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HTP40 - B - 40854 - GB (Instruction Manual)
HTP40 - B - 40854 - GB (Instruction Manual)
HTP 40
HTP 40Error! Use the Home tab to apply Überschrift 9 to the text that you want to appear here.
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Machine Data
Type HTP 40
Number MA 15835-1-1
Ident number 1-2641-451070-7
Year of manufaction 2015
Electrical Data
Voltage 3 x 380 V
Frequency 60 Hz
Power consumption 4 kVA
Manual
Instruction Manual 40854
Printed 04.05.2018
Imprint
Publisher HERZOG Maschinenfabrik GmbH & Co. KG
Auf dem Gehren 1
D-49086 Osnabrück
E-Mail info@herzog-maschinenfabrik.de
Contents
GB-00001
B-01 Preface
General
Important notice
This notice symbol is shown in the instruction manual in cases of
important information. This information is very important for
operating the described machine safely.
General notice
This notice symbol is shown in the instruction manual in cases of
general information. It indicates additional information for operating
the described machine safely.
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GB-00002
B-02 Basic Safety Instructions
The described machine is constructed in accordance with the state of the art
and the recognized safety rules of the European Community and is safe to
operate. Nevertheless, use of the machine may entail the dangers of physical
injury for the operator or third parties and damage to the machine and other
property.
Only operate the machine if it is in a technically perfect condition, doing so
properly, in accordance with the instruction manual, fully aware of the safety
requirements and possible dangers. In particular, have any faults that may
impair the machine’s safety repaired by specialist personnel immediately.
The machine is intended exclusively for use in the area of application described.
Any other application, or any application going beyond the one agreed,
constitutes improper use. The manufacturer is not liable for damage resulting
from such applications; the user alone bears the risk.
Proper use also encompasses the observation of the instruction manual and the
adherence to inspection and maintenance criteria.
Organizational measures
The instruction manual must be kept permanently at the place of use of the
machine.
In addition to the instruction manual, observe general legal and other binding
regulations regarding accident prevention and environmental protection, e.g. the
coolant, oils and grease should be disposed of in accordance with local
regulations.
Personnel whose duties include working with the machine must have read the
instruction manual, in particular the chapter on safety instructions, before
commencing work. It is too late to do this while using the machine. This is
particularly important for personnel who only work with the machine
occasionally, e.g. in setting up the machine, carrying maintenance work or
assisting with machine operation.
Personnel should not wear their hair long, wear loose clothing or jewellery and
should not wear rings. There is a risk of injury due to getting caught up in or
pulled into the machine.
Checks on the personnel’s awareness of safety and danger and observance of
the instruction manual should be carried out at least occasionally.
Observe all safety instructions and danger warnings on the machine. Ensure
that these are always legible.
Work on and with the machine should only be carried out by reliable personnel.
Observe the legally permissible minimum age requirement.
Only use trained or instructed personnel. Clearly state the areas of
responsibility of the personnel for operating, setting up, servicing and repair
work.
Ensure that only authorized personnel are allowed to work on the machine.
Beginners, trainees and apprentices may only operate the machine under the
constant supervision of an experienced person.
Work on electrical systems may be performed only by a qualified electrician or
by trained personnel under the direction and supervision of a qualified
electrician in a manner corresponding to the rules of electrical engineering.
Only personnel with special knowledge and experience of hydraulics may work
on hydraulic equipment.
Welding, burning and grinding work on the machine should only be carried out if
it has been expressly approved. There may be, for example, a danger of fire or
explosion.
Work on hydraulic installations should only be carried out by people with special
knowledge of and experience in hydraulics.
All lines, hoses and pressure lines (hydraulic, compressed air) should be
depressurized before commencing repair work.
Assemble and lay hydraulic and compressed air lines expertly. Do not mix up
connections. Fittings, length and quality of hose lines must fulfil the
requirements.
The pneumatic system must be bled before any servicing, inspection or
maintenance work is commenced. Before switching the compressed air supply
back on, ensure that no one is in the area of operation of the pneumatic drive
systems, as all pneumatically driven components move sharply to their basic
positions.
Noise protection devices on the machine must be in the protection position
during operation.
Wear the personal protective equipment stipulated. For example, safety
glasses, ear protectors etc.
When handling oils, grease or other chemical substances, observe the safety
regulations for the product concerned.
Caution when handling hot service and auxiliary fluids (danger of burns and
scalding).
GB-00633
Special safety instructions and safety devices
Securing the detachable panels or covers
The detachable panels on the machine can only be opened using special
square spanners or double-bit keys.
The cover plate on the machine is screwed on.
WARNING!
Risk of injury!
The machine must only be started with the detachable panels closed and the
cover plate screwed on !
Never open or remove the panels and covers during operation.
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GB-00031
Press
WARNING!
Risk of explosion !
Under unfavourable conditions, a high pressing force may involve serious
heating of the sample material, which may lead to an explosion in the case of
critical materials!
Special care must be taken when pressing oily metal chips, organic materials,
fatty substances and similar combustilbe materials.
Liquids must not be filled into the pressing tool.
Pos : 5 /Betriebsanl eitung/02/Druc kDr uc kbegrenz ungs ventil @ GB\3\GB- 06786_.doc x @ 1249071 @ @ 1
GB-06786
Pressure relief valve for the complete hydraulic system
GB-00028
Pressure relief valve for return of pressing piston
Task
Direct limitation of max. pressure to 100 bar for return of pressing piston.
Protective function
Overload protection for tool die.
Setting
The pressure relief valve has been set to 100 bar at the factory.
See also section B-12 and hydraulic plan.
