV53, which closes logic element 115, is also energised. As a result,
accumulators 18, 18a and 18b are shut off. The press-stroke ends when the cylinder reaches the set pressure, without
using the accumulators. The action of the main cylinder will be slower and steadier, thus allowing the air to be let out
from the powder being pressed. This type of press-stroke requires less power as the pressure in the pump is
proportional to that of the cylinder (from “0” up to the max. value). The use of the accumulators would have caused
the pump to work at the maximum pressure.
6 - 14
014AZ008A
6.4.11 DEAERATION
During deaeration, the upper punches move away from the powder just pressed thereby allowing the air compressed
in the cavity to be released.
As soon as the 1st press stroke is over, the timer that controls deaeration (set from the microprocessor system) starts
clocking. In the mean time, solenoid valve YV40, which closes logic element 116, is de-energised.
Solenoid valve YV70 (cylinder drain) is also de-energised, allowing logic element 118 to open. This logic element
eliminates the pressure created during the first press-stroke from the main cylinder, thereby opening a passage to
reservoir 126.
At this point, YV39, which controls de-aeration proportioner 89, is energized. As a result, a 0 to 3.4 mm stroke for de-
aeration can be performed.
The proportioner 89 pushes the plunger up, thus moving the upper punches away from the powder. In this way, the
air can let out through the openings in the die-set.
Once the time for de-aeration has elapsed, YV39 is de-energized and the proportioner is repositioned.
Note that a timer and a suitable space left free allow de-aeration to be performed (upward movement of the plunger,
expressed in mm). Obviously, the correct adjustment must be performed in the least amount of time, remembering that
the finished tiles must not have any finish defects.
6.4.12 SECOND PRESS-STROKE (LAST PRESS-STROKE)
The last press-stroke is performed in two separate stages, which are:

- SECOND DIRECT PRESS-STROKE
- PRESS-STROKE WITH PRESSURE BOOSTER
6.4.13 SECOND DIRECT PRESS-STROKE
Once the de-aeration time has elapsed, solenoid of valve YV70 is energised to close logic elements 118 and 119.
Solenoid valve YV19 is then energised allowing logic element 117 to be opened thanks to the line pressure. As a result,
the accumulators will be directly connected to the main cylinder.
If the pressure that has been set from the controller is less than 180 bar, the second press-stroke will be completed
when the set point has been reached. If the set pressure is greater than 180 bar, YV19 will be de-energised when BP1
has reached an optimum value, thus shutting off the accumulators. At this point, the press-stroke with pressure booster
will start.
6.4.14 PRESS-STROKE WITH PRESSURE BOOSTER
The first stage of the press-stroke must be performed as described in the paragraph “SECOND DIRECT PRESS-
STROKE”.
When the pressure in the main cylinder reaches the set value (determined by the control system), solenoid valves YV19
is de-energised to close logic element 117. Solenoid valves YV38 and YV41 are energised, thus allowing logic
elements 120 and 131 to open. The oil put under pressure in the pump and the accumulators 18, 18a and 18b flows
to pressure and flow booster 125.
MAX. ALLOWABLE PRESSURE