Pos : 7 /Betriebsanl eitung/03/B- 0300086 _ B- 03 Datenbl att @ GB\1\GB-00086_.doc x @ 1079391 @ 1 @ 1
GB-00086
B-03 Data sheet
Pos : 8 /Betriebsanl eitung/03/ÜbersichtÜbersic ht HT P 40 m. KT P400 @ GB\15\GB-36100_.doc x @ 1892203 @ 2 @ 1
Overview GB-36100
HTP 40 / 60
bd435388-4
1 = Hydraulic unit
2 = Pressing unit
3 = Cross member
4 = Pressure spindle
5 = Operating panel
6 = Shelf
7 = Main switch
Pos : 9 /Betriebsanl eitung/05/Pr esse/Übersic ht HT P mit Mel del euchte 06012015 @ 1 \mod_1420547604456_16.doc x @ 2017007 @ 3 @ 1
Tower lamp
Bd451462-6
HTP 40 HTP 60
Pressing force
maximum 400 600 kN
Hydraulic pump
Flow rate at 50 Hz 1,25 dm3/min
at 60 Hz 1,50 dm3/min
Hydraulic pressure maximum 520 bar
Drive power at 50 Hz 2,1 kW
at 60 Hz 2,4 kW
Pressing unit
Piston stroke 100 mm
Piston diameter 100 130 mm
Distance between the columns (clear width) 218 mm
Distance between the cross members 100 mm
Time for the pressing operation
dependent on the times set in the operating panel
GB-21485
Permissible pressing force
31 490
32 520
33 550
34 590
5 1 35 610
6 2 36 620
7 4 37 620
8 6 38 620
9 10 39 620
10 14 40 620
11 21 41 620
12 29 42 620
13 40 43 620
14 54 44 620
15 70 45 610
16 90 46 610
17 110 47 600
18 140 48 600
19 180 49 590
20 200 50 580
21 220
22 240
23 270
24 290
25 310
26 340
27 370
28 400
29 420
30 450
ATTENTION!
Unconditionally adhere to the maximum pressing force in relation to the
specified piston diameters !
If the pressing force is to high the pressing tool can be damaged.
GB-07308
Press tools for steel rings
Pos : 14 /Betri ebs anleitung/04/Eins atzbereic hEi ns atz ber eic he allgemein @ GB \1\GB-00969_.doc x @ 1102575 @ @ 1
GB-00969
General
Pressing to form pellets is a frequently used method for sample preparation for
X-ray fluorescent analysis. The press was developed specially for this
application and ensures a high level or reproducibility of the sample preparation.
The small size, high level of operating safety and good sound insulation satisfy
the requirements for laboratory installation.
Pos : 15 /Betri ebs anleitung/04/ProbenmaterialPr obenmateriali en 0031 @ GB \1\GB-00970_.doc x @ 1102603 @ @ 1
GB-00970
Sample materials
CAUTION!
The following materials must not be fed into the press tool :
Liquids
Volatile substances
Explosive substances
Substances harmful to health
Pos : 16 /Betri ebs anleitung/02/Spezi alSpez. Sh u. -ei nrichtungen Press e @ GB\1\GB- 00031_.doc x @ 1077907 @ @ 1
GB-00031
Press
WARNING!
Risk of explosion !
Under unfavourable conditions, a high pressing force may involve serious
heating of the sample material, which may lead to an explosion in the case of
critical materials!
Special care must be taken when pressing oily metal chips, organic materials,
fatty substances and similar combustilbe materials.
Liquids must not be filled into the pressing tool.
Pos : 17 /Betri ebs anleitung/05/B-0500088 _ B-05 Z us ätzlic he Ei nrichtungen @ GB\1\GB-00088_.doc x @ 1079447 @ 1 @ 1
GB-00088
B-05 Additional equipment
Pos : 18 /Betri ebs anleitung/05/Press ePress wer kz eug e allgemei n @ GB\3\GB- 06789_.doc x @ 1249099 @ @ 1
GB-06789
Pressing tools (general)
1 = Pressure spindle
2 = Retaining ring, top
3 = Thrust piece
4 = Vulkolan ring
5 = Sample ring (support ring)
6 = Matrix
7 = Retaining pin for spindle (3 ea.)
8 = Compression spring
9 = Stamp
10 = Pressing cylinder
11 = Matrix holder
12 = Sample material
GB-06791
Flow chart for pressing in steel rings
GB-14583
Fitting the pressing tool for pressing in steel rings
Insert the tool together with the rubber cover ring into the tool holding fixture
from above until the matrix rests on the upper shoulder.
IMPORTANT:
When the tool is inserted, the retaining pins which hold the piston must not
project out of the matrix.
Pos : 22 /Betri ebs anleitung/05/ EinbauEinbau Dr uc ks tüc k @ GB\6\GB-14584_.doc x @ 1388511 @ @ 1
GB-14584
Fitting the pressure piece
With the matrix in position, place the pressure piece with polished face upon
the die
Screw out the pressing screw until the mounting ring engages in the fixture on
the pressing screw.
IMPORTANT:
Insert a piece of cloth or paper between the pressure piece and the matrix.
Pos : 23 /Betri ebs anleitung/05/Press e07308 _ Pr ess werkzeuge für Stahlringe @ GB \3\GB-07308_.doc x @ 1255903 @ 3 @ 1
GB-07308
Press tools for steel rings
GB-00973
Steel rings
Pressing tool
bd195078-1
1 = Tool cover
2 = Rubber cover ring
3 = Matrix
4 = Piston
5 = Fixing nut for plunger
6 = Plunger
7 = Sample material
Pressing tool
bd195079-9
Fix the piston (2) in the plunger (4) using the fixing nut (3).
Tighten the nut by means of the pipe spanner (1) provided.
Insert the matrix (7) into the tool holding fixture from above.
ATTENTION !
The upper shoulder must be located in the seal and must be turned until the
adjusting screw engages.
Pressing tool
for pressing in
aluminium cups
bd197110-0
Flow chart for free pressing and for pressing in aluminium GB-40855
cups
Select program for pressing without steel ring on the Operation panel
Open the cross bar and remove the tool cover
Insert the sample cup if applicable
Insert sample material
Replace the tool cover
Close the cross bar
Screw the pressing screw down
until it contacts the press cover, and then a ¼ turn back
Start the program
When the pressing process has been completed,
a prompt to open the cross bar is displayed
Open the cross bar
Remove tool cover
Press program pushbutton 1 / F4 function key
The sample is ejected out of the tool
Remove the sample
The piston is lowered when the time specified has elapsed
In order to enable the aluminium cups to be pressed more easily into the
pressing tool, a new aluminium cup should be inserted at the same time as the
tool during the return stroke of the plunger.
Pressing tool
bd195080-7
GB-06797
Pressing two-component pellets
GB-06901
Fitting the pressing tool for the production of two-component
pellets
The tool is fitted in the same way as the tool for free pressing. In this process,
two different pressure pieces are employed, for creation of the carrier layer and
for finish pressing.
Pos : 32 /Betri ebs anleitung/40/40856 _ Ablaufdiag.2-Komp-Tabl. (Pr og 1- 18) F1 / F 4 @ 3\mod_1430719747314_16.doc x @ 2047250 @ 3 @ 1
Place the pressure piece for the second pressing operation in place
Close the cross bar and adjust the pressure screw
Activate the pushbutton 1 / function key F4 key to continue the
program
When the second pressing operation is complete, open the cross bar
Activate the pushbutton 1 / function key F4 key again to eject the
sample
The sample is ejected
GB-06902
Tool material combinations
The individual tool components may be manufactured from different materials
for the different sample materials.
GB-07101
Ring cleaning (option)
Manual and semi automatic cleaning devices are offered for the different ring
dimensions. The sample material can be collected into container.
Pos : 35 /Betri ebs anleitung/05/M anuellManuelle Ringrei nigung ( Opti on) @ GB \15\GB- 36103_.doc x @ 1892287 @ 34 @ 1
Procedure
Open the viewing window (push up)
Place the ring being cleaned into the ring holder
Close the viewing window
Start the ring cleaning with the hand lever.
Open the viewing window
Take the cleaned ring out of the ring holder.
Close the viewing window again
GB-36104
IMPORTANT
Pay attention to the container's filling level. Empty the container regularly.
1 = Ring input
2 = Ring output
3 = Collecting vessel for rest sample material
Procedure
Put a ring which has to be cleaned into the ring input.
The ring is cleaned automatically.
The ring input accepts a maximum of 3 rings one after the other.
Take the rings out off the ring output..
GB-36104
IMPORTANT
Pay attention to the container's filling level. Empty the container regularly.
1 Screw for manual switchover of the pneumatic valve for the brush cylinder (K1.1)
2 Screw for manual switchover of the pneumatic valve for the sample pusher (K1.0)
The corresponding cylinders can be moved manually via the manual auxiliary actuator if for
example a sample ring has got stuck (shown is the singular valve with two-sided actuation)
Screw for manual switchover of the
pneumatic valve
A = Press in and turn the screw with a
screwdriver
0 = In Automatic mode (Pos. 0)
1 = In Manual mode (Pos. 1)
ATTENTION!
Turn back to position "0" after manual switchover.
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GB-00089
B-06 Process materials
Pos : 41 /Betri ebs anleitung/06/Hilfs mi ttelHilfsstoffe @ GB\15\GB-36106_.doc x @ 1892371 @ @ 1
Auxiliary materials can be used for stabilising materials that are difficult to
compress.
The usual methods are:
a) Pressing in aluminium trays (disposable items)
GB-00393
B-07 Operating procedure
Pos : 43 /Betri ebs anleitung/07/Siehe Absc hnitt B-05 @ GB\3\GB- 07311_.doc x @ 1256015 @ @ 1
GB-07311
Note
See chapter B-05.
Pos : 44 /Betri ebs anleitung/08/00090 - B- 08 Bedienung und Steuerung @ GB\1\GB-00090_.doc x @ 1079503 @ @ 1
GB-00090
B-08 Operating and controlling
Pos : 45 /Betri ebs anleitung/08/Bedi enelement/Bedienelemente HTP mit KPT 400 @ GB \15\GB- 36058_.doc x @ 1890999 @ 2 @ 1
Operating devices
GB-12884
Main switch
Main switch
GB-00145
Front panel
All the operating devices necessary for operating the machine are on the front
panel.
All program processes are started on the Operation Panel by the individual
function keys. Important messages about machine operation are shown on the
display as plain text.
Front panel
Pos : 49 /Betri ebs anleitung/08/T asterT aster Start Pr ogramm I..III @ GB\9\GB- 20801_.doc x @ 1549539 @ @ 1
The operation panel is the interface between operator and machine. All the
necessary parameters are displayed or changed via this interface.
Display
Informs the operator of the machine's state at all times. All of the machine's
functions are operated from here on a touch display.
Faults or messages
are shown in the display in plain text.
Softkeys
Together with the function keys below, the display forms what are known as
softkeys. The text shown in the display provides brief information about the
keys' functions. If no text is shown, the key is deactivated.
1 Touch display
2 F1..F4 - Function keys
HELP button
Call up help
NN-NN Machine or system components
to which the menu refers
Mm Mm Name of the menu (e.g. "System")
Status indicator The background colour of this panel shows the
in the header of machine's status:
the menu screen Red Fault active
Yellow Warning active
Green Machine ready to operate
Blue None of the above active
Machine Messages
Parameter
Status Basic
Menu Position
Counter IO
Status
Flag
Status
The "Loader" screen is displayed after the machine is switched on. If the
START button is pressed there, or if you wait a few seconds, the operating
panel changes to the Start menu.
Depending on the state of the machine, some functions cannot be performed or
some buttons are not visible or operability is restricted. Not all machines have
all buttons, because for example the machine has no Automatic mode or
because there is no synchronisation.