FOR MAIN CYLINDER
PH3020 382
If, for any reason, the max. allowable pressure in the main cylinder is exceeded, pressure switch SP2 (set and sealed
during machine inspection at the factory) will come into action to stop the work-cycle. A fault message will appear on
the display of the microprocessor control system.
6 - 15
014AZ008A
6.4.15 SECOND SEPARATE PRESS-STROKE
If the second press-stroke has to be carried out at a slower and steadier speed, accumulators 18, 18a and 18b can
be shut off by selecting “2ND SEPARATE PRESS-STROKE = YES” in the microprocessor based control system. As
soon as solenoid valve YV19 is energised, the electromagnet of valve YV53 (accumulator shut off), which closes logic
element 115, is inactivated.
The logic element prevents the oil (contained in accumulators 18, 18a and 18b) from flowing into the pressure lines.
As a result, only the oil which comes from main pump 58 will fill the main cylinder.
Solenoid valve YV53 will be energised as soon as the operating time of solenoid valve YV19 has elapsed. If the
pressure setting to be reached in the main cylinder exceeds the line pressure, the pressure booster and the
accumulators must be used. This kind of press-stroke allows the user to save on energy as the pressure in the pump
is proportional with the pressure in the cylinder. The pressure will not remain at its highest level as when the
accumulators are used.
6.4.16 DIE-SET UPSTROKE
Once the last press-stroke has been completed, the delay time for the die-set upstroke set in the micro-processor control
system starts elapsing.
As soon as the delay time has elapsed, solenoid valves YV22s, YV25, YV22a and YV22b will be energised at the same
time. The oil will flow from pump 58 and accumulator 12 into the lower part of cylinders 180a1 and 180b2.
Simultaneously, the oil will be drained from the upper part of cylinders 180b1 and 180a2. The intermediate duct
ensures perfect timing between each pair of cylinders.
As a result, the lower punches will move up once the plunger has moved away. The longer the delay time, the more
time required for the die-set to move up in relation to the plunger upstroke. If “KNOCKOUT BTW PUNCHES = YES”
is selected, the die-set upstroke delay time is ignored and the punches will move up along the plunger.
6.4.17 CYLINDER PRESSURE RECOVERY
This option can be activated from the controller. In any case, this function is operative only if the pressure in the cylinder
is higher than the line pressure.
At the end of the last press-stroke, the oil under pressure in the cylinder is allowed to flow to accumulators 18, 18a and
18b (where the pressure is notably lower), this energising solenoid valve YV19 and opening logic element 117.
The oil will continue to flow until the cylinder pressure falls to a value equal to the line pressure + 30 bar. At this point,
solenoid valve YV19 is de-energised, thereby closing logic element 117.
Solenoid valve YV70 is de-energised, thus allowing the chamber in the cylinder to be completely decompressed when
logic elements 118 and 119 open.
6.4.18 UPSTROKE WITH BRAKE APPLIED
To move the plunger up, eliminate the pressure in the main cylinder which was used for the last press-stroke. This is
done by de-energising solenoid valve YV70 which, in turn, will open logic elements 118 and 119. Logic element 118
will open an oil passage from the main cylinder to tank 126 while 119 joins the flow booster to the tank. Meanwhile,
solenoid valve YV32s, which opens logic element 108, will be energised, thus allowing the oil which comes from pump
58 and accumulators 18, 18a and 18b to flow into the upstroke chamber of the main cylinder. In addition, YV32m is de-
energized so that the oil can flow from the accumulators into the upstroke booster, thus allowing the shutter to open.
This takes place because solenoid valve YV38 remains energised. Logic element 120 is still operated when it opens
and, as a result, the pressure built up in the pressure booster can be relieved by opening a passage to tank 126.
At this point, the pilot system pressure (applied to the shutter) will cause the piston in the pressure booster to move up.
The oil contained in the pressure booster can flow through the shutter up to the tank. The oil contained in the flow booster
reaches the tank through logic element 119, which is operated by drain valve YV70, when de-energised. While the piston
of the booster is moving up, the oil passages between the main cylinder and the tank are opened. In this way, the
pressure exerted in the upstroke chamber of logic element 108 (opened by solenoid valve YV32s) can operate the main
cylinder and the oil is thus allowed to enter the tank.
Solenoid valves YV32s and YV47 are energised at the same time. The latter stays on until the plunger encoder reaches
the setting entered for end of braking during upstroke (only if UPSTROKE BRAKING ON = YES is selected). Solenoid
valve YV47 closes logic element 174 and the oil from main pump 58 and accumulators 18, 18a and 18b is forced to pass
first through logic element 108 and then through restrictor 90 before reaching the chamber for the main cylinder upstroke.
The oil flowing through the restrictor will allow the braking action to be properly adjusted.
6 - 16
014AZ008A
6.4.19 FAST UPSTROKE
When the plunger - whose position is detected by the encoder - is no longer within the predetermined braking range
during upstroke, the oil which comes from logic element 108 can enter the plunger upstroke chamber as solenoid valve
YV47 is de-energised. The plunger will continue to move up at a high speed until the encoder records the settings with
the plunger in a high position. Solenoid valve YV32s is de-energised and closes logic element 108. Meanwhile,
solenoid valve YV38 is de-energised and closes logic element 120.
The plunger will now stop moving.
6.4.20 KNOCK-OUT
To remove the finished tiles from the cavity, energise solenoid valves YV22s, YV25, YV22a and YV22b. This will cause
the lower punches to move up as described in “DIE-SET UPSTROKE”. Set a delay time for the die-set upstroke so
as to determine when the solenoid valve is to be energised. The operator can also decide whether to take out the tiles
from between the punches or remove them in a normal manner. When the die-set is fully raised, i.e. the tiles have been
removed, the filler box comes on to eject the tiles. A new cycle can now begin.
6.4.21 SFS CYCLE: UPPER FORMING DIE (OPTIONAL)
The control cylinders of the SFS system (184) are found in the upper part of the die-set. The system features three-
position solenoid valve YV193, YV172, accumulator 337 and pressure relief valve 336.
The tiles are removed when solenoid valve YV193 has been energised (after the delay time for punch removal, which
is determined before plunger upstroke, has elapsed). This allows the oil to flow from the accumulator 337 to the upper
part of the cylinder 184.
The speed is controlled by flow control 250. The return movement of the punches can be determined by energising
solenoid valve YV172. This solenoid valve can be energised when the filler box is forward, at the end of its backward
stroke or as soon as it starts moving. Energising solenoid valve YV172 will allow the oil to flow from the accumulator
to the lower part of cylinders 184. To adjust the speed, work on flow control 249.
6.4.22 MOBILE DIE
If a mirror finished die-set is installed, move the lower die in order to bring the upper punches into contact with the powder.
A special system is used to move the die. This system includes accumulator 141 and relief valve 140, which controls
the max. pressure in the lines immediately after it. During the press-cycle, the upper punch, which is rigidly mounted
on the plunger, moves down the lower die. The oil which comes from the lower part of cylinders 179 flows back to partially
charge accumulator 141; part of the oil is drained through relief valve 140. Once the press-cycle has been completed,
accumulator 141 will provide the thrusting force and the oil required to move the die as far up as possible. The upstroke
speed is controlled by flow control 145. Check valve 183 is used to prevent the die from moving down in the event of
leakage when the machine remains inoperative for a long period of time.
6.4.23 DIE OVER-TRAVEL
This function is used to clean the lower punches. To enable this function, set the relative data item, turn the key to
manual or SET-UP and press keys 25 and 13 on the control panel to move the diet-set up. As a result, solenoid valves
YV22a and YV22b are energised to operate cylinders 180a1, 180a2, 180b1 and 180b2, thereby allowing the die-set
to slowly reach its highest position + the set value.
Under these conditions, the user can get at the side of the punches so that they can be cleaned or removed. Once the
operation has been completed, press keys 30 and 13 (die-sets down) and turn the selector switch back to its original
position.
6 - 17
014AZ008A
6.4.24 BRUSH OPERATION
The brush is used to keep the punches and die thoroughly clean. An electric motor combined with a belt drive rotates
the brush and advances the filler-box. The brush can be turned only if the press is set for automatic operation, semi-
automatic loading or if the operator has enabled brush operation. If 3 is entered for “rotation enable”, rotation will always
be enabled. If 1 is entered, rotation will be enabled only when the filler box is performing its forward stroke. If 2 is entered,
rotation will be enabled only for filler box return.
The direction of rotation of the brush can be set. When NO is entered for “REVERSE ROTATION” the direction of rotation
can be selected: clockwise = YES, counter-clockwise = NO. In addition, it is also possible for the brush to reverse its
direction of rotation from time to time. To do this, enter YES for “REVERSE ROTATION” and then the number of cycles
between one reverse rotation and another. If a mobile brush is used, it can also move up and down. As soon as the filler-
box has started up, solenoid valve YV192 will be energized, causing the brush to lower until it touches the lower die after
the air cylinders 270 have been brought into action. As soon as the filler-box encoder exceeds the setting entered for
the brush in high position, solenoid valve YV192 will be de-energized, thus allowing the brush to move up. The brush
will remain up for the rest of the cycle.
6.4.25 MOVEMENTS IN MANUAL MODE
A number of operations can be performed in manual mode by using the relevant keys on the control keyboard. In
any case, the allowable movements will in no way endanger the operator. These movements can be performed
provided that the mode key switch on the control keyboard is turned to MAN.
Different situations may be encountered:

- Safety arms raised, light built into key 15 on and the lower punches locked in place: only the die-set can be moved
up and down (push-buttons 25, 30 and 13).
- Safety arms raised, light built into key 15 off and the lower punches released: the machine is stopped and the die-
set cannot be moved up and down.
- with the safety arms up, the light built into key 15 off and the lower punches released,
the following can be selected:
A) “MAGNETIC LOCK = YES” to enable the magnetic lock. In this case the machine will stop and the die-set cannot
move up or down.
B) “MAGNETIC LOCK = NO” to disable the magnetic lock. In this case, only the die-set can move up or down.
- Safety arms down and filler box installed: the plunger can move up and down (push-buttons 25, 30 and 3), the filler
box can move backwards and forwards (push-buttons 27, 29 and 8), the die-set can move up and down (push-buttons
25, 30 and 13), the ALM can move backwards and forwards (push-buttons 21, 27 and 29) and the ACP can move to
the left or right (push-buttons 22, 27 and 29). In addition, the upper punches can move up and down (push-buttons
9, 25 and 30) if the SFS is provided.
6.4.26 MOVEMENTS IN SET-UP MODE
When the mode selector with key found on the control keyboard is turned to set-up only the plunger is enabled to operate
at a speed lower than 16 mm/sec through solenoid valves YV31s and YV31d and the die-set can move upward and
downward (push-buttons 25, 30 and 13).
These movements can also be performed under the following conditions:
- Safety arms down and filler-box mounted not connected to the press
- Safety arms down and tile knockout not present.
6 - 18
014AZ008A
6.4.27 RESETTING THE ENCODERS
Press keys 5 and 28 to execute the automatic reset procedure for the incremental encoders:
PLUNGER ENCODER RESET PROCEDURE (ABSOLUTE)

- Move the plunger fully up.
- Raise the safety arms and set the machine to set-up.
- Enter encoder number 1 = PLUNGER on the ENCODER RESET page.
Refer to the Instructions B Manual - USE OF THE MICROPROCESSOR-BASED CONTROL SYSTEM.
CAL AND ALM ENCODER RESET PROCEDURE

- Move the ALM fully back (keys 27+31 and 21).
- Move the filler-box back to the point at which the count is to be reset (keys 27+31 and 8).
- To reset the filler-box encoder, enter 5 for ENCODER NUMBER on the CONFIG. AXES RESET page with the key
turned to SET-UP.
- Move the filler-box to the set FULLY BACK position (keys 29 and 8).
- To reset the ALM encoder, enter 8 for ENCODER NUMBER on the CONFIG. AXES RESET page with the key turned
to SET-UP.
- Move the ALM to the set FULLY BACK position (keys 29 and 21).
KNOCKOUT ENCODER RESET PROCEDURE

- Perform the last die-set downstroke.
- The die-set will slowly move up until the “zero point” is exceeded by a few millimeters.
- The die-set will then move completely down at low speed.
6 - 19
014AZ008A
6 - 20
014AZ008A
ADJUSTMENT PROCEDURES 7
7 ADJUSTMENT PROCEDURES
7.1 SETTING THE VARIABLE DELIVERY PUMP
See figure 7.1/A.
PUMP START-UP
- Charge the hydraulic system.
- Fill the pump casing by using fitting 4. Be sure that the pump casing is completely full.
- Start the motor by applying small currents for a few seconds until all the air has been let out.
SETTING THE MAX. POWER OUTPUTS FOR THE SYSTEM

The variable delivery pump comes with a power control which limits the power absorbed to a level less than or equal
to the motor rating (see chart) regardless of the pressure reached.
POWER OUTPUT OF
MAIN HYDRAULIC UNIT MOTOR
(kW at 50Hz)
PH3020 90
This can be done by adjusting power control 5. Proceed as directed below:

- Start up the main pump with the safety arms raised.
- Loosen screw 6 of power control 5.
- Close valve 112.
- If the “oil heating cycle” has been activated (YV11r energized), disconnect valve YV11r.
- Make sure the operating pressure is present. If it is not, adjust it (see paragraph SETTING THE OPERATING
PRESSURE) with 112a.
- Keep push-button 28, found on the microprocessor control system, pressed (solenoid valve YV99 is energised thus
allowing the oil delivery pump to be drained through relief valve 111; the pressure will reach the press’ operating
pressure).
- Attach a clamp tester to the supply wires of the motor.
- Turn screw 6 on the power control until the value read (in AMPERES) is the same as that given on the motor’s rating
plate divided by 1.732 if a 50 Hz motor is used. On the other hand, if a 60 Hz motor is used, divide by 1.732 and then
again by 1.15. The reading should be taken on each supply wire and the reference current corresponds to the average
of the readings taken on the three wires. If a clamp tester is not available, use the ammeter in the switchboard
remembering that the current reading corresponds to the total value for the three supply wires. As a rule, the max.
output currents should be the same as that given on the motor’s rating plate if a 50 Hz motor is used. On the other
hand, if a 60 Hz motor is used, it should equal the rated value divided by 1.15.
As the ammeter measures the currents in the switchboard and not in the hydraulic power unit motor, make sure that
all the other equipment is switched off.
NOTE
As a rule, the maximum current should be:
For 50 Hz
- equal to the rated current when the reading is taken on the ammeter in the cabinet;
Ilettura = ITarga
- equal to the rated current divided by 1.732 if the reading is taken on each supply wire;
ILettura = ITarga : 1,732
For 60 Hz
- equal to the rated current divided by 1.15 when the reading is taken on the ammeter in the cabinet;
ILettura = ITarga : 1,15
- equal to the rated current divided by 1.732 and then by 1.15 if the reading is taken on each supply wire;
ILettura = ITarga : (1,732 x 1,15)
- Lock screw 6 in position.