Field/function Description
This menu is used to select and start a processing program. The name of the
program is shown in the small indicator field.
Press one of the “Program..” fields to start of one a maximum of 18 prede-
fined processing programs.
Use the arrow fields to change between the screens.
Pos : 57 /Betri ebs anleitung/08/36309 _ Bil dsc hirm " Start Programm x" @ GB\15\GB-36309_.doc x @ 1898083 @ 3 @ 1
Button Description
Enter your password in the entry field. The relevant rights are assigned
according to the password.
4 users are preset with the associated passwords:
To select the input fields and for entering numbers see the above sections
"Entering numbers" and "Double function ...".
Button Description
The menus for editing the Program parameters have the following structure:
For selecting the input fields and for entering numbers, see the section above
"Keyboard for entering numbers and characters".
Pos : 62 /Betri ebs anleitung/08/36366 _ Aus wahl Bear beitungs modus @ GB\15\GB-36366_.doc x @ 1899679 @ 3 @ 1
This menu is used for selecting the type of input. The parameters can be edited
in text form or in a graphic editor.
Pos : 64 /Betri ebs anleitung/08/36182 _ PPar a. " Verpressen i n Ri nge" @ GB\15\GB-36182_.doc x @ 1894527 @ 3 @ 1
10
11
5
2
12
13
1 3 4 7
10
11
5
2
12
13
1 3 4 6 8
GB-07314
1 Force build up time
min. 0s This parameter determines the duration of building up of the force.
max. 99 s
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GB-30079
2 Press force
min. 0 kN Here the press force can be selected:
max. 99 kN
HTP 40 HTP 60
minimum 30 30 kN
maximum 400 600 kN
GB-07316
3 Force holding time
min. 0s The time for which the press force is held can be selected here.
max. 99 s
Pos : 71 /Betri ebs anleitung/08/PPara 4 Rampe Kr aftabbau @ GB\3\GB-07317_.doc x @ 1256155 @ @ 1
GB-07317
4 Force build down time
min. 0s The duration of force release can be selected here.
max. 99 s
GB-07318
5 Force difference release
min. 0 kN The force difference during the force release time can be selected here.
max. 99 kN Example
A press force of 250 kN and a force difference of 100 kN are selected. The
press force is released down from 250 kN to 150 kN. The piston then travels
back, and the press force drops rapidly down.
Important:
Max. force difference has to be lower then the selected press force!
Pos : 74 /Betri ebs anleitung/08/PPara 6 Entnahmezei t Frei es Verpressen @ GB\15\GB-36320_.doc x @ 1898391 @ 5 @ 1
GB-36320
6 Pick up sample time (free pressing)
min. 0s In free pressing operation, the cross bar is opened following pressing and
max. 99 s the sample ejected. The piston then returns. The time for which the piston
remains in position prior to travelling back is the time for pick up the sample.
During this time the operator can remove the tool cover and confirm the
removal pressing F4. Thereby the predefined removal time can be reduced.
Pos : 76 /Betri ebs anleitung/08/PPara 7 Rüc kl aufz eit Ri ngpr essung @ GB\3\GB- 07320_.doc x @ 1256239 @ @ 1
GB-07320
7 Return time (ring pressing)
min. 0s This time determines how far down the piston moves back in ring pressing.
max. 99 s
Important:
The spring of the pressing tool has to be detensioned after the time reached!
Pos : 77 /Betri ebs anleitung/08/PPara 8 Rüc kl aufz eit Ri ngfrei e Press ung @ GB \3\GB-07321_.doc x @ 1256267 @ @ 1
GB-07321
8 Return time (free pressing)
min. 0 s This time determines how far down the piston moves back in free pressing.
max. 99 s Using this parameter the filling volume of the neccessary quantity of
material can be adjusted (the optimum filling height is 10 mm below the top
edge of the pressing tool).
Machine parameters are used to initially set and determine motions at the
machine. They have already been pre-set at the factory and normally never
require any changes.
Pos : 80 /Betri ebs anleitung/08/M par a/M par a Schaltkr aft Start Rampe @ GB\9\GB-21143_.doc x @ 1560067 @ @ 1
GB-21143
Switch force start ramp
min. 0 kN This determines the force with which the ramp shall start. This value must be
max. 99 kN a minimum of 4 kN lower than the value of „Force piston up“ (see parameter
above).
Important:
For a correct function of the press the following specifications must be observed:
Force up/down min. 25 kN
Switch force ramp min. 20 kN
Pos : 81 /Betri ebs anleitung/08/M par a/M par a Kraft bei Probenausgabe @ GB \9\GB-21144_.doc x @ 1560095 @ @ 1
GB-21144
Force during sample output
min. 0 kN This determines the force with which a sample without ring is discharged.
max. 99 kN
Pos : 83 /Betri ebs anleitung/08/M par a/M par a Kraft Pressz yli nder hoch @ GB\9\GB-21141_.doc x @ 1560011 @ @ 1
GB-21141
Force press piston up
min. 0 kN This determines the force with which the piston is moved up (no pressing).
max. 99 kN
Pos : 84 /Betri ebs anleitung/08/M par a/M par a R üc kl aufkr aft @ GB\9\GB- 21142_.doc x @ 1560039 @ @ 1
GB-21142
Force press piston down
min. 0 kN This determines the force with which the piston is moved down.
max. 99 kN
In this menu the press method can be selected. The selected mode is shown in
green ( ).
Field/Function Description
Display field
/
The display field indicates which press method is selected ( ).
For selecting the input fields and for entering numbers, see the section above
"Keyboard for entering numbers and characters".
Pos : 86 /Betri ebs anleitung/08/Ac htungACHTUN G: Pass endes Press wer kz eug @ GB \15\GB- 36362_.doc x @ 1899567 @ @ 1
GB-36362
ATTENTION!
The correct pressing tool must always be used.
No different samples can be pressed with the same pressing tool (with or without ring).
Pos : 88 /Betri ebs anleitung/08/M par a/36364 _ MPara. Ringrei nigung Kraft @ GB \15\GB- 36364_.doc x @ 1899623 @ 5 @ 1
GB-36364
Ring cleaning on/off
YES The ring cleaning can be activated here.
NO
Pos : 89 /Betri ebs anleitung/08/M par a/M par a Ri ngreinigung vor/z urüc k (Option) @ GB\9\GB- 21146_.doc x @ 1560151 @ @ 1
GB-21146
Ring cleaning forward / back (optional)
min. 0 With machines with ring cleaning it can be adjusted here how often the
max. 99 brush moves forward and back to clean the ring.
The parameters for pressing the carrier layer are set in this menu. This menu is
only enabled if the pressing process "2-component pressing" has been
selected.
The input fields with borders in colour are input fields in which the forces and
the times are defined. The colours relate to the corresponding positions in the
diagram.
GB-06932
Set-up operation
WARNING!
Extreme caution is required when using manual functions.
Locking devices that prevent damage to man and machine in normal
operation may be deactivated in set-up operation.
Improper use of certain functions may therefore lead to machine components
being damaged. The effects of some functions can only be observed after
opening the machine.
For these reasons, set-up operation should only be used by instructed
personnel. The set-up operation may be protected by an password.
NOTE
For set-up operation the machine must be in manual mode.
Pressing one of the buttons calls the corresponding submenu. The following
functions can be executed manually in the submenus:
Function / Description
buttons
Pos : 93 /Betri ebs anleitung/08/M anF kt/M anF kt. H ydraulikmotor @ GB\15\GB-36313_.doc x @ 1898195 @ 5 @ 1
GB-36313
Hydraulic motor
on / off Switch the hydraulic motor on or off
Pos : 94 /Betri ebs anleitung/08/M anF kt/M anF kt. Pr essz yli nder @ GB\15\GB-36314_.doc x @ 1898223 @ 5 @ 1
GB-36314
Press piston
up / down Move the press piston up or down
Target Set the target value for the press force
Actual Displays the actual value of the press force
This function can also be used for adjusting the electronic amplifier (see end of Chapt. B-08).
Pos : 95 /Betri ebs anleitung/08/M anF kt/M anF kt. Ringrei nigung (Opt) @ GB\15\GB-36315_.doc x @ 1898251 @ 5 @ 1
GB-36315
Ring cleaning (option)
forward / back Move the ring cleaning brush forward or back
forward / back Move the cleaning pusher forward or back
Pos : 96 /Betri ebs anleitung/08/M anF kt/M anF kt. Di vers e ( Lampentes t) @ GB\15\GB- 36316_.doc x @ 1898279 @ @ 1
GB-36316
Miscellaneous
Lamp test The indicator lights in the “Start” buttons I, II, III come on.
Field/function Description
The buttons shown in the LOADER image may only be used by service
personnel with special Simatic S7 knowledge, and may not be used by the
operator without prior consultation.
Field/function Description
Password Button
Changes to the PASSWORD menu to edit the passwords.
Pos : 98 /Betri ebs anleitung/08/M enü/27349 - M enü Bildsc hir msc honer allgemein neu @ GB\11\GB- 27349_.doc x @ 1743719 @ 2 @ 1
Field/Function Description
HX-XX Identifier
Shows the designation of the machine.
Conditions All conditions must be complied:
for screen The preselected time must be over “0”
saver
The machine must be in initial position
The machine is not in operational mode
The START menu must be shown
No key is pressed
No breakdown
If all conditions are complied the sreen saver start after the
preselected time.
Conditions One of these conditions must be complied:
to close The screen was touched
sreen saver
The machine is in operation mode, e.g. prepmaster send
start sequence
The machine goes into a breakdown
Pos : 99 /Betri ebs anleitung/08/M enü/36077 - M enü Z ÄHLER @ GB\15\GB-36077_.doc x @ 1891559 @ 2 @ 1
GB-04996
Total sample counter
Each sample started since the last reset is counted by the control.
After calling up the menu, the current count is displayed.
The counter can be reset.
RESET: reset the counter.
Messages Messages, faults etc. can be seen in the submenus called up here.
They show which faults have occurred in the past and why.
Step chain Status In this submenu you can follow which modules of the step chains are
active and which steps are processed. This information is retained
after interference, and the reason for interferences can thus be
determined.
Basic Position This submenu shows which parts of the machineare in basic position.
IO Status This submenu shows the input and output status of the control.
Flag Status This submenu shows the flags status of the control.
Pressing one of the function fields the corresponding submenu is called up.
Depending on the machine's scope of functions, there are no sub-menus or
there could be additional diagnosis functions.
Messages, faults etc. can be seen in the submenus called up here. They show
which faults have occurred in the past and why.
Field/function Description
Current Button
messages Open window with the current messages
Fault Button
messages Open archive in which fault messages that have occurred in the past are
shown.
Message Button
archive Open archive in which messages that have occurred in the past are shown.
System Button
messages SHOW SYSTEM MESSAGES that were generated in response to faults in
communication with the PLC, for example.
Diagnosis Button
messages SHOW diagnosis messages. Program errors are displayed here, for
example.
Field/function Description
Field/function Description
Field/function Description
Field/function Description
Field/function Description
Row Description
Field/function Description
Input field
The respective byte number must be entered in the fields with the yellow
background as described in the table below:
Byte-Nr. Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
EB00 E0.0 E0.1 E0.2 E0.3 E0.4 E0.5 E0.6 E0.7
… … … … … … … … …
EB10 E10.0 E10.1 E10.2 E10.3 E10.4 E10.5 E10.6 E10.7
Display field
/ Indicates which input / output is controlled (controlled = ).
WARNING!
Risk of damage!
This menu is exclusively for diagnosis by the Service staff and will therefore
not be explained further.