After this procedure has been performed, reset the valves (112a, 112 and 10) and reconnect the valve YV11r— see
the SETTING THE SYSTEM PRESSURE and SETTING THE OPERATING PRESSURE paragraphs.
7-1
014AZ008A
SETTING THE MAX. SYSTEM PRESSURE (Oil heating and relief valve)
In order to prevent the system from malfunctioning, a pressure relief valve is provided. This valve (112a + 111) is found
on the control assembly of the lift system and filler-box. To set the pressure limits, perform the following operations:
- Detach connector YV11r (oil heater valve).
- Start up the main pump with the safety bar raised.
- Loosen valve 112a and move it fully back.
- Completely tighten valve 112 mounted on the frame of the hydraulic power unit.
- Press pressure control push-button 28, found on the microprocessor control system; the pressure will reach 10 - 20
bar. Solenoid valve YV99 will be energised and the pump will reach its max. displacement (indicator 9 in position 11)
and the whole delivery line will be drained.
- Slowly tighten relief valve 112a until the pressure gauge for the pump 13 reads the desired pressure.
- After the valve has been set, lock it in the correct position.
- Attach connector YV11r (oil heater valve). As the oil should not be at its correct temperature yet, YV11r will be
activated so as to start oil heating.
Completely loosen relief valve 10, relieve the pressure in the upper accumulators, tighten valve 10 until the desired
pressure for oil heating (150 bar) has been obtained and then tighten the adjustment screw.
MAX. PRESSURE
(bar)
PH3020 250
SETTING THE OPERATING PRESSURE

(See figure 7.1/A)
The valve which controls the operating pressure in the circuit 112 is mounted on the frame of the hydraulic power unit.
To perform this operation, set the pressure as described above. Proceed as directed below:
- Start up the main pump with the safety bar up.
- Loosen pressure relief valve 112 and eliminate the pressure in the accumulators.
- Gradually tighten pressure relief valve 112, with push-button 28 pressed until the desired pressure is read on the
gauge and then tighten the adjustment screw.
Once the adjustment procedure has been performed, pump displacement should be approx. zero (meter 9 should read
10, which corresponds to 0°). Under these conditions, oil will no longer be drained from pressure relief valve 112a.
MAX. PRESSURE
(bar)
PH3020 230
7-2
014AZ008A
CHECKING THE OPERATING CONDITIONS
(See figure 7.1/A)
- With the motor off and the pump stopped displacement meter 9 reads 11.
- With the motor on, the pump running and the safety bar raised displacement meter 9 reads 10. When pump delivery
tends to drop, the line pressure will be 20 bar.
- With press in stand-by mode; motor on; pump running and safety bar lowered, displacement meter 9 reads 10. When
pump displacement drops, the line pressure will be the same as the operating pressure previously set.
If, in these two cases, pump displacement is not zero, this means that there is an oil leak in the system (make sure that
pressure relief valve 112a has been properly set).
- Press cycling automatically with the use of accumulators: the amount of power and current absorbed must be as
indicated (see figure 7.1/1). The power absorbed is limited to 75 kW and reduced to 13 kW, which corresponds to
zero displacement when the line pressure is the same as the set one.
NOTE: Readings were taken to draw up the graphs. They should be used for reference purposes only as a large
number of factors may have influenced the results, i.e.:
- Number of cycles
- Soft filling level
- Max. operating pressure
- Type of machine
7-3
014AZ008A
Figure 7.1/A1- REXROTH VARIABLE DELIVERY PUMP
1 Displacement control ass’y

2 Adjustment screw, Max. displacement limit
3 Adjustment screw, Min. displacement limit
4 Pump inlet and drain ports
5 Power control
6 Adjustment screw, Power control
7 Pressure regulator
8 Adjustment screw, Min. pressure
9 Displacement meter
10 No displacement
11 Max. displacement
12 Pump casing
13 Suction line
14 Delivery line
15 Line pressure control valve
17 Power control mechanism
18 Connection with external pilot system XD
18 7
8
4
5
3
2
12
11
10
15° 15°
0
Pos. 11
Pos. 10
C0190
C0197 (View of pump from above)
7-4
014AZ008A
Figure 7.1/A2 - REXROTH VARIABLE DELIVERY PUMP
HYDRAULIC POWER UNIT

A
T T P1
A
10 B
YV99 P T 15
7 112
YV11r A B
P T 18
6 5
112a SP1
M11
B B
8
M
A
17
78
111 12 2 49
79
U
T
BT4
P
58 3
SP3
P
13 P
14 13 1 4
M M1
C2781
Figure 7.1/B - PRESS CYCLING WITH ACCUMULATORS

pot=10.00 KW (/div)
tswp=5.041 Sec points=3531
Replay Menu Active
Frame # 1-1 FIG 1: CICLO CON ACCUMULATORI X Range [0.06 - 0.40]
1LdData 2SvData 3Commts 4Ca1c 5Retrac 6List 7Title 8Cursor 9Param

10Exit C0303
7-5
014AZ008A
7.2 SETTING AND ZERO-SETTING THE POSITION ENCODER
The reset procedure must be carried out whenever the CPU card, encoder or any other related parts are replaced.
7.2.1 PLUNGER TRANSDUCERS
The encoders mounted on the plunger have a central area where readings are taken and two otter sections where
readings are not taken (see figure) that are 66 mm and 28 mm long respectively.
The operating field of the axis the encoder refers to must be centered with the area where readings are taken.
Figure 7.2.1 - RESETTING THE PLUNGER ENCO DER
* = position not read * ** *

Dead zone
Zona morta
66.0
66.0 mm
mm
** = work zone (2.60
(2.60 in.)
in.)
Blank area
Spazio
28
vuoto
28 mm
(1.00
mm
(1.00 in.)
in.)
Perform the operations given below to reset the encoder:

a) Fully raise the plunger.
b) Raise the safety arms.
c) Turn the selector to SET-UP.
d) Go to the ENCODER RESET page on the microprocessor terminal.
e) Activate the plunger reset procedure.
7.2.2 FILLER BOX ENCODER
The encoders mounted on the knockout do not need to be adjusted. If an encoder is replaced, make sure:
a) The encoder has been properly installed (as directed by SACMI) and that it is able to operate freely (without being
obstructed).
b) The sensor is 0.5 mm below the rest surface of the die-set when the transducer is fully down.
7-6
014AZ008A
MACHINE MAINTENANCE 8
8 MACHINE MAINTENANCE
The checks and maintenance operations which must be performed on the press are described below.
The first operations shown in the chart, are to be performed at the stated intervals. The other operations are to be carried
out as required, i.e. at the discretion of the operator.
WARNING!
E0004P
Before attempting any maintenance, carefully read chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.
8.1 MAINTENANCE SCHEDULE
INITIAL MAINTENANCE TO BE CARRIED OUT THEREAFTER