Wrong handling can cause fatal consequences, because in this menu bits in
the operation panel can be set, which modifiy the program sequence..
Field/function Description
Display field
/
The display field indicates whether the corresponding machine part is in its
basic position ( ).
Pos : 113 /Betriebs anl eitung/08/36310 _ Beschr eibung der Steuerung (11228) @ GB\15\GB- 36310_.doc x @ 1898111 @ 23 @ 1
The following operator functions are possible on the front side of the CPU:
Connect programming unit
Connect OP
The status of the CPU is indicated by LEDs.
CPU S7-1200
(covers removed)
1 = Power supply
2 = 24 V DC inputs
3 = Analog inputs
4 = Memory card plug-in module
5 = Indicator, inputs
6 = Indicator, outputs
7 = 24 V DC outputs
8 = Communication interface
9 = Communication indicators
10 = Operating mode indicator
11 = Front cover plate:
Extension modules
connector
Pos : 115 /Betriebs anl eitung/08/36090 _ Bedeutung Status- + F ehl eranz. S7-1200 @ GB\15\GB-36090_.doc x @ 1891923 @ 3 @ 1
GB-36091
IMPORTANT:
RUN, STOP & MRES mode can only still be run via the Siemens software
TIA-Portal.
Pos : 117 /Betriebs anl eitung/08/36092 _ Url ösc hen (CPU S7-1200) @ GB\15\GB- 36092_.doc x @ 1891979 @ 3 @ 1
IMPORTANT
General reset can only still be performed via the Siemens software TIA-Portal.
GB-40688
Basic setting of the electronic amplifier
Electronic amplifier for setting the hydraulic pressure
The amplifier is located in the switchgear cabinet for the machine.
The pressure, which is defined at the control panel, is converted by the
amplifier into a control current for the pressure control valve of the hydraulic
cylinder so that the amplifier controls the pressure in the hydraulic cylinder by
means of the valve.
Potentiometers P6 – P10
P9 = Current I = min.
P10 = Current I = max.
P6 = Ramp down time
P7 = Ramp up time
P8 = Dither amplitude
Jumpers
B1 - B2 Reference value of the
voltage range:
5V (10 V), 15 V
B3 Dither frequency
open: 60 Hz
shut: 120 Hz
B4 Test mode
The jumpers must be plugged in as follows:
B1 = Open
B2 = Closed
B3 = Open
Terminals (see circuit diagram)
B4 = Open
Potentiometer setting; P8
Pos : 119 /Betriebs anl eitung/08/40689 _ Vers tär ker eins tell en @ 1\mod_1421406125457_16.doc x @ 2019437 @ 34444 @ 1
GB-40689
Adjusting the amplifier
Pos : 121 /Betriebs anl eitung/09/Vor der 1. Inbetri ebnahme si nd folgende: @ GB\2\GB- 03290_.doc x @ 1176159 @ @ 1
GB-03290
Check list
GB-04005
Electrical system installed and tested manually ?
Pos : 123 /Betriebs anl eitung/09/03375 - Sic her ung en und Motorsc hutzsc halter @ GB\2\GB-03375_.doc x @ 1163195 @ @ 1
GB-03375
All fuses and motor protection switches in the control cabinet switched on ?
Pos : 124 /Betriebs anl eitung/09/03376 - H auptsc halter eing esc haltet @ GB\2\GB-03376_.doc x @ 1163223 @ @ 1
GB-03376
Main switch switched on?
GB-03382
Oil level in hydraulic tank checked ?
Pos : 126 /Betriebs anl eitung/09/T üren und H auben gesc hlossen @ GB\2\GB- 03381_.doc x @ 1163363 @ @ 1
GB-03381
All doors and lids closed ?
Pos : 127 /Betriebs anl eitung/09/Pr ogrammparameter am OP eing egeben? @ GB\3\GB-07325_.doc x @ 1260859 @ @ 1
GB-07325
Program parameters entered on the Operation panel ?
Pos : 128 /Betriebs anl eitung/09/Pr ess wer kz eug ric htig ei ngebaut? @ GB\3\GB- 07326_.doc x @ 1260887 @ @ 1
GB-07326
Press tool installed correctly ?
Pos : 129 /Betriebs anl eitung/09/Ric htig.Pr ess verf.eing est. Aus wahl ? @ GB\15\GB-36348_.doc x @ 1899063 @ @ 1
GB-36348
Correct pressing process selected ?
(Selection in the MACHINE PARAMETER menu: Free pressing
Pressing in rings
2-components pressing)
Pos : 130 /Betriebs anl eitung/10/00092 - B-10 Betrei ben @ GB\1\GB- 00092_.doc x @ 1079559 @ 1 @ 1
GB-00092
B-10 Instructions for operation
Pos : 131 /Betriebs anl eitung/09/Materi aleigensc haften @ GB \6\GB-14585_.doc x @ 1388539 @ @ 1
GB-14585
Material characteristics
Binding characteristics
If the sample does not itself have binding characteristics, binding agents must
be added in order for a firm pellet to be attained.
Metal chips
Metal chips must have a cross-section of less than 1.5 mm2, and must deform
fluidly under pressure.
Pulverous materials
The grain size of pulverous materials should not exceed 200 µm.
Material thickness
The material thickness required for a firm pellet is approximately 6 mm. The
press force and the material quantity required are dependent upon the sample
material, and must be determined empirically.
Pos : 132 /Betriebs anl eit ung/10/Bedienungshi nweise @ GB\3\GB-07330_.doc x @ 1260999 @ @ 1
GB-07330
Operation instructions
For operation of the different pressing tools see chapter B-05.
Pos : 133 /Betriebs anl eitung/10/Üb.U mbau auf and.Ri ngdurchm. (htp40) @ GB \10\GB- 23195_.doc x @ 1619791 @ @ 1
IMPORTANT:
The procedure described here refers only to the retrofitting of ring diameters
from 40 mm to 51,5 mm and vice versa.