OPERATIONS EVERY (HOURS) EVERY
(***)
8 40 80 200 500 2000 4000
1 - GENERAL CLEANING OF DIE-SET AND PRESS 8 hours
2 - INSPECT THE FELTS FOR CONDITION 80 hours
3 - LUBRICATE THE PLUNGER BUSHES 80 hours
4 - CHECK THE KNOCKOUT 80 hours
5 - CHECK THE NUTS & BOLTS FOR TIGHTNESS 2000 hours
6 OIL FILTERING AND RECIRCULATION 1000 hours
7 - CLEAN THE INSIDE OF THE ELECTRICAL CABINET 2000 hours
8 - REPLACE THE FILTER ELEMENTS (*)
9 - CHECK FOR LEAKS 200 hours
10 - INSPECT THE VARIABLE DELIVERY PUMP 200 hours
11 - CHECK THE EARTH CONNECTIONS FOR EFFICIENCY (**) 80 hours
12 - CLEAN THE DIE-SET AIR FILTERS 80 hours
13 - CHECK THE SAFETY DEVICES FOR EFFICIENCY 80 hours
14 - REPLACE THE AIR FILTER ELEMENT OF THE 4000 hours
PRESSURISATION SYSTEM
15 - CHECK THE SUCTION SYSTEM FOR EFFICIENCY 500 hours
16 - CHANGE THE OIL IN THE HYDRAULIC POWER UNIT 4000 hours
17 - CHECK THE OIL-WATER HEAT EXCHANGER 200 hours
FOR EFFICIENCY
18 - LUBRICATE KNOCKOUT FEELER PINS 80 hours

19 - REPLACE THE BOOSTER UPSTROKE LINE Every 6,000,000 cycles and in any case at least every 5 years
20 - REPLACE THE PLUNGER UPSTROKE LINE Every 6,000,000 cycles and in any case at least every 5 years
C2223
(*) The operation must only be carried out when indicated.
(**) Inspect each time the die-set is changed.
(***) The intervals at which these operations are to be carried out are automatically indicated on the controller display.
Approximate value.
1 - GENERAL CLEANING OF THE PRESS. The filler-box, grid, slide plate and the part of the die set which rests on
the table need special cleaning.
8-1
014AZ008A
2 - INSPECT THE FELTS which protect the plunger bushes for condition.
3 - LUBRICATE THE PLUNGER BUSHES (this operation must be done manually with the aid of the grease gun
provided. Inject the grease through the grease fittings provided).
4 - INSPECT THE KNOCKOUT. Inspect for oil leaks and loose screws.
5 - INSPECT ALL THE NUTS AND BOLTS FOR TIGHTNESS. Refer to chart 8.3.
6 - OIL FILTERING AND RECIRCULATION. To be carried out after the first 500 hour break-in period and there after
every 500 hours. See paragraph 8.2.5 OIL RECIRCULATION AND FILTERING.
7 - CLEAN THE ELECTRICAL CABINET INSIDE. Clean the electronic and electrical equipment by removing any
extraneous matter with suitable suction devices (do not blow air). Clean the contacts with ether.
8 - REPLACING THE FILTER ELEMENTS. Indicators SP1 (filter on main filtration circuit located in hydraulic power
unit) and SP5 (filter for ejector valve feed valve located on the knockout circuit) will cause fault messages to appear
on the controller display screen when the filter elements are clogged. When the message “Filter clogged (SP1)”
is displayed a counter that signals “Change filter within XX” also appears. The press can continue the production
cycle until the time after which the filter has to be changed is reached. Once this time is over, the press will shut
down, completing the press-cycle in progress. Operation can be re-started only after the filter has been changed.
As a result, the operator can change the filters from the time that spans from the message signaling the filter is
clogged is displayed and the press actually shuts down thereby allowing the job to be planned in advance.
Each time a filter element is replaced, thoroughly clean the filter housing.
Check the condition of the filter gaskets each time the filter housing is opened.
The filters monitored by indicator SP1 should be changed only when signaled by the press’ PLC or whenever the
oil is changed.
The filter monitored by indicator SP5 should be changed when signaled by the press’ PLC or on a yearly basis (when
the machine is shutdown for scheduled maintenance).
Use only genuine SACMI filters to prevent malfunctions from arising.
9 - CHECK FOR LEAKS. Check the logic element and valve seats for oil leaks. Check the level in the oil-leak collector.
10 - INSPECT THE VARIABLE DELIVERY PUMP. Check the seals for wear.
The following conditions must be fully satisfied for proper operation.
Keep the Pressure Control button pressed and make sure that the displacement meter reads “zero” and that the
motor which drives the pump does not exceed the actual power rating. If it does, call in SACMI’s service personnel.
8-2
014AZ008A
11 - EARTH CONNECTIONS
Inspect the earth electrodes of the machine and the earth connection between the crosshead and the plunger. If
required perform the connections again.
Earth terminals:
A - Crosshead
B - Plunger
A
C - Machine base
F - Earth bar in electrical control cabinet
B
C
F C2783
In addition check the earth connections for the die-set (See figure - DIE SET WIRING DIAGRAM, cables D and E,
chapter 4 - INSTALLATION).
E0004P
IMPORTANT!
Before tightening the clamp screws provided, remove any paint from the press body at the points where the earth
conductors are connected. This will improve electrical continuity.
Failure to provide adequate earth connections may cause severe injury to the operator as well as damage to the
machine.
12 - CLEAN THE DIE-SET AIR FILTERS.

Remove the filters and clean with compressed air. Check the filter for condition and the gaskets for tightness (when
the cover is closed). If necessary replace the filter.
13 - CHECK THE SAFETY DEVICES FOR EFFICIENCY.

Make sure all the safety devices operate efficiently (e.g. stop buttons, miniature switches, fixed guards etc....).
14 - REPLACE THE AIR FILTER ELEMENT OF THE PRESSURISATION SYSTEM

Replace coalescent air filter element 271 at least once a year
15 - CHECK THE SUCTION SYSTEM FOR EFFICIENCY.