Pos : 134 /Betriebs anl eitung/10/Pr ess wer kz eug (Htp40) @ GB\10\GB-23191_.doc x @ 1619679 @ @ 1
GB-23191
Pressing tool
Pressing tool
PREREQUISITE
The machine is ready for operation.
Safety fixture
The safety fixture (2, 3) surrounds the danger area once the cross member (1)
is closed. This prevents parts of the press cover or press ring from flying out
and causing injuries if one of these parts breaks.
Pos : 137 /Betriebs anl eitung/10/Noc kensc halter HTP 40 @ GB\14\GB-34869_.doc x @ 1885651 @ @ 1
Cam switch
The cam switch (4) signals "cross member open" to the controller.
Pos : 139 /Betriebs anl eitung/11/00093 - B-11 Verhalten bei Stör ung en @ GB\1\GB-00093_.doc x @ 1079587 @ 1 @ 1
GB-00093
B-11 Procedure in case of malfunction
Pos : 140 /Betriebs anl eitung/11/Stör ung en allgemein @ GB \3\GB-06981_.doc x @ 1253691 @ @ 1
GB-06981
Machine will not start
IMPORTANT!
* Malfunction is not shown on display.
Pos : 142 /Betriebs anl eitung/11/Stör ung S-TStör. Stör meldung en HTP 40 0001 @ GB\15\GB-36358_.doc x @ 1899455 @ @ 1
misaligned
• Groove ring des
Presskolbens verschlissen
B01 Emergency stop Cross bar open durting Close the cross bar and activate
pressing operation the stop button
B02 Motor protection Motor load to high Check motor and activate the
released stop button
B05 Restart PLC Machine was started Activate the stop button
B32 Total time out Working cycle could not be Check all limit switches and
finished in the preset time initiators
B34 Timeout • Pneumatic cylinder jammed • Check the cylinder
Cleaning (option) • Initiator at cylinder damaged • Check initiator resp. adjust it
or misaligned
• Pneumatic valve incorrect • Check the pneumatic valve; if
actuated or damaged damaged, repplace it
• Ring cleaning not installed • Deactivate the ring cleaning
but in the machine parameter option in the MACHINE
activated PARAMETER menu
B36 Critical motor To high temperature in the Wait until the press tool has
temperature hydraulic container cooled; possibly the frequence of
pressing operations to high
B37 Timeout The force build up was not • Check if the piston moves up
Force start reached in the preset time correctly at MANUAL
during while the piston moves FUNCTIONS menu
up • Raise the „Move up piston“
force
• Check the hydraulic
B38 Timeout The press force has not • The increasing ramp is adjusted
Force build up reached the target force after to steep, modify the parameter
the end of the increasing ramp • Check the hydraulic
(see Pressing operation)
Messages GB-36357
Pos : 144 /Betriebs anl eitung/11/Stör ung L-MStör. Mel dungen HT P 40 @ GB\15\GB- 36359_.doc x @ 1899483 @ @ 1
M01 No basic position, The machine is not in its basic Start synchronisation of the GB-36359
start position, e.g. because the machine (see operating panel
synchronisation working program was menu)
interrupted
M04 In operation Pressing operation active Wait until the pressing operation
has finished
M05 Syn in operation Synchronisation active Wait until the synchronisation has
finished
M12 Syn required Pressing operation was aborted Close cross member and press
or machine was started the SYN button to start
synchronisation
M14 Cross member The cross member is open, or Close the cross member or check
open the switch is defective or / adjust the switch
incorrectly set
M19 Cleaning in Ring cleaning in operation Wait until the ring cleaning has
working finished
M26 Ring could not be Material in the ring is too hard Return the ring to ring cleaning. If
cleaned is is not cleaned for a second
time, the material must be
removed in another way.
M40 Press Stop button There is a fault Remedy the fault and press the
Stop button
Pos : 145 /Betriebs anl eitung/11/HinweisHi nweis Störung wird nic ht angez eigt @ GB\1\GB- 00928_.doc x @ 1100699 @ @ 1
GB-00928
NOTE
* =. Malfunction is not indicated on the display
Pos : 146 /Betriebs anl eitung/11/Achtung Nur durch H ydr auli kfac hmann @ GB\1\GB- 01381_.doc x @ 1113019 @ @ 1
GB-01381
CAUTION!
Points marked with *1 should only be carried out by a hydraulics specialist.
Pos : 147 /Betriebs anl eitung/12/00095 _ B-12 Wartung und Pfl ege @ GB\1\GB- 00095_.doc x @ 1079643 @ 1 @ 1
GB-00095
B-12 Instructions for maintenance and care
Pos : 148 /Betriebs anl eitung/12/WartungWartung allgemei n 0002 @ GB\3\GB- 06910_.doc x @ 1250695 @ @ 1
GB-06910
General
WARNING!
Note the following important points during maintenance and servicing work:
Switch off the main switch and padlock
The phase terminals L1, L2 and L3 remain live even when the main switch
is switched off
Pos : 149 /Betriebs anl eitung/12/T ägliche Pflege WartungT ägliche Pfleg e und Wartung 0002 @ GB\3\GB-06911_.doc x @ 1250723 @ @ 1
-
Clean the machine using an industrial vacuum cleaner
-
Check that none of the machine movements is obstructed
-
Check that hoses are secure and are not leaking.
Hydraulic unions may come free as a result of vibration. Drops of oil on the
column base of the machine are evidence of leaks in the hydraulic system.
Reseal the unions by retightening them. Replace any defective
components
-
Remove the pressing tool, clean, and check for wear or damage
Pos : 150 /Betriebs anl eitung/12/Pr ess wer kz eug @ GB\3\GB- 06912_.doc x @ 1250751 @ @ 1
ATTENTION!