Make sure the suction ports are properly connected and the suction system operates in accordance with SACMI
specifications.
16 - CHANGING THE OIL IN THE HYDRAULIC POWER UNIT. Change the oil, taking care to remove any deposits
which may have accumulated in the reservoirs. Only oils which have the characteristics indicated in the “Machine
specifications” paragraph must be used. The specified intervals at which the oil is to be changed are given for
reference purposes only. In fact, the oil should be changed at the intervals specified by the oil manufacturer.
17 - CHECK THE OIL-WATER HEAT EXCHANGER FOR EFFICIENCY

Make sure the oil temperature remains within the set limits and does not increase abruptly. To service the heat
exchanger, refer to the instructions given in paragraph 8.4.
8-3
014AZ008A
18 - LUBRICATE THE KNOCKOUT FEELER PINS
Lubricate the knockout feeler pins as indicated in paragraph 8.1.1.
19 - REPLACE THE BOOSTER UPSTROKE LINE

Make sure the press is in a safe condition, drain the oil and take the cover off the main reservoir to reach the hose.
20 - REPLACE THE PLUNGER UPSTROKE LINE

Make sure the press is in a safe condition, drain the oil from the press and replace the hose.
8.1.1 LUBRICATING THE KNOCKOUT FEELER PINS
Use the equipment provided with the knockout to lubricate with the die-set raised:
- remove the plug from the die-set punch holder block;
- connect the kit to the hole;
- fill the tube 300 mm with low superficial tension lubricant (diesel fuel);
E0004P
WARNING!
Do not use oil or grease.
- attach an air gun to the end of the tube and draw the lubricant inside the die-set to lubricate the feeler pins.
8-4
014AZ008A
8.1.2 VACUUM
If hydraulic components need to be replaced without draining the oil from the press, put the hydraulic circuit under
vacuum with the equipment supplied with the machine. Proceed as follows:
- drain the hydraulic accumulators;
E0004P
ATTENTION!
Before attempting to perform any operations on the press, wait until the accumulators have been completely
discharged.
- disconnect the pressurization circuit from the air line and wait until air no longer flows out of the circuit;
- connect tube A to fitting B for the vacuum device and tube C to fitting D of the vacuum device;
- wait a few minutes.
To avoid damaging the hydraulic circuit the time the press is kept under vacuum should be as short as possible, in any
case less than 60 minutes. In addition, cover any openings in the hydraulic circuit to prevent pollutants from entering.
NOTE: drain the oil from the press when replacing valves with large diameters directly connected to the reservoir i.e.
YV32 and YV70.
Figure 8.1.2 - VACUUM
0 12
C2138
8-5
014AZ008A
8.2 SPECIAL MAINTENANCE
8.2.1 SERVICING THE PLUNGER BUSHES

(Refer to figure 8.2.1)
The bushes need no adjustments. The double seals which keep out the dust and the high quality material used in
manufacturing ensure a long service life. When installing the bush, make sure that the oval section which has “O”
stamped on it, is turned towards the center of the press.
Figure 8.2.1
- SERVICING THE PLUNGER BUSHES
8.2.2 FILLING THE RESERVOIR

(Refer to figure 8.2.2) C0306
The reservoir is filled with the aid of a portable charge pump.

- Loosen the level plug Q, located on the pre-filling tank, so that all the air can be let out.
- Open the ball valve A found on the suction line.
- Put one end of the suction hose B into the oil can C.
- Attach the end of the delivery hose D (delivery) to point N (suction hose).
- Open the ball valve P.
- Turn the switch F to start the charge pump.
- Make sure that the oil filter G is not clogged (indicator H red).
Replace the filter element if necessary (3 µm)

- Make sure the hydraulic unit is completely full of oil, by checking for oil in the hose L.
Once the correct amount of oil has been put in (check with the plunger lowered):
- Turn the switch F to stop the pump.

- Close the ball valve P.
- Remove the hose D from “N”.
E0004P
ATTENTION!
If the optional filling pump has not been purchased, the customer must see that the oil drawn from the cans is
filtered. The filters used should have a 3 µm absolute degree of filtration to assure the cleanliness rating at the press
inlet conforms to ISO 4406:1999 of 19/17/13.
8.2.3 DRAINING OIL FROM THE HYDRAULIC POWER UNIT AND RESERVOIR
(Refer to figure 8.2.3)
- Make sure that the ball valve A is open (suction line).

- Open the check valve 7 located on the accumulator control assembly and fully tighten the relevant screw.
- Place the hose D to the oil can C.
- Connect the drain hose D to point N on the suction line.
- Pressurise the circuit (1 bar).
- Drain the oil from the hydraulic power unit and reservoir.
8-6
014AZ008A
Figure 8.2.2 - FILLING THE OIL RESERVOIR

Q
P
L
N
F
H
G C2224
C D
Figure 8.2.3 - DRAINING THE OIL FROM THE HYDRAULIC

UNIT AND RESERVOIR
A
7
P
D
N
C
C2225
8-7
014AZ008A
8.2.4 DRAINING OIL FROM THE HOSES AND HYDRAULIC CONTROL ASSEMBLIES
- Connect the drain hose D to point M on the aux. equipment control assembly.
- Place the drain hose D to the oil can C.
- Pressurise the circuit (1 bar).
- Remove the nuts on the check valve 7 and tighten the screw. As a result, the oil can flow out, reaching point M.
- To drain the rest of the oil from the hoses connect the hose D to point N and open the cock P.
Figure 8.2.4 - DRAINING OIL FROM THE HOSES AND HYDRAULIC CONTROL ASSEMBLIES
P
C N
M
C2226
8-8
014AZ008A
8.2.5 OIL RECIRCULATION AND FILTERING
- Periodically recirculate and filter the oil (approximately 1000 hours) by connecting the oil pump as shown in the
illustration below.
IMPORTANT!
E0004P
Before connecting the pump, make sure all the hoses and fittings are thoroughly clean.
- Connect the delivery hose D (pump delivery line) at point S (prefilling tank).
- Connect the hose B (pump suction) at point N (suction line).
- Run the oil pump (switch F) for approx. 3 workshifts and during the night.
- Periodically check the pump to make sure it has not stopped because the filters G have been clogged (indicator H
turns red).
- If necessary, replace the filter element (3 µm).
Figure 8.2.5 - OIL RECIRCULATION AND FILTERING
H
P
H
N
C2227
G
8-9
014AZ008A
8.2.6 REPLACING PROPORTIONAL VALVES YV22a AND YV22b FOR THE KNOCKOUT
Proceed as directed below when replacing one of these valves:
- Get the new valve ready by filling the various ports with fresh oil.
- Press the machine shutdown button and relieve the pressure.
- Loosen all the grub screws shown in figure 8.4.3 to drain any oil under pressure. Once this has been done, fully tighten
the grub screws.
E0004P
WARNING!
Be extremely careful not to damage the threading when tightening the grub screws.
- Replace the valve.

- Pressurize as required.
- Loosen the grub screws 1 and let the oil flow out until air is no longer present.
- Fully tighten grub screws 1.
- Start the pump.
- Loosen the grub screws 1.
- Move the die-set up and down a few times until only oil flows out of the grub screws rather than oil mixed with air.
- Fully tighten the grub screws 1.
- Shut off the PLC and then turn it back on to zero set the encoder for the new valve.
Figure 8.2.6 - DRAINING THE CONTROL ASSEMBLIES

1
1
1
C2125 1
8 - 10
014AZ008A
8.2.7 CHECKING ACCUMULATOR PRECHARGE
Gas precharge pressure of the accumulators is set to the standard value indicated in paragraph SPECIFICATIONS at
the time of machine installation.
To check precharge, follow the steps given below:
- Drain the oil from all the accumulators installed in the machine with the cocks provided.
- Make sure the hydraulic circuit is not under pressure.
- Unscrew the cap on the side of inflation valve 38.
- Unscrew the control 39.
- Open the release 40.
- Screw the tester on the inflation valve by hand.
- Secure the fitting directing the gauge block by hand.
- Tighten the control 39 observing the hand of the gauge. When the hand moves away from 0, continue tightening (1/
2 a turn is sufficient; there is no need to tighten completely).
- Read the inflation pressure given on the gauge (check the values obtained with those foreseen for the various
accumulators in paragraph SPECIFICATIONS).
• To reduce the pressure
- Slowly open the release until the desired pressure is reached.
• To increase the pressure
- Take off the knurled cap 41.
- Connect the end of the hose (1/4” BSO at 60°) to fitting 42.
- Connect the other end of the hose to the nitrogen source and put under pressure (it is fundamental to wait for heat
exchange caused by movement of the pressures, to become stable before testing or precharging).
E0004P
ATTENTION!
The accumulators are to be precharged using only dry nitrogen in tanks with reducer. Use of compressed air and/
or oxygen is severely forbidden.
- To disassemble, perform the steps in the reverse order.

- Make certain the inflation valve on the accumulator is tight.
- Tighten the cap on the inflation valve side.
Figure 8.2.7 - CHECKING ACCUMULATOR PRECHARGE
39
41
42
T2543
40
38
8 - 11
014AZ008A
8.3 TORQUES (NUTS & BOLTS)
S.R. = Resisting cross section (sq.mm)

MS = Tightening torque (kgm)
V = Pre-load (corresponding to the tightening torque, kg)
NOTE: 12K class screws must be tightened with a torque wrench. The operation must be done as if they were of
the 10K class.
Example: A 12 mm dia. screw with a 1.75 pitch (class 12K) must be tightened to 12.28 kgm instead of 14.74 kgm.
STANDARD THREAD SCREWS
DIAMETER mm. 4 5 6 8 9 10 12 14 16 18 20 22 24
PITCH mm. 0.70 0.80 1.00 1.25 1.25 1.50 1.75 2.00 2.00 2.50 2.50 2.50 3
S.R. mm2 8.11 13.31 18.68 34.57 45.77 55.28 79.92 110.16 150.49 185.16 236.52 294.16 338
5S MS = kgm 0.22 0.43 0.73 1.81 2.33 3.23 5.46 8.33 12.72 16.02 24.88 33.10 44.00
V = kg 227 373 523 978 1282 1548 2238 3084 4214 5184 6823 8436 9880
8G MS 0.34 0.69 1.16 2.90 3.73 5.18 8.74 13.32 20.36 25.63 35.81 43.36 60.5
V 363 596 837 1549 2050 2477 3580 4935 6742 8295 10596 13178 15800
10K MS 0.49 0.96 1.64 4.07 5.25 7.28 12.28 18.74 28.63 36.04 50.36 60.97 85.3
V 511 839 1177 2178 2884 3483 5035 6940 9481 11665 14900 18532 21740
12K MS 0.58 1.16 1.96 4.89 6.30 8.73 14.74 22.49 34.36 43.25 60.43 73.16 100.9
V 613 1006 1412 2613 3460 4179 6042 8328 11377 13998 17830 22238 26000
FINE THREAD SCREWS
DIAMETER mm. - - - 8 - 10 12 14 16 18 20 22 24
PITCH mm. - - - 1.00 - 1.00 1.50 1.50 1.50 1.50 1.50 1.50 2
S.R. mm2 - - - 37.14 - 61.87 83.83 119.42 161.29 209.44 263.86 324.58 374.5
5S MS = kgm - - - 1.92 - 3.52 5.68 8.83 13.37 17.48 27.16 35.81 45.7
V = kg - - - 1040 - 1732 2347 3344 4516 5864 7688 9388 10800
8G MS - - - 3.08 - 5.63 9.09 14.12 21.39 27.96 38.65 52.10 66.00
V - - - 1664 - 2772 3756 5350 7226 9383 11821 11541 17200
10K MS - - - 4.33 - 7.91 12.78 19.86 30.08 39.32 54.36 73.82 91.00
V - - - 2340 - 3898 5281 7523 10161 13195 16623 21249 24300
12K MS - - - 5.19 - 9.50 15.34 23.83 36.09 47.18 65.23 88.79 110.0
V - - - 2808 - 4677 6338 9005 12194 15834 19948 21538 29200
8 - 12
014AZ008A
8.4 SERVICING THE HEAT EXCHANGER
CLEANING THE HEAT EXCHANGER

- Loosen the nuts on the stay bolts and move the plate away.
- Check the thickness of the liners and replace them if necessary.
- Remove the plates from the frame.
- If they are dirty or covered with calcium deposits, proceed as follows:
Type of deposits Cleaning operations
Solid deposits not stuck to the plates or grilles. Remove them with running water at low pressure.
Sludge Proceed as above.
Solidified sludge Soak the plates and then proceed as above
Calcium deposits Immerse the plates (without removing the gaskets from the
grilles) in a solution containing 10% hydrochloric or nitric
acid. Allow them to soak for about 5 minutes. Thoroughly
rinse under running water. Repeat if necessary.
NOTE: Never remove the grilles or the gaskets from their seats except when the gaskets have to be replaced because
they are worn.
E0004
IMPORTANT!
Never use solvents.
8.4.1 REPLACING THE GASKET
Check the width of the gaskets measuring it along with the plate. The gasket along with the relative plate should not
be less than 4.1 mm. If worn down and less than this value, replace the heat exchanger gaskets and close it taking into
consideration a precharge value for the plates for the new heat exchanger.
- Remove the square mesh grille from the plate.