Switch off the main switch and padlock in this position with the machine in the
initial position.
Procedure
Remove the tool from the tool holding fixture
On the pressing tool for steel rings, remove the retaining pins
Dismantle the tool (if the piston sticks, press it out of the matrix using a plastic
or aluminium piston)
Clean all parts with a soft cloth. Use neutral, non-aggressive cleaning fluid or
paraffin
CAUTION!
Do not use sandpaper
Rub oil only gently into the guide surfaces on the piston and matrix
CAUTION!
Ensure that the sharp edges on the upper face of the piston are not blunted.
Rounded piston edges lead to fouling, and cause the tool to stick
NOTE
After cleaning, press five pellets.
Pos : 151 /Betriebs anl eitung/12/H ydrauli kventil HT P 40 / HP-PA @ GB\15\GB-36060_.doc x @ 1891055 @ 2 @ 1
NOTE
Only when machine is equipped with semi-automatic ring cleaning device.
Maintenance unit
bd238047-5
1 = Pressure regulator
2 = Manometer
3 = Compressed air connection ND 6 mm
GB-21400
Manual movement of pneumatic valves
ATTENTION!
Unconditionally switch back to position „0“ after manual change-over !
Pos : 155 /Betriebs anl eitung/12/Hinweis: Nur M asc h.mit aut. Ringrei nigung @ GB \11\GB- 26443_.doc x @ 1715971 @ @ 1
GB-26443
NOTE
Only when machine is equipped with semi-automatic ring cleaning device.
HTP 40 / 60
bd435388-4
1 = Pressure spindle
2 = Lubricating nipple,
column
3 = Oil tank
NOTE
Before lubricating: Clean all lubrication points!
Oil level in the oil tank: Check every 50 h!
Pos. Lubricating Type of lubrication Lubricant code as per DIN 51502
point
1 Oil tank Filling HLP 32
2 Column Grease gun K2K
3 Pressure Manual lubrication HLP 32
spindle
Pos. Initial filling Quantity Lubrication Lubrication quantity
interval
3 3
1 Chevron EP hydraulic oil 32 17 dm 2000 h 16 dm
3
2 SKF Alfalub LGMT 2 --- 200 h 5 cm
3 Chevron EP hydraulic oil 32 --- 200 h Oil film
Pos : 157 /Betriebs anl eitung/12/Z ylinder ei nfahr en bei Öl kontr olle @ GB \3\GB-06992_.doc x @ 1254923 @ @ 1
GB-06992
Check oil level in the hydraulic container every 50 hours.
ATTENTION!
The cylinder has to be retracted during checking the oil level in the hydraulic
control unit.
GB-31019
Table of lubricant
Lubricant
GB-00073
Type of lubrication
ARAL BP CALYPSO CASTROL CHEVRON ESSO KLUBER MOBIL TEXACO Designition
L DIN 51502
Chevron
Polyurea EP
Grease 2
Chevron
Polyurea EP
Grease 2
5 Aral BP Calypsol Castrol CLS Chevron Esso Entoplex Mobiplex Multifak G1K
ARALUB Energrease D 6024 Grease GP Semifluid H0 44 EP 0
FD 00 HT-EP 00 Grease 0 gear
lubricant oil
6 Aral BP Energol Calypsol Castrol Chevron Nutto Lamora Mobil Rando Oil HLP 32
Vitan HLP-D 32 HLP 32 Hyspin EP H 32 HLP 32 DTE 24 HD A 32
GF 32 AWS 32 Hydr. Oil 32
Alcor Oil
Aral BP Energol DD 32
Vitan HLP 32
DE 32
7 Aral BP Energol Calypsol Castrol Chevron Nutto Lamora Mobil Rando Oil HLP 46
Vitan HLP-D 46 HLP 46 Hyspin EP H 46 HLP 46 DTE 25 HD B 46
GF 46 AWS 46 Hydr. Oil 46
Alcor Oil
Aral BP Energol DD 46
Vitan HLP 32
DE 68
8 Aral BP Calypsol Castrol Chevron Nutto Lamora Mobil Rando Oil HLP 68
Vitan Energol HLP 68 Hyspin EP H 68 HLP 68 DTE 26 HDC-68
GF 68 HLP-D 68 AWS 68 Hydr. Oil 68 Alcor Oil
DD 68
Aral BP Energol
Vitan HLP 68
DE 68
9 Aral BP Energol Calypsol Castrol Chevron Nutto Lamora Mobil Rando Oil HLP 10
Vitan HLP-D 10 HLP 10 Hyspin EP H 10 HLP 10 DTE 21 HDA 10
F10 AWS 10 Hydr. Oil 10
BP Energol
HLP 10
10 Aral BP Energol Calypsol Castrol Chevron Spartan Lamopra Mobil Meropa 68 CLP 68
Degol GR-XP 68 HSR 10 Hyspin EP EP 68 HLP 68 DTE 26
BG 68 AWS 68 Hydr. Oil 68 Mobilgear
626
11 Aral BP Energol Calypsol Castrol Chevron Spartan Lamora 100 Mobil Meropa CLP 100
Degol GR-XP 100 HSR 100 Alpha Non-Leader EP 100 DTE 27 100
BG 100 SP 100 Gear Com- Mobilgear
pound 100 627
12 Aral BP Energol Calypsol Castrol Chevron Spartan Lamora 320 Mobilgear Meropa CLP 320
Degol GR-XP 320 HSR 320 Alpha Non-Leader EP 320 632 320
BG 320 SP 320 Gear Com-
pound 100
Pos : 160 /Betriebs anl eitung/13/28000 - B-13 Ersatzteile, Kundendi enst @ GB\12\GB-28000_.doc x @ 1818899 @ 122 @ 1
Spare parts
We offer a complete range of replacement parts for wearing parts, tools and
machine parts. Refer to separate list of replacement parts.
Customer Service