- Remove the gasket and thoroughly clean the edges of the plate.
If it is difficult to fit on the new gasket, slightly raise the curled edge of the plate with the aid of a spatula.
- Reinstall the grille making sure that it fits into the internal groove which receives the gaskets.
8 - 13
014AZ008A
8.4.2 SECURING THE STAY BOLTS
No special tools are required to perform this operation (e.g. torque wrenches). The value n x A, indicated in the diagram,
can be exceeded (the plate cluster must be more compact) without causing the heat exchanger to malfunction (see the
chart below). Tighten the stay bolts in the following order:
- Secure stay bolts 1, 6, 10, and 5.

- Secure stay bolts 2, 7, 9, and 4.
- Secure stay bolts 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

New gaskets Minimum
A 3.75 3.5
NOTE:
- The first value was used when the heat exchanger was constructed and for exchangers overhauled with new gaskets.
- The min. tightness is the min. allowable value. To compensate for a plate that has worn down in relation to another,
do not exceed this value as when the space between plates is reduced the section for oil and water flow is also
decreased causing greater loses and reducing efficiency of the exchanger.
8 - 14
014AZ008A
DECOMMISSIONING 9
9 DECOMMISSIONING
When the machine is not to be used any longer and is to be dismantled proceed as follows:
1) Rest the plunger on the mechanical stop and secure it in this position so that it can not move in any way
2) Disconnect the machine from the supply mains with the main switch and then unplug the power cable
3) Drain the accumulators with the manual valves provided: in particular accumulators 18, 18a and 18b in the brake
control assembly with cock 153 and accumulator 12 on the aux. equipment control assembly with cock 153a.
4) If present, drain accumulators 141 and 337 through valves 143 and 339
E0004P
WARNING!
Wait until the accumulators have been completely discharged before working on the press.
5) drain the hydraulic fluid in the press as instructed for scheduled maintenance
6) disconnect all the machine parts from the power supply
7) disconnect the water lines for cooling down the oil
8) disconnect the hydraulic lines
9) remove the filler-box
10) remove the control unit for the electrical connections
11) discharge all the accumulators of the gas under pressure that is present in them by using the tool for checking
gassing, available on request
12) remove all the accumulators
13) remove all the hydraulic control units
14) the press can be moved as directed for installing it. Refer to the relevant 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 required personal safety gear when working above shoulder height.
9-1
014AZ008A
9 DECOMMISSIONING
9-2

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

2 MAIN FEATURES ......................................................................................................................................2 - 1

4 INSTALLATION PROCEDURES ...............................................................................................................4 - 1

8 MACHINE MAINTENANCE ...................................................................................................................... 8 - 1

1.2 WHERE TO KEEP THE MANUAL

1.3 HOW TO USE THE MANUAL

1.4 USERS OF THE MANUAL

In this manual the machine operators are categorized as follows:

The above mentioned handbooks supplement this manual.

Hot surfaces - danger of being burnt

Danger - hands can be crushed

High tension - danger of electric shock

Danger of entanglement in moving parts

It is forbidden to use oxygen to recharge the accumulators

Heavy duty gloves must be worn

The indicated point must be effectively grounded

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

2.1 MACHINE DESCRIPTION

2.1.1 MAIN MACHINE ASSEMBLIES

These control assemblies are listed below:

GUARDS AND SUCTION HOODS

Figure 2.1.1 - OVERALL VIEW OF THE PRESS 7

15 Mechanical lock and safety guards

INTENDED USE OF THE MACHINE

UNINTENDED AND PROHIBITED OPERATIONS

MISUSE OR ERRONEOUS USE

ELECTRICAL SYSTEM PH 3020

Operating pressure (bar) 300

Test instruments used

Sound pressure level (ISO/DIS 11202)

LpA Continuous A-weighted sound pressure level.

P1 = Occasional control post

Figure 2.3.2 - POINTS WHERE NOISE LEVEL WAS MEASURED

Front hood S250 2 150 2560 +2.0

(1) Outlets present on tile roller conveyor - rpr-

NOTE: Suction system vacuum before

Figure 2.3.4 - RATING PLATE

2.4.1 HYDRAULIC AND PNEUMATIC DIAGRAMS

YV32m D 18a 18b 18

388 388 144 SQ50a BT4

Figure 2.4.1/B - LOGIC ELEMENT ASSEMBLY

YV32d 258 109

Figure 2.4.1/D - AUX. EQUIPMENT -

153 YV11r 143 183 338 251 142

Figure 2.4.1/E - SPE PROPORTIONAL KNOCKOUT CONTROL ASSEMBLIES (REAR VIEW)

YV22b YV25 YV22s

Figure 2.4.1/F - SPE PROPORTIONAL KNOCKOUT (FRONT VIEW)

2.5.1 COMPRESSED AIR SUPPLY

2.5.2 FAST HEATING

NOTE: With temperatures lower than 5°C, use an external heater.

2.5.3 HEAT EXCHANGER SYSTEM

2.5.5 MAIN PUMP RUNNING - SAFETY BARS ENGAGED (RAISED)

a) the following units start running when key “0” is pressed:

Encoders 1 and 2 (plunger position) “BQ6” and “BQ7”

Encoder 3 (filler box position) “BQ2”

Encoder 6 (ALM position) “BQ10” (only with DCL)

2.5.8 ENCODER RESETTING

2.5.9 DIE-SET CONTROL CIRCUIT

3 SAFETY EQUIPMENT AND PRECAUTIONS

3.1.1 SAFETY GUIDELINES

3.1.2 SAFETY DEVICES & GUARDS INSTALLED IN THE MACHINE

EN 292-1 Safety of machinery - Basic concepts, general principles for design.

3.4 HANDLING PROCEDURES